Yamaha R15 2019 Service Manual
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Yamaha R15 2019 Service Manual

Yamaha R15 2019 Service Manual

This is a service manual for r15 v3 abs models. it was translated from another language so some of the words are a bit messed up but it is very useful and understandable.
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Machine Translated by Google
2019
SERVICE MANUAL
YZF-R15
YZF155
B1P-F8197-S0

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Questions and answers

Billy joe
April 13, 2025

What standard oil level front shock

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1 comments:
Mr. Anderson
April 13, 2025

The standard oil level for the front shock on a Yamaha R15 2019 is 84 mm from the top of the inner tube, with the inner tube fully compressed and without the fork spring.

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Summary of Contents for Yamaha R15 2019

  • Page 1 Machine Translated by Google 2019 SERVICE MANUAL YZF-R15 YZF155 B1P-F8197-S0...
  • Page 2 SAS200071 IMPORTANT This manual has been produced by India Yamaha Motor Pvt. Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this publication to maintain and repair Yamaha vehicles should have a basic knowledge of mechanics and repair techniques for this type of vehicle.
  • Page 3 Machine Translated by Google SAS20004 HOW TO USE THIS MANUAL The purpose of this manual is to provide the mechanic with a convenient and easy-to-read reference. Contains comprehensive explanations of all assembly, disassembly, disassembly, assembly, repair, and testing procedures organized step by step in a sequential manner. • The manual is divided into chapters which in turn are divided into sections.
  • Page 4 Machine Translated by Google SAS20005 SYMBOLS To facilitate the understanding of this manual, the following symbols are used. NOTE The following symbols do not apply to all vehicles. DEFINITION DEFINITION SYMBOL SYMBOL Repairable with motor mounted gear oil Molybdenum Disulfide Oil Liquid Lubricant Brake fluid...
  • Page 5 Machine Translated by Google INDEX SAS10003 GENERAL INFORMATION SPECS CHECKS AND ADJUSTMENTS NEWSPAPERS CHASSIS MOTOR COOLING SYSTEM INJECTION SYSTEM COMBUSTIBLE ELECTRIC SYSTEM TROUBLESHOOTING...
  • Page 6 Machine Translated by Google...

  • Page 7: Table Of Contents

    Machine Translated by Google GENERAL INFORMATION ID....................1-1 IDENTIFICATION NUMBER OF THE VEHICLE ........1-1 ENGINE SERIAL NUMBER ..................1-1 MODEL LABEL ................1-1 FEATURES..................1-2 MULTIFUNCTION DISPLAY ..................1-2 IMPORTANT INFORMATION................1-6 PREPARING FOR DISASSEMBLY AND DISASSEMBLY....1-6 SPARE PARTS ....................1-6 GASKETS, GASKETS OIL AND O-RINGS........1-6 LOCKWASHERS /PLATES AND SPLIT PINS.....1- 6 BEARINGS AND OIL SEALS ..........

  • Page 8: Engine Serial Number

    Machine Translated by Google SAS20007 SAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped on the steering column tube. SAS30004 ENGINE SERIAL NUMBER The engine serial number “1” is stamped on the crankcase. SAS20150 MODEL LABEL The model label “1” is affixed to the frame under the seat.

  • Page 9: Multifunction Display

    Machine Translated by Google CHARACTERISTICS SAS20008 CHARACTERISTICS SAS30982 Speedometer MULTIFUNCTION DISPLAY 1. Speedometer 1. “SELECT” button. The speedometer shows the moving speed of the vehicle. 2. “RESET” button 3. Speedometer 4. Fuel gauge Fuel Gauge 5. VVA (Variable Valve Actuator) Gauge 6.
  • Page 10 Machine Translated by Google CHARACTERISTICS multifunction display This model is equipped with the Variable Valve Actuator System to reduce fuel consumption and improve acceleration at low and high revs. The VVA indicator lights when the variable valve actuator system shifts to high speed.
  • Page 11 Machine Translated by Google CHARACTERISTICS If you do not reset it manually, the reserve tripmeter is Watch reset automatically and returns to the previous reading after refueling and driving 5 km. Odometer 1. Clock The clock uses a 12-hour time system. Setting the clock 1.
  • Page 12 Machine Translated by Google CHARACTERISTICS Average speed NOTE • If the speed is less than 10 km/h, it indicates “_ _._”. • The function of instant consumption of com fuel should be used for general reference only. Do not use this figure to estimate the distance you can drive with the amount of fuel currently in the tank.

  • Page 13: Important Information

    5. Keep all parts away from any source of ignition. SAS2000902 SPARE PARTS Use only genuine Yamaha parts for all replacements. Use Yamaha recommended oil and grease for all greasing operations. Other brands may have similar look and function, but lower quality.
  • Page 14 Machine Translated by Google IMPORTANT INFORMATION SAS20230 SAS1MC1085 BEARINGS AND OIL SEALS Install RUBBER PARTS the bearings “1” and oil seals “2” so that the Check the rubber parts for deterioration manufacturer's marks or numbers are visible. during overhaul. Some rubber parts are When installing the oil seals, grease the lips of sensitive to gasoline, flammable oil, grease, the seals with a thin layer of lithium soap...

  • Page 15: Basic Service Information

    Machine Translated by Google BASIC SERVICE INFORMATION SAS30380 BASIC INFORMATION ABOUT SERVICE SAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener NOTE To remove the quick Screw type 1. Remove: • fastener, push the pin in Quick fastener with a screwdriver and pull the fastener out. NOTE To remove the quick fastener, loosen the screw with a screwdriver/Phillips screwdriver and pull it out.

  • Page 16: Electrical System

    Machine Translated by Google BASIC SERVICE INFORMATION NOTE If it is difficult to disconnect a battery cable due to rust on the battery terminal, remove the rust with hot water. SAS30402 ELECTRIC SYSTEM SCA16760 ATTENTION Handling of electrical parts Check that the battery cables are SCA16600 WARNING connected to the correct terminals.
  • Page 17 Machine Translated by Google BASIC SERVICE INFORMATION SCA16610 NOTE ATTENTION When you reset the ECU by turning the main switch Turn the main switch to “OFF” before to “OFF”, you should wait about 5 seconds before disconnecting or connecting an electrical turning the main switch to “ON”...
  • Page 18 Machine Translated by Google BASIC SERVICE INFORMATION SCA16640 SCA16790 ATTENTION ATTENTION For waterproof couplers, never insert the tester When disconnecting a connector, do not pull on the probes directly into the coupler. When making any wires. Hold the two sections of the connector firmly, checks with a watertight coupler, use the specified and then disconnect it.
  • Page 19 Machine Translated by Google BASIC SERVICE INFORMATION NOTE • If there is no continuity, clean the terminals. • To check the wire harness, follow steps (1) to (3). • As a quick fix, use a contact revitalizer of the kind sold at most parts stores. 4.
  • Page 20 Machine Translated by Google BASIC SERVICE INFORMATION 1-13...

  • Page 21: Special Tools

    Machine Translated by Google SPECIAL TOOLS SAS20012 SPECIAL TOOLS When ordering, please refer to the list below to avoid mistakes. Tool name/reference no. Illustration piston pin changer YSST-207 This tool is used to change the piston pin. YSST-265 Crankshaft Puller (90890-01135) Ø9.5 This tool is used to remove the crankshaft from the crankcase.
  • Page 22 Machine Translated by Google SPECIAL TOOLS Tool name/reference no. Illustration Steering lock on main switch (T-30) YSST-611 A This tool is used to loosen or tighten the ignition lock. scratching post YSST-612 This tool is used to remove sealant from the crankcase surface.
  • Page 23 Machine Translated by Google SPECIAL TOOLS Tool name/reference no. Illustration Upper and lower guide fitter YSST-626 This tool is used to position the upper and lower guides. magnet holder YSST-701 This tool is used to hold the magnet. magnet puller YSST-702 This tool is used to remove the rotor from the magneto with the help of the magneto holder.
  • Page 24 Machine Translated by Google SPECIAL TOOLS Illustration Tool name/reference no. Mechanical seal/bearing fitter YSST-722 This tool is used to install the seal and bearing in the water pump assembly. water pump bearing puller YSST-723 This tool is used to remove the water pump bearing. Clutch hub holder YSST-733A This tool is used to hold the clutch boss while loosening and tightening the boss nut.
  • Page 25 Machine Translated by Google SPECIAL TOOLS Tool name/reference no. Illustration Disc Brake Deflection Tester YSST-890 This tool is used to check runout. disc bearing installer YSST-891 This tool is used to remove the bearing. YSST-893 bushing This tool is used as a supplement to the magneto holder and magneto puller.
  • Page 26 INS-019 (90890-03262) This tool is used to diagnose electrical faults in the advanced fuel injection system. Yamaha bond Nº 1215 (Ver. 3) 90890-85505 (Three Bond Nº 1215-B) This adhesive is used to seal two contact surfaces (eg the crankcase contact surfaces).
  • Page 27 Machine Translated by Google SPECS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS ..............2-2 CHASSIS SPECIFICATIONS..............2-6 ELECTRICAL SYSTEM SPECIFICATIONS..........2-8 TIGHTENING TORQUES ..................2-10 GENERAL TORQUE SPECIFICATIONS.....2-10 ENGINE TORQUES...............2-11 CHASSIS TIGHTENING TORQUES............2-14 GREASING POINTS AND TYPES OF LUBRICANT........2-18 ENGINE ..

  • Page 28: General Specifications

    Machine Translated by Google GENERAL SPECIFICATIONS SAS20013 GENERAL SPECIFICATIONS Model B1P1 Model B2P1 Dimensions Total length 1990 mm (78.3 in) overall width 725 mm (28.5 in) Total height 1135 mm (44.7 in) Distance between axis 1325 mm (52.2 in) height above ground 170 mm (6.69 in) 2.8 minimum turning radius m (9.19 ft)

  • Page 29: Engine Specifications

    Machine Translated by Google ENGINE SPECIFICATIONS SAS20014 ENGINE SPECIFICATIONS Motor combustion cycle 4-stroke Refrigeration system Liquid cooling SOHC 155 cm³ valve actuation system displacement Un cilindro number of cylinders Bore × stroke 58.0 × 58.7 mm (2.28 × 2.31 in) 11.6 : 1 696–896 kPa/550 rpm compression ratio (7.0–9.0 kgf/cm²/550 rpm, 99.0–127.4 psi/...
  • Page 30 Machine Translated by Google ENGINE SPECIFICATIONS Thermostat valve opening temperature 74.0–78.0 °C (165.20–172.40 °F) Valve full opening temperature 90.0 °C (194.00 °F) 7.0 mm (0.28 Valve Lift (Full Open) Plugs) Brand model NGK/MR8E9 Spark plug gap 0.8–0.9 mm (0.031–0.035 in) Butt deformation limit 0.05 mm (0.0020 in)
  • Page 31 Machine Translated by Google ENGINE SPECIFICATIONS valve spring Free length (admission) 33.81 mm (1.33 in) Limit 32.11 mm (1.26 in) Free length (exhaust) 33.81 mm (1.33 in) Limit 32.11 mm (1.26 in) Cylinder Diameter 58.000–58.010 mm (2.2835–2.2839 in) wear limit 58.060 mm (2.2858 in) Piston Diameter...
  • Page 32 Machine Translated by Google ENGINE SPECIFICATIONS 1 unidad Number of discs deformation limit 0.10 mm (0.004 in) 2.20–2.40 mm (0.087–0.094 in) Clutch disc thickness 1 unidad 0.10 mm (0.004 in) Number of discs deformation limit 41.59 mm (1.64 in) 39.51 mm (1.56 in) 0.30 mm (0.012 in) Clutch spring free length Limit...

  • Page 33: Chassis Specifications

    Machine Translated by Google CHASSIS SPECIFICATIONS SAS20015 CHASSIS SPECIFICATIONS Chassis Diamante Frame type 25.5 ° 88 Trailing angle Distance between perpendiculars mm (3.5 in) Front wheel Cast Tire 17M/C × rim type tire size MT2.5 1.0 mm Wheel Radial Runout Limit (0.04 in) 0.5 mm Wheel Runout Limit (0.02 in) 0.25 mm...
  • Page 34 (5.1 in) 267.6 mm (10.54 in) 262.2 mm Fork spring free length Limit (10.32 in) recommended oil Aceite para suspensiones Yamaha G10 Quantity (left) 460.0 cm³ (15.55 US oz, 16.22 Imp.oz) Quantity (right) 460.0 cm³ (15.55 US oz, 16.22 Imp.oz) Level (left) 84 mm (3.3 in) 84 mm (3.3 in) 41 mm...

  • Page 35: Electrical System Specifications

    Machine Translated by Google ELECTRICAL SYSTEM SPECIFICATIONS SAS20016 ELECTRICAL SYSTEM SPECIFICATIONS Voltage 12 V system voltage Ignition system Ignition system TCI (transistor coil fired) Digital Sync Optimizer Type 2.0 °/1400 rpm Ignition Timing (BTDC) engine control unit Model B1P0 (B1P1) BK60 (B2P1) Ignition coil 2.16–2.64 ÿ...
  • Page 36 Machine Translated by Google ELECTRICAL SYSTEM SPECIFICATIONS indicator light neutral indicator light high beam indicator turn signal indicator light coolant temperature warning light engine trouble warning light Starting motor 0.30 kW Power 0.028–0.034 ÿ Armature coil resistance 3.5 mm (0.14 in) Limit of total brush length Manifold limit diameter 16.6 mm (0.65 in)

  • Page 37: Tightening Torques

    Machine Translated by Google TIGHTENING TORQUES SAS20017 TIGHTENING TORQUES SAS30002 GENERAL TORQUE SPECIFICATIONS This table specifies the tightening torques for standard fasteners fitted with standard ISO threads. Torque specifications for special components or assemblies are included in the appropriate chapters of this manual.
  • Page 38 M5, M6 3 Camshaft retainer bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) Timing chain guide bolt (intake side) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Apply Yamaha Timing chain tensioner bolt Adhesive 10 N·m (1.0 kgf·m, 7.4 lb·ft) #1215-B to the screw...
  • Page 39 Machine Translated by Google TIGHTENING TORQUES measure Element of the Ctd. Torque Observations screw thread Air filter case joint clamp bolt 2 N·m (0.2 kgf·m, 1.5 lb·ft) Air filter box bolt 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) exhaust pipe nut 15 N·m (1.5 kgf·m, 11 lb·ft) exhaust assembly bolt 20 N·m (2.0 kgf·m, 15 lb·ft)
  • Page 40 Machine Translated by Google TIGHTENING TORQUES Cylinder head tightening sequence: Magneto cover tightening sequence: 1, 6 3,11 2,10 Clutch cover tightening sequence: 3,13 2,12 Crankcase tightening sequence: 2,13 3,14 A. Left crankcase B. Right crankcase 2-13...
  • Page 41 Machine Translated by Google TIGHTENING TORQUES SAS30017 CHASSIS TIGHTENING TORQUES measure Element of the Ctd. Torque Observations screw thread Top bracket removable rivet 21 N·m (2.1 kgf·m, 15 lb·ft) M10 2 Bottom bracket removable rivet 30 N·m (3.0 kgf·m, 22 lb·ft) M25 1 Lower ring nut (initial tightening) 48 N·m (4.8 kgf·m, 35 lb·ft) Ver NOTA 18...
  • Page 42 Machine Translated by Google TIGHTENING TORQUES measure Element of the Ctd. Torque Observations screw thread M10 1 Link arm and swingarm nut 44 N·m (4.4 kgf·m, 32 lb·ft) M14 1 rear wheel axle nut 59 N·m (5.9 kgf·m, 44 lb·ft) M6 Drive Chain Case Bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) Drive chain adjusting locknut...
  • Page 43 Machine Translated by Google TIGHTENING TORQUES measure Element of the Ctd. Torque Observations screw thread rear brake disc bolt 23 N·m (2.3 kgf·m, 17 lb·ft) Rear brake caliper pin bolt (short) – 12 N·m (1.2 kgf·m, 8.9 lb·ft) Rear brake caliper pin bolt (long) –...
  • Page 44 Machine Translated by Google TIGHTENING TORQUES measure Element of the Ctd. Torque Observations screw thread Fuel tank cover and bracket bolt 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) Front brake master cylinder reservoir cover bolt – 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) Rear brake light switch support bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) speed sensor bolt...
  • Page 45 Machine Translated by Google LUBRICATION POINTS AND TYPES OF LUBRICANT SAS20299 LUBRICATION POINTS AND TYPES OF LUBRICANT SAS1MC1085 MOTOR Lubricant grease point Oil seal lips bearings o-rings Head Bolt Seats, Head Bolt Threads, and Washers Water pump seal and rotor shaft Big end Crankshaft bearing inner surface piston pin...
  • Page 46 Clutch boss nut seat and clutch boss nut thread main shaft and sprockets rear axle and wheel gears shift drum assembly Shift forks and shift fork guide bar axis of change Yamaha bond n.º 1215 90890-85505 Crankshaft Position Sensor Lead Insulator/Stator Assembly (Three Bond Nº 1215-B) Yamaha bond n.º...

