Yamaha R15 2022 Service Manual

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2022

SERVICE MANUAL

YZF155D-A

YZF155-A

BCW-F8197-E0

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Troubleshooting

Summary of Contents for Yamaha R15 2022

Page 1 2022 SERVICE MANUAL YZF155D-A YZF155-A BCW-F8197-E0...
Page 2 EAS200071 IMPORTANT This manual was produced by the India Yamaha Motor Pvt. Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. 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 3 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 4 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Molybdenum disulfide oil Filling fluid Brake fluid Lubricant Wheel bearing grease Special tool Lithium-soap-based grease Tightening torque...
Page 5: Table Of Contents
EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 7: General Information
GENERAL INFORMATION IDENTIFICATION ...................1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 ENGINE SERIAL NUMBER ..............1-1 FEATURES .....................1-2 OUTLINE OF THE TCS (Traction Control System) ........1-2 OUTLINE OF THE FI SYSTEM ..............1-6 FEATURES ....................1-7 OUTLINE OF THE ABS ................1-8 ABS COMPONENT FUNCTIONS ............1-12 ABS OPERATION ..................
Page 8: Identification
INFO IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the steering head pipe. EAS30004 ENGINE SERIAL NUMBER The engine serial number “1” is stamped into the crankcase.
Page 9: Features
INFO FEATURES EAS20008 FEATURES EAS30855 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen- sors, and detects rear wheel slipping according to the difference between the wheel speeds.
Page 10 INFO FEATURES TCS (Traction control system) block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds.
Page 11 INFO FEATURES Traction control system The traction control system (TCS) helps maintain traction when accelerating on slippery surfaces, such as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning), the traction control system assists by regulating engine power as needed until traction is restored. EWA15433 WARNING The traction control system is not a substitute for riding appropriately for the conditions.
Page 12 INFO FEATURES Resetting the traction control system The traction control system will automatically disable when: • the front wheel or rear wheel comes off the ground while riding. • excessive rear wheel spin is detected while riding. • either wheel is rotated with the key turned to “ON” (such as when performing maintenance). •...
Page 13: Outline Of The Fi System
INFO FEATURES OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 14: Features
INFO FEATURES FEATURES The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 250 kPa (2.50 kg/cm², 36.3 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 15: Outline Of The Abs
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 16 INFO FEATURES 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 17 INFO FEATURES 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 18 Slip ratio b. Brake force 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 19: Abs Component Functions
INFO FEATURES 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 20 INFO FEATURES 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 21 INFO FEATURES 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 22 INFO FEATURES 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 23 INFO FEATURES 1. Battery 14. ABS ECU 2. AC magneto 15. ABS motor relay 3. Rectifier/regulator 16. Solenoid relay 4. Main fuse 17. Front brake outlet solenoid 5. ABS motor fuse 18. Front brake inlet solenoid 6. ABS solenoid fuse 19.
Page 24 INFO FEATURES • 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 25: Abs Operation
INFO FEATURES EAS30710 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only. Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is opened and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
Page 26 INFO FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line from the brake master cylinder.
Page 27 INFO FEATURES 2. Pressurizing phase The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the brake caliper.
Page 28: Abs Warning Light And Operation
INFO FEATURES EAS30712 ABS WARNING LIGHT AND OPERATION ABS warning light • If the ABS warning light comes on while riding, stop the vehicle, and then turn the main switch to “OFF”, then back to “ON”. The ABS operation is normal if the ABS warning light goes off after the ve- hicle starts off.
Page 29: Ccu (Communication Control Unit)
• Always concentrate on riding by keeping 1. CCU (Communication Control Unit) your eyes and mind on the road. 2. CCU QR Code 4. When pairing is complete, the Yamaha Mo- ECAN0150 torcycle Connect icon and smartphone bat- The Bluetooth connection may not work in tery level meter will come on.
Page 30: Handlebar Switches
INFO FEATURES EAU1234R EAU54213 HANDLEBAR SWITCHES Stop/Run/Start switch “ / / ” To crank the engine with the starter, set this Left switch to “ ”, and then push the switch down towards “ ”. Set this switch to “ ” to stop the engine in case of an emergency, such as when the vehicle overturns or when the throttle cable is stuck.
Page 31: Indicator Lights And Warning Lights
COOLANTAVGTCS COOLANTAVGTCS km/L/100km km/L/100km tem. If this occurs, have a Yamaha dealer check the on-board diagnostic system. ZAUE4464 1. Coolant temperature warning light “ ” When the vehicle is turned on, the light will come 2. Incoming call indicator light “...
Page 32: Display
MODE. Most of the functions are viewable in ei- light does not come on, or if the light remains on, ther mode, but the layout differs slightly. The fol- have a Yamaha dealer check the vehicle. lowing items can be found on the display: EAUN2781 STREET MODE Incoming call indicator light “...
Page 33 If all the fuel meter display segments flash re- Quick shifter icon (if equipped) This icon comes on when the quick shifter is ac- peatedly, have a Yamaha dealer check the relat- ed circuits. tive and able to shift. When the icon is not visi- ble, the quick shifter will not operate.
Page 34 • LAP, FASTEST, and LATEST are only avail- the vehicle is turned on, this icon should come able in TRACK mode on for a few seconds. Otherwise have a Yamaha • TRIP1, TRIP 2, TRIP F, FASTEST, LATEST, dealer check the CCU and the electrical circuit.
Page 35 INFO FEATURES Odometer: When the fuel tank reserve level has been reached, TRIP F appears automatically and be- gins recording distance traveled from that point. Press and hold (long push) the TRIP switch GEAR GEAR STREET STREET while TRIP F is displayed to reset the tripmeter after refueling.
Page 36 INFO FEATURES Average speed: Battery voltage: GEAR GEAR STREET STREET GEAR GEAR STREET STREET x1000r/min x1000r/min km/h km/h km/h BATT BATT ZAUE4520 ZAUE4522 1. Battery voltage display 1. Average speed display This display shows the current charge state of Shows the average speed travelled since last re- the battery.
Page 37 INFO FEATURES TRACK mode: Latest lap time: GEAR GEAR STREET STREET GEAR GEAR TRACK TRACK x1000r/min x1000r/min km/h km/h LATEST ZAUE4524 ZAUE4528 1. TRACK MODE 1. Latest lap time Allows switching to track mode from the main Shows the last lap time recorded. display screen.
Page 38: Menu Mode
INFO FEATURES EAUN3423 MODE MENU MODE km/h km/h ZAUE4530 ZAUE4529 1. MODE display 1. Menu mode display Cycle between the two main screen display The menu mode contains the following setting modes, STREET MODE and TRACK MODE. modules in order: The icon for the currently selected mode will Module Description...
Page 39 INFO FEATURES A 6 digit message appears on the bottom infor- mation display when the main switch is turned The shift indicator lights will come on/off and on. The default message is 000000. Customize flash as the settings are adjusted. the message one digit at time with this module.
Page 40 INFO FEATURES BRIGHTNESS ALL RESET This module resets everything, except the odometer and clock, to its factory preset or de- fault setting. Select YES to reset all items. Select NO to return to the main menu. km/h EXIT Use this to exit the menu mode and return to the main display.
Page 41: Important Information
5. Keep all parts away from any source of fire. EAS2000902 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 42: Bearings And Oil Seals
INFO IMPORTANT INFORMATION EAS20230 EAS1MC1085 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.
Page 43: Basic Service Information
INFO BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with Screw type a screwdriver, then pull the fastener out. 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver/Phillip screwdriver, then pull the fastener out.
Page 44: Electrical System
INFO BASIC SERVICE INFORMATION If a battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust us- ing hot water. EAS30402 ELECTRICAL SYSTEM ECA16760 Be sure to connect the battery leads to the Electrical parts handling correct battery terminals.
Page 45 INFO BASIC SERVICE INFORMATION ECA16610 When resetting the ECU by turning the main Turn the main switch to “OFF” before dis- switch to “OFF”, be sure to wait approximately connecting or connecting an electrical 5 seconds before turning the main switch back component.
Page 46 INFO BASIC SERVICE INFORMATION ECA16640 ECA16790 For waterproof couplers, never insert the When disconnecting a connector, do not tester probes directly into the coupler. pull the leads. Hold both sections of the When performing any checks using a connector securely, and then disconnect waterproof coupler, use the specified test the connector.
Page 47 INFO BASIC SERVICE INFORMATION • If there is no continuity, clean the terminals. • When checking the wire harness, perform steps (1) to (3). • As a quick remedy, use a contact revitalizer available at most part stores. 4. Connect: •...
Page 48 INFO BASIC SERVICE INFORMATION 1-41...
Page 49 INFO SPECIAL TOOLS EAS20012 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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 50 INFO SPECIAL TOOLS Tool name/Tool No. Illustration Torx bit (T-30) YSST-611 This tool is used to loosen or tighten the cam shifter segment screw. 13sq Main switch steering lock (T-30) YSST-611 A This tool is used to loosen or tighten the ignition lock. Scraper YSST-612 This tool is used to scrap the sealant from crankcase...
Page 51 INFO SPECIAL TOOLS Tool name/Tool No. Illustration Upper and lower race installer YSST-626 This tool is used to install upper and lower races. Magneto holder YSST-701 (90890-01701) (90890-01481) This tool is used to hold the magneto. Magneto puller YSST-702 (90890-04141) This tool is used to remove the magneto rotor with the help of magneto holder.
Page 52 INFO SPECIAL TOOLS Tool name/Tool No. Illustration Front fork damper rod locknut holder (Left & right leg) YSST-778 (90890-01953) This tool is used to hold the damper rod locknut/spe- cial nut when removing or installing the front fork cap bolt. Front fork dumper rod stopper tool (Right leg) YSST-779 (90890-01592)
Page 53 INFO SPECIAL TOOLS Tool name/Tool No. Illustration Scissor jack YSST-892A This tool is used to support the vehicle. While removeing the front wheel, put the scissor jack under the engine of the vehicle so that there is no danger of it falling over. Bush ODØ18 YSST-893...
Page 54 This tool is used to measure engine compression. Injector coupler INS-017 (90890-03210) This tool is used to connect injector to injector cleaner. Yamaha diagnostic tool (USB) INS-018 (90890-03267) This tool is used to diagnose electrical fault in ad- vance fuel injection system.
Page 55: Special Tools
Illustration Fuel injector plate INS-020 This tool is used to hold the fuel infector on injector cleaning machine. Yamaha bond No. 1215 90890-85505 (Three bond No.1215-B) This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces). 1-48...
Page 56 INFO SPECIAL TOOLS 1-49...
Page 57: Specifications
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 ............2-15 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE ....................
Page 58: General Specifications
SPEC GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model BCW1,BCW2,BCW4 Dimensions Overall length 1990 mm (78.3 in) Overall width 725 mm (28.5 in) Overall height 1135 mm (44.7 in) Wheelbase 1325 mm (52.2 in) Ground clearance 170 mm (6.69 in) Minimum turning radius 2.8 m (9.19 ft) Weight Curb weight...
Page 59: Maintenance Specification (Engine)
SPEC MAINTENANCE SPECIFICATION (ENGINE) MAINTENANCE SPECIFICATION (ENGINE) Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train SOHC Displacement 155 cm³ Number of cylinders Single cylinder Bore × stroke 58.0 × 58.7 mm (2.28 × 2.31 in) Compression ratio 11.6 : 1 Compression pressure 696–896 kPa/550 r/min (7.0–9.0 kgf/cm²/ 550 r/min, 99.0–127.4 psi/550 r/min)
Page 60 SPEC MAINTENANCE SPECIFICATION (ENGINE) Cylinder head Warpage limit 0.05 mm (0.0020 in) Camshaft Camshaft lobe dimensions Lobe height limit (Intake) 32.268 mm (1.2704 in) Lobe height limit (Intake high speed) 32.332 mm (1.2729 in) Lobe height limit (Exhaust) 29.516 mm (1.1620 in) Rocker arm/rocker arm shaft Rocker arm inside diameter limit 14.015 mm (0.5518 in)
Page 61 SPEC MAINTENANCE SPECIFICATION (ENGINE) Crankshaft Crank assembly width 47.95–48.00 mm (1.888–1.890 in) Runout limit 0.050 mm (0.0020 in) Clutch Clutch type Wet, multiple-disc Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Assembly width 13.0–14.0 mm (0.51–0.55 in) Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) Plate quantity 1 pcs...
Page 62 SPEC MAINTENANCE SPECIFICATION (ENGINE) Idling condition Engine idling speed 1300–1500 r/min feedback control Active Coolant temperature 80–100 °C (176–212 °F) 0.0–1.3 % Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi) Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
Page 63: Maintenance Specification (Chassis)
SPEC MAINTENANCE SPECIFICATION (CHASSIS) MAINTENANCE SPECIFICATION (CHASSIS) Chassis Caster angle 25.5 ° Trail 88 mm (3.5 in) Front wheel Wheel type Cast wheel 17M/C × MT2.5 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 64 Fork spring free length limit 283.2 mm (11.15 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil 01 Quantity (left) 300.0 cm³ (10.14 US oz, 10.58 Imp.oz) Quantity (right) 363.0 cm³ (12.27 US oz, 12.80 Imp.oz) Level (left) 100 mm (3.9 in)
Page 65: Maintenance Specification (Electrical)
SPEC MAINTENANCE SPECIFICATION (ELECTRICAL) MAINTENANCE SPECIFICATION (ELECTRICAL) Voltage System voltage 12 V Ignition system Ignition timing (B.T.D.C.) 0.0–4.0 °/1400 r/min High altitude ignition timing (B.T.D.C.) 9.2 °/1400 r/min Engine control unit Model BCW0 (YZF155D-A) BCW1 (YZF155-A) Ignition coil 2.34–2.86 Ω Primary coil resistance Secondary coil resistance 9.45–11.55 kΩ...
Page 66 SPEC MAINTENANCE SPECIFICATION (ELECTRICAL) Indicator light Neutral indicator light High beam indicator light Turn signal indicator light Coolant temperature warning light Engine trouble warning light ABS warning light Shift timing indicator light Traction control system indicator light Incoming notification indicator light Incoming call indicator light Starter motor Brush overall length limit...
Page 67: Tightening Torques
SPEC TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30002 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 68: Engine Tightening Torques
8 N·m (0.8 kgf·m, 5.9 lb·ft) Camshaft retainer bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Timing chain guide (intake side) bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Apply Yamaha bond Timing chain tensioner bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) No.1215-B, 1215 to screw thread Radiator bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Page 69 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust assembly bolt 20 N·m (2.0 kgf·m, 15 lb·ft) Exhaust protector bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Exhaust end cap bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) 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)
Page 70 SPEC TIGHTENING TORQUES Cylinder head bolt Tighten the cylinder head bolts “1”–“6” in the proper tightening sequence as follows: 1. Lubricate the cylinder head bolts “1”–“4” threads and mating surface with molybdenum disulfide grease. 2. Tighten the cylinder head bolts “1”–“4” to 12 N·m (1.2 kgf·m, 8.9 lb·ft). 3.
Page 71 SPEC TIGHTENING TORQUES ×2 ×4 Magneto cover tightening sequence: Clutch cover tightening sequence: 3,13 2,12 Crankcase tightening sequence: 2,13 3,14 A. Left crankcase B. Right crankcase 2-14...
Page 72: Chassis Tightening Torques
SPEC TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Handle crown pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) Lower bracket pinch bolt 30 N·m (3.0 kgf·m, 22 lb·ft) Lower ring nut (initial tightening) 48 N·m (4.8 kgf·m, 35 lb·ft) See TIP.
