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Yamaha Tracer MT09TRAH 2017 Service Manual

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Summary of Contents for Yamaha Tracer MT09TRAH 2017

  • Page 1
    2017 SERVICE MANUAL MT09TRA MT09TRAH 2SC-28197-E0…
  • Page 3
    EAS20002 MT09TRA/MT09TRAH SERVICE MANUAL ©2016 by Yamaha Motor Co., Ltd. First edition, November 2016 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: How To Use This Manual

    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: Symbols

    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

    TABLE OF CONTENTS EAS10003 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 D-mode (drive mode)…………….1-16 IMPORTANT INFORMATION ……………..1-17 PREPARATION FOR REMOVAL AND DISASSEMBLY……1-17 REPLACEMENT PARTS…………….1-17 GASKETS, OIL SEALS AND O-RINGS ………..1-17 LOCK WASHERS/PLATES AND COTTER PINS ……..1-17…

  • 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 battery box under the passenger seat. 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. EWA15433 WARNING The traction control system is not a substitute for riding appropriately for the conditions.
  • Page 16
    FEATURES TCS settings can be changed only when the vehicle is stopped and the throttle closed. • Push the “TCS” button to change between TCS settings “1” and “2”. • Push the button for two seconds to turn the traction control system off. •…

  • Page 17: Instrument Functions

    FEATURES use the handlebar switches and buttons. EAS30682 INSTRUMENT FUNCTIONS Multi-function meter unit GEAR A.TEMP °C C.TEMP °C TIME TRIP 0:00 1. Menu switch “MENU” 2. Select switch “ ” 1. “RESET” button 2. “TCS” button Speedometer 3. Clock 4. Tachometer 5.

  • Page 18
    FEATURES Eco indicator ECA20410 NOTICE Do not operate the engine in the tachometer high-rpm zone. Clock 1. Eco indicator “ECO” The eco indicator comes on when the vehicle is being operated in an environmentally friendly, fuel-efficient manner. The indicator goes off 1.
  • Page 19
    FEATURES Drive mode display lect switch “ ” to change the selected infor- mation display. The following items are shown in the information displays: • an odometer display • tripmeter displays • a fuel reserve tripmeter display • an elapsed time display •…
  • Page 20
    FEATURES To reset a tripmeter, use the select switch to dis- play the tripmeter you want to reset. Then push There are also “TIME–2” and “TIME–3” elapsed the “RESET” button briefly so that the tripmeter time displays, but they cannot be set to the infor- flashes, and then push the “RESET”…
  • Page 21
    FEATURES This function calculates the instantaneous fuel consumption (fuel economy) under current rid- The selected information display cannot be switched while the message “Hi” is flashing. ing conditions. The instantaneous fuel con- sumption display can be set to “km/L” or ECA10022 “L/100km”;…
  • Page 22
    FEATURES Display Description Maintenance This function allows you to check and reset the “OIL” oil change interval (distance trav- “Maintenance” eled), and the “FREE-1” and FREE-1 “FREE-2” maintenance inter- vals. This function allows you to FREE-2 check and reset the “TIME–2” and “TIME–3”…
  • Page 23
    FEATURES 4. Use the select switch to move from “km or MENU Maintenance mile” to “km/L or L/100km”. Time Trip 5. Push the menu switch, then use the select Unit switch to toggle between “km/L” and Display “L/100km”, and then push the menu switch to Brightness confirm the selection.
  • Page 24
    FEATURES Adjusting the meter panel brightness 1. Use the select switch to highlight “Bright- Display-1 ness”. A.TEMP MENU Maintenance C.TEMP Time Trip Unit TIME TRIP Display Brightness 4. Use the select switch to select the item you Clock All Reset want to display, and then push the menu switch.

  • Page 25: D-Mode (Drive Mode)

    FEATURES Clock 5 55 4. Push the menu switch, and the minute digits 1. Drive mode switch “MODE” start flashing. 5. Use the select switch to set the minutes. Before using D-mode, make sure you under- 6. Push the menu switch to return to the setting stand its operation along with the operation of mode menu.

  • Page 26: 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 27: Circlips

    IMPORTANT INFORMATION When installing oil seals, lubricate the oil seal contact the parts. lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. ECA13300 NOTICE Do not spin the bearing with compressed air because this will damage the bearing surfac- EAS30011 CIRCLIPS Before reassembly, check all circlips carefully…

  • Page 28: 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 29: 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 30
    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 31
    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 32
    BASIC SERVICE INFORMATION • Make sure all connections are tight. 5. Check: • Resistance Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 The resistance values shown were obtained at the standard measuring temperature of 20 C (68 F).

  • Page 33: Special Tools

    Model 88 Multimeter with tachometer 8-157, 8-161, YU-A1927 8-162, 8-163, 8-164, 8-165, 8-166, 8-167, 8-168, 8-170, 8-171, 8-172, 8-173, 8-174 Yamaha diagnostic tool USB 3-4, 3-11, 4-65, 90890-03250 4-67, 8-34, 8-127, 8-147 Yamaha diagnostic tool (A/I) 3-4, 3-11, 4-65, 90890-03252 4-67, 8-34,…

  • Page 34
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Carburetor angle driver 2 3-10 90890-03173 Steering nut wrench 3-20, 4-89 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-25 90890-01426 Oil filter wrench YU-38411 Pressure gauge 3-26, 7-11 90890-03153…
  • Page 35
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod holder 4-79, 4-84, 4-85 90890-01434 Damper rod holder double ended YM-01434 Damper rod holder (ø27) 4-80, 4-82 90890-01582 Damper rod holder YM-01582 Fork seal driver 4-82, 4-83 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Rod puller 4-83, 4-84, 4-85…
  • Page 36
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Drive chain cut & rivet tool 4-99, 4-101 90890-01550 Drive chain cut & rivet tool YM-01550 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…
  • Page 37
    Valve guide reamer (ø4.5) 5-25 90890-04118 Valve guide reamer (4.5 mm) YM-04118 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®) 1-28…
  • Page 38
    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 39
    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 7-11…
  • Page 40
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness– lean angle sensor (6P) 8-165 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Test harness S– pressure sensor (3P) 8-172 90890-03207 Test harness S– pressure sensor (3P) YU-03207 1-31…

  • Page 41: 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 42: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 2SCL (MT09TRA_EUR/HRV/TUR/ZAF) 2SCM (MT09TRAH) 2SCT (MT09TRA_RUS) Dimensions Overall length 2160 mm (85.0 in) Overall width 950 mm (37.4 in) Overall height 1345/1375 mm (53.0/54.1 in) Seat height 845/860 mm (33.3/33.9 in) Wheelbase 1440 mm (56.7 in) Ground clearance 135 mm (5.31 in) Minimum turning radius…

  • Page 43: 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 44
    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 45
    ENGINE SPECIFICATIONS Wear limit 78.060 mm (3.0732 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) Piston pin outside diameter 16.990–16.995 mm (0.6689–0.6691 in)
  • Page 46
    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 47
    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 1.5–3.5 % Difference in vacuum pressure between the 1.3 kPa (10 mmHg, 0.4 inHg) cylinders Fuel line pressure (at idle)

  • Page 48: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 24.0  Caster angle Trail 100 mm (3.9 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 49
    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 01 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 50
    CHASSIS SPECIFICATIONS Adjustment value from the start position (Hard) Drive chain Size DID525V10 Chain type Sealed type Number of links Drive chain slack 5.0–15.0 mm (0.20–0.59 in) 15-link length limit 239.3 mm (9.42 in)

  • Page 51: 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 TBDF0C (MT09TRAH) TBDFZ7 (MT09TRA) Ignition coil 1.19–1.61  Primary coil resistance Secondary coil resistance 9.35–12.65 k…

  • Page 52
    ELECTRICAL SPECIFICATIONS 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 53: 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 54: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 N·m (2.0 kgf·m, 14 lb·ft) Muffler protector bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) Spark plug 13 N·m (1.3 kgf·m, 9.4 lb·ft) Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) Generator rotor bolt 75 N·m (7.5 kgf·m, 54 lb·ft)

  • Page 55
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake. Drive sprocket nut 95 N·m (9.5 kgf·m, 69 lb·ft) Lower ring nut 1. Tighten the ring nut to approximately 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring nut completely.

