Yamaha TMAX XP500F 2015 Service Manual

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2015

SERVICE MANUAL

XP500F

LIT-11616-28-54

2PW-28197-10

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Page 1 2015 SERVICE MANUAL XP500F LIT-11616-28-54 2PW-28197-10...
Page 2 EAS20002 XP500F SERVICE MANUAL ©2014 by Yamaha Motor Corporation, U.S.A. First edition, November 2014 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-28-54...
Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7: Table Of Contents
EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 MULTI-FUNCTION DISPLAY..............1-4 IMPORTANT INFORMATION ................. 1-9 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-9 REPLACEMENT PARTS................1-9 GASKETS, OIL SEALS AND O-RINGS ............ 1-9 LOCK WASHERS/PLATES AND COTTER PINS ........
Page 10: Identification
IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS30003 MODEL LABEL The model label “1” is affixed to the storage box. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions. 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 EAS30617 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 passage remains open.
Page 13: Multi-Function Display
FEATURES The multi-function display is equipped with the EAS30618 MULTI-FUNCTION DISPLAY following: EWA17650 • 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 FEATURES Odometer and tripmeter modes 1. Fuel reserve tripmeter 1. Odometer/tripmeters/fuel reserve tripmeter To reset a tripmeter, select it by pushing the “SE- LECT” button until “Trip F”, “Trip 1” or “Trip 2” is displayed. While “Trip F”, “Trip 1” or “Trip 2” is displayed, push the “SELECT”...
Page 15 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” ECA20730 NOTICE Do not continue to operate the engine if it is overheating. Oil change indicator “Oil” 1.
Page 16 FEATURES Ambient temperature display, average fuel Average fuel consumption mode consumption, and instantaneous fuel con- sumption modes 1. Average fuel consumption display The average fuel consumption is displayed 1. Ambient temperature/average fuel “AVE_ _._ MPG”. consumption/instantaneous fuel consumption This display shows the average fuel consump- Push the “RESET”...
Page 17 FEATURES Self-diagnosis device 1. Fault code display This model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light comes on and the display indicates a fault code. If the display indicates any fault codes, note the code number, and check the fuel injection sys- tem (Refer to “FUEL INJECTION SYSTEM”...
Page 18: Important Information
5. Keep all parts away from any source of fire. EAS30007 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...
Page 19: Bearings And Oil Seals
IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.
Page 20: Basic Service Information
BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
Page 21: Electrical System
BASIC SERVICE INFORMATION ECA16760 EAS30014 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
Page 22 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special care, and do not subject them to strong Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V. ECA16630 ECA14371 NOTICE NOTICE...
Page 23 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
Page 24 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 re- sistance 5400–6600 Ω@0 °C (5400–6600 Ω@32 °F)
Page 25: Special Tools
SPECIAL TOOLS EAS20012 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 6-3, 6-3 90890-01352 Pressure tester adapter YU-33984 YU-33984 Flywheel puller 5-56 90890-01362 Heavy duty puller YU-33270-B Steering nut wrench 3-24, 4-91 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-83, 4-86 90890-01423 Damping rod holder...
Page 27 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-86 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-82, 4-88 90890-01441 Fork spring compressor YM-01441 Fork seal driver 4-85, 4-85, 4-85 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Oil filter wrench 3-26, 6-7...
Page 28 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Pocket tester 1-15, 1-15, 8-89, 90890-03112 8-90, 8-90, 8-91, Analog pocket tester 8-94, 8-97, 8-97, YU-03112-C 8-98, 8-99, 8-99, 8-99, 8-100, 8-100, 8-102, 8-102, 8-103,...
Page 29 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Carburetor angle driver 2 3-10 90890-03173 Thickness gauge 4-30, 5-21, 5-64 90890-03180 Feeler gauge set YU-26900-9 Fuel pressure adapter 90890-03181 Fuel pressure adapter YM-03181 Digital circuit tester (CD–731a) 5-38, 8-101, 90890-03189 8-105 90890-03189 Model 88 Multimeter with tachometer YU-A1927...
Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha diagnostic tool (US) 8-34 90890-03234 Valve spring compressor 5-24, 5-29 90890-04019 Valve spring compressor YM-04019 Middle driven shaft bearing driver 6-15 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058...
Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide reamer (ø4) 5-26 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Valve spring compressor attachment 5-24, 5-29 90890-04114 Valve spring compressor adapter 19.5 mm YM-04114 Mechanical seal installer 6-15 90890-04132 Water pump seal installer YM-33221-A Sheave spring compressor 5-46, 5-49...
Page 32 Tool name/Tool No. Illustration pages Plane bearing installer 5-78, 5-82 90890-04139 Ignition checker 8-100 90890-06754 Oppama pet–4000 spark checker YM-34487 Digital tachometer 3-8, 3-9 90890-06760 Digital tachometer YU-39951-B Yamaha bond No. 1215 5-18, 5-49, 5-58, 90890-85505 5-74 (Three bond No.1215®) 1-23...
Page 33: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-16 LUBRICATION POINTS AND LUBRICANT TYPES ........2-20 ENGINE....................2-20 CHASSIS....................2-22 LUBRICATION SYSTEM CHART AND DIAGRAMS........
Page 34: General Specifications
GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 2PWD Dimensions Overall length 2200 mm (86.6 in) Overall width 775 mm (30.5 in) Overall height (Lo/Hi) 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 35: Engine Specifications
ENGINE SPECIFICATIONS EAS20014 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 10.9 : 1 Standard compression pressure (at sea level) 1950 kPa/470 r/min (19.5 kgf/cm²/470 r/min, 277.3 psi/470 r/min) Minimum–maximum...
Page 36 ENGINE SPECIFICATIONS Valve full open temperature 85.0 °C (185.00 °F) Valve lift (full open) 8.0 mm (0.31 in) 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)
Page 37 ENGINE SPECIFICATIONS Valve guide inside diameter (exhaust) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.050 mm (0.1594 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.040 mm (0.0016 in) Valve spring...
Page 38 ENGINE SPECIFICATIONS 2nd ring Ring type Taper End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in) Limit 0.75 mm (0.0295 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.100 mm (0.0039 in) Oil ring End gap (installed) 0.10–0.35 mm (0.0039–0.0138 in) Connecting rod Oil clearance 0.036–0.060 mm (0.0014–0.0024 in)
Page 39 ENGINE SPECIFICATIONS Transmission Transmission type V-belt automatic Primary reduction ratio 1.000 Secondary reduction ratio 6.034 (52/32 x 36/22 x 59/26) Final drive Belt Gear ratio 2.041–0.758 : 1 Weight outside diameter 25.0 mm (0.98 in) Limit 24.5 mm (0.96 in) Drive axle runout limit 0.10 mm (0.0039 in) Secondary shaft runout limit...
Page 40: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00 ° Trail 92 mm (3.6 in) Front wheel Wheel type Cast wheel Rim size 15M/C x MT3.50 Rim material Aluminum Wheel travel 120 mm (4.7 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 41 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) Caliper cylinder inside diameter 27.00 mm (1.06 in)
Page 42 CHASSIS SPECIFICATIONS Rear shock absorber assembly travel 43.0 mm (1.69 in) Spring installed length 180.0 mm (7.09 in) Spring rate K1 225.60 N/mm (23.00 kgf/mm, 1288.18 lbf/in) Spring rate K2 294.00 N/mm (29.98 kgf/mm, 1678.74 lbf/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) Enclosed gas/air pressure (STD)
Page 43: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20016 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 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 44 ELECTRICAL SPECIFICATIONS Smart key system indicator light Starter motor Power output 0.70 kW 0.0100–0.0200 Ω Armature coil resistance 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, 21.69–23.45 oz) Mica undercut (depth) 0.70 mm (0.03 in) Starter relay Amperage...
Page 45: Tightening Torques
TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 46: Engine Tightening Torques
TIGHTENING TORQUES EAS30016 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 47 Clutch assembly nut 65 Nm (6.5 m·kgf, 47 ft·lbf) Clutch boss nut 130 Nm (13 m·kgf, 94 ft·lbf) Bearing housing bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) YAMAHA GREASE “G” (Shell Primary sheave nut 160 Nm (16 m·kgf, 116 ft·lbf) Sunlight Grease 3®)
Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size YAMAHA GREASE Secondary sheave nut 90 Nm (9.0 m·kgf, 65 ft·lbf) “H” (Poly- urea Grease®) Secondary sheave spring seat nut 90 Nm (9.0 m·kgf, 65 ft·lbf) V-belt case bearing retainer screw 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
Page 49: Chassis Tightening Torques
TIGHTENING TORQUES EAS30017 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 right low- 45 Nm (4.5 m·kgf, 33 ft·lbf) er side) Engine mounting bolt (front left lower 45 Nm (4.5 m·kgf, 33 ft·lbf) side) Engine mounting nut (rear side)
Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Seat nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fuel tank cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fuel tank cover screw (top) 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Fuel tank cover screw (side) 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Grab bar bolt 16 Nm (1.6 m·kgf, 12 ft·lbf)
Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Handlebar switch screw (left) 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Front brake caliper bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Brake master cylinder reservoir cap 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) screw Brake lever screw 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
Page 52 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size L = 25 mm (0.98 in), L Drive pulley assembly bolt 48 Nm (4.8 m·kgf, 35 ft·lbf) = 90 mm (3.54 in) Pivot shaft 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Pivot shaft nut 100 Nm (10 m·kgf, 72 ft·lbf) Swingarm bolt 40 Nm (4.0 m·kgf, 29 ft·lbf)
Page 53: Lubrication Points And Lubricant Types
Starter clutch and starter clutch gear Primary driven gear spline and main axle spline 1st pinion gear spline and main axle spline 1st wheel gear spline and drive axle spline YAMAHA GREASE “G” Primary sheave spacer and o-ring (Shell Sunlight Grease 3®)
Page 54 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant YAMAHA GREASE “G” Primary sheave nut (Shell Sunlight Grease 3®) YAMAHA GREASE “H” Secondary sheave nut (Polyurea Grease®) Secondary shaft right end bearing Pivot shaft taper roller bearing Yamaha bond No.1215 Crankcase mating surface (Three bond No.1215®)
Page 55: Chassis
Upper bearing cover seal lip and lower bearing dust seal lip Tube guide (throttle grip) inner surface and throttle cables Rear brake lock cable end (lever end) YAMAHA GREASE “F” Brake lever pivoting point and metal-to-metal moving parts YAMAHA GREASE “J”...
Page 56: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-23...
Page 57 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.
Page 58: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-25...
Page 59 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 2-26...
Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Secondary shaft 3. Drive axle 4. Clutch 5. Generator cover 2-28...
Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Intake camshaft 3. Exhaust camshaft 2-30...
Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Generator cover 2. Oil strainer 3. Main gallery 4. Crankcase (right) A. Forward 2-32...
Page 66: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-33...
Page 67 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.
Page 68 COOLING SYSTEM DIAGRAMS 2-35...
Page 69 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.
Page 70: Cable Routing
CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (top side, front side and left side view) 2-37...
Page 71 CABLE ROUTING 1. Rear brake hose 2. Speed sensor lead 3. Horn lead 4. Left handlebar switch lead 5. Right handlebar switch lead 6. Front brake hose 7. Throttle cables 8. Rear brake lock cable 9. Brake light switch connectors A.
Page 72 CABLE ROUTING Front brake (left side and front view) 2-39...
Page 73 CABLE ROUTING 1. Front brake hose 2. Horn lead 3. Speed sensor lead A. Make sure that there is no slack in the horn lead and speed sensor lead in the area shown in the illustration. B. Align the holder with the paint mark on the front brake hose.
Page 74 CABLE ROUTING Frame (front side view) 2-41...
Page 75 CABLE ROUTING 1. Speed sensor lead 2. Meter lead 3. Intake air temperature sensor lead 4. Turn signal/hazard relay 1 5. Steering lock relay 6. Starter relay 7. Handlebar switch coupler (right side) 8. Handlebar switch coupler (left side) 9. Wire harness 10.
Page 76 CABLE ROUTING Frame (left side view) W 10 2-43...
Page 77 CABLE ROUTING 1. Battery T. 60 mm (2.36 in) 2. Sidestand switch coupler U. Fasten the leads with the plastic band. The leads may be routed in any order. 3. Auxiliary DC jack lead V. Face the buckle of the plastic band downward. 4.
Page 78 CABLE ROUTING Frame (right side view) 20 21 2-45...
Page 79 CABLE ROUTING 1. Control switch assembly lead Q. Pass a plastic locking tie through the hole in the steering lock unit bracket, and then fasten the 2. Rear brake lock cable control switch assembly lead and steering lock unit 3. Smart key unit lead lead with the tie.
Page 80 CABLE ROUTING Rear frame (right side view) 2-47...
Page 81 CABLE ROUTING 1. Wire harness 2. Seat lock cable 3. Seat lock solenoid lead 4. Fuel tank breather hose 5. Rear brake lock cable 6. Radiator fan motor lead 7. O sensor lead 8. Tail/brake light lead 9. Rear turn signal light lead A.
