Yamaha FZ 25 2021 Supplementary Service Manual
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Yamaha FZ 25 2021 Supplementary Service Manual

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  • Page 2 FZN250 2017 SERVICE MANUAL: B97-F8197-E0 FZ 25 & FZS 25 (FZN250-A & FZN250D-A) BS-VI 2021 SUPPLEMENTARY SERVICE MANUAL ©2021 by India Yamaha Motor Pvt. Ltd. First edition, July 2020 All rights reserved. Any reproduction or unauthorized use without the written permission of India Yamaha Motor Pvt.
  • Page 3 EAS20071 IMPORTANT This manual was produced by the India Yamaha Motor Pvt. Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic 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 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. The manual is divided into chapters and each chapter is divided into sections.
  • Page 5 EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINTION SYMBOL DEFINTION Serviceable with engine mounted Molybdenum disulfide oil Filling fluid Brake fluid Lubricant Wheel bearing grease Special tool Lithium-soap-based grease Tightening torque...

  • Page 6: Table Of Contents

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

  • Page 8: General Information

    INFO CHAPTER 1 GENERAL INFORMATION FEATURES...................... 1-1 OUTLINE OF THE ABS................1-1 ABS COMPONENT FUNCTIONS ............. 1-5 ABS OPERATION ...................1-10 ABS WARNING LIGHT AND OPERATION..........1-13 INDICATOR LIGHTS AND WARNING LIGHT ........1-15 MULTI-FUNCTION DISPLAY..............1-15 HANDLEBAR SWITCHES............... 1-18 SIDESTAND ....................1-18 SPECIAL TOOLS ..................1-19...
  • Page 9 INFO...

  • Page 10: Features

    EAS30683 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle.
  • Page 11 FEATURES INFO The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. When wheel lock is detected during braking, hydraulic control is performed by the hydraulic system on the front and rear brakes independently.
  • Page 12 FEATURES INFO Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values.
  • Page 13 Side force d. Slip ratio Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.

  • Page 14: Abs Component Functions

    FEATURES INFO ABS block diagram 1. Rear brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10. Rear brake caliper 3. Front brake master cylinder 11. Rear wheel sensor 4. Inlet solenoid valve 12. ABS warning light 5. ABS motor 13.
  • Page 15 FEATURES INFO 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function check is properly completed at a speed of about 10 km/h (6.3 mi/h)).
  • Page 16 FEATURES INFO Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
  • Page 17 FEATURES INFO 3. Brake caliper 4. ABS motor 3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic pressure difference between the brake fluid in the upper brake lines (brake master cylinder side) and the brake fluid in the lower brake lines (brake caliper side).
  • Page 18 FEATURES INFO 1. Battery 14. ABS ECU 2. AC magneto 15. ABS motor relay 16. Solenoid relay 3. Rectifier/regulator 4. Main fuse 17. Front brake outlet solenoid 5. ABS motor fuse 18. Front brake inlet solenoid 6. ABS solenoid fuse 19.

  • Page 19: Abs Operation

    FEATURES INFO • Some types of malfunctions are not recorded in the memory of the ABS ECU (e.g., a blown ABS con- trol unit fuse). • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on.
  • Page 20 FEATURES INFO 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13.
  • Page 21 FEATURES INFO 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13.

  • Page 22: Abs Warning Light And Operation

    FEATURES INFO 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13.
  • Page 23 FEATURES INFO ABS function EWA16521 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is close to the limit.

  • Page 24: Indicator Lights And Warning Light

    This warning light comes on if a problem is de- • Fuel meter tected in the engine or other vehicle control sys- • Odometer tem. If this occurs, have a Yamaha dealer check • Two Tripmeters on-board diagnostic system. • Fuel Reserve Tripmeter •...
  • Page 25 If the last segment continues to flash after fuel- ing, or if all segments are flashing, have a You can manually reset the fuel reserve trip- Yamaha dealer check the electrical system. meter, or after refueling and traveling 5 km (3 mi), it will reset automatically and disappear from the display.
  • Page 26 If the display indicates any error codes, note This shows the average fuel consumption the code number and have a Yamaha dealer since it was last reset. check the vehicle. • “AVE_ _._ Km/L”: The average distance that ECA11591 can be traveled on 1.0 L of fuel is shown.

  • Page 27: Handlebar Switches

    ” to turn off the headlight and check this system regularly and have a DRL will come on to help maintain daylight vis- Yamaha dealer repair it if it does not func- ibility. tion properly. The lights will come on when the engine is...
  • Page 28 SPECIAL TOOLS INFO SPECIAL TOOLS SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Tool name / Tool no.
  • Page 29 SPECIAL TOOLS INFO Tool name / Tool no. Illustration Piston base YSST-604 (90890-01067) This tool is used to support the piston. Small screw driver YSST-609 This tool is used to adjust throttle screw/ retract timing chain tensioner. Torx bit (T-30) YSST-611 This tool is used to loosen or tighten the ...
  • Page 30 SPECIAL TOOLS INFO Tool name / Tool no. Illustration Bearing puller 6202 YSST-624 This tool is used to remove the bearings of front wheel (LH & RH), rear wheel (LH & RH)/ sprocket hub and balancer shaft bearing. Bearing puller 6203 YSST-624 A This tool is used to remove the bearing of drive axle and axle bearing.
  • Page 31 SPECIAL TOOLS INFO Tool name / Tool no. Illustration Socket steering nut (6-Teeth) YSST-721 This tool is used to loosen and tighten the steering ring nut. Clutch hub holder YSST-733 (90890-04086) This tool is used to hold the Clutch boss while loosening &...
  • Page 32 SPECIAL TOOLS INFO Tool name / Tool no. Illustration TFF oil seal installation tool YSST-875 90890-01381 This tools is used to install the oil seal and the dust seal of the front fork legs. Special piler YSST-888 This tool is used to remove and fix weight with wheel.
  • Page 33 SPECIAL TOOLS INFO Tool name / Tool no. Illustration Spark plug socket YSST-1206 This tool is used to remove and install the spark plug. Rocker arm shaft puller YSST-1208 This tool is used to remove the rocker arm pin. Feeler gauge YSST-1215 90890-03180 0.08...
  • Page 34 Yamaha diagnostic tool INS-018 (90890-03267) This tool is used to diagnose electrical fault in advance fuel injection system. Yamaha diagnostic tool (Ver.3) INS-019 (90890-03264) This tool is used to diagnose electrical fault in advance fuel injection system. Sub harness 3...
  • Page 35 INFO 1-26...

  • Page 36: Specifications

    SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 MAINTENANCE SPECIFICATION (ENGINE)..........2-2 MAINTENANCE SPECIFICATION (CHASSIS) ..........2-6 MAINTENANCE SPECIFICATION (ELECTRICAL)........2-8 TIGHTENING TORQUES ................2-10 GENERAL TIGHTENING TORQUE SPECIFICATIONS ......2-10 ENGINE TIGHTENING TORQUES ............2-11 CHASSIS TIGHTENING TORQUES............2-18 CABLE ROUTING ..................2-19...
  • Page 37 SPEC...

