Yamaha 2012 TMAX XP500A Service Manual
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Yamaha 2012 TMAX XP500A Service Manual

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Table Of Contents
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Table of Contents

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2012

SERVICE MANUAL

XP500A
59C-28197-E1

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Summary of Contents for Yamaha 2012 TMAX XP500A

  • Page 1: Service Manual

    2012 SERVICE MANUAL XP500A 59C-28197-E1...
  • Page 2 EAS20040 XP500A SERVICE MANUAL ©2011 by Yamaha Motor Co., Ltd. First edition, November 2011 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4 EAS20091 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20101 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 Gear oil mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: Table Of Contents

    GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL..................1-1 FEATURES ....................1-2 OUTLINE OF FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 MULTI-FUNCTION DISPLAY..............1-4 OUTLINE OF THE ABS ................1-10 ABS COMPONENT FUNCTIONS ............1-16 ABS OPERATION .................1-22 ABS SELF-DIAGNOSIS FUNCTION ............1-25 ABS WARNING LIGHT AND OPERATION...........1-28 IMPORTANT INFORMATION ..............1-29 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-29 REPLACEMENT PARTS...............1-29...

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the storage box. This information will be needed to order spare parts.

  • Page 11: Outline Of Fi System

    FEATURES EAS20170 FEATURES EAS4B51038 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions. In a 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 chamber.

  • Page 12: Fi System

    FEATURES EAS4B51039 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU (engine control unit) energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the pas- sage remains open.

  • Page 13: Multi-Function Display

    FEATURES EAS52240 The multi-function display is equipped with the MULTI-FUNCTION DISPLAY following: EWA12312 • A fuel meter WARNING • A coolant temperature meter Be sure to stop the vehicle before making • An odometer any setting changes to the multi-function •...

  • Page 14: Coolant Temperature Meter

    FEATURES Odo → Trip 1 → Trip 2 → Trip F → V-Belt Trip 5. Push the left set button and then release it → Oil Trip → Odo to start the clock. Odometer and tripmeter modes 1. Fuel reserve tripmeter 1.

  • Page 15: Oil Change Indicator

    FEATURES 3. If the oil change indicator does not come on, check the electrical circuit. (Refer to “SIGNALING SYSTEM” on page 8-19) V-belt replacement indicator “V-Belt” ECA10021 Do not continue to operate the engine if it is overheating. Oil change indicator “Oil” 1.
  • Page 16 FEATURES Ambient temperature display, average fuel For the UK only: 15 °F to 104 °F in 1 °F increments. consumption and instantaneous fuel con- sumption modes The temperature displayed may vary from the ambient temperature. Pushing the right set button switches the ambient temperature dis- play to the average fuel consumption and instantaneous fuel consumption modes.
  • Page 17 FEATURES Self-diagnosis device After resetting an average fuel consumption display, “_ _._” is shown for that display until the vehicle has traveled 1 km (0.6 mi). Instantaneous fuel consumption mode 1. Error code display This model is equipped with a self-diagnosis device for various electrical circuits.
  • Page 18 FEATURES ECA11590 If the display indicates an error code, the vehicle should be checked as soon as pos- sible in order to avoid engine damage.

  • Page 19: Outline Of The Abs

    5. ABS test coupler The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a front brake lever for operating the front brake and a rear brake lever for operating the rear brake.
  • Page 20 FEATURES Useful terms • Wheel speed: The rotation speed of the front and rear wheels. • Chassis speed: The speed of the chassis. When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. •...
  • Page 21 FEATURES Brake force and vehicle stability When the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire and the road surface and brake force is generated. The limit of this brake force is determined by the friction force between the tire and the road surface and is closely related to wheel slippage.
  • Page 22 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. The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is equal to the wheel slip.
  • Page 23 FEATURES ABS operation and vehicle control If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the limit of control. To make the rider aware of this condition, the ABS has been designed to gener- ate a reaction-force pulsating action in the front brake lever and rear brake lever independently.
  • Page 24 FEATURES 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 condition and allows normal braking even if the ABS is not operating properly.

  • Page 25: Abs Component Functions

    FEATURES EAS59C2102 ABS COMPONENT FUNCTIONS Wheel sensors and wheel sensor rotors Wheel sensors “1” detect the wheel rotation speed and transmit the wheel rotation signal to the ABS ECU. Each wheel sensor contains a Hall IC. The wheel sensors are installed in the sensor housing for each wheel.
  • Page 26 FEATURES 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 set 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 func- tion check is properly completed at a speed of about 6 to 10 km/h [3.8 to 6.3 mi/h]).
  • Page 27 FEATURES • Hydraulic control valve The hydraulic control valve is composed of a inlet solenoid valve and outlet solenoid valve. The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cycle control voltage that is supplied to it. Since this voltage is continuously variable, the solenoid valve moves smoothly and the hydraulic pressure is adjusted linearly.
  • Page 28 FEATURES • Buffer chamber The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating. 1. Buffer chamber (pressurizing phase) 2. Buffer chamber (depressurizing phase) 3. Raised piston 1-19...
  • Page 29 FEATURES ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the following block diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 17.Front brake outlet solenoid 1.
  • Page 30 FEATURES ABS control operation The ABS control operation performed in the ABS ECU is divided into the following two parts. • Hydraulic control • Self-diagnosis When a malfunction is detected in the ABS, a fault code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting.

  • Page 31: Abs Operation

    FEATURES EAS59C2103 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following describes the system for the front wheel only. Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
  • Page 32 FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressuriza- tion” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve com- presses the spring and closes the brake line from the brake master cylinder.
  • Page 33 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 34: Abs Self-Diagnosis Function

    FEATURES EAS59C2104 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. It is located in the meter assembly. Instances when the ABS warning light comes on 1. The ABS warning light comes on when the main switch is set to “ON”. The ABS warning light comes on while the ABS is performing a self-diagnosis, then goes off if there are no malfunctions.
  • Page 35 FEATURES 2. The ABS warning light comes on while the start switch is being pushed. g. Comes on a. ABS warning light h. The ABS self-diagnosis is completed (walk- b. Main switch “OFF” ing the vehicle at a speed of faster than 7 c.
  • Page 36 FEATURES c. Goes off a. ABS warning light d. Unstable ABS ECU input b. Comes on 5. The ABS warning light “1” flashes and a fault code “2” is indicated on the multi-function display when the test coupler adapter “3” is connected to the ABS test coupler “4” for troubleshooting the ABS.

  • Page 37: Abs Warning Light And Operation

    FEATURES EAS59C2105 ABS WARNING LIGHT AND OPERATION ABS function EWA59C2103 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the front brake lever or rear brake lever.

  • Page 38: Important Information

    5. Keep all parts away from any source of fire. EAS20200 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 39: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20231 EAS59C1101 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during manufacturer marks or numbers are visible. inspection. Some of the rubber parts are sensi- When installing oil seals, lubricate the oil seal tive to gasoline, flammable oil, grease, etc.

  • Page 40: Basic Service Information

    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, then pull the fastener out.

  • Page 41: Electrical System

    BASIC SERVICE INFORMATION If a battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust using hot water. EAS30402 ELECTRICAL SYSTEM Electrical parts handling ECA16600 ECA16760 Never disconnect a battery lead while the engine is running; otherwise, the electrical Be sure to connect the battery leads to the components could be damaged.
  • Page 42 BASIC SERVICE INFORMATION ECA16610 When resetting the ECU by turning the main Set 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 43 BASIC SERVICE INFORMATION ECA16640 ECA16790 For waterproof couplers, never insert the tester probes directly into the coupler. When disconnecting a connector, do not When performing any checks using a pull the leads. Hold both sections of the waterproof coupler, use the specified test connector securely, and then disconnect harness or a suitable commercially avail- the connector.
  • Page 44 BASIC SERVICE INFORMATION • After disassembling and assembling a cou- pler, pull on the leads to make sure that they are installed securely. 5. Check: • Continuity (with the pocket tester) Pocket tester 90890-03112 Analog pocket tester YU-03112-C • If there is no continuity, clean the terminals. •...
  • Page 45 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor resistance 5.4–6.6 kΩ...

  • Page 46: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 47 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-26, 6-6 90890-01469 YM-01469 66.8 Oil pressure gauge set 3-28 90890-03120 Oil pressure adapter B 3-28 90890-03124 Test coupler adapter 1-27, 4-73, 4-74 90890-03149 Pressure gauge 3-28, 7-4...
  • Page 48 4-86 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 4-86 90890-01374 Replacement 43 mm YM-A5142-3 Yamaha bond No. 1215 5-17, 5-48, 5- 90890-85505 55, 5-72 (Three Bond No.1215®) Valve spring compressor 5-22, 5-28 90890-04019 YM-04019 Valve spring compressor attachment...
  • Page 49 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø4) 5-24 90890-04111 Valve guide remover (4.0 mm) YM-04111 Valve guide installer (ø4) 5-24 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 5-24 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Piston pin puller set 5-30...
  • Page 50 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave spring compressor 5-45, 5-47 90890-04134 YM-04134 Sheave fixed block 5-45, 5-47 90890-04135 Sheave fixed bracket YM-04135 Sheave holder 5-53, 5-55 90890-01701 Primary clutch holder YS-01880-A Flywheel puller 5-53 90890-01362 Heavy duty puller YU-33270-B Rotor holding tool 5-60, 5-64...
  • Page 51 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-60, 5-63 90890-04086 YM-91042 Plane bearing installer 5-76, 5-80 90890-04139 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer...
  • Page 52 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 6-12 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Fuel pressure adapter 90890-03181 YM-03181 Ignition checker 8-135 90890-06754 Oppama pet-4000 spark checker YM-34487 Thickness gauge 5-19, 5-61 90890-03180 Feeler gauge set...
  • Page 53 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 5-37, 8-115, 8- 90890-03189 116, 8-137, 8- Model 88 Multimeter with tachometer YU-A1927 Yamaha diagnostic tool 8-35 90890-03215 1-44...
  • Page 54 SPECIAL TOOLS 1-45...
  • Page 55 SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS...............2-12 TIGHTENING TORQUES................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-14 ENGINE TIGHTENING TORQUES ............2-15 CHASSIS TIGHTENING TORQUES ............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-21 ENGINE ....................2-21 CHASSIS ....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-25 ENGINE OIL LUBRICATION CHART ...........2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS ...............2-35...

  • Page 56: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 59C2 Dimensions Overall length 2200 mm (86.6 in) Overall width 775 mm (30.5 in) Overall height 1420/1475 mm (55.9/58.1 in) Seat height 800 mm (31.5 in) Wheelbase 1580 mm (62.2 in) Ground clearance 125 mm (4.92 in) Minimum turning radius 2800 mm (110.2 in)

  • Page 57: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 530 cm³ Cylinder arrangement Inline 2-cylinder Bore × stroke 68.0 × 73.0 mm (2.68 × 2.87 in) Compression ratio 10.90 : 1 Standard compression pressure (at sea level) 1950 kPa/470 r/min (19.5 kgf/cm²/470 r/min, 282.8 psi/470 r/min) Minimum–maximum...
  • Page 58 ENGINE SPECIFICATIONS Radiator core Width 329.0 mm (12.95 in) Height 149.8 mm (5.90 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single suction centrifugal pump Reduction ratio 23/19 (1.210) Impeller shaft tilt limit 0.15 mm (0.0059 in) Spark plug(s) Manufacturer/model NGK/CR7E...
  • Page 59 ENGINE SPECIFICATIONS Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.22 mm (0.0059–0.0087 in) Exhaust 0.25–0.32 mm (0.0098–0.0126 in) Valve dimensions Valve head diameter (intake) 25.9–26.1 mm (1.0197–1.0276 in) Valve head diameter (exhaust) 21.9–22.1 mm (0.8622–0.8701 in) Valve face width (intake) 1.202–2.475 mm (0.0473–0.0974 in) Valve face width (exhaust) 1.202–2.475 mm (0.0473–0.0974 in)
  • Page 60 ENGINE SPECIFICATIONS Free length (exhaust) 36.73 mm (1.45 in) Limit 34.89 mm (1.37 in) Installed compression spring force (intake) 96.6–111.2 N (9.85–11.34 kgf, 21.72–25.00 lbf) Installed compression spring force (exhaust) 96.6–111.2 N (9.85–11.34 kgf, 21.72–25.00 lbf) Installed length (intake) 30.60 mm (1.20 in) Installed length (exhaust) 30.60 mm (1.20 in) Spring rate K1 (intake)
  • Page 61 ENGINE SPECIFICATIONS Piston ring Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.60 mm (0.04 × 0.10 in) End gap (installed) 0.25–0.35 mm (0.0098–0.0138 in) Limit 0.60 mm (0.0236 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.100 mm (0.0039 in) 2nd ring...
  • Page 62 ENGINE SPECIFICATIONS Balancer Balancer drive method Piston Connecting rod oil clearance 0.036–0.060 mm (0.0014–0.0024 in) Clutch Clutch type Wet, multiple-disc automatic Clutch release method Automatic Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.1110 in) Plate quantity 6 pcs Clutch plate 1 thickness 1.30–1.50 mm (0.051–0.059 in)
  • Page 63 ENGINE SPECIFICATIONS Fuel injection sensor 2.32–2.59 kΩ at 20 °C (68 °F) Coolant temperature sensor resistance 310.0–326.0 Ω at 80 °C (176 °F) Throttle position sensor maximum resistance 2.64–6.16 kΩ Throttle position sensor resistance 0–6.16 kΩ Intake air pressure output voltage 3.57–3.71 V at 101.32 kPa 5.4–6.6 kΩ...

  • Page 64: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00° Trail 92 mm (3.6 in) Front wheel Wheel type Cast wheel 15M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 65 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.0 mm (0.16 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.0 mm (0.16 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 15.00 mm (0.59 in) Caliper cylinder inside diameter 30.23 mm (1.19 in) 27.00 mm (1.06 in) Specified brake fluid...
  • Page 66 CHASSIS SPECIFICATIONS Spring installed length 180.0 mm (7.09 in) Spring rate K1 225.60 N/mm (23.00 kgf/mm, 1288.18 lb/in) Spring rate K2 294.00 N/mm (29.98 kgf/mm, 1678.74 lb/in) Spring stroke K1 0.0–28.8 mm (0.00–1.13 in) Spring stroke K2 28.8–43.0 mm (1.13–1.69 in) Optional spring available Enclosed gas/air pressure (STD) 4900 kPa (49.0 kgf/cm², 696.9 psi)

  • Page 67: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital Ignition timing (B.T.D.C.) 5.0°/1200 r/min 248–372 Ω (Gy-B) Crankshaft position sensor resistance Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.87–2.53 Ω Primary coil resistance Secondary coil resistance 12.00–18.00 kΩ...
  • Page 68 ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Power output 0.70 kW 0.0100–0.0200 Ω Armature coil commutator resistance Armature coil insulation resistance Above 1 MΩ Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.02–6.51 N (614–664 gf, 21.65–23.41 oz) Mica undercut (depth)

  • Page 69: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20331 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
  • Page 70 TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Engine oil check bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) Exhaust pipe stud bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) Cylinder head nut See TIP.
  • Page 71 Bearing housing bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) Shell Sun- light Primary sheave nut 160 Nm (16 m·kgf, 116 ft·lbf) Grease 3® YAMAHA GREASE Secondary sheave nut 90 Nm (9.0 m·kgf, 65 ft·lbf) “H” or Polyurea Grease® Secondary sheave spring seat 90 Nm (9.0 m·kgf, 65 ft·lbf)
  • Page 72 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Secondary shaft bearing retainer 12 Nm (1.2 m·kgf, 8.7 ft·lbf) bolt Stator coil bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Crankshaft position sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Starter motor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) sensor 45 Nm (4.5 m·kgf, 33 ft·lbf)
  • Page 73 TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting nut (front upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting bolt (front lower 45 Nm (4.5 m·kgf, 33 ft·lbf) side) Engine mounting nut (rear side) 105 Nm (10.5 m·kgf, 76 ft·lbf) Rear frame bolt 83 Nm (8.3 m·kgf, 60 ft·lbf)
  • Page 74 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Brake master cylinder cap screw 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Grip end 26 Nm (2.6 m·kgf, 19 ft·lbf) Throttle cable bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Throttle cable adjusting locknut 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Brake hose union bolt (Brake joint 30 Nm (3.0 m·kgf, 22 ft·lbf)
  • Page 75 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rear wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rear brake lock caliper bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Rear brake lock caliper slide pin 17 Nm (1.7 m·kgf, 12 ft·lbf) bolt...