Page 73 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Horn 2 bracket bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Front brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Front brake hose union bolt (caliper) 29 N·m (2.9 kgf·m, 21 lb·ft) Rear wheel axle nut 59 N·m (5.9 kgf·m, 44 lb·ft) Drive chain adjusting nut locknut...
Page 74 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear side cowling and rear panel bolt 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) (M5) Seat bracket cover screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Rear panel screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Battery box bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) Rear fender cowling screw...
Page 75 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Side stand switch bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Rear footrest bracket bolt 28 N·m (2.8 kgf·m, 21 lb·ft) Rider footrest bracket bolt 34 N·m (3.4 kgf·m, 25 lb·ft) Rider footrest bolt 56 N·m (5.6 kgf·m, 41 lb·ft) Brake pedal Bolt...
Page 76 SPEC TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake master cylinder bolt 23 N·m (2.3 kgf·m, 17 lb·ft) Rear brake master cylinder rod locknut 17 N·m (1.7 kgf·m, 13 lb·ft) Brake fluid reservoir bolt 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) Rear wheel sprocket nut 43 N·m (4.3 kgf·m, 32 lb·ft) Rear brake disc bolt...
Page 77: Lubrication Points And Lubricant Types
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS20299 LUBRICATION POINTS AND LUBRICANT TYPES EAS1MC1085 ENGINE Lubrication point Lubricant Oil seal lips Bearings O-rings Cylinder head bolt seats, cylinder head bolt threads and washers Water pump seal and impeller shaft Connecting rod big end Crankshaft bearing inner surface Piston pin Cylinder inner surface, piston, ring grooves, and piston rings...
Page 78 Clutch boss nut seat and clutch boss nut thread Main axle and pinion gears Drive axle and wheel gears Shift drum assembly Shift forks and shift fork guide bar Shift shaft Yamaha bond No. 1215 Crankshaft position sensor/stator assembly lead grommet (Three bond No.1215-B) Yamaha bond No.
Page 79: Chassis
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS1MC1085 CHASSIS Lubrication point Lubricant Front wheel axle nut thread Front wheel oil seal lip Front wheel axle nut seat Rear wheel axle and nut thread Rear wheel axle nut seat Rear wheel drive hub oil seal lip Rear wheel drive hub mating surface Rear wheel oil seal lip Brake lever pivot bolt outer surface...
Page 80 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering head dust seal lip Bolt outer surface (relay arm) Nut seats (relay arm and swingarm) Bolt and nut thread (relay arm and flame) Bolt and nut thread (relay arm and connecting arm) Bolt and nut thread (relay arm and rear shock absorber) Bolt and nut thread (swingarm and connecting arm) Oil seal lips (relay arm and swingarm)
Page 81: Lubrication System Chart And Diagrams
SPEC LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20021 LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil filter element 5. Main axle 6. Drive axle 7. Crankshaft 8. Camshaft 9. Cylinder head cover 2-24...
Page 82 SPEC LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32363 LUBRICATION DIAGRAMS 1. Cylinder head cover 2. Camshaft 3. Crankshaft 4. Oil filter assembly 5. Oil pump assembly 6. Oil strainer 7. Main axle 8. Drive axle 9. Clutch push lever 2-25...
Page 83 SPEC LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 2. Main axle 3. Cylinder head cover 4. Camshaft 5. Crankshaft 6. Oil filter 7. Oil pump 8. Oil strainer 2-26...
Page 84: Cooling System Diagrams
SPEC COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS È Insert the pipe to root. 1 Thermostat assembly É White paint of hose (thermostat to water pump) face 2 Coolant reservoir hose 3 Radiator inlet hose should be right side of the vehicle. Ê...
Page 85 SPEC COOLING SYSTEM DIAGRAMS 1 Air bleed bolt 2 Water pump assembly 3 Water pump inlet hose 2-28...
Page 86 SPEC COOLING SYSTEM DIAGRAMS È Insert the pipe to root. 1 Coolant reservoir hose É Fix the clip before 2-4 mm from water pump inlet hose 2 Radiator inlet hose 3 O-ring end as shown. Ê Direction of the clip up-side of the vehicle. 4 Clip Ë...
Page 87 SPEC COOLING SYSTEM DIAGRAMS È Direction up-side of the vehicle. 1 Hose clamp É Direction right-side of the vehicle. 2 Thermostat assembly Ê Ensure clearance is more than 10 mm. Ë Push in dropped clamp after tightening. Ì Shall not be on spool. Í...
Page 88: Cable Routing
SPEC CABLE ROUTING EAS20021 CABLE ROUTING Front top view 2-31...
Page 89 SPEC CABLE ROUTING A. Fuel pump assembly lead and fuel sender lead 1. Headlight assembly lead shall pass above ABS hydraulic unit. 2. Meter assembly lead B. ABS hydraulic unit lead shall be touched with wire 3. Auxiliary light assembly lead (Right) main harness assembly.
Page 90 SPEC CABLE ROUTING Rear top view 2-33...
Page 91 SPEC CABLE ROUTING 1. Starter relay A. Lead wires shall be clamped by hook of right side fender. (In any random order) 2. Rear brake light switch lead B. Wire harness assembly shall be clamped to right 3. Positive battery lead side of fender at the claw.
Page 92 SPEC CABLE ROUTING Front left view 2-35...
Page 93 SPEC CABLE ROUTING 1. Clutch cable A. Joint connector shall be placed so that rubber opening face downward as shown in drawing. 2. Left side tank rail B. Clamp shall be touched with left side tank rail. 3. Horn lead C.
Page 94 SPEC CABLE ROUTING Rear left view 2-37...
Page 95 SPEC CABLE ROUTING 1. AC magneto connector cover A. Route rear turn signal light lead and license plate light lead as shown. 2. Air filter assembly B. AC magneto lead and neural switch lead and 3. CCU (Communication control unit) negative battery lead shall clamped to the frame 4.
Page 96 SPEC CABLE ROUTING Rear right view 2-39...
Page 97 SPEC CABLE ROUTING 1. Fuse box A. Clamp shall be touched with welding bead of fuel tank fitting bracket. 2. Positive battery lead B. Route the rear brake light switch lead through wire 3. Starter relay guide. 4. Fuel tank fitting bracket C.
Page 98 SPEC CABLE ROUTING Front right view 2-41...
Page 99 SPEC CABLE ROUTING 1. Fuel tank assembly A. Insert spark plug lead of ignition coil into spark plug cap. 2. Fuel tank breather hose B. Clamped coolant temperature sensor lead to frame 3. Throttle cable (Pull) component on white tape. 4.
Page 100 SPEC CABLE ROUTING Steering system 2-43...
Page 101 SPEC CABLE ROUTING 1. Rubber cover A. Right handlebar switches (blue & black connector) & main switch (white connector) shall be connect 2. Right handlebar switch lead under rubber cover not into rubber cover. 3. Main switch lead B. Main switch lead routing shall be parallel with right 4.
Page 102 SPEC CABLE ROUTING Front brake system 2-45...
Page 103 SPEC CABLE ROUTING 1. Frame component 2. Front fork assembly 3. Front wheel sensor assembly lead 4. Front fender 5. Front brake hose 6. Front brake hose (ABS hydraulic unit to front brake caliper) 7. Front brake hose clamp A. Front wheel sensor lead shall be passed to fit to front brake hose assembly profile.
Page 104 SPEC CABLE ROUTING Canister Assembly 1. Fuel tank assembly A. Insert the pipe until the step of hose (Fuel tank to canister assembly). 2. Hose (Fuel tank to canister assembly) B. Clip knob shall be directed backward of the vehicle. 3.
Page 105 SPEC CABLE ROUTING Canister Assembly 1. Hose (Fuel tank to canister assembly) A. Insert the hose till this end. 2. Throttle body 3. Hose (canister to atmosphere) 4. Canister assembly 5. Frame component 6. Clip 2-48...
Page 106 SPEC CABLE ROUTING Canister Assembly 1. Frame component A. Insert the hose (Fuel tank to canister) and hose (canister to check valve) until this surface. 2. Hose (Fuel tank to canister) B. White mark shall be directed upward. 3. Check valve C.
Page 107 SPEC CABLE ROUTING ABS System 1. ABS hydraulic unit 2. ABS hydraulic unit bracket 3. Front brake hose (ABS hydraulic unit to master cylinder) 4. Front brake hose (ABS hydraulic unit to brake caliper) 5. Rear brake hose (ABS hydraulic unit to brake master cylinder) 6.
Page 108 SPEC CABLE ROUTING ABS System 1. ABS hydraulic unit bracket A. To rear brake master cylinder. B. To rear brake caliper. 2. ABS hydraulic unit 3. Rear brake hose (ABS hydraulic unit to brake caliper) 4. Rear brake hose (ABS hydraulic unit to brake master cylinder) 2-51...
Page 109 SPEC CABLE ROUTING ABS System 2-52...
Page 110 SPEC CABLE ROUTING 1. Clamp 2. Rear brake hose holder 3. Rear brake hose (ABS hydraulic unit to brake caliper) 4. Rear brake hose (ABS hydraulic unit to master cylinder) 5. Front brake hose (ABS hydraulic unit to master cylinder) 6.
Page 111: Periodic Checks And Adjustments
EMISSION CONTROL SYSTEM .............3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 ENGINE ......................3-4 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ...............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 ADJUSTING THE ENGINE IDLING SPEED ..........3-6 CHECKING THE THROTTLE GRIP ............3-7 ADJUSTING THE THROTTLE GRIP FREE PLAY ........3-7 CHECKING THE SPARK PLUG ..............3-8...
Page 112 LUBRICATING THE STEERING HEAD ..........3-26 CHECKING THE CHASSIS FASTENERS ..........3-26 LUBRICATING THE CLUTCH LEVER ........... 3-26 LUBRICATING THE BRAKE LEVER ............. 3-26 LUBRICATING THE PEDALS ..............3-27 CHECKING THE SIDESTAND ............... 3-27 LUBRICATING THE SIDESTAND ............3-27 LUBRICATING SHIFT PEDAL ROD JOINT ........... 3-27 LUBRICATING THE REAR SUSPENSION ..........
Page 113: Periodic Maintenance
EAUE0173 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. EAUE0222...
Page 114 PERIODIC MAINTENANCE ODOMETER READING ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 9000 km 13000 km 17000 km 21000 km (600 mi) (3000 mi) (5400 mi) (7800 mi) (10200 mi) (12600 mi) • Check for cracks or damage. √ √...
Page 115 PERIODIC MAINTENANCE ODOMETER READING ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 9000 km 13000 km 17000 km 21000 km (600 mi) (3000 mi) (5400 mi) (7800 mi) (10200 mi) (12600 mi) • Check coolant level and vehicle √ √...
Page 116: Engine
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL • Valve clearance adjustment should be made Use the Yamaha diagnostic tool and check the on a cold engine, at room temperature. vehicle according to the following procedure. • When the valve clearance is to be measured or 1.
Page 117 ENGINE Valve clearance (cold) Intake 0.10–0.14 mm (0.0039–0.0055 in) Exhaust 0.21–0.25 mm (0.0083–0.0098 in) a. Turn the crankshaft counterclockwise. b. Align the TDC mark “a” on the magneto ro- tor with the stationary pointer “b” on the magneto cover. c. When the piston is at TDC on the com- pression stroke, align the “I”...
Page 118: Adjusting The Engine Idling Speed
• Rider seat Refer to “GENERAL CHASSIS (1)” on page WARNING 4-1. Never adjust RPM by screw at pulley “1”. 3. Connect: • Yamaha diagnostic tool Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-32. Yamaha diagnostic tool INS-018 (90890-03267) INS-019 (90890-03264) 4.
Page 119: Checking The Throttle Grip
7. Set the main switch to “OFF”. G088895 8. Disconnect: • Yamaha diagnostic tool 9. Connect: • Yamaha diagnostic tool coupler/ABS test coupler to SCCU. 10.Install: • Lower side cowling (left) • Passenger and rider seat Refer to “GENERAL CHASSIS (3)” on page 4-3.
Page 120: Checking The Spark Plug
ENGINE EAS30620 CHECKING THE SPARK PLUG Spark plug 1. Remove: 13 N·m (1.3 kgf·m, 9.6 lb·ft) • Lower side cowling (right) Refer to “GENERAL CHASSIS (3)” on page 4-3. Before installing the spark plug, clean the spark 2. Disconnect: plug and gasket surface. •...
Page 121: Checking The Engine Oil Level
ENGINE ECA13350 Piston, valves, cylinder head gasket or piston Same as without oil possibly defective → Before removing the spark plug, use com- Repair/Replace. pressed air to blow away any dirt accumulat- ed in the spark plug well to prevent it from 8.
Page 122: Changing The Engine Oil
ENGINE Recommended brand YAMALUBE SAE viscosity grades 10W-40 Recommended engine oil grade API service SL type, JASO standard MA ECA13361 • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “CD”...
Page 123: Adjusting The Clutch Lever Free Play
ENGINE c. Install the oil filter element cover by install- 14.Check: ing the bolts, then tightening them to the • Engine oil pressure specified torque. a. Slightly loosen the oil check bolt “1”. Oil filter element cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) Make sure that the O-ring is properly seated.
Page 124: Replacing The Air Filter Element
ENGINE 2. Adjust: • Clutch lever free play Handlebar end a. Pull back the rubber cover “1”. b. Loosen the locknut “2”. c. Turn the adjusting bolt “3” until the speci- fied clutch lever free play is obtained. c. Tighten the locknut. Clutch cable locknut 7 N·m (0.7 kgf·m, 5.2 lb·ft) 4.
Page 125 ENGINE 4. Lift the fuel tank to disconnect the fuel pump 8. Check: lead, fuel pump coupler, fuel hose, canister • Air filter element Damage/clogged → Replace. hoses and fuel drain hose, and then remove the fuel tank. Refer to “FUEL TANK” on page 7-1. •...
Page 126: Checking The Throttle Body Joint And Air Filter Case Joint
ENGINE If dust or water collects in the air filter check hose, remove the clamp, and then remove the plug to drain the hose. 12.Connect the fuel hose, fuel pump coupler, fuel pump lead, canister hoses and fuel drain hose. 13.Install the fuel tank and tighten the bolts.
Page 127: Checking The Exhaust System
Loose connection → Connect properly. (3)” on page 4-3. ECA14920 Recommended coolant: Make sure the cylinder head breather hose is YAMAHA GENUINE COOLANT routed correctly. 3. Install: ECA13470 • All removed parts • Adding water instead of coolant lowers the EAS30625 antifreeze content of the coolant.
Page 128: Changing The Coolant
ENGINE sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move. 3. Remove: • Coolant drain bolt “1” (along with the copper washer 4. Drain: 3. Install: • Coolant • Lower side cowling (left and right) (from the engine and radiator) Refer to “GENERAL CHASSIS (3)”...
Page 129 0.49 L (0.52 US qt, 0.43 Imp.qt) Coolant reservoir (up to the maxi- mum level mark) 0.15 L (0.16 US qt, 0.13 Imp.qt) Recommended coolant: Handling notes for coolant YAMAHA GENUINE COOLANT Coolant is potentially harmful and should be handled with special care. 13.Install: EWA13040 WARNING •...
Page 130: Chassis
CHASSIS EAS20024 CHASSIS Specified brake fluid DOT 4 EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly → Check the brake system. Refer to “FRONT BRAKE” on page 4-26 and “REAR BRAKE” on page 4-38. Drive on the dry road, operate the front and rear brake separately and check to see if the brakes are operating properly.