Page 82 CABLE ROUTING Frame (top side view) 2-49...
Page 83 CABLE ROUTING 1. Intake air pressure sensor 2. Throttle cables 3. Control switch assembly lead 4. Steering lock unit lead 5. Rear brake lock cable 6. Seat lock cable 7. Fuel injector #2 8. Fuel pump coupler 9. AC magneto lead 10.
Page 84 CABLE ROUTING Rear brake (top side and left side view) 2-51...
Page 85 CABLE ROUTING 1. Rear brake hose 2. Fuel tank mounting bracket 3. Footboard 4. Rear frame 5. Rear cowling (left) 6. Rear brake hose holder (left) 7. Swingarm 8. Drive pulley cover 9. Passenger footrest 10. Rear brake lock cable holder bracket 11.
Page 86 CABLE ROUTING Throttle body (left side view) 2-53...
Page 87 CABLE ROUTING 1. Fast idle plunger inlet coolant hose – – W. Position the clip 1 4 mm (0.04 0.16 in) away from 2. Intake manifold the end of the cylinder head breather hose. The clip may be rotated to any direction. 3.
Page 88 CABLE ROUTING Fuel tank (top side and right side view) 2-55...
Page 89 CABLE ROUTING 1. Fuel hose 2. Fuel tank breather hose 3. Intake air pressure sensor 4. Holder 5. Canister 6. Filler cover 7. Fuel tank cap 8. Fuel tank 9. Bottom center cowling 10. Radiator outlet hose 11. Fuel tank overflow hose 12.
Page 90 CABLE ROUTING Fuel tank (left side view) 2-57...
Page 91 CABLE ROUTING 1. Fuel tank breather hose – – W. 0 3 mm (0 0.12 in) 2. Fuel hose X. Install the fuel tank breather hose and canister 3. Canister purge hose (3-way joint to canister) purge hose (3-way joint to canister) onto the hose fittings of the canister, making sure that each hose 4.
Page 92 CABLE ROUTING 2-59...
Page 93: Periodic Checks And Adjustments
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 .......3-1 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 ........
Page 94 CHANGING THE COOLANT..............3-29 REPLACING THE V-BELT ..............3-31 CHECKING THE BRAKE LIGHT SWITCHES.........3-31 CHECKING AND LUBRICATING THE CABLES ........3-31 LUBRICATING THE REAR SUSPENSION..........3-32 CHECKING THE THROTTLE GRIP............3-32 CHECKING AND CHARGING THE BATTERY........3-33 CHECKING THE FUSES ................3-33 ADJUSTING THE HEADLIGHT BEAMS..........
Page 96: Periodic Maintenance
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 97 PERIODIC MAINTENANCE INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 month 12 month 18 month 24 month 30 month •...
Page 98 Front and rear √ √ √ √ √ √ 26 * • Check operation. brake switches Yamaha • Apply cable lubri- √ √ √ √ √ Control cables cant or other suitable cable lu- bricant thoroughly. • Check operation.
Page 99: Checking The Fuel Line
PERIODIC MAINTENANCE 1. Remove: EAS30619 CHECKING THE FUEL LINE • Radiator cover The following procedure applies to all of the fuel Refer to “GENERAL CHASSIS (2)” on page and breather hoses. 4-8. 1. Remove: 2. Disconnect: • Center cover • Spark plug cap Refer to “GENERAL CHASSIS (2)”...
Page 100: Adjusting The Valve Clearance
PERIODIC MAINTENANCE Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • Spark plug cap 10.Install: • Radiator cover Refer to “GENERAL CHASSIS (2)” on page 4-8. EAS30622 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves.
Page 101 PERIODIC MAINTENANCE haust camshaft sprocket must align with the cylinder head mating surface as shown in the illustration. A. Front d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft clockwise as specified in the following table.
Page 102 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 in- stalled in the correct place.
Page 103: Adjusting The Engine Idling Speed
PERIODIC MAINTENANCE • Install the valve lifter and the valve pad in the 1. Start the engine and let it warm up for several correct place. minutes. 2. Remove: • Radiator cover Refer to “GENERAL CHASSIS (2)” on page 4-8. •...
Page 104: Synchronizing The Throttle Body
PERIODIC MAINTENANCE • Vacuum gauge hose for cylinder #1 “4” EAS31424 SYNCHRONIZING THE THROTTLE BODY • Vacuum gauge hose for cylinder #2 “5” • Vacuum gauge Prior to synchronizing the throttle body, the • Digital tachometer valve clearance and the engine idling speed (onto the spark plug lead of cylinder #1) should be properly adjusted and the ignition tim- Vacuum gauge...
Page 105: Checking The Throttle Body Joints
PERIODIC MAINTENANCE EAS31318 CHECKING THE THROTTLE BODY JOINTS 1. Remove: • Center cover Refer to “GENERAL CHASSIS (2)” on page 4-8. 2. Check: • Throttle body joints “1” Cracks/damage → Replace. • After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
Page 106: Checking The Exhaust System
PERIODIC MAINTENANCE EAS30626 CHECKING THE CANISTER 1. Remove: • Storage box Refer to “GENERAL CHASSIS (5)” on page 4-20. • Fuel tank Refer to “FUEL TANK” on page 7-1. 2. Check: • Canister “1” • Canister purge hoses “2” 3. Install: Cracks/damage →...
Page 107: Cleaning The V-Belt Case Air Filter Element
PERIODIC MAINTENANCE EAS31181 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: • Center cover Refer to “GENERAL CHASSIS (2)” on page 4-8. • Footboards Refer to “GENERAL CHASSIS (2)” on page 4-8. 2. Remove: 3. Check: • V-belt case air filter element (left) “1” •...
Page 108: Checking The Brake Operation
PERIODIC MAINTENANCE EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly → Check the brake system. Refer to “FRONT BRAKE” on page 4-39 and “REAR BRAKE” on page 4-53. Drive on the road, operate the front and rear brakes separately and check to see if the brakes are operating properly.
Page 109: Adjusting The Front Disc Brake
PERIODIC MAINTENANCE EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
Page 110: Adjusting The Rear Disc Brake
PERIODIC MAINTENANCE 1. Operate the brake. EAS30631 ADJUSTING THE REAR DISC BRAKE 2. Check: 1. Adjust: • Rear brake pad • Brake lever position Wear indicators “1” almost touch the brake (distance “a” from the left side grip to the disc →...
Page 111: Checking The Front Brake Hoses
PERIODIC MAINTENANCE EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS30635 CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose holders.
Page 112: Adjusting The Rear Brake Lock Cable
PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the rear 3. Adjust: brake several times. • Clearance between the brake pad and brake 4. Check: disc. • Brake hose ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 113: Checking The Rear Brake Lock Pads
PERIODIC MAINTENANCE Refer to “ADJUSTING THE REAR BRAKE EAS31428 CHECKING THE WHEELS LOCK CABLE” on page 3-17 and “CHECK- The following procedure applies to both of the ING THE REAR BRAKE LOCK PADS” on wheels. page 3-18. 1. Check: 2. Check: •...
Page 114: Checking The Wheel Bearings
2.25 bar) cerning handling characteristics can be giv- Rear en if a tire combination other than one 250 kPa (2.50 kgf/cm², 36 psi, approved by Yamaha is used on this vehicle. 2.50 bar) Loading condition 90–195 kg (198–430 lb) Front tire...
Page 115: Checking The Swingarm
PERIODIC MAINTENANCE 1. Check: • Wheel bearings Refer to “FRONT WHEEL” on page 4-22 and “REAR WHEEL” on page 4-31. EAS31430 CHECKING THE SWINGARM 1. Check: • Swingarm operation Swingarm not working properly → Check the swingarm. Refer to “REMOVING THE SWINGARM” on page 4-101.
Page 116 PERIODIC MAINTENANCE Read side indicator number’s character “c” is c. Read the read side scale at over lap point and smaller than on the belt side. record it on paper etc. Read the small number character “d” on the In this explanation should be read “13.2”. handle for Read side “A”.
Page 117: Lubricating The Drive Pulley And Drive Axle
PERIODIC MAINTENANCE b. Turn both adjusting bolts “2” in direction “b” EWA13120 WARNING and push the rear wheel forward. Securely support the vehicle so that there is c. Turn both left and right adjusting bolts “2” in no danger of it falling over. direction “a”...
Page 118: Checking And Adjusting The Steering Head
• Drive axle “1” • Drive pulley assembly inner part “2” 5. Lubricate: • Drive axle “1” Recommended lubricant YAMAHA GREASE “J” (Shell Al- vania EP Grease R0®) 6. Lubricate: • Drive pulley assembly inner part “2” Recommended lubricant YAMAHA GREASE “J” (Shell Al- vania EP Grease R0®)
Page 119: Checking The Chassis Fasteners
PERIODIC MAINTENANCE Refer to “STEERING HEAD” on page 4-89. e. Install the rubber washer “3”. f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut “2”, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.
Page 120: Checking The Centerstand
PERIODIC MAINTENANCE Recommended lubricant Lithium-soap-based grease EAS30856 CHECKING THE CENTERSTAND 1. Check: • Centerstand operation Check that the centerstand moves smoothly. Rough movement → Repair or replace. EAS30857 EAS30808 LUBRICATING THE CENTERSTAND CHECKING THE REAR SHOCK ABSORBER Lubricate the pivoting point, metal-to-metal mov- ASSEMBLY ing parts and spring contact point of the center- 1.
Page 121: Changing The Engine Oil
PERIODIC MAINTENANCE Recommended brand YAMALUBE Type SAE 10W-30 or 10W-40 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13361 NOTICE • Engine oil also lubricates the clutch and the 4. Drain: wrong oil types or additives could cause •...
Page 122: Measuring The Engine Oil Pressure
PERIODIC MAINTENANCE 11.Check: • Engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL” on page 3-25. 12.Check: • Engine oil pressure ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
Page 123: Checking The Coolant Level
PERIODIC MAINTENANCE 2. Start the engine, warm it up for several min- Oil pressure utes, and then turn it off. 120.0 kPa/1200 r/min@70 °C ECA13410 (17.4 psi/1200 r/min@158 °F) NOTICE When the engine is cold, the engine oil will Out of specification → Adjust. have a higher viscosity, causing the engine Engine oil pressure Possible causes...
Page 124: Checking The Cooling System
PERIODIC MAINTENANCE • Radiator filler hose “12” • Coolant pipe “13” Cracks/damage → Replace. Refer to “RADIATOR” on page 6-1, “THER- MOSTAT” on page 6-8 and “WATER PUMP” on page 6-11. ECA13470 NOTICE • Adding water instead of coolant lowers the antifreeze content of the coolant.
Page 125 PERIODIC MAINTENANCE 3. Drain: 6. Drain: • Coolant • Coolant (from the coolant reservoir) (from the engine and radiator) 4. Remove: 7. Install: • Radiator cap “1” • Coolant drain bolt EWA13030 (along with the O-ring WARNING A hot radiator is under pressure. Therefore, Coolant drain bolt do not remove the radiator cap when the en- 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
Page 126: Replacing The V-Belt
PERIODIC MAINTENANCE ECA13481 EAS31188 REPLACING THE V-BELT NOTICE 1. Remove: • Adding water instead of coolant lowers the • Center cover antifreeze content of the coolant. If water is Refer to “GENERAL CHASSIS (2)” on page used instead of coolant, check, and if nec- 4-8.
Page 127: Lubricating The Rear Suspension
PERIODIC MAINTENANCE 3. Check: EWA13270 WARNING • Throttle grip free play “a” Out of specification → Adjust. Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- Throttle grip free play place damaged outer cable and inner cables 3.0–5.0 mm (0.12–0.20 in) as soon as possible.
Page 128: Checking And Charging The Battery
PERIODIC MAINTENANCE Direction “a” Make sure that the adjusting nut is covered com- Headlight beam moves to the right. pletely by the rubber cover. Direction “b” Headlight beam moves to the left. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
Page 129: Chassis
CHASSIS GENERAL CHASSIS (1) ................. 4-1 REMOVING THE WINDSHIELD ............... 4-4 INSTALLING THE WINDSHIELD.............. 4-4 ADJUSTING THE WINDSHIELD HEIGHT..........4-5 REMOVING THE FRONT UNDER COVER..........4-5 INSTALLING THE FRONT UNDER COVER ..........4-5 REMOVING THE FRONT COVER............4-6 INSTALLING THE FRONT COVER ............4-6 REMOVING THE WINDSHIELD INNER PANEL ........
Page 130 REAR WHEEL ....................4-31 REMOVING THE REAR WHEEL (DISC BRAKE)........4-35 DISASSEMBLING THE REAR WHEEL ..........4-35 CHECKING THE REAR WHEEL............. 4-35 CHECKING THE REAR WHEEL DRIVE HUB ........4-35 CHECKING AND REPLACING THE REAR WHEEL PULLEY ....4-36 ASSEMBLING THE REAR WHEEL ............4-36 ADJUSTING THE REAR WHEEL STATIC BALANCE......