  • Page 76: Lubrication Points And Lubricant Types

    1st pinion gear spline and main axle spline 1st wheel gear spline and drive axle spline Shell Sunlight grease Primary sheave spacer and o-ring 3® Shell Sunlight grease Primary sheave nut 3® YAMAHA GREASE Secondary sheave nut “H” or Polyurea Grease® 2-21...
  • Page 77 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Secondary shaft right end bearing Pivot shaft taper roller bearing Yamaha bond Crankcase mating surface No.1215 (Three bond No.1215®) Yamaha bond Inner V-belt case seal mating surface No.1215 (Three bond No.1215®) Yamaha bond Crankshaft position sensor/stator lead grommet No.1215 (Three bond...
  • Page 78 Steering bearings (upper and lower) Upper bearing cover seal lip and lower bearing dust seal lip Tube guide (throttle grip) inner surface and throttle cables YAMAHA GREASE Rear brake lock cable end (lever end) “F” Brake lever pivoting point and metal-to-metal moving parts...
  • Page 79 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...
  • Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft 3. Timing chain tensioner 4. Connecting rod 5. To piston 6. Starter clutch gear 7. Crankshaft 8. Balancer connecting rod 9. To balancer piston 10.Oil pipe 11.Check valve 12.Relief valve 13.Oil filter 14.Oil cooler 15.Oil tank...
  • Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
  • Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Exhaust camshaft 2. Intake camshaft 3. Delivery pipe 4. Oil pump assembly 5. Scavenge pump 6. Feed pump 7. Oil pipe 8. Oil cooler 9. Oil filter 10.Relief valve 11.Check valve 2-28...
  • Page 84 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 85 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Secondary shaft 3. Drive axle 4. Clutch 5. Generator cover 2-30...
  • Page 86 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 87 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Intake camshaft 3. Exhaust camshaft 2-32...
  • Page 88 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 89 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Generator cover 2. Oil strainer 3. Main gallery 4. Right crankcase A. Forward 2-34...

  • Page 90: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-35...
  • Page 91 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator filler hose 3. Radiator inlet hose 4. Cooling system air bleed hose 5. Coolant pipe 6. Thermostat outlet hose 7. Oil cooler outlet hose 8. Thermostat 9. Oil cooler 10.Coolant hose 11.Water pump inlet pipe 12.Water pump outlet pipe 13.Oil cooler inlet hose 14.Radiator outlet hose...
  • Page 92 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 93 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Thermostat outlet hose 3. Cooling system air bleed hose 4. Radiator cap 5. Radiator filler pipe 6. Radiator filler hose 7. Coolant reservoir hose 8. Radiator 9. Radiator inlet hose 10.Coolant pipe 11.Oil cooler 12.Oil cooler outlet hose 2-38...

  • Page 94: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (top side view) 2-39...
  • Page 95 CABLE ROUTING 1. Front brake hose (hydraulic unit to front brake hose joint) 2. Lead holder 3. Cap bolt cover 4. Front brake master cylinder 5. Right handlebar switch 6. Front brake hose (front brake master cylin- der to hydraulic unit) 7.
  • Page 96 CABLE ROUTING Handlebar (front side and left side view) 2-41...
  • Page 97 K. Install the rear brake lock cable after rotat- ing the rear brake lock lever to the position shown in the illustration. L. Apply YAMAHA GREASE “F” to the end of the rear brake lock cable and install it. 2-42...
  • Page 98 CABLE ROUTING Front brake (front side and left side view) 2-43...
  • Page 99 CABLE ROUTING X. Route the front wheel sensor lead between 1. Holder the front brake caliper and the outer tube. 2. Brake hose 3. Lower bracket cover 4. Horn 5. Horn lead 6. Grommet 7. Front fork 8. Front wheel sensor lead 9.
  • Page 100 CABLE ROUTING Frame (front side view) 2-45...
  • Page 101 CABLE ROUTING 1. Meter lead 2. Ambient temperature sensor lead 3. ABS ECU coupler 4. Fuse box (left) 5. Fuse box lead 6. Lean angle sensor lead 7. ECU (engine control unit) lead 8. Hydraulic unit assembly 9. Wire harness 10.Handlebar switch lead A.
  • Page 102 CABLE ROUTING Frame (left side view) 2-47...
  • Page 103 CABLE ROUTING 1. Battery 2. Sidestand switch coupler 3. Battery negative lead coupler 4. Battery negative lead 5. Starter motor lead 6. AC magneto lead 7. Sidestand switch lead 8. Frame 9. Ignition coil 10.Rectifier/regulator 11.AC magneto coupler 12.Fuel injection system relay 13.Rear brake hose 14.Battery positive lead A.
  • Page 104 CABLE ROUTING Frame (right side view) 2-49...
  • Page 105 CABLE ROUTING 1. ECU (engine control unit) lead 2. Turn signal/hazard relay 3. Couplers 4. Headlight relay 5. Radiator fan motor relay 6. Throttle position sensor sub-wire harness 7. Fuel pump lead 8. Bracket 1 9. Immobilizer lead 10.Main switch leads 11.Turn signal light lead coupler 12.Headlight coupler 13.Headlight sub-wire harness...
  • Page 106 CABLE ROUTING Rear frame (top side and right side view) 2-51...
  • Page 107 CABLE ROUTING R. When inserting the rear wheel sensor lead 1. Fuel pump coupler into the holder, soapy water or silicone fluid 2. Fuel injector #1 may be applied. 3. Fuel tank fitting bracket S. Install it so that the lead passes under the 4.
  • Page 108 CABLE ROUTING Rear brake (top side and left side view) 2-53...
  • Page 109 CABLE ROUTING J. Install the holder, pushing it against the 1. Rear brake hose rear wheel sensor protector end. 2. Fuel tank fitting bracket K. 60–70 mm (2.36–2.76 in) 3. Footboard L. Tighten the union bolt, pushing the brake 4. Rear frame pipe against the projection of the brake cal- 5.
  • Page 110 CABLE ROUTING Throttle body (left side view) 2-55...
  • Page 111 CABLE ROUTING T. Position the clip 1 to 4 mm (0.04 to 0.16 in) 1. Fast idle plunger inlet coolant hose away from the end of the fast idle plunger 2. Intake manifold intake hose. Face the clip to the right of the 3.
  • Page 112 CABLE ROUTING Fuel tank (top side, left side and right side view) 2-57...
  • Page 113 CABLE ROUTING R. Insert the intake pressure sensor hose until 1. Fuel hose it touches the pipe of the intake air pres- 2. Fuel tank breather hose sure sensor. 3. Air filter case S. 0 to 3 mm (0 to 0.12 in) 4.
  • Page 114 CABLE ROUTING Hydraulic unit (top side and front side view) 2-59...
  • Page 115 CABLE ROUTING 1. Front brake hose (hydraulic unit to front brake hose joint) 2. Front brake hose (front brake master cylin- der to hydraulic unit) 3. Rear brake hose (rear brake master cylin- der to hydraulic unit) 4. Rear brake pipe/joint assembly (hydraulic unit to rear brake hose) 5.
  • Page 116 CABLE ROUTING 2-61...
  • Page 117 PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART.....3-2 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 ADJUSTING THE ENGINE IDLING SPEED ..........3-8 SYNCHRONIZING THE THROTTLE BODY ...........3-9 CHECKING THE THROTTLE BODY JOINTS ........3-10 CHECKING THE CYLINDER HEAD BREATHER HOSE .....3-10...
  • Page 118 CHANGING THE COOLANT ..............3-30 REPLACING THE V-BELT ..............3-31 CHECKING THE BRAKE LIGHT SWITCHES ........3-32 CHECKING AND LUBRICATING THE CABLES ........3-32 LUBRICATING THE REAR SUSPENSION ..........3-32 CHECKING THE THROTTLE GRIP .............3-32 CHECKING AND CHARGING THE BATTERY........3-33 CHECKING THE FUSES..............3-33 REPLACING THE HEADLIGHT BULBS..........3-33 ADJUSTING THE HEADLIGHT BEAMS ..........3-34...

