Yamaha XSR 2016 Service Manual
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Yamaha XSR 2016 Service Manual

Yamaha XSR 2016 Service Manual

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2016
SERVICE MANUAL
MTM850
MTM850G
B90-28197-E0

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Summary of Contents for Yamaha XSR 2016

  • Page 1 2016 SERVICE MANUAL MTM850 MTM850G B90-28197-E0...
  • Page 3 EAS20002 MTM850 MTM850G SERVICE MANUAL ©2015 by Yamaha Motor Co., Ltd. First edition, December 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 EAS20003 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 5 EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 6 EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...

  • Page 7: Table Of Contents

    EAS10003 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION....................1-1 VEHICLE IDENTIFICATION NUMBER ............1-1 MODEL LABEL...................1-1 FEATURES .......................1-2 YCC-T (Yamaha Chip Controlled Throttle)..........1-2 OUTLINE OF THE TCS (Traction Control System)........1-4 INSTRUMENT FUNCTIONS ..............1-8 IMPORTANT INFORMATION .................1-13 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-13 REPLACEMENT PARTS................1-13 GASKETS, OIL SEALS AND O-RINGS ...........1-13 LOCK WASHERS/PLATES AND COTTER PINS ........1-13...

  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

  • Page 11: Features

    Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.
  • Page 12 FEATURES YCC-T system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (Engine Control Unit) 5. Sensor input 6. Gear position switch 7. Crankshaft position sensor 8. Rear wheel sensor 9. Coolant temperature sensor...

  • Page 13: Outline Of The Tcs (Traction Control System)

    FEATURES EAS30855 OUTLINE OF THE TCS (Traction Control System) The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating on slippery surfaces, such as unpaved or wet roads. The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen- sors, and detects rear wheel slipping according to the difference between the wheel speeds.
  • Page 14 FEATURES TCS (Traction control system) block diagram The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the ECU calculates the amount of slip according to the difference between the detected front and rear wheel speeds.
  • Page 15 FEATURES Traction control system The traction control system (TCS) helps maintain traction when accelerating on slippery surfaces, such as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning), the traction control system assists by regulating engine power as needed until traction is restored. EWA15432 WARNING The traction control system is not a substitute for riding appropriately for the conditions.
  • Page 16 FEATURES Setting the traction control system With the throttle closed, push traction control system switch down to change from TCS “1” to “2”. Push up to change from TCS “2” to “1”. With the vehicle stopped, push this switch up for two seconds to turn the system off. Push down to turn the system on.

  • Page 17: Instrument Functions

    FEATURES EAS30682 INSTRUMENT FUNCTIONS • Except when switching to the brightness con- Multi-function meter unit trol mode or to display the clock, turn the key to “ON” before using the bottom and top set but- tons. • For the UK: To switch the speedometer and multi-function display between kilometers and miles, set the multi-function display to the odometer mode or a tripmeter mode, and then...
  • Page 18 FEATURES Fuel meter Transmission gear display 1. Frame 1. Neutral indicator light “ ” 2. Fuel meter 2. Transmission gear display The fuel meter indicates the amount of fuel in the This display shows the selected gear. The neu- fuel tank. The display segments of the fuel meter tral position is indicated by “...
  • Page 19 FEATURES Multi-function display or “AVE_ _._ MPG”, coolant temperature “_ _ C”, and ambient temperature, and “Air_ _ C”, and clock “_ _:_ _” in the following order: ODO  TRIP 1  TRIP 2  km/L, L/100 km or MPG ...
  • Page 20 FEATURES The instantaneous fuel consumption display can Coolant temperature be set to either “km/L” or “L/100 km”; or for the UK, to “MPG” as well. • “km/L”: The distance that can be traveled on 1.0 L of fuel under current riding conditions. •...
  • Page 21 FEATURES Clock To adjust the brightness 1. Turn the key to “OFF”. 2. Push and hold the bottom set button. 3. Turn the key to “ON” and continue pushing the bottom set button until the display switch- es to the brightness level display. 4.

  • Page 22: Important Information

    5. Keep all parts away from any source of fire. EAS30007 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 23: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.

  • Page 24: Basic Service Information

    BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

  • Page 25: Electrical System

    BASIC SERVICE INFORMATION If a battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust us- ing hot water. EAS30014 ELECTRICAL SYSTEM Electrical parts handling ECA16600 NOTICE ECA16760 NOTICE Never disconnect a battery lead while the en- Be sure to connect the battery leads to the gine is running;...
  • Page 26 BASIC SERVICE INFORMATION ECA16610 NOTICE When resetting the ECU by turning the main Turn the main switch to “OFF” before dis- switch to “OFF”, be sure to wait approximately connecting or connecting an electrical com- 5 seconds before turning the main switch back ponent.
  • Page 27 BASIC SERVICE INFORMATION ECA16640 NOTICE ECA16790 For waterproof couplers, never insert the NOTICE tester probes directly into the coupler. When When disconnecting a connector, do not pull performing any checks using a waterproof the leads. Hold both sections of the connec- coupler, use the specified test harness or a tor securely, and then disconnect the con- suitable commercially available test har-...
  • Page 28 BASIC SERVICE INFORMATION • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely. • Make sure all connections are tight. 5. Check: • Resistance Pocket tester 90890-03112 Analog pocket tester YU-03112-C The resistance values shown were obtained at the standard measuring temperature of 20 C...

  • Page 29: Special Tools

    SPECIAL TOOLS EAS20012 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 30 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Carburetor angle driver 2 90890-03173 Yamaha diagnostic tool 3-10, 4-56, 4-58, 90890-03250 8-36, 8-121, 8-141 Steering nut wrench 3-19, 4-78 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-24 90890-01426 Oil filter wrench...
  • Page 31 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Damper rod holder (ø27) 4-69, 4-71 90890-01582 Damper rod holder YM-01582 Fork seal driver 4-71, 4-72 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-72, 4-73, 4-74 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10 long)
  • Page 32 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Extension 90890-04136 Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 Pivot shaft wrench 5-7, 5-8 90890-01518 Frame spanner socket YM-01518 Pivot shaft wrench adapter 5-7, 5-8 90890-01476 Camshaft wrench...
  • Page 33 Sheave holder 5-31, 5-32 90890-01701 Primary clutch holder YS-01880-A Flywheel puller 5-31 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-33, 5-58 90890-85505 (Three bond No.1215®) Digital circuit tester 5-36, 8-160, 90890-03174 8-162, 8-166 Model 88 Multimeter with tachometer YU-A1927...
  • Page 34 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-42, 5-46 90890-04086 Universal clutch holder YM-91042 Piston pin puller set 5-62 90890-01304 Piston pin puller YU-01304 YU-01304 Piston installing tool 5-69 90890-04161 Piston installing tool YM-04161 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A...
  • Page 35 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-11 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-11 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Fuel injector pressure adapter 7-12...
  • Page 36 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness– lean angle sensor (6P) 8-160 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Test harness S– pressure sensor (3P) 8-166 90890-03207 Test harness S– pressure sensor (3P) YU-03207 1-27...

  • Page 37: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-7 ELECTRICAL SPECIFICATIONS ..............2-10 TIGHTENING TORQUES ................2-12 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-12 ENGINE TIGHTENING TORQUES............2-13 CHASSIS TIGHTENING TORQUES............2-13 LUBRICATION POINTS AND LUBRICANT TYPES........2-15 ENGINE....................2-15 CHASSIS....................2-16 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-19 ENGINE OIL LUBRICATION CHART ............2-19 LUBRICATION DIAGRAMS ..............2-21 COOLING SYSTEM DIAGRAMS ..............2-31 CABLE ROUTING ..................2-35...

  • Page 38: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model B901 (EUR,ZAF) B902 (AUS) B906 (RUS) B908 (EUR,ZAF) B90A (RUS) Dimensions Overall length 2075 mm (81.7 in) Overall width 815 mm (32.1 in) Overall height 1140 mm (44.9 in) Seat height 830 mm (32.7 in) Wheelbase 1440 mm (56.7 in) Ground clearance...

  • Page 39: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train DOHC Displacement 847 cm³ Cylinder arrangement Inline Number of cylinders 3-cylinder Bore  stroke 78.0  59.1 mm (3.07  2.33 in) Compression ratio 11.5 : 1 Compression pressure 1331–1713 kPa/680 r/min (13.3–17.1 kgf/cm²/680 r/min, 189.3–243.7 psi/680 r/min)
  • Page 40 ENGINE SPECIFICATIONS Water pump Water pump type Single suction centrifugal pump Impeller shaft tilt limit 0.15 mm (0.006 in) Spark plug(s) Manufacturer/model NGK/CPR9EA9 Spark plug gap 0.8–0.9 mm (0.031–0.035 in) Cylinder head Warpage limit 0.10 mm (0.0039 in) Camshaft Camshaft cap inside diameter 24.500–24.521 mm (0.9646–0.9654 in) Camshaft journal diameter 24.459–24.472 mm (0.9630–0.9635 in)
  • Page 41 ENGINE SPECIFICATIONS Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston Diameter 77.975–77.990 mm (3.0699–3.0705 in) Measuring point (from piston skirt bottom) 12.0 mm (0.47 in) Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in) Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in) Limit 17.043 mm (0.6710 in)
  • Page 42 ENGINE SPECIFICATIONS Clutch Clutch type Wet, multiple-disc Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) Friction plate 1 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) Plate quantity 3 pcs Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) Plate quantity...
  • Page 43 ENGINE SPECIFICATIONS Idling condition Engine idling speed 1100–1300 r/min AI system Inactive feedback control Inactive Exhaust gas sampling point Sampling port on the exhaust pipe To be measured Coolant temperature 90–110 C (194–230 F) Temperature Difference in vacuum pressure between the 1.3 kPa (10 mmHg, 0.4 inHg) cylinders 1.5–3.5 %...

  • Page 44: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 25.0  Caster angle Trail 103 mm (4.1 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Rear wheel...
  • Page 45 305.3 mm (12.02 in) Limit 299.1 mm (11.78 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil G10 Quantity (left) 444.0 cm³ (15.01 US oz, 15.66 Imp.oz) Quantity (right) 431.0 cm³ (14.57 US oz, 15.20 Imp.oz) Level (left) 174 mm (6.9 in)
  • Page 46 CHASSIS SPECIFICATIONS Adjustment value from the start position (Soft) Adjustment value from the start position 1-1/2 (STD) Adjustment value from the start position (Hard) Drive chain Size DID525V10 Chain type Sealed type Number of links Drive chain slack (Maintenance stand) 5.0–15.0 mm (0.20–0.59 in) Drive chain slack (Sidestand) 5.0–15.0 mm (0.20–0.59 in)

  • Page 47: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Digital 5.0 1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer TBDFU5/DENSO Ignition coil 1.19–1.61  Primary coil resistance Secondary coil resistance 9.35–12.65 k Lean angle sensor output voltage 65 ...
  • Page 48 ELECTRICAL SPECIFICATIONS Traction control system indicator/warning light Starter motor Power output 0.70 kW 0.0050–0.0150  Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.03–6.52 N (615–665 gf, 21.71–23.47 oz) Mica undercut (depth) 0.70 mm (0.03 in) Oil level switch 484.0–536.0 ...

  • Page 49: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 50: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler protector bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Generator rotor bolt 75 Nm (7.5 m·kgf, 54 ft·lbf)
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake. Drive sprocket nut 95 Nm (9.5 m·kgf, 69 ft·lbf) Lower ring nut 1. Tighten the ring nut to approximately 52 Nm (5.2 m·kgf, 38 ft·lbf) with a torque wrench, then loosen the lower ring nut completely.

  • Page 52: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20018 LUBRICATION POINTS AND LUBRICANT TYPES EAS30018 ENGINE Lubrication point Lubricant Oil seal lips O-rings Water or Coolant hose insertion part Bearing Cylinder head cover bolt gasket and timing chain bolt gasket Camshaft lobes and journals (intake and exhaust) Valve stem seals (intake and exhaust) Valve lifter outer surface (intake and exhaust) Valve stems and stem ends (intake and exhaust)

  • Page 53: Chassis

    Shit drum moving surface Shift fork pin Shift forks guide bar outer surface Shift shaft washer Shift shaft moving surface Yamaha bond No. 1215 Crankcase mating surface (Three bond No. 1215®) Yamaha bond No. 1215 Stator coil assembly lead grommet (Three bond No.
  • Page 54 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Brake caliper piston seal Master cylinder inside Brake caliper piston dust seal Brake caliper bolts 2-17...
  • Page 55 LUBRICATION POINTS AND LUBRICANT TYPES 2-18...

  • Page 56: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-19...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Drive axle 8. Main axle 9. Shift fork (upper) 10.Mission shower 11.Crankshaft 12.AC magneto 13.Oil nozzle 14.Balancer shaft 15.Timing chain tensioner 16.Intake camshaft...

  • Page 58: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-21...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil filter cartridge union bolt 3. Oil filter cartridge 4. Crankshaft 2-22...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Balancer shaft 5. Crankshaft 6. Oil cooler 7. Oil strainer 8. Oil drain bolt 9. Oil pump driven sprocket 2-24...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil filter cartridge 3. Oil level switch 4. Oil strainer 5. Oil pump 6. Main gallery bolt 2-26...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft 2. Crankshaft 3. Main axle 4. Shift fork guide bar (shift fork-C side) 5. Drive axle 6. Sub gallery bolt 7. Shift fork 2-28...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
  • Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Exhaust camshaft 3. Intake camshaft 4. Oil passage to the timing chain tensioner 5. Oil passage to the cylinder head 6. Oil passage to the clutch chamber 7. Oil return passage from the cylinder head 8.

  • Page 68: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-31...
  • Page 69 COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator 2-32...
  • Page 70 COOLING SYSTEM DIAGRAMS 2-33...
  • Page 71 COOLING SYSTEM DIAGRAMS 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir 2-34...