  • Page 47: Chassis

    Machine Translated by Google LUBRICATION POINTS AND TYPES OF LUBRICANT SAS1MC1085 CHASSIS Lubricant grease point Front wheel axle nut thread Front wheel axle nut seat Front wheel oil seal lip Rear wheel axle and nut thread Rear wheel axle nut seat Rear wheel motor hub oil seal lip Rear wheel drive hub contact surface Rear wheel oil seal lip...
  • Page 48 Machine Translated by Google LUBRICATION POINTS AND TYPES OF LUBRICANT Lubricant grease point Steering column dust seal lip Outer surface of bolt (tie bar) Nut Seats (Tie Bar & Rocker) Bolt and nut thread (tie bar and frame) Bolt and nut thread (tie bar and tie arm) Bolt and nut thread (tie bar and rear shock) Bolt and nut thread (rocker and link arm) Oil Seal Lips (Tie Bar and Rocker)
  • Page 49 Machine Translated by Google TABLE AND DIAGRAMS OF THE GREASING SYSTEM SAS20021 TABLE AND DIAGRAMS OF THE GREASING SYSTEM ENGINE LUBRICATION CHART 9876531 2-22...
  • Page 50 Machine Translated by Google TABLE AND DIAGRAMS OF THE GREASING SYSTEM 1. Oil pan 2. Oil strainer 3. Oil pump 4. Oil filter element 5. Main shaft 6. Rear shaft 7. Crankshaft 8. Camshaft 9. Cylinder head cover 2-23...
  • Page 51 Machine Translated by Google TABLE AND DIAGRAMS OF THE GREASING SYSTEM SAS32363 LUBRICATION DIAGRAMS 2-24...
  • Page 52 Machine Translated by Google TABLE AND DIAGRAMS OF THE GREASING SYSTEM 1. Cylinder head cover 2. Camshaft 3. Crankshaft 4. Oil filter assembly 5. Oil pump assembly 6. Oil strainer 7. Main shaft 8. Rear shaft 9. Clutch push lever 2-25...
  • Page 53 Machine Translated by Google TABLE AND DIAGRAMS OF THE GREASING SYSTEM 2-26...
  • Page 54 Machine Translated by Google TABLE AND DIAGRAMS OF THE GREASING SYSTEM 1. Oil strainer 2. Oil pump 3. Oil filter 4. Crankshaft 5. Rear Shaft 6. Main Shaft 7. Camshaft 8. Cylinder Head Cover 2-27...

  • Page 55: Refrigeration System Diagrams

    Machine Translated by Google REFRIGERATION SYSTEM DIAGRAMS SAS20299 REFRIGERATION SYSTEM DIAGRAMS È Insert the pipe into the foot of the trim. É The 1 Tube (thermostat to water pump) 2 Thermostat assembly white paint on the tube (thermostat to fuel pump water) must face to the right of the vehicle.
  • Page 56 Machine Translated by Google REFRIGERATION SYSTEM DIAGRAMS 1 Air bleed bolt È It is allowed to apply grease to prevent falling off during 2 Water pump assembly assembly. 2-29...
  • Page 57 Machine Translated by Google REFRIGERATION SYSTEM DIAGRAMS 1 O-ring È Insert the pipe into the foot of the trim. É Must not be on the reel. Ê Direction of the clip 2 Clip towards the top of the vehicle. Ë Clip direction to the right side of the vehicle.
  • Page 58 Machine Translated by Google REFRIGERATION SYSTEM DIAGRAMS 1 Pipe clamp È Direction to the top of the vehicle. É Steering to the right side of the vehicle. Ê Check that the 2 Thermostat assembly 3 Water pump assembly clearance is greater than 10 mm. Ë Push the flange in after tightening it.
  • Page 59 Machine Translated by Google ROUTING THE CABLES SAS20021 ROUTING THE CABLES Handlebar 18 19 13 16 And 2-32...
  • Page 60 Machine Translated by Google ROUTING THE CABLES 1. Handlebar switch (left) 2. Handlebar switch lead (left) 3. Clutch cable 4. Throttle (acceleration) cable 5. Throttle cable (deceleration) 6. Brake hose 7. Front brake light switch lead 8. Handlebar switch lead (right) 9.
  • Page 61 Machine Translated by Google ROUTING THE CABLES Engine (right view) 2-34...
  • Page 62 Machine Translated by Google ROUTING THE CABLES 1. Starter relay assembly 2. Fuel tank mounting bracket 3. Connector union 4. MAQS (Modulated Air Quantity Sensor) lead 5. FID cable 6. Throttle body assembly 7. Throttle (deceleration) cable 8. Throttle cable (acceleration) 9.
  • Page 63 Machine Translated by Google ROUTING THE CABLES Rear fender (right view) 2-36...
  • Page 64 Machine Translated by Google ROUTING THE CABLES 1. Fuse box 2. Battery positive lead 3. Tail brake light switch 4. Fuse box lead 5. ECU 6. Tail light unit assembly lead A. Rear brake light switch wire through the wire guide. 2-37...
  • Page 65 Machine Translated by Google ROUTING THE CABLES Steering column (left view) B2P1 2-38...
  • Page 66 Machine Translated by Google ROUTING THE CABLES 1. Clutch cable 2. Fuel gauge cable 3. Fuel pipe 4. Fuel pump lead 5. Gear shift position switch lead 6. O2 sensor cable 7. Radiator cap 8. Horn wire 9. Throttle cable (return) 10.
  • Page 67 Machine Translated by Google ROUTING THE CABLES Engine (left view) B1P1 2-40...
  • Page 68 Machine Translated by Google ROUTING THE CABLES 1 Clutch cable 2 Rectifier/Regulator Assembly 3 Side stand switch lead 4 Support 5 Pipe (radiator cap to coolant reservoir) 6 Support 7 Side stand switch 8 Flange È The sidestand switch lead should be attached to the center of the guide rest.
  • Page 69 Machine Translated by Google ROUTING THE CABLES (Top view) B1P1 1. Sidestand switch lead 2. Pipe (radiator È Pass the lead of the side stand switch of the cap to coolant tank) wire harness below the wire harness assembly and above the rectifier/regulator assembly wire 3.
  • Page 70 Machine Translated by Google ROUTING THE CABLES Rear fender (left view) 2-43...
  • Page 71 Machine Translated by Google ROUTING THE CABLES 1 Air filter assembly 2 Lean angle sensor 3 Tail light assembly lead 4 negative cable 5 Rear support 6 Speed sensor wire 7 ACM lead 8 Engine mounting bracket 9 Lean angle sensor wire 0 Frame component A Wire harness assembly B.
  • Page 72 Machine Translated by Google ROUTING THE CABLES Engine (top view) 2-45...
  • Page 73 Machine Translated by Google ROUTING THE CABLES 1 Left front turn signal cable. 2 Wire harness assembly (headlight) 3 Clutch cable 4 Left handlebar switch cable 5 Throttle (traction) cable 6 Throttle cable (return) 7 Right front turn signal light lead. 8 O2 sensor lead 9 VVA lead 0 Ignition coil A Ignition coil lead B Injector assembly lead C Injector...
  • Page 74 Machine Translated by Google ROUTING THE CABLES instrument set 2-47...
  • Page 75 Machine Translated by Google ROUTING THE CABLES 1 Instrument Cluster Cable 2 Support 3 Headlight assembly lead 4 Headlight assembly 5 Wire harness (headlight wire) 6 Instrument support 7 Instrument Cluster 8 Gear shift position switch lead 9 Negative lead 0 ACM lead A Engine mounting bracket B Cross tube (frame component) È...
  • Page 76 Machine Translated by Google ROUTING THE CABLES Rear fender (top view) 2-49...
  • Page 77 Machine Translated by Google ROUTING THE CABLES 1. Right rear turn signal lead 2. License plate light lead 3. Left rear turn signal lead 4. Tail light assembly lead 5. Relay assembly 6. Engine control unit 7. Connector cover 8. Maintenance tool 9.
  • Page 78 Machine Translated by Google ROUTING THE CABLES 2-51...
  • Page 79 Machine Translated by Google PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE (B1P1) ...............3-1 INTRODUCTION..................3-1 EMISSION CONTROL SYSTEM PERIODIC MAINTENANCE CHART ..................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART......3-1 PERIODIC MAINTENANCE (B2P1) ...............3-4 INTRODUCTION..................3-4 EMISSION CONTROL SYSTEM PERIODIC MAINTENANCE CHART ...........
  • Page 80 Machine Translated by Google CHASSIS ..........................3-19 ADJUSTING THE BRAKE LEVER PLAY........3-19 REAR DISC BRAKE ADJUSTMENT ...........3-19 CHECK BRAKE FLUID LEVEL CHECK ....3-19 CHECKING THE FRONT BRAKE PADS ..3-20 CHECKING THE BRAKE PADS REAR....3-20 CHECKING THE FRONT BRAKE PIPE......3-20 CHECKING THE BRAKE PIPE REAR.....3-21 ADJUSTING THE REAR BRAKE LIGHT SWITCH..3-21 BLEEDING OF THE HYDRAULIC BRAKE SYSTEM ........3-21 ADJUSTING THE SLACK OF THE DRIVE...

  • Page 81: Periodic Maintenance (B1P1)

    • After 30,000 km (17,500 mi), repeat the maintenance intervals starting at 6,000 km (3,500 mi). • Items marked with an asterisk must be performed by a Yamaha dealer, as they they require special tools, data and technical knowledge.
  • Page 82 Machine Translated by Google PERIODIC MAINTENANCE (B1P1) ODOMETER INDICATION REVISION N.º ELEMENT COMPROBACIÓN OR REPARACIÓN 1,000 km 6,000 km 12,000 km 18,000 km 24,000 km YEARLY (600 mi) (3,500 mi) (7,000 mi) (10,500 mi) (14,000 mi) • Change. Every 2 years 8 * Brake Fluid •...
  • Page 83 Machine Translated by Google PERIODIC MAINTENANCE (B1P1) ODOMETER INDICATION REVISION N.º ELEMENT COMPROBACIÓN OR REPARACIÓN 1,000 km 6,000 km 12,000 km 18,000 km 24,000 km YEARLY (600 mi) (3,500 mi) (7,000 mi) (10,500 mi) (14,000 mi) Moving parts and ÿÿÿÿÿ 29 * •...

  • Page 84: Periodic Maintenance (B2P1)

    • After 19,000 km (11,800 mi), repeat the maintenance intervals beginning with the than 4,000 km (2,400 mi). • Items marked with an asterisk must be performed by a Yamaha dealer, as they they require special tools, data and technical knowledge.
  • Page 85 Machine Translated by Google PERIODIC MAINTENANCE (B2P1) ODOMETER INDICATION N.º ELEMENT COMPROBACIÓN OR REPARACIÓN 1,000 km 4,000 km 7,000 km 10,000 km 13,000 km 16,000 km (600 mi) (2,400 mi) (4,200 mi) (6,000 mi) (7,800 mi) (9,600 mi) • Check if it is cracked or damaged. • Check ÿÿÿÿÿÿ...
  • Page 86 Machine Translated by Google PERIODIC MAINTENANCE (B2P1) ODOMETER INDICATION N.º ELEMENT COMPROBACIÓN OR REPARACIÓN 1,000 km 4,000 km 7,000 km 10,000 km 13,000 km 16,000 km (600 mi) (2,400 mi) (4,200 mi) (6,000 mi) (7,800 mi) (9,600 mi) ÿÿÿÿÿÿ Moving parts and •...
  • Page 87 Machine Translated by Google MOTOR SAS30622 MOTOR valve clearance (cold) Intake 0.10– VALVE CLEARANCE ADJUSTMENT The 0.14 mm (0.0039–0.0055 in) following procedure is valid for all valves. Escape 0.21–0.25 mm (0.0083–0.0098 in) NOTE a. Rotate the crankshaft in the opposite direction to clockwise.
  • Page 88 Turn adjusting screw “3” in direction “a” or • Driver's seat “b” until the specified valve clearance is See “GENERAL CHASSIS” on page 4-1. obtained. 3. Install: • Yamaha Diagnostic Tool Refer to “FUEL INJECTION SYSTEM” on page 8-41. Ya maha diagnostic tool INS-018 (90890-03256) INS-019 (90890-03262) 4.
  • Page 89 Machine Translated by Google MOTOR NOTE 6. Adjust: • Engine idling speed If you cannot obtain the specified free play of a. Turn the idle speed adjusting screw “1” in the throttle grip on the throttle body side of the the direction “a”...
  • Page 90 Machine Translated by Google MOTOR 2. Disconnect: • 9. Connect: • Spark plug cap 3. Spark plug cap 10.Install: • Side Remove: • Spark plug cover assembly (right) SCA13330 See “GENERAL CHASSIS” on page 4-1. ATTENTION SAS30037 Before removing the spark plug, blow any dirt PRESSURE MEASUREMENT that may have accumulated in the cavity with COMPRESSION...
  • Page 91 Machine Translated by Google MOTOR 8. Remove: • Compression gauge 9. Install: • Spark plug Spark plug 13 N m (1.3 kgf m, 9.6 lb ft) 10.Connect: • Spark plug cap 11.Install: • Side cover assembly • Side panel • Driver's seat See “GENERAL CHASSIS”...
  • Page 92 Machine Translated by Google MOTOR recommended brand YAMALUBE SAE Viscosity Grades 10W-40 Engine oil level ordering API servicio type SG or superior, standard JASO MA SCA13361 ATTENTION • Engine oil also lubricates the em clutch and the use of the wrong type of oil or additives can cause the clutch to slip.