  • Page 120: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

  • Page 121: General Maintenance And Lubrication Chart

    PERIODIC MAINTENANCE EAS59C1303 GENERAL MAINTENANCE AND LUBRICATION CHART ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) √ √ Air filter element •...
  • Page 122 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check coolant level and vehi- √ √ √ √ √...
  • Page 123 PERIODIC MAINTENANCE EAS21030 EAS20680 CHECKING THE FUEL LINE CHECKING THE SPARK PLUGS The following procedure applies to all of the The following procedure applies to all of the fuel and breather hoses. spark plugs. 1. Remove: 1. Remove: • Center cover •...
  • Page 124 PERIODIC MAINTENANCE 8. Install: 7. Remove: • Spark plug • Timing mark accessing plug “1” • Crankshaft end access cover “2” Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Before installing the spark plug, clean the spark plug and gasket surface. 9.
  • Page 125 PERIODIC MAINTENANCE • TDC on the compression stroke can be found when the cylinder #1 camshaft lobes are turned away from each other. • In order to be sure that the piston is at TDC, the alignment mark “c” on the intake cam- shaft sprocket and the alignment mark “d”...
  • Page 126 PERIODIC MAINTENANCE • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • Make a note of the position of each valve lifter “1” and valve pad “2” so that they can be installed in the correct place.
  • Page 127 PERIODIC MAINTENANCE • The valve lifter must turn smoothly when be clean, and the engine should have ade- rotated by hand. quate compression. • Install the valve lifter and the valve pad in the 1. Start the engine and let it warm up for sev- correct place.
  • Page 128 PERIODIC MAINTENANCE 6. Install: • Side cover (right) Refer to “GENERAL CHASSIS” on page 4-1. • Radiator cover Refer to “GENERAL CHASSIS” on page 4-1. EAS20571 SYNCHRONIZING THE THROTTLE BODY Prior to synchronizing the throttle body, the 4. Install: valve clearance and the engine idling speed •...
  • Page 129 PERIODIC MAINTENANCE 5. Start the engine and let it warm up for sev- 8. Measure: eral minutes. • Engine idling speed Out of specification → Adjust. 6. Check: • Engine idling speed Make sure that the vacuum pressure is Out of specification → Adjust. within specification.
  • Page 130 PERIODIC MAINTENANCE • Footboard (right) 3. Press the left set button to select the CO Refer to “GENERAL CHASSIS” on page adjustment mode “Co” or the diagnostic 4-1. monitoring mode “dIAG”. 2. Check: • Cylinder head breather hose “1” Cracks/damage → Replace. Loose connection →...
  • Page 131 PERIODIC MAINTENANCE 2. Check: 3. Check: • Exhaust assembly “1” • Air filter element “1” Cracks/damage → Replace. Damage → Replace. • Gasket “2” Exhaust gas leaks → Replace. • Replace the air filter element every 20000 3. Check: km (12000 mi) of operation. Tightening torque •...
  • Page 132 PERIODIC MAINTENANCE 2. Remove: • V-belt case air filter element (left) “1” 5. Check: • V-belt case air filter elements Damage → Replace. 3. Remove: ECA13440 • V-belt case air filter case cover “1” • V-belt case air filter case “2” Since the V-belt case air filter element is a •...
  • Page 133 PERIODIC MAINTENANCE reaction, leading to poor brake perfor- mance. Drive on the road, operate the front and rear • When refilling, be careful that water does brakes separately and check to see if the not enter the brake master cylinder reser- brakes are operating properly.
  • Page 134 PERIODIC MAINTENANCE • A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is oper- ated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce in loss of control and possibly an accident.
  • Page 135 PERIODIC MAINTENANCE EAS30770 BLEEDING THE HYDRAULIC BRAKE SYS- TEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. ECA17050 • Bleed the brake system in the following order. • 1st step: Front brake calipers •...
  • Page 136 PERIODIC MAINTENANCE l. Tighten the bleed screw to specification. Front brake caliper bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Rear brake caliper bleed screw 6 Nm (0.6 m·kgf, 4.3 ft·lbf) m. Fill the brake master cylinder reservoir to the proper level with the specified brake fluid.
  • Page 137 PERIODIC MAINTENANCE Direction “b” Rear brake lock cable length increased. Direction “c” Rear brake lock cable length decreased. g. Install the cap of the rear brake lock adjust- ing nut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS59C1305 CHECKING THE REAR BRAKE LOCK ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Check: 3.
  • Page 138 PERIODIC MAINTENANCE 4. Check: • Rear brake lock caliper boots Cracks/damage → Replace. Refer to “REAR BRAKE” on page 4-50. EAS59C1301 CHECKING THE REAR BRAKE LOCK PADS The following procedure applies to all of the brake pads. 1. Operate the rear brake lock. 2.
  • Page 139 • Wheel bearings given if a tire combination other than one Refer to “CHECKING THE FRONT approved by Yamaha is used on this vehi- WHEEL” on page 4-20 and “CHECKING cle. THE REAR WHEEL” on page 4-32.
  • Page 140 PERIODIC MAINTENANCE 2. Check: EAS21430 ADJUSTING THE DRIVE BELT SLACK • Drive belt ECA59C1301 External tooth cracks “A” → Replace. Missing teeth “B” → Replace. A drive belt that is too tight will cause loud Hook wear “C” → Replace. noises, and one that is too loose can skip Stone damage “D”...
  • Page 141 PERIODIC MAINTENANCE Measure the drive belt slack after setting the • Push the rear wheel forward to make sure tension gauge at 13.4 position on the scale. that there is no clearance between the adjusting block and the ends of the swingarm.
  • Page 142 PERIODIC MAINTENANCE 5. Lubricate: • Drive axle “1” Recommended lubricant YAMAHA GREASE “H” or Polyurea Grease® 6. Lubricate: • Drive pulley assembly inner part “2” Recommended lubricant YAMAHA GREASE “H” or Polyurea Grease® 7. Install: • All removed parts 8. Adjust: •...
  • Page 143 PERIODIC MAINTENANCE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ in both directions. If any binding is felt, a. Remove the lock washer “1”, the upper ring remove the lower bracket and check the nut “2”, and the rubber washer “3”. upper and lower bearings. Refer to “STEERING HEAD” on page 4-89. e.
  • Page 144 PERIODIC MAINTENANCE EAS21720 LUBRICATING THE SIDESTAND Lubricate the pivoting point, metal-to-metal moving parts and spring contact point of the sidestand. Recommended lubricant Lithium-soap-based grease EAS30860 CHECKING THE CENTERSTAND 1. Check: • Centerstand operation EAS59C1306 CHECKING THE REAR SHOCK ABSORBER Check that the centerstand moves ASSEMBLY smoothly.
  • Page 145 PERIODIC MAINTENANCE EAS20791 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • Engine oil filler cap “1” (along with the O-ring) •...
  • Page 146 PERIODIC MAINTENANCE Engine oil quantity Total amount 3.50 L (3.70 US qt, 3.08 Imp.qt) Without filter cartridge replacement 2.70 L (2.85 US qt, 2.38 Imp.qt) With oil filter cartridge replace- ment 2.90 L (3.07 US qt, 2.55 Imp.qt) 8. Install: b.
  • Page 147 PERIODIC MAINTENANCE f. Tighten the oil check bolt to specification. Oil pressure gauge set 90890-03120 Engine oil check bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Oil pressure adapter B g. Install the bottom side cowling and bottom 90890-03124 center cowling. Pressure gauge Refer to “GENERAL CHASSIS”...
  • Page 148 PERIODIC MAINTENANCE 3. Start the engine, warm it up for several Engine oil pressure check point minutes, and then turn it off. plug 4. Check: 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • Coolant level EAS21110 CHECKING THE COOLANT LEVEL Before checking the coolant level, wait a few 1.
  • Page 149 PERIODIC MAINTENANCE 3. Install: press down on the radiator cap and turn it • Footboards counterclockwise to remove. Refer to “GENERAL CHASSIS” on page 4-1. When removing the radiator cap, hold the radi- • Side covers ator filler pipe “2”. Refer to “GENERAL CHASSIS”...
  • Page 150 PERIODIC MAINTENANCE Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Radiator capacity (including all routes) 1.50 L (1.59 US qt, 1.32 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 12.
  • Page 151 PERIODIC MAINTENANCE 2. Check: Recommended lubricant • V-belt Engine oil or a suitable cable Cranks/damage/wear → Replace. lubricant Grease/oil → Clean the primary and sec- ondary pulleys. Refer to “V-BELT AUTOMATIC TRANS- Hold the cable end upright and pour a few MISSION”...
  • Page 152 PERIODIC MAINTENANCE EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-127. EAS21770 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8- 127. EAS21790 REPLACING THE HEADLIGHT BULBS 4. Adjust: The following procedure applies to both of the •...
  • Page 153 PERIODIC MAINTENANCE ECA13690 Other than the socket wrench, the adjusting Avoid touching the glass part of the head- screws can be turned with a screwdriver (Phil- light bulb to keep it free from oil, otherwise lips No. 2) “2” as shown in the illustration. the transparency of the glass, the life of the Left headlight bulb and the luminous flux will be...
  • Page 154 PERIODIC MAINTENANCE 3-35...
  • Page 155 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE WINDSHIELD.............4-9 INSTALLING THE WINDSHIELD............4-9 ADJUSTING THE WINDSHIELD HEIGHT ...........4-10 REMOVING THE FRONT COVER ............4-10 INSTALLING THE FRONT COVER ............4-11 REMOVING THE WINDSHIELD INNER PANEL ........4-11 INSTALLING THE WINDSHIELD INNER PANEL .........4-12 REMOVING THE SIDE PANEL ............4-12 INSTALLING THE SIDE PANEL ............4-12 REMOVING THE CENTER COVER.............4-13 INSTALLING THE CENTER COVER............4-13...
  • Page 156 FRONT BRAKE ..................4-37 INTRODUCTION ..................4-42 CHECKING THE FRONT BRAKE DISCS ..........4-42 REPLACING THE FRONT BRAKE PADS ..........4-43 REMOVING THE FRONT BRAKE CALIPERS ........4-44 DISASSEMBLING THE FRONT BRAKE CALIPERS ......4-44 CHECKING THE FRONT BRAKE CALIPERS ........4-45 ASSEMBLING THE FRONT BRAKE CALIPERS .........4-45 INSTALLING THE FRONT BRAKE CALIPERS........4-46 REMOVING THE FRONT BRAKE MASTER CYLINDER.....4-47 CHECKING THE FRONT BRAKE MASTER CYLINDER .....4-47...
  • Page 157 FRONT FORK.....................4-81 REMOVING THE FRONT FORK LEGS ..........4-83 DISASSEMBLING THE FRONT FORK LEGS ........4-83 CHECKING THE FRONT FORK LEGS..........4-84 ASSEMBLING THE FRONT FORK LEGS ...........4-85 INSTALLING THE FRONT FORK LEGS ..........4-87 STEERING HEAD..................4-89 REMOVING THE LOWER BRACKET ..........4-90 CHECKING THE STEERING HEAD ............4-90 INSTALLING THE STEERING HEAD...........4-91 BELT DRIVE ....................4-92 CHECKING THE DRIVE BELT .............4-93...
  • Page 158 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the windshield and front cowling assembly Order Job/Parts to remove Q’ty Remarks Front left storage box Refer to “GENERAL CHASSIS” on page 4-1. Radiator cover Refer to “GENERAL CHASSIS” on page 4-1. Side panel Refer to “GENERAL CHASSIS”...
  • Page 159 GENERAL CHASSIS Disassembling the front cowling assembly Order Job/Parts to remove Q’ty Remarks Side cowling Headlight under panel Turn signal light coupler Disconnect. Auxiliary light coupler Disconnect. Left turn signal light Right turn signal light Headlight sub-wire harness Headlight bulb For assembly, reverse the disassembly pro- cedure.
  • Page 160 GENERAL CHASSIS Removing the storage compartment Order Job/Parts to remove Q’ty Remarks Front cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Inner panel center cover Front left storage box Battery Meter coupler Disconnect. Meter panel assembly Meter assembly Meter cover Front right storage box Storage compartment For installation, reverse the removal proce-...
  • Page 161 GENERAL CHASSIS Removing the bottom cowling Order Job/Parts to remove Q’ty Remarks Footboard mat Radiator cover Side panel Center cover Side cover Bottom side cowling Bottom center cowling Side cover moulding Footboard For installation, reverse the removal proce- dure.
  • Page 162 GENERAL CHASSIS Removing the rear cowling assembly Order Job/Parts to remove Q’ty Remarks Side panel Refer to “GENERAL CHASSIS” on page 4-1. Footboard Refer to “GENERAL CHASSIS” on page 4-1. sensor lead Refer to “ENGINE REMOVAL” on page 5-3. Seat Fuel tank cover Grab bar Rear cover...
  • Page 163 GENERAL CHASSIS Removing the rear cowling assembly Order Job/Parts to remove Q’ty Remarks Rear fender Rear cowling assembly For installation, reverse the removal proce- dure.
  • Page 164 GENERAL CHASSIS Disassembling the rear cowling assembly Order Job/Parts to remove Q’ty Remarks Taillight bracket Left rear cowling Right rear cowling Left turn signal light Right turn signal light Taillight Taillight cover For assembly, reverse the disassembly pro- cedure.
  • Page 165 GENERAL CHASSIS Removing the storage box Order Job/Parts to remove Q’ty Remarks Fuel pump coupler access cover Fuel pump coupler Disconnect. Fuel hose connector cover Fuel hose Disconnect. Fuel tank overflow hose Storage box inner mat Seat lock Storage box light connector Disconnect.
  • Page 166 GENERAL CHASSIS EAS59C1407 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ REMOVING THE WINDSHIELD a. Assembling the windshield “1” and wind- 1. Remove: shield brackets “2” with the windshield • Windshield cover screws “3”. b. Installing the windshield assembly with the windshield bracket bolts “4”. Windshield screw 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Windshield bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 167 GENERAL CHASSIS EAS59C1427 EAS59C1409 ADJUSTING THE WINDSHIELD HEIGHT REMOVING THE FRONT COVER 1. Adjust: 1. Remove: • Windshield height • Front cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the windshield cover and wind- shield assembly. Refer to “REMOVING THE WINDSHIELD” on page 4-9. b.
  • Page 168 GENERAL CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Fit the two metal clips “4” and six claws “5” of the front cover. EAS59C1410 INSTALLING THE FRONT COVER 1. Install: • Front cover ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS59C1411 REMOVING THE WINDSHIELD INNER ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ PANEL a. Insert the three projections “1” of the front 1.
  • Page 169 GENERAL CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. Removing the quick fasteners “1”. b. Removing the screws “2”. EAS59C1412 INSTALLING THE WINDSHIELD INNER c. Remove the metal clip “3”. PANEL 1. Install: • Windshield inner panel ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS59C1414 INSTALLING THE SIDE PANEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1.
  • Page 170 GENERAL CHASSIS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the four claws “1”. b. Installing the screws “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS59C1415 REMOVING THE CENTER COVER ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Remove: • Center cover EAS59C1417 REMOVING THE SIDE COVER 1. Remove: • Side cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Removing the screws “1”. b.
  • Page 171 GENERAL CHASSIS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS59C1420 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INSTALLING THE SIDE COVER MOULDING a. Insert the five projections “1”. 1. Install: b. Insert the five claws “2”. • Side cover moulding c. Installing the bolts “3”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the five claws “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 172 GENERAL CHASSIS b. Fit the three claws “1”. c. Installing the bolts “2”. d. Installing the screws “3”. A. Left side B. Right side c. Remove the three claws “3”. d. Slide the footboard upwards, pull it toward you, and then remove it. A.
  • Page 173 GENERAL CHASSIS b. Holding the rear side of the rear cover and slightly applying a force upward, slide the cover rearward to remove it. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Removing the screws “1”. b. There are six claws “2”. Remove them, starting from the top. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 174 GENERAL CHASSIS EAS59C1428 2. Install: REMOVING THE FUEL HOSE • Fuel hose connector cover 1. Remove: ECA59C1702 • Fuel hose connector cover “1” 2. Disconnect: When installing the fuel hose, make sure • Fuel hose “2” that it is securely connected, and that the EWA15910 fuel hose connector cover is in the correct WARNING...

  • Page 175: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs Order Job/Parts to remove Q’ty Remarks Front cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Front wheel sensor coupler Disconnect. Front brake hose holder Cable guide Front wheel sensor Front brake caliper Front wheel axle pinch bolt Loosen.
  • Page 176 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing (right) Collar Wheel bearing (left) Air valve For assembly, reverse the disassembly pro- cedure. 4-19...
  • Page 177 FRONT WHEEL EAS21900 • Do not drop the wheel sensor rotor or REMOVING THE FRONT WHEEL subject it to shocks. ECA59C2405 • If any solvent gets on the wheel sensor rotor, wipe it off immediately. Keep magnets (including magnetic pick-up 1.
  • Page 178 FRONT WHEEL EWA13460 WARNING Do not attempt to straighten a bent wheel axle. EAS22010 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ECA59C2407 • Handle the ABS components with care 2. Check: since they have been accurately adjusted. • Tire Keep them away from dirt and do not sub- •...
  • Page 179 FRONT WHEEL c. If the deflection is above specification, remove the sensor rotor from the wheel, rotate it by one bolt hole, and then install it. Wheel sensor rotor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LOCTITE® ECA59C2408 Replace the wheel sensor rotor bolts with new ones.
  • Page 180 FRONT WHEEL d. Install the new oil seals ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. 45°–55° 2. Install: A. Wheel rotation direction • Air valve B. Left side • Fasten air valve nut “1” and tighten air valve ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ locknut “2” to 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf). •...
  • Page 181 FRONT WHEEL e. When the wheel stops, put an “X ” mark at d. Repeat steps (b) and (c) until the front wheel is balanced. the bottom of the wheel. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown.
  • Page 182 FRONT WHEEL 2. Check: • Distance “a” • Front brake discs (between the wheel sensor rotor “1” and Refer to “CHECKING THE FRONT wheel sensor housing “2”) Out of specification → Reinstall the bear- BRAKE DISCS” on page 4-42. 3. Lubricate: ing or replace the wheel sensor rotor.
  • Page 183 FRONT WHEEL 8. Check: • Front wheel sensor installation Check if the wheel sensor housing is installed properly. 4-26...

  • Page 184: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Side cover (right) Refer to “GENERAL CHASSIS” on page 4-1. Rear wheel sensor coupler Disconnect. Rear brake hose holder (right) Rear wheel sensor lead holder Rear wheel sensor Rear brake caliper Rear brake pad...
  • Page 185 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Wheel axle nut Washer Adjusting block (right) Rear wheel axle Adjusting block (left) Rear wheel Rear brake caliper bracket Caliper bolt boot Rear wheel sensor housing Collar (right) Collar (left) Dust cover For installation, reverse the removal proce-...
  • Page 186 REAR WHEEL Removing the rear brake disc and rear wheel pulley Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sensor rotor Drive belt guide Rear wheel pulley Rear wheel For installation, reverse the removal proce- dure. 4-29...
  • Page 187 REAR WHEEL Disassembling the rear wheel assembly Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing (left) Collar Wheel bearing (right) For assembly, reverse the disassembly pro- cedure. 4-30...
  • Page 188 REAR WHEEL EAS22040 REMOVING THE REAR WHEEL (DISC) ECA59C2410 Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the wheel sensor rotor equipped in the wheel hub may be damaged, resulting in improper performance of the ABS system.
  • Page 189 REAR WHEEL EAS22091 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ CHECKING THE REAR WHEEL a. Remove the drive belt guide bolts and the 1. Check: drive belt guide. • Wheel axle b. Remove the rear wheel pulley bolts and the • Wheel bearings rear wheel pulley. •...
  • Page 190 REAR WHEEL EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ECA59C2411 • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. • The rear wheel sensor cannot be disas- sembled.

  • Page 191: Installing Rear Wheel

    REAR WHEEL EAS22160 INSTALLING THE REAR WHEEL (DISC) Use a socket “4” that matches the diameter of 1. Install: the wheel bearing outer race. • Rear brake disc Rear brake disc bolt 30Nm (3.0 m·kgf, 22 ft·lbf) LOCTITE® ECA59C1401 Replace the brake disc bolts with new ones.
  • Page 192 REAR WHEEL • When installing the rear brake caliper bracket and the rear wheel sensor housing, align the projection “c” on the rear brake caliper bracket with the slot “d” of the rear wheel sensor housing. • After installing the rear wheel to the vehicle, make sure that the projection “e”...
  • Page 193 REAR WHEEL 8. Measure: 10. Check: • Rear wheel sensor installation Check if the wheel sensor housing is Measure the distance “a” only if the wheel installed properly. bearings, wheel sensor rotor, or both were replaced. • Distance “a” (between the wheel sensor rotor “1” and wheel sensor housing “2”) Out of specification →...
  • Page 194 FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Front brake hose holder bolt Front brake caliper bolt Front brake caliper Brake pad clip Brake pad pin Brake pad spring Front brake pad...