Page 131: Checking The Front Brake Pads
CHASSIS EAS30633 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • Front brake pad Wear indicator groove “1” has almost disap- peared → Replace the brake pads as a set. Refer to “FRONT BRAKE”...
Page 132: Adjusting The Rear Brake Light Switch
CHASSIS EAS21330 EWA15740 ADJUSTING THE REAR BRAKE LIGHT WARNING SWITCH Bleed the ABS whenever: • the system is disassembled. The rear brake light switch is operated by move- • a brake hose is loosened, disconnected or ment of the brake pedal. The rear brake light replaced.
Page 133: Adjusting The Drive Chain Slack
CHASSIS d. Place the other end of the hose into a con- EAS30644 ADJUSTING THE DRIVE CHAIN SLACK tainer. e. Slowly apply the brake several times. The drive chain slack must be checked at the f. Fully pull the brake lever or fully press tightest point on the chain.
Page 134: Lubricating The Drive Chain
CHASSIS 5. Adjust: b. After adjusting, be sure to tighten each • Drive chain slack chain adjust locknut. Then tighten the axle a. Loosen the wheel axle nut “1”. nut to the specified torque. b. Loosen both drive chain adjusting lock- c.
Page 135: Checking And Adjusting The Steering Head
CHASSIS d. Spray the lubricant inside the chain be- b. Tighten the lower ring nut “4” with a steer- tween inner/outer plates, roller and bush- ing nut socket “5”. e. After spraying wait for 15 minutes. • Set the torque wrench at a right angle to the f.
Page 136: Checking The Front Fork
CHASSIS d. Check the steering head for looseness or 4. Check: binding by turning the front fork all the way • Front fork operation in both directions. If any binding is felt, re- Push down hard on the handlebar several move the lower bracket and check the up- times and check if the front fork rebounds per and lower bearings.
Page 137 , 33 psi) concerning handling characteristics can be 2 persons given if a tire combination other than one ap- Front proved by Yamaha is used on this vehicle. 200 kPa (2.00 kgf/cm , 29 psi) Rear 225 kPa (2.25 kgf/cm...
Page 138: Checking The Wheels
CHASSIS EAS30638 1. Check: CHECKING THE WHEELS • Outer cable The following procedure applies to both of the Damage → Replace. wheels. 2. Check: 1. Check: • Cable operation • Wheel Rough movement → Lubricate cable end/Re- Damage/out-of-round → Replace. place.
Page 139: Lubricating The Pedals
CHASSIS EAS30649 LUBRICATING THE PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the pedals. Recommended lubricant Lithium-soap-based grease CHECKING THE SIDESTAND 1. Check: • Sidestand operation Check that sidestand moves smoothly. Rough movement → Lubricate, repair or re- place.
Page 140: Electrical System
ELECTRICAL SYSTEM EAS20025 ELECTRICAL SYSTEM EAS30816 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-143. EAS30121 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-142. c. License plate light burnt-out bulb “3” by pulling it out.
Page 141 ELECTRICAL SYSTEM Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. Headlight beam adjusting condition • Headlight should be in low beam. • Rider weight : 75 kg (1 Person). • Height at low beam line “a” : 74.3 cm •...
Page 142 ELECTRICAL SYSTEM 3-30...
Page 143 CHASSIS GENERAL CHASSIS (1) ................4-1 GENERAL CHASSIS (2) ................4-2 GENERAL CHASSIS (3) ................4-3 GENERAL CHASSIS (4) ................4-4 GENERAL CHASSIS (5) ................4-5 REMOVING THE REAR VIEW MIRROR ASSEMBLY ......4-7 INSTALLING THE REAR VIEW MIRROR ASSEMBLY ......4-7 GENERAL CHASSIS (6) ................4-8 INSTALLING THE AIR FILTER CASE .............4-9 GENERAL CHASSIS (7) ................
Page 144 FRONT BRAKE .................... 4-26 INTRODUCTION ..................4-31 CHECKING THE FRONT BRAKE DISC ..........4-31 REPLACING THE FRONT BRAKE PADS ..........4-32 REMOVING THE FRONT BRAKE CALIPER ......... 4-33 DISASSEMBLING THE FRONT BRAKE CALIPER ....... 4-33 CHECKING THE FRONT BRAKE CALIPER ......... 4-34 ASSEMBLING THE FRONT BRAKE CALIPER ........
Page 145 STEERING HEAD ..................4-75 REMOVING THE LOWER BRACKET ............ 4-77 CHECKING THE STEERING HEAD ............4-77 INSTALLING THE STEERING HEAD ............ 4-77 REAR SHOCK ABSORBER ASSEMBLY ........... 4-79 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ....4-80 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ....4-80 CHECKING THE CONNECTING ARMS AND RELAY ARM ....
Page 146 CHAS GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery Order Job/Parts to remove Q’ty Remarks Passenger seat Center cover (between rider & passenger seat) Rider seat Negative battery lead Disconnect. Positive battery lead Disconnect. Battery band Battery For installation, reverse the removal procedure.
Page 147 CHAS GENERAL CHASSIS (2) GENERAL CHASSIS (2) Removing the rear side cowlings Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Passenger seat and rider seat 4-1. Side cover (Left and right) Rear side cowling (Left and right) Tail/brake light outer cover For installation, reverse the removal procedure.
Page 148 CHAS GENERAL CHASSIS (3) GENERAL CHASSIS (3) Removing the inner panel and cowlings Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Passenger seat and rider seat 4-1. Refer to “GENERAL CHASSIS (2)” on page Side cover (Left and right) 4-2.
Page 149 CHAS GENERAL CHASSIS (4) GENERAL CHASSIS (4) Removing the meter assembly Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (3)” on page Upper panel (Left and right) 4-3. Meter assembly mounting bolt / quick fastener Disconnect. Meter coupler After connect the coupler slide the rubber cover in original position.
Page 150 CHAS GENERAL CHASSIS (5) GENERAL CHASSIS (5) Removing the headlight assembly Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (4)” on page Meter assembly 4-4. Refer to “GENERAL CHASSIS (3)” on page Upper side cowling (Left and right) 4-3.
Page 151 CHAS GENERAL CHASSIS (5) Removing the headlight assembly Order Job/Parts to remove Q’ty Remarks Front upper body (Auxiliary light) Rubber cover Headlight cover Headlight assembly Headlight stay For installation, reverse the removal proce- dure.
Page 152: General Chassis (1)
CHAS GENERAL CHASSIS (5) REMOVING THE REAR VIEW MIRROR INSTALLING THE REAR VIEW MIRROR ASSEMBLY ASSEMBLY 1. Remove the rear view mirror bolt caps “1” 1. Install the collars “1” and rubber plates “2”. from the rear view mirror bolts. 2.
Page 153 CHAS GENERAL CHASSIS (6) GENERAL CHASSIS (6) Removing the air filter case Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Passenger seat and rider seat 4-1. Refer to “GENERAL CHASSIS (2)” on page Side cover (Left and right) 4-2.
Page 154: Installing The Air Filter Case
CHAS GENERAL CHASSIS (6) EAS30968 INSTALLING THE AIR FILTER CASE 1. Install: • Air filter case joint clamp Align the projection “a” on the air filter case with the slot “b” in the air filter case joint clamp.
Page 155: General Chassis (7)
CHAS GENERAL CHASSIS (7) GENERAL CHASSIS (7) Removing the taillight assembly/rear fender f·m, 0.73 lb·ft) N·m f·m, 2.8 lb·ft) 9 N·m 9 N·m f·m, 0.18 lb·ft) f·m, 1.1 lb·ft) 0.89 N·m 0.089 0.65 f·m, 1.8 lb·ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”...
Page 156 CHAS GENERAL CHASSIS (7) Removing the taillight assembly/rear fender f·m, 0.73 lb·ft) N·m f·m, 2.8 lb·ft) 9 N·m 9 N·m f·m, 0.18 lb·ft) f·m, 1.1 lb·ft) 0.89 N·m 0.089 0.65 f·m, 1.8 lb·ft) Order Job/Parts to remove Q’ty Remarks Rear side reflector (Left and right) Skip step 1 to 7.
Page 157 CHAS GENERAL CHASSIS (8) GENERAL CHASSIS (8) Removing the QSS (Quick shift system) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (3)” on page Lower side cowling (left) 4-3. QSS (Quick shift system) coupler Disconnect. Shift arm bolt Footrest bracket bolt (left) QSS (Quick shift system) assembly along with footrest...
Page 158: Front Wheel
CHAS FRONT WHEEL AS20028 FRONT WHEEL Removing the front wheel and brake disc 38 N·m (3.8 kgf·m, 28 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 35 N·m (3.5 kgf·m, 26 lb·ft) Order Job/Parts to remove...
Page 159 CHAS FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Use bearing puller YSST-624 Spacer For assembly, reverse the disassembly pro- cedure. 4-14...
Page 160: Removing The Front Wheel
CHAS FRONT WHEEL EAS30145 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface by using maintenance front wheel stand. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Elevate: •...
Page 161: Assembling The Front Wheel
CHAS FRONT WHEEL EAS30151 ASSEMBLING THE FRONT WHEEL 1. Install: • Wheel bearings • Oil seals a. Install the new wheel bearings and oil seals in the reverse order of disassembly. ECA18110 Do not contact the wheel bearing inner race “1”...
Page 162 CHAS FRONT WHEEL 1. Check: • Wheel sensor “1” Do not touch the surface of the wheel sensor ro- Cracks/bends/distortion → Replace. tor with a sharp object. Iron powder/dust → Clean. 2. Check: • Wheel sensor rotor “1” Cracks/damage/scratches → Replace the wheel sensor rotor.
Page 163: Installing The Front Wheel
CHAS FRONT WHEEL 4. Install: • Collars • Front wheel • Front wheel axle • Front wheel axle nut • Install the front wheel with the mark “a” on the front tire pointing in the direction of wheel rota- tion. •...
Page 164 CHAS FRONT WHEEL • When installing the front wheel sensor, check the wheel sensor lead for twists. • To route the front wheel sensor lead, refer to “CABLE ROUTING” on page 2-31. 7. Install: • Front brake caliper along with wheel sensor lead holder •...
Page 165: Rear Wheel
CHAS REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 59 N·m (5.9 kgf·m, 44 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) 16 N·m (1.6 kgf·m, 12 lb·ft) Order Job/Parts to remove...
Page 166 CHAS REAR WHEEL Removing the rear brake disc and rear wheel sprocket 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 Oil seal Bearing Use bearing puller YSST-624 Collar Oil seal...
Page 167: Removing The Rear Wheel
CHAS REAR WHEEL EAS30156 REMOVING THE REAR WHEEL Push the rear wheel forward and remove the ECA21030 drive chain from the rear wheel sprocket. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, DISASSEMBLING THE REAR WHEEL etc.) away from the rear wheel sensor or 1.
Page 168: Checking And Replacing The Rear Wheel Sprocket
CHAS REAR WHEEL EAS30161 • Keep any type of magnets (including mag- CHECKING AND REPLACING THE REAR netic pick-up tools, magnetic screwdrivers, WHEEL SPROCKET etc.) away from the wheel sensor or wheel 1. Check: sensor rotor. • Rear wheel sprocket •...
Page 169 CHAS REAR WHEEL 1. Install: 5. Lubricate: • Rear wheel sprocket • Rear brake caliper bolt Refer to “REAR WHEEL” on page 4-20. Recommended lubricant 2. Check: Silicone grease • Rear brake disc Refer to “CHECKING THE FRONT BRAKE 6. Install: DISC”...
Page 170 CHAS REAR WHEEL 10.Measure: • Distance “a” (between the rear wheel sensor rotor “1” and rear wheel sensor “2”) Out of specification → Check the wheel bear- ing for looseness, and the rear wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE®...
Page 171: Front Brake
CHAS FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 35 N·m (3.5 kgf·m, 26 lb·ft) Order Job/Parts to remove Q’ty Remarks Front brake caliper bolt Front brake caliper Brake pad clip Brake pad pin Brake pad (inner) Brake pad (outer) Brake pad spring Brake pad support For installation, reverse the removal proce-...
Page 172 CHAS FRONT BRAKE Removing the front brake master cylinder N·m (0. kgf·m, . lb·ft) N·m (0. kgf·m, . lb·ft) N·m (0. kgf·m, . lb·ft) . N·m (0. kgf·m, . 0 88 lb·ft) 9.0 N·m (0.9 kgf·m, 6.6 lb·ft) Order Job/Parts to remove Q’ty Remarks Drain.
Page 173 CHAS FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-28...
Page 174 CHAS FRONT BRAKE Removing the front brake caliper 29 N·m (2.9 kgf·m, 21 lb·ft) Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-20. Front brake hose union bolt (brake caliper side) Brake hose gasket Front brake hose (brake hose joint to brake caliper)
Page 175 CHAS FRONT BRAKE Disassembling the front brake caliper Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Front brake pad Brake pad spring Brake pad support Brake caliper bracket Brake caliper piston Brake caliper piston dust seal...
Page 176: Checking The Front Brake Disc
CHAS FRONT BRAKE EAS30168 d. Install the disc brake face out tool on INTRODUCTION mounting “1”. EWA14101 e. Install the dial gauge on the other side of WARNING the tool. Disc brake components rarely require disas- f. Tighten dial gauge “2” properly by screw sembly.
Page 177: Replacing The Front Brake Pads
CHAS FRONT BRAKE 4. Adjust: • Brake disc runout a. Remove front wheel and then remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. Front brake disc bolt 23 N·m (2.3 kgf·m, 17 lb·ft) LOCTITE®...
Page 178: Removing The Front Brake Caliper
CHAS FRONT BRAKE 4. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-18. EAS30172 DISASSEMBLING THE FRONT BRAKE CALIPER 1.
Page 179: Checking The Front Brake Caliper
CHAS FRONT BRAKE EAS30173 • Whenever a brake caliper is disassembled, CHECKING THE FRONT BRAKE CALIPER replace the brake caliper piston kits. Recommended brake component replacement schedule Specified brake fluid DOT 4 Brake pads If necessary Brake caliper piston kits If necessary EAS30934 Brake hose Every four years...
Page 180: Removing The Front Brake Master Cylinder
CHAS FRONT BRAKE Front brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Sensor lead holder bolt 7 N·m (0.7 kgf·m, 5.2lb·ft) Refer to “REPLACING THE FRONT BRAKE PADS” on page 4-32. 4. Fill: • Brake master cylinder reservoir (with the specified amount of the specified 7.
Page 181: Assembling The Front Brake Master Cylinder
CHAS FRONT BRAKE 3. Check: Front brake hose union bolt • Brake hose (master cylinder) Cracks/damage/wear → Replace. 29 N·m (2.9 kgf·m, 21 lb·ft) EAS30181 ASSEMBLING THE FRONT BRAKE MASTER EWA13531 WARNING CYLINDER Proper brake hose routing is essential to in- EWA13520 WARNING sure safe vehicle operation.
Page 182 CHAS FRONT BRAKE ECA13540 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-20. 5. Check: •...
Page 183: Rear Brake
CHAS REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake pad retaining bolt Rear brake pad Brake pad shim Brake pad spring For installation, reverse the removal proce- dure. 4-38...
Page 184 CHAS REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-20. Brake hose union bolt Copper washer Rear brake hose Footrest plate assembly Brake fluid reservoir hose Rear brake master cylinder Brake fluid reservoir assembly...
Page 185 CHAS REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake hose joint Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-40...
Page 186 CHAS REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Rear wheel sensor Refer to “REAR WHEEL” on page 4-20. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-20. Rear wheel Refer to “REAR WHEEL”...