  • Page 93: Engine

    Machine Translated by Google MOTOR Oil filter element cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) NOTE Check that the o-ring is properly seated. 7. Check: • Oil strainer Dirt ÿ Clean. b. Start the engine and idle until oil starts to 8.

  • Page 94: The Clutch Lever Free Play

    Machine Translated by Google MOTOR Handlebar end a. SAS30050 CLEANING THE FILTER ELEMENT Slide back the rubber cover NOTE "1". b. Loosen the lock nut “2”. c. Turn the adjusting bolt “3” until the There is a header tube “1” at the bottom of the specified clutch lever free play is obtained.

  • Page 95: Joint

    Machine Translated by Google MOTOR 6. Install: 2. Check: • • Air cleaner element • Air Fuel pipe “1” cleaner case cover (with gaskets) Cracks/damage ÿ Replace. • Fuel pipe clip Loose connection ÿ Connect correctly. SCA20480 ATTENTION Never start the engine without the air filter element installed.
  • Page 96 Recommended soda: to install and tighten the nuts and bolts in the ORIGINAL SODA correct order. See “ENGINE REMOVAL” on YAMAHA page 5-1. Exhaust pipe nut 15 N m (1.5 kgf m, 11 lb ft) Exhaust assembly bolt 20 N m (2.0 kgf m, 15 lb ft)

  • Page 97: Coolant

    Machine Translated by Google MOTOR • Thermostat assembly “5” dual. When it stops whistling, press down • Water pump inlet tube “6” on the radiator cap and turn it Cracks/damage ÿ Replace. counterclockwise to remove it. See “RADIATOR” on page 6-1. 3.
  • Page 98 Machine Translated by Google MOTOR Amount of coolant Recommended soda: YA ORIGINAL REFRIGERANT Radiator (including all steps) MANY 0.49 L (0.52 US qt, 0.43 Imp.qt) 13.Install: Coolant reservoir (up to the maximum level mark) • Coolant reservoir cap 14.Start the 0.15 L (0.16 US qt, 0.13 Imp.qt) engine, warm it up for a few minutes, then loosen the coolant bleed bolt “1”...

  • Page 99: Chassis

    Machine Translated by Google CHASSIS c. Turn the adjusting nut “5” until the specified SAS20024 CHASSIS position of the brake pedal is obtained. BRAKE LEVER PLAY ADJUSTMENT There should be no play at the “1” end of the brake lever. If there is play, check the brake system.

  • Page 100: Checking The Front Brake Pipe

    Machine Translated by Google CHASSIS 1. Apply the brake. 2. Check: • Front brake pad The wear indicator groove “1” has almost disappeared ÿ Replace the brake pads as a set. See “FRONT BRAKE” on page 4-19. SAS30634 CHECKING THE REAR BRAKE PADS The following procedure is valid for all brake pads.

  • Page 101: Light Switch

    Machine Translated by Google CHASSIS 3. Keep the vehicle upright and apply the front Address “to” brake several times. The brake light comes on earlier. 4. Check: address “b” • Brake pipe The brake light comes on afterwards. Brake fluid leak ÿ Replace the damaged tube.
  • Page 102 Machine Translated by Google CHASSIS d. Place the other end of the tube in a container. and. Slowly apply the brake several times. F. Fully squeeze the brake lever or fully depress the brake pedal and hold it in that position. g. Loosen the bleed screw.
  • Page 103 Machine Translated by Google CHASSIS NOTE Wheel axle nut 59 N m Place the vehicle on a suitable stand so that (5.9 kgf m, 44 lb ft) the rear wheel does not touch the ground. and. Tighten the drive chain adjusting 2.

  • Page 104: Head

    Machine Translated by Google CHASSIS Lower ring nut (initial tightening torque) 48 N·m (4.8 kgf·m, 35 lb·ft) c. Loosen the lower ring nut “4” completely, and then tighten it to the specified torque with a steering nut socket. 3. Remove: SWA13140 CAVEAT •...
  • Page 105 Machine Translated by Google CHASSIS SAS30653 SWA13181 FRONT FORK CHECK 1. Remove the CAVEAT vehicle from the stand. • The tire pressure should only be checked and adjusted when the temperature of 2. Keep the vehicle upright and apply the front the tires is equal to the ambient brake.
  • Page 106 SWA14090 1. Check: • CAVEAT Rim Damage/ After extensive testing, India Yamaha Motor circumferential deformation ÿ Replace. Pvt. Ltd. has approved the tires listed below for this model. The front and rear tires must SWA13260 CAVEAT always be of the same brand and of the same design.

  • Page 107: Lubrication Of The Brake Lever

    Machine Translated by Google CHASSIS SAS30660 SAS30119 CHECKING AND GREASING THE GREASE THE REAR SUSPENSION Lubricate CABLE ENDS The following procedure is the pivot point and moving metal-to-metal parts valid for all inner and outer cables. of the rear suspension. SWA13270 CAVEAT recommended lubricant...

  • Page 108: Electric System

    Machine Translated by Google ELECTRIC SYSTEM SAS20025 ELECTRIC SYSTEM SAS30816 TESTING AND CHARGING THE BATTERY See “TESTING AND CHARGING THE BATTERY” on page 8-78. SAS30121 CHECKING THE FUSES See “CHECKING THE FUSES” on page 8-78. SAS30664 HEADLIGHT BEAM ADJUSTMENT The following procedure works for both fa ros.
  • Page 109 Machine Translated by Google ELECTRIC SYSTEM 3-29...
  • Page 110 Machine Translated by Google CHASSIS OVERALL CHASSIS..................4-1 REMOVING THE MIRROR ASSEMBLY ......4-5 INSTALLING THE MIRROR ASSEMBLY..........4-5 INSTALLING THE AIR FILTER CASE..........4-7 FRONT WHEEL ..................4-8 REMOVING THE FRONT WHEEL (DISC)......4-10 DISASSEMBLY OF THE FRONT WHEEL..........4-10 CHECKING THE FRONT WHEEL ....
  • Page 111 Machine Translated by Google BACK BRAKE..................4-30 INTRODUCTION......................4-35 CHECKING THE REAR BRAKE DISC ......4-35 REPLACING THE REAR BRAKE PADS ......4-35 REMOVING REAR BRAKE CALIPER DISASSEMBLY ........4-36 DISASSEMBLY OF THE REAR BRAKE CALIPER ........4-37 CHECKING THE REAR BRAKE CALIPER......4-37 CHECKING THE REAR BRAKE CALIPER BRACKET ..........
  • Page 112 Machine Translated by Google CHAIN DRIVE................4-64 REMOVING THE DRIVE CHAIN WITH THE CHAIN CUTTER ..................4-65 CHECKING THE DRIVE CHAIN ......4-65 CHECKING THE DRIVE SPROCKET ..............4-66 CHECKING THE SPROCKET SPROCKET REAR WHEEL ........4-66 CHECKING THE REAR WHEEL DRIVE HUB....4-66 INSTALLING THE DRIVE CHAIN WITH THE RIVETER CHAIN..........
  • Page 113 Machine Translated by Google OVERALL CHASSIS SAS20026 OVERALL CHASSIS Removing the seats and battery 13 N·m (1.3 kgf·m, 9.6 lb·ft) 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) Order Ctd. Observations Work/parts to disassemble driver's seat passenger seat Disconnect. Negative battery cable Disconnect.

  • Page 114: Overall Chassis

    Machine Translated by Google OVERALL CHASSIS Removing the rear side fairings Order Ctd. Observations Work/parts to disassemble Driver's seat/Passenger's seat See “GENERAL CHASSIS” on page 4-1. Panel lateral rear panel rear side fairing For assembly, follow the reverse order of disassembly.
  • Page 115 Machine Translated by Google OVERALL CHASSIS Disassembly of the lower fairings Order Ctd. Observations Work/parts to disassemble driver's seat See “GENERAL CHASSIS” on page 4-1. side panels See “GENERAL CHASSIS” on page 4-1. Panel superior Disconnect Turn signal connector (left/right) Wire harness clamp Unlock Side cover assembly (left/right)
  • Page 116 Machine Translated by Google OVERALL CHASSIS Removing the headlight assembly and the instrument assembly Order Ctd. Observations Work/parts to disassemble driver's seat See “GENERAL CHASSIS” on page 4-1. Side covers (left/right) See “GENERAL CHASSIS” on page 4-1. Left mirror Right rearview Windshield Disconnect headlight coupler...
  • Page 117 Machine Translated by Google OVERALL CHASSIS MIRROR ASSEMBLY REMOVAL 1. INSTALLING THE MIRROR Remove the bolt caps “1” from the ASSEMBLY 1. Install the collars mirror. “1” and the rubber plates visor. “2”. 2. Remove the extra left mirror “2” NOTE going pins “3”.
  • Page 118 Machine Translated by Google OVERALL CHASSIS Removing the air filter box 1.2 N·m (0.12 k gf·m, 0.88 lb·ft) 3.8 N m (0.3 · 8 kgf·m, 2.8 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 2 N·m (0.2 kgf·m, 1.5 lb·ft) Order Observations Work/parts to disassemble Ctd.
  • Page 119 Machine Translated by Google OVERALL CHASSIS SAS30968 AIR FILTER HOUSING INSTALLATION 1. Install: • Air filter case joint flange NOTE Align the projection “a” on the air filter case with the groove “b” on the air filter case joint flange.
  • Page 120 Machine Translated by Google FRONT WHEEL SAS20028 FRONT WHEEL Removing the front wheel and brake disc 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 38 N·m (3.8 kgf·m, 28 lb·ft) 35 N·m (3.5 kgf·m, 26 lb·ft) 23 N·m (2.3 kgf·m, 17 lb·ft) Order Ctd.
  • Page 121 Machine Translated by Google FRONT WHEEL Front wheel disassembly Order Ctd. Observations Work/parts to disassemble oil seal Bearing spacer For assembly, follow the reverse order of disassembly.

  • Page 122: Front Wheel

    Machine Translated by Google FRONT WHEEL SAS30145 REMOVING THE FRONT WHEEL (DISC) 1. Place the vehicle on a level surface. zontal. SWA13120 CAVEAT Securely support the vehicle so that it cannot fall over. 2. Raise: • Front wheel bearing puller Place the vehicle on a suitable stand so that YSST-624 the front wheel is raised.

  • Page 123: Adjusting The Static Wheel Balance

    Machine Translated by Google FRONT WHEEL bearing punch YSST-951 SAS30152 ADJUSTING THE STATIC BALANCE OF THE FRONT WHEEL NOTE • After changing the tire or wheel or both, the static balance of the front wheel must be adjusted. 4. Check: • •...
  • Page 124 Machine Translated by Google FRONT WHEEL 3. Adjust: • Front wheel static balance a. Place a weight “1” on the rim flange at the exact opposite location of the heaviest point “X”. b. If the front wheel does not stay stationary in all positions, rebalance it.
  • Page 125 Machine Translated by Google FRONT WHEEL SWA13500 CAVEAT Check that the brake pipe is correctly positioned. SCA19760 ATTENTION Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly. 4-13...

  • Page 126: Rear Wheel

    Machine Translated by Google REAR WHEEL SAS20029 REAR WHEEL Rear wheel disassembly 59 N·m (5.9 kgf·m, 44 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 16 N·m (1.6 kgf·m, 12 lb·ft) Order Ctd. Observations Work/parts to disassemble NOTE Place the vehicle on a suitable support so that the rear wheel does not touch the ground.
  • Page 127 Machine Translated by Google REAR WHEEL Rear wheel disassembly Order Ctd. Observations Work/parts to disassemble sprocket spacer rear wheel sprocket rear wheel motor hub elastic support Brake disc oil seal Bearing Collar oil seal Bearing Collar For assembly, follow the reverse order of disassembly. 4-15...

  • Page 128: Removing The Rear Wheel (Disc)

    Machine Translated by Google REAR WHEEL SAS30156 SAS30159 REMOVING THE REAR WHEEL (DISC) CHECKING THE REAR WHEEL 1. Check: • Rear wheel axle • Rear wheel • Wheel bearings 1. Place the vehicle on a level surface. • Oil seals See “CHECKING THE FRONT zontal.
  • Page 129 Machine Translated by Google REAR WHEEL SAS30164 STATIC BALANCING OF THE WHEEL REAR NOTE • After changing the tire or rear wheel or both, the static balance of the rear wheel must be adjusted. • Adjust the static balance of the rear wheel with the brake disc mounted.
  • Page 130 Machine Translated by Google REAR WHEEL 5. Adjust: • Drive chain slack See “ADJUSTING THE AC CLEARANCE TRANSMISSION DENA” on page 3-22. Drive chain slack 30.0–40.0 mm (1.18–1.57 in) 6. Tighten: • Rear wheel axle nut Rear wheel axle nut 59 N m (5.9 kgf m, 44 lb ft) 4-18...

  • Page 131: Front Brake

    Machine Translated by Google FRONT BRAKE SAS20030 FRONT BRAKE Removing the front brake pads 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 35 N·m (3.5 kgf·m, 26 lb·ft) Order Ctd. Observations Work/parts to disassemble Front brake pipe clamp Front brake caliper bolt front brake caliper brake pad clip brake pad pin...
  • Page 132 Machine Translated by Google FRONT BRAKE Front brake master cylinder removal 24 N·m (2.4 kgf·m, 18 lb·ft) 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) 9.0 N·m (0.9 kgf·m, 6.6 lb·ft) 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) 6.0 N·m (0.6 kgf·m, 4.4 lb·ft) Order Ctd.
  • Page 133 Machine Translated by Google FRONT BRAKE Front brake master cylinder disassembly Order Ctd. Observations Work/parts to disassemble master cylinder assembly master cylinder body For assembly, follow the reverse order of disassembly. 4-21...
  • Page 134 Machine Translated by Google FRONT BRAKE Front brake caliper removal 35 N·m (3.5 kgf·m, 26 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) Order Ctd. Observations Work/parts to disassemble Empty. See “HI DRAULIC BRAKE SYSTEM PURGE” on page Brake fluid 3-21. Brake pipe union bolt copper washer front brake pipe...
  • Page 135 Machine Translated by Google FRONT BRAKE Front brake caliper disassembly Order Ctd. Observations Work/parts to disassemble The following procedure is valid for both front brake calipers. brake pad clip brake pad pin front brake pad brake pad clip brake pad support brake caliper support Brake caliper piston Brake caliper piston dust seal...