  • Page 72: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (top view) 2-35...
  • Page 73 CABLE ROUTING 1. Front brake master cylinder 2. Throttle cable 3. Rubber cover 4. Handlebar 5. Front brake light switch connector 6. Front brake light switch 7. Front brake hose A. When installing the rubber cover, silicone water or soapy water may be applied to the inside of the rubber cover.
  • Page 74 CABLE ROUTING Handlebar (front view) 2-37...
  • Page 75 CABLE ROUTING N. Vehicle forward direction 1. Throttle cable O. Install the clamp of the horn lead to the head- 2. Meter assembly light stay as shown in the illustration. 3. Meter assembly lead P. The terminals should face the outside of the 4.
  • Page 76 CABLE ROUTING Headlight (front view) 2-39...
  • Page 77 CABLE ROUTING 1. Handlebar switch coupler 2 (left) 2. Handlebar switch coupler 1 (left) 3. Turn signal light coupler (left)/Turn signal light coupler (right) 4. Auxiliary light coupler 5. Handlebar switch coupler 1 (right) 6. Handlebar switch coupler 2 (right) 7.
  • Page 78 CABLE ROUTING Radiator (front side view and right side view) 2-41...
  • Page 79 CABLE ROUTING 1. Radiator cap 2. Radiator 3. Radiator fan 4. Radiator outlet hose 5. Thermostat assembly 6. Water jacket joint 7. Coolant reservoir 8. Radiator inlet hose A. Install the radiator outlet hose with its white paint mark facing inward. B.
  • Page 80 CABLE ROUTING Fuel tank (left and bottom view) 2-43...
  • Page 81 CABLE ROUTING 1. Fuel tank 2. Fuel pump 3. Fuel hose 4. Fuel tank drain hose 5. Fuel tank breather hose A. Atmosphere B. Insert the fuel tank drain hose up to the sec- tion where the fuel tank pipe increases in diameter.
  • Page 82 CABLE ROUTING Canister (top view and left side view) 2-45...
  • Page 83 CABLE ROUTING 1. Frame 2. Clamp 3. Canister 4. Canister holder 5. Canister breather hose 6. Fuel tank drain hose 7. Fuel tank breather hose 8. Canister purge hose 9. Fuel tank 10.Rear shock absorber assembly 11.Canister bracket A. Front side of the vehicle B.
  • Page 84 CABLE ROUTING Air filter case and throttle body (top view and left side view) 2-47...
  • Page 85 CABLE ROUTING 1. Air filter case joint clamp 2. ECU (Engine Control Unit) 3. Air filter case 4. Throttle body 5. Clip 6. Cylinder head breather hose 7. Throttle cable (decelerator cable) (white plat- ing) 8. Throttle cable (accelerator cable) (black plat- ing) 9.
  • Page 86 CABLE ROUTING Air cut-off valve (left side view) 2-49...
  • Page 87 CABLE ROUTING 1. Radiator fan cover 2. Air filter case 3. Clip 4. Air induction system hose (air filter case to air cut-off valve) 5. Air induction system hose (air cut-off valve to reed valve cover #1) 6. Air induction system hose (air cut-off valve to reed valve cover #2/#3) 7.
  • Page 88 CABLE ROUTING Frame and engine (right side view) 2-51...
  • Page 89 CABLE ROUTING R. Route O sensor lead inside to the protrusion 1. Clamp of the adapter bracket. 2. Rear brake light switch lead S. Inside vehicle 3. Main switch lead/Immobilizer unit lead T. Attach the fuse box 1 to the rubber clamp and 4.
  • Page 90 CABLE ROUTING Frame and engine (left side view) 2-53...
  • Page 91 CABLE ROUTING J. Route the intake air temperature sensor lead 1. Air induction system hose (air filter case to air above the throttle cable in the frame, and cut-off valve) feed it outside the vehicle through the triangle 2. Air filter case hole in the frame.
  • Page 92 CABLE ROUTING Frame (top view) 2-55...
  • Page 93 CABLE ROUTING 1. Injector #1 coupler 2. Injector #2 coupler 3. Clamp 4. Ignition coil #1 coupler 5. Ignition coil #2 coupler 6. Air cut-off valve coupler 7. Ignition coil #3 coupler 8. Injector #3 coupler 9. Throttle position sensor coupler 10.Throttle servo motor coupler 11.Cross tube 12.Accelerator position sensor coupler...
  • Page 94 CABLE ROUTING Frame (top view) 2-57...
  • Page 95 CABLE ROUTING 1. Stator coil assembly lead 2. Oil level switch coupler 3. Canister 4. Rear brake light switch coupler 5. Sidestand switch coupler 6. Negative battery lead 2 coupler 7. Gear position switch coupler 1 8. Gear position switch coupler 2 9.
  • Page 96 CABLE ROUTING Frame (top view) 2-59...
  • Page 97 I. End section of guide J. Connect the turn signal light coupler to the corresponding coupler of the same color. K. Insert the Yamaha diagnostic tool coupler to the battery box. L. Install the rubber bracket of the relay unit in the battery box.
  • Page 98 CABLE ROUTING Front brake (right side view) 2-61...
  • Page 99 CABLE ROUTING O. Fasten the front wheel sensor lead with the 1. Brake hose (front brake master cylinder to holder on the front wheel sensor protector. hydraulic unit) P. Fasten the grommet on the front wheel sen- 2. Brake hose (hydraulic unit to left brake cali- sor lead with the front wheel sensor lead per) holder.
  • Page 100 CABLE ROUTING Front brake (front view and left side view) 2-63...
  • Page 101 CABLE ROUTING 1. Clamp 2. Headlight stay 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose holder 5. Brake hose (left brake caliper to right brake caliper) 6. Brake hose (hydraulic unit to left brake cali- per) 7.
  • Page 102 CABLE ROUTING Rear brake 2-65...
  • Page 103 CABLE ROUTING 1. Rear frame 2. Rear wheel sensor 3. Rear wheel sensor lead 4. Rear brake caliper 5. Rear brake hose 6. Clamp 7. Swingarm assembly A. Install the brake pipe so that it contact with the protrusion on the master cylinder at out- side vehicle.
  • Page 104 CABLE ROUTING Hydraulic unit (top view and left side view) 2-67...
  • Page 105 CABLE ROUTING 1. Wire harness 2. Battery box 3. Brake hose (front brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to front brake cali- pers) 5. Brake hose (rear brake master cylinder to hydraulic unit) 6. Brake hose (hydraulic unit to rear brake cali- per) 7.
  • Page 106 CABLE ROUTING 2-69...

  • Page 107: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ..............3-4 ADJUSTING THE VALVE CLEARANCE ...........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-8 SYNCHRONIZING THE THROTTLE BODIES...........3-8 CHECKING THE THROTTLE BODY JOINTS .........3-10 CHECKING THE CANISTER ..............3-10...
  • Page 108 MEASURING THE ENGINE OIL PRESSURE .........3-24 CHECKING THE COOLANT LEVEL............3-25 CHECKING THE COOLING SYSTEM .............3-26 CHANGING THE COOLANT..............3-26 CHECKING THE FRONT BRAKE LIGHT SWITCH .........3-28 ADJUSTING THE REAR BRAKE LIGHT SWITCH ........3-28 CHECKING AND LUBRICATING THE CABLES ........3-28 CHECKING THE THROTTLE GRIP............3-28 CHECKING AND CHARGING THE BATTERY........3-29 CHECKING THE FUSES .................3-29 REPLACING THE HEADLIGHT BULB.............3-29...

  • Page 109: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 110 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check for cracks or damage.     ...
  • Page 111 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check coolant level and vehi-     ...

  • Page 112: Checking The Fuel Line

    PERIODIC MAINTENANCE 4-1. EAS30619 CHECKING THE FUEL LINE • Fuel tank cover The following procedure applies to all of the fuel, Refer to “GENERAL CHASSIS (2)” on page drain and breather hoses. 4-3. 1. Remove: • Fuel tank • Rider seat Refer to “FUEL TANK”...

  • Page 113: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE Refer to “GENERAL CHASSIS (2)” on page 4-3. • Air cut-off valve Refer to “AIR INDUCTION SYSTEM” on page 7-15. • Radiator Refer to “RADIATOR” on page 6-1. 2. Remove: • Ignition coils • Spark plugs • Cylinder head cover 7.
  • Page 114 PERIODIC MAINTENANCE when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thickness gauge “1”. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 B. Degrees that the crankshaft is turned coun- terclockwise C. Cylinder D.
  • Page 115 PERIODIC MAINTENANCE stalled in the correct place. Last digit Rounded value 0, 1, 2 3, 4, 5, 6 7, 8, 9 Refer to the following table for the available valve pads. Valve pad range Nos. 150–240 b. Calculate the difference between the speci- 1.50–2.40 mm Valve pad thickness (0.0590–0.0944 in)

  • Page 116: Checking The Engine Idling Speed

    “02”  Clean the throttle bodies. Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-9. 4. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. • Vacuum gauge “1” Use the diagnostic code number “67”. Vacuum gauge Refer to “SELF-DIAGNOSTIC FUNCTION 90890-03094 AND DIAGNOSTIC CODE TABLE”...
  • Page 117 PERIODIC MAINTENANCE dard. Otherwise, the engine may run roughly at idle and the throttle bodies may not oper- ate properly. • Turn the bypass air screw using the carburetor angle driver. • After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.

  • Page 118: Checking The Throttle Body Joints

    For more information, refer to the opera- • Throttle bodies tion manual of the Yamaha diagnostic tool. Refer to “THROTTLE BODIES” on page 7-6. 1. Connect the Yamaha diagnostic tool to the 2. Check: coupler. For information about connecting the • Throttle body joints “1”...

  • Page 119: Replacing The Air Filter Element

    PERIODIC MAINTENANCE rapid wear of engine parts and may damage EAS30628 REPLACING THE AIR FILTER ELEMENT the engine. Operating the engine without the 1. Remove: air filter element will also affect throttle body • Rider seat synchronization, leading to poor engine per- Refer to “GENERAL CHASSIS (1)”...

  • Page 120: Checking The Brake Operation

    PERIODIC MAINTENANCE Drive on the dry road, operate the front and rear brakes separately and check to see if the brakes are operating properly. EAS30632 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. • Place the vehicle on a maintenance stand. •...

  • Page 121: Adjusting The Front Disc Brake

    PERIODIC MAINTENANCE may result in a harmful chemical reaction, system. Before the vehicle is operated, the leading to poor brake performance. air must be removed by bleeding the brake • When refilling, be careful that water does system. Air in the brake system will consid- not enter the brake fluid reservoir.

  • Page 122: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE EAS30635 Rear brake master cylinder lock CHECKING THE FRONT BRAKE HOSES The following procedure applies to all of the 18 Nm (1.8 m·kgf, 13 ft·lbf) brake hoses and brake hose holders. 1. Check: EWA17030 • Brake hose WARNING Cracks/damage/wear ...

  • Page 123: Checking The Wheels

    PERIODIC MAINTENANCE • brake operation is faulty. the brake pedal and hold it in position. g. Loosen the bleed screw. • Be careful not to spill any brake fluid or allow Loosening the bleed screw will release the pres- the brake master cylinder reservoir or brake sure and cause the brake lever to contact the fluid reservoir to overflow.

  • Page 124: Checking The Tires

    Tire air pressure (measured on cerning handling characteristics can be giv- cold tires) en if a tire combination other than one 1 person approved by Yamaha is used on this vehicle. Front 250 kPa (2.50 kgf/cm², 36 psi) Front tire Rear Size 290 kPa (2.90 kgf/cm², 42 psi)

  • Page 125: Checking The Wheel Bearings

    PERIODIC MAINTENANCE should be traveled at normal speed before EAS31923 DRIVE CHAIN SLACK any high-speed riding is done. Checking the drive chain slack EWA13120 WARNING For tires with a direction of rotation mark “1”: • Install the tire with the mark pointing in the di- Securely support the vehicle so that there is rection of wheel rotation.

  • Page 126: Lubricating The Drive Chain

    PERIODIC MAINTENANCE Adjusting the drive chain slack Chain puller adjusting bolt lock- EWA13120 WARNING 16 Nm (1.6 m·kgf, 12 ft·lbf) Securely support the vehicle so that there is no danger of it falling over. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Loosen: • Wheel axle nut “1” EAS30803 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting...

  • Page 127: Lubricating The Steering Head

    PERIODIC MAINTENANCE lower bearings. Refer to “STEERING HEAD” on page 4-76. e. Install the rubber washer “7”. f. Install the upper ring nut “8”. g. Finger tighten the upper ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned.

  • Page 128: Lubricating The Pedal

    PERIODIC MAINTENANCE moving parts of the lever. Recommended lubricant Lithium-soap-based grease EAS30649 LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal. Recommended lubricant Lithium-soap-based grease c. Tighten both locknuts. d. Make sure the installed shift rod length is EAS30851 within specification.

  • Page 129: Adjusting The Front Fork Legs

    PERIODIC MAINTENANCE smoothly. Rough movement  Repair. Refer to “FRONT FORK” on page 4-65. A. Left side B. Right side The spring preload setting is determined by EAS30806 ADJUSTING THE FRONT FORK LEGS measuring the distance “c” shown in the illustra- The following procedure applies to both of the tion.

  • Page 130: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE Spring preload Direction “a” ECA13590 Rebound damping is increased (sus- NOTICE pension is harder). Never go beyond the maximum or minimum Direction “b” adjustment positions. Rebound damping is decreased (sus- pension is softer). 1. Adjust: • Spring preload Rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 131: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE minimum level mark “a” and maximum level Direction “a” mark “b”. Rebound damping is increased (sus- Below the minimum level mark  Add the pension is harder). recommended engine oil to the proper level. Direction “b” Rebound damping is decreased (sus- pension is softer).

  • Page 132: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m·kgf, 12 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Engine oil drain bolt (along with the gasket Engine oil drain bolt 4.

  • Page 133: Checking The Coolant Level

    PERIODIC MAINTENANCE 2. Start the engine, warm it up for several min- 5. Measure: utes, and then turn it off. • Engine oil pressure (at the following conditions) ECA13410 NOTICE Oil pressure When the engine is cold, the engine oil will 230.0 kPa/5000 r/min (2.30 have a higher viscosity, causing the engine kgf/cm²/5000 r/min, 33.4...

  • Page 134: Checking The Cooling System

    PERIODIC MAINTENANCE ECA21281 NOTICE • Adding water instead of coolant dilutes the antifreeze concentration of the coolant. If water is used instead of coolant; check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
  • Page 135 PERIODIC MAINTENANCE • Coolant reservoir cover “2” • Coolant reservoir • Coolant reservoir “3” • Coolant reservoir cover • Collars “4” • Coolant reservoir bolt Coolant reservoir bolt (M5) 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf) Coolant reservoir bolt (M6) 9 Nm (0.9 m·kgf, 6.5 ft·lbf) 9.

  • Page 136: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE • Radiator cap adjusting nut “2” in direction “a” or “b” until the • Radiator cap bolt rear brake light comes on at the proper time. Radiator cap bolt Direction “a” 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Brake light comes on sooner. Direction “b”...

  • Page 137: Checking And Charging The Battery

    PERIODIC MAINTENANCE Refer to “HANDLEBAR” on page 4-60. 2. Check: • Throttle grip movement Rough movement  Lubricate or replace the defective part(s). Recommended lubricant Suitable cable lubricant With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle d.

  • Page 138: Adjusting The Headlight Beam

    PERIODIC MAINTENANCE Headlight lens unit bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) EAS30664 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • Headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw “1” in direction “a” or “b”. 4. Detach: Direction “a” • Headlight bulb holder “5” Headlight beam is raised.