  • Page 38: General Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS SPECIFICATIONS Model Model B9X1 (FZN250A ABS BS-VI) B0Y1 (FZN250D-A ABS BS-VI) Dimensions Overall length 2015 mm (79.3 in) Overall width 775 mm (30.5 in) (FZN250-A) 820 mm (32.3 in) (FZN250D-A) Overall height 1075 mm (42.3 in) (FZN250-A) 1105 mm (43.5 in) (FZN250D-A) Wheelbase 1360 mm (53.5 in)

  • Page 39: Maintenance Specification (Engine)

    SPEC MAINTENANCE SPECIFICATION (ENGINE) MAINTENANCE SPECIFICATION (ENGINE) Engine Combustion cycle 4-stroke Cooling system Air cooled Valve train SOHC Displacement 249 cm³ Number of cylinders Single cylinder Bore  stroke 74.0  58.0 mm (2.91  2.28 in) Compression ratio 9.8 : 1 Compression pressure 1044-1344 kPa/700 r/min (10.4–13.4 kgf/cm...
  • Page 40 SPEC MAINTENANCE SPECIFICATION (ENGINE) Camshaft Camshaft lobe dimensions Lobe height (Intake) 36.890–36.990 mm (1.4524–1.4563 in) Limit 36.790 mm (1.4484 in) Lobe height (Exhaust) 36.891–36.991 mm (1.4524–1.4563 in) Limit 36.791 mm (1.4485 in) Camshaft runout limit 0.030 mm (0.0012 in) Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Limit...
  • Page 41 SPEC MAINTENANCE SPECIFICATION (ENGINE) Cylinder Bore 74.000–74.016 mm (2.9134–2.9140 in) Wear limit 74.066 mm (2.9160 in) Piston Diameter D 73.983–73.998 mm (2.9127–2.9133 in) Measuring point (from piston skirt bottom) 5.0 mm (0.20 in) Piston-to-cylinder clearance 0.010–0.025 mm (0.0004–0.0010 in) Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0.6710 in)
  • Page 42 SPEC MAINTENANCE SPECIFICATION (ENGINE) Drivetrain Primary reduction ratio 3.083 (74/24) Transmission type Constant mesh 5-speed Gear ratio 2.571 (36/14) 1.684 (32/19) 1.273 (28/22) 1.040 (26/25) 0.852 (23/27) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Main axle assembly width 102.20–102.40 mm (4.02–4.03 in) Secondary reduction ratio...

  • Page 43: Maintenance Specification (Chassis)

    SPEC MAINTENANCE SPECIFICATION (CHASSIS) MAINTENANCE SPECIFICATION (CHASSIS) Chassis Frame type Diamond Caster angle 24.5 ° Trail 98 mm (3.9 in) Front wheel Wheel type Cast wheel 17M/C  MT2.50 Rim size Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Wheel axle bending limit 0.25 mm (0.01 in)
  • Page 44 Quantity (right) 469.0 cm (15.86 US oz, 16.54 Imp.oz) Level (left) 75 mm (3.0 in) Level (right) 75 mm (3.0 in) Recommended oil Yamaha Suspension Oil G10 Rear suspension Type Swingarm Spring Coil spring Shock absorber Hydraulic damper Spring preload...

  • Page 45: Maintenance Specification (Electrical)

    SPEC MAINTENANCE SPECIFICATION (ELECTRICAL) MAINTENANCE SPECIFICATION (ELECTRICAL) Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 8.0°–12.0°/1400 r/min High altitude ignition timing (B.T.D.C.) 19.9°/1400 r/min Engine control unit Model TBDF4E Ignition coil 2.34–2.86  Primary coil resistance Secondary coil resistance 9.45–11.55 k...
  • Page 46 SPEC MAINTENANCE SPECIFICATION (ELECTRICAL) Starter motor Brush overall length 10.0 mm (0.39 in) Limit 3.50 mm (0.14 in) Brush spring force 5.52–8.28 N (563–844 gf, 19.87–29.80 oz) Mica undercut (depth) 1.50 mm (0.06 in) Fuel sender unit 10.0–14.0  Sender unit resistance (full) 267.0–273.0 ...

  • Page 47: Tightening Torques

    SPEC TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 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 48: Engine Tightening Torques

    60 N·m (6.0 kgf·m, 44 lb·ft) Camshaft sprocket cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Timing chain tensioner plug 8 N·m (0.8 kgf·m, 5.9 lb·ft) Apply Yamaha Timing chain tensioner bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) bond No. 1215B to screw thread Oil pump assembly bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft)
  • Page 49 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Left side crankcase bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) AC magneto cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Clutch cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Drive sprocket nut 110 N·m (11.0 kgf·m, 81 lb·ft) Timing mark accessing screw 3 N·m (0.3 kgf·m, 2.2 lb·ft)
  • Page 50 SPEC TIGHTENING TORQUES Cylinder head tightening sequence: AC Magneto cover tightening sequence: 11,2 11,2 Clutch cover tightening sequence: 2,15 2,15 2-13...
  • Page 51 SPEC TIGHTENING TORQUES Crankcase tightening sequence: 14,2 14,2 2-14...

  • Page 52: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket and frame nut (front side) 43 N·m (4.3 kgf·m, 32 lb·ft) Engine bracket and engine nut (front 43 N·m (4.3 kgf·m, 32 lb·ft) side) Engine and frame nut (rear lower side) 43 N·m (4.3 kgf·m, 32 lb·ft) Engine and frame nut (rear upper side) 43 N·m (4.3 kgf·m, 32 lb·ft)
  • Page 53 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear shock absorber and frame nut 40 N·m (4.0 kgf·m, 30 lb·ft) Mud protector assembly bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Mud guard and stay bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Rear stay assembly bolt (LH &...
  • Page 54 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake master cylinder cap screw – 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) Front brake hose union bolt 24 N·m (2.4 kgf·m, 18 lb·ft) Brake hose holder and front fork outer 7 N·m (0.7 kgf·m, 5.2 lb·ft) tube bolt Brake hose holder and lower bracket bolt...
  • Page 55 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Hydraulic unit assembly bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Front wheel sensor rotor screw 8 N·m (0.8 kgf·m, 5.9 lb·ft) Front wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Rear wheel sensor rotor screw 8 N·m (0.8 kgf·m, 5.9 lb·ft) Rear wheel sensor bolt...
  • Page 56 SPEC CABLE ROUTING CABLE ROUTING - Chassis (Front view) 2-19...
  • Page 57 SPEC CABLE ROUTING È Clamp the right handlebar switch lead at 1 Throttle cable (Return side) Throttle cable (Pull side) straight portion of right handlebar. Left handlebar switch lead É Clamp the clutch switch lead and the han- Clutch cable dlebar switch lead at straight portion of left Clutch switch lead handlebar.
  • Page 58 SPEC CABLE ROUTING CABLE ROUTING - Meter assembly 2-21...
  • Page 59 SPEC CABLE ROUTING È 1 Rubber cover Rubber cover shall be inserted into upper cover. É Insert the hang shape into hole of upper 2 Upper cover 3 Headlight assembly lead cover (left & right). 4 Meter assembly lead Ê Edge of rubber cover shall be at outside 5 Left handlebar switch leads and couplers edge of upper cover.
  • Page 60 SPEC CABLE ROUTING CABLE ROUTING - Handlebar (Top view) 2-23...
  • Page 61 SPEC CABLE ROUTING È Right handlebar switch lead shall not be pinched 1 Meter assembly 2 Headlight stay between meter assembly and headlight stay. É Pass the leads to upper side of clutch cable. 3 Right handlebar switch lead Ê Pass the throttle cables (both) to guide of stay. 4 Main switch lead Ë...
  • Page 62 SPEC CABLE ROUTING CABLE ROUTING - Top view (Rear side) È Pass the wire harness (OBD) from lower side of 1 ECU (Engine control unit assembly) turn signal relay. 2 OBD coupler É Pass the wire harness (OBD) and turn signal 3 Wire harness (OBD) relay lead from upper side of couplers cover.
  • Page 63 SPEC CABLE ROUTING CABLE ROUTING - Sidestand switch (Left view) 2-26...
  • Page 64 SPEC CABLE ROUTING È All the couplers shall be properly covered with 1 Coupler cover 2 Sidestand switch lead couplers cover, after connecting. Layout of leads 3 Sidestand switch can be in random order. É Band shall be touched to frame. 4 ACM Lead Ê...
  • Page 65 SPEC CABLE ROUTING CABLE ROUTING - Air induction system (Right view) È Insert the wire harness clamp in the hole of 1 Air induction system hose (Air induction system solenoid to air induction system pipe) bracket. É Pass the switch lead from the right side of the 2 Air induction system solenoid 3 Air induction system hose (Air induction system main switch steering lock.
  • Page 66 SPEC CABLE ROUTING CABLE ROUTING - Air induction system (Left view) È Knob of the clip shall be upper side of the vehi- 1 Frame 2 Air induction system solenoid cle. É Knob of the clip shall be lower side of the vehi- 3 Clip 4 Air induction system hose (Air induction system cle.
  • Page 67 SPEC CABLE ROUTING CABLE ROUTING - Chassis (rear right view) È Fix the air induction system solenoid assembly 1 Frame 2 Air induction system solenoid onto the bracket knobs and push till it get fixed 3 Bracket properly. É Ensure mark of white paint shall be upper side of the vehicle.
  • Page 68 SPEC CABLE ROUTING CABLE ROUTING - Chassis (Rear right view) 2-31...
  • Page 69 SPEC CABLE ROUTING È Wire harness shall be passed from inside the 1 Taillight lead 2 Battery seat rail, also it should not touch the rectifier reg- 3 Relay ulator. É Fix clamp to the end of bracket tank fitting of 4 Positive battery lead 5 MAQS (Modularized air quantity sensor) frame.