  • Page 136: Introduction

    Machine Translated by Google FRONT BRAKE SAS30168 a. Place the vehicle on a suitable stand so INTRODUCTION that the front wheel is raised. b. Before SWA14101 measuring the deflection of the front CAVEAT brake disc, turn the handlebar to the right or It is rarely necessary to disassemble disc left to check that the front wheel does not brake components.
  • Page 137 Machine Translated by Google FRONT BRAKE and. Measure the deflection of the brake disc. F. If it is out of specification, repeat the adjustment operation until the deflection of the brake disc is corrected. g. If the brake disc deflection cannot be corrected to the specified value, replace the disc.
  • Page 138 Machine Translated by Google FRONT BRAKE 1. Remove: • Brake pipe union bolt “1” • Copper washers “2” • Brake pipe “3” NOTE Place the end of the brake hose in a container and carefully pump the fluid out. b. Remove the brake caliper piston seals and dust seals.
  • Page 139 Machine Translated by Google FRONT BRAKE • Brake pad springs • Brake SAS30174 BRAKE CALIPER ASSEMBLY pad pins • Brake pad clips • Front FORWARD brake caliper SWA20680 CAVEAT • Before installation, all internal brake Front brake caliper bolt components must be cleaned and lubricated with clean or new brake fluid.
  • Page 140 Machine Translated by Google FRONT BRAKE SAS30181 MASTER MASTER ASSEMBLY FORWARD SWA13520 CAVEAT • Before installation, all internal brake components must be cleaned and lubricated with clean brake fluid or new. • Never use solvents on the compo 7. Check: • Brake internal brake components.
  • Page 141 Machine Translated by Google FRONT BRAKE SWA13531 SCA13540 CAVEAT CAUTION The correct positioning of the brake hose Brake fluid can damage painted surfaces and is essential for the safe operation of the plastic parts. Therefore, always wipe up any vehicle. spilled brake fluid immediately.

  • Page 142: Back Brake

    Machine Translated by Google BACK BRAKE SAS20031 BACK BRAKE Removing the rear brake pads Order Ctd. Observations Work/parts to disassemble Rear brake pad retaining bolt rear brake pad brake pad wedge brake pad spring For assembly, follow the reverse order of disassembly. 4-30...
  • Page 143 Machine Translated by Google BACK BRAKE Rear brake master cylinder removal Order Ctd. Observations Work/parts to disassemble Empty. See “BLEEDING THE BRAKE SYSTEM HI Brake fluid DRAULIC” on page 3-21. Brake pipe union bolt copper washer rear brake pipe footpeg plate assembly Brake fluid reservoir tube rear master cylinder brake fluid reservoir assembly...
  • Page 144 Machine Translated by Google BACK BRAKE Rear brake master cylinder disassembly 17 N•m (1.7 kgf•m, 13 lb•ft) Order Ctd. Observations Work/parts to disassemble Brake pipe fitting master cylinder assembly master cylinder body For assembly, follow the reverse order of disassembly. 4-32...
  • Page 145 Machine Translated by Google BACK BRAKE Rear brake caliper removal 30 N·m (3.0 kgf·m, 22 lb·ft) Order Ctd. Observations Work/parts to disassemble Empty. See “HI DRAULIC BRAKE SYSTEM PURGE” on page Brake fluid 3-21. rear wheel See “REAR WHEEL” on page 4-14. Rear brake pipe union bolt copper washer rear brake pipe...
  • Page 146 Machine Translated by Google BACK BRAKE Rear brake caliper disassembly Order Ctd. Observations Work/parts to disassemble Brake pad retaining bolts rear brake pad brake pad shims brake pad spring Brake caliper piston Brake caliper piston seal Brake caliper piston dust seal brake caliper support bleed screw For assembly, follow the reverse order of disassembly.

  • Page 147: Introduction

    Machine Translated by Google BACK BRAKE SAS30183 INTRODUCTION Brake disc thickness limit 4.0 mm (0.16 in) SWA14101 CAVEAT It is rarely necessary to disassemble disc brake components. Therefore, always adopt 5. Adjust: these preventive measures: • Never • Brake disc deflection Refer disassemble brake components unless to “CHECKING THE FRONT BRAKE absolutely necessary.
  • Page 148 Machine Translated by Google BACK BRAKE NOTE Always replace the set of brake pads, shims and spring. UPPER a. Attach a clear plastic tube “1” snugly to LOWER the bleed screw “2”. Place the other end of the tube in an open container.
  • Page 149 Machine Translated by Google BACK BRAKE SAS30187 1. Check: • DISASSEMBLY OF THE REAR BRAKE Brake caliper piston “1” CALIPER 1. Remove: Rust/scratches/wear ÿ Replace the brake caliper piston. • Brake caliper cylinder “2” • Brake caliper piston “1” • Brake caliper piston dust seal Scratches/wear ÿ...

  • Page 150: Rear Brake Caliper

    Machine Translated by Google BACK BRAKE SAS30190 SWA13090 REAR BRAKE CALIPER CAVEAT INSTALLATION 1. Install: • brake pad • Use only the specified brake fluid. Other spring • Brake pads • Brake pad brake fluids can cause the rubber seals to retaining bolt Refer to “REAR BRAKE deteriorate, leading to leaks and poor PAD REPLACEMENT”...

  • Page 151: Master Master Assembly

    Machine Translated by Google BACK BRAKE 1. Remove: • Brake pipe union bolt “1” • Copper washers Specified brake fluid DOT 3 o 4 “2” • Brake pipe “3” • Footrest plate assembly NOTE To collect any remaining brake fluid, SAS30196 place a container under the master cylinder REAR BRAKE CYLINDER CYLINDER...
  • Page 152 Machine Translated by Google BACK BRAKE • When refilling, avoid getting water into the brake fluid reservoir. Water significantly lowers the boiling point of brake fluid and can cause vapor lock. SCA13540 ATTENTION Brake fluid can damage painted surfaces and plastic parts. Therefore, always wipe up any spilled brake fluid immediately.

  • Page 153: Handlebars

    Machine Translated by Google HANDLEBARS SAS20033 HANDLEBARS Removing the handlebars Order Ctd. Observations Work/parts to disassemble Cuff end (left) Handlebar weight (left) handlebar grip Disconnect. clutch switch coupler Handlebar switch (left) clutch contact Disconnect. Clutch cable Clutch handle Clutch lever support Fist end (right) Handlebar weight (right) Right handlebar switch (right)
  • Page 154 Machine Translated by Google HANDLEBARS Removing the handlebars Order Ctd. Observations Work/parts to disassemble throttle cable Disconnect. throttle grip Front brake master cylinder mount front master cylinder Plug handlebar bolt Removable handlebar rivet Handlebar (left) Handlebar (right) For assembly, follow the reverse order of disassembly. 4-42...

  • Page 155: Checking The Handlebars

    Machine Translated by Google HANDLEBARS SAS30203 • Align the end of the master cylinder holder with the REMOVING THE HANDLEBARS 1. Place perforated mark “a” on the handlebar. the vehicle on a level surface. zontal. • Tighten the upper bolt first, then the lower bolt. SWA13120 stronger CAVEAT...
  • Page 156 Machine Translated by Google HANDLEBARS 8. Install: • Handlebar switch (left) “1” NOTE Align the projection “a” on the left handlebar switch with the hole “b” on the left handlebar. 5. Install: • Clutch lever support “1” Clutch handle bracket bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) 9.
  • Page 157 Machine Translated by Google HANDLEBARS NOTE Check that the main switch lead, brake pipe, throttle cables, clutch cable and handlebar switch leads are routed correctly. See “ROUTING THE CABLES” on page 2-32. 12.Adjust: • Clutch lever free play See “ADJUSTING THE CLUTCH LEVER FREE PLAY”...

  • Page 158: Front Fork

    Machine Translated by Google FRONT FORK SAS20034 FRONT FORK Removing the front fork legs Order Ctd. Observations Work/parts to disassemble The following procedure is valid for both front fork legs. See “FRONT WHEEL” on page 4-8. Front wheel front fender handlebar bolt Loosen up.
  • Page 159 Machine Translated by Google FRONT FORK Disassembly of the front fork legs 23 N·m (2.3 kgf·m, 17 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) Order Ctd. Observations Work/parts to disassemble The following procedure is valid for both front fork legs. cappuccino bolt o-ring Washer...
  • Page 160 Machine Translated by Google FRONT FORK Disassembly of the front fork legs 23 N·m (2.3 kgf·m, 17 lb·ft) 30 N·m (3.0 kgf·m, 22 lb·ft) Order Ctd. Observations Work/parts to disassemble Oil circulation stop oil seal Oil Seal Washer Inner tube sleeve (upper) Inner tube sleeve (lower) outer tube For arming, follow the reverse order of disarming.
  • Page 161 Machine Translated by Google FRONT FORK REMOVING THE FRONT FORK LEGS The following procedure is valid for both front fork legs. 1. Place the vehicle on a level surface. zontal. CAVEAT Securely support the vehicle so that it cannot fall over. 3.
  • Page 162 Machine Translated by Google FRONT FORK a. Hold the front fork leg horizontally. b. NOTICE Clamp the brake caliper bracket securely Allow the shock rod to slide slowly down in a soft-jawed vise. c. Separate the inner tube from the outer tube by pulling hard the inner tube until it protrudes from the bottom of the inner tube.
  • Page 163 Machine Translated by Google FRONT FORK 1. Install: Front fork oil seal installer • Damper rod 2. Lubricate: YSST-875 • External surface of the inner tube recommended oil ATTENTION Oil for suspensions Ya maha Check that the numbered side of the oil seal is facing up.
  • Page 164 Machine Translated by Google FRONT FORK 7. Install: 10.Before measuring the fork oil level, wait ten minutes until the oil has settled and any air • Dust seal “1” bubbles have dispersed. (with front fork oil seal driver “2”) Front fork oil seal installer Don't forget to bleed any residual air that may be left in the front fork leg.
  • Page 165 Machine Translated by Google FRONT FORK NOTE • Before installing the front fork cap bolt, lubricate the O-ring with grease. • Insert the front fork cap bolt into the inner tube and check that the cap is secure. • Temporarily tighten the cap bolt. INSTALLING THE FRONT FORK LEGS The following procedure is valid for both front fork legs.

  • Page 166: Steering Column

    Machine Translated by Google STEERING COLUMN SAS20035 STEERING COLUMN Bottom Bracket Removal 18 N·m (1.8 kgf·m, 13 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 48 N·m (4.8 kgf·m, 35 lb·ft) 18 N·m (1.8 kgf·m, 13 lb·ft) *Removing and installing the ignition lock screw with the special tool [steering lock on main switch (T-30)].
  • Page 167 Machine Translated by Google STEERING COLUMN Bottom Bracket Removal 18 N·m (1.8 kgf·m, 13 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 48 N·m (4.8 kgf·m, 35 lb·ft) 18 N·m (1.8 kgf·m, 13 lb·ft) *Removing and installing the ignition lock screw with the special tool [steering lock on main switch (T-30)]. Order Ctd.

  • Page 168: Steering Head

    Machine Translated by Google STEERING COLUMN a. Drive out the bearing races from the SAS30213 LOWER STAND REMOVAL 1. Place the steering column tube with a long rod “1” vehicle on a level surface. and a hammer. b. Remove the bearing zontal.
  • Page 169 Machine Translated by Google STEERING COLUMN 2. Install: NOTE • Lower ring nut • Temporarily tighten the steering stem bolt. Rubber washer • Upper ring nut • Lock washer 4. Install: See “CHECKING AND ADJUSTING THE • Front fork legs See “FRONT STEERING HEAD”...
  • Page 170 Machine Translated by Google REAR SHOCK ABSORBER ASSEMBLY SAS20036 REAR SHOCK ABSORBER ASSEMBLY Rear Shock Assembly Removal 44 N·m (4.4 kgf·m, 32 lb·ft) 44 N·m (4.4 kgf·m, 32 lb·ft) Order Ctd. Observations Work/parts to disassemble rear wheel See “REAR WHEEL” on page 4-14. 2/2 M10 ×...

  • Page 171: Rear Shock Absorber Assy

    Machine Translated by Google REAR SHOCK ABSORBER ASSEMBLY SAS31304 REAR SHOCK ABSORBER recommended lubricant ASSEMBLY REMOVAL 1. Place the lithium soap grease vehicle on a level surface. 2. Install: zontal. SWA13120 • Bearing CAVEAT “1” (to tie bar) • Oil seal “2” Securely support the vehicle so that it cannot fall over.
  • Page 172 Machine Translated by Google REAR SHOCK ABSORBER ASSEMBLY 2. Tighten: • Shock assembly upper nut rear Rear shock absorber assembly upper nut 44 N m (4.4 kgf m, 32 lb ft) • Tie bar nut Tie rod nut 44 N·m (4.4 kgf·m, 32 lb·ft) •...
  • Page 173 Machine Translated by Google TIPPING SAS20037 TIPPING swingarm disassembly 70 N·m (7.0 kgf·m, 52 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 16 N·m (1.6 kgf·m, 12 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft) Order Ctd. Observations Work/parts to disassemble rear wheel See “REAR WHEEL”...

  • Page 174: Swingarm Assembly 1

    Machine Translated by Google TIPPING SAS30226 SWINGARM REMOVAL 1. Place the vehicle on a level surface. zontal. SWA13120 CAVEAT Securely support the vehicle so that it cannot fall over. Place the vehicle on a suitable support so that the rear wheel does not touch the ground. 3.
  • Page 175 Machine Translated by Google TIPPING a 12 1 A. Left side B. Right side 3. Install: • Rear shock absorber assembly • Tie bar • Tie arms • Rear wheel See “REAR SHOCK ABSORBER ASSEMBLY” on page 4-58. 4. Adjust: •...

  • Page 176: Chain Drive

    Machine Translated by Google CHAIN DRIVE SAS20038 CHAIN DRIVE Disassembly of the transmission chain 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Ctd. Observations Work/parts to disassemble Loosen the drive chain adjusting locknut and wheel axle nut and push the wheel forward.

  • Page 177: Removing The Drive Chain With The Chain Cutter

    Machine Translated by Google CHAIN DRIVE SAS32683 NOTE REMOVING THE DRIVE CHAIN Check that the link pin comes out while tightening WITH THE CHAIN CUTTER 1. Place the the cap bolt. vehicle on a level surface. SAS30230 zontal. CHECKING THE DRIVE CHAIN 1. SWA13120 Measure: •...

  • Page 178: Drive Hub

    Machine Translated by Google CHAIN DRIVE SAS30233 CHECKING THE REAR WHEEL DRIVE HUB Refer to “CHECKING THE REAR WHEEL DRIVE HUB” on page 4-16. SAS32684 ASSEMBLING THE DRIVE CHAIN WITH THE CHAIN RIVETER 1. Attach the cutting tip “1” with the pressure bolt to the flange holder “2”.
  • Page 179 Machine Translated by Google CHAIN DRIVE IMPORTANT: 5. During the installation of the entrance panel "1", remember that the "side written R" must 1. Remove the special tool and measure the face out. flare of the riveted pins; should be 4.75 +0.2 mm.