  • Page 139: Replacing The License Plate Light Bulb

    PERIODIC MAINTENANCE EAS31831 REPLACING THE LICENSE PLATE LIGHT License plate light nut 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) BULB 1. Remove: 7. Install: • Mudguard assembly • Lower fender cover Refer to “GENERAL CHASSIS (1)” on page • Quick fastener 4-1.
  • Page 140 PERIODIC MAINTENANCE 3-32...

  • Page 141: Chassis

    CHASSIS GENERAL CHASSIS (1) ..................4-1 GENERAL CHASSIS (2) ..................4-3 INSTALLING THE FUEL TANK COVERS ..........4-9 FRONT WHEEL....................4-10 REMOVING THE FRONT WHEEL............4-12 DISASSEMBLING THE FRONT WHEEL..........4-12 CHECKING THE FRONT WHEEL ............4-12 ASSEMBLING THE FRONT WHEEL............4-13 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR....................4-14 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-15 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ....4-16...
  • Page 142 CHECKING THE REAR BRAKE CALIPER..........4-47 ASSEMBLING THE REAR BRAKE CALIPER .........4-48 INSTALLING THE REAR BRAKE CALIPER..........4-48 REMOVING THE REAR BRAKE MASTER CYLINDER ......4-49 CHECKING THE REAR BRAKE MASTER CYLINDER ......4-49 ASSEMBLING THE REAR BRAKE MASTER CYLINDER.......4-50 INSTALLING THE REAR BRAKE MASTER CYLINDER ......4-50 ABS (ANTI-LOCK BRAKE SYSTEM)............4-51 ABS COMPONENTS CHART ..............4-53 REMOVING THE HYDRAULIC UNIT ASSEMBLY ........4-54...
  • Page 143 CHECKING THE DRIVE CHAIN ..............4-88 CHECKING THE DRIVE SPROCKET............4-89 CHECKING THE REAR WHEEL SPROCKET.........4-89 CHECKING THE REAR WHEEL DRIVE HUB .........4-89 INSTALLING THE DRIVE CHAIN ............4-90...
  • Page 144 GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seat and battery 2.2 Nm (0.22 m kgf, 1.6 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Rider seat Battery band Battery seat Negative battery lead Disconnect. Positive battery lead Disconnect.
  • Page 145 GENERAL CHASSIS (1) Removing the rear side covers and mudguard assembly 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 0.7 Nm (0.07 m kgf, 0.51 ft lbf) • •...
  • Page 146 GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the headlight 6 Nm (0.6 m kgf, 4.3 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • 3.8 Nm (0.38 m kgf, 2.8 ft lbf)
  • Page 147 GENERAL CHASSIS (2) Removing the headlight stay 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) •...
  • Page 148 GENERAL CHASSIS (2) Removing the side panel (left) 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Plate Side panel (left) Rubber cover Intake air temperature sensor...
  • Page 149 GENERAL CHASSIS (2) Removing the side panel (right) 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Plate Side panel (right) Rubber cover Wire harness (Fuse box/Radiator fan motor coupler/Headlight relay/Auxiliary DC outlet)
  • Page 150 GENERAL CHASSIS (2) Removing the fuel tank covers 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank top cover...
  • Page 151 GENERAL CHASSIS (2) Removing the air filter case 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • (10) 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...

  • Page 152: General Chassis (1)

    GENERAL CHASSIS (2) EAS31927 INSTALLING THE FUEL TANK COVERS The following procedure applies to both of the fuel tank covers. 1. Install: • Fuel tank cover “1” • Align the hole “a” in the fuel tank cover with the projection “b” on the fuel tank bracket. •...

  • Page 153: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 35 Nm (3.5 m kgf, 25 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) •...
  • Page 154 FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer 4-11...

  • Page 155: Removing The Front Wheel

    FRONT WHEEL • If any solvent gets on the wheel sensor ro- EAS31148 REMOVING THE FRONT WHEEL tor, wipe it off immediately. ECA21380 NOTICE 1. Remove: • Oil seals Keep magnets (including magnetic pick-up • Wheel bearings tools, magnetic screwdrivers, etc.) away from the front wheel sensor “1”, otherwise ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 156: Assembling The Front Wheel

    FRONT WHEEL EAS31150 ASSEMBLING THE FRONT WHEEL ECA21340 NOTICE • Do not drop the wheel sensor rotor or sub- ject it to shocks. • If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. 1. Install: •...

  • Page 157: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL d. Install the new oil seals. front wheel sensor rotor. • Do not drop or shock the wheel sensor or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the wheel sensor rotor. 2. Install: • Front wheel sensor rotor 1. Check: • Front wheel sensor “1” Wheel sensor rotor bolt Cracks/bends/distortion ...

  • Page 158: Adjusting The Front Wheel Static Balance

    FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90 so that the “X ” mark is positioned as shown. d. Release the front wheel. e.

  • Page 159: Installing The Front Wheel (Front Brake Discs)

    FRONT WHEEL c. If the heavy spot does not stay in that posi- 2. Check: tion, install a heavier weight. • Front brake discs d. Repeat steps (b) and (c) until the front wheel Refer to “CHECKING THE FRONT BRAKE is balanced.
  • Page 160 FRONT WHEEL Distance “a” (between the wheel Check that wheel axle end “a” is flush with front sensor rotor and wheel sensor) fork surface “b” and then tighten the wheel axle 0.9–1.5 mm (0.04–0.06 in) pinch bolt. If end “a” is not flush with surface “b”, align the ends manually or with a plastic ham- mer.

  • Page 161: Rear Wheel

    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 150 Nm (15 m kgf, 108 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) •...
  • Page 162 REAR WHEEL Removing the brake disc and rear wheel sprocket 30 Nm (3.0 m kgf, 22 ft Ibf) • • 80 Nm (8.0 m kgf, 58 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Bracket Rear wheel sprocket Collar Collar...
  • Page 163 REAR WHEEL Disassembling the rear wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear wheel sensor rotor Oil seal Wheel bearing Spacer Wheel bearing 4-20...

  • Page 164: Removing The Rear Wheel

    REAR WHEEL EAS30910 REMOVING THE REAR WHEEL ECA21390 NOTICE Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor “1”, otherwise the wheel sensor may be damaged, resulting in improper performance of the ABS. 4. Remove: •...

  • Page 165: Checking The Rear Wheel

    REAR WHEEL EAS30159 CHECKING THE REAR WHEEL 1. Check: • Wheel axle • Wheel bearings • Oil seals Refer to “CHECKING THE FRONT WHEEL” on page 4-12. 2. Check: • Tire • Rear wheel Damage/wear  Replace. b. Correct Refer to “CHECKING THE TIRES” on page 1.

  • Page 166: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL • Oil seal EAS31157 INSTALLING THE REAR WHEEL (REAR Refer to “ASSEMBLING THE FRONT BRAKE DISC) WHEEL” on page 4-13. 1. Install: • Rear brake disc EAS31156 MAINTENANCE OF THE REAR WHEEL Rear brake disc bolt SENSOR AND SENSOR ROTOR 30 Nm (3.0 m·kgf, 22 ft·lbf) ECA21060 NOTICE...
  • Page 167 REAR WHEEL should be no clearance “a” between the adjust- ing block “1” and adjusting bolt “2”. 8. Install: • Rear wheel sensor Rear wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ECA21080 NOTICE Make sure there are no foreign materials in A.
  • Page 168 REAR WHEEL installed. This may damage the rear wheel sen- sor rotor and the rear wheel sensor. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 4-25...

  • Page 169: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft lbf) • • 35 Nm (3.5 m kgf, 25 ft lbf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 170 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) •...
  • Page 171 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-28...
  • Page 172 FRONT BRAKE Removing the front brake calipers 35 Nm (3.5 m kgf, 25 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft lbf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 173 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

  • Page 174: Introduction

    FRONT BRAKE d. Hold the dial gauge at a right angle against EAS30168 INTRODUCTION the brake disc surface. EWA14101 e. Measure the runout 1.5 mm (0.06 in) below WARNING the edge of the brake disc. Disc brake components rarely require disas- sembly.

  • Page 175: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc runout. 3. Measure: e. If out of specification, repeat the adjustment • Brake pad wear limit “a” steps until the brake disc runout is within Out of specification  Replace the brake specification. pads as a set.

  • Page 176: Removing The Front Brake Calipers

    FRONT BRAKE c. Tighten the bleed screw. 8. Check: • Brake lever operation Brake caliper bleed screw Soft or spongy feeling  Bleed the brake sys- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) tem. d. Install the brake pads and brake pad spring. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...

  • Page 177: Disassembling The Front Brake Calipers

    FRONT BRAKE EAS30172 DISASSEMBLING THE FRONT BRAKE Recommended brake component replacement schedule CALIPERS The following procedure applies to both of the Brake pads If necessary brake calipers. Piston seals Every two years 1. Remove: • Brake caliper pistons “1” Piston dust seals Every two years •...

  • Page 178: Installing The Front Brake Calipers

    FRONT BRAKE replace the brake caliper piston dust seals 2. Remove: and brake caliper piston seals. • Front brake caliper 3. Install: • Brake pads Specified brake fluid DOT 4 • Brake pad spring • Brake pad pin • Brake pad clips EAS30175 INSTALLING THE FRONT BRAKE CALIPERS •...

  • Page 179: Removing The Front Brake Master Cylinder

    FRONT BRAKE (brake master cylinder body) Obstruction  Blow out with compressed air. 2. Check: • Brake master cylinder kit Damage/scratches/wear  Replace. 3. Check: • Brake master cylinder reservoir “1” • Brake master cylinder reservoir diaphragm holder “2” Cracks/damage  Replace. •...
  • Page 180 FRONT BRAKE • Align the end of the front brake master cylinder 3. Fill: holder with the punch mark “b” on the handle- • Brake master cylinder reservoir bar. (with the specified amount of the specified • First, tighten the upper bolt, then the lower bolt. brake fluid) •...
  • Page 181 FRONT BRAKE BRAKE SYSTEM (ABS)” on page 3-14. 4-38...

  • Page 182: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad retaining bolt Rear brake caliper Brake pad Brake pad shim Brake pad insulator Brake pad spring Bleed screw 4-39...
  • Page 183 REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • 110 Nm (11 m kgf, 80 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft lbf) •...
  • Page 184 REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • 110 Nm (11 m kgf, 80 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft lbf) •...
  • Page 185 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-42...
  • Page 186 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-14. Brake hose union bolt Brake hose gasket Brake hose Rear brake caliper 4-43...
  • Page 187 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Screw plug Brake pad retaining bolt Brake pad Brake pad shim Brake pad insulator Brake pad spring Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw 4-44...

  • Page 188: Introduction

    REAR BRAKE EAS30183 INTRODUCTION Brake disc thickness limit 4.5 mm (0.18 in) EWA14101 WARNING 5. Adjust: Disc brake components rarely require disas- • Brake disc runout sembly. Therefore, always follow these pre- Refer to “CHECKING THE FRONT BRAKE ventive measures: DISCS”...

  • Page 189: Removing The Rear Brake Caliper

    REAR BRAKE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Recommended lubricant a. Connect a clear plastic hose “1” tightly to the Silicone grease bleed screw “2”. Put the other end of the hose into an open container. ECA14150 b. Loosen the bleed screw and push the brake NOTICE caliper piston into the brake caliper with your •...

  • Page 190: Disassembling The Rear Brake Caliper

    REAR BRAKE • Brake hose gaskets “2” • Brake hose “3” Put the end of the brake hose into a container and pump out the brake fluid carefully. b. Remove the brake caliper piston dust seal and brake caliper piston seal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 191: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: EWA13531 WARNING • Rear brake caliper bracket “1” Cracks/damage  Replace. Proper brake hose routing is essential to in- sure safe vehicle operation. Refer to “REAR WHEEL” on page 4-18. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a”...

  • Page 192: Removing The Rear Brake Master Cylinder

    REAR BRAKE 4. Fill: EAS30193 REMOVING THE REAR BRAKE MASTER • Brake fluid reservoir CYLINDER (with the specified amount of the specified 1. Remove: brake fluid) • Brake hose union bolt “1” Specified brake fluid • Brake hose gaskets “2” DOT 4 •...

  • Page 193: Assembling The Rear Brake Master Cylinder

    REAR BRAKE EAS30195 EWA13090 ASSEMBLING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other EWA13520 brake fluids may cause the rubber seals to WARNING deteriorate, causing leakage and poor • Before installation, all internal brake com- brake performance.

  • Page 194: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 Nm (3.0 m kgf, 22 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 2.0 Nm (0.20 m kgf, 1.4 ft lbf) •...
  • Page 195 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 Nm (3.0 m kgf, 22 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 2.0 Nm (0.20 m kgf, 1.4 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...

  • Page 196: Abs Components Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30728 ABS COMPONENTS CHART 1. Hydraulic unit assembly 2. Fuse box 2 3. Yamaha diagnostic tool coupler 4. Rear wheel sensor 5. Rear wheel sensor rotor 6. Front wheel sensor 7. Front wheel sensor rotor 8. ABS warning light 9.

  • Page 197: Removing The Hydraulic Unit Assembly

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30197 REMOVING THE HYDRAULIC UNIT Do not operate the brake lever and brake pedal ASSEMBLY while removing the brake hoses. ECA21091 NOTICE ECA18251 NOTICE Unless necessary, avoid removing and in- When removing the brake hoses, cover the stalling the brake hoses of the hydraulic unit area around the hydraulic unit assembly to assembly.
  • Page 198 ABS (ANTI-LOCK BRAKE SYSTEM) Do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses when installing the hydraulic unit assembly. 2. Remove: • Rubber plugs or bolts (M10  1.0) 3. Install: • Front brake hose (front brake master cylinder to hydraulic unit) “1”...

  • Page 199: Hydraulic Unit Operation Tests

    WARNING Securely support the vehicle so that there is no danger of it falling over. 6. Start the Yamaha diagnostic tool and display • For the brake line routing confirmation, use the the diagnosis of function screen. diagnosis of function of the Yamaha diagnostic 7.
  • Page 200 Securely support the vehicle so that there is no danger of it falling over. • For the ABS reaction-force confirmation, use the diagnosis of function of the Yamaha diag- nostic tool. For more information, refer to the operation manual of the Yamaha diagnostic tool.
  • Page 201 “1” and continues for a few seconds. • The reaction-force pulsating action consists of 6. Start the Yamaha diagnostic tool and display quick pulses. the diagnosis of function screen. • Be sure to continue operating the brake lever 7.

  • Page 202: Checking The Abs Warning Light

    12.Turn the main switch to “OFF”. 13.Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler, and then in- stall the protective cap. 14.Turn the main switch to “ON”.