Page 131 FRONT FORK....................4-78 REMOVING THE FRONT FORK LEGS..........4-82 DISASSEMBLING THE FRONT FORK LEGS ........4-82 CHECKING THE FRONT FORK LEGS ..........4-83 ASSEMBLING THE FRONT FORK LEGS ..........4-84 INSTALLING THE FRONT FORK LEGS ..........4-88 STEERING HEAD..................4-89 REMOVING THE LOWER BRACKET.............4-91 CHECKING THE STEERING HEAD ............4-91 INSTALLING THE STEERING HEAD .............4-92 BELT DRIVE....................
Page 132 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the windshield and front cowling assembly 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 133: General Chassis (1)
GENERAL CHASSIS (1) Removing the windshield and front cowling assembly 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf)
Page 134 GENERAL CHASSIS (1) Disassembling the front cowling assembly Order Job/Parts to remove Q’ty Remarks Front turn signal/position light coupler Disconnect. Headlight coupler Disconnect. Headlight sub-wire harness Auxiliary light coupler (left) Disconnect. Auxiliary light coupler (right) Disconnect. Front turn signal/position light (left) Front turn signal/position light (right) Side cowling Headlight under panel...
Page 135: Removing The Windshield
GENERAL CHASSIS (1) EAS30140 REMOVING THE WINDSHIELD 1. Remove: • Windshield cover ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Assembling the windshield “1” and wind- shield brackets “2” with the windshield screws “3”.
Page 136: Adjusting The Windshield Height
GENERAL CHASSIS (1) e. Tighten the bolts to the specified torque. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31397 Windshield bracket bolt ADJUSTING THE WINDSHIELD HEIGHT 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 1.
Page 137: Removing The Front Cover
GENERAL CHASSIS (1) c. Pull the projections “4” of the front cover to the front side and remove them. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert the claws “1” of the front under cover. b.
Page 138: Removing The Windshield Inner Panel
GENERAL CHASSIS (1) EAS31400 REMOVING THE WINDSHIELD INNER PANEL 1. Remove: • Windshield inner panel ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 139 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) 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...
Page 140: Removing The Side Panel
GENERAL CHASSIS (2) EAS31290 REMOVING THE SIDE PANEL 1. Remove: • Side panel ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31094 REMOVING THE CENTER COVER 1. Remove: ▼ ▼▼▼ ▼...
Page 141: Removing The Side Cover
GENERAL CHASSIS (2) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ a. Insert the claws “1”. EAS31520 b.
Page 142: Installing The Side Cover Moulding
GENERAL CHASSIS (2) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ a. Removing the quick fastener “1”. EAS31523 b.
Page 143: Installing The Footboard
GENERAL CHASSIS (2) d. Slide the footboard upwards, pull it toward you, and then remove it. A. Left side B. Right side ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲...
Page 144 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the leg shield Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Front cowling assembly 4-1. Refer to “GENERAL CHASSIS (2)” on page Footboard 4-8. Inner panel center cover Auxiliary DC jack assembly cover Inner panel cover (left side) Auxiliary DC jack assembly...
Page 145 GENERAL CHASSIS (3) Removing the leg shield Order Job/Parts to remove Q’ty Remarks Meter cover Remote control unit coupler Disconnect. Storage box (front right side) Remote control unit Applicable unit range: SJ13Y-0000635 and Seat lock cable cover after. Seat lock cable Disconnect.
Page 146: Removing The Inner Panel Center Cover
GENERAL CHASSIS (3) EAS31525 REMOVING THE INNER PANEL CENTER COVER 1. Remove: • Inner panel center cover ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...
Page 147 GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the rear cowling assembly (3) (2) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Footboard 4-8. sensor lead Refer to “ENGINE REMOVAL” on page 5-2. Seat Fuel tank cover Grab bar Rear cover Tail/brake light lead cover...
Page 148 GENERAL CHASSIS (4) Removing the rear cowling assembly Order Job/Parts to remove Q’ty Remarks Tail/brake light assembly coupler Disconnect. License plate light lead coupler Disconnect. Rear turn signal light lead coupler Disconnect. Mudguard Rear fender Rear cowling assembly 4-17...
Page 149 GENERAL CHASSIS (4) Disassembling the rear cowling assembly Order Job/Parts to remove Q’ty Remarks Tail/brake light bracket Rear cowling (left) Rear cowling (right) Turn signal light (left) Turn signal light (right) Tail/brake light Tail/brake light cover 4-18...
Page 150: Removing The Rear Cover
GENERAL CHASSIS (4) EAS31412 REMOVING THE REAR COVER 1. Remove: • Rear cowling ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 151 GENERAL CHASSIS (5) EAS20158 GENERAL CHASSIS (5) Removing the storage box Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (4)” on page Rear cowling assembly 4-16. Fuel pump coupler access cover Fuel pump coupler Disconnect. Fuel hose connector cover Fuel hose Disconnect.
Page 152: Removing The Fuel Hose
GENERAL CHASSIS (5) 2. Install: EAS31414 REMOVING THE FUEL HOSE • Fuel hose connector cover 1. Remove: ECA22030 • Fuel hose connector cover “1” NOTICE 2. Disconnect: When installing the fuel hose, make sure that • Fuel hose “2” it is securely connected, and that the fuel EWA15910 hose connector cover is in the correct posi- WARNING...
Page 153: Front Wheel
FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 91 Nm (9.1 m kgf, 66 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) •...
Page 154 FRONT WHEEL Removing the front wheel and brake discs 91 Nm (9.1 m kgf, 66 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 155 FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Speed sensor rotor Oil seal Wheel bearing (right) Collar Wheel bearing (left) Air valve 4-24...
Page 156: Removing The Front Wheel
FRONT WHEEL EAS30145 REMOVING THE FRONT WHEEL To prevent damaging the wheel, place a rag “2” ECA22340 NOTICE between the screwdriver and the wheel surface. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the speed sensor or speed sensor rotor;...
Page 157: Assembling The Front Wheel
FRONT WHEEL • Front wheel 1. Install: Damage/wear → Replace. • Wheel bearings Refer to “CHECKING THE TIRES” on page • Oil seals 3-18 and “CHECKING THE WHEELS” on ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
Page 158: Adjusting The Front Wheel Static Balance
FRONT WHEEL ECA22380 NOTICE • Do not drop the speed sensor rotor or sub- ject it to shocks. • If any solvent gets on the speed sensor ro- tor, wipe it off immediately. • Replace the brake disc bolts and speed sensor rotor bolts with new ones.
Page 159: Installing The Front Wheel (Front Brake Disc)
FRONT WHEEL ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.
Page 160 FRONT WHEEL • Front wheel axle bolt Install the front wheel with the mark “a” on the front tire pointing in the direction of wheel rota- tion. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 161 FRONT WHEEL front wheel while the thickness gauge is in- stalled. This may damage the speed sensor ro- tor and the speed sensor. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 8. Install: • Front brake calipers • Front brake hose/lead holders Front brake caliper bolt 35 Nm (3.5 m·kgf, 25 ft·lbf) Front brake hose/lead holder bolt...
Page 162: Rear Wheel
REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel * When replacing the rear brake caliper or rear brake caliper bracket, replace them as a set. Order Job/Parts to remove Q’ty Remarks Rear brake caliper Rear brake pad Rear brake lock cable adjusting nut Rear brake lock spring Rear brake lock caliper Drive belt upper guard...
Page 163 REAR WHEEL Removing the rear wheel * When replacing the rear brake caliper or rear brake caliper bracket, replace them as a set. Order Job/Parts to remove Q’ty Remarks Washer Adjusting block (right) Rear wheel axle Adjusting block (left) Rear wheel Rear brake caliper bracket Caliper bolt boot Collar (right)
Page 164 REAR WHEEL Removing the rear brake disc and rear wheel pulley Order Job/Parts to remove Q’ty Remarks Rear brake disc Drive belt guide Rear wheel pulley Rear wheel 4-33...
Page 165 REAR WHEEL Disassembling the rear wheel assembly Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing (left) Collar Wheel bearing (right) 4-34...
Page 166: Removing The Rear Wheel (Disc Brake)
REAR WHEEL EAS30156 REMOVING THE REAR WHEEL (DISC BRAKE) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on the centerstand so that the rear wheel is elevated.
Page 167: Checking And Replacing The Rear Wheel Pulley
REAR WHEEL EAS30162 CHECKING AND REPLACING THE REAR WHEEL PULLEY 1. Check: • Rear wheel pulley Surface plating has come off → Replace the rear wheel pulley. Bent teeth → Replace the rear wheel pulley. • Drive belt guide Cracks/damage/wear → Replace the drive belt guide.
Page 168: Adjusting The Rear Wheel Static Balance
REAR WHEEL 2. Check: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Rear brake disc 2. Lubricate: Refer to “CHECKING THE REAR BRAKE • Oil seal lips DISC” on page 4-62. Recommended lubricant 3.
Page 169 REAR WHEEL 4. Install: 7. Tighten: • Dust cover • Wheel axle nut • Collars • Rear brake caliper bolts • Brake caliper bracket • Rear brake lock caliper bolts • Rear wheel Rear wheel axle nut • Adjusting blocks 160 Nm (16 m·kgf, 116 ft·lbf) •...
Page 170: Front Brake
FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf)
Page 171 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Upper handlebar cover Refer to “HANDLEBAR” on page 4-72. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm hold- Brake master cylinder reservoir diaphragm Front brake lever...
Page 172 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Front brake hose Brake hose gasket Front brake master cylinder holder Front brake master cylinder Front brake light switch 4-41...
Page 173 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-42...
Page 174 FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
Page 175 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 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...
Page 176: Introduction
FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 e. Measure the deflection 1.5 mm (0.06 in) be- WARNING low the edge of the brake disc. Disc brake components rarely require disas- sembly.
Page 177: Replacing The Front Brake Pads
FRONT BRAKE d. Measure the brake disc deflection. 3. Measure: e. If out of specification, repeat the adjustment • Brake pad wear limit “a” Out of specification → Replace the brake steps until the brake disc deflection is within specification. pads as a set.
Page 178: Removing The Front Brake Calipers
FRONT BRAKE c. Tighten the bleed screw. 8. Check: • Brake lever operation Front brake caliper bleed screw Soft or spongy feeling → Bleed the brake sys- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) tem. Refer to “BLEEDING THE HYDRAULIC d. Install a brake pads and brake pad spring. BRAKE SYSTEM”...
Page 179: Checking The Front Brake Calipers
FRONT BRAKE Recommended brake component replacement schedule Piston seals Every two years Piston dust seals Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake is disassembled 1. Check: ▼ ▼▼▼ ▼ ▼▼▼ ▼...
Page 180: Installing The Front Brake Calipers
FRONT BRAKE Refer to “REPLACING THE FRONT BRAKE Specified brake fluid PADS” on page 4-46. DOT 4 4. Fill: • Brake master cylinder reservoir EAS30934 (with the specified amount of the specified INSTALLING THE FRONT BRAKE CALIPERS brake fluid) The following procedure applies to both of the brake calipers.
Page 181: Removing The Front Brake Master Cylinder
FRONT BRAKE 7. Check: • Brake master cylinder reservoir diaphragm • Brake lever operation holder “3” Soft or spongy feeling → Bleed the brake sys- Cracks/damage → Replace. tem. • Brake master cylinder reservoir diaphragm Refer to “BLEEDING THE HYDRAULIC “4”...
Page 182 FRONT BRAKE 3. Fill: • Brake master cylinder reservoir • Install the brake master cylinder holder with the (with the specified amount of the specified “ ” mark “a” facing up. brake fluid) • Align the end of the brake master cylinder hold- er with the welding line “b”...
Page 183 FRONT BRAKE Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. 4-52...
Page 184: Rear Brake
REAR BRAKE EAS20031 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 4-53...
Page 185 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Upper handlebar cover Refer to “HANDLEBAR” on page 4-72. Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm hold- Brake master cylinder reservoir diaphragm Rear brake lever...
Page 186 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Rear brake hose Brake hose gasket Rear brake master cylinder holder Rear brake master cylinder Rear brake light switch 4-55...
Page 187 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-56...
Page 188 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” on page 3-15. Brake hose union bolt Brake hose gasket Rear brake hose Rear brake caliper bolt Rear brake caliper Rear brake pad Brake pad support...
Page 189 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 4-58...
Page 190 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 4-59...
Page 191 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 4-60...
Page 192 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 193: Introduction
REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 194: Removing The Rear Brake Caliper
REAR BRAKE • Rear brake caliper bolts Brake pad lining thickness (in- ner) Rear brake caliper bolt 8.0 mm (0.31 in) 27 Nm (2.7 m·kgf, 20 ft·lbf) Limit 0.8 mm (0.03 in) 6. Check: Brake pad lining thickness (out- • Brake fluid level Below the minimum level mark “a”→...