  • Page 180: Cleaning And Lubrication Of The Drive Chain

    Machine Translated by Google CHAIN DRIVE gasoline, certain solvents (eg benzene) or a CLEANING AND LUBRICATION OF THE stiff brush to clean the drive chain. High- DRIVE CHAIN 1. Place the vehicle on a level pressure cleaning methods can force dirt surface.
  • Page 181 Machine Translated by Google CHAIN DRIVE 4-69...
  • Page 182 Machine Translated by Google MOTOR ENGINE DISASSEMBLY................5-1 MOUNTING THE ENGINE..................5-5 INSTALLING THE SHIFT BAR ............5-5 INSTALLING THE EXHAUST ASSEMBLY...........5-5 STOCK .........................5-7 STOCK DISASSEMBLY ............5-9 CHECKING THE STOCK..............5-10 CHECKING THE CAMSHAFT SPROCKET AND THE TIMING CHAIN GUIDE..........
  • Page 183 Machine Translated by Google CLUTCH ....................5 -39 REMOVING THE CLUTCH ..............5-43 CHECKING THE FRICTION PLATES ........5-43 CHECKING THE CLUTCH DISCS ........5-43 CHECKING THE CLUTCH SPRINGS ......5-44 CHECKING THE CLUTCH HOUSING ........5-44 CHECK THE CLUTCH BOSS ........5-44 CHECK THE PRESSURE PLATE ..........5-44 CHECK CLUTCH PUSH LEVER AND ROD CLUTCH SHORT THRUST........5-44 CHECKING THE PRIMARY DRIVE...
  • Page 184 Machine Translated by Google GEARBOX .......................5-64 CHECKING THE SHIFT FORKS......5-67 CHECKING THE SHIFT DRUM ASSEMBLY ....5-67 CHECKING THE GEARBOX ...........5-67 CHECKING THE CLUTCH PUSH RODS ........................5-68 AS...
  • Page 185 Machine Translated by Google ENGINE REMOVAL SAS20042 ENGINE REMOVAL Disassembly of the exhaust assembly 8 N·m (0.8 kgf·m, 5.9 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft) 15 N·m (1.5 kgf·m, 11 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft) Order Ctd. Observations Work/parts to disassemble Lower fairing (right) / side cover (right)
  • Page 186 Machine Translated by Google ENGINE REMOVAL Disconnecting cables and couplers Order Observations Work/parts to disassemble Ctd. ATTENTION Disconnect the negative battery cable first, then the positive. See “CHECKING AND CHARGING Negative battery cable/Positive battery cable THE BATTERY” on page 8-78. Empty.
  • Page 187 Machine Translated by Google ENGINE REMOVAL Disconnecting cables and couplers Order Ctd. Observations Work/parts to disassemble Disconnect. spark plug cap Coolant temperature sensor coupler Disconnect. Stator coil coupler/Crankshaft position sensor coupler Disconnect. Gear Shift Position Switch Coupler Disconnect. Disconnect. Side stand switch (B1P1 only) Disconnect.

  • Page 188: Motor

    Machine Translated by Google ENGINE REMOVAL engine disassembly Order Ctd. Observations Work/parts to disassemble NOTE Place a suitable support under the engine. Engine mounting bolt (front) Engine mounting bolt/nut (rear top) Engine mounting bolt/nut (lower rear) Motor For assembly, follow the reverse order of disassembly.
  • Page 189 Machine Translated by Google ENGINE REMOVAL SAS30251 NOTE ENGINE MOUNTING 1. Install: Check that the distances “a” and “b” between • Engine the center of the shift shaft “2” and the center of the shift pedal “3” are within the specified values. “1”...
  • Page 190 Machine Translated by Google ENGINE REMOVAL...
  • Page 191 See “CLUTCH” on page 5-39. See “FUEL TANK” on page 7-1. Fuel tank See “THROTTLE BODY” on page 7-4. Throttle body/intake manifold Radiator/Coolant Reservoir Pipe/Thermostat See “RADIATOR” on page 6-1. Water Pump See “WATER PUMP” on page 6-5. * YAMAHA BOND N.º 1215-B...
  • Page 192 VVA (Variable Valve Actuator) Solenoid cylinder head cover cylinder head cover gasket Clutch cable fastening timing chain tensioner Timing Chain Tensioner Gasket camshaft sprocket Decompression cam Butt head gasket For assembly, follow the reverse order of disassembly. * YAMAHA BOND N.º 1215-B...
  • Page 193 Machine Translated by Google BUTT 4. Loosen: SAS30276 HEAD REMOVAL 1. Remove: • Camshaft sprocket bolt “1” NOTE • Crankshaft end access bolt “1” and timing While holding the magneto rotor nut with a mark access bolt “2” with O-ring, using wrench “2”, loosen the camshaft sprocket bolt.
  • Page 194 Machine Translated by Google BUTT b. Measure the deformation. SAS30277 CYLINDER HEAD CHECK 1. Eliminate: c. If it exceeds the limit, reface the cylinder head as follows. d. Place 400–600 wet sandpaper on the • Accumulations of carbon in the chamber of face plate and grind the stock in a figure eight motion.
  • Page 195 Machine Translated by Google BUTT c. Without operating the release lever SAS30266 TIMING CHAIN TENSIONER CHECK 1. check that the decompression cam “2” Check: • Timing chain tensioner Cracks/ protrudes from the camshaft (exhaust damage/irregular movement ÿ Replace. cam) as shown in illustration “A”. d. a.
  • Page 196 “I” mark “c” on the camshaft sprocket with a. Apply sealant to the threads of the timing chain tensioner bolt. the “d” mark on the camshaft stopper plate. Yamaha bond n.º 1215 90890-85505 (Three Bond Nº 1215-B) d. Install the timing chain on the camshaft sprocket, and then install the sprocket on the camshaft.
  • Page 197 Machine Translated by Google BUTT 7. Tighten: • Camshaft sprocket bolt Camshaft sprocket bolt 30 N m (3.0 kgf m, 22 lb ft) SCA20610 NOTICE Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibility of it coming loose and causing engine damage.
  • Page 198 Machine Translated by Google CAMSHAFT SAS20043 CAMSHAFT Remove rocker arms and camshaft 7 N•m (0.7 kgf•m, 5.2 lb•ft) 13 12 8 N•m (0.8 kgf•m, 5.9 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft) Order Ctd. Observations Work/parts to disassemble cylinder head cover See “STOCK”...

  • Page 199: Camshaft

    Machine Translated by Google CAMSHAFT SAS30256 SAS30257 CAMSHAFT REMOVAL 1. Loosen: CAMSHAFT CHECK 1. Check: • • Lock nut “1” • Valve clearance Camshaft lobes Blue discoloration/pitting/ adjusting screw “2” (intake/exhaust) scratches ÿ Replace the camshaft. Measure: • Dimensions of the camshaft lobes “a”...
  • Page 200 Machine Translated by Google CAMSHAFT SAS30259 CHECKING THE ROCKERS AND ROCKER Measure: • Rocker arm shaft outer diameter “a” SHAFTS The following procedure applies to all Out of specification ÿ Change. rockers and rocker shafts. Rocker arm shaft outer diameter 1.
  • Page 201 Machine Translated by Google CAMSHAFT SAS30270 CAMSHAFT AND ROCKER ARM ASSEMBLY 1. Lubricate: • Camshaft assembly O-ring recommended lubricant camshaft o-ring Molybde Disulfide Oil camshaft bearing engine oil 2. Lubricate: Check that the bearing puller is centered over the camshaft •...
  • Page 202 Machine Translated by Google CAMSHAFT b. While pushing the intake rocker arm 1 “2” and intake rocker arm 2 “3” in the direction of the arrow shown in the illustration, install the intake shaft assembly. your. Install the camshaft with the perforated mark “a”...

  • Page 203: Valves And Valve Springs

    Machine Translated by Google VALVES AND VALVE SPRINGS SAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Ctd. Observations Work/parts to disassemble Butt See “STOCK” on page 5-7. Rocker arms/camshaft See “CAMSHAFT” on page 5-14. valve key top spring seat valve spring Admission valve...
  • Page 204 Machine Translated by Google VALVES AND VALVE SPRINGS SAS30283 VALVE DISASSEMBLY The following procedure is valid for all valves and related components. Before removing the internal parts of the cylinder head (for example, valves, valve springs and valve seats), check that the valves close tightly. 1.

  • Page 205: Valve Seats

    Machine Translated by Google VALVES AND VALVE SPRINGS Rod-to-guide clearance (intake) Valve stem runout 0.010 mm (0.0004 in) 0.010–0.037 mm (0.0004–0.0015 Limit 0.080 mm (0.0032 in) Stem-to-guide clearance (es cape) 0.025–0.052 mm (0.0010– 0.0020 in) Limit 0.100 mm (0.0039 in) SAS30285 CHECKING THE VALVE SEATS The following procedure is valid for all valves...
  • Page 206 Machine Translated by Google VALVES AND VALVE SPRINGS c. Install the valve in the cylinder b. Install the valve in the cylinder head. d. Turn the valve until the front and the head. c. Push the valve through the guide seat are polished evenly, then remove all and onto the seat so that the impression is lapping compound.

  • Page 207: Springs

    Machine Translated by Google VALVES AND VALVE SPRINGS 2. Lubricate: SAS30286 CHECKING THE VALVE SPRINGS The • Valve stem “1” • Valve following procedure is valid for all valve stem seal “2” springs. (with recommended lubricant) recommended lubricant Molybde Disulfide Oil Measure: •...
  • Page 208 Machine Translated by Google VALVES AND VALVE SPRINGS b. minor step 4. Install: • Valve cotters “1” Install the valve cotters by compressing the spring with the valve spring compressor and adapter “2”. valve spring compressor YSST-603 (90890-04109) Valve Spring Compressor Adapter YSST-603 A 5.

  • Page 209: Cylinder And Piston

    Machine Translated by Google CYLINDER AND PISTON SAS20046 CYLINDER AND PISTON Cylinder and Piston Disassembly 10 N•m (1.0 kgf•m, 7.4 lb•ft) Order Ctd. Observations Work/parts to disassemble Butt See “STOCK” on page 5-7. Cylinder cylinder gasket centering pin piston pin clip piston pin Piston Aro superior...

  • Page 210: Removing The Piston 1

    Machine Translated by Google CYLINDER AND PISTON SAS30289 SAS30291 REMOVING THE PISTON 1. CHECKING THE CYLINDER AND PISTON 1. Check: • Piston wall • Cylinder wall Remove: • Piston Pin Clips “1” • Piston Pin “2” • Piston “3” Vertical scratches ÿ Replace the cylinder and SCA13810 replace the piston and ring assembly.
  • Page 211 Machine Translated by Google CYLINDER AND PISTON Piston rings Top ring Ring side clearance 0.030–0.065 mm (0.0012– 0.0026 in) Side clearance limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) b. 5.0 mm (0.20 in) from the bottom edge of the Side clearance limit 0.115 mm piston (0.0045 in)

  • Page 212: Installing The Piston And Cylinder

    Machine Translated by Google CYLINDER AND PISTON Piston Hoops Top Hoop Distance Between Piston Hoop Ends 0.10–0.25 mm (0.0039– 0.0098 in) Piston ring end gap limit 0.50 mm (0.0197 in) 2nd ring Piston ring end gap 0.35–0.50 mm (0.0138–0.0197 in) 4.
  • Page 213 Machine Translated by Google CYLINDER AND PISTON 5. Install: • Before installing the piston pin clips, cover the crankcase opening with a clean cloth to prevent the clips from • Centering pins • Cylinder gasket falling into the crankcase. • When attaching the snap ring, •...

  • Page 214: Magneto And Starting Clutch

    Machine Translated by Google MAGNETO AND STARTING CLUTCH SAS20140 MAGNETO AND STARTING CLUTCH Disassembly of the starter magneto and clutch 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 70 N·m (7.0 kgf·m, 52 lb·ft) Order Ctd.
  • Page 215 Machine Translated by Google MAGNETO AND STARTING CLUTCH Disassembly of the starter magneto and clutch 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 14 N·m (1.4 kgf·m, 10 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 70 N·m (7.0 kgf·m, 52 lb·ft) Order Ctd.

  • Page 216: Removing The Magneto 1

    Machine Translated by Google MAGNETO AND STARTING CLUTCH SAS30867 REMOVING THE MAGNETO 1. Remove: • Magneto rotor nut “1” • Washer NOTE • While holding the magneto rotor “2” with the magneto holder “3”, loosen the magneto rotor nut. • Keep the magnet holder from touching the rotor boss.
  • Page 217 Machine Translated by Google MAGNETO AND STARTING CLUTCH 2. Check: • Starter clutch idle gear • Starter clutch gear Burrs/chips/roughness/wear ÿ Replace the defective parts. 3. Check: • Contact surfaces of starter clutch gear Damage/pitting/wear ÿ Replace the starter clutch gear. 4.
  • Page 218 Machine Translated by Google MAGNETO AND STARTING CLUTCH 3. Apply: • Sealer (at crankshaft/stator position sensor lead insulator) Yamaha bond n.º 1215 90890-85505 (Three Bond Nº 1215-B) 4. Install: • Magnet cover Magneto cover bolt 10 N m (1.0 kgf m, 7.4 lb ft) Tighten the magneto cover bolts in the proper sequence, as shown.

  • Page 219: Electrical Start

    Machine Translated by Google ELECTRICAL START SAS20052 ELECTRICAL START Disassembly of the starter motor 10 N·m (1.0 kgf·m, 7.4 lb·ft) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) Order Ctd. Observations Work/parts to disassemble Driver's seat/side panels/side covers See “GENERAL CHASSIS” on page 4-1. Starting motor Disconnect.
  • Page 220 Machine Translated by Google ELECTRICAL START starter motor disassembly Order Ctd. Observations Work/parts to disassemble o-ring starter motor linkage yoke Council Collector Starter front cover/brush holder assembly Brush brush spring For assembly, follow the reverse order of disassembly. 5-36...
  • Page 221 Machine Translated by Google ELECTRICAL START SAS30325 STARTER MOTOR CHECK 1. Check: • multimeter Collector Dirt ÿ Clean with 600 sandpaper. INS-003 (90890-03189) b. If there is no connectivity, change the starter 2. Measure: motor. • Manifold diameter “a” Out of specification ÿ Replace the starter motor. Manifold limit diameter 16.6 mm (0.65 in) 1.
  • Page 222 Machine Translated by Google ELECTRICAL START • Oil seal Damage/wear ÿ Replace the starter motor front cover/brush holder assembly. SAS30326 STARTER MOTOR ASSEMBLY 1. Install: • Starter motor front cover/with brush holder assembly “1” • Starter motor linkage yoke “2” NOTE Align the marks “a”...
  • Page 223 Machine Translated by Google CLUTCH SAS20055 CLUTCH Clutch cover removal 7 N·m (0.7 kgf·m, 5.2 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Ctd. Observations Work/parts to disassemble Empty. engine oil See “CHANGING ENGINE OIL” on page 3-12. Lower side fairing (right) See “GENERAL CHASSIS”...
  • Page 224 Machine Translated by Google CLUTCH Clutch disassembly 70 N·m (7.0 kgf·m, 52 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) Order Ctd. Observations Work/parts to disassemble Locknut pressure plate 1 clutch spring pressure plate 2 Short Clutch Push Rod Clutch push rod holder She was Long Clutch Push Rod Friction disc 1 (black - smaller width)
  • Page 225 Machine Translated by Google CLUTCH Clutch disassembly 70 N·m (7.0 kgf·m, 52 lb·ft) 12 N·m (1.2 kgf·m, 8.9 lb·ft) Order Ctd. Observations Work/parts to disassemble lock washer Clutch Highlight pressure washer Clutch box Conical spring washer For assembly, follow the reverse order of disassembly. 5-41...
  • Page 226 Machine Translated by Google CLUTCH Push Lever Disassembly Order Ctd. Observations Work/parts to disassemble Clutch push lever Clutch push lever spring Elastic ring oil seal Bearing For assembly, follow the reverse order of disassembly. 5-42...
  • Page 227 Machine Translated by Google CLUTCH SAS30346 CLUTCH REMOVAL 1. Straighten the tab on the lock washer. ridity. 2. Loosen: • Clutch projection nut “1” NOTE While holding the clutch boss “2” with the clutch hub holder “3”, loosen the boss nut. A.
  • Page 228 Machine Translated by Google CLUTCH Clutch Disc Thickness 1 2.18– NOTE Pitting of the clutch housing slippers 2.42 mm (0.085–0.095 in) will cause erratic clutch operation. Deformation limit 0.10 mm (0.0039 in) Clutch disc thickness 2 2.20–2.40 mm (0.086–0.094 in) Deformation limit 0.10 mm (0.0039 in) 2.