  • Page 203: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft lbf) 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • • • 17 Nm (1.7 m kgf, 12 ft lbf) 26 Nm (2.6 m kgf, 19 ft lbf) •...
  • Page 204 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kgf, 5.1 ft lbf) 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • • • 17 Nm (1.7 m kgf, 12 ft lbf) 26 Nm (2.6 m kgf, 19 ft lbf) •...

  • Page 205: Removing The Handlebar

    HANDLEBAR EAS30203 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” Blow compressed air between the left handlebar EAS30205 and the handlebar grip, and gradually push the INSTALLING THE HANDLEBAR...
  • Page 206 HANDLEBAR 3. Tighten: 7. Install: • Lower handlebar holder nuts • Clutch lever holder “1” • Clutch cable Lower handlebar holder nut 40 Nm (4.0 m·kgf, 29 ft·lbf) Clutch lever holder pinch bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) 4. Install: •...
  • Page 207 HANDLEBAR ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 9. Install: • Handlebar switch screw (left) Handlebar switch screw 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf) Align the projection “a” on the left handlebar switch with the hole “b” in the handlebar. 10.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP”...

  • Page 208: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 9 Nm (0.9 m kgf, 6.5 ft lbf) 26 Nm (2.6 m kgf, 19 ft lbf) 9 Nm (0.9 m kgf, 6.5 ft lbf) • • • • • • 23 Nm (2.3 m kgf, 17 ft lbf)
  • Page 209 FRONT FORK Disassembling the left front fork leg Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Washer Spacer Fork spring Locknut Dust seal Oil seal clip Outer tube Oil seal Washer Outer tube bushing Inner tube bushing Damper rod assembly bolt Copper washer Damper rod assembly Inner tube...
  • Page 210 FRONT FORK Disassembling the right front fork leg Order Job/Parts to remove Q’ty Remarks Cap bolt O-ring Washer Spacer Fork spring Locknut Damper adjusting rod Dust seal Oil seal clip Outer tube Oil seal Washer Outer tube bushing Inner tube bushing Damper rod assembly bolt Copper washer Damper rod assembly...

  • Page 211: Removing The Front Fork Legs

    FRONT FORK • Locknut “4” EAS30206 REMOVING THE FRONT FORK LEGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following procedure applies to both of the a. Press down on the spacer with the fork spring front fork legs. compressor “5”. b. Install the rod holder “6” between the locknut Each front fork leg is equipped with a spring pre- “4”...

  • Page 212: Checking The Front Fork Legs

    FRONT FORK • Oil seal clip “2” Damper rod holder (ø27) (with a flat-head screwdriver) 90890-01582 ECA19100 Damper rod holder NOTICE YM-01582 Do not scratch the outer tube. 4. Remove: EAS30208 • Outer tube CHECKING THE FRONT FORK LEGS The following procedure applies to both of the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼...

  • Page 213: Assembling The Front Fork Legs

    FRONT FORK –Oil seal –Oil seal clip –Dust seal –Copper washer –O-ring • Before assembling the front fork leg, make sure all of the components are clean. 1. Install: • Damper rod assembly “1” ECA19120 NOTICE 3. Check: Allow the damper rod assembly to slide •...
  • Page 214 3. Lubricate: 90890-01442 • Inner tube’s outer surface Adjustable fork seal driver (36–46 Recommended oil YM-01442 Yamaha Suspension Oil G10 4. Install: • Dust seal “1” • Oil seal clip “2” • Oil seal “3” • Washer “4” • Outer tube bushing “5”...
  • Page 215 • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil 9. Install: Yamaha Suspension Oil G10 • Dust seal “1” Quantity (left) (with the fork seal driver “2”) 444.0 cm³ (15.01 US oz, 15.66 Imp.oz)
  • Page 216 FRONT FORK Be sure to bleed the front fork leg of any residual air. 14.Measure: • Front fork leg oil level “a” (from the top of the outer tube, with the outer tube fully compressed and without the fork spring) Out of specification ...
  • Page 217 FRONT FORK ment. j. Install the washer and cap bolt, and then fin- ger tighten the cap bolt. EWA13670 WARNING Always use a new cap bolt O-ring. k. Hold the cap bolt “5” and tighten the locknut “3” to specification. Front fork cap bolt locknut 15 Nm (1.5 m·kgf, 11 ft·lbf) c.

  • Page 218: Installing The Front Fork Legs

    FRONT FORK ment. n. Remove the rod holder and fork spring com- j. Position the locknut “3” as specified “b”. pressor. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Distance “b” 17.Install: 12 mm (0.47 in) • Cap bolt (to the outer tube) • Temporarily tighten the cap bolt. •...

  • Page 219: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft lbf) • • 52 Nm (5.2 m kgf, 38 ft lbf) • • 18 Nm (1.8 m kgf, 13 ft lbf) • • Order Job/Parts to remove Q’ty Remarks...
  • Page 220 STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft lbf) • • 52 Nm (5.2 m kgf, 38 ft lbf) • • 18 Nm (1.8 m kgf, 13 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Wire harness clamp...

  • Page 221: Removing The Lower Bracket

    STEERING HEAD Damage/pitting  Replace the bearings and EAS30213 REMOVING THE LOWER BRACKET bearing races as a set. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2.

  • Page 222: Installing The Steering Head

    STEERING HEAD pinch bolts. 5. Tighten: • Steering stem nut Steering stem nut 110 Nm (11 m·kgf, 80 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage  Replace. EAS30216 INSTALLING THE STEERING HEAD 1.

  • Page 223: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 44 Nm (4.4 m kgf, 32 ft lbf) • • 61 Nm (6.1 m kgf, 44 ft lbf) • • 44 Nm (4.4 m kgf, 32 ft lbf) •...

  • Page 224: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a maintenance stand so EWA13740 that the rear wheel is elevated. WARNING This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Connecting arm lower nut “1” the rear shock absorber, read and make sure •...

  • Page 225: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY Damage/wear  Replace. 2. Check: • Bearing • Oil seals Damage/pitting  Replace. 3. Check: • Collars Damage/scratches  Replace. EAS30222 INSTALLING THE RELAY ARM 3. Relay arm 1. Lubricate: 4. Connecting arm • Collars 5. Rear shock absorber assembly •...
  • Page 226 REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly nut (upper) 44 Nm (4.4 m·kgf, 32 ft·lbf) Relay arm nut 61 Nm (6.1 m·kgf, 44 ft·lbf) Connecting arm lower nut 55 Nm (5.5 m·kgf, 40 ft·lbf) 4-83...

  • Page 227: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm 110 Nm (11 m kgf, 80 ft lbf) • • 55 Nm (5.5 m kgf, 40 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) •...

  • Page 228: Removing The Swingarm

    SWINGARM EAS30226 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a maintenance stand so that the rear wheel is elevated. 2.

  • Page 229: Installing The Swingarm

    SWINGARM • Collars “3” Damage/scratches  Replace. • Bearing “4” Damage/pitting  Replace. A. Left side B. Right side 3. Install: • Swingarm EAS30228 • Pivot shaft INSTALLING THE SWINGARM 1. Lubricate: Pivot shaft nut • Dust covers 110 Nm (11 m·kgf, 80 ft·lbf) •...

  • Page 230: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 95 Nm (9.5 m kgf, 69 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...

  • Page 231: Removing The Drive Chain

    CHAIN DRIVE Drive chain 15-link section length “a” = EAS30229 REMOVING THE DRIVE CHAIN (length “b” between pin inner sides + length 1. Stand the vehicle on a level surface. “c” between pin outer sides)/2 EWA13120 WARNING • When measuring a 15-link section of the drive Securely support the vehicle so that there is chain, make sure that the drive chain is taut.
  • Page 232 CHAIN DRIVE ECA19090 NOTICE • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.
  • Page 233 CHAIN DRIVE EAS30234 INSTALLING THE DRIVE CHAIN 1. Install: • Drive chain ECA17410 NOTICE Be sure to put on safety goggles when work- ing. Install the drive chain joint with the drive chain cut & rivet tool. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Lubricate: Drive chain cut &...
  • Page 234 CHAIN DRIVE 5. Adjust: • Drive chain slack Refer to “Adjusting the drive chain slack” on page 3-18. Drive chain slack (Maintenance stand) 5.0–15.0 mm (0.20–0.59 in) Drive chain slack (Sidestand) 5.0–15.0 mm (0.20–0.59 in) ECA13550 NOTICE A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident.

  • Page 235: Engine

    ENGINE ENGINE INSPECTION ..................5-1 MEASURE THE COMPRESSION PRESSURE.........5-1 ENGINE REMOVAL..................5-3 REMOVING THE ENGINE .................5-7 INSTALLING THE ENGINE................5-7 CAMSHAFTS....................5-9 REMOVING THE CAMSHAFTS...............5-11 CHECKING THE CAMSHAFTS ...............5-12 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-13 CHECKING THE TIMING CHAIN GUIDES..........5-13 CHECKING THE TIMING CHAIN TENSIONER........5-13 INSTALLING THE CAMSHAFTS .............5-14 CYLINDER HEAD...................5-19 REMOVING THE CYLINDER HEAD............5-20...
  • Page 236 CHECKING THE CLUTCH HOUSING .............5-44 CHECKING THE CLUTCH BOSS............5-45 CHECKING THE PRESSURE PLATE .............5-45 CHECKING THE PRIMARY DRIVE GEAR..........5-45 CHECKING THE PRIMARY DRIVEN GEAR ...........5-45 CHECKING THE PULL LEVER SHAFT AND PULL ROD .......5-45 INSTALLING THE CLUTCH..............5-46 SHIFT SHAFT....................5-49 CHECKING THE SHIFT SHAFT ..............5-50 CHECKING THE STOPPER LEVER ............5-50 INSTALLING THE SHIFT SHAFT ............5-50 OIL PUMP.......................5-51...
  • Page 237 CHECKING THE SHIFT DRUM ASSEMBLY...........5-82 CHECKING THE TRANSMISSION ............5-82 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .......5-82 INSTALLING THE TRANSMISSION ............5-83...

  • Page 238: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION EAS30249 MEASURE THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Measure: 5. Measure: • Valve clearance • Compression pressure Out of specification ...
  • Page 239 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Piston ring(s) wear or Higher than without oil damage  Repair. Piston, valves, cylinder Same as without oil head gasket possibly defective  Repair. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6. Install: • Spark plugs Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) 7.

  • Page 240: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 20 Nm (2.0 m kgf, 14 ft lbf) • • 20 Nm (2.0 m kgf, 14 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • •...
  • Page 241 ENGINE REMOVAL Disconnecting the leads and hoses 12 Nm (1.2 m kgf, 8.7 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 242 ENGINE REMOVAL Disconnecting the leads and hoses 12 Nm (1.2 m kgf, 8.7 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Gear position switch coupler Disconnect. Crankshaft position sensor coupler Disconnect.
  • Page 243 ENGINE REMOVAL Removing the engine 7 Nm (0.7 m kgf, 5.1 ft Ibf) 45 Nm (4.5 m kgf, 33 ft Ibf) • • • • 45 Nm (4.5 m kgf, 33 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...

  • Page 244: Removing The Engine

    ENGINE REMOVAL EAS30250 REMOVING THE ENGINE 1. Loosen: • Engine mounting adjust bolt (front) Loosen the engine mounting adjust bolt with the pivot shaft wrench “1”. Pivot shaft wrench 90890-01485 Frame mount insert wrench EAS30251 YM-01485 INSTALLING THE ENGINE 1. Install: •...
  • Page 245 ENGINE REMOVAL 7. Tighten: • Engine mounting adjust bolts (rear) “2” • Tighten the engine mounting adjust bolts to specification with the pivot shaft wrench and pivot shaft wrench adapter. • Make sure that the flange on the engine mounting adjust bolt contacts the engine. Engine mounting adjust bolt (rear) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

  • Page 246: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 247 CAMSHAFTS Removing the camshafts 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) •...

  • Page 248: Removing The Camshafts

    CAMSHAFTS 4. Remove: EAS30256 REMOVING THE CAMSHAFTS • Camshaft cap “1” 1. Remove: • Intake camshaft cap “2” • Timing mark accessing bolt “1” • Exhaust camshaft cap “3” • Crankshaft end cover “2” ECA13720 NOTICE To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.

  • Page 249: Checking The Camshafts

    CAMSHAFTS Camshaft wrench 90890-04162 Camshaft wrench YM-04162 4. Measure: • Camshaft-journal-to-camshaft-cap clearance Out of specification  Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance EAS30257 0.028–0.062 mm (0.0011–0.0024 CHECKING THE CAMSHAFTS 1. Check: Limit • Camshaft lobes 0.080 mm (0.0032 in) Blue discoloration/pitting/scratches ...

  • Page 250: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ a. 1/4 tooth b. Correct 5. Measure: • Camshaft journal diameter “a” 1. Timing chain Out of specification  Replace the camshaft. 2. Camshaft sprocket Within specification  Replace the cylinder head and the camshaft caps as a set. EAS30265 CHECKING THE TIMING CHAIN GUIDES Camshaft journal diameter...

  • Page 251: Installing The Camshafts

    CAMSHAFTS b. Make sure that the timing chain tensioner rod ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ moves in and out of the timing chain tension- 3. Install: er housing smoothly. If there is rough move- • Intake camshaft sprocket “1” ment, replace the timing chain tensioner. •...
  • Page 252 CAMSHAFTS shaft faces up. • When installing the camshaft, no need to align Tighten the camshaft cap bolts in the tightening the mark “b” on the camshaft sprocket. sequence as shown. ECA17430 NOTICE • Lubricate the camshaft cap bolts with the engine oil.
  • Page 253 CAMSHAFTS 8. Check: c. Tighten the timing chain tensioner bolts to the • Camshaft punch mark “a” specified torque. Make sure the punch mark “a” on the cam- Timing chain tensioner bolt shaft is aligned with the camshaft cap align- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ment mark “b”.
  • Page 254 CAMSHAFTS 10.Turn: • Crankshaft (several turns counterclockwise) 11.Check: • Mark “a” Make sure the mark “a” on the generator rotor is aligned with the generator rotor cover mark “b”. • Camshaft punch mark “c” Make sure the punch mark “c” on the cam- shaft is aligned with the camshaft cap align- 14.Install: ment mark “d”.
  • Page 255 CAMSHAFTS Install the ignition coils “1” in the direction shown in the illustration. 5-18...

  • Page 256: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 25 Nm (2.5 m kgf, 18 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf), • • Specified angle 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...