Page 195: Disassembling The Rear Brake Caliper
REAR BRAKE 1. Check: EAS30187 DISASSEMBLING THE REAR BRAKE • Brake caliper piston “1” CALIPER Rust/scratches/wear → Replace the brake 1. Remove: caliper piston. • Brake caliper piston “1” • Brake caliper cylinder “2” • Brake caliper piston dust seal “2” Scratches/wear →...
Page 196: Installing The Rear Brake Caliper
REAR BRAKE • Whenever a brake caliper is disassembled, 4. Fill: replace the brake caliper piston dust seal • Brake master cylinder reservoir and brake caliper piston seal. (with the specified amount of the specified brake fluid) Specified brake fluid Specified brake fluid DOT 4 DOT 4...
Page 197: Removing The Rear Brake Master Cylinder
REAR BRAKE 7. Check: 4. Check: • Brake lever operation • Brake hose Soft or spongy feeling → Bleed the brake sys- Cracks/damage/wear → Replace. tem. EAS30195 Refer to “BLEEDING THE HYDRAULIC ASSEMBLING THE REAR BRAKE MASTER BRAKE SYSTEM” on page 3-15. CYLINDER EWA13520 EAS30193...
Page 198: Replacing The Rear Brake Lock Pads
REAR BRAKE 4. Bleed: EWA13531 WARNING • Brake system Proper brake hose routing is essential to in- Refer to “BLEEDING THE HYDRAULIC sure safe vehicle operation. BRAKE SYSTEM” on page 3-15. 5. Check: ECA14160 NOTICE • Brake fluid level Below the minimum level mark “a”→ Add the When installing the brake hose onto the specified brake fluid to the proper level.
Page 199 REAR BRAKE ECA22110 NOTICE Avoid scratching the dust seal on the side of the piston adjusting bolt carefully. 3. Remove: • Rear brake lock pad (left side) “1” ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 200: Replacing The Rear Brake Lock Cable
REAR BRAKE • Rear brake lock caliper bolts EAS31419 REMOVING THE REAR BRAKE LOCK • Rear brake lock spring CALIPER • Pin 1. Remove: • Rear brake lock cable adjusting nut • Rear brake lock cable adjusting nut “1” • Pin “2” Rear brake lock caliper bolt •...
Page 201: Assembling The Rear Brake Lock Caliper
REAR BRAKE EAS31421 ASSEMBLING THE REAR BRAKE LOCK CALIPER 1. Install: • Slide pin bolt “1” (to the rear brake lock caliper bracket) Rear brake lock caliper slide pin bolt 17 Nm (1.7 m·kgf, 12 ft·lbf) 5. Install: Recommended lubricant •...
Page 202: Installing The Rear Brake Lock Caliper
REAR BRAKE Rear brake lock caliper bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Install: • Boot • Rear brake lock caliper arm 2.
Page 203: Handlebar
HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar YAMAHA GREASE “F” Order Job/Parts to remove Q’ty Remarks Loosen. Rear brake lock cable adjusting nut Refer to “REAR BRAKE” on page 4-53. Refer to “GENERAL CHASSIS (1)” on page Front cowling assembly 4-1.
Page 204 HANDLEBAR Removing the handlebar YAMAHA GREASE “F” Order Job/Parts to remove Q’ty Remarks Throttle cable Disconnect. Throttle grip Front brake master cylinder holder Front brake master cylinder assembly Rear brake light switch connector Disconnect. Rear brake lock holder Rear brake lock lever Rear brake lock cable Disconnect.
Page 205 HANDLEBAR Removing the handlebar YAMAHA GREASE “F” Order Job/Parts to remove Q’ty Remarks Lower handlebar cover Upper handlebar holder Handlebar Lower handlebar holder Holder bracket 4-74...
Page 206: Removing The Handlebar
HANDLEBAR EAS30203 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” Blow compressed air between the left handlebar EAS30205 INSTALLING THE HANDLEBAR and the handlebar grip, and gradually push the...
Page 207 “b” on the handlebar. Lubricate the rear brake lock cable end with • First, tighten the upper bolt, then the lower bolt. YAMAHA GREASE “F”. 8. Install: • Handlebar switch (left) “1” • Rear brake lock lever •...
Page 208 HANDLEBAR 12.Install: • Handlebar switch (right) “1” EWA13720 WARNING Make sure the throttle grip operates smooth- Align the projection “a” on the right handlebar switch with the hole “b” in the handlebar. 13.Connect: • Front brake light switch connector 14.Adjust: •...
Page 209: Front Fork
FRONT FORK EAS20034 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. Refer to “GENERAL CHASSIS (3)” on page Meter assembly/Leg shield 4-13. Front wheel/Front fender Refer to “FRONT WHEEL”...
Page 210 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Front fork leg Lower bracket cover Horn bracket 4-79...
Page 211 FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs.
Page 212 FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil seal Washer Outer tube bushing Inner tube bushing Inner tube 4-81...
Page 213: Removing The Front Fork Legs
FRONT FORK 1. Remove: EAS30206 REMOVING THE FRONT FORK LEGS • Cap bolt “1” The following procedure applies to both of the • Spacer “2” front fork legs. • Damper rod locknut “3” 1. Stand the vehicle on a level surface. ▼...
Page 214: Checking The Front Fork Legs
FRONT FORK 3. Remove: • Damper rod assembly bolt • Damper rod assembly ECA17400 NOTICE For the damper rod assembly, the right side is used for the rebound operation and left side for the compression. Pay attention not to mistake the right and left. 5.
Page 215: Assembling The Front Fork Legs
FRONT FORK EAS30209 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. EWA13660 WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
Page 216 FRONT FORK 6. Install: • Oil seal clip “1” Adjust the oil seal clip so that it fits into the outer tube groove. 3. Install: • Outer tube (to the inner tube) 4. Install: • Outer tube bushing “1” • Washer “2” 7.
Page 217 FRONT FORK ECA17400 NOTICE Damper rod holder 90890-01423 For the damper rod assembly, the right side Damping rod holder is used for the rebound operation and left YM-01423 side for the compression. Pay attention not to mistake the right and left. The left side (for the compression) damper rod assembly has the holes “a”...
Page 218 FRONT FORK 15.Install: ECA14230 NOTICE • Damper rod locknut “1” • Be sure to use the recommended fork oil. • Fork spring “2” Other oils may have an adverse effect on • Spacer “3” front fork performance. • Cap bolt “4” •...
Page 219: Installing The Front Fork Legs
FRONT FORK j. Remove the rod holder and fork spring com- Fork spring compressor pressor. 90890-01441 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ Fork spring compressor YM-01441 EAS30210 INSTALLING THE FRONT FORK LEGS Rod holder The following procedure applies to both of the 90890-01434...
Page 220: Steering Head
STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Front cowling assembly 4-1. Refer to “GENERAL CHASSIS (3)” on page Meter assembly 4-13. Front wheel Refer to “FRONT WHEEL” on page 4-22. Handlebar Refer to “HANDLEBAR”...
Page 221 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Lower ring nut Lower bracket Upper bearing cover Upper bearing Lower bearing Dust seal Steering lock unit 4-90...
Page 222: Removing The Lower Bracket
STEERING HEAD EAS30213 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 223: Installing The Steering Head
STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •...
Page 224: Belt Drive
BELT DRIVE EAS20039 BELT DRIVE Removing the drive belt YAMAHA ® * Filling the GREASE “J” (Shell Alvania EP Grease R0 Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-31. Rear brake lock cable holder (swingarm)
Page 225 BELT DRIVE Removing the drive belt YAMAHA ® * Filling the GREASE “J” (Shell Alvania EP Grease R0 Order Job/Parts to remove Q’ty Remarks Drive pulley Collar Drive belt 4-94...
Page 226: Checking The Drive Belt
BELT DRIVE EAS30236 CHECKING THE DRIVE BELT 1. Clean: • Drive belt ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Wipe the drive belt with a clean cloth. b. Put the drive belt in a mixture of mild deter- gent and water.
Page 227 REAR SHOCK ABSORBER ASSEMBLY EAS20036 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 5-2. Rear shock absorber assembly bolt (front side) Lock washer Collar Rear shock absorber assembly bolt/nut (rear side) Rear shock absorber assembly...
Page 228: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 WARNING rear wheel is elevated. 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 information.
Page 229 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 as- sembly, lift up the swingarm. 3.
Page 230: Swingarm
SWINGARM EAS20037 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Refer to “REAR SHOCK ABSORBER AS- Rear shock absorber assembly SEMBLY” on page 4-96. Drive belt Refer to “BELT DRIVE” on page 4-93. Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-2. Drive belt inner guard Non-disassemble Swingarm (left)
Page 231 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Outer race Bearing Bearing housing O-ring Collar Oil seal Bearing 4-100...
Page 232: Removing The Swingarm
SWINGARM 3. Remove: EAS30226 REMOVING THE SWINGARM • Drive belt 1. Stand the vehicle on a level surface. Refer to “BELT DRIVE” on page 4-93. EWA13120 4. Remove: WARNING • Drive pulley assembly bolt Securely support the vehicle so that there is •...
Page 233 SWINGARM Install the parts to the swingarm “4” temporarily, 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 234 SWINGARM 4-103...
Page 235: Engine
ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-2 INSTALLING THE ENGINE............... 5-9 CAMSHAFTS....................5-10 REMOVING THE CAMSHAFTS..............5-13 CHECKING THE CAMSHAFTS ..............5-14 CHECKING THE CAMSHAFT SPROCKETS .........5-15 CHECKING THE TIMING CHAIN GUIDES..........5-15 CHECKING THE TIMING CHAIN TENSIONER........5-16 INSTALLING THE CAMSHAFTS ............
Page 236 V-BELT AUTOMATIC TRANSMISSION ............5-40 REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE..5-46 DISASSEMBLY THE SECONDARY SHEAVE........5-46 CHECKING THE V-BELT................5-47 CHECKING THE PRIMARY SHEAVE ............5-47 CHECKING THE V-BELT CASE AIR DUCT ...........5-47 CHECKING THE PRIMARY SHEAVE WEIGHTS........5-47 CHECKING THE SLIDERS ..............5-47 CHECKING THE SECONDARY SHEAVE ..........
Page 237 CRANKSHAFT ....................5-76 REMOVING THE CONNECTING RODS ..........5-78 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-78 CHECKING THE CRANKSHAFT AND CONNECTING RODS....5-78 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS.....5-82 INSTALLING THE CONNECTING RODS..........5-82 INSTALLING THE CRANKSHAFT ASSEMBLY........5-84 TRANSMISSION.................... 5-85 CHECKING THE TRANSMISSION ............5-86...
Page 238: Engine Inspection
ENGINE INSPECTION EAS20041 ENGINE INSPECTION Standard compression pressure (at sea level) 1950 kPa/470 r/min (19.5 EAS30249 MEASURE THE COMPRESSION PRESSURE kgf/cm²/470 r/min, 277.3 psi/470 The following procedure applies to all of the cyl- r/min) inders. Minimum–maximum 1697–2184 kPa/470 r/min (17.0– 21.8 kgf/cm²/470 r/min, 241.4–...
Page 239: Engine Removal
ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the exhaust assembly Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Side cover (right) 4-8. sensor coupler Disconnect. Remove the O sensor only when neccessa- sensor Exhaust assembly Gasket Front muffler protector Center muffler protector Upper muffler protector...
Page 240 ENGINE REMOVAL Removing the exhaust assembly Order Job/Parts to remove Q’ty Remarks When installing the muffler end, face the Muffler end dummy bolt to the upper side of the muffler. It is not required to remove the dummy bolt. Muffler end bracket...
Page 241 ENGINE REMOVAL Disconnecting the leads Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (3)” on page Battery 4-13. Refer to “GENERAL CHASSIS (1)” on page Front cowling assembly 4-1. Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20.
Page 242 ENGINE REMOVAL Disconnecting the leads Order Job/Parts to remove Q’ty Remarks Radiator bracket Refer to “RADIATOR” on page 6-1. Water pump inlet pipe Refer to “WATER PUMP” on page 6-11. Oil cooler outlet hose Refer to “OIL COOLER” on page 6-5. Exhaust assembly Refer to “ENGINE REMOVAL”...
Page 243 ENGINE REMOVAL Disconnecting the leads Order Job/Parts to remove Q’ty Remarks Ground lead Disconnect. Starter motor lead Disconnect. Rear brake lock cable holder (crankcase) Wire harness Disconnect.
Page 244 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Refer to “V-BELT AUTOMATIC TRANSMIS- Passenger footrest (right) SION” on page 5-40. Damper Rear frame bolt Engine mounting nut (rear side) Engine mounting bolt (rear side) Spacer Rear frame Engine mounting bolt (front left lower side) Footboard bracket (left) Sidestand...
Page 245 ENGINE REMOVAL Removing the engine Order Job/Parts to remove Q’ty Remarks Engine mounting bolt (front upper side) Engine...