Page 187 CHAS REAR BRAKE Disassembling the rear brake caliper 17 N·m (1.7 kgf·m, 13 lb·ft) 22 N·m (2.2 kgf·m, 16 lb·ft) 5 N·m (0.5 kgf·m, 3.7 lb·ft) Order Job/Parts to remove Q’ty Remarks Brake pad retaining bolts Rear brake pad Brake pad shims Brake pad spring Brake caliper piston Brake caliper piston dust seal...
Page 188: Introduction
CHAS REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 4.0 mm (0.16 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc runout ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 189: Removing The Rear Brake Caliper
CHAS REAR BRAKE Always replace the brake pads, brake pad shims and brake pad spring as a set. a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. 6.
Page 190: Disassembling The Rear Brake Caliper
CHAS REAR BRAKE EAS30188 CHECKING THE REAR BRAKE CALIPER Put the end of the brake hose into a container Recommended brake component and pump out the brake fluid carefully. replacement schedule 2. Remove: Brake pads If necessary • Rear wheel Piston seals Every two years Refer to “REAR WHEEL”...
Page 191: Assembling The Rear Brake Caliper
CHAS REAR BRAKE EAS30189 EWA13531 ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA17080 Proper brake hose routing is essential to in- WARNING sure safe vehicle operation. • Before installation, all internal brake com- Refer to “CABLE ROUTING” on page 2-31. ponents should be cleaned and lubricated ECA26360 with clean or new brake fluid.
Page 192: Removing The Rear Brake Master Cylinder
CHAS REAR BRAKE 5. Check: EAS30194 CHECKING THE REAR BRAKE MASTER • Brake fluid level CYLINDER Below the minimum level mark “a” → Add the 1. Check: recommended brake fluid to the proper level. • Brake master cylinder Refer to “CHECKING THE BRAKE FLUID Damage/scratches/wear →...
Page 193: Rear Brake Hose Installation
CHAS REAR BRAKE ECA14160 4. Check: • Brake fluid level Below the minimum level mark “a” → Add the When installing the brake hose onto the brake master cylinder, make sure the brake recommended brake fluid to the proper level. pipe “a”...
Page 194: Abs (Anti-Lock Brake System)
CHAS ABS (ANTI-LOCK BRAKE SYSTEM) EAS20033 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 29 N·m (2.9 kgf·m, 21 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 29 N·m (2.9 kgf·m, 21 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 29 N·m (2.9 kgf·m, 21 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
Page 195 CHAS ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 29 N·m (2.9 kgf·m, 21 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 29 N·m (2.9 kgf·m, 21 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 2 N·m 2 ( .9 kgf·m, 21 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
Page 196: Removing The Hydraulic Unit Assembly
CHAS ABS (ANTI-LOCK BRAKE SYSTEM) EAS30197 2. Remove: REMOVING THE HYDRAULIC UNIT • Brake hoses ASSEMBLY ECA21091 Do not operate the brake lever and brake pedal while removing the brake hoses. Unless necessary, avoid removing and in- stalling the brake hoses of the hydraulic unit ECA14530 assembly.
Page 197: Installing The Hydraulic Unit Assembly
CHAS ABS (ANTI-LOCK BRAKE SYSTEM) EAS30200 tighten the union bolt for the brake hose INSTALLING THE HYDRAULIC UNIT (front brake master cylinder to hydraulic ASSEMBLY unit). 1. Install: c. Temporarily tighten the union bolt for the • Hydraulic unit assembly rear brake hose (hydraulic unit to rear brake master cylinder) “1”.
Page 198: Hydraulic Unit Operation Tests
• For the brake line routing confirmation, use the diagnosis mode of the Yamaha diagnostic tool. • When refilling, be careful that water does • Before performing the brake line routing confir- not enter the brake fluid reservoir.
Page 199 INS-018 der. 90890-03267 INS-019 90890-03264 6. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 7. Select code No. 2, “Brake line routing confir- mation”. 8. Click “Actuator Check” “1”, and then operate the brake lever “2” and brake pedal “3” simul- taneously.
Page 200 CHAS ABS (ANTI-LOCK BRAKE SYSTEM) 6. Start the Yamaha diagnostic tool and display the diagnosis mode screen. • For the ABS reaction-force confirmation, use 7. Select code No. 1, “ABS reaction-force con- the diagnosis mode of the Yamaha diagnostic firmation”.
Page 201: Checking The Abs Warning Light
12.Turn the main switch to “OFF”. 10.After the pulsating action has stopped in the 13.Remove the Yamaha diagnostic tool from the brake lever, it is generated in the brake pedal Yamaha diagnostic tool coupler, and then in- “1”...
Page 202 CHAS HANDLEBARS EAS20033 HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Handle crown Refer to “STEERING HEAD” on page 4-75. Grip end (left) Handlebar weight (left) Handlebar grip Clutch switch coupler Disconnect. Handlebar switch (left) Clutch switch Clutch cable Disconnect.
Page 203 CHAS HANDLEBARS Removing the handlebars Order Job/Parts to remove Q’ty Remarks Handlebar weight (right) Handlebar switch (right) Throttle cable Disconnect. Throttle grip Front brake master cylinder holder Front brake master cylinder Handlebar pinch bolt Loosen. Handlebar (right) For installation, reverse the removal proce- dure.
Page 204: Handlebars
CHAS HANDLEBARS EAS30203 REMOVING THE HANDLEBARS • Install the brake master cylinder holder with the 1. Stand the vehicle on a level surface. “UP” mark facing up. EWA13120 WARNING • Align the end of the brake master cylinder hold- er with the punch mark “a” on the handlebar. Securely support the vehicle so that there is •...
Page 205 CHAS HANDLEBARS Lubricate the end of the clutch cable with a thin coat of lithium-soap-based grease. 8. Install: • Handlebar switch (left) “1” Align the projection “a” on the left handlebar switch with the hole “b” in the left handlebar. 5.
Page 206 CHAS HANDLEBARS 11.Check: • Cable routing Make sure the main switch lead, brake hose, throttle cables, clutch cable, and handlebar switch leads are routed properly. Refer to “CABLE ROUTING” on page 2-31. 12.Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY”...
Page 207: Front Fork
CHAS FRONT FORK EAS20034 FRONT FORK Removing the front fork legs Before removing the front wheel, place the scissor jack “a” YSST-892A under the engine as shown and stand the vehicle on maintenance stand. Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs.
Page 208 CHAS FRONT FORK Disassembling the front fork leg (right) Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring After removal cap bolt, drain front fork oil. Special nut Rubber Dust seal Oil seal clip Outer tube Inner tube bushing Outer tube bushing Washer Oil seal Dumper rod stopper...
Page 209 CHAS FRONT FORK Disassembling the front fork leg (left) Order Job/Parts to remove Q’ty Remarks Cap bolt After removal cap bolt, drain front fork oil. O-ring Collar Locknut Spacer Fork spring Dust seal Oil seal clip Outer tube Inner tube bushing Outer tube bushing Washer Oil seal...
Page 210: Removing The Front Fork Legs
CHAS FRONT FORK EAS30206 a. Gently press collar “2” downward as direc- REMOVING THE FRONT FORK LEGS tion shown in illustration. The following procedure applies to both of the b. Hold locknut “3” with front fork damper front fork legs. rod locknut holder “4”...
Page 211: Checking The Front Fork Legs
CHAS FRONT FORK 8. Remove: • Damper rod assembly bolt “1” • Copper washer “2” • Damper rod assembly • Securely clamp the fender bracket in a vise with soft jaws. • Loosen the damper rod assembly bolt “1” by using 8mm T-handle “3”.
Page 212: Assembling The Front Fork Leg (Left)
• Damper rod assembly • Inner tube’s outer surface Damage/wear → Replace. Recommended oil Obstruction → Blow out all of the oil passag- Yamaha Suspension Oil 01 es with compressed air. (right front fork leg only) 4. Install: ECA20650 • Dust seal “1”...
Page 213 CHAS FRONT FORK 9. Install: Front fork oil seal installer • Fork spring“1” YSST-775A • Spacer “2” (90890-01442) • Locknut “3” • Collar “4” • Cap bolt “5” (along with the O-ring 7. Install: • Oil seal clip “1” Adjust the oil seal clip so that it fits into the outer Front fork damper rod locknut tube’s groove.
Page 214 100 mm (3.9 in) • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Yamaha Suspension Oil 01 Quantity 300.0 cm (10.14 US oz, 10.58 Imp.oz) • Be sure to use the recommended fork oil.
Page 215: Installing The Front Fork Legs
CHAS FRONT FORK INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg Temporarily tighten the upper and lower bracket pinch bolts. 2. Tighten: • Cap bolt Front fork cap bolt 23 N·m (2.3 kgf·m, 17 lb·ft) Front fork damper rod locknut holder (left &...
Page 216: Assembling The Front Fork Leg (Right)
• Before assembling the front fork leg, make sure all of the components are clean. 1. Lubricate: • Inner tube’s outer surface Recommended oil Yamaha Suspension Oil 01 2. Install: • Dust seal “1” 7. Remove: • Oil seal clip “2”...
Page 217 CHAS FRONT FORK ECA19660 4. Install: • Front fork spring “1” Make sure to face the numbered side of the oil seal toward the bottom end of the inner Install the fork spring with its smaller pitch “a” tube. downward. •...
Page 218 CHAS FRONT FORK 6. Tighten: 9. Install: • Damper rod stopper bolt “1” into inner tube by • Cap bolt with finger tighten using front fork damper rod stopper tool 10.Tighten: (Right leg) YSST-779 “2”. • Tighten special nut by holding cap bolt. Special nut 17 N·m (1.7 kgf·m, 13 lb·ft) 11.Tighten:...
Page 219 Oil level (right leg) 119 mm (4.7 in) 15.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Yamaha Suspension Oil G01 Quantity 363.0 cm (12.27 US oz, 12.80 lmp.oz) 19.Install: • Cap bolt (to the outer tube) •...
Page 220: Steering Head
CHAS STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket � 7.0 N-m (0.7 kgf.m, 5.2 lb-ft) 1st 48 N-m (4.8 kgf.m, 35 lb-ft) � 2nd 18 N-m (1.8 k f.m, 13 lb-ft) * Removing and installing the ignition lock screw by using special tool [Main switch steering lock YSST-611 A (T-30)].
Page 221 CHAS STEERING HEAD Removing the lower bracket 1st 48 N-m (4.8 kgf-m, 35 lb-ft) 2nd 18 N-m (1.8 kgf-m, 13 lb-ft) * Removing and installing the ignition lock screw by using special tool [Main switch steering lock YSST-611 A (T-30)]. Order Job/Parts to remove Q’ty...
Page 222: Removing The Lower Bracket
CHAS STEERING HEAD EAS30213 a. Remove the bearing races from the steer- REMOVING THE LOWER BRACKET ing head pipe with a long rod “1” and ham- 1. Stand the vehicle on a level surface. mer. EWA13120 b. Remove the bearing race from the lower WARNING bracket with a floor chisel “2”...
Page 223 CHAS STEERING HEAD 3. Install: Recommended lubricant • Upper bracket Lithium-soap-based grease • Washer • Steering stem bolt 2. Install: • Lower ring nut Temporarily tighten the steering stem bolt. • Rubber washer • Upper ring nut 4. Install: • Lock washer •...
Page 224 CHAS REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly N·m (4.4 kgf·m, 32 lb·ft) N·m (4.4 kgf·m, 32 lb·ft) NOTE : Apply “Lithium-soap-based grease” on part serial number :- 1,2,3,6,8,9,10 Order Job/Parts to remove Q’ty Remarks Rear shock absorber assembly lower nut/bolt...
Page 225: Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS31304 2. Install: REMOVING THE REAR SHOCK ABSORBER • Bearing “1” ASSEMBLY (to the relay arm) 1. Stand the vehicle on a level surface. • Oil seal “2” EWA13120 (to the relay arm) WARNING Securely support the vehicle so that there is Oil seal installed depth “a”...
Page 226: Swingarm
CHAS REAR SHOCK ABSORBER ASSEMBLY 2. Tighten: • Rear shock absorber assembly upper nut Rear shock absorber assembly upper nut 44 N·m (4.4 kgf·m, 32 lb·ft) • Relay arm nut Relay arm nut 44 N·m (4.4 kgf·m, 32 lb·ft) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 44 N·m (4.4 kgf·m, 32 lb·ft)
Page 227 CHAS SWINGARM EAS20037 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-20. Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly/Relay arm ASSEMBLY” on page 4-79. Drive chain Refer to “CHAIN DRIVE” on page 4-85. Brake hose holder Rear fender Drive chain guide...
Page 228: Removing The Swingarm
CHAS SWINGARM EAS30226 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a maintenance stand so that the rear wheel is elevated. 3.
Page 229 CHAS SWINGARM A. Left side B. Right side 3. Install: • Rear shock absorber assembly • Relay arm • Connecting arms • Rear wheel Refer to “REAR SHOCK ABSORBER ASSEMBLY” on page 4-79. 4. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...
Page 230: Chain Drive
CHAS CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain Order Job/Parts to remove Q’ty Remarks Loose the drive chain adjusting locknut and wheel axle nut and push the wheel forward. Drive sprocket cover Drive chain Chain link O-ring Outer plate Drive sprocket retainer Use rotor holder tool (S 1113) to hold drive Drive sprocket...
Page 231: Removing The Drive Chain By Using Chain Cutter
CHAS CHAIN DRIVE EAS32683 REMOVING THE DRIVE CHAIN BY USING CHAIN CUTTER 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a maintenance stand so that the rear wheel is elevated.
Page 232: Checking The Drive Sprocket
CHAS CHAIN DRIVE 2. Check: b. Correct • Drive chain 1. Drive chain roller Stiffness → Clean and lubricate or replace. 2. Drive chain sprocket EAS30232 CHECKING THE REAR WHEEL SPROCKET Refer to “CHECKING AND REPLACING THE REAR WHEEL SPROCKET” on page 4-23. EAS30233 CHECKING THE REAR WHEEL DRIVE HUB Refer to “CHECKING THE REAR WHEEL...
Page 233 CHAS CHAIN DRIVE 3. Install new chain link “1” with O-rings “2” and fix on drive chain “3”. Clamp holder locking screw should be set on “A” position. 7. After installing the joint plate “1” from special tool, remove pressure plate and adjust the clamp to “B”...
Page 234: Cleaning And Lubricating The Drive Chain
CHAS CHAIN DRIVE 9. Install: • Drive chain sprocket cover • Shake the cleaner well before use. • During washing of vehicle, never use kero- Be sure not to pinch the gear position switch sene, petrol or any other solvent for cleaning. lead when installing the drive sprocket cover.
Page 235: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-5 INSTALLING THE SHIFT ARM ..............5-5 INSTALLING THE EXHAUST ASSEMBLY ..........5-5 CYLINDER HEAD ...................5-7 REMOVING THE CYLINDER HEAD ............5-10 CHECKING THE CYLINDER HEAD ............5-11 CHECKING THE CAMSHAFT SPROCKET AND TIMING CHAIN GUIDE ................. 5-11 CHECKING THE TIMING CHAIN TENSIONER ........
Page 236 CLUTCH ....................... 5-41 REMOVING THE CLUTCH ..............5-45 CHECKING THE FRICTION PLATES ............ 5-45 CHECKING THE CLUTCH PLATES ............5-45 CHECKING THE CLUTCH SPRINGS ............ 5-46 CHECKING THE CLUTCH HOUSING ........... 5-46 CHECKING THE CLUTCH BOSS ............5-46 CHECKING THE PRESSURE PLATE ........... 5-46 CHECKING THE CLUTCH PUSH LEVER AND SHORT CLUTCH PUSH ROD ...............