  • Page 257: Removing The Cylinder Head

    CYLINDER HEAD Damage/scratches  Replace. EAS30276 REMOVING THE CYLINDER HEAD • Cylinder head water jacket 1. Remove: Mineral deposits/rust  Eliminate. • Intake camshaft 3. Measure: • Exhaust camshaft • Cylinder head warpage Refer to “REMOVING THE CAMSHAFTS” Out of specification  Resurface the cylinder on page 5-11.

  • Page 258: Installing The Cylinder Head

    CYLINDER HEAD 4. Install: EAS30282 INSTALLING THE CYLINDER HEAD • Exhaust camshaft 1. Install: • Intake camshaft • Timing chain guide (exhaust side) “1” Refer to “INSTALLING THE CAMSHAFTS” • Cylinder head gasket “2” on page 5-14. • Dowel pins “3” 2.
  • Page 259 VALVES AND VALVE SPRINGS EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-19. Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal...

  • Page 260: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS30283 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.
  • Page 261 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification  Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 b. Install the new valve guide with the valve guide installer “2”...

  • Page 262: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 2. Check: Valve guide remover (ø4.5) • Valve seat 90890-04116 Pitting/wear  Replace the cylinder head. Valve guide remover (4.5 mm) 3. Measure: YM-04116 • Valve seat contact width “a” Valve guide installer (ø4.5) Out of specification  Replace the cylinder 90890-04117 head.

  • Page 263: Checking The Valve Springs

    VALVES AND VALVE SPRINGS After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a coarse lapping compound “a” to the valve face. ECA13790 NOTICE Do not let the lapping compound enter the h.

  • Page 264: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 1. Deburr: • Valve stem end (with an oil stone) 2. Measure: • Valve spring tilt “a” Out of specification  Replace the valve spring. 2. Lubricate: • Valve stem “1” Spring tilt (intake) • Valve stem seal “2” 1.7 mm (0.07 in) (with the recommended lubricant) Spring tilt (exhaust)
  • Page 265 VALVES AND VALVE SPRINGS 6. Lubricate: b. Smaller pitch • Valve pad 4. Install: (with the recommended lubricant) • Valve cotters “1” Recommended lubricant Molybdenum disulfide oil Install the valve cotters by compressing the valve spring with the valve spring compressor •...

  • Page 266: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) 75 Nm (7.5 m...
  • Page 267 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) 75 Nm (7.5 m kgf, 54 ft...

  • Page 268: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS30867 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. Sheave holder EAS30868 90890-01701 REMOVING THE STARTER CLUTCH Primary clutch holder 1.

  • Page 269: Installing The Starter Clutch

    GENERATOR AND STARTER CLUTCH erator rotor “2” and hold the generator rotor. b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. c.
  • Page 270 GENERATOR AND STARTER CLUTCH 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 4. Install: • Generator cover gasket • Generator cover Generator cover bolt “1” 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE®...
  • Page 271 ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 272 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket Brush holder set Starter motor rear cover 5-35...

  • Page 273: Electric Starter

    ELECTRIC STARTER EAS30325 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt  Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification  Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut (depth) 1.

  • Page 274: Assembling The Starter Motor

    ELECTRIC STARTER 6. Check: Starter motor bolt • Gear teeth 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Damage/wear  Replace the starter motor. 7. Check: 2. Connect: • Bearing • Starter motor lead • Oil seal Damage/wear  Replace the starter motor. EAS30326 ASSEMBLING THE STARTER MOTOR 1.

  • Page 275: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover 12 Nm (1.2 m kgf, 8.7 ft lbf) 7 Nm (0.7 m kgf, 5.1 ft lbf) • • • • 12 Nm (1.2 m kgf, 8.7 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) •...
  • Page 276 CLUTCH Removing the pull lever shaft 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Install the clutch cover damper plate with its Clutch cover damper plate folded-up side facing upward.
  • Page 277 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Oil pump driven sprocket Refer to “OIL PUMP” on page 5-51. Pressure plate 1 Clutch spring Absorber...
  • Page 278 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Thrust plate Clutch housing Oil pump drive chain Bearing Spacer Thrust plate Thrust plate 5-41...

  • Page 279: Removing The Clutch

    CLUTCH 4. Remove: EAS30346 REMOVING THE CLUTCH • Friction plates 1 “1” 1. Remove: • Cover “1” • Clutch cover “2” • Gasket Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 280: Checking The Friction Plates

    CLUTCH 8. Remove: A. Friction plate 1 • Clutch boss nut B. Friction plate 2 • Conical spring washer EAS30349 • Washer CHECKING THE CLUTCH PLATES • Clutch boss The following procedure applies to all of the • Thrust plate clutch plates.

  • Page 281: Checking The Clutch Springs

    CLUTCH Out of specification  Adjust. Assembly width 42.7–43.5 mm (1.68–1.71 in) • Perform the thickness measurement without applying the oil. • This step should be performed only if the fric- tion plates and clutch plates were replaced. • To measure the total width of the friction plates and clutch plates, combine 9 friction plates and ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...

  • Page 282: Checking The Clutch Boss

    CLUTCH Cracks/damage  Replace. • Bearing “3” Damage/wear  Replace. 2. Check: • Oil pump drive sprocket “1” Cracks/damage/wear  Replace. EAS30356 CHECKING THE PRIMARY DRIVE GEAR 1. Check: • Primary drive gear Damage/wear  Replace the crankshaft and clutch housing as a set. Excessive noise during operation ...

  • Page 283: Installing The Clutch

    CLUTCH Universal clutch holder 90890-04086 Universal clutch holder YM-91042 2. Check: • Pull rod bearing Damage/wear  Replace. EAS30363 INSTALLING THE CLUTCH 1. Install: • Oil pump drive chain “1” • Clutch housing “2” Install the oil pump drive chain onto the oil pump drive sprocket “a”.
  • Page 284 CLUTCH • Clutch springs a crisscross pattern. • Pressure plate 1 6. Install: • Clutch spring bolts “1” • Pull lever Clutch spring bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Install the pull lever with the “O” mark facing to- ward lower side.
  • Page 285 CLUTCH 8. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-11. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 5-48...
  • Page 286 SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-38. Shift arm Refer to “CHAIN DRIVE” on page 4-87. Circlip Washer Shift shaft...

  • Page 287: Shift Shaft

    SHIFT SHAFT EAS30377 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft “1” Bends/damage/wear  Replace. • Shift shaft spring “2” • Collar Damage/wear  Replace. 2. Install: • Bearing • Oil seal • Washer “1” • Circlip “2” • Lubricate the oil seal lips with lithium-soap- based grease.

  • Page 288: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks...
  • Page 289 OIL PUMP Disassembling the oil pump 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Hold down the washer when removing the Circlip circlip.

  • Page 290: Checking The Sprocket And Chain

    OIL PUMP EAS30336 CHECKING THE SPROCKET AND CHAIN Inner-rotor-to-outer-rotor-tip clearance 1. Check: Less than 0.120 mm (0.0047 in) • Oil pump drive sprocket Limit Refer to “CHECKING THE CLUTCH HOUS- 0.200 mm (0.0079 in) ING” on page 5-44. Outer-rotor-to-oil-pump-housing 2. Check: clearance •...

  • Page 291: Assembling The Oil Pump

    OIL PUMP Oil pump bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Oil pump driven sprocket “3” Oil pump driven sprocket bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) LOCTITE® ECA20940 NOTICE EAS30342 After installing the oil pump drive chain and ASSEMBLING THE OIL PUMP driven sprocket, make sure the oil pump 1.

  • Page 292: Oil Pan

    OIL PAN EAS20177 OIL PAN Removing the oil pan 43 Nm (4.3 m kgf, 31 ft lbf) • • (13) 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • Order Job/Parts to remove Q’ty...

  • Page 293: Removing The Oil Pan

    OIL PAN EAS31068 EWA12820 REMOVING THE OIL PAN WARNING 1. Remove: Always use new copper washers. • Oil level switch “1” • Oil pan “2” • Tighten the oil pan bolts in stages and in a • Oil pan gasket crisscross pattern.

  • Page 294: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 25 Nm (2.5 m kgf, 18 ft Ibf) 24 Nm (2.4 m kgf, 17 ft Ibf) • • • • 18 Nm (1.8 m kgf, 13 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 295: Disassembling The Crankcase

    Recommended lubricant Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings, or balancer shaft journal bearings.
  • Page 296 CRANKCASE 4. Set the shift drum assembly and transmission gears in the neutral position. 5. Install: 19 20 • Lower crankcase “1” 21 22 23 24 (onto the upper crankcase “2”) ECA13980 NOTICE Before tightening the crankcase bolts, make sure the transmission gears shift correctly when the shift drum assembly is turned by hand.
  • Page 297 CRANKCASE 8. Tighten: • Crankcase bolts “9”–“30” Crankcase bolts “9”–“14” 24 Nm (2.4 m·kgf, 17 ft·lbf) Crankcase bolts “15”–“30” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the bolts in the tightening sequence cast on the crankcase. 19 20 23 24 5-60...

  • Page 298: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 20 Nm (2.0 m kgf, 14 ft Ibf) • • Specified angle 175–185˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-57. Connecting rod cap Big end lower bearing Piston pin clip...

  • Page 299: Removing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS30745 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: • Connecting rod cap “1” • Connecting rod • Big end bearings • Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 300: Checking The Piston Rings

    CONNECTING RODS AND PISTONS Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Bore 78.000–78.010 mm (3.0709– 3.0713 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) a. 12.0 mm (0.47 in) from the bottom edge of the piston “C”...

  • Page 301: Checking The Piston Pin

    CONNECTING RODS AND PISTONS Piston ring Top ring Ring side clearance 0.030–0.065 mm (0.0012–0.0026 Side clearance limit 0.115 mm (0.0045 in) 2nd ring Ring side clearance 0.020–0.055 mm (0.0008–0.0022 b. Upper of cylinder Side clearance limit 0.115 mm (0.0045 in) EAS30749 CHECKING THE PISTON PIN The following procedure applies to all of the pis-...

  • Page 302: Checking The Connecting Rods

    CONNECTING RODS AND PISTONS connecting rod cap. 4. Calculate: c. Put a piece of Plastigauge® “1” on the crank- • Piston-pin-to-piston-pin-bore clearance Out of specification  Replace the piston pin shaft pin. and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore inside diameter “b”...
  • Page 303 CONNECTING RODS AND PISTONS order to assemble in the most suitable condition. Connecting rod bolt (1st) e. Tighten the connecting rod bolt while check- 20 Nm (2.0 m·kgf, 14 ft·lbf) ing that the sections shown “a” and “b” are h. Put a mark “1” on the corner of the connecting flush with each other by touching the surface.

  • Page 304: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS k. Remove the connecting rod and big end bearings. l. Measure the compressed Plastigauge® width on the crankshaft pin. If the crankshaft- pin-to-big-end-bearing clearance is out of specification, select replacement big end bearings. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: •...
  • Page 305 CONNECTING RODS AND PISTONS a. Side machined face b. Thrusting faces e. Loosen the connecting rod bolt, remove the connecting rod and connecting rod cap and install these parts to the crankshaft with the big end bearing kept in the current condition. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 306 CONNECTING RODS AND PISTONS Recommended lubricant Engine oil 8. Install: • Piston assemblies “1” (into the cylinder “2” and onto the crankshaft pin) Piston installing tool 90890-04161 Piston installing tool YM-04161 ECA21490 NOTICE If the projection “a” of the piston installing tool damages, you cannot use it.
  • Page 307 CONNECTING RODS AND PISTONS 180˚ 10.Tighten: EWA16610 WARNING • Connecting rod bolts “1” If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new one and perform the procedure again.

  • Page 308: Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS20178 CRANKSHAFT AND BALANCER SHAFT Removing the crankshaft and balancer shaft Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-57. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-62. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing...

  • Page 309: Removing The Crankshaft And Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT EAS31171 REMOVING THE CRANKSHAFT AND BALANCER SHAFT 1. Remove: • Balancer shaft “1” • Balancer shaft journal bearing • Crankshaft assembly “2” • Crankshaft journal bearings Identify the position of each balancer shaft jour- nal bearings and crankshaft journal bearings so that it can be reinstalled in its original place.
  • Page 310 CRANKSHAFT AND BALANCER SHAFT nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. d. Put a piece of Plastigauge® “1” on each crankshaft journal. Do not put the Plastigauge® over the oil hole in ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the crankshaft journal. 4.

  • Page 311: Checking The Balancer Shaft

    CRANKSHAFT AND BALANCER SHAFT Balancer shaft journal to balancer shaft bearing clearance 0.024–0.048 mm (0.0009–0.0019 ECA18400 NOTICE Do not interchange the balancer shaft jour- nal bearings. To obtain the correct balancer shaft-journal-to-balancer shaft-journal-bear- ing clearance and prevent engine damage, the balancer shaft journal bearings must be installed in their original positions.

  • Page 312: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT e. Install the balancer shaft journal lower bear- ancer shaft web “J ” numbers are 5 and 2 re- ings “1” into the lower crankcase and assem- spectively, then the bearing size for “J ” is: ble the crankcase halves.

  • Page 313: Installing The Balancer Assembly

    CRANKSHAFT AND BALANCER SHAFT • Crankshaft journal lower bearings (into the lower crankcase) • Crankshaft • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcase. • Be sure to install each crankshaft journal bear- ings in its original place.

  • Page 314: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 315 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Bearing housing Bearing Main axle 5-78...
  • Page 316 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear Circlip Washer...
  • Page 317 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle 5-80...

  • Page 318: Removing The Transmission

    TRANSMISSION EAS30430 REMOVING THE TRANSMISSION 1. Remove: • Drive axle assembly “1” • Shift drum retainers “2” • Shift fork guide bars • Shift fork-L • Shift fork-R • Shift drum assembly • Shift fork-C EAS30431 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks.
  • Page 319 TRANSMISSION Out of specification  Replace the drive axle. Drive axle runout limit 0.08 mm (0.0032 in) EAS30432 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • Shift drum groove Damage/scratches/wear  Replace the shift drum assembly. • Shift drum segment “1” 3.
  • Page 320 TRANSMISSION tainer. • Be sure the circlip sharp-edged corner “a” is positioned opposite side to the toothed washer and gear. • Align the opening between the ends “b” of the circlip with a groove “c” in the axle. • Install the circlip so that a spline “d” is in the center of the gap between the circlip ends “e”...
  • Page 321 TRANSMISSION • Touch the protrusion “d” on the shift fork guide bar to the side of the shift drum retainer. • Make sure that the drive axle bearing circlip “4” is inserted into the grooves “e” in the upper crankcase. 3.
  • Page 322 TRANSMISSION 5-85...