  • Page 56: 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 57: Chassis

    Shift 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 58
    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Front wheel oil seal (left and right) 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 59
    LUBRICATION POINTS AND LUBRICANT TYPES 2-18…

  • Page 60: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-19…

  • Page 61
    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 62: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-21…

  • Page 63
    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil filter cartridge union bolt 3. Oil filter cartridge 4. Crankshaft 2-22…
  • Page 64
    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-23…
  • Page 65
    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 66
    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-25…
  • Page 67
    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 68
    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-27…
  • Page 69
    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 70
    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29…
  • Page 71
    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 72: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-31…

  • Page 73
    COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator 2-32…
  • Page 74
    COOLING SYSTEM DIAGRAMS 2-33…
  • Page 75
    COOLING SYSTEM DIAGRAMS 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir 2-34…

  • Page 76: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (top view) 2-35…

  • Page 77
    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 78
    CABLE ROUTING Handlebar (front view) 2-37…
  • Page 79
    CABLE ROUTING 1. Throttle cable 2. Clutch cable 3. Handlebar switch lead (left) 4. Main switch lead/Immobilizer lead 5. Steering stopper 6. Horn lead 7. Handlebar switch lead (right) 8. Front brake hose A. Fasten the handlebar switch lead (right) onto the handlebar with the clamp.
  • Page 80
    CABLE ROUTING Radiator (front side view and right side view) 2-39…
  • Page 81
    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 82
    CABLE ROUTING Fuel tank (left and bottom view) 2-41…
  • Page 83
    CABLE ROUTING 1. Frame 2. Fuel tank 3. Fuel pump 4. Fuel tank drain hose 5. Clip 6. Fuel hose assembly A. Insert the fuel tank drain hose up to the sec- tion where the fuel tank pipe increases in diameter.
  • Page 84
    CABLE ROUTING Canister (top view and left side view) 2-43…
  • Page 85
    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 86
    CABLE ROUTING Air filter case and throttle body (top view and left side view) 2-45…
  • Page 87
    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 88
    CABLE ROUTING Air cut-off valve (left side view) 2-47…
  • Page 89
    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 90
    CABLE ROUTING Frame and engine (right side view) 2-49…
  • Page 91
    CABLE ROUTING 1. Clamp 2. Rear brake light switch lead 3. O sensor coupler 4. Radiator fan motor coupler 5. Handlebar switch coupler (right) 6. Inner panel 7. Front right turn signal light coupler 8. Fuse box 1 9. Front turn signal light lead (right) 10.Bracket 11.Fuse box 2 12.Coupler cover…
  • Page 92
    CABLE ROUTING Frame and engine (right side view) 2-51…
  • Page 93
    CABLE ROUTING I. Fasten the auxiliary light lead and auxiliary 1. Guide DC jack lead with the clamp and then insert 2. Wire harness the clamp into the hole in the headlight stay. 3. Pipe (headlight stay) J. Fasten the main switch lead to the coupler 4.
  • Page 94
    CABLE ROUTING Frame and engine (left side view) 2-53…
  • Page 95
    CABLE ROUTING N. Align each rounded end of the sidestand 1. Air induction system hose (air filter case to air switch lead, oil level switch lead and drain cut-off valve) hose, and clamp them. The opening of the 2. Air filter case clamp should face toward the rear side of the 3.
  • Page 96
    CABLE ROUTING Frame (top view) 2-55…
  • Page 97
    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 98
    CABLE ROUTING Frame (top view) 2-57…
  • Page 99
    CABLE ROUTING 1. Stator coil assembly lead 2. Oil level switch coupler 3. Rear brake light switch coupler 4. Sidestand switch coupler 5. Gear position switch coupler 1 6. Gear position switch coupler 2 7. Negative battery lead coupler 8. Lean angle sensor 9.
  • Page 100
    CABLE ROUTING Frame (top view) 2-59…
  • Page 101
    CABLE ROUTING M. Insert the Yamaha diagnostic tool coupler to 1. Rear wheel sensor coupler the battery box. 2. Negative battery lead coupler N. Install the rubber bracket of the starter relay 3. Positive battery terminal in the battery box.
  • Page 102
    CABLE ROUTING Front brake (right side view and left side view) 2-61…
  • Page 103
    CABLE ROUTING 1. Front brake hose assembly 1 2. Front wheel sensor lead 3. Clamp 4. Bracket 5. Brake caliper (right) 6. Front fender 7. Reflector (left and right) 8. Brake caliper (left) 9. Clamp 10.Clamp A. Make sure that the bracket has contact with the axle bracket, and install it.
  • Page 104
    CABLE ROUTING Rear brake 2-63…
  • Page 105
    CABLE ROUTING 1. Brake fluid reservoir 2. Rear frame 3. Rear frame (welded portion) 4. Rear brake master cylinder 5. Rear wheel sensor 6. Rear wheel sensor lead 7. Rear brake caliper 8. Rear brake hose 9. Clamp 10.Brake fluid reservoir hose 11.Swingarm assembly A.
  • Page 106
    CABLE ROUTING Hydraulic unit (top view and left side view) 2-65…
  • Page 107
    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 108
    CABLE ROUTING 2-67…

  • Page 109: Periodic Checks And Adjustments

    INTRODUCTION ………………3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ………………..3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ……3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL ………………….3-4 CHECKING THE FUEL LINE …………..3-4 CHECKING THE SPARK PLUGS …………..3-5 ADJUSTING THE VALVE CLEARANCE ………..3-5 CHECKING THE ENGINE IDLING SPEED ……….3-8…

  • Page 110
    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY….3-23 CHECKING THE CONNECTING ARM AND RELAY ARM……3-24 CHECKING THE ENGINE OIL LEVEL………….3-24 CHANGING THE ENGINE OIL …………..3-24 MEASURING THE ENGINE OIL PRESSURE ………3-25 CHECKING THE COOLANT LEVEL…………3-26 CHECKING THE COOLING SYSTEM ………….3-26 CHANGING THE COOLANT…………..3-27 CHECKING THE FRONT BRAKE LIGHT SWITCH ………3-28 ADJUSTING THE REAR BRAKE LIGHT SWITCH ……..3-29 CHECKING AND LUBRICATING THE CABLES ……..3-29…

  • Page 111: 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 112
    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 operation, fluid level, and for fluid leakage.  …
  • Page 113
    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) Rear suspension • Check operation. relay arm and   …

  • Page 114: Checking The Vehicle Using The Yamaha Diagnostic Tool

    CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel, Use the Yamaha diagnostic tool and check the drain and breather hoses. vehicle according to the following procedure. 1. Remove: 1.