Page 246: Installing The Engine
ENGINE REMOVAL EAS30251 INSTALLING THE ENGINE 1. Install: • All removed parts • Apply locking agent (LOCTITE®) to engine mounting bolts (front right lower side) “2”, en- gine mounting bolts (front left lower side) “3”, and rear frame bolts “5”. •...
Page 247: Camshafts
CAMSHAFTS EAS20043 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 7-6. Spark plug cap Disconnect. Spark plug Cylinder head breather hose Disconnect.
Page 248 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-29. Refer to “V-BELT AUTOMATIC TRANSMIS- Crankshaft end access cover SION” on page 5-40. Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20.
Page 249 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Dowel pin During removal, the dowel pins may still be connected to the camshaft caps. Intake camshaft Exhaust camshaft 5-12...
Page 250: Removing The Camshafts
CAMSHAFTS 2. Remove: EAS30256 REMOVING THE CAMSHAFTS • Timing chain tensioner “1” 1. Align: • Timing chain tensioner gasket • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) ▼ ▼▼▼ ▼ ▼▼▼ ▼...
Page 251: Checking The Camshafts
CAMSHAFTS 3. Measure: EAS30257 CHECKING THE CAMSHAFTS • Camshaft runout Out of specification → Replace. 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches → Re- Camshaft runout limit 0.030 mm (0.0012 in) place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →...
Page 252: Checking The Camshaft Sprockets
CAMSHAFTS c. Install the dowel pins and camshaft caps. • When tightening the camshaft cap, tighten the four bolts on the both ends of the cap tempo- rarily to lower the entire cap, while paying at- tention not to twist the dowel pins and camshaft journal.
Page 253: Checking The Timing Chain Tensioner
CAMSHAFTS EAS30266 EAS30269 CHECKING THE TIMING CHAIN TENSIONER INSTALLING THE CAMSHAFTS 1. Check: 1. Install: • Timing chain tensioner • Exhaust camshaft “1” Cracks/damage → Replace. • Intake camshaft “2” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 254 CAMSHAFTS • The camshafts should be installed onto the cyl- ECA13730 NOTICE inder head so that the alignment marks “c” on The camshaft cap bolts must be tightened the intake camshaft sprocket and the align- evenly or damage to the cylinder head, cam- ment marks “d”...
Page 255 “c” shown. 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 gas- kets. Yamaha bond No. 1215 90890-85505 ▲...
Page 256 CAMSHAFTS Cylinder head cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the cylinder head cover bolts in stages and in a crisscross pattern. 5-19...
Page 257: Cylinder Head
CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head Order Job/Parts to remove Q’ty Remarks Camshafts Refer to “CAMSHAFTS” on page 5-10. Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-2. Thermostat/Coolant temperature sensor Refer to “THERMOSTAT” on page 6-8. Radiator bracket Refer to “RADIATOR”...
Page 258: Removing The Cylinder Head
CYLINDER HEAD EAS30276 REMOVING THE CYLINDER HEAD 1. Remove: • Cylinder head bolts • Cylinder head nuts • Loosen the bolts and nuts in the proper se- quence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
Page 259 CYLINDER HEAD • Lubricate the cylinder head nuts and washers with engine oil. 3. Tighten: • Cylinder head nuts “1”–“6” • Cylinder head bolts “7”, “8” • Cylinder bolt “9” Cylinder head nut 1st: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 2nd: 20 Nm (2.0 m·kgf, 14 ft·lbf) 3rd: 120°...
Page 260 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs * Silicone fluid Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Intake valve Exhaust valve...
Page 261: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
Page 262 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...
Page 263: Checking The Valve Seats
VALVES AND VALVE SPRINGS Valve guide remover (ø4) 90890-04111 Valve guide remover (4.0 mm) YM-04111 Valve guide installer (ø4) 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 90890-04113 Valve guide reamer (4.0 mm) EAS30285 YM-04113 CHECKING THE VALVE SEATS The following procedure applies to all of the ▲...
Page 264 VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. c. Install the valve into the cylinder head. c. Press the valve through the valve guide and d. Turn the valve until the valve face and valve onto the valve seat to make a clear impres- seat are evenly polished, then clean off all of sion.
Page 265: Checking The Valve Springs
VALVES AND VALVE SPRINGS Installed compression spring force (intake) 96.60–111.20 N (9.85–11.34 kgf, 21.72–25.00 lbf) Installed compression spring force (exhaust) 96.60–111.20 N (9.85–11.34 kgf, 21.72–25.00 lbf) Installed length (intake) 30.60 mm (1.20 in) Installed length (exhaust) ▲ ▲▲▲ ▲ ▲▲▲ ▲...
Page 266: Installing The Valves
VALVES AND VALVE SPRINGS • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up. EAS30288 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1.
Page 267 VALVES AND VALVE SPRINGS • Each valve lifter and valve pad must be rein- stalled in its original position. 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve.
Page 268 CYLINDER AND PISTONS EAS20046 CYLINDER AND PISTONS Removing the cylinder and pistons Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Coolant hose Refer to “WATER PUMP” on page 6-11. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin...
Page 269: Cylinder And Pistons
CYLINDER AND PISTONS • Oil ring EAS30289 REMOVING THE PISTON The following procedure applies to all of the pis- When removing a piston ring, open the end gap ton. with your fingers and lift the other side of the ring 1.
Page 270: Checking The Piston Rings
CYLINDER AND PISTONS Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring Top ring Ring side clearance 0.030–0.065 mm (0.0012– 0.0026 in) b. If out of specification, replace the cylinder, Limit piston and piston rings as a set.
Page 271: Checking The Piston Pins
CYLINDER AND PISTONS Piston ring Top ring End gap (installed) 0.25–0.35 mm (0.0098–0.0138 Limit 0.60 mm (0.0236 in) 2nd ring End gap (installed) 0.35–0.50 mm (0.0138–0.0197 3. Measure: Limit • Piston pin bore inside diameter “b” 0.75 mm (0.0295 in) Out of specification →...
Page 272 CYLINDER AND PISTONS • Cylinder gasket Be sure to install the top and 2nd rings so that 4. Lubricate: the manufacturer marks or numbers “a” face up. • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5.
Page 273: Electric Starter
ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20. Fuel tank Refer to “FUEL TANK” on page 7-1. Ground lead Disconnect. Starter motor lead Disconnect.
Page 274 ELECTRIC STARTER Disassembling the starter motor * When replacing any of the starter motor front cover, armature assembly, starter motor yoke, insulator, and starter motor rear cover, replace the starter motor assembly. Order Job/Parts to remove Q’ty Remarks Starter motor front cover Armature assembly Starter motor yoke O-ring...
Page 275: Checking The Starter Motor
ELECTRIC STARTER EAS30325 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. 1.
Page 276: Assembling The Starter Motor
ELECTRIC STARTER 6. Check: • Gear teeth Damage/wear → Replace the starter motor assembly. 7. Check: • Bearing Damage/pitting → Replace the starter motor assembly. EAS30326 ASSEMBLING THE STARTER MOTOR 1. Install: EAS30327 INSTALLING THE STARTER MOTOR • Insulator “1” 1.
Page 277 V-BELT AUTOMATIC TRANSMISSION EAS20050 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover * Water Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Footboard (right) 4-8. Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20. V-belt case air filter element (left) Refer to “WATER PUMP”...
Page 278 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover * Water Order Job/Parts to remove Q’ty Remarks V-belt case air filter element (right) Rear brake lock cable holder (crankcase) Rear brake lock cable holder bracket Outer V-belt case Outer V-belt case gasket Bearing retainer Bearing Circlip...
Page 279 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave YAMAHA ® *1 Apply GREASE “G” (Shell Sunlight Grease 3 YAMAHA ® *2 Apply GREASE “H” (Polyurea Grease Order Job/Parts to remove Q’ty Remarks Primary sheave nut Spacer O-ring Primary sheave assembly...
Page 280: V-Belt Automatic Transmission
V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave YAMAHA ® *1 Apply GREASE “G” (Shell Sunlight Grease 3 YAMAHA ® *2 Apply GREASE “H” (Polyurea Grease Order Job/Parts to remove Q’ty Remarks Inner V-belt case Dowel pin Plate Inner V-belt case seal...
Page 281 V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave YAMAHA ® *1 Apply GREASE “H” (Polyurea Grease *2 When replacing the primary sliding sheave or collar, replace them as a set. Order Job/Parts to remove Q’ty Remarks Slider Primary sheave weight Primary sliding sheave...
Page 282 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave YAMAHA ® * Apply GREASE “H” (Polyurea Grease Order Job/Parts to remove Q’ty Remarks Secondary sheave spring seat nut Upper spring seat Secondary sheave compression spring Spring seat Guide pin Secondary sliding sheave...
Page 283: Removing The Primary Sheave And Secondary Sheave
V-BELT AUTOMATIC TRANSMISSION EAS31435 EAS30312 REMOVING THE PRIMARY SHEAVE AND DISASSEMBLY THE SECONDARY SHEAVE SECONDARY SHEAVE 1. Loosen: 1. Remove: • Secondary sheave spring seat nut “1” • Primary sheave nut “1” • Secondary sheave nut “2” • While holding the secondary fixed sheave “2” with the sheave holder “3”, loosen the second- While holding the primary and secondary ary sheave spring seat nut with the locknut...
Page 284: Checking The V-Belt
V-BELT AUTOMATIC TRANSMISSION EAS31436 CHECKING THE V-BELT CASE AIR DUCT 1. Check • V-belt case air duct Cracks/damage → Replace. EAS30317 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: EAS30315 •...
Page 285: Assembling The Primary Sheave
• Secondary sliding sheave inner surface “2” • Oil seals 3. Lubricate: (with the recommended lubricant) • Guide pin groove “1” • O-rings “2” Recommended lubricant (with the recommended lubricant) YAMAHA GREASE “H” (Poly- urea Grease®) Recommended lubricant YAMAHA GREASE “H” (Poly- urea Grease®) 5-48...
Page 286: Installing The Primary Sheave Assembly, Secondary Sheave Assembly And V-Belt
INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1. Apply: • Sealant (onto the inner V-belt case seal) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 2. Install: • V-belt case air duct joint clamp “1” 5. Tighten: •...
Page 287 V-belt the primary sheave side. Recommended lubricant • Align the “a” and “b” during reassembly. YAMAHA GREASE “G” (Shell Sunlight Grease 3®) While holding the primary sheave with the sheave holder “2”, tighten the primary sheave nut.
Page 288: Installing The V-Belt Case
V-BELT AUTOMATIC TRANSMISSION EAS31235 INSTALLING THE V-BELT CASE 1. Install: • Oil seal “1” (into outer V-belt case) Installed depth of oil seal “a” 4.0–4.3 mm (0.16–0.17 in) 2. Fill the space “b” shown in the illustration with 10 g (0.35 oz) or more of lithium-soap-based grease.
Page 289: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS20140 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 3-29.
Page 290 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Rear brake hose holder Passenger footrest (left) Crankshaft position sensor coupler Disconnect. Stator coil coupler Disconnect. Generator cover Generator cover gasket Dowel pin Starter clutch idle gear shaft Starter clutch idle gear Generator rotor nut...
Page 291 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Woodruff key Starter clutch gear Washer 5-54...
Page 292 GENERATOR AND STARTER CLUTCH Removing the stator coil and oil tank * When replacing the crankshaft position sensor or stator coil, replace them as a set. Order Job/Parts to remove Q’ty Remarks Oil tank Oil tank gasket Dowel pin Oil strainer Crankshaft position sensor Stator coil Bearing cover...
Page 293: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR Flywheel puller 1. Remove: 90890-01362 • Generator cover Heavy duty puller YU-33270-B Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 294: Checking The Oil Strainer
GENERATOR AND STARTER CLUTCH EAS31439 CHECKING THE OIL STRAINER 1. Check: • Oil strainer Damage → Replace. Contaminants → Clean with solvent. EAS31440 ASSEMBLING THE OIL TANK 1. Install: • Bearing 2. Check: • Starter clutch idle gear “1” Seal “a” is adhered only on one side of the bear- •...
Page 295: Installing The Generator
• Lubricate the generator rotor nut seats and threads with engine oil. 3. Apply: • Sealant (onto the crankshaft position sensor/stator lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 2. Tighten: • Generator rotor nut “1” Generator rotor nut (1st) 65 Nm (6.5 m·kgf, 47 ft·lbf)
Page 296 GENERATOR AND STARTER CLUTCH Tighten the generator cover bolts in stages and in a crisscross pattern. 5-59...
Page 297: Clutch
CLUTCH EAS20055 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Generator cover CLUTCH” on page 5-52. Clutch assembly nut Clutch assembly Washer 5-60...
Page 298 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 299 CLUTCH Disassembling the clutch Order Job/Parts to remove Q’ty Remarks Thrust plate Clutch weight Clutch housing 5-62...