  • Page 323: Cooling System

    COOLING SYSTEM RADIATOR......................6-1 CHECKING THE RADIATOR..............6-2 INSTALLING THE RADIATOR..............6-2 OIL COOLER....................6-4 CHECKING THE OIL COOLER ..............6-5 INSTALLING THE OIL COOLER ...............6-5 THERMOSTAT....................6-6 CHECKING THE THERMOSTAT...............6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP ....................6-8 DISASSEMBLING THE WATER PUMP...........6-10 CHECKING THE WATER PUMP .............6-10 ASSEMBLING THE WATER PUMP............6-10...

  • Page 324: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 5 Nm (0.5 m kgf, 3.6 ft lbf) • • 0.5 Nm (0.05 m kgf, 0.36 ft lbf) •...

  • Page 325: Checking The Radiator

    RADIATOR EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction  Clean. Apply compressed air to the rear of the radia- tor. Damage  Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 326 RADIATOR b. Apply 122.7 kPa (1.23 kgf/cm², 17.8 psi) of pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap valve opening pressure Below the specified pressure  Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.

  • Page 327: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Coolant reservoir Refer to “RADIATOR” on page 6-1. Muffler assembly Refer to “ENGINE REMOVAL”...

  • Page 328: Checking The Oil Cooler

    OIL COOLER 3. Fill: EAS30441 CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage  Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-26. • Oil cooler inlet hose •...

  • Page 329: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Muffler assembly Refer to “ENGINE REMOVAL” on page 5-3. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-26.

  • Page 330: Checking The Thermostat

    THERMOSTAT EAS30443 CHECKING THE THERMOSTAT 1. Check: • Thermostat assembly “1” Cracks/damage  Replace. EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: • Thermostat assembly 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-26.

  • Page 331: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-26. Water pump inlet hose Disconnect. Water pump assembly...
  • Page 332 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Water pump driven gear Washer Impeller shaft Mechanical seal Bearing Oil seal...

  • Page 333: Disassembling The Water Pump

    WATER PUMP EAS30446 EAS30447 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (housing side) “1” • Water pump housing cover “1” • Impeller shaft “2” Cracks/damage/wear  Replace. Remove the mechanical seal (housing side) from the inside of the water pump housing “2”.
  • Page 334 WATER PUMP 4. Measure: ECA20330 NOTICE • Impeller shaft tilt Out of specification  Repeat steps (3) and Never lubricate the mechanical seal (hous- ing side) surface with oil or grease. (4). ECA20340 NOTICE Use the special tools and a press to press the Make sure the mechanical seal (impeller mechanical seal (housing side) straight in until it side) is flush with the impeller.

  • Page 335: Fuel System

    FUEL SYSTEM FUEL TANK ......................7-1 REMOVING THE FUEL TANK ..............7-4 REMOVING THE FUEL PUMP ..............7-4 CHECKING THE FUEL PUMP BODY............7-4 CHECKING THE FUEL PUMP OPERATION..........7-4 INSTALLING THE FUEL PUMP..............7-5 INSTALLING THE FUEL TANK..............7-5 THROTTLE BODIES ..................7-6 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-9 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ........7-9 REMOVING THE INJECTORS ..............7-9 CHECKING THE INJECTORS ..............7-9...

  • Page 336: Fuel Tank

    FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) •...
  • Page 337 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft lbf) •...
  • Page 338 FUEL TANK Removing the canister 7 Nm (0.7 m kgf, 5.1 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1. Refer to “GENERAL CHASSIS (2)” on page Fuel tank cover 4-3.

  • Page 339: Removing The Fuel Tank

    FUEL TANK EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Rider seat • Fuel tank cover Refer to “GENERAL CHASSIS (2)” on page 4-3. 3.

  • Page 340: Installing The Fuel Pump

    FUEL TANK EAS30456 INSTALLING THE FUEL PUMP 1. Install: • Fuel pump gasket • Fuel pump • Fuel pump bracket • Fuel pump bolts Fuel pump bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) 2. Connect: • Do not damage the installation surfaces of the •...

  • Page 341: Throttle Bodies

    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 4.5 Nm (0.45 m kgf, 3.3 ft lbf) • • 3.0 Nm (0.30 m kgf, 2.2 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.
  • Page 342 THROTTLE BODIES Removing the sensors 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • 3.5 Nm (0.35 m kgf, 2.5 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Negative pressure hose Hose joint Canister purge hose Hose joint Intake air pressure sensor 2 Intake air pressure sensor 1 Throttle position sensor...
  • Page 343 THROTTLE BODIES Removing the injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Throttle bodies/Throttle body joint Refer to “THROTTLE BODIES” on page 7-6. Fuel rail Injector Injector coupler...

  • Page 344: Checking The Injectors (Before Removing)

    THROTTLE BODIES hose may cause the fuel to spray out. Place EAS30475 CHECKING THE INJECTORS (BEFORE a container or rag under the hose to catch REMOVING) any fuel that spills. Always clean up any 1. Check: spilt fuel immediately. • Injectors •...
  • Page 345 • Do not turn the bypass air screws “a”; oth- erwise, the throttle body synchronization will be affected. Recommended cleaning solvent Yamaha Oil & Brake Cleaner d. Apply the recommended cleaning solvent to the throttle valves and the inside of the throt- tle bodies to remove any carbon deposits.

  • Page 346: Replacing The Throttle Bodies

    THROTTLE BODIES • Do not allow carbon deposits or other for- 5. Place the vehicle on a maintenance stand so eign materials to enter any of the passages that the rear wheel is elevated. in each throttle body or in the space be- 6.

  • Page 347: Checking The Fuel Pressure

    THROTTLE BODIES to the fuel rail joint “2”, and then connect an ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ air compressor “3” to the adapter. a. Remove the rider seat and fuel tank cover. b. Connect the pressure gauge “4” to the fuel in- Refer to “GENERAL CHASSIS (1)” on page jector pressure adapter “1”.

  • Page 348: Installing The Fuel Hose (Fuel Rail Side)

    • Fuel hose (fuel rail side) d. Remove the protective cap “1”, and then con- ECA17500 nect the Yamaha diagnostic tool to coupler. NOTICE When installing the fuel hose, make sure that For information about using the Yamaha diag-...

  • Page 349: Adjusting The Accelerator Position Sensor

    95–109, adjust the accelerator position sensor angle. For information about using the Yamaha diag- q. Repeat steps (f) to (p) until the Yamaha diag- nostic tool, refer to the operation manual that is nostic tool screen values are within the spec- included with the tool.

  • Page 350: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15...
  • Page 351 AIR INDUCTION SYSTEM 1. Air filter case 2. Air induction system hose (air filter case to air cut-off valve) 3. Air cut-off valve 4. Air induction system hose (air cut-off valve to reed valve cover) 7-16...
  • Page 352 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)” on page Rider seat 4-1.

  • Page 353: Checking The Air Induction System

    AIR INDUCTION SYSTEM Cracks/damage  Replace the reed valve EAS30488 CHECKING THE AIR INDUCTION SYSTEM assembly. Air injection 3. Measure: The air induction system burns unburned ex- • Reed valve bending limit “a” haust gases by injecting fresh air (secondary air) Out of specification ...
  • Page 354 AIR INDUCTION SYSTEM 2. Install: • Reed valve assembly 1 • Reed valve assembly 2 • Install the reed valve assembly 1 so that the open side turns to the exhaust side of the en- gine. • Install the reed valve assembly 2 so that the open side turns to the intake side of the engine.

  • Page 355: Electrical System

    COOLING SYSTEM..................8-29 CIRCUIT DIAGRAM .................8-29 TROUBLESHOOTING ................8-31 FUEL INJECTION SYSTEM................8-33 CIRCUIT DIAGRAM .................8-33 ECU SELF-DIAGNOSTIC FUNCTION.............8-35 TROUBLESHOOTING METHOD.............8-35 YAMAHA DIAGNOSTIC TOOL ..............8-36 TROUBLESHOOTING DETAILS (FAULT CODE) ........8-37 TROUBLESHOOTING DETAILS (EVENT CODE)........8-94 FUEL PUMP SYSTEM..................8-97 CIRCUIT DIAGRAM .................8-97 TROUBLESHOOTING ................8-99 IMMOBILIZER SYSTEM................8-101 CIRCUIT DIAGRAM ................8-101...
  • Page 356 ABS (ANTI-LOCK BRAKE SYSTEM)............8-111 CIRCUIT DIAGRAM ................8-111 ABS COMPONENTS CHART ..............8-113 ABS COUPLER LOCATION CHART .............8-115 MAINTENANCE OF THE ABS ECU ............8-117 ABS TROUBLESHOOTING OUTLINE...........8-117 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......8-118 BASIC PROCESS FOR TROUBLESHOOTING ........8-119 [A] CHECKING THE ABS WARNING LIGHT.........8-120 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON....8-120 [A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON ................8-120...

  • Page 358: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM...
  • Page 359 IGNITION SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 16.Battery 17.Engine ground 18.Fuel injection system fuse 21.Joint connector 22.Joint coupler 23.Relay unit 27.ECU (Engine Control Unit) 28.Ignition coil #1 29.Ignition coil #2 30.Ignition coil #3 31.Spark plug 37.Crankshaft position sensor 42.Lean angle sensor 66.Gear position switch 69.Sidestand switch...

  • Page 360: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM EAS30491 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.

  • Page 361: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank cover 3. Fuel tank 4. Air filter case 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 362 IGNITION SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-167. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-147. OK...
  • Page 363 IGNITION SYSTEM...

  • Page 364: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM...
  • Page 365 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 16.Battery 17.Engine ground 18.Fuel injection system fuse 19.Starter relay 20.Starter motor 21.Joint connector 22.Joint coupler 23.Relay unit 24.Starting circuit cut-off relay 66.Gear position switch 69.Sidestand switch 70.Handlebar switch (right) 72.Start/engine stop switch 77.Handlebar switch (left) 78.Clutch switch...

  • Page 366: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS30494 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 367 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HAN- DLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Start/engine stop switch 6.

  • Page 368: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank cover 3. Fuel tank 4. Air filter case 5. Throttle bodies 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 369 ELECTRIC STARTING SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-167. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-147. OK...

  • Page 370: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13...
  • Page 371 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 16.Battery 17.Engine ground A. Wire harness D. Negative battery sub-wire harness 8-14...

  • Page 372: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Rear side cover 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” NG on page 8-151. OK...
  • Page 373 CHARGING SYSTEM 8-16...

  • Page 374: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17...
  • Page 375 LIGHTING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 14.Headlight fuse 16.Battery 17.Engine ground 21.Joint connector 22.Joint coupler 27.ECU (Engine Control Unit) 50.Meter assembly 53.Meter light 61.High beam indicator light 77.Handlebar switch (left) 83.Pass switch 84.Dimmer switch 89.Headlight 90.Auxiliary light 91.License plate light...

  • Page 376: Troubleshooting

    LIGHTING SYSTEM EAS30499 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank cover 3. Fuel tank 4. Rear side cover 5.
  • Page 377 LIGHTING SYSTEM 8. Check the entire lighting system’s wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. NG page 8-17. OK Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-152. 8-20...

  • Page 378: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21...
  • Page 379 SIGNALING SYSTEM 3. Main switch 4. Main fuse 10.Parking lighting fuse 11.Ignition fuse 13.Signaling system fuse 16.Battery 17.Engine ground 21.Joint connector 22.Joint coupler 23.Relay unit 27.ECU (Engine Control Unit) 39.Coolant temperature sensor 44.Rear wheel sensor 45.ABS ECU (electronic control unit) 50.Meter assembly 52.Neutral indicator light 54.Tachometer...

  • Page 380: Troubleshooting

    SIGNALING SYSTEM EAS30501 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
  • Page 381 SIGNALING SYSTEM 3. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK This circuit is OK. The tail/brake light fails to come on. 1. Check the front brake light switch. Refer to “CHECKING THE Replace the front brake light switch.
  • Page 382 SIGNALING SYSTEM 5. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK Replace the meter assembly. The neutral indicator light fails to come on. 1. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch.
  • Page 383 SIGNALING SYSTEM 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-152. The speedometer fails to operate.
  • Page 384 SIGNALING SYSTEM 2. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. NG page 8-21. OK Replace the ECU or meter assembly. Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-152. 8-27...
  • Page 385 SIGNALING SYSTEM 8-28...

  • Page 386: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-29...
  • Page 387 COOLING SYSTEM 3. Main switch 4. Main fuse 9. Radiator fan motor fuse 11.Ignition fuse 16.Battery 17.Engine ground 21.Joint connector 22.Joint coupler 27.ECU (Engine Control Unit) 39.Coolant temperature sensor 94.Radiator fan motor relay 95.Radiator fan motor A. Wire harness C. Sub-wire harness (Coolant temperature sen- sor) D.

  • Page 388: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank cover 3. Fuel tank 4. Air filter case 5. Canister 6. Throttle bodies 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s).
  • Page 389 COOLING SYSTEM 8-32...

  • Page 390: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-33...
  • Page 391 42.Lean angle sensor 44.Rear wheel sensor 45.ABS ECU (electronic control unit) 46.Throttle servo motor 47.Accelerator position sensor 48.Throttle position sensor 49.Yamaha diagnostic tool coupler 50.Meter assembly 55.Multi-function meter 58.Engine trouble warning light 60.Traction control system indicator light 66.Gear position switch 68.Fuel pump...

  • Page 392: Ecu Self-Diagnostic Function

    • Fault code number ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Check the fault code numbers that have a condition of “Detected” using the Yamaha diagnostic tool. b. Identify the faulty system with the fault code number. c. Identify the probable cause of the malfunction.

  • Page 393: Yamaha Diagnostic Tool

    EAS30951 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03250 A generic scan tool can also be used to identify malfunctions.