  • Page 115: Checking The Spark Plugs

    PERIODIC MAINTENANCE 4-6. Spark plug gap 0.8–0.9 mm (0.031–0.035 in) EAS30620 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • Fuel tank front cover/Front side panel/Front side cowling Refer to “GENERAL CHASSIS (2)” on page 4-6.

  • Page 116
    PERIODIC MAINTENANCE Refer to “GENERAL CHASSIS (2)” on page 4-6. • Passenger seat/Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-13. • Fuel tank Refer to “FUEL TANK” on page 7-1. •…
  • Page 117
    PERIODIC MAINTENANCE d. To measure the valve clearances of the other prevent the valve pad from falling into the cylinders, starting with cylinder #1 at TDC, crankcase. • Make a note of the position of each valve lifter turn the crankshaft counterclockwise as specified in the following table.

  • Page 118: Checking The Engine Idling Speed

    “02”  Clean the throttle bodies. Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-8. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION g. Install the exhaust and intake camshafts, tim- AND DIAGNOSTIC CODE TABLE”…

  • Page 119: Synchronizing The Throttle Bodies

    PERIODIC MAINTENANCE EAS30797 SYNCHRONIZING THE THROTTLE BODIES Before synchronizing the throttle bodies, check the following items: • Valve clearance • Spark plugs • Air filter element • Throttle body joints • Fuel hose • Exhaust system 5. Install: • Breather hoses •…

  • Page 120: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE dard. Otherwise, the engine may run roughly 4-6. at idle and the throttle bodies may not oper- 5. Adjust: ate properly. • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-29. • Turn the bypass air screw using the carburetor angle driver.

  • Page 121: Adjusting The Exhaust Gas Volume

    4-6. tion manual of the Yamaha diagnostic tool. • Passenger seat/Rider seat Refer to “GENERAL CHASSIS (1)” on page 1. Connect the Yamaha diagnostic tool to the 4-1. coupler. For information about connecting the • Fuel tank cover Yamaha diagnostic tool, refer to “YAMAHA Refer to “GENERAL CHASSIS (3)”…

  • Page 122: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE are riding in unusually wet or dusty areas. 2. Adjust: • Clutch lever free play 4. Install: • Air filter element ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Air filter case cover Handlebar side • ECU (Engine Control Unit) a. Turn the adjusting bolt “1” in direction “a” or “b”…

  • Page 123: Checking The Brake Operation

    PERIODIC MAINTENANCE Clutch cable locknut 7 N·m (0.7 kgf·m, 5.1 lb·ft) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly  Check the brake system. A. Front brake Refer to “FRONT BRAKE” on page 4-35 and B.

  • Page 124: Checking The Front Brake Pads

    PERIODIC MAINTENANCE • While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. • Be sure to align the setting on the adjusting dial with the arrow mark “2” on the brake lever hold- Position #1 Distance “a”…

  • Page 125: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE EAS30636 CHECKING THE REAR BRAKE HOSE 1. Check: • Brake hose Cracks/damage/wear  Replace. 2. Check: • Brake hose holder Loose Connection  Tighten the holder bolt. 3. Hold the vehicle upright and apply the rear brake several times. 4.

  • Page 126: Checking The Wheels

    PERIODIC MAINTENANCE hydraulic unit. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Fill the brake master cylinder reservoir or k. After operating the ABS, repeat steps (e) to (i), brake fluid reservoir to the proper level with and then fill the brake master cylinder reservoir the specified brake fluid. or brake fluid reservoir to the proper level with b.

  • Page 127
    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 128: Checking The Wheel Bearings

    PERIODIC MAINTENANCE 3. Check: EAS30641 CHECKING THE WHEEL BEARINGS • Drive chain slack “a” The following procedure applies to all of the Out of specification  Adjust. wheel bearings. 1. Check: • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” on page 4-21 and “CHECKING THE REAR WHEEL”…

  • Page 129: Lubricating The Drive Chain

    PERIODIC MAINTENANCE 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 front wheel is elevated. 2. Check: • Steering head Grasp the bottom of the front fork legs and gently rock the front fork.

  • Page 130: Lubricating The Steering Head

    PERIODIC MAINTENANCE EAS30646 Steering nut wrench LUBRICATING THE STEERING HEAD 90890-01403 1. Lubricate: Exhaust flange nut wrench • Upper bearing YU-A9472 • Lower bearing • Bearing race Lower ring nut (initial tightening Recommended lubricant torque) Lithium-soap-based grease 52 N·m (5.2 kgf·m, 38 lb·ft) EAS31186 c.

  • Page 131: Checking The Sidestand

    PERIODIC MAINTENANCE EAS30856 CHECKING THE CENTERSTAND 1. Check: • Centerstand operation Check that the centerstand moves smoothly. Rough movement  Repair or replace. EAS30857 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. 2. Adjust: Recommended lubricant •…

  • Page 132
    PERIODIC MAINTENANCE front fork legs. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload EWA17040 WARNING Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. Spring preload Minimum ECA13590…

  • Page 133: Checking The Rear Shock Absorber Assembly

    PERIODIC MAINTENANCE range. To obtain a precise adjustment, it would Spring preload be advisable to check the number of clicks of Adjustment value (Soft) each damping force adjusting mechanism and to modify the specifications as necessary. Adjustment value (STD) Adjustment value (Hard) 3 2 1 7 6 5 4 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲…

  • Page 134: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE ifications listed due to small differences in ECA13361 NOTICE production. • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of “CD”…

  • Page 135: Engine

    PERIODIC MAINTENANCE 4. Drain: 7. Fill: • Engine oil • Crankcase (completely from the crankcase) (with the specified amount of the recom- 5. If the oil filter cartridge is also to be replaced, mended engine oil) perform the following procedure. Engine oil quantity ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…

  • Page 136: Checking The Coolant Level

    PERIODIC MAINTENANCE 6. Install: EWA12980 WARNING • Main gallery bolt The engine, muffler and engine oil are ex- Main gallery bolt tremely hot. 8 N·m (0.8 kgf·m, 5.8 lb·ft) EAS30811 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. •…

  • Page 137: Changing The Coolant

    PERIODIC MAINTENANCE • Oil cooler “4” • Oil cooler inlet hose “5” • Oil cooler outlet hose “6” • Water jacket joint “7” • Water pump inlet hose “8” Cracks/damage  Replace. Refer to “RADIATOR” on page 6-1, “OIL COOLER” on page 6-4, “THERMOSTAT” on page 6-6 and “WATER PUMP”…

  • Page 138: Cooling System

    PERIODIC MAINTENANCE and if necessary, correct the antifreeze 6. Drain: • Coolant concentration of the coolant. • Use only distilled water. However, if dis- (from the engine and radiator) 7. Install: tilled water is not available, soft water may • Water pump drain bolt be used.

  • Page 139: Adjusting The Rear Brake Light Switch

    PERIODIC MAINTENANCE EAS30659 ADJUSTING THE REAR BRAKE LIGHT Recommended lubricant Engine oil or a suitable cable lu- SWITCH bricant The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light Hold the cable end upright and pour a few drops switch is properly adjusted when the brake light of lubricant into the cable sheath or use a suit- comes on just before the braking effect starts.

  • Page 140: Checking And Charging The Battery

    PERIODIC MAINTENANCE tle body synchronization should be adjusted properly. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slide back the rubber cover “1”. b. Loosen the locknut “2”. c. Turn the adjusting nut “3” in direction “a” or “b” until the specified throttle grip free play is ob- tained.