  • Page 195: Front Brake

    FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Upper handlebar cover Refer to “HANDLEBAR” on page 4-76. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm...
  • Page 196 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. 4-39...
  • Page 197 FRONT BRAKE Removing the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. Front brake hose holder bolt Brake hose union bolt Brake hose gasket Front brake hose...
  • Page 198 FRONT BRAKE Disassembling the front brake calipers 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 Brake pad spring Front brake pad Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Left brake caliper side...
  • Page 199 FRONT BRAKE EAS22221 c. Remove the brake caliper. INTRODUCTION d. Hold the dial gauge at a right angle against EWA14101 the brake disc surface. WARNING e. Measure the deflection 1.5 mm (0.06 in) Disc brake components rarely require dis- below the edge of the brake disc. assembly.
  • Page 200 FRONT BRAKE 2. Remove: • Brake pads “1” Tighten the brake disc bolts in stages and in a crisscross pattern. 3. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake d. Measure the brake disc deflection. e.
  • Page 201 FRONT BRAKE 7. Check: c. Tighten the bleed screw. • Brake lever operation Soft or spongy feeling → Bleed the brake Bleed screw system. 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. d.
  • Page 202 FRONT BRAKE EAS22391 CHECKING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. Recommended brake component replace- ment schedule Brake pads If necessary Piston seals Every two years Piston dust seals Every two years Brake hoses Every four years ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 203 FRONT BRAKE • Never use solvents on internal brake 3. Install: components as they will cause the brake • Brake pads caliper piston dust seals and brake cali- • Brake pad spring per piston seals to swell and distort. • Brake pad pin •...
  • Page 204 FRONT BRAKE 6. Check: EAS22500 CHECKING THE FRONT BRAKE MASTER • Brake fluid level CYLINDER Below the minimum level mark “a”→ Add 1. Check: the specified brake fluid to the proper • Brake master cylinder level. Damage/scratches/wear → Replace. Refer to “CHECKING THE BRAKE •...
  • Page 205 FRONT BRAKE EAS22530 (e.g., wire harness, cables, leads). Correct if INSTALLING THE FRONT BRAKE MASTER necessary. CYLINDER 1. Install: • Brake master cylinder “1” • Brake master cylinder holder “2” Brake master cylinder holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) •...
  • Page 206 FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. 4-49...
  • Page 207 REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Rear brake pad Brake pad support Bleed screw For installation, reverse the removal proce- dure. 4-50...

  • Page 208: Rear Brake

    REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Upper handlebar cover Refer to “HANDLEBAR” on page 4-76. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm...
  • Page 209 REAR BRAKE Disassembling the rear 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. 4-52...
  • Page 210 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. Brake hose union bolt Brake hose gasket Rear brake hose Rear brake caliper bolt Rear brake caliper Rear brake pad Brake pad support...
  • Page 211 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper body For assembly, reverse the disassembly pro- cedure. 4-54...
  • Page 212 REAR BRAKE Removing the rear brake lock pads Order Job/Parts to remove Q’ty Remarks Rear brake lock cable adjusting nut Rear brake lock spring Rear brake lock caliper Rear brake lock pad For installation, reverse the removal proce- dure. 4-55...
  • Page 213 REAR BRAKE Removing the rear brake lock caliper Order Job/Parts to remove Q’ty Remarks Rear brake lock cable adjusting nut Rear brake lock spring Rear brake lock caliper For installation, reverse the removal proce- dure. 4-56...
  • Page 214 REAR BRAKE Disassembling the rear brake lock caliper Order Job/Parts to remove Q’ty Remarks Rear brake lock adjusting nut Rear brake lock caliper arm Boot Rear brake lock pad Caliper piston assembly Boot Sleeve Boot Rear brake lock caliper bracket bolt Rear brake lock caliper bracket Slide pin bolt Rear brake lock caliper...
  • Page 215 REAR BRAKE EAS22561 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 in) WARNING 5. Adjust: Disc brake components rarely require dis- • Brake disc deflection assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISCS” on page 4-42. •...
  • Page 216 REAR BRAKE d. Install brake pad supports and brake pads. Brake lining thickness ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ (inner) 5. Install: 8.0 mm (0.31 in) • Rear brake caliper Limit • Rear brake caliper bolts 0.8 mm (0.03 in) Brake lining thickness Rear brake caliper bolt (outer) 27 Nm (2.7 m·kgf, 20 ft·lbf) 8.0 mm (0.31 in)
  • Page 217 REAR BRAKE EAS22642 CHECKING THE REAR BRAKE CALIPER Recommended brake component replace- ment schedule Brake pads If necessary Piston seal Every two years Piston dust seal Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake is disassembled EAS22601...
  • Page 218 REAR BRAKE 2. Remove: EAS22651 ASSEMBLING THE REAR BRAKE CALIPER • Rear brake caliper EWA59C1404 3. Install: WARNING • Brake pad supports • Before installation, all internal brake com- • Rear brake pads ponents should be cleaned and lubricated • Rear brake caliper with clean or new brake fluid.
  • Page 219 REAR BRAKE 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. 6. 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”...
  • Page 220 REAR BRAKE Brake master cylinder holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Install the brake master cylinder holder with the “ ” mark “a” facing up. • Align the end of the brake master cylinder holder with the welding line “b” on the han- dlebar.
  • Page 221 REAR BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake Push on the back of the pad using a rod with a system. round end. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-16. 4.
  • Page 222 REAR BRAKE Rear brake lock caliper bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) 10. Adjust: • Rear brake lock cable length Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE” on page 3-17. EAS59C1431 REPLACING THE REAR BRAKE LOCK CABLE 1. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 223 REAR BRAKE EAS59C1402 REMOVING THE REAR BRAKE LOCK CALI- Slide pin bolt 17 Nm (1.7 m·kgf, 12 ft·lbf) 1. Remove: • Rear brake lock cable adjusting nut “1” Recommended lubricant • Pin “2” Silicone grease • Rear brake lock spring “3” •...
  • Page 224 REAR BRAKE 5. Install: • Shaft L “1” • Piston adjusting bolt “2” • Locknut “3” Recommended lubricant Silicone grease Locknut 22 Nm (2.2 m·kgf, 16 ft·lbf) Left-hand thread 8. Install: • Rear brake lock adjusting nut • Cap Rear brake lock adjusting nut 15 Nm (1.5 m·kgf, 11 ft·lbf) 9.
  • Page 225 ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly Order Job/Parts to remove Q’ty Remarks Battery negative lead Refer to “GENERAL CHASSIS” on page 4-1. Front cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Drain.
  • Page 226 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly Order Job/Parts to remove Q’ty Remarks Rear brake hose (rear brake pipe/joint assembly Disconnect. to rear brake caliper) Rear brake pipe/joint assembly (hydraulic unit to rear brake hose) Hydraulic unit assembly bracket Hydraulic unit assembly For installation, reverse the removal proce- dure.
  • Page 227 ABS (ANTI-LOCK BRAKE SYSTEM) EAS59C2401 2. Disconnect: REMOVING THE HYDRAULIC UNIT ASSEM- • ABS ECU coupler “1” ECA4B56013 Pull up the coupler ejection slider to discon- nect the ABS ECU coupler. Unless necessary, avoid removing and installing the brake pipes of the hydraulic unit assembly.
  • Page 228 ABS (ANTI-LOCK BRAKE SYSTEM) EAS59C2403 4. Install: CHECKING THE BRAKE PIPES • Rear brake pipe/joint assembly “1” The following procedure applies to all of the • Rear brake pipe/joint assembly bolt brake pipes. • Brake hose gaskets 1. Check: • Brake hose union bolt “2” •...
  • Page 229 ABS (ANTI-LOCK BRAKE SYSTEM) Rear brake hose flare nut Specified brake fluid 16 Nm (1.6 m·kgf, 12 ft·lbf) DOT 4 Front brake hose flare nut EWA59C2401 16 Nm (1.6 m·kgf, 12 ft·lbf) WARNING Brake hose union bolt • Use only the designated brake fluid. 30 Nm (3.0 m·kgf, 22 ft·lbf) Other brake fluids may cause the rubber ECA59C2413...
  • Page 230 ABS (ANTI-LOCK BRAKE SYSTEM) • Hydraulic unit operation test 1: this test checks the function of the ABS after the sys- tem was disassembled, adjusted, or ser- viced. • Hydraulic unit operation test 2: this test gen- erates the same reaction-force pulsating action that is generated in the brake levers when the ABS is activated.
  • Page 231 ABS (ANTI-LOCK BRAKE SYSTEM) • If the pulse is felt in the rear brake lever 5. Connect the test coupler adapter “1” to the before it is felt in the front brake lever, ABS test coupler “2”. check that the brake hoses and brake Test coupler adapter pipes are connected correctly to the 90890-03149...
  • Page 232 ABS (ANTI-LOCK BRAKE SYSTEM) 10. A reaction-force pulsating action is gener- ECA59C2403 ated in the front brake lever “1” 0.5 second after the brake levers are operated simulta- • Check that the pulse is felt in the front neously and continues for approximately brake lever, rear brake lever, and again in 1.5 seconds.
  • Page 233 BRAKE SYSTEM (ABS)” on page 3-16. Upper handlebar cover Holder Grip end Front brake light switch connector Disconnect. Right handlebar switch Throttle cable Disconnect. Throttle grip Front brake hose Disconnect. Front brake master cylinder holder * YAMAHA GREASE “F” 4-76...
  • Page 234 Rear brake master cylinder holder Rear brake master cylinder assembly Handlebar grip Lower handlebar cover Upper handlebar holder Handlebar Front brake pipe/joint assembly Lower handlebar holder Brake hose bracket For installation, reverse the removal proce- dure. * YAMAHA GREASE “F” 4-77...
  • Page 235 HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” EAS22931 INSTALLING THE HANDLEBAR Blow compressed air between the left handle- 1.
  • Page 236 • First, tighten the upper bolt, then the lower (to rear brake lock lever) bolt. Lubricate the rear brake lock cable end with YAMAHA GREASE “F”. 8. Install: • Left handlebar switch “1” • Rear brake lock lever • Rear brake lock lever holder •...
  • Page 237 HANDLEBAR Lubricate the inside of the throttle grip with a thin coat of lithium-soap-based grease and install it onto the handlebar. 12. Install: • Right handlebar switch “1” EWA13720 WARNING Make sure the throttle grip operates smoothly. Align the projection “a” on the right handlebar switch with the hole “b”...

  • Page 238: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Meter assembly Refer to “GENERAL CHASSIS” on page 4-1. Storage compartment Refer to “GENERAL CHASSIS” on page 4-1. Front wheel/Front fender Refer to “FRONT WHEEL”...
  • Page 239 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Fork spring seat Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod Rebound spring...
  • Page 240 FRONT FORK EAS22960 EAS22980 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Stand the vehicle on a level surface. 1.
  • Page 241 FRONT FORK EAS23011 CHECKING THE FRONT FORK LEGS While holding the damper rod with the damper The following procedure applies to both of the rod holder “2” and T-handle “3”, loosen the front fork legs. damper rod bolt. 1. Check: •...
  • Page 242 FRONT FORK 2. Install: • Oil flow stopper “1” 3. Lubricate: • Inner tube’s outer surface “2” Recommended oil Fork oil 10W or equivalent EAS23031 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA13660 WARNING •...
  • Page 243 FRONT FORK 6. Install: • Outer tube bushing “1” • Washer “2” (with the fork seal driver weight “3” and fork seal driver attachment “4”) Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 8. Install: 90890-01374 •...
  • Page 244 FRONT FORK Recommended oil Fork oil 10W or equivalent Quantity 517.0 cm³ (17.48 US oz, 18.23 Imp.oz) ECA14230 • Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. 14. Install: •...
  • Page 245 FRONT FORK Upper bracket pinch bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) 3. Install: • Cap bolt cover (right front fork side) 4-88...

  • Page 246: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Front cowling assembly Refer to “GENERAL CHASSIS” on page 4-1. Meter assembly Refer to “GENERAL CHASSIS” on page 4-1. Front wheel Refer to “FRONT WHEEL” on page 4-18. Handlebar Refer to “HANDLEBAR”...
  • Page 247 STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Upper ring nut • Rubber washer •...
  • Page 248 STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •...

  • Page 249: Belt Drive

    Rear brake hose holder (right) Rear brake hose holder (left) Drive pulley cover Dust cover Drive pulley Circlip Bearing Holder Collar Drive belt For installation, reverse the removal proce- dure. * Filling the YAMAHA GREASE “H” or Polyurea Grease®. 4-92...
  • Page 250 BELT DRIVE EAS23530 EAS23540 CHECKING THE DRIVE BELT INSTALLING THE DRIVE BELT 1. Clean: 1. Install: • Drive belt • Drive belt 2. Adjust: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wipe the drive belt with a clean cloth. • Drive belt slack b. Put the drive belt in a mixture of mild deter- Refer to “ADJUSTING THE DRIVE BELT gent and water.
  • Page 251 REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-3. Rear shock absorber assembly front bolt Lock washer Collar Rear shock absorber assembly rear nut/bolt Rear shock absorber assembly Collar Washer...
  • Page 252 REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that EWA13740 the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly bolts “1” the rear shock absorber, read and make sure you understand the following informa- •...
  • Page 253 REAR SHOCK ABSORBER ASSEMBLY Recommended lubricant Lithium-soap-based grease 2. Install: • Rear shock absorber assembly • Make sure that the warning label “1” on the rear shock absorber assembly faces up. • When installing the rear shock absorber assembly, lift up the swingarm. 3.
  • Page 254 SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Refer to “REAR SHOCK ABSORBER Rear shock absorber assembly ASSEMBLY” on page 4-94. Drive belt Refer to “BELT DRIVE” on page 4-92. Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-3. Drive belt inner guard Non-disassemble Left swingarm...
  • Page 255 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Collar Oil seal Bearing For installation, reverse the removal proce- dure. 4-98...
  • Page 256 SWINGARM EAS23340 3. Remove: REMOVING THE SWINGARM • Drive belt 1. Stand the vehicle on a level surface. Refer to “BELT DRIVE” on page 4-92. EWA13120 4. Remove: WARNING • Drive pulley assembly bolt Securely support the vehicle so that there •...
  • Page 257 SWINGARM Install the parts to the swingarm “4” tempo- rarily, making sure that the portion “a” of the pivot shaft does not protrude past the swingarm surface “b”. 3. Install: • Dowel pins • Swingarm • Swingarm bolts • Drive pulley assembly •...
  • Page 258 SWINGARM 4-101...
  • Page 259 ENGINE ENGINE INSPECTION..................5-1 MEASURING THE COMPRESSION PRESSURE .........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE ENGINE ..............5-7 CAMSHAFTS....................5-8 REMOVING THE CAMSHAFTS ............5-11 CHECKING THE CAMSHAFTS ............5-12 CHECKING THE CAMSHAFT SPROCKETS........5-13 CHECKING THE TIMING CHAIN GUIDES ..........5-14 CHECKING THE TIMING CHAIN TENSIONER ........5-14 INSTALLING THE CAMSHAFTS ............5-14 CYLINDER HEAD..................5-18 REMOVING THE CYLINDER HEAD ............5-19...
  • Page 260 V-BELT AUTOMATIC TRANSMISSION .............5-39 REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE....................5-44 DISASSEMBLING THE SECONDARY SHEAVE .........5-44 CHECKING THE V-BELT..............5-45 CHECKING THE PRIMARY SHEAVE ..........5-45 CHECKING THE V-BELT CASE AIR DUCT .........5-45 CHECKING THE PRIMARY SHEAVE WEIGHTS ........5-45 CHECKING THE SLIDERS ..............5-45 CHECKING THE SECONDARY SHEAVE ..........5-46 ASSEMBLING THE PRIMARY SHEAVE..........5-46 ASSEMBLING THE SECONDARY SHEAVE ........5-46...
  • Page 261 CRANKCASE .....................5-69 DISASSEMBLING THE CRANKCASE ..........5-72 CHECKING THE CRANKCASE ............5-72 CHECKING THE TIMING CHAIN ............5-72 ASSEMBLING THE CRANKCASE ............5-72 CRANKSHAFT ...................5-74 REMOVING THE CONNECTING RODS..........5-76 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ....5-76 CHECKING THE CRANKSHAFT AND CONNECTING RODS ....5-76 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS ....5-80 INSTALLING THE CONNECTING RODS..........5-80 INSTALLING THE CRANKSHAFT ASSEMBLY........5-82 TRANSMISSION..................5-83...
  • Page 262 ENGINE INSPECTION EAS59C1501 7. Measure: ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) EAS59C1502 and (d). MEASURING THE COMPRESSION PRES- SURE Standard compression pres- The following procedure applies to all of the sure (at sea level) cylinders.
  • Page 263 ENGINE INSPECTION 9. Connect: • Spark plug caps 10. Install: • Radiator cover Refer to “GENERAL CHASSIS” on page 4-1.