  • Page 394: Troubleshooting Details (Fault Code)

    Write the VIN/frame number in the ECU. View logs: Displays the logging data. However, the Yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such as adjusting the ignition timing. Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
  • Page 395 Check the locking condition of function mode of the Yamaha the coupler. diagnostic tool. Disconnect the coupler and Condition is “Recovered”  Go check the pins (bent or broken to item 6 and finish the service.
  • Page 396 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 6 and finish the service.
  • Page 397 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 398 FUEL INJECTION SYSTEM Disconnect the ECU coupler from the ECU. Disconnect the intake air pressure sensor 1 coupler from the intake air pressure sensor 1. [For P0107] Ground short circuit Between intake air pressure sensor 1 coupler and ground: pink–ground If there is continuity, replace the wire harness.
  • Page 399 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 400 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 401 FUEL INJECTION SYSTEM Br/W Br/W 1. Intake air temperature sensor 2. ECU 3. Sensor output lead 4. Sensor ground lead Disconnect the ECU coupler from the ECU. Disconnect the intake air temperature sensor coupler from the intake air temperature sensor. [For P0112] Ground short circuit Between intake air temperature sensor coupler and ground: brown/white–ground If there is continuity, replace the wire harness.
  • Page 402 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 403 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 404 FUEL INJECTION SYSTEM [For P0117] Ground short circuit Between coolant temperature sensor coupler and ground: green/white–ground If there is continuity, replace the wire harness. [For P0118] Open circuit Between coolant temperature sensor coupler and ECU coupler: green/white–green/white If there is no continuity, replace the wire harness. G/W B/L [For P0118] Open circuit Between coolant temperature sensor coupler and ECU coupler: black/blue–black/blue...
  • Page 405 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 406 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 407 FUEL INJECTION SYSTEM [For P0122] Ground short circuit Between throttle position sensor coupler and ground: white–ground If there is continuity, replace the wire harness. [For P0123] Open circuit Between throttle position sensor coupler and ECU coupler: white–white If there is no continuity, replace the wire harness. [For P0222] Ground short circuit Between throttle position sensor coupler and ground: black–ground If there is continuity, replace the wire harness.
  • Page 408 FUEL INJECTION SYSTEM [For P0123/P0223] Open circuit Between throttle position sensor coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness. [For P0123/P0223] Open circuit Between throttle position sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness. Disconnect the couplers from the parts that are connected to the ECU.
  • Page 409 Improperly installed sensor  the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha Refer to “ADJUSTING THE diagnostic tool. Condition is “Recovered”  Go THROTTLE POSITION SEN- SOR”...
  • Page 410 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 411 Actuates fuel injector #1 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #1 is actuated Procedure five times by listening for the operating sound.
  • Page 412 Actuates fuel injector #2 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #2 is actuated Procedure five times by listening for the operating sound.
  • Page 413 Actuates Fuel injector #3 five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the fuel injector is actuated. Disconnect the fuel pump coupler. Check that fuel injector #3 is actuated Procedure five times by listening for the operating sound.
  • Page 414 5 seconds. light goes off. Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Fault code No. P0335 Fault code No. P0335 Crankshaft position sensor: no normal signals are received from Item the crankshaft position sensor.
  • Page 415 Disconnect the coupler and mode of the Yamaha diagnostic check the pins (bent or broken tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 416 FUEL INJECTION SYSTEM Actuates the cylinder-#1 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 417 Diagnostic code No. Actuates the cylinder-#2 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 418 Diagnostic code No. Actuates the cylinder-#3 ignition coil five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on each time the ignition coil is actuated. Check that a spark is generated five times.
  • Page 419 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 420 FUEL INJECTION SYSTEM Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Rear wheel speed pulse Tool display 0–999 Check that the number increases when the rear wheel is rotated. The Procedure number is cumulative and does not reset each time the wheel is stopped. Probable cause of malfunc- Confirmation of service com- Item...
  • Page 421 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 422 FUEL INJECTION SYSTEM Value does not increase  Go Locate the malfunction. Execute the diagnostic mode. (Code No. 07) to item A-2 for the rear wheel Rotate the rear wheel by hand sensor. and check that the indicated value increases. Incorrect indication ...
  • Page 423 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 424 FUEL INJECTION SYSTEM Value does not increase  Go Locate the malfunction. Execute the diagnostic mode. (Code No. 07) to item A-2 for the rear wheel Rotate the rear wheel by hand sensor. and check that the indicated value increases. Incorrect indication ...
  • Page 425 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 426 8-13. Check the condition of the fault Defective rectifier/regulator or code using the malfunction AC magneto  Replace. mode of the Yamaha diagnostic Defective connection in the tool. charging system circuit  Prop- Condition is “Recovered”  Go erly connect or replace the wire to item 2 and finish the service.
  • Page 427 CO EEPROM. the fault code using the mal- concentration of cylinder #1. Refer to “ADJUSTING THE function mode of the Yamaha EXHAUST GAS VOLUME” on diagnostic tool. Condition is “Recovered”  Go page 3-10. After this adjustment is made, to item 7 and finish the service.
  • Page 428 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 429 Actuates the relay unit five times at one-second intervals. Actuation The “check” indicator on the Yamaha diagnostic tool screen come on each time the relay is actuated. Check that the relay unit is actuated five times by listening for the operat- Procedure ing sound.
  • Page 430 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 431 (Code No. 03) and then check the condition of When engine is stopped: the fault code using the mal- Atmospheric pressure at the function mode of the Yamaha current altitude and weather diagnostic tool. Condition is “Recovered”  Go conditions is indicated.
  • Page 432 Actuates the air induction system solenoid five times at one-second inter- vals. Actuation The “check” indicator on the Yamaha diagnostic tool screen come on each time the air induction system solenoid is actuated. Check that the air induction system solenoid is actuated five times by lis- Procedure tening for the operating sound.
  • Page 433 Between air induction system the fault code using the mal- solenoid coupler and ECU cou- function mode of the Yamaha pler. diagnostic tool. Condition is “Recovered”  Go brown/red–brown/red Between air induction system to item 6 and finish the service.
  • Page 434 Check the condition of the fault Disconnect the coupler and code using the malfunction check the pins (bent or broken mode of the Yamaha diagnostic terminals and locking condition tool. Condition is “Recovered”  Go of the pins).
  • Page 435 (loose bolts). function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 436 Between battery terminal and the fault code using the mal- starter relay. function mode of the Yamaha red–red diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 6.
  • Page 437 “OFF”, and then back to “ON”. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Go to item 4.
  • Page 438 “OFF”, and then back to page 8-159. “ON”. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Go to item 5.
  • Page 439 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 7 and finish the service.
  • Page 440 FUEL INJECTION SYSTEM 1. Intake air pressure sensor 2. ECU 3. Sensor input lead 4. Sensor output lead 5. Sensor ground lead Disconnect the ECU coupler from the ECU. Disconnect the Intake air pressure sensor 2 coupler from the Intake air pressure sensor 2. [For P1606] Ground short circuit Between Intake air pressure sensor 2 coupler and ground: pink/white–ground If there is continuity, replace the wire harness.
  • Page 441 Improperly installed sensor  the fault code using the mal- Reinstall or replace the sensor. function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 442 (Code No. 04) check the condition of the fault When engine is stopped: code using the malfunction Atmospheric pressure at the mode of the Yamaha diagnostic current altitude and weather tool. Condition is “Recovered”  Go conditions is indicated. At sea level: Approx. 101 kPa to item 7 and finish the service.
  • Page 443 Check the locking condition of replace the wire harness. the fault code using the mal- the coupler. function mode of the Yamaha Disconnect the coupler and diagnostic tool. Condition is “Recovered”  Go check the pins (bent or broken terminals and locking condition to item 8 and finish the service.
  • Page 444 FUEL INJECTION SYSTEM 1. Accelerator position sensor 2. ECU 3. Sensor input lead 4. Sensor output lead 1 5. Sensor output lead 2 6. Sensor ground lead Disconnect the ECU coupler from the ECU. Disconnect the accelerator position sensor coupler from the accelerator position sensor. [For P2122] Ground short circuit Between accelerator position sensor coupler and ground: white–ground If there is continuity, replace the wire harness.
  • Page 445 FUEL INJECTION SYSTEM [For P2127] Ground short circuit Between accelerator position sensor coupler and ground: black–ground If there is continuity, replace the wire harness. [For P2128] Open circuit Between accelerator position sensor coupler and ECU coupler: black–black If there is no continuity, replace the wire harness. [For P2122/P2128] Open circuit Between accelerator position sensor coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 446 Improperly installed sensor  the fault code using the mal- Reinstall or adjust the sensor. function mode of the Yamaha Refer to “ADJUSTING THE diagnostic tool. Condition is “Recovered”  Go ACCELERATOR POSITION SENSOR”...
  • Page 447 1. and then check the condition of Execute the diagnostic mode. the fault code using the mal- (Code No. 14) function mode of the Yamaha When the throttle grip is fully diagnostic tool. Condition is “Recovered”  Go closed: A value of 12–22 is indicated.
  • Page 448 FUEL INJECTION SYSTEM Locate the malfunction. If the ABS warning light is on, refer to “BASIC INSTRUC- TIONS FOR TROUBLESHOOT- ING” on page 8-118. If the ABS warning light is off, perform the following procedure. Execute the diagnostic mode. (Code No. 16) Rotate the front wheel by hand and check that the indicated value increases.
  • Page 449 (12 to 19 mph). Confirm that the fault code has a condition of “Recovered” using the malfunction mode of the Yamaha diagnostic tool, and then delete the fault code. Delete this fault code even if it has a condition of “Detected”.
  • Page 450 Check the condition of the fault Check the locking condition of code using the malfunction the coupler. mode of the Yamaha diagnostic Disconnect the coupler and tool. check the pins (bent or broken Condition is “Recovered”  Go terminals and locking condition to item 8 and finish the service.
  • Page 451 • “Err” is displayed on the clock display of the multi-function meter, but the engine trouble warning light does not come on. • When the Yamaha diagnostic tool is used, event code No. U0155 is displayed as a fault code. Event code No.
  • Page 452 Between meter assembly cou- the fault code using the mal- pler and joint coupler. function mode of the Yamaha Lg/L–Lg/L diagnostic tool. Condition is “Recovered”  Go Lg/W–Lg/W Between joint coupler and ECU to item 6 and finish the service.
  • Page 453 FUEL INJECTION SYSTEM Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ON”, (Code No. 08) then to “OFF”, and then back to Replace if defective. “ON”. Refer to “CHECKING THE Engine trouble warning light does not come on  Service is LEAN ANGLE SENSOR”...
  • Page 454 FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-97...
  • Page 455 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 16.Battery 17.Engine ground 18.Fuel injection system fuse 21.Joint connector 22.Joint coupler 23.Relay unit 25.Fuel pump relay 27.ECU (Engine Control Unit) 68.Fuel pump 70.Handlebar switch (right) 72.Start/engine stop switch A. Wire harness D.
  • Page 456 FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Fuel tank cover 3. Fuel tank 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s). NG...
  • Page 457 FUEL PUMP SYSTEM 8-100...
  • Page 458 IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-101...
  • Page 459 IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 8. Backup fuse 11.Ignition fuse 16.Battery 17.Engine ground 21.Joint connector 22.Joint coupler 26.Immobilizer unit 27.ECU (Engine Control Unit) 50.Meter assembly 51.Immobilizer system indicator light 55.Multi-function meter A. Wire harness D. Negative battery sub-wire harness 8-102...
  • Page 460 IMMOBILIZER SYSTEM EAS30520 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • A code re-registering key (with a red bow) • Two standard keys (with a black bow) that can be re-registered with new codes •...
  • Page 461 IMMOBILIZER SYSTEM Parts to be replaced Main switch/ Key registration immobilizer unit Acces- requirement Standard sory lock* and key Main Immobi- switch lizer unit  Standard key is lost New standard key All keys have been lost Code re-registering  ...
  • Page 462 IMMOBILIZER SYSTEM Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Do not start the engine with a standard key that has not been registered. If the main switch is turned “ON”...
  • Page 463 IMMOBILIZER SYSTEM Standard key code voiding method a. Main switch “ON” b. Main switch “OFF” c. LED on d. LED off e. Less than 5.0 s f. Code re-registering key g. Remaining standard key h. Registration mode A. If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is registered, the second standard key cannot be registered.
  • Page 464 IMMOBILIZER SYSTEM EAS30522 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s). Refer to “CHECKING THE FUSES” NG on page 8-151.
  • Page 465 IMMOBILIZER SYSTEM EAS30523 SELF-DIAGNOSIS FAULT CODE INDICATION When a system failure occurs, the immobilizer system indicator light blinks. The pattern of blinking shows the fault code. Fault Part Symptom Cause Action code IMMOBILIZER Code cannot be trans- 1. Radio wave interfer- 1.
  • Page 466 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code Unidentified code is Noise interference or dis- 1. Check the wire received. connected lead/cable. harness and con- nector. 2. Replace the main switch/immobi- lizer unit. 3. Replace the ECU. Refer to “REPLACING THE ECU (Engine Control Unit)”...
  • Page 467 IMMOBILIZER SYSTEM 8-110...
  • Page 468 ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-111...
  • Page 469 23.Relay unit 24.Starting circuit cut-off relay 27.ECU (Engine Control Unit) 43.Front wheel sensor 44.Rear wheel sensor 45.ABS ECU (electronic control unit) 49.Yamaha diagnostic tool coupler 50.Meter assembly 55.Multi-function meter 64.ABS warning light 70.Handlebar switch (right) 72.Start/engine stop switch 74.Front brake light switch 75.Rear brake light switch...
  • Page 470 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30525 ABS COMPONENTS CHART 8-113...
  • Page 471 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Hydraulic unit assembly 2. Fuse box 2 3. Yamaha diagnostic tool coupler 4. Rear wheel sensor 5. Rear wheel sensor rotor 6. Front wheel sensor 7. Front wheel sensor rotor 8. ABS warning light 9. Fuse box 1...
  • Page 472 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART 8-115...
  • Page 473 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. ABS ECU coupler 4. Yamaha diagnostic tool coupler 5. Front wheel sensor coupler 8-116...
  • Page 474 The following troubleshooting describes the problem identification and service method using the Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG- NOSIS USING THE FAULT CODES” on page 8-121. For troubleshooting items other than the following items, follow the normal service method.
  • Page 475 ABS (ANTI-LOCK BRAKE SYSTEM) The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in- formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES”...
  • Page 476 • Can the tool communicate with is defective. the ABS ECU? Can communicate [A-5] ABS ECU and FI ECU The connection with the Yamaha • Return to [A]. fail to communicate. diagnostic tool is defective. • The wire harness is defective.
  • Page 477 EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di- agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that is included with the tool.) Check that communication with the ABS ECU is possible.
  • Page 478 Check for continuity between black/yellow terminal of the ABS ECU coupler and the ground. If there is no continuity, the wire harness is defective. Replace the wire harness. • Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou- pler.
  • Page 479 Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle. Once all the work is complete, delete the fault codes. [B-3] Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn- ing the main switch off. Fault code table Record all of the fault codes displayed and inspect the check points.
  • Page 480 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the rear wheel sen- pulse period is abnormal while the vehicle is traveling.) •...
  • Page 481 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Brake light switch or Brake light signal is not • Defective signaling system tail/brake light received properly while the (tail/brake light or brake vehicle is traveling. (Brake light switch) light circuit, or front or rear •...
  • Page 482 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault incorrect depressurization) mittently while the vehicle code No.
  • Page 483 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Hydraulic unit assembly Abnormal data is detected in • Defective hydraulic unit (defective ABS ECU) the hydraulic unit assembly. assembly Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit (abnormal internal power the power supply circuit in assembly...
  • Page 484 ABS (ANTI-LOCK BRAKE SYSTEM) With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code No. 11) or for longer than about 2 seconds (fault code No. 25). Fault code No. 12 Fault code No. Item Rear wheel sensor (intermittent pulses or no pulses) Rear wheel sensor signal is not received properly.
  • Page 485 ABS (ANTI-LOCK BRAKE SYSTEM) • If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record- ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re- corded.
  • Page 486 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the front wheel sensor. Order Item/components and probable cause Check or maintenance job Open or short circuit in the wire harness •...
  • Page 487 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor (open or short circuit) Symptom Open or short circuit is detected in the rear wheel sensor. Order Item/components and probable cause Check or maintenance job Open or short circuit in the wire harness •...
  • Page 488 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
  • Page 489 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 21 Fault code No. Item Hydraulic unit assembly (defective solenoid drive circuit) Solenoid drive circuit in the hydraulic unit assembly is open or Symptom short-circuited. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 490 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Hydraulic unit assembly (abnormal ABS solenoid power supply) Power is not supplied to the solenoid circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Defective coupler between the battery •...
  • Page 491 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Hydraulic unit assembly (abnormal ABS motor power supply) Power is not supplied to the motor circuit in the hydraulic unit Symptom assembly. Order Item/components and probable cause Check or maintenance job Open or short circuit in the wire harness •...
  • Page 492 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Front wheel ABS (intermittent wheel speed pulses or incorrect Item depressurization) • Pulses from the front wheel sensor are received intermittently while the vehicle is traveling. Symptom • Front wheel will not recover from the locking tendency even though the signal is transmitted from the ABS ECU to reduce the hydraulic pressure.
  • Page 493 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 43 Fault code No. Item Front wheel sensor (missing pulses) Front wheel sensor signal is not received properly. (Missing pulses Symptom are detected in the signal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor...
  • Page 494 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 51, 52 Fault code No. • Vehicle system power supply (voltage of ABS ECU power supply is high) (for fault code No. 51) Item • Vehicle system power supply (voltage of wheel sensor power sup- ply is high) (for fault code No.
  • Page 495 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 54 Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS motor Item power supply circuits) Abnormality is detected in the solenoid or motor power supply cir- Symptom cuit in the hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective battery...
  • Page 496 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. 56 Fault code No. Item Hydraulic unit assembly (abnormal internal power supply) Abnormality is detected in the power supply circuit in the hydraulic Symptom unit assembly. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 497 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the front wheel sensor Symptom is too low. Order Item/components and probable cause Check or maintenance job Defective hydraulic unit assembly Replace the hydraulic unit assembly.
  • Page 498 EAS31167 [B-3] DELETING THE FAULT CODES To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault codes, refer to the operation manual of the Yamaha diagnostic tool. Check that all the displayed fault codes are deleted.
  • Page 499 ABS (ANTI-LOCK BRAKE SYSTEM) • Open circuit between the ABS ECU and the meter assembly. Check for continuity between green/red terminal of the ABS ECU coupler and green/red terminal of the meter assembly coupler. • Malfunction in the meter assembly circuit. •...
  • Page 500 ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-143...
  • Page 501 ELECTRICAL COMPONENTS 1. Main switch/Immobilizer unit 2. Clutch switch 3. Front brake light switch 4. Hydraulic unit assembly 5. Battery 6. Fuse box 2 7. Main fuse 8. Fuel injection system fuse 9. Starter relay 10.Rectifier/regulator 11.Rear wheel sensor 12.Rear brake light switch 13.Gear position switch 14.Sidestand switch 15.O...
  • Page 502 ELECTRICAL COMPONENTS 8-145...
  • Page 503 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Headlight relay 3. ECU (Engine Control Unit) 4. Fuel pump 5. Lean angle sensor 6. Radiator fan motor relay 7. Turn signal/hazard relay 8. Relay unit 9. Stator coil 10.Crankshaft position sensor 11.Coolant temperature sensor 12.Throttle servo motor 13.Accelerator position sensor...
  • Page 504 ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES 8-147...
  • Page 505 ELECTRICAL COMPONENTS 1. Dimmer switch 2. Pass switch 3. Turn signal switch 4. Horn switch 5. Traction control system switch 6. Clutch switch 7. Oil level switch 8. Sidestand switch 9. Hazard switch 10.Start/engine stop switch 11.Drive mode switch 12.Front brake light switch 13.Main switch 14.Rear brake light switch 8-148...
  • Page 506 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
  • Page 507 ELECTRICAL COMPONENTS keep flammable products and your hands EAS30550 CHECKING THE BULBS AND BULB away from the bulb until it has cooled down. SOCKETS ECA14381 Check each bulb and bulb socket for damage or NOTICE wear, proper connections, and also for continuity •...
  • Page 508 ELECTRICAL COMPONENTS 1. Check: 3. Replace: • Bulb socket (for continuity) • Blown fuse (with the pocket tester) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ No continuity  Replace. a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage Pocket tester rating.
  • Page 509 ELECTRICAL COMPONENTS deteriorate. EAS31006 REPLACING THE ECU (Engine Control Unit) • Charging time, charging amperage and 1. Turn the main switch to “OFF”. charging voltage for a VRLA (Valve Regu- 2. Replace the ECU (engine control unit). lated Lead Acid) battery are different from 3.
  • Page 510 ELECTRICAL COMPONENTS 5. Charge: • Positive tester probe  • Battery positive battery terminal • Negative tester probe  (refer to the appropriate charging method) negative battery terminal EWA13300 WARNING Do not quick charge a battery. • The charge state of a VRLA (Valve Regulated ECA13671 Lead Acid) battery can be checked by measur- NOTICE...
  • Page 511 ELECTRICAL COMPONENTS g. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 512 ELECTRICAL COMPONENTS Starter relay 8. Check: 1. Positive battery terminal • Battery terminals Dirt  Clean with a wire brush. 2. Negative battery terminal 3. Positive tester probe Loose connection  Connect properly. 4. Negative tester probe 9. Lubricate: • Battery terminals Relay operation Recommended lubricant Continuity...
  • Page 513 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) Radiator fan motor relay 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe Result Result Continuity...
  • Page 514 ELECTRICAL COMPONENTS EAS30795 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification  Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Turn the main switch to “ON”. The pocket tester or the analog pocket tester c.
  • Page 515 ELECTRICAL COMPONENTS c. Measure the primary coil resistance. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ wire harness. 2. Check: b. Connect the pocket tester (  1) to the relay • Secondary coil resistance unit terminal as shown. Out of specification ...
  • Page 516 ELECTRICAL COMPONENTS Minimum ignition spark gap Pocket tester 6.0 mm (0.24 in) 90890-03112 Analog pocket tester YU-03112-C If the ignition spark gap is within specification, the ignition system circuit is operating normally. • Positive tester probe gray “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Negative tester probe a.
  • Page 517 ELECTRICAL COMPONENTS fluid is in the vicinity. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Test harness– lean angle sensor (6P) 90890-03209 Test harness– lean angle sensor (6P) YU-03209 • Positive tester probe b. Check the starter motor operation. yellow/green (wire harness color) •...
  • Page 518 ELECTRICAL COMPONENTS b. Measure the stator coil resistance. c. Start the engine and let it run at approximate- ly 5000 r/min. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Measure the rectifier/regulator input voltage. EAS30680 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE RECTIFIER/REGULATOR 2. Check: 1. Check: • Rectifier/regulator output voltage •...
  • Page 519 ELECTRICAL COMPONENTS EAS30569 CHECKING THE HORN Oil level switch Oil level switch resistance (maxi- 1. Check: mum level position) • Horn resistance 484.0–536.0  Out of specification  Replace. Oil level switch resistance (mini- Horn mum level position) 114.0–126.0  Coil resistance 1.07–1.11 ...
  • Page 520 ELECTRICAL COMPONENTS Warning light does not come on  Replace assembly. the meter assembly. Sender unit resistance (full) Warning light flashes eight times, then goes 9.0–11.0  off for 3 seconds in a repeated cycle (mal- Sender unit resistance (empty) function detected in fuel sender) ...
  • Page 521 ELECTRICAL COMPONENTS • Positive tester probe Make sure the coolant temperature sensor ter- blue “1” • Negative tester probe minals do not get wet. black “2” c. Place a thermometer “3” in the coolant. c. Measure the radiator fan motor movement. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
  • Page 522 ELECTRICAL COMPONENTS tance Resistance Out of specification  Replace the accelera- 1.20–2.80 k tor position sensor. Resistance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1 k) to the 1.08–2.52 k throttle position sensor terminals as shown. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Pocket tester a.
  • Page 523 ELECTRICAL COMPONENTS ECA17660 • Positive tester probe  NOTICE Air induction system solenoid terminal “1” • Negative tester probe  Do not use a 12 V battery to operate the throt- Air induction system solenoid terminal “2” tle servo motor. Do not use old batteries to operate the throttle servo motor.
  • Page 524 ELECTRICAL COMPONENTS • Positive tester probe Intake air temperature sensor re- pink (wire harness color) (intake air pressure sistance sensor 1) 5400.0–6600.0  at 0 C (5400.0– pink/white (wire harness color) (intake air pres- 6600.0  at 32 F) sure sensor 2) •...
  • Page 525 ELECTRICAL COMPONENTS tion switch. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Result Neutral position Continuity Positive tester probe EAS30681 sky blue “1” CHECKING THE FUEL INJECTORS Negative tester probe The following procedure applies to all of the fuel Sensor terminal “a” injectors.
  • Page 526 ELECTRICAL COMPONENTS 8-169...
  • Page 527 TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ................9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED .............9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......9-2 FAULTY GEAR SHIFTING.................9-2 SHIFT PEDAL DOES NOT MOVE .............9-2 JUMPS OUT OF GEAR................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING ................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM .........9-3 TROUBLESHOOTING AT THE ABS WARNING LIGHT ......9-4...