  • Page 229: Gear

    Machine Translated by Google CLUTCH • Pressure washer “1” SAS30356 PRIMARY DRIVE GEAR CHECK 1. NOTE Remove: • Primary drive gear Check that the angle with the sharp edge of the lock washer “a” is located on the opposite See “BALANCER GEAR” on page 5-52. side of the clutch boss.
  • Page 230 Machine Translated by Google CLUTCH 11.Install: • Long push rod • Ball 12.Install: • Pressure plate • Clutch springs “1” • Clutch spring bolts “2” Clutch Spring Bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) 5. Bend the tab of the lock washer along a flat side of the nut.
  • Page 231 Machine Translated by Google CLUTCH 14.Install: 16.Adjust: • Clutch cover oil seal “1” (with the help of the • Clutch cable free play bearing punch and the appropriate shim) See “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13. Oil seal installed depth “a” 1.4–1.9 mm (0.055–0.075 in) bearing punch YSST-951...

  • Page 232: Oil Pump

    Machine Translated by Google OIL PUMP SAS20054 OIL PUMP Disassembly of the oil pump 4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft) Order Observations Ctd. Work/parts to disassemble Clutch box See “CLUTCH” on page 5-39. See “BALANCER GEAR” on page 5-52. Balancer Drive Gear oil baffle plate oil pump assembly...
  • Page 233 Machine Translated by Google OIL PUMP SAS30337 OIL PUMP CHECK 1. Check: • Oil pump drive gear • Oil pump driven gear • Oil pump case cover Cracks/ damage/wear ÿ Replace the defective parts. 2. Check: • Oil pump operation Rough movement ÿ Replace SAS30343 OIL PUMP INSTALLATION 1.

  • Page 234: Axis Of Change

    Machine Translated by Google AXIS OF CHANGE SAS20057 AXIS OF CHANGE Removing the shift shaft and stopper lever 10 N•m (1.0 kgf•m, 7.4 lb•ft) Order Ctd. Observations Work/parts to disassemble Clutch box See “CLUTCH” on page 5-39. See “ENGINE REMOVAL” on page 5-1. shift pedal axis of change Elastic ring...
  • Page 235 Machine Translated by Google AXIS OF CHANGE SAS30377 SHIFT SHAFT CHECK 1. Check: • Shift shaft Warpage/damage/wear ÿ Replace. • Shift shaft spring Damage/wear ÿ Replace. SAS30378 STOPPER LEVER CHECK 1. Check: • Stopper lever Warpage/damage ÿ Replace. 3. Tighten the stopper lever bolt “1”. NOTE Apply sealant (LOCTITE®) to the bolt thread of The roller rotates irregularly ÿ...

  • Page 236: Balancer Gear

    Machine Translated by Google BALANCER GEAR SAS20219 BALANCER GEAR Disassembly of primary drive gear and balancer gears 60 N·m (6.0 kgf·m, 44 lb·ft) 35 N·m (3.5 kgf·m, 26 lb·ft) Order Ctd. Observations Work/parts to disassemble Clutch box See “CLUTCH” on page 5-39. Primary drive gear nut Balancer Driven Gear Nut Washer...

  • Page 237: Balancer Gears

    Machine Translated by Google BALANCER GEAR ASSEMBLY BALANCER DRIVE GEAR 1. SAS32459 PRIMARY DRIVE GEAR AND Assemble: • Stop boss “1” • Balancer Driven BALANCER GEARS REMOVAL 1. Gear “2” Loosen: • Primary drive gear nut “1” NOTE NOTE Align the punch mark “a” on the stopper boss Place the aluminum plate “a”...
  • Page 238 Machine Translated by Google BALANCER GEAR 2. Tighten: • Trim tab driven gear nut “1” • Primary drive gear nut “2” Balancer Drive Gear Nut 35 N m (3.5 kgf m, 26 lb ft) Primary drive gear nut 60 N m (6.0 kgf m, 44 lb ft) •...

  • Page 239: Crankcase Separation

    Machine Translated by Google SUMP SAS20059 SUMP Crankcase Separation Order Observations Ctd. Work/parts to disassemble See “ENGINE REMOVAL” on page 5-1. Motor Butt See “STOCK” on page 5-7. See “CYLINDER AND PISTON” on p Cylinder/Piston 5-25. Clutch box See “CLUTCH” on page 5-39. See “OIL PUMP”...
  • Page 240 Machine Translated by Google SUMP Crankcase Separation 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Ctd.
  • Page 241 Machine Translated by Google SUMP Removing the oil seal and bearings 7 N•m (0.7 kgf•m, 5.2 lb•ft) Order Observations Ctd. Work/parts to disassemble Crankshaft/Compensator See “CRANKSHAFT” on page 5-61. Gearbox See “GEARBOX” on page 5-64. oil seal bearing retainer Bearing For assembly, follow the reverse order of disassembly.
  • Page 242 Machine Translated by Google SUMP SAS32673 SCA13900 SEPARATION OF THE CAUTION CRANKCASE 1. Remove: • Strike one side of the crankcase with a soft Crankcase bolts mallet. Strike only the reinforced parts of the NOTE crankcase, not the contact surfaces. Proceed Loosen all bolts 1/4 turn at a time, in stages and slowly and carefully and check that the in a zigzag pattern.

  • Page 243: Crankcase Assembly

    Machine Translated by Google SUMP • Compensator bearing (with SAS31766 BEARINGS AND OIL SEAL CHECK 1. Check: • the help of the bearing punch and the Bearings Clean and grease the bearings, and then appropriate shim “1”) rotate the inner race with your finger. bearing punch YSST-951 Irregular movement ÿ...
  • Page 244 • M6 × 55 mm: “15”, “16” • 2. Apply: • M6 × 45 mm: “1–6”, “11” Sealer (to crankcase mating surfaces) Yamaha bond n.º 1215 90890-85505 (Three Bond Nº 1215-B) 2,13 Avoid contact of the sealant with the oil passage.

  • Page 245: Crankshaft

    Machine Translated by Google CRANKSHAFT SAS20061 CRANKSHAFT Remove the crankshaft and compensator Order Ctd. Observations Work/parts to disassemble Pull apart. Sump See “CRANKCASE” on page 5-55. compensator Crankshaft For assembly, follow the reverse order of disassembly. 5-61...

  • Page 246: Removing The Crankshaft

    Machine Translated by Google CRANKSHAFT SAS30416 REMOVING THE CRANKSHAFT Measure: • Crankshaft 1. Extract: • Crankshaft “1” width Out of specification ÿ Replace the crankshaft. NOTE Width of crankshaft assembly • Remove the crankshaft with the crankcase spacer. 47.95–48.00 mm (1.888–1.890 in) have "2".
  • Page 247 Machine Translated by Google CRANKSHAFT NOTE Hold the connecting rod at TDC with one hand while turning the crankshaft journal bolt nut with the other hand. Turn the crankshaft driver bolt until it bottoms out in the bearing. 5-63...
  • Page 248 Machine Translated by Google GEARBOX SAS20062 GEARBOX Removing the gearbox, shift drum assembly and shift forks Order Ctd. Observations Work/parts to disassemble Pull apart. Sump See “CRANKCASE” on page 5-55. shift fork guide bar Dock shift drum assembly Deadpoint Dock shift fork R shift fork C shift fork L...
  • Page 249 Machine Translated by Google GEARBOX Disassembly of the main shaft Order Ctd. Observations Work/parts to disassemble 2nd gear 6th gear 3rd/4th gear Elastic ring toothed washer 5th gear Mainshaft/1st gear For assembly, follow the reverse order of disassembly. 5-65...
  • Page 250 Machine Translated by Google GEARBOX Rear axle disassembly Order Ctd. Observations Work/parts to disassemble Elastic ring Washer 2nd gear 6th gear Washer 1st gear spacer 5th gear Elastic ring toothed washer 4th gear 3rd gear rear axle For assembly, follow the reverse order of disassembly. 5-66...
  • Page 251 Machine Translated by Google GEARBOX SAS30431 SAS30432 SHIFT DRUM ASSEMBLY CHECK 1. CHECKING THE SHIFT FORKS The following procedure applies to all shift forks. Check: • Shift drum groove 1. Check: • Damage/scratches/wear ÿ Replace the Shift fork cam pin shift drum assembly.
  • Page 252 Machine Translated by Google GEARBOX SAS30435 ASSEMBLY OF MAIN SHAFT AND REAR SHAFT 1. Install: • Toothed washer “1” • Snap ring “2” • The snap ring must be positioned so that the sharp edge “a” faces away from the toothed washer and gear. • Check that the end of the snap ring “b”...
  • Page 253 Machine Translated by Google GEARBOX NOTE The stamped marks on the shift forks should face the right side of the engine and in the following sequence: “R”, “C”, “L”. 2. Check: • Gearbox Irregular movement ÿ Repair. • Apply engine oil to all gears and bearings. • Before assembling the crankcase, check that the gear is in neutral and that the gears rotate freely.
  • Page 254 Machine Translated by Google COOLING SYSTEM RADIATOR........................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR ..............6-3 THERMOSTAT....................6-4 CHECKING THE THERMOSTAT ASSEMBLY......6-4 INSTALLING THE THERMOSTAT ASSEMBLY...........6-4 WATER PUMP....................6-5 DISASSEMBLY OF THE PUMP OF WATER..........6-7 CHECKING THE WATER PUMP ..........6-7 ASSEMBLY OF THE WATER PUMP ..........
  • Page 255 Machine Translated by Google RADIATOR SAS20063 RADIATOR radiator removal 9 N·m (0.9 kgf·m, 6.6 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) Order Observations Ctd. Work/parts to disassemble Empty. See “CHANGING THE COOLANT” on page Soda 3-17.
  • Page 256 Machine Translated by Google RADIATOR radiator removal 9 N·m (0.9 kgf·m, 6.6 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Ctd. Observations Work/parts to disassemble radiator cap Radiator Radiator cap radiator fan Thermostat...
  • Page 257 Machine Translated by Google RADIATOR SAS30439 RADIATOR CHECK 1. Check: • Radiator fins Obstruction ÿ Clean. Apply compressed air to the back of the radiator. Damage ÿ Repair or replace. Straighten crooked fins with a fine flathead screwdriver. b. Apply the specified pressure for ten seconds and verify that there is no drop in pressure.
  • Page 258 Machine Translated by Google THERMOSTAT SAS20065 THERMOSTAT SAS31248 THERMOSTAT ASSEMBLY CHECK 1. Check: • Thermostat “1” 0.5 mm 7 mm (0.02 in) Does not open at 74–78 °C (165–172 °F) ÿ (0.28 in) Change. 74 – 78ÿC 90ÿC (165 – 172ÿF) (194ÿF) A.
  • Page 259 Machine Translated by Google WATER PUMP SAS20066 WATER PUMP Disassembly of the water pump 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Observations Ctd. Work/parts to disassemble It is not necessary to remove the water pump, unless the coolant level is extremely low or the coolant contains engine oil.
  • Page 260 Machine Translated by Google WATER PUMP Disassembly of the water pump 10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Order Ctd. Observations Work/parts to disassemble o-ring radiator support Water pump housing cover Water pump housing cover gasket Elastic ring rotor shaft water pump gasket...
  • Page 261 Machine Translated by Google WATER PUMP SAS30446 DISASSEMBLY OF THE WATER PUMP 1. Extract: • Water pump gasket “1” Remove the water pump gasket from the inside of the pump case “2”. A. Press down 3. Mechanical seal driver 4. Intermediate driven shaft bearing driver SAS30447 WATER PUMP CHECK 1.
  • Page 262 Machine Translated by Google WATER PUMP Water pump assembly bolt 10 N m (1.0 kgf m, 7.4 lb ft) NOTE • Align the projection “a” on the rotor shaft with the slot “b” on the camshaft sprocket bolt. • Lubricate the O-ring with a thin layer of lithium soap grease.
  • Page 263 Machine Translated by Google WATER PUMP...
  • Page 264 Machine Translated by Google FUEL INJECTION SYSTEM FUEL TANK .................7-1 REMOVING THE FUEL TANK..........7-2 REMOVING THE FUEL PUMP........7-2 CHECKING THE FUEL PUMP BODY........................7-2 INSTALLING THE FUEL PUMP ASSEMBLY ....7-2 INSTALLING THE FUEL TANK.............7-3 CHECKING THE FUEL PRESSURE ........7- 3 BUTTERFLY BODY..........
  • Page 265 Machine Translated by Google FUEL TANK SAS20067 FUEL TANK Removing the fuel tank and pump 1.8 N.m (0.18 kgf.m, 1.3 lb. ft) 10 N.m (1.0 kgf.m, 7.4 lb.ft) 10 N.m (1.0 kgf.m, 7.4 lb.ft) 4.5 N.m (0.45 kgf.m, 3.3 lb.ft) 6 N.m (0.6 kgf.m, 4.4 lb.ft) 25 N.m (2.5 kgf.m, 18 lb.ft) 7 N.m (0.7 kgf.m, 5.2 lb.ft)
  • Page 266 Machine Translated by Google FUEL TANK SAS26630 SAS26640 FUEL TANK REMOVAL 1. Using a pump, FUEL PUMP REMOVAL 1. Remove: • Fuel pump retainer • Fuel pump • Fuel pump draw the fuel out of the fuel tank cap. gasket 2.
  • Page 267 Machine Translated by Google FUEL TANK SCA3C11005 b. Tilt the fuel tank. c. Disconnect the pipe “1” FUEL TANK INSTALLATION 1. Install: from the fuel pump “2”. • Fuel tank 2. Connect: • Fuel pipe SWA3C11008 CAVEAT When you uncouple the fuel pipes, cover the SCA3C11005 connections with a rag.
  • Page 268 Machine Translated by Google BUTTERFLY BODY SAS20070 BUTTERFLY BODY Disassembly of the throttle body Order Observations Work/parts to disassemble Ctd. See “FUEL TANK” on page 7-1. Fuel tank air filter box See “GENERAL CHASSIS” on page 4-1. Disconnect. fuel pipe fuel injector cap Disconnect.
  • Page 269 Machine Translated by Google BUTTERFLY BODY Disassembly of the throttle body Order Ctd. Observations Work/parts to disassemble Disconnect. Throttle cable (acceleration) Disconnect. Throttle cable (deceleration) SCA22690 ATTENTION butterfly body The body of the butterfly should not be des arms. Intake manifold intake manifold gasket...
  • Page 270 Machine Translated by Google BUTTERFLY BODY SAS3C11025 SAS3C11028 THROTTLE BODY REMOVAL 1. FUEL INJECTOR CHECK 1. Check: • Using a pump, draw the fuel out of the Fuel injector Damage ÿ Replace. fuel tank filler hole. 2. Disconnect: • fuel pipe FUEL INJECTOR INSTALLATION CAVEAT...
  • Page 271 “1” at the end of the pipe in the direction of the arrow shown. 4. Check: • Engine idling speed • Sensor assembly • Throttle body with Yamaha scan tool Ya maha diagnostic tool INS-018 (90890-03256) INS-019...
  • Page 272 TABLE OF SELF-DIAGNOSTIC FUNCTIONS AND DIAGNOSTIC CODES.....................8-47 CHART OF SELF-DIAGNOSTIC FUNCTIONS........8-47 DIAGNOSTIC CODE: SENSOR OPERATION CHART.......................8-47 DIAGNOSTIC CODE: ACTUATORS OPERATION CHART ......................8-49 TABLE OF INCIDENT CODES..............8-50 YAMAHA DIAGNOSTIC TOOL ..........8 -51 TROUBLESHOOTING DETAILS .............8-51...
  • Page 273 Machine Translated by Google FUEL PUMP SYSTEM ..............8 -71 ELECTRICAL DIAGRAM (B1P1)..............8-71 ELECTRICAL DIAGRAM (B2P1)............8-73 TROUBLESHOOTING................8-75 ELECTRIC COMPONENTS..............8-76 CHECKING THE SWITCHES..........8-77 CHECKING THE FUSES ............8-78 CHECK AND CHARGE THE BATTERY........8-78 CHECK THE RELAYS ........
  • Page 274 Machine Translated by Google...