  • Page 70: Cable Routing

    SPEC CABLE ROUTING - Handlebar (Top view) CABLE ROUTING - Engine (Front left view) 2-33...
  • Page 71 SPEC CABLE ROUTING È Pass the clutch cable from cable guide of brake 1 Front brake hose (ABS Hydraulic unit to front brake master cylinder) hose holder. É O 2 Front brake hose holder sensor lead and front wheel sensor lead shall sensor lead be passed over the brake hose.
  • Page 72 SPEC CABLE ROUTING CABLE ROUTING - ABS (Hydraulic unit) È Clamp shall be inserted in the hole of frame. 1 Battery box 2 ABS hydraulic unit 3 ABS hydraulic unit lead 4 Air filter assembly 2-35...
  • Page 73 SPEC CABLE ROUTING CABLE ROUTING - ABS (Rear brake) 2-36...
  • Page 74 SPEC CABLE ROUTING È Fix the clamp on the paint mark of brake hose 1 Rear wheel speed sensor lead 2 Plain washer protector and white tape of wheel speed sensor. É Air shall be completely removed. 3 Brake hose union bolt Ê...
  • Page 75 SPEC CABLE ROUTING CABLE ROUTING - ABS front brake (Right view) 2-38...
  • Page 76 SPEC CABLE ROUTING È Clamp shall be attached on paint mark of front 1 Frame 2 Front fender brake hose. É Pin of front brake hose (ABS hydraulic unit to 3 Front fork 4 Lead holder brake caliper) shall touch the brake hose 5 Front wheel speed sensor bracket.
  • Page 77 SPEC CABLE ROUTING CABLE ROUTING - ABS front brake (Left view) È Clamp shall be inserted in the hole of engine 1 Front brake hose (ABS hydraulic unit to front brake master cylinder) stay. 2 Front brake hose bracket É Both front brake hoses should properly set to 3 Frame clamp.
  • Page 78 SPEC CABLE ROUTING CABLE ROUTING - ABS Hydraulic unit (Top view) È Pin of rear brake hose (to rear brake master cyl- 1 ABS hydraulic unit 2 Rear brake hose (to rear brake master cylinder) inder) shall touch to end fitting of rear brake 3 Rear brake hose (to rear brake caliper) hose (to rear brake caliper).

  • Page 79: Periodic Checks And Adjustments

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENT PERIODIC MAINTENANCE ................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION  CONTROL SYSTEM ................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ....... 3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 ELECTRICAL SYSTEM................... 3-6 ADJUSTING THE HEADLIGHT BEAM .............

  • Page 80: Periodic Maintenance

    EAUE4020 ● From 25000 km (15000 mi), repeat the maintenance intervals starting from 5000 km (3000 mi). Items marked with an asterisk (*) should be performed by a Yamaha dealer as they require special ● tools, data and technical skills.
  • Page 81 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ITEM 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km** (600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi) • Check operation, fluid level    ...
  • Page 82 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ITEM 1000 km 5000 km 10000 km 15000 km** 20000 km** 25000 km** (600 mi) (3000 mi) (6000 mi) (9000 mi) (12000 mi) (15000 mi) • Check operation and for oil   ...

  • Page 83: Engine

    ENGINE ENGINE Center plug spanner ADJUSTING THE VALVE CLEARANCE YSST-625 The following procedure applies to all of the 5. Measure: valves. • Valve clearance Out of specification  Adjust. o Valve clearance adjustment should be made on a cold engine, at room temperature. ●...
  • Page 84 ENGINE Tappet screw holder YSST-706 (90890-04154) Tappet adjusting socket YSST-806A (90890-04150) d.Hold the adjusting screw to prevent it from moving and tighten the locknut to specification. Locknut 14 N·m (1.4 kgf·m, 10 lb·ft) Adjust inlet valve clearance from right side of the vehicle and exhaust valve clearance from e.Measure the valve clearance again.

  • Page 85: Electrical System

    ELECTRICAL SYSTEM ELECTRICAL SYSTEM ADJUSTING THE HEADLIGHT BEAM The following procedure applies to the adjust- ment of the headlight beam. Adjust the headlight beam by rotating the headlight beam adjusting screw with the help of philip screwdriver “1” in direction “a” or “b” from right side of headlight.