  • Page 264: Engine Removal

    ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust assembly Order Job/Parts to remove Q’ty Remarks Side cover (right) Refer to “GENERAL CHASSIS” on page 4-1. sensor coupler Disconnect. sensor Exhaust assembly Gasket Front muffler protector Center muffler protector Upper muffler protector When installing the muffler end, face the Muffler end dummy bolt to the upper side of the muffler.
  • Page 265 ENGINE REMOVAL Disconnecting the leads Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS” on page 4-1. Front cowling assembly/Storage box Refer to “GENERAL CHASSIS” on page 4-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-26.
  • Page 266 ENGINE REMOVAL Disconnecting the leads Order Job/Parts to remove Q’ty Remarks Spark plug cap Disconnect. Crankshaft position sensor coupler Disconnect. Stator coil coupler Disconnect. Sidestand switch coupler Disconnect. Coolant temperature sensor coupler Disconnect. Ground lead Disconnect. Starter motor lead Disconnect. Rear brake lock cable holder (crankcase) Wire harness Disconnect.
  • Page 267 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Refer to “V-BELT AUTOMATIC TRANSMIS- Right passenger footrest SION” on page 5-39. Damper Rear frame bolt Engine mounting nut (rear side) Engine mounting bolt (rear side) Spacer Rear frame Engine mounting bolt (front left lower side) Left footboard bracket Sidestand...
  • Page 268 ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • All removed parts • Apply locking agent (LOCTITE®) to engine mounting bolts (front right lower side) “2”, engine mounting bolts (front left lower side) “3”, and rear frame bolts “5”. • For installation, reverse the removal proce- dure.
  • Page 269 CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-26. Air filter case Refer to “THROTTLE BODY” on page 7-5. Spark plug cap Disconnect. Spark plug Cylinder head breather hose Disconnect.
  • Page 270 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30. Refer to “V-BELT AUTOMATIC TRANSMIS- Crankshaft end access cover SION” on page 5-39. Storage box Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK”...
  • Page 271 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks During removal, the dowel pins may still be Dowel pin connected to the camshaft caps. Intake camshaft Exhaust camshaft For installation, reverse the removal proce- dure. 5-10...
  • Page 272 CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the generator cover) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Remove: • Timing chain tensioner “1” • Timing chain tensioner gasket b.
  • Page 273 CAMSHAFTS Camshaft lobe dimensions Intake A 32.490–32.590 mm (1.2791– 1.2831 in) Limit 32.390 mm (1.2752 in) Intake B 24.950–25.050 mm (0.9823– 0.9862 in) Limit 24.850 mm (0.9783 in) Exhaust A 32.690–32.790 mm (1.2870– 1.2909 in) Limit 32.590 mm (1.2831 in) Exhaust B 24.950–25.050 mm (0.9823–...
  • Page 274 CAMSHAFTS the camshaft using a soft-face hammer (both for temporary and final tightening). • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clear- ance with the Plastigauge®. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) d. Remove the camshaft caps and then mea- sure the width of the Plastigauge®...
  • Page 275 CAMSHAFTS a. 1/4 tooth b. Correct b. Lock the timing chain tensioner rod by set- ting the circlip “3” to groove “4” while push- 1. Timing chain ing the timing chain tensioner rod. 2. Camshaft sprocket EAS23950 CHECKING THE TIMING CHAIN GUIDES 1.
  • Page 276 CAMSHAFTS sprocket align with the cylinder head mating surface, as shown in the illustration. ECA4B51015 Do not turn the crankshaft when installing the camshafts to avoid damage or improper valve timing. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install: •...
  • Page 277 CAMSHAFTS c. Install the timing chain tensioner to the cyl- inder block. • Lubricate the camshaft cap bolt seats with the engine oil. • When tightening the camshaft cap, tighten Always use a new gasket. the four bolts on the both ends of the cap temporarily to lower the entire cap, while pay- Timing chain tensioner bolt ing attention not to twist the dowel pins and...
  • Page 278 CLEARANCE” on page 3-5. 8. Install: • Timing chain guide (upper side) • Gaskets (to the cylinder head cover) Apply Yamaha bond No.1215 “1” onto the mat- ing surfaces of the cylinder head cover and gaskets. Yamaha bond No.1215 90890-85505 (Three bond No.1215®)

  • Page 279: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Camshafts Refer to “CAMSHAFTS” on page 5-8. Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-3. Thermostat/Coolant temperature sensor Refer to “THERMOSTAT” on page 6-7. Radiator bracket Refer to “RADIATOR”...
  • Page 280 CYLINDER HEAD EAS24120 3. Measure: REMOVING THE CYLINDER HEAD • Cylinder head warpage 1. Remove: Out of specification → Resurface the cyl- • Cylinder head bolts inder head. • Cylinder head nuts Warpage limit 0.03 mm (0.0012 in) • Loosen the bolts and nuts in the proper sequence as shown.
  • Page 281 CYLINDER HEAD 2. Install: • Cylinder head • Washers • Cylinder head nuts • Cylinder head bolts • Pass the timing chain through the timing chain cavity. • Lubricate the cylinder head nuts and wash- ers with engine oil. 3. Tighten: •...
  • Page 282 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-18. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Intake valve Exhaust valve Valve stem seal...
  • Page 283 VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 284 VALVES AND VALVE SPRINGS 2. Replace: EAS24290 • Valve guide CHECKING THE VALVES AND VALVE GUIDES To ease valve guide removal and installation, The following procedure applies to all of the and to maintain the correct fit, heat the cylinder valves and valve guides.
  • Page 285 VALVES AND VALVE SPRINGS 6. Measure: • Valve stem runout After replacing the valve guide, reface the Out of specification → Replace the valve. valve seat. • When installing a new valve, always replace Valve guide remover (ø4) the valve guide. 90890-04111 •...
  • Page 286 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Valve seat width (intake) a. Apply a coarse lapping compound “a” to 0.90–1.10 mm (0.0354–0.0433 the valve face. ECA13790 Limit 1.6 mm (0.06 in) Do not let the lapping compound enter the Valve seat width (exhaust) gap between the valve stem and the valve 0.90–1.10 mm (0.0354–0.0433 guide.
  • Page 287 VALVES AND VALVE SPRINGS f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. 2. Measure: • Compressed valve spring force “a” Out of specification →...
  • Page 288 VALVES AND VALVE SPRINGS 3. Install: EAS24320 CHECKING THE VALVE LIFTERS • Valve spring seat “1” The following procedure applies to all of the • Valve stem seal “2” valve lifters. • Valve “3” 1. Check: • Valve spring “4” •...
  • Page 289 VALVES AND VALVE SPRINGS “2” and the valve spring compressor attach- Recommended lubricant ment “3”. Engine oil Valve spring compressor 8. Install: 90890-04019 • Valve pad YM-04019 • Valve lifter Valve spring compressor ECA4B51016 attachment 90890-04114 After making sure that the valve pads are Valve spring compressor fully inserted, install the valve lifter taking adapter 19.5 mm...
  • Page 290 CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-18. Coolant hose Refer to “WATER PUMP” on page 6-9. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin...
  • Page 291 CYLINDER AND PISTONS EAS24380 2. Remove: REMOVING THE PISTONS • Top ring The following procedure applies to all of the • 2nd ring piston. • Oil ring 1. Remove: • Piston pin clips “1” When removing a piston ring, open the end •...
  • Page 292 CYLINDER AND PISTONS Bore = maximum of D –D Piston-to-cylinder clearance 0.010–0.035 (0.0004– Taper limit = maximum of D or D - maxi- 0.0014 in) mum of D or D Limit Out of round limit = maximum of D or D 0.15 mm (0.0059 in) - minimum of D or D...
  • Page 293 CYLINDER AND PISTONS 3. Measure: Piston pin outside diameter • Piston ring end gap 15.991–16.000 mm (0.6296– Out of specification → Replace the piston 0.6299 in) ring set. Limit 15.971 mm (0.6288 in) The oil ring expander spacer’s end gap cannot be measured.
  • Page 294 CYLINDER AND PISTONS EAS24470 INSTALLING THE PISTONS AND CYLINDER The following procedure applies to all of the pistons and cylinders. 1. Install: • Oil ring expander “1” • Lower oil ring rail “2” • Upper oil ring rail “3” • 2nd ring “4” •...
  • Page 295 CYLINDER AND PISTONS 6. Install: • Cylinder • Cylinder bolt • While compressing the piston rings, install the cylinder. • Pass the timing chain and timing chain guide (intake side) through the timing chain cavity. 7. Tighten: • Cylinder bolt Cylinder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 5-34...

  • Page 296: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Storage box Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Ground lead Disconnect. Starter motor lead Disconnect. Starter motor assembly For installation, reverse the removal proce- dure.
  • Page 297 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Armature assembly Starter motor yoke O-ring Brush holder set Insulator Starter motor rear cover For assembly, reverse the disassembly pro- cedure. * When replacing any of the starter motor front cover, armature assembly, starter motor yoke, insu- lator, and starter motor rear cover, replace the starter motor assembly.
  • Page 298 ELECTRIC STARTER EAS24791 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
  • Page 299 ELECTRIC STARTER 6. Check: • Gear teeth Damage/wear → Replace the starter motor assembly. 7. Check: • Bearing Damage/pitting → Replace the starter motor assembly. EAS24810 INSTALLING THE STARTER MOTOR 1. Connect: EAS24800 ASSEMBLING THE STARTER MOTOR • Battery negative lead “1” 1.
  • Page 300 V-BELT AUTOMATIC TRANSMISSION EAS24610 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover Order Job/Parts to remove Q’ty Remarks Footboard (right) Refer to “GENERAL CHASSIS” on page 4-1. Storage box Refer to “GENERAL CHASSIS” on page 4-1. V-belt case air filter element (left) Refer to “WATER PUMP”...
  • Page 301 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover Order Job/Parts to remove Q’ty Remarks Bearing retainer Bearing Circlip Oil seal Bearing For installation, reverse the removal proce- dure. * Water 5-40...
  • Page 302 V-belt case air duct Inner V-belt case plate Inner V-belt case Dowel pin Plate Inner V-belt case seal For installation, reverse the removal proce- dure. *1 Apply Shell Sunlight Grease 3®. *2 Apply YAMAHA GREASE “H” or Polyurea Grease®. 5-41...
  • Page 303 Slider Primary sheave weight Primary sliding sheave Collar Oil seal For assembly, reverse the disassembly pro- cedure. *1 Apply YAMAHA GREASE “H” or Polyurea Grease®. *2 When replacing the primary sliding sheave or collar, replace them as a set. 5-42...
  • Page 304 Secondary sheave spring seat nut Upper spring seat Secondary sheave compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave For assembly, reverse the disassembly pro- cedure. * Apply YAMAHA GREASE “H” or Polyurea Grease®. 5-43...
  • Page 305 V-BELT AUTOMATIC TRANSMISSION EAS4B51022 REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE 1. Remove: • Primary sheave nut “1” • Secondary sheave nut “2” While holding the primary and secondary sheave with the sheave holder “3”, loosen the nut. Sheave holder EAS24640 DISASSEMBLING THE SECONDARY 90890-01481...
  • Page 306 V-BELT AUTOMATIC TRANSMISSION EAS24680 Sheave spring compressor CHECKING THE PRIMARY SHEAVE 90890-04134 1. Check: YM-04134 • Primary sliding sheave Locknut wrench • Primary fixed sheave Cracks/damage/wear → Replace the pri- 90890-01348 YM-01348 mary sliding sheave and primary fixed Sheave fixed block sheave as a set.
  • Page 307 (with the recommended lubricant) 2. Check: Recommended lubricant • Torque cam groove “1” Damage/wear → Replace the secondary YAMAHA GREASE “H” or Polyurea Grease® fixed and sliding sheaves as a set. 3. Check: • Guide pin “2” Damage/wear → Replace the secondary fixed and sliding sheaves as a set.
  • Page 308 3. Lubricate: • Guide pin groove “1” • O-rings “2” (with the recommended lubricant) Recommended lubricant YAMAHA GREASE “H” or Polyurea Grease® 5. Tighten: • Secondary sheave spring seat nut “1” While holding the secondary fixed sheave “2” with the sheave holder “3”, tighten the second- ary sheave spring seat nut “1”...
  • Page 309 V-belt. Make sure to install the V-belt with • Sealant the arrow facing in the direction shown. (onto the inner V-belt case seal) • Install the V-belt and secondary sheave Yamaha bond No.1215 assembly then pass the V-belt the primary 90890-85505 sheave side. (Three bond No.1215®) •...
  • Page 310 V-BELT AUTOMATIC TRANSMISSION tions of the cam are fitted firmly into the serrations of the crankshaft. • Also, make sure that cam is properly seated. • Apply grease to the thread and seat of the primary sheave nut. Recommended lubricant Shell Sunlight Grease 3®...
  • Page 311 GENERATOR AND STARTER CLUTCH EAS59C1503 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-26. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30.
  • Page 312 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Starter clutch idle gear shaft Starter clutch idle gear Generator rotor nut Spacer Generator rotor Starter clutch Woodruff key Starter clutch gear Washer For installation, reverse the removal proce- dure.
  • Page 313 GENERATOR AND STARTER CLUTCH Removing the stator coil and oil tank Order Job/Parts to remove Q’ty Remarks Oil tank Oil tank gasket Dowel pin Oil strainer Crankshaft position sensor Stator coil Bearing cover Oil seal Bearing Bearing For installation, reverse the removal proce- dure.
  • Page 314 GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR Make sure the flywheel puller is centered over 1. Remove: the generator rotor. • Generator cover Flywheel puller Loosen each bolt 1/4 of a turn at a time, in 90890-01362 stages and in a crisscross pattern. Heavy duty puller After all of the bolts are fully loosened, remove YU-33270-B...
  • Page 315 GENERATOR AND STARTER CLUTCH 2. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Starter clutch idle gear “1” • Starter clutch gear “2” EAS24990 Burrs/chips/roughness/wear → Replace CHECKING THE OIL STRAINER 1. Check: the defective part(s). • Oil strainer Damage → Replace. Contaminants → Clean with solvent. EAS59C1505 ASSEMBLING THE OIL TANK 1.
  • Page 316 2. Tighten: (onto the crankshaft position sensor/sta- • Generator rotor nut “1” tor lead grommet) Generator rotor nut (1st) Yamaha bond No.1215 65 Nm (6.5 m·kgf, 47 ft·lbf) 90890-85505 (Three bond No.1215®) • While holding the generator rotor “2” with the sheave holder “3”, tighten the generator rotor...
  • Page 317 GENERATOR AND STARTER CLUTCH 4. Install: • Generator cover Generator cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the generator cover bolts in stages and in a crisscross pattern. 5-56...
  • Page 318 CLUTCH EAS25061 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Generator cover CLUTCH” on page 5-50. Clutch assembly nut Clutch assembly Washer For installation, reverse the removal proce- dure. 5-57...
  • Page 319 CLUTCH Disassembling the clutch Order Job/Parts to remove Q’ty Remarks Clip Spring stopper plate Clutch spring plate Pressure plate Clutch plate 2 Clutch damper spring Friction plate Clutch plate 1 Clutch spring Thrust plate Clutch boss nut Primary drive gear Bearing Clutch boss Collar...
  • Page 320 CLUTCH Disassembling the clutch Order Job/Parts to remove Q’ty Remarks Thrust plate Clutch weight Clutch housing For assembly, reverse the disassembly pro- cedure. 5-59...
  • Page 321 CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch assembly nut “1” • Clutch assembly “2” • Before removal, put alignment marks “a” and “b” as shown. • While holding the clutch assembly with the rotor holding tool “3”, loosen the clutch assembly nut.
  • Page 322 CLUTCH EAS25100 CHECKING THE FRICTION PLATES Warpage limit The following procedure applies to all of the Clutch plate 1 friction plates. 0.10 mm (0.0039 in) 1. Check: Clutch plate 2 • Friction plate 0.20 mm (0.0079 in) Damage/wear → Replace the friction plates as a set.
  • Page 323 CLUTCH Clutch spring plate height 4.70 mm (0.19 in) Minimum height 4.40 mm (0.17 in) EAS25160 CHECKING THE CLUTCH BOSS 1. Check: • Clutch boss splines Damage/pitting/wear → Replace the clutch boss. EAS25140 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the Pitting on the clutch boss splines will cause clutch springs.
  • Page 324 CLUTCH EAS4B51029 ASSEMBLING THE CLUTCH 1. Install: • Clutch boss • Primary drive gear • Clutch boss nut 2. Tighten: • Clutch boss nut “1” Clutch boss nut 130 Nm (13 m·kgf, 94 ft·lbf) While holding the clutch boss “2” with the uni- versal clutch holder “3”, tighten the clutch boss nut.
  • Page 325 CLUTCH EAS25240 INSTALLING THE CLUTCH 1. Install: • Clutch assembly “1” • Clutch assembly nut “2” Clutch assembly nut 65 Nm (6.5 m·kgf, 47 ft·lbf) • Align the “a” and “b” during reassembly. • While holding the clutch assembly with the rotor holding tool “3”, tighten the clutch assembly nut.