  • Page 275: Ignition System

    Machine Translated by Google IGNITION SYSTEM SAS20072 IGNITION SYSTEM SAS30490 ELECTRICAL DIAGRAM (B1P1)
  • Page 276 Machine Translated by Google IGNITION SYSTEM IGNITION SYSTEM (B1P1) 1. Crankshaft Position Sensor 4. Fuse Box 6. Main Fuse 8. Battery 9. Engine ground 10. Main switch 13. Handlebar switch (right) 15. Engine stop switch 23. ECU (engine control unit) 24.

  • Page 277: Electrical Diagram (B2P1)

    Machine Translated by Google IGNITION SYSTEM SAS30490 ELECTRICAL DIAGRAM (B2P1)
  • Page 278 Machine Translated by Google IGNITION SYSTEM IGNITION SYSTEM (B2P1) 1. Crankshaft Position Sensor 4. Fuse Box 6. Main Fuse 8. Battery 9. Engine ground 10. Main switch 13. Handlebar switch (right) 15. Engine stop switch 23. ECU (engine control unit) 24.
  • Page 279 Machine Translated by Google IGNITION SYSTEM SAS30492 TROUBLESHOOTING Ignition system does not work (no spark or intermittent spark). NOTE • Before troubleshooting, remove the following parts: 1. Rider's seat 2. Top panel (right and left) 3. Side panel (right and left) 4.
  • Page 280 Machine Translated by Google IGNITION SYSTEM 8. Check the main switch. incorrect ÿ See “CHECKING THE Change the main switch. SWITCHES” on page 8-77. correct ÿ incorrect ÿ 9. Check the engine stop switch. The engine stop switch is faulty. Change See “CHECKING THE the right handlebar switch.

  • Page 281: Electric Starting System

    Machine Translated by Google ELECTRIC STARTING SYSTEM SAS20073 ELECTRIC STARTING SYSTEM SAS30493 ELECTRICAL DIAGRAM (B1P1)
  • Page 282 Machine Translated by Google ELECTRIC STARTING SYSTEM STARTING SYSTEM (B1P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 11. Starter relay 12. Starter motor 13. Handlebar switch (right) 14. Starter switch 15. Engine stop switch 16.

  • Page 283: Electrical Diagram (B2P1)

    Machine Translated by Google ELECTRIC STARTING SYSTEM SAS30493 ELECTRICAL DIAGRAM (B2P1)
  • Page 284 Machine Translated by Google ELECTRIC STARTING SYSTEM STARTING SYSTEM (B2P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 11. Starter relay 12. Starter motor 13. Handlebar switch (right) 14. Starter switch 15. Engine stop switch 16. Diode 1 35.

  • Page 285: Operation Of The Starting Circuit Cut-Off System (B1P1)

    Machine Translated by Google ELECTRIC STARTING SYSTEM SAS30494 OPERATION OF THE STARTING CIRCUIT CUT-OFF SYSTEM (B1P1) “ ” If the engine stop switch is on and the main switch is “ON” (both switches closed), the starter motor will only operate if at least one of the following conditions is met: • The gear is in neutral (the gearbox is in neutral) . neutral switch is closed), the clutch lever is pulled toward the handlebar (clutch switch is closed), and the sidestand is up (sidestand switch is closed).
  • Page 286 Machine Translated by Google ELECTRIC STARTING SYSTEM SAS30494 OPERATION OF THE STARTING CIRCUIT CUT-OFF SYSTEM (B2P1) “ ” If the engine stop switch is on and the main switch is “ON” (both switches closed), the starter motor will only operate if at least one of the following conditions is met: • The gear is in neutral (the gearbox is in neutral) . neutral switch is closed).
  • Page 287 Machine Translated by Google ELECTRIC STARTING SYSTEM SAS30495 TROUBLESHOOTING Starter does not turn. NOTE • Before troubleshooting, remove the following parts: 1. Rider's seat 2. Top panel (right and left) 3. Side panel (right and left) 4. Side cover (right and left) 5.
  • Page 288 Machine Translated by Google ELECTRIC STARTING SYSTEM incorrect ÿ 8. Check point switch dead. See “CHECKING THE SWITCHES” Change the neutral switch. on page 8-77. correct ÿ 9. Check side stand switch (B1P1). incorrect ÿ See “CHECKING THE SWITCHES” Replace side stand switch. on page 8-77.

  • Page 289: Charging System

    Machine Translated by Google CHARGING SYSTEM SAS20074 CHARGING SYSTEM SAS30496 ELECTRICAL DIAGRAM (B1P1) 8-15...
  • Page 290 Machine Translated by Google CHARGING SYSTEM LOADING SYSTEM (B1P1) 2. Magneto CA 3. Rectifier/Regulator 4. Fuse Box 6. Main Fuse 8. Battery 9. Engine ground 8-16...

  • Page 291: Electrical Diagram (B2P1)

    Machine Translated by Google CHARGING SYSTEM SAS30496 ELECTRICAL DIAGRAM (B2P1) 8-17...
  • Page 292 Machine Translated by Google CHARGING SYSTEM LOADING SYSTEM (B2P1) 2. Magneto CA 3. Rectifier/Regulator 4. Fuse Box 6. Main Fuse 8. Battery 9. Engine ground 8-18...
  • Page 293 Machine Translated by Google CHARGING SYSTEM SAS30497 TROUBLESHOOTING Battery does not charge. NOTE • Before troubleshooting, remove the following parts: 1. Rider's seat 2. Top panel (left) 3. Side panel (left) 4. Side cover (left) 1. Check the fuse. incorrect ÿ (Principal) Change the fuse.
  • Page 294 Machine Translated by Google CHARGING SYSTEM 8-20...

  • Page 295: Lighting System

    Machine Translated by Google LIGHTING SYSTEM SAS20075 LIGHTING SYSTEM SAS30498 ELECTRICAL DIAGRAM (B1P1) 8-21...
  • Page 296 Machine Translated by Google LIGHTING SYSTEM LIGHTING SYSTEM (B1P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 23. ECU (engine control unit) 35. Connection 2 36. Connection 1 41. Handlebar switch (left) 42. Light switch and flash switch 48. Instrument cluster 51. Instrument light 53.

  • Page 297: Diagram (B2P1)

    Machine Translated by Google LIGHTING SYSTEM SAS30498 ELECTRICAL DIAGRAM (B2P1) 8-23...
  • Page 298 Machine Translated by Google LIGHTING SYSTEM LIGHTING SYSTEM (B2P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 23. ECU (engine control unit) 35. Connection 2 36. Connection 1 41. Handlebar switch (left) 42. Light switch and flash switch 48. Instrument cluster 51. Instrument light 53.
  • Page 299 Machine Translated by Google LIGHTING SYSTEM SAS30499 TROUBLESHOOTING Any of the following lights do not come on: headlights, high beam indicator, taillight, license plate light, front position light, or instrument lights. NOTE • Before troubleshooting, remove the following parts: 1. Rider and passenger seat 2.
  • Page 300 Machine Translated by Google LIGHTING SYSTEM 7. Check the wiring of the entire incorrect ÿ lighting system. See “WIRING DIAGRAM Correctly connect or change the wire harness. (B1P1)” on page 8-21 or “WIRING DIAGRAM (B2P1)” on page 8-23. correct ÿ Replace ECU, instrument cluster or tail/brake light assembly.

  • Page 301: Signaling System

    Machine Translated by Google SIGNALING SYSTEM SAS20076 SIGNALING SYSTEM SAS30500 ELECTRICAL DIAGRAM (B1P1) 8-27...
  • Page 302 Machine Translated by Google SIGNALING SYSTEM SIGNALING SYSTEM (B1P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 22. Speed sensor 23. ECU (engine control unit) 32. Fuel gauge 35. Connection 2 36. Connection 1 37.
  • Page 303 Machine Translated by Google SIGNALING SYSTEM SAS30500 ELECTRICAL DIAGRAM (B2P1) 8-29...
  • Page 304 Machine Translated by Google SIGNALING SYSTEM SIGNALING SYSTEM (B2P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 22. Speed sensor 23. ECU (engine control unit) 32. Fuel gauge 35. Connection 2 36. Connection 1 37.
  • Page 305 Machine Translated by Google SIGNALING SYSTEM SAS30501 TROUBLESHOOTING • Any of the following lights do not come on: turn signals, brake light, or indicator lights. • The horn does not sound. • The fuel level indicator does not work. • The speedometer does not work. NOTE •...
  • Page 306 Machine Translated by Google SIGNALING SYSTEM 2. Check the wiring of the entire incorrect ÿ signaling system. Correctly connect or change the wire harness. See “WIRING DIAGRAM (B1P1)” on page 8-27 or “WIRING DIAGRAM (B2P1)” on page 8-29. correct ÿ This circuit is correct.
  • Page 307 Machine Translated by Google SIGNALING SYSTEM incorrect ÿ 4. Check the wiring of the entire signaling system. Correctly connect or change the wire harness. See “WIRING DIAGRAM (B1P1)” on page 8-27 or “WIRING DIAGRAM (B2P1)” on page 8-29. correct ÿ Change instrument cluster.
  • Page 308 Machine Translated by Google SIGNALING SYSTEM 2. Check the wiring of the entire incorrect ÿ signaling system. See “WIRING DIAGRAM Correctly connect or change the wire harness. (B1P1)” on page 8-27 or “WIRING DIAGRAM (B2P1)” on page 8-29. correct ÿ Replace ECU or instrument cluster.

  • Page 309: Refrigeration System

    Machine Translated by Google REFRIGERATION SYSTEM SAS20077 REFRIGERATION SYSTEM SAS30502 ELECTRICAL DIAGRAM (B1P1) 8-35...
  • Page 310 Machine Translated by Google REFRIGERATION SYSTEM COOLING SYSTEM (B1P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 23. ECU (engine control unit) 28. Coolant temperature sensor 35. Connection 2 36. Connection 1 46. Radiator fan motor relay 47.
  • Page 311 Machine Translated by Google REFRIGERATION SYSTEM SAS30502 ELECTRICAL DIAGRAM (B2P1) 8-37...
  • Page 312 Machine Translated by Google REFRIGERATION SYSTEM COOLING SYSTEM (B2P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 23. ECU (engine control unit) 28. Coolant temperature sensor 35. Connection 2 36. Connection 1 46. Radiator fan motor relay 47.
  • Page 313 Machine Translated by Google REFRIGERATION SYSTEM SAS30503 TROUBLESHOOTING NOTE • Before troubleshooting, remove the following parts: 1. Rider and passenger seat 2. Side covers (left and right) 3. Front panels (left and right) 4. Front covers (left and right) incorrect ÿ 1.
  • Page 314 Machine Translated by Google REFRIGERATION SYSTEM 8-40...

  • Page 315: Fuel Injection System

    Machine Translated by Google FUEL INJECTION SYSTEM SAS20078 FUEL INJECTION SYSTEM SAS30504 ELECTRICAL DIAGRAM (B1P1) 8-41...
  • Page 316 Engine stop switch 17. Throttle body sensor assembly 18. Intake air pressure assembly 19. Intake air temperature sensor 20. Throttle position sensor 21. Coupler Yamaha diagnostic tool 22. Speed sensor 23. ECU (engine control unit) 24. Ignition coil Spark plug 26.

  • Page 317: Electrical Diagram (B2P1)

    Machine Translated by Google FUEL INJECTION SYSTEM SAS30504 ELECTRICAL DIAGRAM (B2P1) 8-43...
  • Page 318 17. Throttle body sensor assembly 18. Intake air pressure assembly 19. Intake air temperature sensor 20. Throttle position sensor 21. Coupler of Yamaha diagnostic tool 22. Speed sensor 23. ECU (Engine Control Unit) 24. Ignition coil 25. Spark plug 26.
  • Page 319 Machine Translated by Google FUEL INJECTION SYSTEM SAS30505 ECU SELF- DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function to ensure the normal operation of the fuel injection system. If this feature detects an abnormality in the system, it immediately runs the engine with alternate characteristics and illuminates the engine trouble warning light to alert the driver that a system abnormality has occurred.

  • Page 320: Troubleshooting Method

    Machine Translated by Google FUEL INJECTION SYSTEM When an abnormal signal is received from a sensor, the ECU processes the specified values that are programmed for each sensor to send alternative operating instructions to the engine that allow it to continue to run or stop running, depending on conditions. SAS30506 TROUBLESHOOTING METHOD The engine operation is abnormal and the engine trouble warning light comes on.

  • Page 321: Diagnostic Code: Sensor Operation Chart

    Machine Translated by Google TABLE OF SELF-DIAGNOSTIC FUNCTIONS AND CODES OF DIAGNOSIS SAS20116 TABLE OF SELF-DIAGNOSTIC FUNCTIONS AND TROUBLESHOOTING CODES DIAGNOSIS SAS31118 SELF-DIAGNOSTIC FUNCTION TABLE fault code Element Crankshaft Position Sensor - Normal signals are not received from the crankshaft position sensor. Intake air pressure sensor: open or short circuit detected.
  • Page 322 — To erase the ECU adaptation data, click on the “Check the ECU adaptation data has been actuator” button on the Yamaha A/F Control Adaptation Data cleared. 01 ECU adaptation data diagnostic window three times in 5 has not been cleared.