Page 237 TRANSMISSION ................... 5-66 CHECKING THE SHIFT FORKS ............5-68 CHECKING THE SHIFT DRUM ASSEMBLY ......... 5-68 CHECKING THE TRANSMISSION ............5-68 ASSEMBLING THE DRIVE AXLE ............5-69 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ..5-69...
Page 238: Engine Removal
ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the exhaust assembly 8 N·m (0.8 kgf·m, 5.9 lb·ft) 25 N·m (2.5 kgf·m, 18 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (3)” on page Inner fender 4-3.
Page 239 ENGINE REMOVAL Disconnecting the leads and couplers 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (3)” on page Lower side cowling (Left and right) 4-3.
Page 240 ENGINE REMOVAL Disconnecting the leads and couplers 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) Order Job/Parts to remove Q’ty Remarks Spark plug cap Disconnect.
Page 241 ENGINE REMOVAL Removing the engine 45 N·m (4.5 kgf·m, 33 lb·ft) 45 N·m (4.5 kgf·m, 33 lb·ft) ’ Order Job/Parts to remove Remarks Place a maintenance stand under the en- gine. Engine mounting bolt (front side) Engine mounting bolt/nut (rear upper side) Engine mounting bolt/nut (rear lower side) Engine For installation, reverse the removal...
Page 242: Installing The Engine
ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE Shift pedal distance “a” 1. Install: 15.5 mm (0.61 in) • Engine “1” Shift pedal distance “b” • Engine mounting bolt/nut (rear lower side) “2” 15.4 mm (0.60 in) • Engine mounting bolt (front side) “3” •...
Page 243 ENGINE REMOVAL Install exhaust gasket with a claw at the cylinder head side.
Page 244: Cylinder Head
Refer to “FUEL TANK” on page 7-1. Throttle body/Intake manifold Refer to “THROTTLE BODY” on page 7-7. Radiator/Coolant reservoir hose/Thermostat Refer to “RADIATOR” on page 6-1. Water pump Refer to “WATER PUMP” on page 6-6. * Yamaha bond No. 1215 90890-85505 (Three bond No.1215-B)
Page 245 Crankshaft end accessing screw Timing mark accessing screw Spark plug Coolant temperature sensor Cylinder head breather hose VVA solenoid VVA solenoid gasket Cylinder head cover Cylinder head cover gasket Dowel pin VVA solenoid rod * Yamaha bond No. 1215 90890-85505 (Three bond No.1215-B)
Page 246 Cylinder head cover breather plate gasket Oil seal Timing chain tensioner Timing chain tensioner gasket Camshaft sprocket Decompression cam Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal procedure. * Yamaha bond No. 1215 90890-85505 (Three bond No.1215-B)
Page 247: Removing The Cylinder Head
CYLINDER HEAD EAS30276 4. Loosen: REMOVING THE CYLINDER HEAD • Camshaft sprocket bolt “1” 1. Remove: • Crank shaft end accessing screw “1” and tim- While holding the magneto rotor nut with a ing mark accessing screw “2” with its cap wrench “2”, loosen the camshaft sprocket bolt.
Page 248: Checking The Cylinder Head
CYLINDER HEAD a. Place a straightedge “1” and a feeler gauge “2” across the cylinder head. • Loosen the bolts in the proper sequence as shown. • Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove bolts 1, 2, 4, and 6, and then remove the cylinder head with bolts 3 and 5 installed in the bolt holes.
Page 249: Checking The Timing Chain Tensioner
CYLINDER HEAD EAS30266 c. Without operating the decompression le- CHECKING THE TIMING CHAIN TENSIONER ver, check that the decompression cam 1. Check: “2” projects from the camshaft (exhaust • Timing chain tensioner cam) as shown in the illustration “A”. Cracks/damage/rough movement → Re- d.
Page 250 Apply sealant to the timing chain tensioner 3. Install: bolt threads. • Camshaft sprocket a. Turn the crankshaft counterclockwise. Yamaha bond No. 1215 b. Align the “I” mark “a” on the magneto rotor 90890-85505 with the stationary pointer “b” on the mag- (Three bond No.1215-B) neto cover.
Page 251 CYLINDER HEAD 7. Tighten: • Camshaft sprocket bolt Camshaft sprocket bolt 30 N·m (3.0 kgf·m, 22 lb·ft) ECA20610 Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil- ity of the bolt coming loose and damaging the engine.
Page 252 CYLINDER HEAD 10.Install: • All removed parts Refer to “GENERAL CHASSIS (1)” on page 4-1. • Seats Refer to “GENERAL CHASSIS (1)” on page 4-1. 5-15...
Page 253: Camshaft
CAMSHAFT EAS20043 CAMSHAFT Removing the rocker arms and camshaft N·m (0.7 kgf·m, 5.2 lb·ft) N·m (0.8 kgf·m, 5.9 lb·ft) N·m (0.7 kgf·m, 5.2 lb·ft) Order Job/Parts to remove ’ Remarks cover Refer to “CYLINDER HEAD” on page 5-7. Cylinder head Camshaft stopper plate Locknut Rocker arm shaft...
Page 254: Removing The Camshaft
CAMSHAFT EAS30256 EAS30257 REMOVING THE CAMSHAFT CHECKING THE CAMSHAFT 1. Loosen: 1. Check: • Locknut “1” • Camshaft lobes Blue discoloration/pitting/scratches → Re- • Valve clearance adjusting screw “2” (intake/ exhaust) place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” Out of specification →...
Page 255: Checking The Rocker Arms And Rocker Arm Shafts
CAMSHAFT EAS30259 4. Measure: CHECKING THE ROCKER ARMS AND • Rocker arm shaft outside diameter “a” ROCKER ARM SHAFTS Out of specification → Replace. The following procedure applies to all of the rocker arms and rocker arm shafts. Rocker arm shaft outside diame- 1.
Page 256: Installing The Camshaft And Rocker Arms
CAMSHAFT Recommended lubricant Rocker arm shaft Intake rocker arm stopper pin Molybdenum disulfide oil Spring Rocker arm roller Molybdenum disulfide oil 3. Install: • Spring “1” Install the spring so that the ends “a” of the spring are positioned at the locations shown in the illustration.
Page 257 CAMSHAFT 5. Install: • Camshaft stopper plate Camshaft stopper plate bolt (M5×16) 8 N·m (0.8 kgf·m, 5.9 lb·ft) Camshaft stopper plate bolt (M6×14) 8 N·m (0.8 kgf·m, 5.9 lb·ft) Before installing the camshaft stopper plate, make sure that the slots “a” in the rocker arm shafts “1”...
Page 258 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove ’ Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-7. Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-16. Valve cotter Upper spring seat Valve spring Intake valve...
Page 259: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
Page 260: Checking The Valve Seats
VALVES AND VALVE SPRINGS EAS30285 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: • Carbon deposits (from the valve face and valve seat) 2. Check: • Valve seat Pitting/wear → Replace the cylinder head. G088960 3.
Page 261 VALVES AND VALVE SPRINGS Where the valve seat and valve face contacted For the best lapping results, lightly tap the valve one another, the blue layout fluid will have been seat while rotating the valve back and forth be- removed. tween your hands.
Page 262: Checking The Valve Springs
VALVES AND VALVE SPRINGS EAS30286 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. Free length (intake) Limit 3. Install: 32.11 mm (1.26 in) •...
Page 263 VALVES AND VALVE SPRINGS Valve spring compressor YSST-603 (90890-04019) Valve spring compressor attach- ment YSST-603 A (90890-04109) 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve.
Page 264: Cylinder And Piston
CYLINDER AND PISTON EAS20046 CYLINDER AND PISTON Removing the cylinder and piston 10 N·m (1.0 kgf·m, 7.4 lb·ft) F W F W Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-7. Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin...
Page 265: Removing The Piston
CYLINDER AND PISTON EAS30289 EAS30291 REMOVING THE PISTON CHECKING THE CYLINDER AND PISTON 1. Remove: 1. Check: • Piston pin clips “1” • Piston wall • Piston pin “2” • Cylinder wall Vertical scratches → Replace the cylinder, and • Piston “3” replace the piston and piston rings as a set.
Page 266: Checking The Piston Rings
CYLINDER AND PISTON 2. Install: b. 6.0 mm (0.24 in) from the bottom edge of the piston • Piston ring (into the cylinder) Piston Diameter Level the piston ring into the cylinder with the 57.962–57.985 mm (2.2820– piston crown. 2.2829 in) d.
Page 267: Installing The Piston And Cylinder
CYLINDER AND PISTON 2. Measure: • Piston pin outside diameter “a” Out of specification → Replace the piston pin. Piston pin outside diameter Limit 13.975 mm (0.5502 in) 2. Install: • Piston “1” • Piston pin “2” • Piston pin clips “3” •...
Page 268 CYLINDER AND PISTON 4. Offset: • Piston ring end gaps a. Top ring b. 2nd ring c. Upper oil ring rail d. Oil ring expander e. Lower oil ring rail A. Exhaust side 5. Install: • Dowel pins • Cylinder head gasket •...
Page 269: Magneto And Starter Clutch
MAGNETO AND STARTER CLUTCH EAS20140 MAGNETO AND STARTER CLUTCH Removing the magneto and starter clutch Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-10. Refer to “GENERAL CHASSIS (3)” on page Upper side cowling (left) 4-3.
Page 270 MAGNETO AND STARTER CLUTCH Removing the magneto and starter clutch 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 70 N·m (7.0 kgf·m, 52 lb·ft) Order Job/Parts to remove Q’ty...
Page 271: Removing The Magneto
MAGNETO AND STARTER CLUTCH EAS30867 REMOVING THE MAGNETO Magneto puller 1. Remove: YSST-702 • Magneto rotor nut “1” (90890-04141) • Washer Bush YSST-893 • While holding the magneto rotor “2” with the mag- neto holder “3”, loosen the magneto rotor nut. •...
Page 272: Installing The Starter Clutch
MAGNETO AND STARTER CLUTCH • While holding the magneto rotor “2” with the magneto holder “3”, tighten the starter clutch bolts. • Do not allow the magneto holder to touch the projection on the magneto rotor. • Stake the end “a” of each starter clutch bolt. Magneto holder YSST-701 (90890-01701)
Page 273 10 N·m (1.0 kgf·m, 7.4 lb·ft) (90890-01481) Tighten the magneto cover bolts in the proper tightening sequence as shown. 3. Apply: • Sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 (90890-85505) (Three bond No.1215-B) 5-36...
Page 274: Electric Starter
ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove ’ Remarks Refer to “GENERAL CHASSIS (3)” on page Lower side cowling 4-3. Starter motor Starter motor lead Disconnect. For installation, reverse the removal procedure. 5-37...
Page 275 ELECTRIC STARTER Disassembling the starter motor ’ Order Job/Parts to remove Remarks O-ring Starter motor yoke Gasket Commutator Starter motor front cover/brush holder set Brush set Brush Brush spring For assembly, reverse the disassembly procedure. 5-38...
Page 276: Checking The Starter Motor
ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR Multimeter 1. Check: INS-003 • Commutator (90890-03189) Dirt → Clean with 600 grit sandpaper. 2. Measure: Armature coil resistance • Commutator diameter “a” 0.028–0.034 Ω Out of specification → Replace the starter motor. b.
Page 277: Assembling The Starter Motor
ELECTRIC STARTER • Oil seal Damage/wear → Replace the starter motor front cover/brush holder set. EAS30326 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor front cover/brush holder set “1” • Starter motor yoke “2” Align the marks “a” on the starter motor yoke and starter motor front cover/brush holder set.
Page 278: Clutch
CLUTCH EAS20055 CLUTCH Removing the clutch cover Order Job/Parts to remove ’ Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-10. Refer to “GENERAL CHASSIS (3)” on page Lower side cowling (right) 4-3. Clutch cable Disconnect. Oil filter element cover Oil filter element Clutch cover...
Page 279 CLUTCH Removing the clutch ’ Order Job/Parts to remove Remarks Clutch cover Refer to “CLUTCH” on page 5-41. Locknut & washer Pressure plate 1 Clutch spring Pressure plate 2 Short clutch push rod Clutch push rod holder Ball Long clutch push rod Take out with the help of magnetic driver.
Page 280 CLUTCH Removing the clutch ’ Order Job/Parts to remove Remarks Lock washer Clutch boss Thrust washer Clutch housing Conical spring washer For installation, reverse the removal procedure. 5-43...
Page 281 CLUTCH Removing the push lever ’ Order Job/Parts to remove Remarks Pressure plate 2 Refer to “CLUTCH” on page 5-41. Clutch push lever Clutch push lever spring Circlip Oil seal Bearing For installation, reverse the removal procedure. 5-44...
Page 282: Removing The Clutch
CLUTCH EAS30346 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: • Clutch boss nut “1” While holding the clutch boss “2” with the clutch hub holder “3”, loosen the clutch boss nut. Clutch hub holder YSST-733A A. Friction plate 1 (Black color - Thinner (90890-04086) width) B.
Page 283: Checking The Clutch Springs
CLUTCH Clutch plate thickness 1 Pitting on the clutch housing dogs will cause er- 2.18–2.42 mm (0.085–0.095 in) ratic clutch operation. Warpage limit 0.10 mm (0.004 in) Clutch plate thickness 2 2.20–2.40 mm (0.086–0.094 in) Warpage limit 0.10 mm (0.0039 in) 2.
Page 284: Checking The Primary Drive Gear
CLUTCH EAS30356 CHECKING THE PRIMARY DRIVE GEAR Install the conical spring washer as shown in the 1. Remove: illustration. • Primary drive gear Refer to “BALANCER GEAR” on page 5-54. 2. Check: • Primary drive gear Damage/wear → Replace the primary drive gear and clutch housing as a set.
Page 285 CLUTCH 8. Lubricate: Clutch boss nut • Bearing 70 N·m (7.0 kgf·m, 52 lb·ft) • Oil seal • Clutch push lever 9. Install: While holding the clutch boss “2” with the clutch • Bearing hub holder “3”, tighten the clutch boss nut. •...
Page 286 CLUTCH • Loosen the locknut “2”. • With the clutch push lever fully pushed in • Apply engine oil to inside surface of cover boss direction “c”, turn the short clutch push rod and outside surface of oil seal. “3” in or out until projection “a” aligns with •...
Page 287: Oil Pump
OIL PUMP EAS20054 OIL PUMP Removing the oil pump Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-41. Balancer drive gear Refer to “BALANCER GEAR” on page 5-54. Oil pump baffle plate Oil pump assembly Oil pump drive gear For installation, reverse the removal procedure.
Page 288: Checking The Oil Pump
OIL PUMP EAS30337 CHECKING THE OIL PUMP 1. Check: • Oil pump drive gear • Oil pump driven gear • Oil pump housing cover Cracks/damage/wear → Replace the defec- tive part(s). 2. Check: • Oil pump operation Rough movement → Replace EAS30343 INSTALLING THE OIL PUMP 1.
Page 289: Shift Shaft
SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-41. Shift pedal Refer to “ENGINE REMOVAL” on page 5-1. Shift shaft Circlip Shift shaft spring Stopper lever Stopper lever spring Oil seal...
Page 290: Checking The Shift Shaft
SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS30378 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever 3. Tighten the stopper lever bolt “1”. Bends/damage → Replace. Roller turns roughly →...