  • Page 141
    CHASSIS GENERAL CHASSIS (1) ………………4-1 INSTALLING THE SEATS…………….4-4 GENERAL CHASSIS (2) ………………4-6 REMOVING THE FUEL TANK FRONT COVER……..4-10 INSTALLING THE FUEL TANK FRONT COVER ……..4-10 REMOVING THE FRONT SIDE COWLINGS ……….4-10 INSTALLING THE FRONT SIDE COWLINGS ………4-11 ADJUSTING THE WINDSHIELD HEIGHT……….4-12 GENERAL CHASSIS (3) …………….4-13 REMOVING THE FUEL TANK COVERS……….4-17 INSTALLING THE FUEL TANK COVERS ……….4-17…
  • Page 142
    ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ….4-45 INSTALLING THE FRONT BRAKE MASTER CYLINDER…….4-45 REAR BRAKE ………………..4-48 INTRODUCTION ………………4-54 CHECKING THE REAR BRAKE DISC………….4-54 REPLACING THE REAR BRAKE PADS……….4-54 REMOVING THE REAR BRAKE CALIPER ……….4-55 DISASSEMBLING THE REAR BRAKE CALIPER ……..4-56 CHECKING THE REAR BRAKE CALIPER……….4-56 ASSEMBLING THE REAR BRAKE CALIPER ………4-57 INSTALLING THE REAR BRAKE CALIPER……….4-57…
  • Page 143
    INSTALLING THE RELAY ARM……………4-93 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ….4-93 SWINGARM………………..4-95 REMOVING THE SWINGARM…………..4-96 CHECKING THE SWINGARM …………..4-96 INSTALLING THE SWINGARM ……………4-97 CHAIN DRIVE………………..4-98 REMOVING THE DRIVE CHAIN…………..4-99 CHECKING THE DRIVE CHAIN …………..4-99 CHECKING THE DRIVE SPROCKET…………4-100 CHECKING THE REAR WHEEL SPROCKET……..4-100 CHECKING THE REAR WHEEL DRIVE HUB ……..4-100 INSTALLING THE DRIVE CHAIN …………4-101…
  • Page 144
    GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 2.2 N ・ m (0.22 kgf ・ m, 1.6 lb ・ ft) 25 N ・ m (2.5 kgf ・ m, 18 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) Order Job/Parts to remove Q’ty…
  • Page 145
    GENERAL CHASSIS (1) Removing the rear side covers 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.4 lb ・ ft) 26 N ・…
  • Page 146
    GENERAL CHASSIS (1) Removing the tail/brake light and mudguard assembly 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS (1)”…

  • Page 147: General Chassis (1)

    GENERAL CHASSIS (1) EAS30125 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INSTALLING THE SEATS To install the rider seat in the low position 1. Install: a. Insert the projection “a” on the rider seat • Rider seat height position adjuster “1” height position adjuster into the grommet “b”. •…

  • Page 148: General Chassis (2)

    GENERAL CHASSIS (1)

  • Page 149
    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the fuel tank front cover, front side panels and front side cowlings 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 2.9 lb ・ ft) 4.0 N ・…
  • Page 150
    GENERAL CHASSIS (2) Removing the headlight assembly and meter assembly 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 2.8 N ・…
  • Page 151
    GENERAL CHASSIS (2) Disassembling the headlight assembly Order Job/Parts to remove Q’ty Remarks Headlight top cover (left) Headlight top cover (right) Headlight side cover (left) Headlight side cover (right) Center cover Headlight control unit coupler Disconnect. Headlight control unit…
  • Page 152
    GENERAL CHASSIS (2) Removing the headlight stay 33 N ・ m (3.3 kgf ・ m, 24 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)” on page cowling 4-6.

  • Page 153: Removing The Fuel Tank Front Cover

    GENERAL CHASSIS (2) EAS31379 REMOVING THE FUEL TANK FRONT COVER Fuel tank front cover bolt 4.0 N·m (0.40 kgf·m, 2.9 lb·ft) 1. Remove: • Fuel tank front cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the quick fastener screws “2” and fuel tank front cover bolts “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲…

  • Page 154: Installing The Front Side Cowlings

    GENERAL CHASSIS (2) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31382 INSTALLING THE FRONT SIDE COWLINGS 1. Install: • Front side cowling (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the slot “a” into the projection “b”, and then install the front side cowling as shown in the illustration. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲…

  • Page 155: Adjusting The Windshield Height

    GENERAL CHASSIS (2) 2. Install: EAS31383 ADJUSTING THE WINDSHIELD HEIGHT • Front side cowling (right) “1” 1. Adjust: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Windshield height position a. Insert the slot “a” into the projection “b”, and ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ then install the front side cowling as shown in a.

  • Page 156: General Chassis (3)

    GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the fuel tank covers and fuel tank protector 4.0 N ・ m (0.40 kgf ・ m, 2.9 lb ・ ft) 4.0 N ・ m (0.40 kgf ・ m, 2.9 lb ・ ft) Order Job/Parts to remove Q’ty…

  • Page 157
    GENERAL CHASSIS (3) Removing the electrical components tray (left) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)” on page cowling 4-6.
  • Page 158
    GENERAL CHASSIS (3) Removing the electrical components tray (right) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…
  • Page 159
    GENERAL CHASSIS (3) Removing the air filter case 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) (10) 1.6 N ・ m (0.16 kgf ・ m, 1.2 lb ・ ft) 2.8 N ・ m (0.28 kgf ・ m, 2.0 lb ・ ft) Order Job/Parts to remove Q’ty…

  • Page 160: Removing The Fuel Tank Covers

    GENERAL CHASSIS (3) then install the fuel tank cover as shown in EAS31384 REMOVING THE FUEL TANK COVERS the illustration. 1. Remove: • Fuel tank front cover • Front side panel • Front side cowling 2. Remove: • Passenger seat •…

  • Page 161
    GENERAL CHASSIS (3) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Rider seat • Passenger seat 4. Install: • Front side cowling • Front side panel • Fuel tank front cover 4-18…
  • Page 162
    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 65 N ・ m (6.5 kgf ・ m, 47 lb ・ ft) 23 N ・…
  • Page 163
    FRONT WHEEL Disassembling the front wheel 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer 4-20…

  • Page 164: Front Wheel

    FRONT WHEEL tor, wipe it off immediately. EAS30145 REMOVING THE FRONT WHEEL 1. Remove: ECA21380 • Oil seals NOTICE • Wheel bearings Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ from the front wheel sensor “1”, otherwise a.

  • Page 165: Assembling The Front Wheel

    FRONT WHEEL EAS30151 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 166: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL • 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  Replace. 8 N·m (0.8 kgf·m, 5.8 lb·ft) Iron powder/dust …

  • Page 167: 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 168: Installing The Front Wheel (Disc Brake)

    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 169
    FRONT WHEEL sor rotor and the front wheel sensor. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 6. Install: • Front wheel sensor • Front wheel sensor bracket Front wheel sensor bolt 7 N·m (0.7 kgf·m, 5.1 lb·ft) ECA21020 NOTICE Make sure there are no foreign materials in the front wheel sensor rotor and front wheel sensor.
  • Page 170
    REAR WHEEL EAS20029 REAR WHEEL Removing the rear wheel 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 150 N ・ m (15 kgf ・ m, 108 lb ・ ft) 16 N ・ m (1.6 kgf ・ m, 12 lb ・ ft) 16 N ・…
  • Page 171
    REAR WHEEL Removing the brake disc and rear wheel sprocket 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 80 N ・ m (8.0 kgf ・ m, 58 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear brake disc Bracket Rear wheel sprocket…
  • Page 172
    REAR WHEEL Disassembling the rear wheel 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Rear wheel sensor rotor Oil seal Wheel bearing Spacer Wheel bearing 4-29…

  • Page 173: Rear Wheel

    REAR WHEEL EAS30156 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 174: 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 4-21. 2. Check: • Tire • Rear wheel Damage/wear  Replace. b. Correct Refer to “CHECKING THE TIRES” on page 1.