  • Page 326: Oil Pump

    OIL PUMP EAS24901 OIL PUMP Removing the oil pump assembly Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Starter clutch gear CLUTCH” on page 5-50. Oil pump assembly Oil pump drive chain Gasket Oil delivery pipe Oil pipe Relief valve assembly For installation, reverse the removal proce- dure.
  • Page 327 OIL PUMP Disassembling the oil pump assembly Order Job/Parts to remove Q’ty Remarks Oil pump housing 1 Dowel pin Oil pump outer rotor 1 Oil pump inner rotor 1 Washer Oil pump housing center Oil pump outer rotor 2 Oil pump inner rotor 2 Oil pump driven gear Oil pump housing 2 For assembly, reverse the disassembly pro-...
  • Page 328 OIL PUMP EAS24960 CHECKING THE OIL PUMP 1. Check: • Oil pump driven gear “1” • Oil pump housing 2 “2” • Oil pump housing 1 “3” Cracks/damage/wear → Replace the oil pump assembly. EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: •...
  • Page 329 OIL PUMP ECA13890 After tightening the bolts, make sure the oil pump turns smoothly. 5-68...
  • Page 330 CRANKCASE EAS25540 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Cylinder head Refer to “CYLINDER HEAD” on page 5-18. Refer to “CYLINDER AND PISTONS” on Cylinder/Pistons page 5-29. Oil cooler Refer to “OIL COOLER”...
  • Page 331 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Left crankcase Dowel pin Oil strainer Right crankcase For installation, reverse the removal proce- dure. 5-70...
  • Page 332 CRANKCASE Removing the oil seals and bearings Order Job/Parts to remove Q’ty Remarks Crankshaft assembly Refer to “CRANKSHAFT” on page 5-74. Transmission Refer to “TRANSMISSION” on page 5-83. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure. 5-71...
  • Page 333 Tap only on reinforced • Sealant portions of the crankcase, not on the (onto the crankcase mating surfaces) crankcase mating surfaces. Work slowly Yamaha bond No.1215 and carefully and make sure the crankcase 90890-85505 halves separate evenly. (Three bond No.1215®)
  • Page 334 CRANKCASE 5. Install: • Crankcase bolts (M8) • Crankcase bolts (M6) Crankcase bolt (M8) 24 Nm (2.4 m·kgf, 17 ft·lbf) Crankcase bolt (M6) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.
  • Page 335 CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft assembly Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-69. Dowel pin Balancer cylinder Crankshaft assembly Oil seal Crankshaft journal bearing For installation, reverse the removal proce- dure. 5-74...
  • Page 336 CRANKSHAFT Removing the connecting rods 60 Nm (6.0 m kgf, 43 ft Ibf) Order Job/Parts to remove Q’ty Remarks Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing Circlip Balancer piston pin Balancer piston Balancer connecting rod cap Balancer big end lower bearing Balancer connecting rod Balancer big end upper bearing...
  • Page 337 CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the connecting rods. 1. Remove: • Connecting rod cap “1” • Connecting rod “2” • Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place.
  • Page 338 CRANKSHAFT 3. Measure: • Crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings. clearance (using plastigauge®) Connecting rod 0.040–0.064 (0.0016– 0.0025 in) Balancer connecting rod d. Assemble the connecting rod halves. 0.036–0.060 (0.0014– 0.0024 in) • Do not move the connecting rod or crank- shaft until the clearance measurement has The following procedure applies to all of the been completed.
  • Page 339 CRANKSHAFT For example, if the connecting rod P the crankshaft web P numbers are 5 and 1 respectively, then the bearing size for P (connecting rod) - P (crankshaft) 5 - 1 = 4 (green) Bearing color code 1.Blue 2.Black 3.Brown 4.Green ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 340 CRANKSHAFT places. If it is out of specification, replace • J –J refer to the bearings shown in the the crankshaft. crankshaft illustration. Crankshaft journal diameter 54.984–55.000 mm (2.1647– 2.1654 in) d. Measure the crankshaft journal bearing inside diameter “b” of each crankshaft jour- nal bearing at two places.
  • Page 341 CRANKSHAFT Bearing color code 1.Blue 2.Black 3.Brown 4.Green Bearing thickness Blue: 2.495–2.508 (0.0982–0.0987 in) Black: 2.491–2.504 (0.0981–0.0986 in) Brown: 2.487–2.500 (0.0979–0.0984 in) Green: 2.483–2.496 (0.0978–0.0983 in) EAS25630 INSTALLING THE CRANKSHAFT JOUR- NAL BEARINGS The following procedure applies to both of the crankshaft journal bearings.
  • Page 342 CRANKSHAFT • Make sure the characters “d” on both the c. Tighten the connecting rod nuts further to connecting rod and connecting rod cap are reach the specified angle 90°. aligned. Connecting rod nut (2nd) Specified angle 90° EWA13400 WARNING If the connecting rod nut is tightened more than the specified angle, do not loosen the nut and then retighten it.
  • Page 343 CRANKSHAFT • Make sure the characters “d” on both the bal- Balancer cylinder bolt ancer connecting rod and balancer connect- 58 Nm (5.8 m·kgf, 42 ft·lbf) ing rod cap are aligned. LOCTITE® ECA4B51023 To avoid scratching the crankshaft and to ease the installation procedure, apply grease onto the oil seal lips and apply engine oil onto each bearing.
  • Page 344 TRANSMISSION EAS26241 TRANSMISSION Removing the transmission Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-69. Secondary shaft Collar Primary driven gear When installing main axle, install the main Main axle axle with groove “a” facing to the primary driven gear.
  • Page 345 TRANSMISSION EAS31560 CHECKING THE TRANSMISSION 1. Check: • Transmission gears Blue discoloration/pitting/wear → Replace. 2. Check: • Transmission gear movement Rough movement → Replace the defec- tive part(s). 3. Check: • Main axle Cracks/damage/wear → Replace the main axle. 4. Measure: •...
  • Page 346 TRANSMISSION 5-85...
  • Page 347 COOLING SYSTEM RADIATOR....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 OIL COOLER ....................6-5 CHECKING THE OIL COOLER..............6-6 INSTALLING THE OIL COOLER ............6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT............6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP..........6-11 CHECKING THE WATER PUMP ............6-11 ASSEMBLING THE WATER PUMP............6-11 INSTALLING THE WATER PUMP ............6-12...
  • Page 348 RADIATOR EAS26380 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Footboards Refer to “GENERAL CHASSIS” on page 4-1. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30. Coolant reservoir hose Coolant reservoir Coolant reservoir cap Coolant reservoir breather hose Remove/Install it with the radiator filler pipe Radiator cap held.
  • Page 349 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Radiator Radiator fan Radiator inlet hose Radiator bracket For installation, reverse the removal proce- dure.
  • Page 350 RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. 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 351 RADIATOR b. Apply 137.3 kPa (1.37 kgf/cm , 19.9 psi) of pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 352 OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Storage box Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-26.
  • Page 353 OIL COOLER EAS26420 4. Fill: CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-30. • Oil cooler inlet hose •...
  • Page 354 THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Storage box Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30. Coolant temperature sensor coupler Disconnect.
  • Page 355 THERMOSTAT EAS26450 CHECKING THE THERMOSTAT If the accuracy of the thermostat is in doubt, 1. Check: replace it. A faulty thermostat could cause seri- • Thermostat ous overheating or overcooling. Does not open at 71–85 °C (159.8–185.0 °F) → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 356: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks Footboard (left) Refer to “GENERAL CHASSIS” on page 4-1. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30. V-belt case air filter element joint clamp Loosen.
  • Page 357 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump housing cover Circlip Impeller shaft Water pump seal Bearing Oil seal Water pump housing For assembly, reverse the disassembly pro- cedure. 6-10...
  • Page 358 WATER PUMP EAS26510 EAS26541 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Rubber damper holder “1” • Water pump housing cover “1” • Rubber damper “2” • Water pump housing “2” (from the impeller, with a thin, flathead •...
  • Page 359 • Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 “2” to the water pump housing “3”. 4. Measure: • Impeller shaft tilt Mechanical seal installer Out of specification →...
  • Page 360 WATER PUMP 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-30. 3. Check: • Cooling system Leaks → Repair or replace any faulty part. Refer to “INSTALLING THE RADIATOR” on page 6-3.
  • Page 361 FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL HOSE ...............7-2 REMOVING THE FUEL TANK ..............7-2 REMOVING THE FUEL PUMP...............7-2 CHECKING THE FUEL PUMP BODY ............7-2 CHECKING THE FUEL PUMP OPERATION .........7-2 CHECKING THE ROLLOVER VALVE ............7-2 INSTALLING THE FUEL PUMP..............7-3 INSTALLING THE FUEL TANK...............7-3 INSTALLING THE FUEL HOSE..............7-3 CHECKING THE FUEL PRESSURE............7-3...
  • Page 362 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Storage box Refer to “GENERAL CHASSIS” on page 4-1. Fuel pump coupler Disconnect. Fuel hose connector cover Fuel hose Disconnect. Fuel tank overflow hose Fuel tank breather hose Rollover valve Fuel tank Fuel tank cap...

  • Page 363: Fuel Tank

    FUEL TANK EAS59C1701 2. Remove: REMOVING THE FUEL HOSE • Fuel tank overflow hose 1. Remove: • Fuel tank breather hoses • Fuel hose connector cover “1” • Rollover valve 2. Disconnect: 3. Disconnect: • Fuel hose “2” • Fuel pump coupler EWA15910 4.
  • Page 364 FUEL TANK 2. Connect: • Fuel pump coupler 3. Install: • Fuel tank overflow hose • Fuel tank breather hoses • Rollover valve EAS59C1704 INSTALLING THE FUEL HOSE 1. Connect: • Fuel hose EAS59C1703 2. Install: INSTALLING THE FUEL PUMP •...
  • Page 365 FUEL TANK ECA59C17001 Fuel line pressure (at idle) 220–300 kPa (2.20–3.00 kgf/ • Be sure to disconnect the fuel hose by cm², 31.3–42.7 psi) hand. Do not forcefully disconnect the hose with tools. e. Set the main switch to “OFF”. •...

  • Page 366: Throttle Body

    THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body Order Job/Parts to remove Q’ty Remarks Storage box Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-30.
  • Page 367 THROTTLE BODY Removing the throttle body Order Job/Parts to remove Q’ty Remarks Throttle position sensor sub-wire harness cou- Disconnect. pler Throttle body joint clamp Loosen. Throttle body assembly Throttle position sensor sub-wire harness Throttle body joint Fuel hose Fuel injector coupler Disconnect.
  • Page 368 THROTTLE BODY Disassembling the throttle body assembly Order Job/Parts to remove Q’ty Remarks Before disassembling the throttle body assembly, make sure to note the number of times the air screw is turned out from the seated position to its set position. Throttle position sensor Idling speed adjusting screw set Plunger...
  • Page 369 THROTTLE BODY EAS59C1705 2. Check: REMOVING THE FUEL HOSE (INJECTOR • Fuel passages SIDE) Obstructions → Clean. 1. Disconnect: ECA59C1703 • Fuel hose (injector side) EWA15910 Do not adjust the stop screw “1”. WARNING Cover fuel hose connections with a cloth when disconnecting them.
  • Page 370 THROTTLE BODY 3. Install a new seal onto the end of each EAS59C1706 ADJUSTING THE THROTTLE POSITION injector. SENSOR EWA59C1701 WARNING • Handle the throttle position sensor with special care. • Never subject the throttle position sensor to strong shocks. If the throttle position sensor is dropped, replace it.
  • Page 371 THROTTLE BODY Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7-10...
  • Page 372 THROTTLE BODY 7-11...

  • Page 373: General Information

    CIRCUIT DIAGRAM................8-25 TROUBLESHOOTING ................8-27 FUEL INJECTION SYSTEM ...............8-29 CIRCUIT DIAGRAM................8-29 ECU SELF-DIAGNOSTIC FUNCTION ..........8-31 TROUBLESHOOTING METHOD ............8-33 DIAGNOSTIC MODE................8-34 YAMAHA DIAGNOSTIC TOOL .............8-35 TROUBLESHOOTING DETAILS ............8-37 DIAGNOSTIC CODE TABLE ..............8-68 FUEL PUMP SYSTEM................8-71 CIRCUIT DIAGRAM................8-71 TROUBLESHOOTING ................8-73 IMMOBILIZER SYSTEM................8-75 CIRCUIT DIAGRAM................8-75 GENERAL INFORMATION ..............8-77...
  • Page 374 ABS (ANTI-LOCK BRAKE SYSTEM) ............8-85 CIRCUIT DIAGRAM................8-85 ABS COMPONENTS CHART...............8-87 ABS COUPLER LOCATION CHART ............8-89 MAINTENANCE OF THE ABS ECU.............8-91 ABS TROUBLESHOOTING OUTLINE ..........8-91 BASIC INSTRUCTIONS FOR TROUBLESHOOTING......8-92 BASIC PROCESS FOR TROUBLESHOOTING ........8-93 [A] CHECKING THE ABS WARNING LIGHT ........8-94 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON ...8-94 [A-2] THE ABS WARNING LIGHT AND ALL OTHER INDICATOR LIGHTS FAIL TO COME ON ..........8-94...