Page 291: Balancer Gear
BALANCER GEAR EAS20219 BALANCER GEAR Removing the primary drive gear and balancer gears ’ Order Job/Parts to remove Remarks Clutch housing Refer to “CLUTCH” on page 5-41. Primary drive gear nut Balancer driven gear nut Washer Primary drive gear Spacer Balancer drive gear Straight key Lock washer...
Page 292: Removing The Primary Drive Gear And Balancer Gears
BALANCER GEAR EAS32459 ASSEMBLING THE BALANCER DRIVEN REMOVING THE PRIMARY DRIVE GEAR GEAR AND BALANCER GEARS 1. Assemble: 1. Loosen: • Buffer boss “1” • Primary drive gear nut “1” • Balancer driven gear “2” Place the aluminum plate “a” between the bal- Align the punch mark “a”...
Page 293 BALANCER GEAR 2. Tighten: • Balancer driven gear nut “1” • Primary drive gear nut “2” Balancer driven gear nut 35 N·m (3.5 kgf·m, 26 lb·ft) Primary drive gear nut 60 N·m (6.0 kgf·m, 44 lb·ft) • Place the aluminum plate “a” between the bal- ancer drive gear “3”...
Page 294: Crankcase
CRANKCASE EAS20059 CRANKCASE Separating the crankcase Order Job/Parts to remove ’ Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Cylinder head Refer to “CYLINDER HEAD” on page 5-7. Refer to “CYLINDER AND PISTON” on Cylinder/Piston page 5-27. Clutch housing Refer to “CLUTCH”...
Page 295 CRANKCASE Separating the crankcase ’ Order Job/Parts to remove Remarks Plug with O-ring Timing chain guide (intake side) Chain cover Timing chain Engine oil drain plug Spring Engine oil strainer Gear position switch Crankcase (right) Dowel pin Crankcase (left) For installation, reverse the removal procedure.
Page 296 CRANKCASE Removing the oil seal and bearings ’ Order Job/Parts to remove Remarks Crankshaft/Balancer Refer to “CRANKSHAFT” on page 5-63. Transmission Refer to “TRANSMISSION” on page 5-66. Oil seal Bearing retainer Bearing For installation, reverse the removal procedure. 5-59...
Page 297: Separating The Crankcase
CRANKCASE EAS32673 ECA13900 SEPARATING THE CRANKCASE 1. Remove: Tap on one side of the crankcase with a • Crankcase bolts soft-face hammer. Tap only on reinforced portions of the crankcase, not on the crank- Loosen each bolt 1/4 of a turn at a time, in stag- case mating surfaces.
Page 298: Checking The Crankcase
CRANKCASE EAS31766 CHECKING THE BEARINGS AND OIL SEAL Bearing punch with pilot driver 1. Check: YSST-951 • Bearings Clean and lubricate the bearings, and then rotate the inner race with your finger. Rough movement → Replace. • Oil seal Damage/wear → Replace. EAS31603 INSTALLING THE BEARING RETAINER 1.
Page 299 • M6 × 55 mm: “15”, “16” • M6 × 45 mm: “1–6”, “11” 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 2,13 (Three bond No.1215-B) 3,14 • Do not allow any sealant to come into contact with the oil gallery.
Page 300: Crankshaft
CRANKSHAFT EAS20061 CRANKSHAFT Removing the crankshaft and balancer Order Job/Parts to remove ’ Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-57. Balancer Crankshaft For installation, reverse the removal procedure. 5-63...
Page 301: Removing The Crankshaft
CRANKSHAFT EAS30416 2. Measure: REMOVING THE CRANKSHAFT • Crankshaft width 1. Remove: Out of specification → Replace the crank- • Crankshaft “1” shaft. Crank assembly width • Remove the crankshaft with the crankcase 47.95–48.00 mm (1.888–1.890 in) separating tool “2”. •...
Page 302 CRANKSHAFT Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft bot- toms against the bearing. 5-65...
Page 303: Transmission
TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove ’ Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-57. Shift fork guide bar Spring Use torx bit (T-30) YSST-611 for dismantling Shift drum assembly shift drum assembly and cam shifter seg- ment.
Page 304 TRANSMISSION Disassembling the drive axle ’ Order Job/Parts to remove Remarks Circlip Washer 2nd wheel gear 6th wheel gear Washer 1st wheel gear Spacer 5th wheel gear Circlip Toothed washer 4th wheel gear 3rd wheel gear Drive axle For assembly, reverse the disassembly procedure.
Page 305: Checking The Shift Forks
TRANSMISSION EAS30431 EAS30432 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum groove Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.
Page 306: Assembling The Drive Axle
TRANSMISSION 3. Check: 2. Install: • Transmission gears • 2nd pinion gear “1” Blue discoloration/pitting/wear → Replace the defective gear(s). Press the 2nd pinion gear into the main axle “2”, • Transmission gear dogs as shown in the illustration. Cracks/damage/rounded edges → Replace the defective gear(s).
Page 307 TRANSMISSION 2. Check: • Transmission Rough movement → Repair. • Apply engine oil to each gear and bearing thor- oughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 5-70...
Page 308 TRANSMISSION 5-71...
Page 309: Cooling System
COOLING SYSTEM RADIATOR .....................6-1 CHECKING THE RADIATOR ..............6-3 INSTALLING THE RADIATOR ..............6-3 THERMOSTAT ....................6-5 CHECKING THE THERMOSTAT ASSEMBLY ........6-5 INSTALLING THE THERMOSTAT ASSEMBLY ........6-5 WATER PUMP ....................6-6 DISASSEMBLING THE WATER PUMP ...........6-8 CHECKING THE WATER PUMP .............6-8 ASSEMBLING THE WATER PUMP ............6-8 INSTALLING THE WATER PUMP ............6-8...
Page 310: Radiator
COOL RADIATOR EAS20063 RADIATOR Removing the radiator ’ Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS (3)” on page Lower side cowling (left and right) 4-3. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-16. Fuel tank Refer to “FUEL TANK” on page 7-1. Throttle cables Refer to “THROTTLE BODY”...
Page 311 COOL RADIATOR Removing the radiator ’ Order Job/Parts to remove Remarks Radiator cap Radiator Radiator fan Radiator cover Thermostat For installation, reverse the removal procedure.
Page 312: Checking The Radiator
COOL RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
Page 313 COOL RADIATOR c. Measure the indicated pressure with the gauge. 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.
Page 314: Thermostat
COOL THERMOSTAT EAS20065 THERMOSTAT EAS31248 CHECKING THE THERMOSTAT ASSEMBLY 1. Check: • Thermostat “1” Does not open at 74–78°C (165–172°F) → 0.5 mm (0.02 in) 7 mm Replace. (0.28 in) 74 – 78˚C 90˚C (165 – 172˚F) (194˚F) A. Fully closed B.
Page 315: Water Pump
COOL WATER PUMP EAS20066 WATER PUMP Removing the water pump 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Job/Parts to remove ’ Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.
Page 316 COOL WATER PUMP Disassembling the water pump ’ Order Job/Parts to remove Remarks O-ring Radiator bracket Water pump housing cover Water pump housing cover gasket Circlip Impeller shaft Water pump seal Bearing For removing, use YSST-723 Water pump housing For assembly, reverse the disassembly procedure.
Page 317: Disassembling The Water Pump
COOL WATER PUMP EAS30446 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” Remove the water pump seal from the inside of the water pump housing “2”. A. Push down 3. Mechanical seal installer 4. Middle driven shaft bearing driver EAS30447 CHECKING THE WATER PUMP 1.
Page 318 COOL WATER PUMP Water pump assembly bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) • Align the projection “a” on the impeller shaft with the slit “b” on the camshaft sprocket bolt. • Lubricate the O-ring with a thin coat of lithium- soap-based grease.
Page 319: Fuel System
FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK ..............7-4 REMOVING THE FUEL PUMP ..............7-4 CHECKING THE FUEL PUMP BODY ............7-4 INSTALLING THE FUEL PUMP ASSEMBLY ..........7-4 INSTALLING THE FUEL TANK ..............7-5 CHECKING THE FUEL PRESSURE ............7-5 THROTTLE BODY ..................7-7 REMOVING THE THROTTLE BODY ............7-9 CHECKING THE FUEL INJECTOR ............7-9 INSTALLING THE FUEL INJECTOR ............7-9...
Page 320: Fuel Tank
FUEL TANK EAS20067 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Passenger and rider seat 4-1. Refer to “GENERAL CHASSIS (2)” on page Side cover (left and right) Fuel tank cover bolts (left/ right) Fuel tank cover (left/ right) Fuel tank top cover...
Page 321 FUEL TANK Removing the fuel tank and fuel pump Order Job/Parts to remove Q’ty Remarks Fuel tank mounting bracket Fuel pump retainer Fuel pump assembly Fuel pump gasket Fuel sender unit assembly For installation, reverse the removal proce- dure.
Page 322 FUEL TANK Removing the canister Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Side cover (left and right) 4-2. Refer to “GENERAL CHASSIS (3)” on page Lower side cowling (left and right) 4-3. Canister mounting bolt / Collar Hose (canister to throttle body) Disconnect.
Page 323: Removing The Fuel Tank
FUEL TANK EAS26630 EAS26640 REMOVING THE FUEL TANK REMOVING THE FUEL PUMP 1. Extract the fuel in the fuel tank through the 1. Remove: fuel tank cap with a pump. • Fuel pump retainer 2. Remove • Fuel pump • Fuel tank assembly mounting bolt & screws •...
Page 324: Installing The Fuel Tank
FUEL TANK 4 N·m (0.4 kgf·m,3.0 lb·ft) 3. Connect: ECA3C11005 INSTALLING THE FUEL TANK • Fuel hose 1. Install: • Fuel overflow hose • Fuel tank • Hose (fuel tank to canister) 2. Connect: • Fuel sender coupler • Fuel hose •...
Page 325 FUEL TANK ECA20020 4. Install: • Fuel tank assembly mounting bolt & screws Although the fuel has been removed from Refer to “FUEL TANK” on page 7-1. the fuel tank, be careful when removing the • Side covers fuel hose, since there may be fuel remaining Refer to “GENERAL CHASSIS (3)”...
Page 326: Throttle Body
THROTTLE BODY EAS20070 THROTTLE BODY Removing the throttle body Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS (6)” on page Air filter case 4-8. Fuel hose Disconnect. Fuel injector cover Fuel injector coupler Disconnect.
Page 327 THROTTLE BODY Removing the throttle body Order Job/Parts to remove Q’ty Remarks Throttle cable (accelerator cable) Disconnect. Throttle cable (decelerator cable) Disconnect. Hose (Throttle body to canister) Disconnect. ECA22690 Throttle body The throttle body should not disassem- bled. Intake manifold For installation, reverse the removal procedure.
Page 328: Removing The Throttle Body
THROTTLE BODY EAS3C11025 EAS3C11028 REMOVING THE THROTTLE BODY CHECKING THE FUEL INJECTOR 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank filler hole with a pump. • Fuel injector Damage → Replace. 2. Disconnect: • Fuel hose INSTALLING THE FUEL INJECTOR WARNING 1.
Page 329 THROTTLE BODY 4. Check: • Engine idling speed • Sensor assembly • Throttle body with Yamaha diagnostic tool Yamaha diagnostic tool INS-018 (90890-03267) INS-019 (90890-03264) 2. Adjust: • Throttle grip free play Refer to “ADJUSTING THE THROTTLE GRIP FREE PLAY” on page 3-7.
Page 330 THROTTLE BODY 7-11...
Page 331: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION ......8-2 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM ..............8-5 CIRCUIT DIAGRAM .................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-6 TROUBLESHOOTING ................8-7 CHARGING SYSTEM ..................8-9 CIRCUIT DIAGRAM .................8-9 TROUBLESHOOTING ................8-10 LIGHTING SYSTEM ..................
Page 332 ABS (ANTI-LOCK BRAKE SYSTEM) ............8-101 CIRCUIT DIAGRAM ................8-101 ABS COUPLER LOCATION CHART ...........8-103 MAINTENANCE OF THE ABS ECU ............8-104 ABS TROUBLESHOOTING OUTLINE ..........8-104 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-105 BASIC PROCESS FOR TROUBLESHOOTING ........8-107 [A] CHECKING THE ABS WARNING LIGHT ........8-108 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON ..8-108 [A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ......8-108 [A-3] THE ABS WARNING LIGHT COMES ON ........8-108...
Page 334: Ignition System
ELEC – IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM R Br Br/W R R/L SPARE SPARE Ch Y/B B/R R/W L/G R/B P/W Or/B W/Y W/R Y G Br R Lg/L W G/R Y/G Y/L B/Y L Lg/W W/B B/L B/W Br/W Gy/G Y/W B/L P/B Or...
Page 335: Engine Stopping Due To Sidestand Operation
ELEC – IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 336: Troubleshooting
ELEC – IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Passenger seat and rider seat 2. Side cover (left and right) 3. Fuel tank cover (left and right) 4.
Page 337 ELEC – IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-139. OK ↓ NG → 9. Check the engine stop / start switch. The engine stop / start switch is faulty. Refer to “CHECKING THE Replace the right handlebar switch.
Page 338: Electric Starting System
ELEC – ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM R Br Br/W R R/L SPARE SPARE Br/L Br/W Br/L L/W Br/W START Dg Ch CONNECTED R/W R/W Ch Y/B B/R Dg W/B Br R/B B B B/Y B R/W R/W R/W Ch Y/B B B/R B B/W 5.
Page 339: Starting Circuit Cut-Off System Operation
ELEC – ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop/start 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 340: Troubleshooting
ELEC – ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Passenger seat and rider seat 2. Side cover (left and right) 3. Fuel tank cover (left and right) 4. Upper panel (left and right) 5.
Page 341 ELEC – ELECTRIC STARTING SYSTEM NG → 8. Check the gear position switch (neutral switch). Replace the gear position switch (neutral Refer to “CHECKING THE switch). SWITCHES” on page 8-139. OK ↓ NG → 9. Check the clutch switch. Refer to “CHECKING THE Replace the clutch switch.
Page 342: Charging System
ELEC – CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM R Br R R/L Br/W SPARE SPARE 1. AC magneto assembly 3. AC magneto 4. Rectifier/regulator 5. Fuse box 8. Main fuse 12.Battery...
Page 343: Troubleshooting
ELEC – CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Passenger seat and rider seat 2. Side cover (left) 3. Fuel tank cover (left) and upper panel (left) 4. Upper side cowling (left) and lower side cowling (left) NG →...
Page 344 ELEC – CHARGING SYSTEM 8-11...
Page 345: Lighting System
ELEC – LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM R Br Br/W R R/L SPARE SPARE Ch Y/B B/R R/W L/G R/B P/W Or/B W/Y W/R Y G Br R Lg/L W G/R Y/G Y/L B/Y L Lg/W W/B B/L B/W Br/W Gy/G Y/W B/L P/B Or...
Page 346 ELEC – LIGHTING SYSTEM 5. Fuse box 6. Accessories fuse 8. Main fuse 11.Accessories socket 12.Battery 14.Handlebar switch (right) 15.Engine stop / start switch 23.ECU (Engine Control Unit) 39.Engine ground 40.Main switch 41.Meter assembly 43.Multi-function display 50.High beam indicator light 60.Handlebar switch (left) 61.Dimmer / pass switch 68.Junction 1...
Page 347: Troubleshooting
ELEC – LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary light or meter lights. • Before troubleshooting, remove the following part(s): 1. Passenger seat and rider seat 2.
Page 348 ELEC – LIGHTING SYSTEM 8-15...