  • Page 175: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL 1. Install: EAS30165 INSTALLING THE REAR WHEEL (DISC • Wheel bearings BRAKE) • Oil seal 1. Install: Refer to “ASSEMBLING THE FRONT • Rear brake disc WHEEL” on page 4-22. Rear brake disc bolt EAS30167 30 N·m (3.0 kgf·m, 22 lb·ft) MAINTENANCE OF THE REAR WHEEL LOCTITE®…

  • Page 176
    REAR WHEEL 8. Install: • Rear wheel sensor Rear wheel sensor bolt 7 N·m (0.7 kgf·m, 5.1 lb·ft) ECA21080 NOTICE Make sure there are no foreign materials in the rear wheel sensor rotor and rear wheel sensor. Foreign materials cause damage to the rear wheel sensor rotor and rear wheel A.
  • Page 177
    REAR WHEEL Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 4-34…

  • Page 178: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

  • Page 179
    FRONT BRAKE Removing the front brake master cylinder 1.0 N ・ m (0.10 kgf ・ m, 0.72 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 17 N ・…
  • Page 180
    FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-37…
  • Page 181
    FRONT BRAKE Removing the front brake calipers 35 N ・ m (3.5 kgf ・ m, 25 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 182
    FRONT BRAKE Disassembling the front brake calipers 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

  • Page 183: 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 184: Replacing The Front Brake Pads

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

  • Page 185: 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 N·m (0.5 kgf·m, 3.6 lb·ft) tem. d. Install the brake pads and brake pad spring. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”…

  • Page 186: 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 187: 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: Specified brake fluid • Brake pads DOT 4 • Brake pad spring • Brake pad pin • Brake pad clips EAS30175 INSTALLING THE FRONT BRAKE CALIPERS •…

  • Page 188: 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 189
    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 190
    FRONT BRAKE BRAKE SYSTEM (ABS)” on page 3-15. 4-47…

  • Page 191: Rear Brake

    REAR BRAKE EAS20031 REAR BRAKE Removing the rear brake pads 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 17 N ・…

  • Page 192
    REAR BRAKE Removing the rear brake master cylinder 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 30 N ・…
  • Page 193
    REAR BRAKE Removing the rear brake master cylinder 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 30 N ・…
  • Page 194
    REAR BRAKE Disassembling the rear brake master cylinder 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake master cylinder yoke Brake master cylinder kit Hose joint Bushing Brake master cylinder body 4-51…
  • Page 195
    REAR BRAKE Removing the rear brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 27 N ・ m (2.7 kgf ・ m, 20 lb ・ ft) Order Job/Parts to remove Q’ty…
  • Page 196
    REAR BRAKE Disassembling the rear brake caliper 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) Order Job/Parts to remove Q’ty…

  • Page 197: 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 198: 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 199: 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 200: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: EWA13531 WARNING • Rear brake caliper bracket “1” Proper brake hose routing is essential to in- Cracks/damage  Replace. sure safe vehicle operation. Refer to “REAR WHEEL” on page 4-27. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a”…

  • Page 201: Removing The Rear Brake Master Cylinder

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

  • Page 202: 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 203: Abs (Anti-Lock Brake System)

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20032 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・…

  • Page 204
    ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 7 N ・…

  • Page 205: Abs Components Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30728 ABS COMPONENTS CHART 1. Hydraulic unit assembly 2. Fuse box 3 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 206: 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 207
    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 208: Hydraulic Unit Operation Tests

    • For the brake line routing confirmation, use the diagnosis of function of the Yamaha diagnostic 6. Start the Yamaha diagnostic tool and display tool. the diagnosis of function screen. • Before performing the brake line routing confir- 7.

  • Page 209
    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 210
    • “ON” and “OFF” on the tool screen indicate 6. Start the Yamaha diagnostic tool and display when the brakes are being applied and re- the diagnosis of function screen.

  • Page 211: 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 212: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 1/2 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 4.3 N ・ m (0.43 kgf ・ m, 3.1 lb ・ ft) 17 N ・…

  • Page 213
    HANDLEBAR Removing the handlebar 2/2 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) 11 N ・…

  • Page 214: Adjusting The Handlebar Position

    HANDLEBAR d. Install the handlebar “2” and upper handlebar EAS31396 ADJUSTING THE HANDLEBAR POSITION holders “1”. 1. Check: • Handlebar position Upper handlebar holder bolt 22 N·m (2.2 kgf·m, 16 lb·ft) The handlebar position can be adjusted in two ECA19130 positions to suit the rider’s preference.

  • Page 215: 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 handlebar (left) and the handlebar grip, and gradually push EAS30205 INSTALLING THE HANDLEBAR…

  • Page 216
    HANDLEBAR • Clutch cable Lower handlebar holder nut 40 N·m (4.0 kgf·m, 29 lb·ft) Clutch lever holder pinch bolt 11 N·m (1.1 kgf·m, 8.0 lb·ft) 4. Install: • Throttle grip “1” • Throttle cables Align the center of slit on the clutch lever holder •…

  • Page 217: Installing The Rearview Mirrors And Handguards

    HANDLEBAR EWA13700 WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-29. b. Tighten the handguard bracket bolts “3” to Throttle grip free play specification.

  • Page 218
    HANDLEBAR b. Tighten the handguard bracket bolts “3” to specification. Handguard bracket bolt 7 N·m (0.7 kgf·m, 5.1 lb·ft) c. Tighten the rearview mirror locknut “4” to specification. Rearview mirror locknut 17 N·m (1.7 kgf·m, 12 lb·ft) d. Tighten the handguard bolt “5” to specifica- tion.

  • Page 219: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 10 N ・…

  • Page 220
    FRONT FORK Disassembling the left front fork leg 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty…
  • Page 221
    FRONT FORK Disassembling the right front fork leg 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) 23 N ・ m (2.3 kgf ・ m, 17 lb ・ ft) Order Job/Parts to remove Q’ty…

  • Page 222: 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 223: 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 224: 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 225
    3. Lubricate: 90890-01442 • Inner tube’s outer surface Adjustable fork seal driver (36–46 Recommended oil YM-01442 Yamaha Suspension Oil 01 4. Install: • Dust seal “1” • Oil seal clip “2” • Oil seal “3” • Washer “4” • Outer tube bushing “5”…
  • Page 226
    • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil 9. Install: Yamaha Suspension Oil 01 • Dust seal “1” Quantity (left) (with the fork seal driver “2”) 444.0 cm³ (15.01 US oz, 15.66 Imp.oz)
  • Page 227
    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 228
    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 N·m (1.5 kgf·m, 11 lb·ft) c.

  • Page 229: Installing The Front Fork Legs

    FRONT FORK ment. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ j. Position the locknut “3” as specified “b”. 17.Install: • Cap bolt Distance “b” (to the outer tube) 12 mm (0.47 in) • Temporarily tighten the cap bolt. • When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts.