  • Page 86: Chassis

    CHASSIS EAS20024 CHASSIS EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA13100 WARNING Always bleed the brake system when the brake related parts are removed. ECA18050 NOTICE • Bleed the brake system in the following or- der. • 1st step: Front brake calipers •...
  • Page 87 CHASSIS ECA18060 NOTICE Make sure that the main switch is turned to “OFF” before checking the operation of the hydraulic unit. k. After operating the ABS, repeat steps (e) to (i), and then fill the brake master cylin- der reservoir or brake fluid reservoir to the proper level with the specified brake fluid.
  • Page 88 CHAS CHAPTER 4 GENERAL CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL....................4-7 REMOVING THE FRONT WHEEL............4-8 MAINTENANCE OF THE WHEEL SENSOR AND SENSOR ROTOR ..4-8 INSTALLING THE FRONT WHEEL ............4-9 REAR WHEEL ....................4-11 REMOVING THE REAR WHEEL ............4-13 MAINTENANCE OF THE REAR WHEEL SENSOR AND ...
  • Page 89 CHAS...
  • Page 90 CHAS GENERAL CHASSIS GENERAL CHASSIS GENERAL CHASSIS Removing the under cover Order Job/Parts to remove Q’ty Remarks Passenger seat Rider seat Left side cover Right side cover Left seat handle Right seat handle Tail cover Left rear side cover Right rear side cover Mud protector Left side panel assembly Right side panel assembly...
  • Page 91 CHAS GENERAL CHASSIS Removing the headlight assembly / meter assembly / auxiliary light assembly Order Job/Parts to remove Q’ty Remarks Licence plate stay Windshield Headlight assembly bolt (upper) Headlight coupler Disconnect. Auxiliary light coupler Disconnect. Headlight assembly bolt (lower) Head light assembly Meter coupler Disconnect.
  • Page 92 CHAS GENERAL CHASSIS Removing the headlight assembly / meter assembly / auxiliary light assembly Order Job/Parts to remove Q’ty Remarks Headlight stay with indicators lgnition switch connectors Main switch steering lock For installation, reverse the removal proce- dure. * Removing and installing the main switch steering lock screw by using special tool [Main switch steering lock (T-30) - (YSST-611A)].
  • Page 93 CHAS GENERAL CHASSIS Removing the windshield (for B0Y1) Order Job/Parts to remove Q’ty Remarks Licence plate stay Windshield Meter cover For installation, reverse the removal proce- dure.
  • Page 94 CHAS GENERAL CHASSIS Removing the brush gaurd (for B0Y1) 9 N·m (0.9 kgf·m, 6.6 lb·ft) 9 N·m (0.9 kgf·m, 6.6 lb·ft) Order Job/Parts to remove Q’ty Remarks Rear view mirror assy Disconnect. End grip Brush guard assembly Brush guard bracket bolts Loosen.
  • Page 95 CHAS GENERAL CHASSIS Removing the air filter case A: Engine breather pipe B: Air induction system solenoid Order Job/Parts to remove Q’ty Remarks Passenger seat, rider seat, Left side cover, Refer to “GENERAL CHASSIS” on Right side cover, Tail cover, Left rear side page 4-1.
  • Page 96 CHAS FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake disc 38 N·m (3.8 kgf·m, 28 lb·ft) Order Job/Parts to remove Q’ty Remarks Front brake hose holder Sensor lead holder Front brake caliper Front wheel sensor Front wheel axle nut Washer Front wheel axle Front wheel...

  • Page 97: Front Wheel

    CHAS FRONT WHEEL REMOVING THE FRONT WHEEL • The wheel sensor cannot be disassembled. Do not attempt to disassemble it. If faulty, 1. Stand the vehicle on a level surface. replace with a new one. WARNING • Keep any type of magnets (including mag- Securely support the vehicle so that there netic pick-up tools, magnetic screwdrivers, is no danger of it falling over.

  • Page 98: Installing The Front Wheel

    CHAS FRONT WHEEL • Use “Torx bit T-25” for opening/tightening Wheel sensor rotor runout limit wheel sensor rotor bolt. limit 0.25 mm (0.0098 in) a. Hold the dial gauge at a right angle against the wheel sensor rotor surface. b. Measure the wheel sensor rotor runout limit.
  • Page 99 CHAS FRONT WHEEL ECA14140 Feeler gauge NOTICE YSST-1215 (90890-03180) Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth- 4. Install: • Front wheel sensor Front wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) ECA21020 G088903...

  • Page 100: Rear Wheel

    CHAS REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” in base ser- Mud protector vice manual B97-F8197-E0 on page 4-1. Rear wheel speed sensor Axle nut Washer Drive chain adjusting locknut Loosen.
  • Page 101 CHAS REAR WHEEL Removing the rear brake disc and rear wheel sprocket 43 N·m (4.3 kgf·m, 32 lb·ft) 8.0 N·m (0.8 kgf·m, 5.9 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) Order Job/Parts to remove Q’ty Remarks Rear wheel sprocket Rear wheel drive hub Rear wheel drive hub damper Rear brake disc Rear wheel sensor rotor...

  • Page 102: Removing The Rear Wheel

    CHAS REAR WHEEL EAS30156 REMOVING THE REAR WHEEL MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ECA21030 NOTICE NOTICE • Keep any type of magnets (including mag- • Handle the ABS components with care netic pick-up tools, magnetic screwdrivers, since they have been accurately adjusted.
  • Page 103 CHAS REAR WHEEL • Apply lithium-soap-based grease to the con- tact surface and threads of the rear wheel axle nut. G088900 G088891 1. Install: • Rear wheel sprocket Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” in base 5. Lubricate: service manual B97-F8197-E0 on page 4-14.
  • Page 104 CHAS REAR WHEEL 9. Install: • Rear wheel sensor Rear wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) ECA21080 NOTICE Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel G088906 sensor. Foreign materials cause damage to the rear wheel sensor rotor and rear wheel sensor.

  • Page 105: Front Brake

    CHAS FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-7. Front brake hose union bolt (brake caliper side) Brake hose gasket Front brake hose (brake hose joint to brake cali- per) Front brake caliper bolt...

  • Page 106: Removing The Front Brake Caliper

    CHAS FRONT BRAKE EAS30724 REMOVING THE FRONT BRAKE CALIPER Front brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Before removing the brake caliper, drain the Front brake hose union bolt brake fluid from the entire brake system. (brake caliper side) 29 N·m (2.9 kgf·m, 21 lb·ft) ECA20981 NOTICE...
  • Page 107 CHAS FRONT BRAKE • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts.

  • Page 108: Rear Brake

    CHAS REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Rear wheel sensor Refer to “REAR WHEEL” on page 4-11. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-7. Rear wheel Refer to “REAR WHEEL”...

  • Page 109: Removing The Rear Brake Caliper

    CHAS REAR BRAKE • Rear brake caliper “1” along with rear wheel EAS30186 REMOVING THE REAR BRAKE CALIPER • Rear wheel sensor Refer to “REPLACING THE REAR BRAKE Before disassembling the brake caliper, drain PADS” in base service manual B97-F8197- the brake fluid from the entire brake system.
  • Page 110 CHAS REAR BRAKE 3. Fill: 6. Check: • Brake fluid reservoir • Brake pedal operation Soft or spongy feeling  Bleed the brake (with the specified amount of the specified brake fluid) system. Refer to “BLEEDING THE HYDRAULIC Specified brake fluid BRAKE SYSTEM (ABS)”...

  • Page 111: Abs (Anti-Lock Brake System)

    CHAS ABS (ANTI-LOCK BRAKE SYSTEM) EAS20033 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to“BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-7. Refer to “GENERAL CHASSIS (1)” in base Rider and passenger seat service manual B97-F8197-E0 on page 4-1.
  • Page 112 CHAS ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly Order Job/Parts to remove Q’ty Remarks ABS ECU coupler Rear brake hose (hydraulic unit to rear brake caliper) Rear brake hose joint Rear brake hose bracket Rear brake hose (hydraulic unit to rear brake master cylinder) Front brake hose (hydraulic unit to front brake master cylinder)

  • Page 113: Removing The Hydraulic Unit Assembly

    CHAS ABS (ANTI-LOCK BRAKE SYSTEM) 2. Remove: EAS30197 REMOVING THE HYDRAULIC UNIT • Brake hoses ASSEMBLY ECA21091 Do not operate the brake lever and brake pedal NOTICE while removing the brake hoses. Unless necessary, avoid removing and in- stalling the brake hoses of the hydraulic unit ECA14530 assembly.

  • Page 114: Installing The Hydraulic Unit Assembly

    CHAS ABS (ANTI-LOCK BRAKE SYSTEM) c. Position the front brake hose (hydraulic EAS30200 INSTALLING THE HYDRAULIC UNIT unit to front brake master cylinder) “1” so ASSEMBLY that pin shall contact “b” of front brake 1. Install: hose (hydraulic unit to front brake caliper) •...