Page 349: Signaling System
ELEC – SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM R Br Br/W R R/L SPARE SPARE Ch Y/B B/R R/W L/G R/B P/W Or/B W/Y W/R Y G Br R Lg/L W G/R Y/G Y/L B/Y L Lg/W W/B B/L B/W Br/W Gy/G Y/W B/L P/B Or...
Page 350 15.Engine stop / start switch 16.Trip / information switch 17.Hazard switch 18.Front brake light switch 23.ECU (Engine control unit) 28.Coolant temperature sensor 32.Fuel sender 34.Yamaha diagnostic tool coupler/ABS test coupler 35.CCU (Communication control unit) 36.Quick shift switch 39.Engine ground 40.Main switch 41.Meter assembly 42.Neutral indicator light...
Page 351: Troubleshooting
ELEC – SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal lights, brake light or indicator lights. • The horn fails to sound. • The fuel meter fails to operate. • The speedometer fails to operate. •...
Page 352 ELEC – SIGNALING SYSTEM NG → 2. Check the horn. Refer to “CHECKING THE HORN” Replace the horn. on page 8-151. OK ↓ NG → 3. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness.
Page 353 ELEC – SIGNALING SYSTEM NG → 4. Check the turn signal relay. Refer to “CHECKING THE Replace the turn signal relay. RELAYS” on page 8-146. OK ↓ NG → 5. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM”...
Page 354 ELEC – SIGNALING SYSTEM QS (Quick Shift System) does not operate. NG → 1. Check that the engine trouble and system warning light does not come Repair the faulty parts. OK ↓ NG → Check the QS operating conditions 2. Check that the QS is working under explained in the owner’s manual and normal QS operating conditions.
Page 355 ELEC – SIGNALING SYSTEM The speedometer fails to operate. NG → 1. Check the front wheel sensor. Refer to “CHECKING THE SPEED Replace the front wheel sensor. SENSOR” on page 8-152. OK ↓ NG → 2. Check the entire signaling system wiring.
Page 356 ELEC – SIGNALING SYSTEM The coolant temperature warning light fails to come on. NG → 1. Check the coolant temperature sensor. Refer to “CHECKING THE COOL- Replace the coolant temperature sensor. ANT TEMPERATURE SENSOR” on page 8-152. OK ↓ NG → 2.
Page 357: Cooling System
ELEC – COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM R Br Br/W R R/L SPARE SPARE Ch Y/B B/R R/W L/G R/B P/W Or/B W/Y W/R Y G Br R Lg/L W G/R Y/G Y/L B/Y L Lg/W W/B B/L B/W Gy/G Y/W B/L P/B Or Br/W...
Page 358: Troubleshooting
ELEC – COOLING SYSTEM EAS27320 TROUBLESHOOTING • The radiator fan motor fails to turn. • The coolant temperature warning light fails to come on. • Before troubleshooting, remove the following part(s): 1. Passenger seat and rider seat 2. Side cover (left and right) 3.
Page 359 ELEC – COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or replace the cooling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-24. OK ↓ Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (engine control unit)”...
Page 360 ELEC – COOLING SYSTEM 8-27...
Page 361: Fuel Injection System
ELEC – FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM R Br R R/L Br/W SPARE SPARE R R R Ch Y/B B/R R/W L/G R/B P/W Or/B W/Y W/R Y G Br R Lg/L W G/R Y/G Y/L B/Y L Lg/W W/B B/L B/W Br/W Gy/G Y/W B/L...
Page 362 27.FID (Fast idle device) 28.Coolant temperature sensor 29.VVA (variable valve actuation) solenoid 30.Lean angle sensor 31.Fuel pump 33.Fuel injector 34.Yamaha diagnostic tool coupler/ABS test coupler 35.CCU (Communication control unit) 36.Quick shift switch 39.Engine ground 40.Main switch 41.Meter assembly 43.Multi-function display 44.Traction control indicator light...
Page 363 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 364 Erase the malfunction history: Turning the main switch to “OFF” will not erase the malfunction history. Erase the malfunction history in the diagnostic mode. Refer to “Operation of the Yamaha diagnostic tool (Fault diagnosis mode) (Step no. 12)”. *For when engine trouble warning light is lit.
Page 365 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 366 Records and saves the sensor output value in actual driving condi- tions. Writing VIN/frame number: Write the VIN/frame number in the ECU. View logs: Displays the logging data. However, the Yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such as adjusting the ignition timing. 8-33...
Page 367 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. 1. Detected The malfunction currently occurred are displayed. 2. Recovered The malfunction detected in the past (already recovered) are displayed.
Page 368 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 369 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 turn off engine trouble warning light, use YDT (Yamaha diagnostic tool) to erase all fault codes.
Page 370: Self-Diagnostic Function And Diagnostic Code Table
SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault code Item Symptom Possible cause Remarks P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate. sensor: normal sig- between crankshaft started. nals are not received position sensor and from the crankshaft ECU.
Page 371 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Fault code Item Symptom Possible cause Remarks P0122 [P0122] Throttle posi- [P0122] Low voltage Engine idling speed is Change in the throttle P0123 tion sensor (open or of the throttle position high. opening value is 0 short to ground circuit sensor circuit (0.2 V...
Page 372 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Fault code Item Symptom Possible cause Remarks P00D1 sensor: heater per- sensor voltage: Increased exhaust feedback is not emissions. formance deteriorat- 0.25 V or less and carried out. ed. (normal signal is 0.4 V or more.
Page 373 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Fault code Item Symptom Possible cause Remarks P0351 Ignition system (nor- • Defective coupler Engine stops. When engine is run- mal signal is not re- between ignition coil Loss of engine power. ning: ceived from the and ECU.
Page 374 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Fault code Item Symptom Possible cause Remarks P2158 Rear wheel sensor • Open or short cir- TCS (Traction Con- TCS (Traction Con- (normal signal is not cuit in wire harness trol System) does not trol System) does not received from the rear between rear wheel...
Page 375 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Fault code Item Symptom Possible cause Remarks P1601 Sidestand switch • Defective coupler Engine cannot be Engine is forcefully Open or short circuit between sidestand started. stopped (Ignition and in wire of the ECU is switch and ECU.
Page 376 SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE Fault code Item Symptom Possible cause Remarks P1604 [P1604] Lean angle [P1604] Low voltage Engine cannot be When engine is run- P1605 sensor (short to of the lean angle sen- started. ning: Engine is force- ground circuit is de- sor circuit (0.2 V or Engine stops.
Page 377: Diagnostic Code: Sensor Operation Table
SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic Item Tool display Procedure code No. Throttle position sensor sig- 0–125 • Fully closed position 13–21 Check the fully closed throt- tle valve. • Fully opened position 92–107 Check the fully opened throt- tle valve.
Page 378 : Indicated OFF feedback learning data To erase the O feedback feedback learning data erasure learning data, click the has been erased. Yamaha diagnostic tool “Actuator Check” button feedback learning data three times within 5 seconds. has not been erased. 8-45...
Page 379: Diagnostic Code: Actuator Operation Table
SELF-DIAGNOSTIC FUNCTION AND ELEC – DIAGNOSTIC CODE TABLE EAS32426 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE Diagnostic Item Actuation Procedure code No. Ignition coil Actuates the ignition coil five Check the energization of times at one-second inter- the ignition coil. vals. Check the sparking perfor- The “CHECK”...
Page 380: Fault Code Table
ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING FUEL INJECTION SYSTEM TROUBLESHOOTING EAS33149 FAULT CODE TABLE Fail-safe system Fault code Diagnostic Symptom Starting the Driving the code engine vehicle sensor heater: defective heater or heater “P0030” Able Able — driver ON / OFF command and error signal is mismatching.
Page 381 Able — wheel sensor. Normal signal is not received from the VVA “P2645” Able Able solenoid circuit while driving the VVA solenoid. COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL Fail-safe system Fault code Diagnostic Symptom Starting the Driving the code...
Page 382 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING COMMUNICATION ERROR WITH THE METER Fault code Probable cause of Fail-safe system Item Vehicle symptom malfunction operation ECU internal • Open or short circuit Signals cannot be Normally operated malfunction (Output in wire harness be- transmitted between except for the meter.
Page 383 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0106 Do not remove the throttle body sensor assembly from the throttle body. If fault code numbers “P0107/P0108” and “P0106” are indicated at the same time, perform the check/ service for fault code number “P0107/P0108”...
Page 384 “Recovered” us- light goes off. ing the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0107, P0108 Do not remove the throttle body sensor assembly from the throttle body.
Page 385 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0107, P0108 [P0107] Intake air pressure sensor: open or short to ground circuit is Item detected. [P0108] Intake air pressure sensor: short to power circuit is detected. Br/W Br/W B L / B L / 1.
Page 386 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0107, P0108 [P0107] Intake air pressure sensor: open or short to ground circuit is Item detected. [P0108] Intake air pressure sensor: short to power circuit is detected. [For P0107] Open circuit Between intake air pressure sensor coupler and ECU coupler: pink/white–pink/white If there is no continuity, replace the wire harness.
Page 387 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0107, P0108 [P0107] Intake air pressure sensor: open or short to ground circuit is Item detected. [P0108] Intake air pressure sensor: short to power circuit is detected. Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”, body sensor assembly.
Page 388 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0112, P0113 Do not remove the throttle body sensor assembly from the throttle body. Perform this procedure when the engine is cold. Fault code No. P0112, P0113 [P0112] Intake air temperature sensor: short to ground circuit is de- tected.
Page 389 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0112, P0113 [P0112] Intake air temperature sensor: short to ground circuit is de- tected. Item [P0113] Intake air temperature sensor: open or short to power circuit is detected. 1. Throttle body sensor assembly 2.
Page 390 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0112, P0113 [P0112] Intake air temperature sensor: short to ground circuit is de- tected. Item [P0113] Intake air temperature sensor: open or short to power circuit is detected. [For P0113] Open circuit Between intake air temperature sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness.
Page 391 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0112, P0113 [P0112] Intake air temperature sensor: short to ground circuit is de- tected. Item [P0113] Intake air temperature sensor: open or short to power circuit is detected. Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recover”...
Page 392 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0117, P0118 [P0117] Coolant temperature sensor: short to ground circuit is de- tected. Item [P0118] Coolant temperature sensor: open or short to power circuit is detected. G R / G R / B L / B L / 1.
Page 393 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0117, P0118 [P0117] Coolant temperature sensor: short to ground circuit is de- tected. Item [P0118] Coolant temperature sensor: open or short to power circuit is detected. [For P0118] Open circuit Between coolant temperature sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness.
Page 394 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0117, P0118 [P0117] Coolant temperature sensor: short to ground circuit is de- tected. Item [P0118] Coolant temperature sensor: open or short to power circuit is detected. Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recover”...
Page 395 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0122, P0123 [P0122] Throttle position sensor: open or short to ground circuit is Item detected. [P0123] Throttle position sensor: short to power circuit is detected. Br/W Br/W B L / B L / 1.
Page 396 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0122, P0123 [P0122] Throttle position sensor: open or short to ground circuit is Item detected. [P0123] Throttle position sensor: short to power circuit is detected. [For P0122] Open circuit Between throttle position sensor coupler and ECU coupler: yellow/white–yellow/white If there is no continuity, replace the wire harness.
Page 397 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0122, P0123 [P0122] Throttle position sensor: open or short to ground circuit is Item detected. [P0123] Throttle position sensor: short to power circuit is detected. Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”, body sensor assembly.
Page 398 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0030 Fault code No. P0030 sensor: defective heater or heater driver ON/OFF command and Item error signal is mismatching. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. —...
Page 399 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0030 sensor: defective heater or heater driver ON/OFF command and Item error signal is mismatching. Open or short circuit → Properly Wire harness continuity. Turn the main switch to “ON”, and then check the fault code connect or replace the wire har- using the malfunction mode of ness.
Page 400 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0132 Fault code No. P0132 sensor: short to power circuit is detected. Item Normal signal is not received from the O sensor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 401 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0132 sensor: short to power circuit is detected. Item Normal signal is not received from the O sensor. Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recover”...
Page 402 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0201 Item Fuel injector: malfunction in fuel injector. Open or short circuit → Replace Wire harness continuity. Execute the diagnostic mode. the wire harness. (Code No. 36) Operating sound → Go to item Between fuel injector coupler and ECU coupler.
Page 403 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0335 Crankshaft position sensor: normal signals are not received from Item the crankshaft position sensor. Open or short circuit → Replace Wire harness continuity. Crank the engine, and then the wire harness. check the fault code using the Between crankshaft position malfunction mode of the YDT.
Page 404 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0351 Fault code No. P0351 Ignition coil: open or short circuit is detected in the lead of the igni- Item tion coil. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
Page 405 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0351 Ignition coil: open or short circuit is detected in the lead of the igni- Item tion coil. Defective ignition coil. Measure the primary coil resis- Start the engine and let it idle for tance of the ignition coil (2.2–...
Page 406 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0480 Item Normal signal is not received from the radiator fan motor relay. Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ON”, the wire harness. and then check the condition of Between ECU coupler and radi- the fault code using the mal-...
Page 407 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0500 Front wheel sensor: normal signals are not received from the front Item wheel sensor. Improperly connected → Con- Connection of ABS ECU cou- Execute the diagnostic mode. pler. nect the coupler securely or re- (Code No.
Page 408 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0500 Front wheel sensor: normal signals are not received from the front Item wheel sensor. Malfunction in ECU. Replace the ECU. Execute the diagnostic mode. (Code No. 07) Rotate the front wheel by hand and check the condition of the fault code using the malfunction mode of the YDT.
Page 409 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0511 FID solenoid valve malfunction is detected. (Open or short circuit is Item detected between FID solenoid valve and ECU.) Open or short circuit → Replace Wire harness continuity. Turn the main switch to “ON”, the wire harness.
Page 410 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0560, P0563 [P0560] Battery charging voltage is abnormal. (Discharged condi- tion) Item [P0563] Battery charging voltage is abnormal. (Overcharged condi- tion) Delete the fault code and check Confirm that the fault code has that the engine trouble warning a condition of “Recover”...
Page 411 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P062F EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. “01” is indicated in the diagnos- Activate the CO volume adjust- Turn the main switch to “ON”, tic mode (Code No.
Page 412 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P0657 Fault code No. P0657 Fuel system voltage: normal voltage is not supplied to the fuel injec- Item tor and fuel pump. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 413 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P1601 Fault code No. P1601 Item Sidestand switch: open or short circuit is detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Sidestand switch Tool display •...
Page 414 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P1602 Fault code No. P1602 Malfunction in ECU internal circuit (malfunction of ECU power cut- Item off function). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. —...
Page 415 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P1602 Malfunction in ECU internal circuit (malfunction of ECU power cut- Item off function). Improperly connected → Con- Connection of ECU coupler. Turn the main switch to “ON”, Check the locking condition of nect the coupler securely or re- crank the engine, and then turn the coupler.
Page 416 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P1604, P1605 [P1604] Lean angle sensor: short to ground circuit is detected. Item [P1605] Lean angle sensor: open or short to power circuit is detected. Open or short circuit → Replace Wire harness continuity.
Page 417 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P1604, P1605 [P1604] Lean angle sensor: short to ground circuit is detected. Item [P1605] Lean angle sensor: open or short to power circuit is detected. [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
Page 418 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P1604, P1605 [P1604] Lean angle sensor: short to ground circuit is detected. Item [P1605] Lean angle sensor: open or short to power circuit is detected. [For P1605] Short circuit Between lean angle sensor output terminal (yellow/green) “a” of ECU coupler and any other ECU coupler terminal “b”.