Page 300: Removing The Clutch
CLUTCH EAS30346 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 ro- tor holding tool “3”, loosen the clutch assembly nut.
Page 301: Checking The Friction Plates
CLUTCH EAS30348 CHECKING THE FRICTION PLATES Clutch plate 1 thickness The following procedure applies to all of the fric- 1.30–1.50 mm (0.051–0.059 in) tion plates. Warpage limit 1. Check: 0.10 mm (0.004 in) Clutch plate 2 thickness • Friction plate Damage/wear →...
Page 302: Checking The Clutch Springs
CLUTCH 2. Measure: • Clutch spring plate free height “a” Pitting on the clutch housing dogs will cause er- Out of specification → Replace the clutch ratic clutch operation. spring plate. Clutch spring plate height 4.70 mm (0.19 in) Minimum height 4.40 mm (0.17 in) EAS30353 CHECKING THE CLUTCH BOSS...
Page 303: Assembling The Clutch
CLUTCH EAS31444 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 univer- sal clutch holder “3”, tighten the clutch boss nut.
Page 304: Installing The Clutch
CLUTCH EAS30363 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 ro- tor holding tool “3”, tighten the clutch assembly nut.
Page 305: Oil Pump
OIL PUMP EAS20054 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 5-52. Oil pump assembly Oil pump drive chain Gasket Oil delivery pipe Oil pipe Relief valve assembly 5-68...
Page 306 OIL PUMP Disassembling the oil pump assembly * When replacing any of the part, replace 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...
Page 307: Checking The Oil Pump
OIL PUMP EAS30337 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. EAS30342 ASSEMBLING THE OIL PUMP 1. Lubricate: •...
Page 308: Crankcase
CRANKCASE EAS20059 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-2. Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Refer to “CYLINDER AND PISTONS” on Cylinder/Pistons page 5-31. Oil cooler Refer to “OIL COOLER”...
Page 309 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Bearing housing Refer to “SWINGARM” on page 4-99. Centerstand assembly Timing chain Timing chain guide (intake side) Crankcase (left) Dowel pin Oil strainer Crankcase (right) 5-72...
Page 310 CRANKCASE Removing the oil seals and bearings Order Job/Parts to remove Q’ty Remarks Crankshaft assembly Refer to “CRANKSHAFT” on page 5-76. Transmission Refer to “TRANSMISSION” on page 5-85. Bearing retainer Oil seal Bearing 5-73...
Page 311: Disassembling The Crankcase
• Sealant tions of the crankcase, not on the crankcase (onto the crankcase mating surfaces) mating surfaces. Work slowly and carefully and make sure the crankcase halves sepa- Yamaha bond No. 1215 rate evenly. 90890-85505 (Three bond No.1215®) EAS30390 CHECKING THE CRANKCASE 1.
Page 312 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 stag- es and in a crisscross pattern.
Page 313: Crankshaft
CRANKSHAFT EAS20061 CRANKSHAFT Removing the crankshaft assembly Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-71. Dowel pin Balancer cylinder Crankshaft assembly Oil seal Crankshaft journal bearing 5-76...
Page 314 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 315: Removing The Connecting Rods
CRANKSHAFT EAS30415 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting 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 316 CRANKSHAFT 3. Measure: • Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Connecting rod Oil clearance 0.036–0.060 mm (0.0014–0.0024 Balancer connecting rod Oil clearance d. Assemble the connecting rod halves. 0.036–0.060 mm (0.0014–0.0024 • Do not move the connecting rod or crankshaft The following procedure applies to all of the until the clearance measurement has been connecting rods and balancer connecting...
Page 317 CRANKSHAFT For example, if the connecting rod P and the crankshaft web P numbers are 5 and 1 re- spectively, then the bearing size for P (connecting rod) - P (crankshaft) = 5 - 1 = 4 (green) Bearing color code 0.
Page 318 CRANKSHAFT Crankshaft journal diameter 54.984-55.000 mm (2.1647- 2.1654 in) d. Measure the crankshaft journal bearing in- side diameter “b” of each crankshaft journal bearing at two places. e. If crankshaft journal bearing inside diameter is “55.03” and crankshaft journal diameter is “54.98”, then the journal oil clearance is: For example, if the crankcase J and the...
Page 319: Installing The Crankshaft Journal Bearings
CRANKSHAFT Bearing color code 0. White 1.Blue 2.Black 3.Brown 4.Green 5.Yellow Bearing thickness White: 2.499–2.512 mm (0.0984– 0.0989 in) Blue: 2.495–2.508 mm (0.0982– 0.0987 in) Black: 2.491–2.504 mm (0.0981– 0.0986 in) Brown: 2.487–2.500 mm (0.0979–0.0984 in) Green: 2.483–2.496 mm (0.0978– 0.0983 in) Yellow: 2.479–2.492 mm (0.0976–0.0981 in)
Page 320 CRANKSHAFT • Make sure the “Y” marks “c” on the connecting rods face towards the left side of the crank- shaft. • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. c. Tighten the connecting rod nuts further to reach the specified angle 90°.
Page 321: Installing The Crankshaft Assembly
CRANKSHAFT between 30 Nm (3.0 m·kgf, 22 ft·lbf) and 60 Nm (6.0 m·kgf, 43 ft·lbf), loosen the nut to less than • Align the projections “a” on the balancer big 30 Nm (3.0 m·kgf, 22 ft·lbf) and start again. end bearings with the notches “b” in the bal- ancer connecting rod and balancer connecting EAS30428 rod cap.
Page 322: Transmission
TRANSMISSION EAS20062 TRANSMISSION Removing the transmission Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-71. 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 323: Checking The Transmission
TRANSMISSION EAS30433 CHECKING THE TRANSMISSION 1. Check: • Transmission gears Blue discoloration/pitting/wear → Replace. 2. Check: • Transmission gear movement Rough movement → Replace the defective part(s). 3. Check: • Main axle Cracks/damage/wear → Replace the main axle. 4. Measure: •...
Page 324 TRANSMISSION 5-87...
Page 325: Cooling System
COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-5 CHECKING THE OIL COOLER ..............6-7 INSTALLING THE OIL COOLER .............. 6-7 THERMOSTAT ....................6-8 CHECKING THE THERMOSTAT............6-10 INSTALLING THE THERMOSTAT ASSEMBLY ........6-10 WATER PUMP....................6-11 DISASSEMBLING THE WATER PUMP..........6-14 CHECKING THE WATER PUMP ............
Page 326 RADIATOR EAS20063 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Footboards 4-8. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-29. Coolant reservoir hose Coolant reservoir Coolant reservoir cap Coolant reservoir breather hose Radiator cap Remove/Install it with the radiator filler pipe held.
Page 327 RADIATOR Removing the radiator Order Job/Parts to remove Q’ty Remarks Cooling system air bleed hose Disconnect. Radiator filler pipe Radiator filler hose Fast idle plunger outlet coolant hose Disconnect. Radiator outlet hose Disconnect. Radiator fan motor coupler Disconnect. Radiator Radiator fan Radiator inlet hose Radiator bracket...
Page 328 RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flathead screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
Page 329 RADIATOR b. Apply 137.3 kPa (1.37 kgf/cm , 19.9 psi) of pressure. c. Measure the indicated pressure with the gauge. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...
Page 330 OIL COOLER EAS20064 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-26.
Page 331 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Radiator inlet hose Disconnect. Coolant pipe Thermostat outlet hose Oil filter cartridge union bolt Oil cooler...
Page 332 OIL COOLER 4. Fill: EAS30441 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 3-29. • Oil cooler inlet hose •...
Page 333 THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-29. Coolant temperature sensor coupler Disconnect.
Page 334 THERMOSTAT Removing the thermostat Order Job/Parts to remove Q’ty Remarks Thermostat Fast idle plunger inlet coolant hose Disconnect. Coolant hose Disconnect.
Page 335 THERMOSTAT 2. Check: EAS30443 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 71–85 °C (159.8–185.0 °F) EAS30445 INSTALLING THE THERMOSTAT → Replace. ASSEMBLY 1. Install: • Thermostat Install the thermostat with its breather hole “a” facing forward.
Page 336 WATER PUMP EAS20066 WATER PUMP Removing the water pump * Water or silicone fluid Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (2)” on page Footboard (left) 4-8. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-29. V-belt case air filter element joint clamp Loosen.
Page 337 WATER PUMP Removing the water pump * Water or silicone fluid Order Job/Parts to remove Q’ty Remarks Radiator outlet hose Disconnect. Water pump inlet pipe Water pump outlet pipe Water pump assembly 6-12...
Page 338 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump housing cover Circlip Impeller shaft Mechanical seal Bearing Oil seal Water pump housing 6-13...
Page 339 WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (impeller side) “1” • Water pump housing cover “1” (from the impeller, with a thin, flathead screw- • Water pump housing “2” driver) •...
Page 340 WATER PUMP 4. Measure: ECA20330 NOTICE • Impeller shaft tilt Out of specification → Repeat step (3) and Never lubricate the mechanical seal (hous- ing side) surface with oil or grease. (4). ECA20340 NOTICE Use the special tool and a press to press the me- Make sure the mechanical seal (impeller chanical seal (housing side) straight in until it side) is flush with the impeller.
Page 341 WATER PUMP 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-29. 3. Check: • Cooling system Leaks → Repair or replace any faulty part. Refer to “INSTALLING THE RADIATOR” on page 6-3.
Page 342 WATER PUMP 6-17...
Page 343: Fuel System
FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL HOSE ..............7-3 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE FUEL PUMP OPERATION..........7-3 CHECKING THE ROLLOVER VALVE ............7-3 INSTALLING THE FUEL PUMP..............7-4 INSTALLING THE FUEL TANK..............7-4 INSTALLING THE FUEL HOSE ..............7-4 CHECKING THE FUEL PRESSURE ............7-4 THROTTLE BODY...................
Page 344 FUEL TANK EAS20067 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20. Fuel pump coupler Disconnect. Fuel hose connector cover Fuel hose Disconnect. Fuel tank overflow hose Fuel tank breather hose Rollover valve Fuel tank...
Page 345 FUEL TANK Removing the canister Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20. Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel tank breather hose Canister purge hose (3-way joint to canister) Canister purge hose (throttle body to 3-way joint) Canister...
Page 346 FUEL TANK EAS31447 EAS30450 REMOVING THE FUEL HOSE REMOVING THE FUEL TANK 1. Remove: 1. Extract the fuel in the fuel tank through the • Fuel hose connector cover “1” fuel tank cap with a pump. 2. Disconnect: 2. Remove: •...
Page 347 FUEL TANK 3. Install: • Fuel tank overflow hose • Fuel tank breather hoses • Rollover valve EAS31448 INSTALLING THE FUEL HOSE 1. Connect: • Fuel hose 2. Install: • Fuel hose connector cover ECA22030 EAS30456 INSTALLING THE FUEL PUMP NOTICE 1.
Page 348 FUEL TANK • Although the fuel has been removed from f. Remove the pressure gauge and fuel pres- the fuel tank, be careful when removing the sure adapter. fuel hose, since there may be fuel remain- ing in it. Before removing the special tools, place a few •...
Page 349 THROTTLE BODY EAS20070 THROTTLE BODY Removing the throttle body Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (5)” on page Storage box 4-20. Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-29.
Page 350 THROTTLE BODY Removing the throttle body Order Job/Parts to remove Q’ty Remarks Fast idle plunger inlet coolant hose Disconnect. 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...
Page 351 THROTTLE BODY Disassembling the throttle body assembly Order Job/Parts to remove Q’ty Remarks Before disassembling the throttle body as- sembly, 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 352 THROTTLE BODY 2. Check: EAS30840 REMOVING THE FUEL HOSE (INJECTOR • Fuel passages SIDE) Obstructions → Clean. 1. Disconnect: ECA21770 • Fuel hose (injector side) NOTICE EWA15910 Do not adjust the stop screw “1”. WARNING Cover fuel hose connections with a cloth when disconnecting them.
Page 353 THROTTLE BODY 1. Install a new O-ring onto the end of each in- jector. 2. Install the injectors “1” to the fuel rail “2”, mak- ing sure to install them in the correct direc- tion. 3. Install a new seal onto the end of each injec- tor.
Page 354 THROTTLE BODY f. Diagnostic code number “d:01” is selected. g. Adjust the position of the throttle position sen- sor angle so that 14–20 can appear in the meter. h. After adjusting the throttle position sensor an- gle, tighten the throttle position sensor screws “2”.
Page 355: Electrical System
TROUBLESHOOTING ................8-21 COOLING SYSTEM..................8-27 CIRCUIT DIAGRAM ................8-27 TROUBLESHOOTING ................8-29 FUEL INJECTION SYSTEM................8-31 CIRCUIT DIAGRAM ................8-31 ECU SELF-DIAGNOSTIC FUNCTION............8-33 TROUBLESHOOTING METHOD............8-33 YAMAHA DIAGNOSTIC TOOL ...............8-34 TROUBLESHOOTING DETAILS ............8-37 FUEL PUMP SYSTEM...................8-63 CIRCUIT DIAGRAM ................8-63 TROUBLESHOOTING ................8-65...