  • Page 323: Diagnostic Code: Actuators Operation Chart

    The engine trouble warning light illuminates. “ ” The “CHECK” indicator y on the display of the Yamaha diagnostic tool lights each time the injector is activated. Remove the VVA (Variable Operates the VVA (Variable Valve VVA Solenoid (Variable Valve...

  • Page 324: Table Of Incident Codes

    Machine Translated by Google TABLE OF INCIDENT CODES diagnostic Element Action Process code Fault history code deletion — • No history • There is history 00 • Displays the total Save the fault history on the number of faults, including computer, and then delete current ones, that have the fault codes.

  • Page 325: Troubleshooting Details

    SAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify faults. For information on using the Yamaha Diagnostic Tool, refer to the operation manual that came with the tool. diagnostic tool Yamaha INS-018...
  • Page 326 Machine Translated by Google TABLE OF INCIDENT CODES Fault code: Fault code displayed on the fault code screen when the engine stopped running correctly. Diagnostic Code: Diagnostic code to be used with the diagnostic function. See “TABLE OF SELF-DIAGNOSTIC FUNCTIONS AND DIAGNOSTIC CODES” on page 8-47. Breakdown code n.o 12 Breakdown code Crankshaft Position Sensor - Normal signals are not received from the crankshaft...
  • Page 327 Machine Translated by Google TABLE OF INCIDENT CODES Fault code 13 fault code Intake air pressure sensor: open or short circuit detected. Element The engine can be started failsafe system The vehicle can be driven diagnostic code Indicated Shows the intake air pressure. Operate the accelerator while squeezing the brake lever and pressing the Process start switch”.
  • Page 328 Machine Translated by Google TABLE OF INCIDENT CODES fault code Intake air pressure sensor: open or short circuit detected. Element Faulty intake air pressure Run diagnostic function. (Code Turn the main switch to “ON”. sensor. D03) When the engine is stopped: No fault code is displayed indicates the atmospheric ÿ...
  • Page 329 Machine Translated by Google TABLE OF INCIDENT CODES fault code Intake air pressure sensor failure (loose or plugged hole). Element Faulty intake air pressure Run diagnostic function. (Code sensor. D03) When the engine is stopped: indicates the atmospheric pressure at altitude and current weather conditions.
  • Page 330 Machine Translated by Google TABLE OF INCIDENT CODES fault code Throttle position sensor: open or short circuit detected. Element Wrong connection ÿ Connect Throttle body sensor Turn the main switch to “ON”. the coupler well or change the assembly coupler connection. wire harness.
  • Page 331 Machine Translated by Google TABLE OF INCIDENT CODES fault code Throttle position sensor: open or short circuit detected. Element Fault in the ECU. Change the ECU. Breakdown code n.o 16 Breakdown code Throttle position sensor: jammed throttle position sensor detected. Element (throttle position sensor signal does not change) The engine can be started...
  • Page 332 Check the status of the trouble Check the closing status of the code using the failure mode of coupler. the Yamaha diagnostic tool. Disconnect the coupler and check the plugs (bent or broken The status is “Recover” ÿ Go terminals and closing state of to item 7 and end the service.
  • Page 333 Between diode 3 and ECU coupler. blue/green–blue/green between diode Check the status of the trouble code 3 and the side stand switch. blue/ using the failure mode of the Yamaha diagnostic tool. green–blue/green The status is “Recover” ÿ Go to item 7 and end the service.
  • Page 334 Machine Translated by Google TABLE OF INCIDENT CODES fault code Coolant Temperature Sensor: Open or short circuit detected. Element Wrong connection ÿ Connect the Wire harness ECU coupler Turn the main switch to “ON”. connection. coupler well or change the wire harness.
  • Page 335 Machine Translated by Google TABLE OF INCIDENT CODES fault code Intake air temperature sensor: open or short circuit detected. Element Wrong connection ÿ Connect Intake air temperature Turn the main switch to “ON”. sensor coupler connection. the coupler well or change the wire harness.
  • Page 336 Machine Translated by Google TABLE OF INCIDENT CODES Breakdown code n.o 24 Breakdown code Element O2 Sensor : Normal signals are not being received from the O2 sensor. The engine can be started failsafe system The vehicle can be driven —...
  • Page 337 The engine trouble warning light illuminates. Action ” “ The “CHECK” indicator y on the Yamaha Diagnostic Tool screen lights up each time the injector is activated. Listen to the running noise to see if the injector actuates five times. Process...
  • Page 338 Machine Translated by Google TABLE OF INCIDENT CODES fault code Element Fuel injector: open or short circuit detected. Wrong connection ÿ Connect the Injector coupler connection. Run diagnostic function. (Code D36) coupler well or change the wire harness. Check the closing status of the No running noise ÿ...
  • Page 339 Machine Translated by Google TABLE OF INCIDENT CODES fault code Lean angle sensor: open or short circuit detected. Element Wrong connection ÿ Connect the Lean angle sensor coupler Turn the main switch to “ON”, then connection. coupler well or change the wire to “OFF”, and then back to “ON”.
  • Page 340 Machine Translated by Google TABLE OF INCIDENT CODES fault code Speed Sensor: Normal speed sensor signals are not being received. Element Wrong connection ÿ Connect the Speed sensor coupler connection. Turn the main switch to “ON”, then coupler well or change the wire harness. turn the rear wheel by hand a few turns.
  • Page 341 Machine Translated by Google TABLE OF INCIDENT CODES fault code EEPROM Fault Code: An error has been detected while reading or writing to the Element EEPROM. Locate the anomaly. — Run diagnostic function. (Code D60) 00: Perform the procedure of item 3. 12: Perform the procedure of item 2.
  • Page 342 Operates the VVA (Variable Valve Actuator) solenoid five times at three second intervals. “ ” The “CHECK” indicator and on the Yamaha Diagnostic Tool display light up each time the VVA Operation (Variable Valve Actuator) solenoid is actuated.
  • Page 343 Machine Translated by Google TABLE OF INCIDENT CODES fault code VVA (Variable Valve Actuator) Solenoid: Open or short circuit detected. Element Wire harness continuity. Open circuit or short circuit ÿ Replace Turn the main switch to “ON” and start the wire harness. the engine.
  • Page 344 Machine Translated by Google TABLE OF INCIDENT CODES 8-70...

  • Page 345: Fuel Pump System

    Machine Translated by Google FUEL PUMP SYSTEM SAS20081 FUEL PUMP SYSTEM SAS30513 ELECTRICAL DIAGRAM (B1P1) 8-71...
  • Page 346 Machine Translated by Google FUEL PUMP SYSTEM FUEL PUMP SYSTEM (B1P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 13. Handlebar switch (right) 15. Engine stop switch 23. ECU (engine control unit) 31. Fuel pump 35. Connection 2 36.

  • Page 347: Electrical Diagram (B2P1)

    Machine Translated by Google FUEL PUMP SYSTEM SAS30513 ELECTRICAL DIAGRAM (B2P1) 8-73...
  • Page 348 Machine Translated by Google FUEL PUMP SYSTEM FUEL PUMP SYSTEM (B2P1) 4. Fuse box 6. Main fuse 8. Battery 9. Engine ground 10. Main switch 13. Handlebar switch (right) 15. Engine stop switch 23. ECU (engine control unit) 31. Fuel pump 35. Connection 2 36.

  • Page 349: Troubleshooting

    Machine Translated by Google FUEL PUMP SYSTEM SAS30514 TROUBLESHOOTING If the fuel pump does not work. 1. Check the fuses. incorrect ÿ (Main and Power) Change the fuses. See “CHECKING THE FUSES” on page 8-78. correct ÿ 2. Check the battery. incorrect ÿ...

  • Page 350: Electric Components

    Machine Translated by Google ELECTRIC COMPONENTS SAS20089 ELECTRIC COMPONENTS 1. Main switch 2. Front brake 19.Rear brake light switch 20.Lean angle sensor light switch 3. Clutch contact 4. Rectifier/regulator 5. 21.Starter motor 22.Gear shift position switch Spark plug 6. Ignition coil 23.Side stand switch (B1P1) 24.Speed sensor 25.AC 7.
  • Page 351 Machine Translated by Google ELECTRIC COMPONENTS SAS30549 CHECKING THE SWITCHES Check the continuity of all the switches with the multimeter. If the continuity indication is incorrect, check the wiring connections and, if necessary, replace the switch. 1. Main switch 2. Front brake light switch 3.
  • Page 352 Machine Translated by Google ELECTRIC COMPONENTS 4. Install: SAS30551 CHECKING THE FUSES The following procedure • Driver's seat is valid for all fuses. See “GENERAL CHASSIS” on page 4-1. SAS30552 SCA20520 CHECK AND CHARGE THE BATTERY ATTENTION CAVEAT To avoid a short circuit, always turn the main switch to “OFF”...

  • Page 353: The Battery

    Machine Translated by Google ELECTRIC COMPONENTS NOTE Example Open Circuit Voltage = 12.0 V Since VRLA (Valve Regulated Lead Acid) batteries Charge Time = 6.5 hours Battery are sealed, their state of charge cannot be checked Charge = 20-30% by measuring the density of the electrolyte. Therefore, the battery charge should be checked by measuring the voltage at the terminals.
  • Page 354 Machine Translated by Google ELECTRIC COMPONENTS • Remove the battery from the vehicle to b. Connect a charger and ammeter to the charge it. (If you must charge the vehicle- battery and start charging. mounted battery, disconnect the negative NOTE cable from the terminal.) •...
  • Page 355 Machine Translated by Google ELECTRIC COMPONENTS SAS30553 NOTE CHECK THE RELAYS Check the continuity If the current is less than the standard charging of all the switches with the multimeter. If the continuity current marked on the battery, this type of charger indication is incorrect, replace the relay.
  • Page 356 Machine Translated by Google ELECTRIC COMPONENTS • Tester positive probe ÿ brown/white “1” • Tester Result negative probe ÿ Continuity (between “3” and “4”) time SAS30554 CHECK FLASH/HAZARD RELAY 1. Check: • Flash/Hazard relay input voltage Out of specification ÿ Wiring circuit from main switch to flash/hazard relay coupler.
  • Page 357 Machine Translated by Google ELECTRIC COMPONENTS a. Disconnect the diode from the wire harness. b. • Tester positive probe ÿ red/white “1” • Tester negative probe ÿ Connect the multimeter (ÿ × 1) to the diode terminals as orange “2” shown.
  • Page 358 Machine Translated by Google ELECTRIC COMPONENTS SAS30556 IGNITION SPARK GAP CHECK 1. Check: • Crankshaft position sensor Ignition spark gap Out of specification ÿ Perform resistance 228–342 ÿ the ignition system troubleshooting process beginning with step 5. a. Connect the multimeter (ÿ × 100) to the crankshaft position sensor coupler, as shown.
  • Page 359 Machine Translated by Google ELECTRIC COMPONENTS multimeter INS-003 (90890-03189) • Tester positive probe ÿ blue • Tester negative probe ÿ black/blue b. Check the operation of the starter motor. SAS30566 STATOR COIL CHECK 1. Disconnect: • Stator coil coupler (from wire 50°...
  • Page 360 Machine Translated by Google ELECTRIC COMPONENTS a. Connect the engine tachometer to the • Tester positive probe ÿ green/blue spark plug wire. b. Connect the “1” • Tester negative probe ÿ multimeter (20 VDC) to the rectifier/regulator orange/white “2” coupler as shown. show.
  • Page 361 Machine Translated by Google ELECTRIC COMPONENTS • Never subject the coolant temperature sensor to strong shocks. If the coolant temperature sensor falls off, replace it. 2. Check: • Coolant temperature sensor resistance Out of specification ÿ Replace. b. Set the main switch to “ON” and Coolant temperature sensor put neutral.
  • Page 362 Machine Translated by Google ELECTRIC COMPONENTS SAS30596 CHECKING THE ASSEMBLY OF THE Throttle position sensor output BUTTERFLY BODY SENSOR voltage (closed position) SWA20700 CAVEAT 0.63–0.73 V • Do not remove the sensor assembly from the throttle body. • Handle the throttle body sensor assembly with special care.
  • Page 363 Machine Translated by Google ELECTRIC COMPONENTS Intake air temperature sensor 1. Check: • c. Measure the resistance of the FID (fast idle Intake air temperature sensor resistance Out of solenoid). specification ÿ Replace the throttle body. Out of specification ÿ Replace the throttle body assembly.
  • Page 364 Machine Translated by Google TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION..................9-1 FAULTS STARTING ................9-1 ENGINE IDLE SPEED INCORRECT............9-1 LOW PERFORMANCE AT MEDIUM AND HIGH RPM....9-2 PROBLEMS WHEN SHIFTING GEARS............9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 GEARS JUMP....
  • Page 365 Machine Translated by Google TROUBLESHOOTING Electrical System 1. SAS28450 Battery • Dead battery TROUBLESHOOTING • Faulty battery 2. Fuse(s) • Blown, damaged, or SAS28460 GENERAL INFORMATION incorrect fuse • Incorrectly fitted fuse 3. Spark plug • Spark plug gap incorrect The following troubleshooting guide does not cover all possible causes of problems.
  • Page 366 Machine Translated by Google TROUBLESHOOTING SAS28550 Electrical system 1. THE MARCH JUMP Battery Shift shaft • • Battery discharged • Battery defective 2. Incorrect shift pedal position • Incorrect detent lever return Spark plug • Gap between spark plug electrodes incorrect Shift forks •...
  • Page 367 Machine Translated by Google TROUBLESHOOTING Cooling System 1. SAS28650 FRONT FORK BARS Coolant • Low coolant level FAULTED 2. Radiator • Damaged or Oil leak • Inner leaking radiator • Defective tube bent, damaged, or rusted • Outer radiator cap • Bent or damaged tube cracked or damaged •...
  • Page 368 Machine Translated by Google TROUBLESHOOTING Wheel(s) Turn signals flash fast • Bad turn signal bulb • Faulty turn signal relay • Burnt out • Improper wheel balancing • Warped cast rim • Damaged wheel bearing • turn signal bulb Bent or loose wheel axle • Excessive wheel runout No horn sounds •...
  • Page 369 Black red assembly 18.Intake air pressure Black/Yellow assembly 19.Intake air 69.Side stand switch 70.Diode 3 Black White temperature sensor 20.Position sensor 21.Yamaha Diagnostic Br/W Brown/White Tool Coupler 22.Speed Sensor Green/Black 23.ECU (Engine Control Unit) Green Blue Green red Gy/R Grey/Red...
  • Page 370 Black/Blue 68.Tail/brake light assembly Black red assembly 18.Intake air pressure assembly 19.Intake air Black/Yellow temperature sensor 20.Position Black White sensor 21.Yamaha Diagnostic Br/W Brown/White Tool Coupler 22.Speed Sensor Green/Black 23.ECU (Engine Control Unit) Green Blue Green red Gy/R Grey/Red White blue...
  • Page 371 Machine Translated by Google...
  • Page 372 Machine Translated by Google B1P-F8197-E0...
  • Page 373 Machine Translated by Google YZF155 2019 ELECTRICAL DIAGRAM (B1P1)
  • Page 374 Machine Translated by Google YZF155 2019 ELECTRICAL DIAGRAM (B2P1)
  • Page 375 Machine Translated by Google B1P-F8197-S0 2Y182(SM-01)1285-09-18-S0...

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