Page 419 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P2158 Fault code No. P2158 Rear wheel sensor: normal signals are not received from the rear Item wheel sensor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. —...
Page 420 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P2158 Rear wheel sensor: normal signals are not received from the rear Item wheel sensor. Open or short circuit → Replace Wire harness continuity. Check the rear wheel speed the wire harness. with YDT monitor item.
Page 421 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P00D1, P2195 Fault code No. P00D1, P2195 [P00D1] O sensor: heater performance deteriorated. Normal signal Item is not received from the O sensor while driving the O sensor. [P2195] O sensor: Open circuit is detected. Able to start engine Fail-safe system Able to drive vehicle...
Page 422 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P00D1, P2195 [P00D1] O sensor: heater performance deteriorated. Normal signal Item is not received from the O sensor while driving the O sensor. [P2195] O sensor: Open circuit is detected. Open or short circuit → Replace Wire harness continuity.
Page 423 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P2645 Fault code No. P2645 VVA (Variable Valve Actuator): Normal signal is not received from Item the VVA solenoid circuit while driving the VVA solenoid. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 424 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. P2645 VVA (Variable Valve Actuator): Normal signal is not received from Item the VVA solenoid circuit while driving the VVA solenoid. Faulty VVA solenoid operation. Measure the VVA solenoid re- Set the main switch to “ON”. sistance.
Page 425 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Event code No. Item Latch up detected. Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ON”, (Code No. 08) then to “OFF”, and then back to Replace if defective. “ON”, and then check the condition of the MIL.
Page 426 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING COMMUNICATION ERROR WITH THE METER Fault code No. Er-1 Fault code No. Er-1 Item Normal signal is not received from the ECU. Able to start engine (Unable when ECU is malfunctioning) Fail-safe system Able to drive vehicle (Unable when ECU is malfunctioning) Diagnostic code No.
Page 427 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. Er-2 Fault code No. Er-2 Normal signal is not received from the ECU within the specification Item duration. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. —...
Page 428 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. Er-3 Fault code No. Er-3 Item Data from the ECU cannot be received correctly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Tool display — Procedure —...
Page 429 ELEC – FUEL INJECTION SYSTEM TROUBLESHOOTING Fault code No. Er-4 Fault code No. Er-4 Item Normal signal is not received from the meter assembly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Tool display —...
Page 430 ELEC – EVENT CODE TABLE EAS20164 EVENT CODE TABLE Fuel injection system Item Symptom Possible cause Remarks Latch up detected Detects a vehicle fall • Vehicle fall down Perform the checks and (Lean angle sensor) down (Latch up detect- • Sensor installation im- maintenance jobs for ed condition) properly...
Page 431 ELEC – EVENT CODE TABLE Item Symptom Possible cause Remarks Difficult/unable to start Engine starting difficult/ • Empty fuel tank • If a fault code is indi- engine unable condition de- • Defective fuel injec- cated, perform the tected tion system checks and mainte- •...
Page 432 ELEC – FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM R Br Br/W R R/L SPARE SPARE Ch Y/B B/R R/W L/G R/B P/W Or/B W/Y W/R Y G Br R Lg/L W G/R Y/G Y/L B/Y L Lg/W W/B B/L B/W Gy/G Y/W B/L P/B Or Br/W...
Page 433 ELEC – FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Passenger seat and rider seat 2. Side cover (left and right) 3. Fuel tank cover (left and right) and fuel tank top cover 4. Fuel tank If the fuel pump fails to operate.
Page 434 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM R Br R R/L Br/W SPARE SPARE Br/W Ch Y/B B/R R/W L/G R/B P/W Or/B W/Y W/R Y G Br R Lg/L W G/R Y/G Y/L B/Y L Lg/W W/B B/L B/W Br/W Gy/G Y/W B/L...
Page 435 9. ABS motor fuse 10.ABS solenoid fuse 12.Battery 14.Handlebar switch (right) 15.Engine stop / start switch 18.Front brake light switch 23.ECU (Engine control unit) 34.Yamaha diagnostic tool coupler/ABS test coupler 35.CCU (Communication control unit) 39.Engine ground 40.Main switch 41.Meter assembly 43.Multi-function display 54.ABS warning indicator light...
Page 436 P/W Y/W B W W/L W/B R/L Gy Br/W L/R L/B B/W Lg/L Lg/W 1. Front wheel sensor coupler 2. Rear wheel sensor coupler 3. Yamaha diagnostic tool coupler / ABS test coupler 4. ABS ECU coupler 5. Meter assembly coupler 8-103...
Page 437 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) EAS30845 MAINTENANCE OF THE ABS ECU Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are connected to the assembly as a set. •...
Page 438 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Self-diagnosis and servicing The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal- function history.
Page 439 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) 8-106...
Page 440 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) EAS30530 BASIC PROCESS FOR TROUBLESHOOTING Fails to Turn the main switch to “ON”, [A-1] Does only the ABS • The ABS warning light (LED) is come on and check the ABS warning warning light fail to defective.
Page 441 EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the YDT to the Yamaha diagnostic tool coupler / ABS test coupler and execute functional di- agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that is included with the tool.)
Page 442 ABS ECU coupler and ground. If there is no continuity, the wire harness is defective. Replace the wire harness. • Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou- pler / ABS test coupler.
Page 443 ABS (Anti-lock Brake System))” on page 8-112. Refer to this chart and check the vehicle. Once all the work is complete, delete the fault codes. [B-3] Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn- ing the main switch off.
Page 444 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) 3. The diagnosis codes related to the detected malfunction are displayed. A. Detected malfunction B. Recovered malfunction 4. ECU The types of the control units are displayed. (e.g., FI, ABS) 5. Status of malfunction The current conditions are displayed.
Page 445 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System)) For details of the fault code, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 8-105. Fail-safe system Diag- Fault code Start- Driving Item Symptom Check point nostic ing the the ve-...
Page 446 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fail-safe system Diag- Fault code Start- Driving Item Symptom Check point nostic ing the the ve- code engine hicle Rear wheel sensor Rear wheel sensor • Foreign material (abnormal pulse pe- signal is not re- adhered around riod) ceived properly.
Page 447 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fail-safe system Diag- Fault code Start- Driving Item Symptom Check point nostic ing the the ve- code engine hicle Front wheel sensor Front wheel sensor • Foreign material (missing pulses) signal is not re- adhered around ceived properly.
Page 448 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fail-safe system Diag- Fault code Start- Driving Item Symptom Check point nostic ing the the ve- code engine hicle Brake light switch or Brake light signal is • Defective signaling tail/brake light not received proper- system (tail/brake ly while the vehicle light or brake light...
Page 449 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fail-safe system Diag- Fault code Start- Driving Item Symptom Check point nostic ing the the ve- code engine hicle Hydraulic unit as- Power is not sup- • Blown ABS motor sembly (abnormal plied to the motor fuse ABS motor power circuit in the hydrau-...
Page 450 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fail-safe system Diag- Fault code Start- Driving Item Symptom Check point nostic ing the the ve- code engine hicle Front wheel sensor Front wheel sensor • Foreign material (missing pulses) signal is not re- adhered around ceived properly.
Page 451 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fail-safe system Diag- Fault code Start- Driving Item Symptom Check point nostic ing the the ve- code engine hicle Vehicle system pow- Power voltage sup- • Defective battery er supply (voltage of plied to the ABS •...
Page 452 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fail-safe system Diag- Fault code Start- Driving Item Symptom Check point nostic ing the the ve- code engine hicle Rear wheel sensor Power voltage sup- • Short circuit in the power supply (volt- plied from the ABS wire harness be- age of power supply ECU to the rear...
Page 453 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) BASIC INSTRUCTIONS FOR TROUBLESHOOTING - 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 454 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (intermittent pulses or no pulses) Rear wheel sensor signal is not received properly. (Pulses are not re- Symptom ceived or are received intermittently while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective rear wheel sensor or incorrect...
Page 455 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 14, 27 • If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record- ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re- corded.
Page 456 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 Open or short circuit in the wire harness •...
Page 457 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 458 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 459 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 Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed...
Page 460 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 31 Turn the main switch to “OFF” before disconnecting or connecting a coupler. Fault code No. Item Hydraulic unit assembly (abnormal ABS solenoid power supply) Power is not supplied to the solenoid circuit in the hydraulic unit as- Symptom sembly.
Page 461 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) 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. Order Item/components and probable cause Check or maintenance job Defective coupler between the battery •...
Page 462 ELEC – ABS (ANTI-LOCK BRAKE SYSTEM) 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 • Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
Page 463 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 464 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 Symptom are detected in the signal 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 465 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 466 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 467 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 Symptom is too low. Order Item/components and probable cause Check or maintenance job Short circuit in the wire harness between...
Page 468 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 469 EAS31167 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
Page 470 ELEC – ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 12,13,14,15 8-137...
Page 471 ELEC – ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Rectifier/regulator 5. Turn signal relay 6. Radiator fan motor relay 7. Hydraulic unit assembly 8. Spark plug 9. Ignition coil 10. Fuel sender 11. Fuel pump 12.
Page 472 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/L Ch Y/B B/R Dg W/B PASS START Dg Ch TRIP...
Page 473 ELEC – ELECTRICAL COMPONENTS ECA14371 Never insert the multimeter probes into the coupler terminal slots. Always insert the probes from the opposite end “a” of the coupler, taking care not to loosen or damage the leads. Multimeter INS-003 (90890-03189) When checking for continuity, switch back and forth between the switch positions a few times. The switches and their terminal connections are illustrated as in the following example of the main switch.
Page 474 ELEC – ELECTRICAL COMPONENTS EAS30550 CHECKING THE BULBS AND BULB Multimeter SOCKETS INS-003 (90890-03189) Do not check any of the lights that use LEDs. a. Connect the positive tester probe to termi- Check each bulb and bulb socket for damage or nal “1”...
Page 475 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 may cause extensive damage to the electri- To avoid a short circuit, always turn the main cal system, cause the lighting and ignition...
Page 476 ELEC – ELECTRICAL COMPONENTS INSTALLING THE ECU (engine control unit) 1. Remove: 1. Connect: • Rider seat • ECU coupler “1” Refer to “GENERAL CHASSIS (1)” on page 4-1. 2. Disconnect: Make sure that the ECU coupler is connected in •...
Page 477 ELEC – ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehi- cle, disconnect the negative battery lead from the battery terminal.) •...
Page 478 ELEC – ELECTRICAL COMPONENTS Charging method using a variable-current (volt- age) charger Voltage should be measured 30 minutes after a. Measure the open-circuit voltage prior to the engine is stopped. charging. b. Connect a charger and ammeter to the Voltage should be measured 30 minutes after battery and start charging.
Page 479 ELEC – ELECTRICAL COMPONENTS 8. Check: Radiator fan motor relay • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • Battery terminals Recommended lubricant Dielectric grease 10.Install: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 1.
Page 480 ELEC – ELECTRICAL COMPONENTS b. Set the main switch to “ON”. For diode 1: c. Measure the turn signal relay input volt- Continuity age. Positive tester probe → sky/ 2. Check: blue “1” • Turn signal relay output voltage Negative tester probe → red/ Out of specification →...
Page 481 ELEC – ELECTRICAL COMPONENTS 2. Check: Multimeter • Secondary coil resistance INS-003 Out of specification → Replace. (90890-03189) Secondary coil resistance 9.45–11.55 kΩ a. Disconnect the spark plug cap from the ig- nition coil. b. Connect the multimeter (Ω × 1k) to the ig- nition coil as shown.
Page 482 • Crankshaft position sensor coupler angle (from the wire harness) 3.7–4.4 V 2. Check: Connecting the Yamaha diagnostic tool. • Crankshaft position sensor resistance Out of specification → Replace the crank- Refer to “FUEL INJECTION SYSTEM” on page 8-28. shaft position sensor/stator assembly.
Page 483 ELEC – ELECTRICAL COMPONENTS EWA13810 WARNING • A wire that is used as a jumper lead must have at least the same capacity of the bat- tery lead, otherwise the jumper lead may burn. • This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity.
Page 484 ELEC – ELECTRICAL COMPONENTS a. Connect the multimeter (Ω × 10) to the fuel CHECKING THE HORN 1. Check: sender coupler as shown. • Horn resistance Multimeter Out of specification → Replace. INS-003 (90890-03189) Coil resistance 1.35–1.75 Ω • Positive tester probe → a.
Page 485 0–999 2777 Ω at 68 °F) Coolant temperature sensor re- Connecting the Yamaha diagnostic tool. sistance Refer to “YAMAHA DIAGNOSTIC TOOL” on 210–221 Ω at 100 °C (210–221 Ω page 8-32. at 212 °F) EAS30577 a. Connect the multimeter (Ω × 100) to the...
Page 486 Out of specification → Replace the throttle Throttle position sensor body assembly. 1. Check: • Throttle position sensor with Yamaha diag- FID (fast idle solenoid) resistance nostic tool 31.5–38.5 Ω Connecting the Yamaha diagnostic tool. Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-32.
Page 487 ELEC – ELECTRICAL COMPONENTS Multimeter INS-003 (90890-03189) • Positive tester probe → solenoid terminal “1” • Negative tester probe → solenoid terminal “2” c. Measure the fuel injector resistance. c. Measure the VVA solenoid resistance. EAS30681 CHECKING THE FUEL INJECTOR 1.
Page 488 ELEC – ELECTRICAL COMPONENTS 8-155...
Page 489: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ...........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING ...............9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-3 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4...
Page 490: Troubleshooting
TRBL SHTG TROUBLESHOOTING EAS28450 4. Canister TROUBLESHOOTING • Hose clogged • Hose band / twisted EAS28460 GENERAL INFORMATION Electrical system 1. Battery The following guide for troubleshooting does not • Discharged battery cover all the possible causes of trouble. It should •...
Page 491: Poor Medium-And-High-Speed Performance
TRBL SHTG TROUBLESHOOTING Fuel system Transmission • Seized transmission gear 1. Throttle body • Foreign object between transmission gears • Damaged or loose throttle body joint • Improperly assembled transmission • Improperly adjusted engine idling speed (idle adjusting screw) EAS28550 •...
Page 492: Overheating
TRBL SHTG TROUBLESHOOTING EAS28600 EAS28610 OVERHEATING OVERCOOLING Engine Cooling system 1. Engine clogged 1. Thermostat • Clogged coolant passages • Thermostat stays opened • Clogged engine oil passages • Faulty coolant temperature sensor • Heavy carbon buildup on piston top & valves EAS28640 head.
Page 493: Faulty Lighting Or Signaling System
TRBL SHTG TROUBLESHOOTING 2. Front fork leg(s) Tail/brake light bulb burnt out • Wrong tail/brake light bulb (LED) • Unevenly oil levels (both front fork legs) • Unevenly tensioned fork spring (both front • Faulty battery fork legs) • Incorrectly adjusted rear brake light switch •...
Page 494 84. Headlight (High beam) 32. Fuel sender Yellow/Black 85. Headlight (Low beam) 33. Fuel injector Yellow/Green 86. License plate light 34. Yamaha diagnostic tool cou- Yellow/Blue 87. Auxiliary light (Right) pler/ABS test coupler Yellow/Red 88. Auxiliary light (Left) Yellow/White 35. CCU (Communication control...
Page 496 BCW-F8197-E0 1Y245(SM-01)1578-10-21-E...
Page 497 YZF155D-A 2022 WIRING DIAGRAM...

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R15m 2022 Yzf155d-a 2022 Yzf155-a 2022

Yamaha R15 2022 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel System

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha R15 2022