Page 356 SMART KEY SYSTEM .................. 8-67 CIRCUIT DIAGRAM ................8-67 TROUBLESHOOTING ................8-69 SMART KEY SYSTEM SELF-DIAGNOSIS..........8-72 SMART KEY SYSTEM EMERGENCY MODE ........8-75 REGISTERING A SMART KEY...............8-77 DISABLING A SMART KEY ..............8-79 REPLACING THE SMART KEY UNIT, STEERING LOCK, AND ECU ... 8-79 REPLACING THE SMART KEY UNIT ............8-80 REPLACING THE STEERING LOCK UNIT ..........8-80 REPLACING THE ECU ................8-80...
Page 358 IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
Page 359 IGNITION SYSTEM 1. Smart key unit 9. Crankshaft position sensor 12.Smart key system relay 14.Ignition fuse 18.Backup fuse 19.Joint coupler 20.Battery 21.Engine ground 22.Main fuse 30.Sidestand switch 31.Handlebar switch (right) 32.Engine stop switch 36.ECU (engine control unit) 37.Ignition coil 38.Spark plug 44.Lean angle sensor A.
Page 360 IGNITION SYSTEM EAS30492 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 NG → 1. Check the fuses. (Main, ignition and backup) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
Page 361 IGNITION SYSTEM NG → 9. Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-87. OK ↓ NG → 10.Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch.
Page 362 ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
Page 363 ELECTRIC STARTING SYSTEM 1. Smart key unit 12.Smart key system relay 13.Signaling system fuse 14.Ignition fuse 19.Joint coupler 20.Battery 21.Engine ground 22.Main fuse 23.Starter relay 24.Starter motor 25.Diode 1 26.Starting circuit cut-off relay 27.Sidestand relay 28.Diode 2 30.Sidestand switch 31.Handlebar switch (right) 32.Engine stop switch 33.ON/start switch 35.Front brake light switch...
Page 364 ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and pressing the ON/start switch “ ” for one second, the start- er motor can only operate if at least one of the following conditions is met: •...
Page 365 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Smart key system relay 4. Smart key unit 5. Signaling system fuse 6. Ignition fuse 7. Front brake light switch 8. Rear brake light switch 9. Engine stop switch 10. Diode 2 11.
Page 366 ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s).
Page 367 ELECTRIC STARTING SYSTEM NG → 8. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay. LAYS” on page 8-94. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch.
Page 368 CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-11...
Page 369 CHARGING SYSTEM 10.AC magneto 11.Rectifier/regulator 20.Battery 21.Engine ground 22.Main fuse A. Wire harness B. Negative battery sub-wire harness 8-12...
Page 370 CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 371 CHARGING SYSTEM 8-14...
Page 372 LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-15...
Page 373 14.Ignition fuse 15.Parking lighting fuse 18.Backup fuse 19.Joint coupler 20.Battery 21.Engine ground 22.Main fuse 36.ECU (engine control unit) 41.Yamaha diagnostic tool coupler 53.License plate light 54.Tail/brake light assembly 56.Handlebar switch (left) 57.Pass switch 58.Dimmer switch 63.Headlight relay 66.Auxiliary light 71.Headlight control unit 72.Headlight (low)
Page 374 LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, auxiliary light, front position light, high beam indicator light, tail/brake light, license plate light, meter light or storage box light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2.
Page 375 LIGHTING SYSTEM NG → 8. Check the storage box light switch. Refer to “CHECKING THE Replace the storage box light switch. SWITCHES” on page 8-87. OK ↓ NG → 9. Check the entire lighting system’s wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM”...
Page 376 SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-19...
Page 377 30.Sidestand switch 31.Handlebar switch (right) 34.Hazard switch 35.Front brake light switch 36.ECU (engine control unit) 39.Coolant temperature sensor 40.Intake air temperature sensor 41.Yamaha diagnostic tool coupler 45.Speed sensor 50.Fuel sender 54.Tail/brake light assembly 55.Tail/brake light 56.Handlebar switch (left) 59.Horn switch 60.Turn signal switch...
Page 378 SIGNALING SYSTEM EAS30501 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 379 SIGNALING SYSTEM NG → 2. Check the entire signaling system’s wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the horn or smart key unit. The tail/brake light fails to come on. NG →...
Page 380 SIGNALING SYSTEM NG → 5. Check the entire signaling system’s wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the meter assembly or smart key unit. The fuel meter fails to operate. NG →...
Page 381 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the ECU or meter assembly. The tachometer fails to operate. NG → 1.
Page 382 SIGNALING SYSTEM The oil change indicator fails to come on. NG → 1. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-19. OK ↓ Replace the meter assembly. The buzzer does not sound.
Page 383 SIGNALING SYSTEM 8-26...
Page 384 COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27...
Page 385 18.Backup fuse 19.Joint coupler 20.Battery 21.Engine ground 22.Main fuse 36.ECU (engine control unit) 39.Coolant temperature sensor 41.Yamaha diagnostic tool coupler 51.Radiator fan motor relay 52.Radiator fan motor 80.Meter assembly 88.Multi-function meter A. Wire harness B. Negative battery sub-wire harness 8-28...
Page 386 COOLING SYSTEM EAS30503 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition, radiator fan motor and backup) Replace the fuse(s).
Page 387 COOLING SYSTEM 8-30...
Page 388 FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31...
Page 389 32.Engine stop switch 36.ECU (engine control unit) 37.Ignition coil 38.Spark plug 39.Coolant temperature sensor 40.Intake air temperature sensor 41.Yamaha diagnostic tool coupler 42.Intake air pressure sensor 43.Throttle position sensor 44.Lean angle sensor 45.Speed sensor 46.Fuel injector #1 47.Fuel injector #2 48.O...
Page 390 FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 391 EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool (US) 90890-03234 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.
Page 392 Disconnect the Yamaha diagnostic tool coupler “1”, and then connect the Yamaha diagnostic tool “2” 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 393 FUEL INJECTION SYSTEM 1. Recovered The item list of the malfunction detected in the past (already recovered) are displayed. 2. Detected The item list of the malfunction currently occurred are displayed. 3. Code The following icons and the fault code numbers for the detected malfunctions are displayed. A.
Page 394 FUEL INJECTION SYSTEM 6. Condition The current conditions are displayed. (Detected/Recovered) 7. Symptom The symptoms of the detected malfunction are displayed. 8. Diagnosis code The diagnosis codes related to the detected malfunction are displayed. 9. FFD (only for models that can display freeze frame data) The mark “...
Page 395 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from the Item crankshaft position sensor. Poor connection → Connect it Connection of ECU coupler. Crank the engine, and check the Check the locking condition of securely, or replace the wire fault code indication.
Page 396 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Poor connection → Connect it Connection of intake air pres- Push the ON/start switch sure sensor coupler. securely, or replace the wire “ ”, and check the fault Check the locking condition of harness.
Page 397 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Intake air pressure sensor mal- Check in the diagnostic mode Push the ON/start switch function. (Code No. 03). “ ”, and check the fault When engine is stopped: Atmo- code indication.
Page 398 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged or de- Item tached hose). The intake air pressure sensor Repair or replace the sensor Start and idle the engine for ap- hose is damaged, disconnect- hose.
Page 399 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Probable cause of malfunc- Confirmation of service com- Item Maintenance job tion and check pletion Poor connection → Connect it Connection of throttle position Push the ON/start switch sensor coupler.
Page 400 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Supply voltage of throttle posi- Check the supply voltage. Push the ON/start switch tion sensor lead. Blue–Black/Blue “ ”, and check the fault Black/Blue–Yellow code indication. No fault code indicated.
Page 401 FUEL INJECTION SYSTEM Fault code No. Throttle position sensor: stuck throttle position sensor is detected. Item (Signal from throttle position sensor will not change.) Sensor installation status. Check for loose mounting, Push the ON/start switch pinched mounting, or hard “ ”, and then open and mounting.
Page 402 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the light green lead of Item the ECU is detected. Poor connection → Connect it Connection of smart key unit Push the ON/start switch coupler. securely, or replace the wire “...
Page 403 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Poor connection → Connect it Connection of coolant tempera- Push the ON/start switch ture sensor coupler. securely, or replace the wire “ ”, and check the fault Check the locking condition of harness.
Page 404 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. • Displays the intake air temperature. Indicated • Displays temperature closer to air temperature (when engine is cold). •...
Page 405 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Intake air temperature sensor Check in the diagnostic mode Push the ON/start switch malfunction. (Code No. 05). “ ”, and check the fault Confirmation of service comple- code indication.
Page 406 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Open or short circuit → Connect Continuity of wire harness. Either start and warm up the en- it securely, or replace the wire gine, and then racing it, or reset harness.
Page 407 Actuates the ignition coil five times at one-second intervals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Check that a spark is generated five times. Procedure •...
Page 408 FUEL INJECTION SYSTEM Fault code No. Item Ignition coil: open or short circuit detected. Poor connection → Connect it Connection of ignition coil con- Start and idle the engine for ap- nectors. securely or replace the wire har- proximately 5 seconds. Check the locking condition of ness.
Page 409 FUEL INJECTION SYSTEM Fault code No. Item Fast idle plunger: engine speed is high when the engine is idling. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Actuation — Procedure — Probable cause of malfunc- Confirmation of service com- Item Maintenance job...
Page 410 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Poor connection → Connect it Connection of lean angle sensor Push the ON/start switch coupler. securely, or replace the wire “ ”, then push the Check the locking condition of harness.
Page 411 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sen- Item sor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Vehicle speed pulse Indicated 0–999 Check that the number increases when the front wheel is rotated. The Procedure number is cumulative and does not reset each time the wheel is stopped.
Page 412 Actuates the fuel injection system relay five times at one-second inter- vals. Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen come on each time the fuel injector is actuated. Check that the fuel injection system relay is actuated five times by listen- Procedure ing for the operating sound.
Page 413 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injection Item system relay, fuel injector and fuel pump. Fuel injection system relay mal- Check in the diagnostic mode Start and idle the engine for ap- function.
Page 414 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Charging system malfunction. Check the charging system. Start and idle the engine for ap- Refer to “CHARGING SYSTEM” proximately 5 seconds. on page 8-11. Then, check the fault code indi- Check the rectifier/regulator, AC cation.
Page 415 Fault code indicated. → Go to Yellow/Blue–Yellow/Blue Between joint coupler and item 4. Yamaha diagnostic tool coupler. Yellow/Blue–Yellow/Blue Between Yamaha diagnostic tool coupler and ECU coupler. Yellow/Blue–Yellow/Blue Abnormal meter unit operation. Replace the meter assembly.
Page 416 Fault code indicated. → Go to Yellow/Blue–Yellow/Blue Between joint coupler and item 4. Yamaha diagnostic tool coupler. Yellow/Blue–Yellow/Blue Between Yamaha diagnostic tool coupler and ECU coupler. Yellow/Blue–Yellow/Blue Abnormal meter unit operation. Replace the meter assembly.
Page 417 Fault code indicated. → Go to Yellow/Blue–Yellow/Blue Between joint coupler and item 4. Yamaha diagnostic tool coupler. Yellow/Blue–Yellow/Blue Between Yamaha diagnostic tool coupler and ECU coupler. Yellow/Blue–Yellow/Blue Abnormal meter unit operation. Replace the meter assembly.
Page 418 Fault code indicated. → Go to Yellow/Blue–Yellow/Blue Between joint coupler and item 4. Yamaha diagnostic coupler. Yellow/Blue–Yellow/Blue Between Yamaha diagnostic coupler and ECU coupler. Yellow/Blue–Yellow/Blue Abnormal meter unit operation. Replace the meter assembly.
Page 419 FUEL INJECTION SYSTEM 8-62...
Page 420 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-63...
Page 421 FUEL PUMP SYSTEM 1. Smart key unit 12.Smart key system relay 14.Ignition fuse 17.Fuel injection system fuse 18.Backup fuse 19.Joint coupler 20.Battery 21.Engine ground 22.Main fuse 29.Fuel injection system relay 31.Handlebar switch (right) 32.Engine stop switch 36.ECU (engine control unit) 49.Fuel pump A.
Page 422 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box NG → 1. Check the fuses. (Main, ignition, backup and fuel in- jection system) Replace the fuse(s).
Page 423 FUEL PUMP SYSTEM 8-66...
Page 424 SMART KEY SYSTEM EAS20201 SMART KEY SYSTEM EAS31452 CIRCUIT DIAGRAM 8-67...