  • Page 230: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 18 N ・…

  • Page 231
    STEERING HEAD Removing the lower bracket 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 52 N ・ m (5.2 kgf ・ m, 38 lb ・ ft) 18 N ・…

  • Page 232: Removing The Lower Bracket

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

  • Page 233: Installing The Steering Head

    STEERING HEAD ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage  Replace. EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •…

  • Page 234
    REAR SHOCK ABSORBER ASSEMBLY EAS20036 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 44 N ・ m (4.4 kgf ・ m, 32 lb ・ ft) 61 N ・ m (6.1 kgf ・ m, 44 lb ・ ft) 44 N ・ m (4.4 kgf ・ m, 32 lb ・ ft) 55 N ・…

  • Page 235: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 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 236: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY 2. Check: • Bearings • Oil seals Damage/pitting  Replace. 3. Check: • Collars Damage/scratches  Replace. EAS30222 INSTALLING THE RELAY ARM 1. Lubricate: • Collars 3. Relay arm • Oil seals 4. Connecting arm 5. Rear shock absorber assembly Recommended lubricant A.

  • Page 237
    REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly nut (upper) 44 N·m (4.4 kgf·m, 32 lb·ft) Relay arm nut 61 N·m (6.1 kgf·m, 44 lb·ft) Connecting arm lower nut 55 N·m (5.5 kgf·m, 40 lb·ft) 4-94…

  • Page 238: Swingarm

    SWINGARM EAS20037 SWINGARM Removing the swingarm 110 N ・ m (11 kgf ・ m, 80 lb ・ ft) 55 N ・ m (5.5 kgf ・ m, 40 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・…

  • Page 239: 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 the centerstand so that the rear wheel is elevated. 2.

  • Page 240: Installing The Swingarm

    SWINGARM • Collars “3” Damage/scratches  Replace. • Bearings “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 N·m (11 kgf·m, 80 lb·ft) •…

  • Page 241: Chain Drive

    CHAIN DRIVE EAS20038 CHAIN DRIVE Removing the drive chain 95 N ・ m (9.5 kgf ・ m, 69 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 14 N ・…

  • Page 242: 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 243: Checking The Drive Sprocket

    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 244: Installing The Drive Chain

    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 245
    CHAIN DRIVE 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-18. Drive chain slack 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 246
    CHAIN DRIVE 4-103…
  • Page 247
    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 248
    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 249
    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 250: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION Compression gauge 90890-03081 Engine compression tester EAS30249 MEASURE THE COMPRESSION PRESSURE YU-33223 The following procedure applies to all of the cyl- Extension inders. 90890-04136 Insufficient compression pressure will result in a loss of performance. 1. Measure: •…

  • Page 251
    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 N·m (1.3 kgf·m, 9.4 lb·ft) 7.

  • Page 252: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 12 N ・…

  • Page 253
    ENGINE REMOVAL Disconnecting the leads and hoses 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…
  • Page 254
    ENGINE REMOVAL Disconnecting the leads and hoses 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Gear position switch coupler Disconnect.
  • Page 255
    ENGINE REMOVAL Removing the engine 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 45 N ・ m (4.5 kgf ・ m, 33 lb ・ ft) 12 N ・…

  • Page 256: 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 YM-01485 EAS30251 INSTALLING THE ENGINE 1. Install: •…

  • Page 257
    ENGINE REMOVAL 7. Tighten: • Engine mounting adjust bolt (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 N·m (0.7 kgf·m, 5.1 lb·ft)

  • Page 258: Camshafts

    CAMSHAFTS EAS20043 CAMSHAFTS Removing the cylinder head cover 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 13 N ・ m (1.3 kgf ・ m, 9.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…

  • Page 259
    CAMSHAFTS Removing the camshafts 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 24 N ・…

  • Page 260: 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 261: 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 262: 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 263: 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 264
    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 265
    CAMSHAFTS 8. Check: c. Tighten the timing chain tensioner bolts to the • Camshaft punch mark “a” specified torque. Make sure the camshaft punch mark “a” on Timing chain tensioner bolt the camshaft is aligned with the camshaft cap 10 N·m (1.0 kgf·m, 7.2 lb·ft) alignment mark “b”.
  • Page 266
    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 camshaft punch mark “c” on the camshaft is aligned with the camshaft cap 14.Install: alignment mark “d”.
  • Page 267
    CAMSHAFTS Install the ignition coils “1” in the direction shown in the illustration. 5-18…

  • Page 268: Cylinder Head

    CYLINDER HEAD EAS20044 CYLINDER HEAD Removing the cylinder head 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 12 lb ・ ft) 10 N ・…

  • Page 269: Removing The Cylinder Head

    CYLINDER HEAD 2. Check: EAS30276 REMOVING THE CYLINDER HEAD • Cylinder head 1. Remove: Damage/scratches  Replace. • Intake camshaft • Cylinder head water jacket • Exhaust camshaft Mineral deposits/rust  Eliminate. Refer to “REMOVING THE CAMSHAFTS” 3. Measure: on page 5-11. •…

  • Page 270: 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 271
    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 272: 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 273
    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 274: 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 275: 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 276: 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 277
    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 278
    GENERATOR AND STARTER CLUTCH EAS20140 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) 14 N ・…
  • Page 279
    GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 32 N ・ m (3.2 kgf ・ m, 23 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 75 N ・…

  • Page 280: Generator And Starter Clutch

    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 281: 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 282
    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 N·m (1.2 kgf·m, 8.7 lb·ft) LOCTITE®…

  • Page 283: Electric Starter

    ELECTRIC STARTER EAS20052 ELECTRIC STARTER Removing the starter motor 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…

  • Page 284
    ELECTRIC STARTER Disassembling the starter motor 11 N ・ m (1.1 kgf ・ m, 8.0 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Starter motor yoke Armature assembly Gasket…

  • Page 285: Checking The Starter Motor

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

  • Page 286: Assembling The Starter Motor

    ELECTRIC STARTER 6. Check: Starter motor bolt • Gear teeth 12 N·m (1.2 kgf·m, 8.7 lb·ft) 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 287: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 1.5 N ・…

  • Page 288
    CLUTCH Removing the pull lever shaft 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 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 289
    CLUTCH Removing the clutch 125 N ・ m (12.5 kgf ・ m, 90 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 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 290
    CLUTCH Removing the clutch 125 N ・ m (12.5 kgf ・ m, 90 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Thrust plate Clutch housing Oil pump drive chain Bearing Spacer Thrust plate…

  • Page 291: 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 292: 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 293: 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 294: Checking The Clutch Boss

    CLUTCH • Pressure plate 2 “2” 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.