  • Page 528: Troubleshooting

    TROUBLESHOOTING 2. Fuse(s) EAS20090 TROUBLESHOOTING • Blown, damaged or incorrect fuse • Improperly installed fuse EAS30599 3. Spark plug(s) GENERAL INFORMATION • Incorrect spark plug gap • Incorrect spark plug heat range The following guide for troubleshooting does not • Fouled spark plug cover all the possible causes of trouble.

  • Page 529: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Worn or damaged electrode EAS30849 FAULTY CLUTCH • Worn or damaged insulator Clutch slips 3. Ignition coil(s) 1. Clutch • Broken or shorted primary or secondary coils • Improperly assembled clutch • Cracked or broken ignition coil • Improperly adjusted clutch cable 4.

  • Page 530: Overcooling

    TROUBLESHOOTING • Damaged pipe • Incorrect oil viscosity • Improperly connected pipe • Incorrect oil level Fuel system EAS30611 1. Throttle body (-ies) UNSTABLE HANDLING • Damaged or loose throttle body joint Handlebar 2. Air filter • Bent or improperly installed handlebar •...

  • Page 531: Troubleshooting At The Abs Warning Light

    TROUBLESHOOTING • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Faulty dimmer switch • Headlight bulb life expired Tail/brake light does not come on • Too many electrical accessories • Incorrect connection Turn signal does not come on •...

  • Page 532: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31794 SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM) For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-35. Fault Probable cause of Fail-safe system Item Vehicle symptom code No.
  • Page 533 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan motor P0118 perature sensor of the coolant temper- start.
  • Page 534 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0132 sensor (short cir- [P0132] High voltage Increased exhaust feedback is not of the O sensor cir- emissions. cuit detected (power carried out.
  • Page 535 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. Injection to the appli- P0352 ignition coil (open or between ignition coil Loss of engine power. cable cylinder group is P0353 short circuit detected...
  • Page 536 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P0601 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be ECU (ROM data started. started. error) (When this mal- function is detected in the ECU, the fault code number might...
  • Page 537 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P1004 Intake air pressure • Malfunction in ECU. Engine is difficult to Intake air pressure is sensor 1 or intake air •...
  • Page 538 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P1602 Malfunction in ECU • Open or short cir- Engine idling speed is feedback learning internal circuit (mal- cuit in wire harness unstable.
  • Page 539 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Fault Probable cause of Fail-safe system Item Vehicle symptom code No. malfunction operation P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in acceler- P2123 position sensor (open voltage of the acceler- poor.

  • Page 540: Communication Error With The Meter

    Vehicle symptom code No. malfunction operation U0155 CAN communication Communication Defective meter dis- Grip warmer output: (Yamaha error (with the meter) between the ECU and play. OFF is fixed. diagnostic the meter is not possi- Traction control does MAP changeover: tool) not work.
  • Page 541 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Air temperature Displays the air temperature. Compare the actually mea- sured air temperature with the tool display value. Coolant temperature When engine is cold: Dis- Compare the actually mea- plays temperature closer to sured coolant temperature air temperature.
  • Page 542 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Tool display Procedure code No. Sidestand switch Extend and retract the sides- tand (with the transmission in • Stand retracted gear). • Stand extended gear position switch and Operate the transmission, clutch switch clutch lever, and sidestand.

  • Page 543: Diagnostic Code: Actuator Operation Table

    • Connect an ignition The “check” indicator on the checker. Yamaha diagnostic tool screen come on each time the ignition coil is actuated. Cylinder-#2 ignition coil Actuates the cylinder-#2 igni- Check that a spark is gener- tion coil five times at one- ated five times.
  • Page 544 The “check” indicator on the operating sound. Yamaha diagnostic tool screen come on each time the air induction system sole- noid is actuated. Relay unit Actuates the relay unit five...
  • Page 545 EVENT CODE TABLE EAS20164 EVENT CODE TABLE Item Symptom Possible causes Note Latch up detected Latch up detected • Vehicle has overturned Perform the checks and • Improperly installed maintenance jobs for event sensor code number 30. • Sensor malfunction •...
  • Page 546 EVENT CODE TABLE Item Symptom Possible causes Note sensor During O feedback, • Open or short circuit in • If a fault code is occurring, the wire harness respond to that first. (Stuck at the the adjustment is between the sensor * Rarely, Code 241 occurs lower limit for maintained at the...
  • Page 547 White/Yellow 46. Throttle servo motor ness Yellow/Black 47. Accelerator position sensor Yellow/Green 48. Throttle position sensor Yellow/Blue 49. Yamaha diagnostic tool cou- Yellow/Red pler Yellow/White 50. Meter assembly 51. Immobilizer system indicator light 52. Neutral indicator light 53. Meter light...
  • Page 551 MTM850/MTM850G 2016 MTM850/MTM850G 2016 MTM850/MTM850G 2016 MTM850/MTM850G 2016 MTM850/MTM850G 2016 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO...
  • Page 552 MTM850/MTM850G 2016 MTM850/MTM850G 2016 MTM850/MTM850G 2016 MTM850/MTM850G 2016 MTM850/MTM850G 2016 WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO...

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