  • Page 115: Hydraulic Unit Operation Tests

    NOTICE • For the brake line routing confirmation, use the Brake fluid may damage painted surfaces diagnosis mode of the Yamaha diagnostic tool. and plastic parts. Therefore, always clean up • Before performing the brake line routing confir- any spilt brake fluid immediately.
  • Page 116 CHAS ABS (ANTI-LOCK BRAKE SYSTEM) 4. Check: 6. Start the Yamaha diagnostic tool and display • Battery voltage the diagnosis mode screen. Lower than 12.8 V  Charge or replace the 7. Select code No. 2, “Brake line routing confir- battery.
  • Page 117 10.If the operation of the hydraulic unit is normal, delete all of the fault codes. 5. Removing the protective cap “1”, and then ABS reaction-force confirmation connect the Yamaha diagnostic tool “2” to the ABS test coupler “3” (4 Pin). EWA13120 WARNING...
  • Page 118 CHAS ABS (ANTI-LOCK BRAKE SYSTEM) 6. Start the Yamaha diagnostic tool and display • “ON” and “OFF” on the tool screen indicate the diagnosis mode screen. when the brakes are being applied and re- 7. Select code No. 1, “ABS reaction-force con- leased respectively.

  • Page 119: 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 120: Engine

    CHAPTER 5 ENGINE ENGINE REMOVAL ..................5-1 CRANKCASE ....................5-5...
  • Page 122 ENGINE REMOVAL ENGINE REMOVAL ENGINE Removing the muffler Order Job/Parts to remove Q’ty Remarks Under cowling Refer to “GENERAL CHASSIS” on page 4-1. sensor coupler Disconnect. Muffler Exhaust pipe gasket For installation, reverse the removal proce- dure While installing muffler, first tighten all bolts temporary then tighten cylinder head side nuts as per specified torque valve.
  • Page 123 ENGINE REMOVAL Disconnecting the leads and couplers 3.7 N.m (0.37 kgf.m, 2.7 lb.ft) Order Job/Parts to remove Q’ty Remarks NOTICE First, disconnect the negative battery lead, and then the positive battery lead. Rider seat and passenger seat, Side covers Refer to “GENERAL CHASSIS” on page 4-1. LH &...
  • Page 124 ENGINE REMOVAL Disconnecting the leads and couplers 3.7 N.m (0.37 kgf.m, 2.7 lb.ft) Order Job/Parts to remove Q’ty Remarks Stator coil coupler/crankshaft sensor coupler Disconnect. Sidestand switch coupler Disconnect. Sidestand switch Shift arm Drive chain sprocket cover Drive chain Horn leads Disconnect.
  • Page 125 ENGINE REMOVAL Removing the engine 43 N·m (4.3 kgf·m, 32 lb·ft) 43 N·m (4.3 kgf·m, 32 lb·ft) N·m ( . kgf·m, lb·ft) N·m ( . kgf·m, lb·ft) N·m ( . kgf·m, lb·ft) 43 N·m (4.3 kgf·m, 32 lb·ft) 43 N·m (4.3 kgf·m, 32 lb·ft) Order Job/Parts to remove Q’ty...
  • Page 126 CRANKCASE CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “CYLINDER HEAD” in base manual Cylinder head B97-F8197-E0 on page 5-6. Refer to “CYLINDER AND PISTON” in base Cylinder/Piston manual B97-F8197-E0 on page 5-23. Refer to “CLUTCH” in base manual B97- Clutch housing F8197-E0 on page 5-38.
  • Page 127 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Timing chain Timing chain guide (intake side) Circlip Rotor Circlip Drive sprocket nut Lock washer Drive sprocket Neutral switch Right crankcase Dowel pin Left crankcase For installation, reverse the removal proce- dure...

  • Page 129: Electrical System

    TROUBLESHOOTING DETAILS (FAULT CODE) ........6-28 TROUBLESHOOTING DETAILS ............6-29 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..6-30 SELF-DIAGNOSTIC FUNCTION TABLE ..........6-30 COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL ..6-36 DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........ 6-37 EVENT CODE TABLE...................6-66 FUEL PUMP SYSTEM...................6-68 CIRCUIT DIAGRAM ................
  • Page 130 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM)............6-71 CIRCUIT DIAGRAM ................6-71 ABS COUPLER LOCATION CHART ............6-73 MAINTENANCE OF THE ABS ECU ............6-74 ABS TROUBLESHOOTING OUTLINE............6-74 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......6-75 BASIC PROCESS FOR TROUBLESHOOTING ........6-76 [A] CHECKING THE ABS WARNING LIGHT.......... 6-77 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.....

  • Page 131: Ignition System

    ELEC – IGNITION SYSTEM IGNITION SYSTEM ELECTRICAL SYSTEM CIRCUIT DIAGRAM...
  • Page 132 ELEC – IGNITION SYSTEM 2. Crankshaft position sensor 13.Battery positive lead 14.Battery 15.Battery negative lead 16.Engine ground 17.Main switch 18.Fuse 23.Right handlebar switch 25.Engine stop switch 33.Lean angle sensor 35.ECU(Engine control unit) 36.Ignition coil 37.Spark plug 42.Sidestand switch 44.Joint connection 1 45.Joint connection 2...

  • Page 133: Troubleshooting

    ELEC – IGNITION SYSTEM TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Passenger and rider seat 2. Left side cover and right side cover 3. Fuel tank panels 4.
  • Page 134 ELEC – IGNITION SYSTEM 8. Check the lean angle sensor. NG Refer to “CHECKING THE LEAN Replace the lean angle sensor. ANGLE SENSOR” in base service manual B97-F8197-E0 on page 7-68. OK 9. Check the engine stop switch. NG The engine stop switch is faulty. Replace Refer to“CHECKING THE the right handlebar switch.

  • Page 135: Electric Starting System

    ELEC – ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM...
  • Page 136 ELEC – ELECTRIC STARTING SYSTEM 1. Neutral switch 13.Battery positive lead 14.Battery 15.Battery negative lead 16.Engine ground 17.Main switch 18.Fuse 19.Starter relay 20.Starter motor 21.Starting circuit cut off relay 22.Clutch switch 23.Right handlebar switch 24.Start switch 25.Engine stop switch 27.Diode 42.Sidestand switch 44.Joint connection 1 45.Joint connection 2...

  • Page 137: Starting Circuit Cut-Off System Operation

    ELEC – 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 138: Troubleshooting

    ELEC – ELECTRIC STARTING SYSTEM TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Passenger and rider seat 2. Left side cover and right side cover 3. Remove headlight assembly NG 1. Check the fuse. Refer to “CHECKING THE FUSES”...
  • Page 139 ELEC – ELECTRIC STARTING SYSTEM NG 8. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 6-105. OK NG 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch.

  • Page 140: Charging System

    ELEC – CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM 6-10...
  • Page 141 ELEC – CHARGING SYSTEM 3. Stator coil 4. Rectifier/Regulator 13.Battery positive lead 14.Battery 15.Battery negative lead 16.Engine ground 18.Fuse 6-11...

  • Page 142: Troubleshooting

    ELEC – CHARGING SYSTEM TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Passenger and rider seat 2. Right side cover NG 1. Check the fuse. Refer to “CHECKING THE FUSES” Replace the fuse. on page 6-106.