  • Page 295: 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 296
    CLUTCH • Clutch springs a crisscross pattern. • Pressure plate 1 6. Install: • Clutch spring bolts “1” • Pull lever Clutch spring bolt • Install the pull lever with the “O” mark facing to- 10 N·m (1.0 kgf·m, 7.2 lb·ft) ward lower side.
  • Page 297
    CLUTCH 8. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12. Clutch lever free play 10.0–15.0 mm (0.39–0.59 in) 5-48…

  • Page 298: Shift Shaft

    SHIFT SHAFT EAS20057 SHIFT SHAFT Removing the shift shaft and stopper lever 22 N ・ m (2.2 kgf ・ m, 16 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH” on page 5-38. Shift arm Refer to “CHAIN DRIVE”…

  • Page 299: Checking The 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 300: Oil Pump

    OIL PUMP EAS20054 OIL PUMP Removing the oil pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 15 N ・ m (1.5 kgf ・ m, 11 lb ・ ft) Order Job/Parts to remove Q’ty…

  • Page 301
    OIL PUMP Disassembling the oil pump 3.8 N ・ m (0.38 kgf ・ m, 2.8 lb ・ ft) 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 302: 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- 0.20 mm (0.0079 in) ING” on page 5-44. Outer-rotor-to-oil-pump-housing 2. Check: clearance •…

  • Page 303: Assembling The Oil Pump

    OIL PUMP Oil pump bolt 10 N·m (1.0 kgf·m, 7.2 lb·ft) • Oil pump driven sprocket “3” Oil pump driven sprocket bolt 15 N·m (1.5 kgf·m, 11 lb·ft) 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 304: Oil Pan

    OIL PAN EAS20177 OIL PAN Removing the oil pan 43 N ・ m (4.3 kgf ・ m, 31 lb ・ ft) (13) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty…

  • Page 305: 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 306: Crankcase

    CRANKCASE EAS20059 CRANKCASE Separating the crankcase 24 N ・ m (2.4 kgf ・ m, 17 lb ・ ft) 25 N ・ m (2.5 kgf ・ m, 18 lb ・ ft) 18 N ・ m (1.8 kgf ・ m, 13 lb ・ ft) 10 N ・…

  • Page 307: 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 308
    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 309
    CRANKCASE 8. Tighten: • Crankcase bolts “9”–“30” Crankcase bolts “9”–“14” 24 N·m (2.4 kgf·m, 17 lb·ft) Crankcase bolts “15”–“30” 10 N·m (1.0 kgf·m, 7.2 lb·ft) Tighten the bolts in the tightening sequence cast on the crankcase. 19 20 23 24 5-60…
  • Page 310
    CONNECTING RODS AND PISTONS EAS20132 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons 20 N ・ m (2.0 kgf ・ m, 14 lb ・ ft) 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 311: 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 312: Checking The Piston Rings

    CONNECTING RODS AND PISTONS Piston-to-cylinder clearance Measure cylinder bore “C” by taking side-to-side 0.010–0.035 mm (0.0004–0.0014 and front-to-back measurements of the cylinder. Bore f. If out of specification, replace the cylinder, 78.000–78.010 mm (3.0709– and replace the piston and piston rings as a 3.0713 in) set.

  • Page 313: Checking The Piston Pin

    CONNECTING RODS AND PISTONS 3. Measure: • Piston ring end gap Out of specification  Replace the piston ring. The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Top ring End gap (installed) 3.

  • Page 314
    CONNECTING RODS AND PISTONS • Make sure that the projection “a” on the con- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ necting rod cap faces the same direction as the The following procedure applies to all of the “Y” mark “b” on the connecting rod. connecting rods. •…
  • Page 315
    CONNECTING RODS AND PISTONS tighten it. Instead, replace the bolt with a new necting rod cap faces the same direction as the “Y” mark “b” on the connecting rod. one and perform the procedure again. • Make sure the “Y” marks “b” on the connecting ECA20890 rods face towards the left side of the crank- NOTICE…

  • Page 316: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS ings with the notches “b” in the connecting rods Bearing color code and connecting rod caps. Code 1 • Make sure that the projection “c” on the con- Blue necting rod cap faces the same direction as the Code 2 “Y”…

  • Page 317
    CONNECTING RODS AND PISTONS • Install the piston pin clips, so that the clip ends are 3 mm (0.12 in) “c” or more from the cutout To install the big end bearing, care should be taken not to install it at an angle and the position in the piston.
  • Page 318
    CONNECTING RODS AND PISTONS 7. Lubricate: • Crankshaft pins • Connecting rod big end bearing inner surface (with the recommended lubricant) Recommended lubricant Engine oil 8. Install: • Piston assemblies “1” (into the cylinder “2” and onto the crankshaft 10.Tighten: pin) •…
  • Page 319
    CONNECTING RODS AND PISTONS 180˚ EWA16610 WARNING 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. ECA20890 NOTICE Do not use a torque wrench to tighten the…
  • Page 320
    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 321: 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 322
    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 323: 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 324: 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 325: 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 326: Transmission

    TRANSMISSION EAS20062 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty…

  • Page 327
    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 328
    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 329
    TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle 5-80…

  • Page 330: 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 331
    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 332
    TRANSMISSION 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 333
    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 334
    TRANSMISSION 5-85…
  • Page 335
    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 336: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 0.5 N ・ m (0.05 kgf ・ m, 0.36 lb ・ ft) 10 N ・…

  • Page 337: 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 338
    RADIATOR pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure  Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.

  • Page 339: Oil Cooler

    OIL COOLER EAS20064 OIL COOLER Removing the oil cooler 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Coolant reservoir Refer to “RADIATOR”…

  • Page 340: Checking The Oil Cooler

    OIL COOLER 5. Measure: EAS30441 CHECKING THE OIL COOLER • Radiator cap valve opening pressure 1. Check: Below the specified pressure  Replace the • Oil cooler radiator cap. Cracks/damage  Replace. Refer to “CHECKING THE RADIATOR” on 2. Check: page 6-2.

  • Page 341: Thermostat

    THERMOSTAT EAS20065 THERMOSTAT Removing the thermostat assembly 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 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 3-27.

  • Page 342: 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 3-27.

  • Page 343: Water Pump

    WATER PUMP EAS20066 WATER PUMP Removing the water pump 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-27. Water pump inlet hose Disconnect.

  • Page 344
    WATER PUMP Disassembling the water pump 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 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 345: 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) •…

  • Page 346
    WATER PUMP 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. touches the water pump housing.

  • Page 347: Fuel System

    FUEL SYSTEM FUEL TANK ………………….7-1 REMOVING THE FUEL TANK …………..7-3 REMOVING THE FUEL PUMP …………..7-3 CHECKING THE FUEL PUMP BODY…………7-3 CHECKING THE FUEL PUMP OPERATION……….7-3 INSTALLING THE FUEL PUMP…………..7-4 INSTALLING THE FUEL TANK…………..7-4 THROTTLE BODIES ………………7-5 CHECKING THE INJECTORS (BEFORE REMOVING) ……7-8 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ……..7-8 REMOVING THE INJECTORS …………..7-8 CHECKING THE INJECTORS …………..7-8…

  • Page 348
    FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) 4.0 N ・…
  • Page 349
    FUEL TANK Removing the canister 7 N ・ m (0.7 kgf ・ m, 5.1 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)” on page cowling 4-6. Refer to “GENERAL CHASSIS (1)” on page Passenger seat/Rider seat 4-1.

  • Page 350: 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: • Fuel tank front cover/Front side panel/Front side cowling Refer to “GENERAL CHASSIS (2)” on page 4-6.