  • Page 376: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 377 IGNITION SYSTEM 1. Crankshaft position sensor 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 26.Right handlebar switch 27.Engine stop switch 38.Sidestand switch 39.ECU (engine control unit) 40.Ignition coil 41.Spark plug 49.Lean angle sensor...
  • Page 378 IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Footboards 2. Front cowling assembly 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-127.
  • Page 379 IGNITION SYSTEM 8. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit. SWITCHES” on page 8-123. OK↓ 9. Check the engine stop switch. NG→ The engine stop switch is faulty. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...

  • Page 380: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 381 ELECTRIC STARTING SYSTEM 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 14.Signaling system fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 22.Starter relay 23.Starter motor 24.Starting circuit cut-off relay 2 25.Diode 1 26.Right handlebar switch 27.Engine stop switch 28.Start switch 30.Front brake light switch 33.Diode 2...
  • Page 382 ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 383 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Signaling system fuse 5. Ignition fuse 6. Engine stop switch 7. Diode 2 8. Starting circuit cut-off relay 1 9. Front brake light switch 10.Rear brake light switch 11.Sidestand switch 12.Starting circuit cut-off relay 2 13.Start switch...
  • Page 384 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 1. Check the fuses. NG→ (Main, ignition and signaling sys- tem) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 385 ELECTRIC STARTING SYSTEM 8. Check the starter relay. NG→ Refer to “CHECKING THE Replace the starter relay. RELAYS” on page 8-131. OK↓ 9. Check the main switch. NG→ Replace the main switch/immobilizer Refer to “CHECKING THE unit. SWITCHES” on page 8-123. OK↓...

  • Page 386: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
  • Page 387 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Frame ground 5. Joint 19.Battery 20.Negative lead 21.Main fuse 8-12...
  • Page 388 CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 1. Check the fuse. NG→ (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-127. OK↓...
  • Page 389 CHARGING SYSTEM 8-14...

  • Page 390: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
  • Page 391 LIGHTING SYSTEM 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 9. Storage box light switch 10.Storage box light 13.Backup fuse 15.Headlight fuse 16.Ignition fuse 18.Parking lighting fuse 19.Battery 20.Negative lead 21.Main fuse 39.ECU (engine control unit) 63.License plate light 64.Tail/brake light 67.Left handlebar switch 68.Pass switch...
  • Page 392 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, high beam indicator light, taillight, license plate light, meter light or storage box light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Mudguard 1.
  • Page 393 LIGHTING SYSTEM 8. Check the storage box light switch. NG→ Refer to “CHECKING THE Replace the storage box light switch. SWITCHES” on page 8-123. OK↓ 9. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring.

  • Page 394: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
  • Page 395 SIGNALING SYSTEM 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 13.Backup fuse 14.Signaling system fuse 16.Ignition fuse 18.Parking lighting fuse 19.Battery 20.Negative lead 21.Main fuse 26.Right handlebar switch 29.Hazard switch 30.Front brake light switch 37.Fuel sender 39.ECU (engine control unit) 50.Diagnostic tool coupler 51.Wheel sensor shield ground 52.ABS ECU (electronic control unit)
  • Page 396 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to operate. • The speedometer fails to operate. •...
  • Page 397 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-19. OK↓ This circuit is OK. The tail/brake light fails to come on. 1. Check the front brake light switch. NG→...
  • Page 398 SIGNALING SYSTEM 5. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 8-19. OK↓ Replace the meter assembly. The fuel meter fails to operate. 1. Check the fuel sender. NG→...
  • Page 399 SIGNALING SYSTEM 8-24...

  • Page 400: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25...
  • Page 401 COOLING SYSTEM 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 13.Backup fuse 16.Ignition fuse 17.Radiator fan fuse 19.Battery 20.Negative lead 21.Main fuse 39.ECU (engine control unit) 44.Coolant temperature sensor 50.Diagnostic tool coupler 60.Radiator fan motor relay 61.Radiator fan motor 82.Meter assembly 92.Multi-function meter 8-26...
  • Page 402 COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank 1. Check the fuses. NG→ (Main, ignition, radiator fan and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-127.
  • Page 403 COOLING SYSTEM 7. Check the entire cooling system’s NG→ wiring. Properly connect or repair the cooling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-25. OK↓ Replace the ECU (engine control unit) or meter assembly. 8-28...

  • Page 404: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29...
  • Page 405 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 12.Fuel injection system fuse 13.Backup fuse 14.Signaling system fuse 15.Headlight fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 26.Right handlebar switch 27.Engine stop switch 33.Diode 2 34.Starting circuit cut-off relay 1 35.Fuel injection system relay...
  • Page 406 FUEL INJECTION SYSTEM EAS27351 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 engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
  • Page 407 FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
  • Page 408 FUEL INJECTION SYSTEM EAS27402 The engine operation is not normal, but the TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of the following sen- engine trouble warning light comes on. sors and actuators in the diagnostic mode.
  • Page 409 FUEL INJECTION SYSTEM EAS27431 DIAGNOSTIC MODE Setting the diagnostic mode 1. Set the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the left set button “1” and right set button “2”, set the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
  • Page 410 FUEL INJECTION SYSTEM EAS59C1803 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03215...
  • Page 411 Disconnect the coupler (Yellow/blue, Red/green, Black/white) “1”, and then connect the Yamaha diagnostic tool to the coupler. When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation.

  • Page 412: Troubleshooting

    FUEL INJECTION SYSTEM EAS27462 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part have been completed, reset the meter display according to the reinstatement method.
  • Page 413 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause...
  • Page 414 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: open or short circuit detected. (no nor- Item mal signals are received from the intake air pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:03 Meter display Displays the intake air pressure.
  • Page 415 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: open or short circuit detected. (no nor- Item mal signals are received from the intake air pressure sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:03 Meter display Displays the intake air pressure.
  • Page 416 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or Item detached hose). Intake system malfunction (the pressure is not sup- plied to the intake air pressure sensor in a stable condition). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 417 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or Item detached hose). Intake system malfunction (the pressure is not sup- plied to the intake air pressure sensor in a stable condition). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 418 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: open or short circuit detected. (no normal Item signals are received from the throttle position sensor.) Under certain conditions Fail-safe system Under certain conditions Diagnostic code No. d:01 Throttle position sensor Meter display •...
  • Page 419 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: open or short circuit detected. (no normal Item signals are received from the throttle position sensor.) Under certain conditions Fail-safe system Under certain conditions Diagnostic code No. d:01 Throttle position sensor Meter display •...
  • Page 420 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: stuck throttle position sensor detected. Item (signal from throttle position sensor will not change.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:01 Throttle position sensor Meter display •...
  • Page 421 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the light green lead of Item the ECU is detected. (no normal signals are received from the side- stand switch.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
  • Page 422 FUEL INJECTION SYSTEM Fault code No. Coolant temperature sensor: open or short circuit detected. (no nor- Item mal signals are received from the coolant temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:06 Meter display Displays the coolant temperature.
  • Page 423 FUEL INJECTION SYSTEM Fault code No. Coolant temperature sensor: open or short circuit detected. (no nor- Item mal signals are received from the coolant temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:06 Meter display Displays the coolant temperature.
  • Page 424 FUEL INJECTION SYSTEM Fault code No. Intake air temperature sensor: open or short circuit detected. (no Item normal signals are received from the intake air temperature sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:05 Meter display Displays the intake air temperature.
  • Page 425 FUEL INJECTION SYSTEM Fault code No. sensor: Not activated. (no normal signals are received from the Item sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 426 FUEL INJECTION SYSTEM Fault code No. sensor: Not activated. (no normal signals are received from the Item sensor.) Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 427 FUEL INJECTION SYSTEM Fault code No. Latch up detected. Item No normal signals are received from the lean angle sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
  • Page 428 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead of the Item ignition coil. (no normal signals are received from the ignition sys- tem.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
  • Page 429 FUEL INJECTION SYSTEM Fault code No. Ignition coil: open or short circuit detected in the primary lead of the Item ignition coil. (no normal signals are received from the ignition sys- tem.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
  • Page 430 FUEL INJECTION SYSTEM Fault code No. Item Engine speed is high when the engine is idling. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure...
  • Page 431 FUEL INJECTION SYSTEM Fault code No. Lean angle sensor: open or short circuit detected. (no normal sig- Item nals are received from the lean angle sensor.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
  • Page 432 FUEL INJECTION SYSTEM Fault code No. Lean angle sensor: open or short circuit detected. (no normal sig- Item nals are received from the lean angle sensor.) Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display •...
  • Page 433 FUEL INJECTION SYSTEM Fault code No. Item No normal signals are received from the front wheel sensor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:07 Meter display Vehicle speed pulses: 0–999 Check that the number increases when the front wheel is rotated. Procedure The number is cumulative and does not reset each time the wheel is stopped.
  • Page 434 FUEL INJECTION SYSTEM Fault code No. Item No normal signals are received from the front wheel sensor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:07 Meter display Vehicle speed pulses: 0–999 Check that the number increases when the front wheel is rotated. Procedure The number is cumulative and does not reset each time the wheel is stopped.
  • Page 435 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:09, d:50 Fuel system voltage (battery voltage) Meter display Approximately 12.0 d:09...
  • Page 436 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:09, d:50 Fuel system voltage (battery voltage) Meter display Approximately 12.0 d:09...
  • Page 437 FUEL INJECTION SYSTEM Fault code No. Error is detected while reading or writing on EEPROM (CO adjust- Item ment value). Under certain conditions Fail-safe system Under certain conditions Diagnostic code No. d:60 EEPROM fault code display • 00 (no history) Meter display •...
  • Page 438 FUEL INJECTION SYSTEM Fault code No. Item Incorrect voltage is supplied to the ECU. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Item/components and Sensor inspection proce- Check or maintenance job probable cause dure Charging system malfunction Check the charging system.
  • Page 439 FUEL INJECTION SYSTEM Fault code No. Er-1 ECU internal malfunction (output signal error): no signals are Item received from the ECU. Able to start engine (Unable if ECU Failure) Fail-safe system Able to drive vehicle (Unable if ECU Failure) Diagnostic code No. —...
  • Page 440 FUEL INJECTION SYSTEM Fault code No. Er-2 ECU internal malfunction (output signal error): no signals are Item received from the ECU within the specified duration. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display —...
  • Page 441 FUEL INJECTION SYSTEM Fault code No. Er-3 ECU internal malfunction (output signal error): data from the ECU Item cannot be received correctly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure —...
  • Page 442 FUEL INJECTION SYSTEM Fault code No. Er-4 ECU internal malfunction (input signal error): non-registered data Item has been received from the meter. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure —...
  • Page 443 FUEL INJECTION SYSTEM EAS30660 DIAGNOSTIC CODE TABLE The following tables contain information about diagnostic code numbers that do not have a corre- sponding fault code number. (These items are not listed in “TROUBLESHOOTING DETAILS”.) Diag- nostic Item Meter display/Actuation Procedure code d:36 Fuel injector #1...
  • Page 444 FUEL INJECTION SYSTEM Diag- nostic Item Meter display/Actuation Procedure code d:61 Malfunction history code — display • No history • History exists Fault code Nos. 12–50 • (If more than one code number is detected, the dis- play alternates every two seconds to show all the detected code numbers.
  • Page 445 FUEL INJECTION SYSTEM 8-70...
  • Page 446 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-71...
  • Page 447 FUEL PUMP SYSTEM 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 12.Fuel injection system fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 26.Right handlebar switch 27.Engine stop switch 35.Fuel injection system relay 36.Fuel pump 39.ECU (engine control unit) 8-72...
  • Page 448 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 1. Check the fuses. NG→ (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
  • Page 449 FUEL PUMP SYSTEM 8-74...