  • Page 143: Lighting System

    ELEC – LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM 6-13...
  • Page 144 ELEC – LIGHTING SYSTEM 13.Battery positive lead 14.Battery 15.Battery negative lead 16.Engine ground 17.Main switch 18.Fuse 35.ECU(Engine control unit) 44.Joint connection 1 45.Joint connection 2 46.Meter assembly 51.Meter light 53.High beam indicator light 58.Auxiliary light with DRL 59.Joint 1 60.Left handlebar switch 61.Headlight switch 62.Pass switch 63.Dimmer switch...

  • Page 145: Troubleshooting

    ELEC – LIGHTING SYSTEM TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. • Before troubleshooting, remove the following part(s): 1. Passenger and rider seat 2. Left side cover and right side cover 3.

  • Page 146: Signaling System

    ELEC – SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM 6-16...
  • Page 147 ELEC – SIGNALING SYSTEM 1. Neutral switch 13.Battery positive lead 14.Battery 15.Battery negative lead 16.Engine ground 17.Main switch 18.Fuse 23.Right handlebar switch 26.Front brake light switch 35.ECU(Engine control unit) 43.Rear brake light switch 44.Joint connection 1 45.Joint connection 2 46.Meter assembly 48.Multi function display 49.Neutral indicator light 52.Turn signal indicator light...

  • Page 148: Troubleshooting

    ELEC – SIGNALING SYSTEM TROUBLESHOOTING • Any of the following fail to light: turn signal lights, brake light or indicator lights. • The horn fails to sound. • The fuel gauge fails to operate. • Before troubleshooting, remove the following part(s): 1.
  • Page 149 ELEC – SIGNALING SYSTEM NG 3. Check the entire signaling system Properly connect or repair the signaling wiring. system wiring. OK This circuit is OK. The brake/tail light fails to come on. 1. Check the brake/tail light bulb and NG socket.
  • Page 150 ELEC – SIGNALING SYSTEM 3. Check the turn signal relay. NG Refer to “CHECKING THE TURN SIGNAL RELAY” in base service Replace the turn signal relay. manual B97-F8197-E0 on page 7-65. OK NG 4. Check the entire signaling system Properly connect or repair the signaling wiring.
  • Page 151 ELEC – SIGNALING SYSTEM The speedometer fails to operate. 1. Check the speed sensor. NG Refer to “CHECKING THE FUEL Replace the speed sensor. SENDER” in base service manual B97-F8197-E0 on page 7-70. OK NG 2. Check the entire signaling system Properly connect or repair the signaling wiring.

  • Page 152: Fuel Injection System

    ELEC – FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM 6-22...
  • Page 153 34.FID (Fast idle device) 35.ECU(Engine control unit) 36.Ignition coil 37.Spark plug 38.Air induction system solenoid 39.Fuel injection 40.O sensor 41.Yamaha diagnostic tool coupler 42.Sidestand switch 44.Joint connection 1 45.Joint connection 2 46.Meter assembly 47.Engine trouble warning light 48.Multi function display 55.Fuel pump...

  • Page 154: Ecu Self-Diagnostic Function

    ELEC – 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 155: Troubleshooting Method

    ELEC – FUEL INJECTION SYSTEM EAS30506 TROUBLESHOOTING METHOD • If any of the following have been performed, reset the A/F control learning data (code No. D87). - Replace the ECU. - Replace or clean the throttle body. - Replace the TPS. •...

  • Page 156: Yamaha Diagnostic Tool

    If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the engine. 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 INS-018 90890-03267...
  • Page 157 ELEC – FUEL INJECTION SYSTEM Operation of the Yamaha diagnostic tool (Fault diagnosis mode) Malfunction results are displayed in the top part of the window area. YAMAHA DIAGNOSTIC TOOL Trouble List Trouble Information FFD data FFD graph Select function ME1RG591BJ0000130 MTN155 : 12 Km Deendayal...

  • Page 158: Troubleshooting Details (Fault Code)

    Yamaha diagnostic tool according to the reinstatement method. Fault code No.: Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally. Diagnostic code No.: Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS- TIC FUNCTION AND DIAGNOSTIC CODE TABLE”...

  • Page 159: Troubleshooting Details

    This model is equipped with OBD1 (On Board Diagnostic), due to OBD1 system adoption, en- gine trouble warning light will glow continuously even the fault has been rectified. To off engine trouble warning light, use YDT (Yamaha diagnostic tool) to erase all fault codes. For erase the fault codes follow below steps.

  • Page 160: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31118 SELF-DIAGNOSTIC FUNCTION TABLE For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page x-xx Operation System example for Abnormal Start Probable Vehicle Item Travel Direct cause...
  • Page 161 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Operation System example for Abnormal Start Probable Vehicle Item Travel Direct cause operation on causing code engine malfunction symptoms failure abnormal state - Sensor module Faulty throttle High idling Intake air Remove the disconnected body (clogged or Instable idling...
  • Page 162 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Operation System example for Abnormal Start Probable Vehicle Item Travel Direct cause operation on causing code engine malfunction symptoms failure abnormal state - Coupler malfunc- No normal sig- Startability Intake air (P0112) tion between nals are received deterioration.
  • Page 163 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Operation System example for Abnormal Start Probable Vehicle Item Travel Direct cause operation on causing code engine malfunction symptoms failure abnormal state - Defective cou- No normal sig- Insufficient Engine run- While engine ning ...
  • Page 164 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Operation System example for Abnormal Start Probable Vehicle Item Travel Direct cause operation on causing code engine malfunction symptoms failure abnormal state - Battery over- The regulator Startability O2FB learn- Unable to de- charging does not work deterioration.
  • Page 165 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Operation System example for Abnormal Start Probable Vehicle Item Travel Direct cause operation on causing code engine malfunction symptoms failure abnormal state - Incorrect installa- No normal sig- Exhaust gas feedback Disconnect tion of the sen- nals are received deterioration.

  • Page 166: Communication Error With The Yamaha Diagnostic Tool

    3 above twice in suc- cession, turn ON the main switch again. EAS31259 COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 6-25. LCD Display Symptom Probable cause of malfunction Er-1...