Page 425 22.Main fuse 30.Sidestand switch 31.Handlebar switch 33.ON/start switch 34.Hazard switch 36.ECU (engine control unit) 41.Yamaha diagnostic tool coupler 56.Handlebar switch (left) 60.Turn signal switch 64.Turn signal/hazard relay 2 67.Front turn signal/position light (left) 68.Front turn signal/position light (right) 69.Rear turn signal light (left) 70.Rear turn signal light (right)
Page 426 SMART KEY SYSTEM EAS31453 TROUBLESHOOTING Vehicle power does not turn on. (Meter light and tail/brake light do not come on.) Engine does not start even though vehicle power is turned on. Seat does not open. (Vehicle power is turned on.) Before troubleshooting, remove the following part(s): 1.
Page 427 SMART KEY SYSTEM Checking the smart key system Before checking the smart key system, make sure that the smart key is located within the operating range of the smart key system and that the key is turned on. Vehicle power does not turn on. (Meter light and tail/brake light do not come on.) •...
Page 428 SMART KEY SYSTEM YES → 5. The smart key system indicator light “ ” flashes. (The indicator light repeatedly Steering lock unit data error or malfunction flashes 3 times, and then goes off → Replace the steering lock unit. after approximately 20 seconds.) Refer to “SMART KEY SYSTEM SELF-DIAGNOSIS”...
Page 429 SMART KEY SYSTEM NG → 2. Check the smart key switch assem- bly. Replace the smart key switch assembly. Refer to “CHECKING THE SWITCHES” on page 8-87. OK ↓ YES → 3. Check that the smart key system in- dicator light “ ” flashes when the •...
Page 430 SMART KEY SYSTEM The smart key system indicator light “ ” comes on for 1 second when the ON/start switch “ ” is pushed. If one of the following malfunctions is detected, the indicator light starts flashing. Flashing time/number Malfunction and check Item Flash pattern of flashes...
Page 431 SMART KEY SYSTEM Flashing time/number Malfunction and check Item Flash pattern of flashes point Check the wire harness. 0.3 (s) Check the ECU. • ECU communication Flashes continuously Check the smart key error until the error is re- unit. • Data error solved./flashes 4 times 0.3 (s) 1.0 (s)
Page 432 SMART KEY SYSTEM Device that de- Fault code Check or maintenance tected the mal- Symptom Cause function Smart key unit Codes transmitted be- Radio wave noise inter- • Register the smart tween the ECU and the ference or disconnect- key. smart key unit do not ed lead.
Page 433 SMART KEY SYSTEM 3. Open the seat. Check that the storage box light comes on when the seat is opened. If the storage box light does not come on, check the storage box light and storage box light switch. 4. Push the ON/start switch “ ”.
Page 434 SMART KEY SYSTEM Release the seat open/parking switch after the smart key system indicator light “ ” flashes 1 time. → The first digit of the identification number has been set as 1. → Push and hold the seat open/parking switch again. → Release the seat open/parking switch after the smart key system indicator light “...
Page 435 SMART KEY SYSTEM 1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the smart key unit. 2. Perform steps 1–8 in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-75. 3. While the smart key system indicator light “ ” is on for 10 seconds, push the seat open/parking switch “1”...
Page 436 SMART KEY SYSTEM EAS31537 DISABLING A SMART KEY If a smart key is lost or stolen, the smart key can be disabled. 1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com- munication.
Page 437 SMART KEY SYSTEM EAS31539 REPLACING THE SMART KEY UNIT 1. Replace the smart key unit, and then place only 1 previously used smart key within 80 cm (31.5 in) of the smart key unit. 2. Push the ON/start switch “ ”.
Page 438 SMART KEY SYSTEM Required item when re- Replacement parts (when an item is required placing parts in order to replace parts)   : Required. : Replace. Smart key identifi- cation number or  × : Do not replace. smart key is re- Faulty part Remarks quired.
Page 439 SMART KEY SYSTEM Required item when re- Replacement parts (when an item is required placing parts in order to replace parts)   : Required. : Replace. Smart key identifi- cation number or  × : Do not replace. smart key is re- Faulty part Remarks quired.
Page 440 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-83...
Page 441 ELECTRICAL COMPONENTS 1. Front brake light switch 2. Fuse box 3. Diode 3 4. Turn signal/hazard relay 1 5. Steering lock relay 6. Intake air temperature sensor 7. Rear brake light switch 8. Main fuse 9. Starter relay 10.Battery 11.Starting circuit cut-off relay 12.Sidestand relay 13.Fuel injection system relay 14.Diode 1...
Page 442 ELECTRICAL COMPONENTS 8-85...
Page 443 ELECTRICAL COMPONENTS 1. Auxiliary DC jack 2. Steering lock unit 3. Intake air pressure sensor 4. Fuel injector 5. Coolant temperature sensor 6. Fuel pump 7. Seat lock solenoid 8. O sensor 9. Crankshaft position sensor 10.AC magneto 11.Sidestand switch 12.Spark plug 13.Radiator fan motor 14.Speed sensor...
Page 444 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES B/Y L/Y Br P Br/W Y Br/W Br B/Y L/Y B Br/W R/B R/W L/W B L/W B Br/W 8-87...
Page 445 ELECTRICAL COMPONENTS 1. Pass switch 2. Dimmer switch 3. Horn switch 4. Turn signal switch 5. Rear brake light switch 6. Smart key switch assembly 7. Engine stop switch 8. ON/start switch 9. Hazard switch 10.Front brake light switch 11.Sidestand switch 12.Storage box light switch 8-88...
Page 446 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. ECA18520 NOTICE 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 447 ELECTRICAL COMPONENTS • Avoid touching the glass part of a headlight EAS30550 CHECKING THE BULBS AND BULB bulb to keep it free from oil, otherwise the SOCKETS transparency of the glass, the life of the bulb, and the luminous flux will be adverse- Do not check any of the lights that use LEDs.
Page 448 ELECTRICAL COMPONENTS Amperage Fuses Q’ty rating Check each bulb socket for continuity in the same manner as described in the bulb section, Main 40 A however, note the following. Headlight 10 A ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
Page 449 ELECTRICAL COMPONENTS • KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL • Skin — Wash with water. •...
Page 450 ELECTRICAL COMPONENTS • If the battery becomes hot to the touch at D. These values vary with the temperature, the condition of the battery plates, and the any time during the charging process, dis- electrolyte level. connect the battery charger and let the bat- tery cool before reconnecting it.
Page 451 ELECTRICAL COMPONENTS • Standard charging current is reached 12.8 V or more --- Charging is complete. Battery is good. 12.7 V or less --- Recharging is required. • Standard charging current is not reached Under 12.0 V --- Replace the battery. Replace the battery.
Page 452 ELECTRICAL COMPONENTS 1. Disconnect the relay from the wire harness. Headlight relay 2. Connect the pocket tester (Ω × 1) and battery First step: (12 V) to the relay terminal as shown. Check the relay operation. Out of specification → Replace. Starting circuit cut-off relay L/B Y/B 1.
Page 453 ELECTRICAL COMPONENTS Radiator fan motor relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) Turn signal/hazard relay 1 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4.
Page 454 ELECTRICAL COMPONENTS Seat open relay ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay 2 terminal as shown. Pocket tester 90890-03112 Analog pocket tester...
Page 455 ELECTRICAL COMPONENTS b. Press the ON/start switch “ ”. c. Measure the turn signal/hazard relay 2 output voltage. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS30555 CHECKING THE DIODES 1.
Page 456 ELECTRICAL COMPONENTS 2. Check: Pocket tester • Secondary coil resistance 90890-03112 Out of specification → Replace. Analog pocket tester YU-03112-C Secondary coil resistance 12.00–18.00 kΩ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 457 E L E C T R I C A L C O M P O N E N T S Ignition checker 90890-06754 Oppama pet–4000 spark checker YM-34487 c. Push the ON/start switch “ ” and the en- gine stop switch to “ ”.
Page 458 ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the stator coil. Stator coil resistance 0.224–0.336 Ω (W-W) c. Push the ON/start switch “ ”.
Page 459 ELECTRICAL COMPONENTS Refer to “CHECKING THE STATOR COIL” Pocket tester on page 8-101. 90890-03112 Analog pocket tester Battery charging voltage YU-03112-C above 14 V at 5000 r/min • Positive tester probe → ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
Page 460 ELECTRICAL COMPONENTS Fuel meter/fuel level warning indicator flash- c. Push the ON/start switch “ ”. es eight times, then goes off for 3 seconds in d. Elevate the front wheel and slowly rotate it. a repeated cycle (malfunction detected in fuel e.
Page 461 ELECTRICAL COMPONENTS Coolant temperature sensor re- Coolant temperature sensor sistance 18 Nm (1.8 m·kgf, 13 ft·lbf) 2320–2590 Ω@20 °C (2320–2590 Ω@68 °F) EAS30581 CHECKING THE THROTTLE POSITION Coolant temperature sensor re- sistance SENSOR 310–329 Ω@80 °C (310–329 1. Remove: Ω@176 °F) •...
Page 462 ELECTRICAL COMPONENTS The resistance does not change or it changes • Positive tester probe → abruptly → Replace the throttle position sen- Pink/White (wire harness color) • Negative tester probe → sor. Black/Blue (wire harness color) Resistance 0–6.16 kΩ ▲ ▲▲▲...
Page 463 ELECTRICAL COMPONENTS b. Immerse the intake air temperature sensor “1” in a container filled with water “2”. Make sure that the intake air temperature sensor terminals do not get wet. c. Place a thermometer “3” in the water. c. Measure the fuel injector resistance. ▲...
Page 464 ELECTRICAL COMPONENTS EAS31554 CHECKING THE SEAT LOCK SOLENOID 1. Check: • Seat lock solenoid resistance Out of specification → Replace the seat lock assembly. Seat lock solenoid resistance 2.85–3.15 Ω ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 465: Troubleshooting
FAULTY LIGHTING OR SIGNALING SYSTEM ........9-4 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE....9-5 SELF-DIAGNOSTIC FUNCTION TABLE ..........9-5 COMMUNICATION ERROR WITH THE METER OR YAMAHA DIAGNOSTIC TOOL ..............9-5 DIAGNOSTIC CODE: SENSOR OPERATION TABLE ......9-6 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......9-8...
Page 466 TROUBLESHOOTING 3. Throttle body EAS20090 TROUBLESHOOTING • Deteriorated or contaminated fuel • Sucked-in air EAS30599 GENERAL INFORMATION Electrical system 1. Battery The following guide for troubleshooting does not • Discharged battery cover all the possible causes of trouble. It should •...
Page 467 TROUBLESHOOTING • Improperly synchronized throttle body 4. Transmission gear(s) • Improperly adjusted engine idling speed (idle • Damaged transmission gear adjusting screw) Clutch slips • Improper throttle grip free play 1. Clutch • Flooded throttle body • Improperly assembled clutch Electrical system •...
Page 468 TROUBLESHOOTING Cooling system • Incorrect brake fluid level 1. Coolant EAS30610 • Low coolant level FAULTY FRONT FORK LEGS 2. Radiator • Damaged or leaking radiator Leaking oil • Faulty radiator cap • Bent, damaged or rusty inner tube • Bent or damaged radiator fin •...
Page 469 TROUBLESHOOTING • Bent or loose wheel axle Horn does not sound • Excessive wheel runout • Improperly adjusted horn 8. Frame • Damaged or faulty horn • Bent frame • Faulty smart key unit • Damaged steering head pipe • Faulty horn switch •...
Page 470 Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear.) Engine idling stop EAS31373 COMMUNICATION ERROR WITH THE METER OR YAMAHA DIAGNOSTIC TOOL For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-33. Fault code No. Item...
Page 471 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31120 DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic Item Display Procedure code No. Throttle position sensor sig- • Fully closed position 14–20 Check with throttle valves fully closed. • Fully open position 97–107 Check with throttle valves fully open.
Page 472 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Display Procedure code No. EEPROM fault code display • No history — • No malfunctions detected • History exists 01–02 (Cylinder fault code) — • (If more than one cylinder is defective, the display al- ternates every two seconds to show all the detected cylinder numbers.
Page 473 • Connect an ignition check- The “CHECK” indicator and “ ” on the Yamaha diag- nostic tool screen come on each time the ignition coil is actuated. Fuel injector #1 Actuates fuel injector #1 five...
Page 474 38. Spark plug Yellow/Black 39. Coolant temperature sensor Yellow/Green Yellow/Blue 40. Intake air temperature sensor Yellow/Red 41. Yamaha diagnostic tool coupler Yellow/White 42. Intake air pressure sensor 43. Throttle position sensor 44. Lean angle sensor 45. Speed sensor 46. Fuel injector #1 47.
Page 477 XP500F 2015 WIRING DIAGRAM Lg L/G Br/W R/B G/L L/R Br/L B/W B/W B/L B/L B/L B/L B/L G G/Y L/W Y/L B L R/G B/L B/L (Dg) L/W L/W L/W Br/W Br/W Br/W Br/W Br/W Br/W Br/L B/L P/W L Br/L L/Y L/R L B/W R/G...
Page 478 XP500F 2015 WIRING DIAGRAM (Dg) (Gy) (Gy) (Gy) 72 73 72 73...

Yamaha TMAX XP500F 2015 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

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