  • Page 450: Immobilizer System

    IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-75...
  • Page 451 IMMOBILIZER SYSTEM 4. Frame ground 5. Joint 6. Main switch 7. Immobilizer unit 8. Joint coupler 13.Backup fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 39.ECU (engine control unit) 50.Diagnostic tool coupler 82.Meter assembly 83.Immobilizer system indicator light 92.Multi-function meter 8-76...
  • Page 452 IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 453 IMMOBILIZER SYSTEM EAS27691 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS In the course of use, you may encounter the following cases where replacement of parts and regis- tration of code re-registering/standard keys are required. Each standard key is registered during production, therefore re-registering at purchase is not neces- sary.
  • Page 454 IMMOBILIZER SYSTEM Standby mode: To enable the immobilizer system, set the ignition key to “OFF”. 30 seconds later, the indicator light will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the indicator light will stop flashing, but the immobilizer system is still enabled. Standby mode d.
  • Page 455 IMMOBILIZER SYSTEM Standard key registration i. Registration mode a. Main switch “ON” b. Main switch “OFF” A. Registration of the second standard key is c. LED on complete. d. LED off B. Immobilizer system indicator light stops e. Less than 5.0 s flashing when the registration of the second f.
  • Page 456 IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is set to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. NG→ (Main, ignition and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-127.
  • Page 457 IMMOBILIZER SYSTEM EAS27721 SELF-DIAGNOSIS FAULT CODE INDICATION When a system malfunction occurs, the fault code number is indicated in the LCD display of the meter assembly and the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the fault code.
  • Page 458 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes transmitted Noise interference or dis- 1. Register the UNIT between the ECU connected lead/cable. code re-register- (engine control unit) 1. Interference due to ing key. and the immobilizer radio wave noise. 2.
  • Page 459 IMMOBILIZER SYSTEM 8-84...
  • Page 460 ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM 8-85...
  • Page 461 ABS (ANTI-LOCK BRAKE SYSTEM) 4. Frame ground 5. Joint 6. Main switch 8. Joint coupler 13.Backup fuse 14.Signaling system fuse 16.Ignition fuse 19.Battery 20.Negative lead 21.Main fuse 22.Starter relay 24.Starting circuit cut-off relay 2 25.Diode 1 26.Right handlebar switch 27.Engine stop switch 28.Start switch 30.Front brake light switch 31.ABS motor fuse...
  • Page 462 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 8-87...
  • Page 463 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Hydraulic unit assembly (ABS ECU) 2. Fuse box (right) 3. Fuse box (left) 4. ABS warning light 5. ABS test coupler 6. Rear wheel sensor rotor 7. Rear wheel sensor 8. Front wheel sensor 9. Front wheel sensor rotor 8-88...
  • Page 464 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART 8-89...
  • Page 465 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Front wheel sensor coupler 2. Meter assembly coupler 3. ABS test coupler 4. Rear wheel sensor coupler 5. ABS ECU coupler 8-90...
  • Page 466 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 MAINTENANCE OF THE ABS ECU Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damages → Replace the hydraulic unit assembly and the brake pipes that are con- nected to the assembly as a set. •...
  • Page 467 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 malfunction history. The multi-function display indicates all the fault codes recorded in the ABS ECU. Note all of the indicated fault codes if fault codes are stored in the memory.
  • Page 468 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING 8-93...
  • Page 469 ABS (ANTI-LOCK BRAKE SYSTEM) EWA59C2803 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[C-3] FINAL CHECK” on page 8-117.) EAS27830 [A] CHECKING THE ABS WARNING LIGHT Set the main switch to “ON”.
  • Page 470 ABS (ANTI-LOCK BRAKE SYSTEM) EAS59C2803 [A-3] THE ABS WARNING LIGHT FLASHES 1. Checking the test coupler adapter • Check if the test coupler adapter is connected to the ABS test coupler. • If the test coupler adapter is connected, disconnect it, install the protective cap onto the ABS test coupler and then start over from the beginning.
  • Page 471 ABS (ANTI-LOCK BRAKE SYSTEM) EAS59C2805 [B-1] THE MULTI-FUNCTION DISPLAY DOES NOT DISPLAY THE FAULT CODE 1. A malfunction that keeps the ABS warning light on is detected. [B-2] 2. The ABS warning light flashes every 0.5 second for more than 6 seconds. No malfunction is detected.
  • Page 472 ABS (ANTI-LOCK BRAKE SYSTEM) 6. The meter assembly circuit is defective. • Disconnect the ABS ECU coupler. • The White/Red terminal of the ABS ECU coupler is short-circuited to the ground. • Set the main switch to “ON”, and then check the ABS warning light. •...
  • Page 473 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. • Front wheel sensor rotor ABS_17 Missing pulses detected in the front • Front wheel sensor housing ABS_45 wheel sensor signal. • Front wheel • Rear wheel sensor rotor ABS_18 Missing pulses detected in the rear •...
  • Page 474 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. • Battery voltage • Connection of the ABS ECU coupler ABS_53 Power voltage is too low. • Wire harness • Refer to “CHARGING SYSTEM” on page 8- • Battery voltage •...
  • Page 475 ABS (ANTI-LOCK BRAKE SYSTEM) ABS_11 Front wheel sensor signal is not received prop- Fault code No. Symptom ABS_25 erly. Item/components and probable Order Check or maintenance job cause Defective sensor rotor. Check the surface of the sensor rotor for damage. Replace the sensor rotor if there is visible damage.
  • Page 476 ABS (ANTI-LOCK BRAKE SYSTEM) ABS_13 Incorrect signal from the front wheel sensor is Fault code No. Symptom ABS_26 detected. Item/components and probable Order Check or maintenance job cause Defective sensor rotor. Check the surface of the sensor rotor for damage. If there is visible damage, replace the sensor rotor.
  • Page 477 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_15 Symptom No continuity in the front wheel sensor circuit. Item/components and probable Order Check or maintenance job cause Connections • Check the coupler for any pins that may be pulled • Front wheel sensor coupler out.
  • Page 478 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_16 Symptom No continuity in the rear wheel sensor circuit. Item/components and probable Order Check or maintenance job cause Connections • Check the coupler for any pins that may be pulled • Rear wheel sensor coupler out.
  • Page 479 ABS (ANTI-LOCK BRAKE SYSTEM) ABS_17 Missing pulses detected in the front wheel sen- Fault code No. Symptom ABS_45 sor signal. Item/components and probable Order Check or maintenance job cause Installed condition of wheel bear- Check the components for looseness, distortion, and ings, axle, sensor housing, and bends.
  • Page 480 ABS (ANTI-LOCK BRAKE SYSTEM) Start switch signal is not received properly (start Fault code No. ABS_22 Symptom switch circuit or start switch monitor circuit). Item/components and probable Order Check or maintenance job cause Connections • Check the coupler for any pins that may be pulled •...
  • Page 481 ABS (ANTI-LOCK BRAKE SYSTEM) Solenoid relay is defective. Fault code No. ABS_31 Symptom Power is not supplied to the solenoid relay. Item/components and probable Order Check or maintenance job cause Battery voltage Recharge or replace the battery. Refer to “CHECKING AND CHARGING THE BAT- TERY”...
  • Page 482 ABS (ANTI-LOCK BRAKE SYSTEM) ABS motor is defective. Fault code No. ABS_33 Symptom Power is not supplied to the ABS motor. Item/components and probable Order Check or maintenance job cause Connections • Check the coupler for any pins that may be pulled •...
  • Page 483 Brake lines • Check the brake lines for kinks and deterioration. EWA59C2804 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from...
  • Page 484 (particularly between the hydraulic unit and the rear brake caliper). EWA59C2804 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
  • Page 485 ABS (ANTI-LOCK BRAKE SYSTEM) EWA59C2806 WARNING The rear brake will not function properly if the connections are reversed. • Rear brake hose (rear brake master cylinder to hydraulic unit) “1”: from the rear brake mas- ter cylinder • Rear brake pipe/joint assembly (hydraulic unit to rear brake hose) “2”: to the rear brake cal- iper •...
  • Page 486 ABS (ANTI-LOCK BRAKE SYSTEM) Incorrect signal from the rear wheel sensor is Fault code No. ABS_44 Symptom detected. Item/components and probable Order Check or maintenance job cause Defective sensor rotor. • Check the surface of the sensor rotor for damage. •...
  • Page 487 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_54 Symptom Power voltage is too low. Item/components and probable Order Check or maintenance job cause Connections • Check the coupler for any pins that may be pulled • ABS ECU coupler out. •...
  • Page 488 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_63 Symptom Front wheel sensor power is abnormal. Item/components and probable Order Check or maintenance job cause Short circuit in front wheel sensor • Check that there is no short circuit between the lead.
  • Page 489 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_64 Symptom Rear wheel sensor power is abnormal. Item/components and probable Order Check or maintenance job cause Short circuit in rear wheel sensor • Check that there is no short circuit between the lead.
  • Page 490 ABS (ANTI-LOCK BRAKE SYSTEM) EAS59C2808 7. Set the main switch to “ON” again. [C-1] DELETING THE FAULT CODES ECA59C2802 If fault codes are still displayed in the multi- function display, the malfunctions have not Since the fault codes remain in the memory been repaired.
  • Page 491 ABS (ANTI-LOCK BRAKE SYSTEM) Start switch “ON”: less than 1 V Start switch “OFF”: more than 12 V ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the digital circuit tester (DC 12 V) to the ABS ECU coupler. Digital circuit tester 90890-03189 Model 88 Multimeter with b.
  • Page 492 ABS (ANTI-LOCK BRAKE SYSTEM) EAS59C2810 [C-3] FINAL CHECK Checking procedures 1. Check the brake fluid level in the brake master cylinder reservoir. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-14. 2. Check the wheel sensor housings and wheel sensors for proper installation. Refer to “INSTALLING THE FRONT WHEEL (DISCS)”...
  • Page 493 ABS (ANTI-LOCK BRAKE SYSTEM) 8-118...

  • Page 494: Electrical Components

    ELECTRICAL COMPONENTS EAS27973 ELECTRICAL COMPONENTS 8-119...
  • Page 495 ELECTRICAL COMPONENTS 1. Hydraulic unit assembly 2. Fuse box (left) 3. Rear brake light switch 4. Battery 5. Fuel injection system relay 6. Starting circuit cut-off relay 1 7. Starting circuit cut-off relay 2 8. Main fuse 9. Starter relay 10.Diode 2 11.Diode 1 12.Rectifier/regulator...
  • Page 496 ELECTRICAL COMPONENTS 8-121...
  • Page 497 ELECTRICAL COMPONENTS 1. Main switch/immobilizer unit 2. Intake air pressure sensor 3. Coolant temperature sensor 4. Fuel pump 5. Rear wheel sensor 6. O sensor 7. Crankshaft position sensor 8. Stator coil 9. Sidestand switch 10.Radiator fan 11.Front wheel sensor 12.Throttle position sensor 13.Intake air temperature sensor 14.Ambient temperature sensor...
  • Page 498 ELECTRICAL COMPONENTS EAS27981 CHECKING THE SWITCHES 8-123...
  • Page 499 ELECTRICAL COMPONENTS 1. Pass switch 2. Dimmer switch 3. Horn switch 4. Turn signal switch 5. Rear brake light switch 6. Engine stop switch 7. Start switch 8. Hazard switch 9. Front brake light switch 10.Sidestand switch 11.Main switch 12.Storage box light switch 8-124...
  • Page 500 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
  • Page 501 ELECTRICAL COMPONENTS EAS27990 • Avoid touching the glass part of the head- CHECKING THE BULBS AND BULB SOCK- light bulb to keep it free from oil, other- wise the transparency of the glass, the life of the bulb, and the luminous flux will Do not check any of the lights that use LEDs.
  • Page 502 ELECTRICAL COMPONENTS d. If the fuse immediately blows again, check the electrical circuit. Check each bulb socket for continuity in the same manner as described in the bulb section, Amperage Fuses Q’ty however, note the following. rating Main 40 A ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...
  • Page 503 ELECTRICAL COMPONENTS • Keep batteries away from fire, sparks or ECA13640 open flames (e.g., welding equipment, lighted cigarettes). First, disconnect the battery negative lead • DO NOT SMOKE when charging or han- “1”, and then battery positive lead “2”. dling batteries. •...
  • Page 504 ELECTRICAL COMPONENTS on the vehicle, disconnect the battery negative lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the bat- tery charger leads are connected to the battery. • Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
  • Page 505 ELECTRICAL COMPONENTS b. Connect a charger and ammeter to the bat- c. Make sure that the current is higher than tery and start charging. the standard charging current written on the battery. Set the charging voltage to 16–17 V. If the set- ting is lower, charging will be insufficient.
  • Page 506 ELECTRICAL COMPONENTS Starting circuit cut-off relay 2 Recommended lubricant Dielectric grease 10. Install: • Front left storage box Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each switch for continuity with the pocket tester. If the continuity reading is incor- 1.
  • Page 507 ELECTRICAL COMPONENTS Headlight relay Fuel injection system relay 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe Result Result Continuity...
  • Page 508 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → Blue “1” b. Set the main switch to “ON”. •...
  • Page 509 ELECTRICAL COMPONENTS c. Check the diode 2 for continuity. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ d. Check the diode 2 for no continuity. a. Disconnect the ignition coil connectors from the ignition coil terminals. b. Connect the pocket tester (Ω × 1) to the When you switch the positive and negative ignition coil as shown.
  • Page 510 ELECTRICAL COMPONENTS e. Crank the engine by pushing the start switch “ ” and gradually increase the spark gap until a misfire occurs. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1. Disconnect: • Crankshaft position sensor coupler (from the wire harness) c.
  • Page 511 ELECTRICAL COMPONENTS 2. Check: EAS28940 CHECKING THE STARTER MOTOR OPERA- • Lean angle sensor output voltage TION Out of specification → Replace. 1. Check: Lean angle sensor output volt- • Starter motor operation Does not operate → Perform the electric Less than 45°: 0.4–1.4 V starting system troubleshooting, starting More than 45°: 3.7–4.4 V...
  • Page 512 ELECTRICAL COMPONENTS b. Connect the pocket tester (AC 20 V) to the Digital circuit tester battery terminal as shown. 90890-03189 Model 88 Multimeter with Pocket tester tachometer 90890-03112 YU-A1927 Analog pocket tester YU-03112-C • Positive tester probe → • Positive tester probe → White “1”...
  • Page 513 ELECTRICAL COMPONENTS b. Move the fuel sender float to empty fuel tank position “3” and full fuel tank position “4” level position. c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: c. Measure the fuel sender resistance. • Horn sound Faulty sound → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 514: Specifications

    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Immerse the coolant temperature sensor a. Disconnect the radiator fan motor coupler “1” in a container filled with coolant “2”. from the wire harness. b. Connect the battery (DC 12 V) as shown. Make sure the coolant temperature sensor ter- •...
  • Page 515 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Throttle position sensor maxi- a. Connect the test harness S- pressure sen- mum resistance sor (3P) “1” to the intake air pressure sen- 2.64–6.16 kΩ sor and wire harness as shown. c. Connect the pocket tester (Ω × 1 k) to the ECA16730 throttle position sensor as shown.
  • Page 516 ELECTRICAL COMPONENTS • Never subject the intake air temperature EAS59C1801 CHECKING THE FUEL INJECTORS sensor to strong shocks. If the intake air 1. Check: temperature sensor is dropped, replace it. • Fuel injector resistance 2. Check: Out of specification → Replace the fuel •...

  • Page 517: Engine

    TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURE/HARD STARTING ..........9-1 POOR ENGINE IDLING SPEED PERFORMANCE .......9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY CLUTCH ...................9-2 OVERHEATING ..................9-2 OVERCOOLING ..................9-3 POOR BRAKING PERFORMANCE ............9-3 FAULTY FRONT FORK LEGS ..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4 TROUBLESHOOTING AT THE ABS WARNING LIGHT......9-4 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..9-5...

  • Page 518: Troubleshooting

    TROUBLESHOOTING EAS28451 3. Throttle body TROUBLESHOOTING • Deteriorated or contaminated fuel • Sucked-in air EAS28460 GENERAL INFORMATION Electrical system 1. Battery The following guide for troubleshooting does • Discharged battery not cover all the possible causes of trouble. It • Faulty battery should be helpful, however, as a guide to basic 2.

  • Page 519: Fuel System

    TROUBLESHOOTING Fuel system 2. Primary pulley cam and primary pulley 1. Throttle body slider • Damaged or loose throttle body joint • Damaged or worn primary pulley cam • Improperly synchronized throttle body • Damaged or worn primary pulley slider •...

  • Page 520: Chassis

    TROUBLESHOOTING 2. Engine oil • Faulty brake caliper seal • Incorrect oil level • Loose union bolt • Incorrect oil viscosity • Damaged brake hose • Inferior oil quality • Oil or grease on the brake disc • Oil or grease on the brake pad Cooling system •...

  • Page 521: Troubleshooting

    TROUBLESHOOTING 6. Tire(s) • Faulty battery • Uneven tire pressures (front and rear) • Blown, damaged or incorrect fuse • Incorrect tire pressure Turn signal blinks slowly • Uneven tire wear • Faulty turn signal/hazard relay 7. Wheel(s) • Faulty main switch •...
  • Page 522 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS59C1001 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Self-Diagnostic function table Fault Reference Fault Reference Item Item code No. pages code No. pages Crankshaft position 8-37 Lean angle sensor 8-51 sensor (turnover of vehicle) Intake air pressure 8-38 Ignition coil 8-53...
  • Page 523 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Communication error with the meter Fault Reference Fault Reference Item Item code No. pages code No. pages Er-1 ECU internal mal- 8-64 Er-3 ECU internal mal- 8-66 function (output sig- function (output sig- nal error) nal error) Er-2 ECU internal mal-...
  • Page 524 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diag- nostic Item Meter display Checking method code d:09 Fuel system voltage Approximately 12.0 Set the engine stop switch (battery voltage) to “ ”, and then compare with the actually measured battery voltage. (If the bat- tery voltage is lower, per- form recharging.) d:20...
  • Page 525 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic code: actuator operation table Diag- nostic Item Actuation Checking method code d:30 Ignition coil Actuates the ignition coil five Check the spark five times. times at one-second inter- • Connect an ignition vals. checker.

  • Page 526: Wiring Diagram

    EAS28740 57. Grip warmer switch Sky blue WIRING DIAGRAM 58. Left grip warmer White 59. Right grip warmer XP500A 2012 Yellow 60. Radiator fan motor relay 1. Crankshaft position sensor Black/Blue 61. Radiator fan motor 2. AC magneto Black/White 62. Turn signal/hazard relay 3.
  • Page 529 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES XP500A XP500A XP500A XP500A DE XP500A...
  • Page 530 WIRING DIAGRAM SCHEMA DE CABLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA DE CONEXIONES XP500A XP500A XP500A XP500A DE XP500A...

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