  • Page 167: Diagnostic Code: Sensor Operation Table

    Check if the ignition coil every second. is energized. According to whether it is ON/OFF, the Ignition coil Operation - Check the occurrence “CHECK” indicator and the “ ” indicator of spark. on the Yamaha diagnostic tool screen will come on. 6-37...
  • Page 168 “CHECK” indicator and the “ ” indicator injector or visually con- on the Yamaha diagnostic tool screen will firming the operation. come on. The AI solenoid turns ON/OFF five times Determine whether the every second.
  • Page 169 Crank the engine and check the sensor coupler. connect or replace the harness. condition of the fault code in the Check the locking condition of diagnostic mode of the Yamaha the coupler. diagnostic tool. Condition is Recovered  Go to Disconnect the coupler and check the pins (bent or broken item 7 and finish the service.
  • Page 170 Crank the engine and check the 1. Connect the multimeter ( × condition of the fault code in the 100) to the crankshaft position diagnostic mode of the Yamaha sensor coupler. diagnostic tool. Condition is Recovered  Go to Tester plus lead, red “1”...
  • Page 171 Check the locking condition of the fault code in diagnostic the coupler. mode of the Yamaha diagnostic tool. Disconnect the coupler and Condition is Recovered  Go to check the pins (bent or broken item 6 and finish the service.
  • Page 172 No. D03). and then check the condition of When engine is stopped: Atmo- the fault code in diagnostic spheric pressure at the current mode of the Yamaha diagnostic tool. altitude and weather conditions Condition is Recovered  Go to is indicated.
  • Page 173 After the above work is finished, check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool. Condition is Recovered  Go to item 3 and finish the service. Condition is Detected  Go to item 2.
  • Page 174 Check the locking condition of the fault code in diagnostic the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. Condition is Recovered  Go to check the pins (bent or broken terminals and locking condition item 7 and finish the service.
  • Page 175 No. D01). and then check the condition of Throttle fully closed: 13-21 are the fault code in diagnostic indicated. mode of the Yamaha diagnostic Throttle fully open: 92-102 are tool. Condition is Recovered  Go to indicated. An indicated value is out of the item 7 and finish the service.
  • Page 176 Between ECU and the intake air the fault code in diagnostic temperature sensor. mode of the Yamaha diagnostic In the case of P0113, check the tool. Condition is Recovered  Go to following: Between the intake air tempera- item 7 and finish the service.
  • Page 177 After the above work is finished, check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool. Condition is Recovered  Go to item 8 and finish the service. Condition is Detected  Go to item 2.
  • Page 178 6-4. After the above work is finished, check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool. Condition is Recovered  Go to item 8 and finish the service. Condition is Detected  Go to item 6.
  • Page 179 Check if the mounting position Yamaha diagnostic tool. Condition is Recovered  Go to is OK. item 5 and finish the service. Condition is Detected  Go to item 3.
  • Page 180 (bent or broken code in diagnostic mode of the terminals and locking condition Yamaha diagnostic tool. Condition is Recovered  Go to of the pins). item 7 and finish the service.
  • Page 181 Fault code delete operation fault code. After starting the engine, let it idle and leave it for about 5 seconds. After the above operation, delete the fault code with the status “Recovered” in the diagnostic mode of the Yamaha diagnostic tool. 6-51...
  • Page 182 Disconnect the coupler and code in diagnostic mode of the check the pins (bent or broken Yamaha diagnostic tool. Condition is Recovered  Go to terminals and locking condition item 6 and finish the service.
  • Page 183 Yamaha diagnostic tool. Condition is Recovered  Go to item 8 and finish the service. Condition is Detected  Go to item 2.
  • Page 184 Between ABS unit - ECU After the above work is finished, check the condition of the fault code in diagnostic mode of the Yamaha diagnostic tool. Condition is Recovered  Go to item 8 and finish the service. Condition is Detected  Go to item 5.
  • Page 185 And then check the condition of Disconnect the coupler and the fault code in diagnostic check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is Recovered  Go to of the pins).
  • Page 186 5 and finish the service. For details, refer to the instruc- Condition is Detected  Return tion manual for the Yamaha di- to item 1 and check again. agnostic tool. If there is no change in the situ-...
  • Page 187 Check the locking condition of the fault code in diagnostic mode the coupler. of the Yamaha diagnostic tool. Condition is Recovered  Go to Disconnect the coupler and check the pins (bent or broken item 6 and finish the service.
  • Page 188 Check the locking condition of mode of the Yamaha diagnostic the coupler. tool. Disconnect the coupler and Condition is Recovered  Go to check the pins (bent or broken item 6 and finish the service.
  • Page 189 Turn the main switch to “ON”, and then check the condition of place the O sensor. the fault code in diagnostic mode of the Yamaha diagnostic tool. Condition is Recovered  Go to item 6 and finish the service. Condition is Detected  Start...
  • Page 190 ECU coupler connect or replace the harness. and then check the condition of Check the locking condition of the fault code in diagnostic mode of the Yamaha diagnostic the coupler. tool. Disconnect the coupler and Condition is Recovered  Go to...
  • Page 191 Check the locking condition of the fault code in diagnostic mode the coupler. of the Yamaha diagnostic tool. Condition is Recovered  Go to Disconnect the coupler and check the pins (bent or broken item 7 and finish the service.
  • Page 192 (bent or broken code in diagnostic mode of the terminals and locking condition Yamaha diagnostic tool. Condition is Recovered  Go to of the pins). item 6 and finish the service.
  • Page 193 Disconnect the coupler and of the Yamaha diagnostic tool. Condition is Recovered  Go to check the pins (bent or broken terminals and locking condition item 6 and finish the service.
  • Page 194 OFF twice, then not come off. check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is Recovered  Go to item 7 and finish the service. Condition is Detected  Go to item 4.
  • Page 195 Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. of the pins). Condition is Recovered  Go to item 7 and finish the service.

  • Page 196: Event Code Table

    ELEC – EVENT CODE TABLE EAS20164 EVENT CODE TABLE Fuel injection system Item Symptom Possible cause Annotation Intake air pressure Instantaneous Same as fault code No. Perform the inspection sensor 1 abnormality of the P0107/P0108 points listed for fault intake air pressure code P0107/P0108 in sensor 1 detected.
  • Page 197 ELEC – EVENT CODE TABLE Item Symptom Possible cause Annotation Crank position sensor Instantaneous Same as fault code No. Perform the inspection abnormality of the P0335 points listed for fault crank position sensor code P0335 in the detected. service manual. The correction value is - If a fault code is sensor...

  • Page 198: Fuel Pump System

    ELEC – FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM 6-68...
  • Page 199 ELEC – FUEL PUMP SYSTEM 13.Battery positive lead 14.Battery 15.Battery negative lead 16.Engine ground 17.Main switch 18.Fuse 23.Right handlebar switch 25.Engine stop switch 35.ECU(Engine control unit) 44.Joint connection 1 55.Fuel pump 6-69...

  • Page 200: Troubleshooting

    ELEC – FUEL PUMP SYSTEM TROUBLESHOOTING The fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Passenger and rider seat 2. Left side cover and right side cover 3. Headlight assembly NG 1. Check the fuse. Refer to “CHECKING THE FUSES”...

  • Page 201: Abs (Anti-Lock Brake System)

    ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 6-71...
  • Page 202 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) 5. Fuse box 1 8. ABS control unit fuse 9. Fuse box 2 11.ABS motor fuse 12.ABS solenoid fuse 13.Battery positive lead 14.Battery 15.Battery negative lead 16.Engine ground 17.Main switch 18.Fuse 23.Right handlebar switch 26.Front brake light switch 35.ECU(Engine control unit) 43.Rear brake light switch...

  • Page 203: Abs Coupler Location Chart

    ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. ABS test coupler 4. ABS ECU coupler 5. Front wheel sensor coupler 6-73...

  • Page 204: 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 6-78. For troubleshooting items other than the following items, follow the normal service method.

  • Page 205: 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 206: Basic Process For Troubleshooting

    • The hydraulic unit assembly is with the ABS ECU? defective. 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 207: [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 208: [A-4] Only The Abs Ecu Fails To Communicate (The Select Unit Screen Does Not Appear.)

    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 209 Removing the passenger seat. Refer to “GENERAL CHASSIS (1)” in base service manual B97-F8197- E0 on page 4-1. Removing the protective cap “1”, and then connect the Yamaha diagnostic tool “2” to the ABS Coupler “3”. Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle.
  • Page 210 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) 1. Detected The malfunction currently occurred are displayed. 2. Recovered The malfunction detected in the past (already recovered) are displayed. 3. Diagnosis code the diagnosis codes related to the detected malfunction are displayed. A. Detected malfunction B.
  • Page 211 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code table Record all of the fault codes displayed and inspect the check points. Fault code No. Item Symptom Check point Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered tent pulses or no pulses) not received properly.
  • Page 212 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Front wheel sensor (open or Open or short circuit is de- • Defective coupler between short circuit) tected in the front wheel sen- the front wheel sensor and sor.
  • Page 213 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Brake light switch or Brake light signal is not re- • Defective signaling system tail/brake light ceived properly while the ve- (tail/brake light or brake hicle is traveling. (Brake light light switch) circuit, or front or rear brake •...
  • Page 214 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault code No.
  • Page 215 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Symptom Check point Hydraulic unit assembly (de- Abnormality is detected in • Defective battery fective ABS solenoid and the solenoid or motor power • Defective coupler between ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau- cuits)
  • Page 216 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 11, 25 With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code No. 11) or for longer than about 2 seconds (fault code No. 25). Fault code No.
  • Page 217 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 13, 26 • If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record- ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re- corded.
  • Page 218 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (abnormal pulse period) Rear wheel sensor signal is not received properly. (The pulse period Symptom is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Incorrect installation of the rear wheel Check the components for looseness, distortion, and...
  • Page 219 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Order Item/components and probable cause Check or maintenance job • Check for continuity between the green terminal “1” Open or short circuit in the wire harness between the front wheel sensor and the and the green terminal “4”...
  • Page 220 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 16 Turn the main switch to “OFF” before disconnecting or connecting a coupler. Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Order Item/components and probable cause Check or maintenance job Defective coupler between the rear wheel...
  • Page 221 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 17, 45 If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code No.
  • Page 222 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing pulses are Symptom detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
  • Page 223 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Brake light switch or tail/brake light Brake light signal is not received properly while the vehicle is travel- Symptom ing (Brake light circuit, or front or rear brake light switch circuit). Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly...
  • Page 224 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 33 Turn the main switch to “OFF” before disconnecting or connecting a coupler. Fault code No. Item Hydraulic unit assembly (abnormal ABS motor power supply) Power is not supplied to the motor circuit in the hydraulic unit assem- Symptom bly.
  • Page 225 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 41 Fault code No. Front wheel ABS (intermittent wheel speed pulses or incorrect de- Item pressurization) • Pulses from the front wheel sensor are received intermittently while the vehicle is traveling. Symptom •...
  • Page 226 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Rear wheel ABS (intermittent wheel speed pulses or incorrect depres- Item surization) • Pulses from the rear wheel sensor are received intermittently while the vehicle is traveling. (for fault code No. 42) Symptom •...
  • Page 227 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 44 Fault code No. Item Rear wheel sensor (missing pulses) Rear wheel sensor signal is not received properly. (Missing pulses are Symptom detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the rear...
  • Page 228 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 53 Turn the main switch to “OFF” before disconnecting or connecting a coupler. Fault code No. Vehicle system power supply (voltage of ABS ECU power supply is Item low) Power voltage supplied to the ABS ECU in the hydraulic unit assem- Symptom bly is too low.
  • Page 229 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS motor Item power supply circuits) Abnormality is detected in the solenoid or motor power supply circuit Symptom in the hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective charging system Check the charging system.
  • Page 230 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 63 Fault code No. Item Front wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the front wheel sensor is Symptom too low. Order Item/components and probable cause Check or maintenance job Short circuit in the wire harness between...
  • Page 231 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 64 Fault code No. Item Rear wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the rear wheel sensor is Symptom too low. Order Item/components and probable cause Check or maintenance job Short circuit in the wire harness between...

  • Page 232: [B-3] Deleting The Fault Codes

    NS-018 90890-03267 INS-019 90890-03264 Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool “2” to the ABS Coupler “3”. EAS31168 [C-1] FINAL CHECK Check all the following items to complete the inspection.

  • Page 233: Electrical Components

    ELEC – ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. Main switch steering lock 9. Battery 2. Clutch switch 10.Rear brake light switch 3. Front brake light switch 11.AC magneto 4. Ignition coil 12.Crankshaft position sensor 5. Fuel sender 13.Starter motor 6. Fuel pump 14.Throttle body sensor assembly 7.
  • Page 234 ELEC – ELECTRICAL COMPONENTS 16. Starter relay 23.Neutral switch 17. Rectifier/regulator 24.Engine temperature sensor 18.ECU (Engine Control Unit) 25.Horn 19. Turn signal relay 26.Front wheel sensor 20.Rear wheel sensor 27.O sensor 21. Hydraulic unit assembly 28.Lean angle sensor 22.Sidestand switch 6-104...

  • Page 235: Checking The Switches

    ELEC – ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Check each switch for continuity with the multimeter. If the continuity reading is incorrect, check the wir- ing connections and if necessary, replace the switch. Br/W Br/W Dg B/W 1. Main switch 11.Turn signal light switch 2.

  • Page 236: Checking The Fuses

    ELEC – ELECTRICAL COMPONENTS EAS30551 EWA13310 CHECKING THE FUSES WARNING The following procedure applies to all of the fus- Never use a fuse with an amperage rating other than that specified. Improvising or us- ECA20520 ing a fuse with the wrong amperage rating NOTICE may cause extensive damage to the electri- To avoid a short circuit, always turn the main...

  • Page 237: Troubleshooting

    TRBL SHTG CHAPTER 7 TROUBLESHOOTING TROUBLESHOOTING..................7-1 GENERAL INFORMATION ............... 7-1 STARTING FAILURES................7-1 INCORRECT ENGINE IDLING SPEED ............ 7-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......7-2 FAULTY GEAR SHIFTING ................ 7-2 SHIFT PEDAL DOES NOT MOVE ............7-2 JUMPS OUT OF GEAR................7-2 FAULTY CLUTCH ..................
  • Page 238 TRBL SHTG...

  • Page 239: Troubleshooting

    TRBL TROUBLESHOOTING SHTG Electrical system TROUBLESHOOTING EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 GENERAL INFORMATION • Faulty battery 2. Fuse(s) The following guide for troubleshooting does not • Blown, damaged or incorrect fuse cover all the possible causes of trouble. It should •...

  • Page 240: Poor Medium-And-High-Speed Performance

    TRBL TROUBLESHOOTING SHTG Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery Shift shaft • Discharged battery • Faulty battery • Incorrect shift pedal position 2. Spark plug • Improperly returned stopper lever • Incorrect spark plug gap Shift forks •...

  • Page 241: Poor Braking Performance

    TRBL TROUBLESHOOTING SHTG Engine oil EAS28650 FAULTY FRONT FORK LEGS • Incorrect engine oil level • Improper engine oil quality Leaking oil • Low engine oil quality • Bent, damaged or rusty inner tube Cooling system • Cracked or damaged outer tube •...

  • Page 242: Faulty Lighting Or Signaling System

    TRBL TROUBLESHOOTING SHTG Wheel(s) Turn signal remains lit • Incorrect wheel balance • Faulty turn signal relay • Deformed cast wheel • Burnt-out turn signal bulb • Damaged wheel bearing Turn signal blinks quickly • Bent or loose wheel axle •...
  • Page 243 TRBL TROUBLESHOOTING SHTG...
  • Page 244 34.FID (Fast idle device) 79.Joint 4 35.ECU (Engine control unit) 80.ABS test coupler 36.Ignition coil 37.Spark plug 38.Air induction system sole- noid 39.Fuel injection 40.O sensor 41.Yamaha diagnostic tool coupler 42.Sidestand switch 43.Rear brake light switch 44.Joint connection 1 45.Joint connection 2...
  • Page 246 FZN250-A 2020 (B9X1) FZN250D-A 2020 (B0Y1) WIRING DIAGRAM...
  • Page 247 B9X-F8197-E0 87 7...

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