  • Page 351
    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 N·m (0.40 kgf·m, 2.9 lb·ft) 2. Connect: • Do not damage the installation surfaces of the •…
  • Page 352
    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 4.5 N ・ m (0.45 kgf ・ m, 3.3 lb ・ ft) 3.0 N ・ m (0.30 kgf ・ m, 2.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…
  • Page 353
    THROTTLE BODIES Removing the sensors 3.5 N ・ m (0.35 kgf ・ m, 2.5 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.5 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Negative pressure hose Hose joint Canister purge hose Hose joint Intake air pressure sensor 2…
  • Page 354
    THROTTLE BODIES Removing the injectors 5 N ・ m (0.5 kgf ・ m, 3.6 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Throttle bodies/Throttle body joint Refer to “THROTTLE BODIES” on page 7-5. Fuel rail Injector Injector coupler…
  • Page 355
    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 356
    • 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 357
    THROTTLE BODIES • Do not allow carbon deposits or other for- 5. Place the vehicle on the centerstand so that eign materials to enter any of the passages the rear wheel is elevated. in each throttle body or in the space be- 6.
  • Page 358
    THROTTLE BODIES to the fuel rail joint “2”, and then connect an side cowling air compressor “3” to the adapter. Refer to “GENERAL CHASSIS (2)” on page b. Connect the pressure gauge “4” to the fuel in- 4-6. jector pressure adapter “1”. •…
  • Page 359
    • 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 360
    Connect the throttle cables to the throttle bod- ies. e. Remove the protective cap “1”, and then con- nect the Yamaha diagnostic tool to coupler. e. Diagnostic code number “01” is selected. For information about using the Yamaha diag- f.
  • Page 361
    If the Yamaha diagnostic tool screen value is not 95–109, adjust the accelerator position sensor angle. q. Repeat steps (f) to (p) until the Yamaha diag- nostic tool screen values are within the spec- ified ranges. r. If the Yamaha diagnostic tool screen values…

  • Page 362: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15…

  • Page 363
    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 364
    AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and reed valves 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side…
  • Page 365
    AIR INDUCTION SYSTEM 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Reed valve assembly 2 Reed valve plate 7-18…
  • Page 366
    AIR INDUCTION SYSTEM • Reed valve seat EAS30488 CHECKING THE AIR INDUCTION SYSTEM Cracks/damage  Replace the reed valve Air injection assembly. The air induction system burns unburned ex- 3. Measure: haust gases by injecting fresh air (secondary air) • Reed valve bending limit “a” into the exhaust port, reducing the emission of Out of specification …
  • Page 367
    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 368
    AIR INDUCTION SYSTEM 7-21…

  • Page 369: Electrical System

    COOLING SYSTEM………………8-27 CIRCUIT DIAGRAM ……………..8-27 TROUBLESHOOTING …………….8-29 FUEL INJECTION SYSTEM…………….8-31 CIRCUIT DIAGRAM ……………..8-31 ECU SELF-DIAGNOSTIC FUNCTION………….8-33 TROUBLESHOOTING METHOD………….8-33 YAMAHA DIAGNOSTIC TOOL …………..8-34 TROUBLESHOOTING DETAILS (FAULT CODE) ……..8-35 FUEL PUMP SYSTEM………………8-103 CIRCUIT DIAGRAM …………….8-103 TROUBLESHOOTING …………….8-105 IMMOBILIZER SYSTEM…………….8-107 CIRCUIT DIAGRAM …………….8-107 GENERAL INFORMATION …………..8-109…

  • Page 370
    ABS (ANTI-LOCK BRAKE SYSTEM)…………8-117 CIRCUIT DIAGRAM …………….8-117 ABS COMPONENTS CHART …………..8-119 ABS COUPLER LOCATION CHART ………….8-121 MAINTENANCE OF THE ABS ECU …………8-123 ABS TROUBLESHOOTING OUTLINE………..8-123 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ……8-124 BASIC PROCESS FOR TROUBLESHOOTING ……..8-125 [A] CHECKING THE ABS WARNING LIGHT………8-126 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON….8-126 [A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON …………..8-126…
  • Page 372
    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM…
  • Page 373
    IGNITION SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 20.Joint connector 21.Joint coupler 22.Relay unit 25.Sidestand switch 28.ECU (Engine Control Unit) 29.Ignition coil #1 30.Ignition coil #2 31.Ignition coil #3 32.Spark plug 40.Crankshaft position sensor 45.Lean angle sensor 67.Gear position switch…
  • Page 374
    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 375
    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5.
  • Page 376
    IGNITION SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-173. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-153. OK…
  • Page 377
    IGNITION SYSTEM…

  • Page 378: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM…

  • Page 379
    ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 18.Starter relay 19.Starter motor 20.Joint connector 21.Joint coupler 22.Relay unit 23.Starting circuit cut-off relay 25.Sidestand switch 67.Gear position switch 70.Handlebar switch (right) 72.Start/engine stop switch 77.Handlebar switch (left) 78.Clutch switch…
  • Page 380
    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 381
    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 382
    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6.
  • Page 383
    ELECTRIC STARTING SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-173. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-153. OK…
  • Page 384
    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13…
  • Page 385
    CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 15.Battery 16.Engine ground A. Wire harness D. Negative battery sub-wire harness 8-14…
  • Page 386
    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Passenger seat/Rider seat 2. Rear side cover (left)/Lower tail cover 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” NG…
  • Page 387
    CHARGING SYSTEM 8-16…
  • Page 388
    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17…
  • Page 389
    LIGHTING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 28.ECU (Engine Control Unit) 53.Meter assembly 56.Meter light 62.High beam indicator light 77.Handlebar switch (left) 84.Dimmer/pass switch 89.Headlight control unit 90.Headlight (high beam) 91.Headlight (low beam) 92.Auxiliary light (right)
  • Page 390
    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. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3.
  • Page 391
    LIGHTING SYSTEM 8-20…
  • Page 392
    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21…
  • Page 393
    SIGNALING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 22.Relay unit 28.ECU (Engine Control Unit) 42.Coolant temperature sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 53.Meter assembly 55.Neutral indicator light 57.Tachometer 58.Multi-function meter 59.Oil level warning light…
  • Page 394
    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 comeon. • The speedometer fails to operate. •…
  • Page 395
    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 396
    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 397
    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 8-157. The speedometer fails to operate.
  • Page 398
    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27…
  • Page 399
    COOLING SYSTEM 3. Main switch 4. Main fuse 9. Radiator fan motor fuse 11.Ignition fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 28.ECU (Engine Control Unit) 42.Coolant temperature sensor 96.Radiator fan motor relay 97.Radiator fan motor A. Wire harness C. Sub-wire harness (Coolant temperature sen- sor) D.
  • Page 400
    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Canister 7. Throttle bodies 1.
  • Page 401
    COOLING SYSTEM 8-30…
  • Page 402
    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31…
  • Page 403
    45.Lean angle sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 49.Throttle servo motor 50.Accelerator position sensor 51.Throttle position sensor 52.Yamaha diagnostic tool coupler 53.Meter assembly 58.Multi-function meter 60.Engine trouble warning light 67.Gear position switch 69.Fuel pump 70.Handlebar switch (right) 71.Drive mode switch…
  • Page 404
    • 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 405
    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 USB 90890-03250 Yamaha diagnostic tool (A/I) 90890-03252 A generic scan tool can also be used to identify malfunctions.
  • Page 406
    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 407
    FUEL INJECTION SYSTEM Parts connected to the ECU The following parts are connected to the ECU. When checking for a power short circuit, the couplers must be disconnected from all of the following parts beforehand. • Crankshaft position sensor • Intake air temperature sensor •…
  • Page 408
    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 409
    Turn the main switch to “ON”, and then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 6 and finish the service. Condition is “Detected”  Start the engine, and then check the condition of the fault code.
  • Page 410
    Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 411
    FUEL INJECTION SYSTEM Fault code No. P0107, P0108 [P0107] Intake air pressure sensor 1: ground short circuit detected. Item [P0108] Intake air pressure sensor 1: open or power short circuit detected. [For P0108] Open circuit Between intake air pressure sensor 1 coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 412
    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 413
    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 414
    FUEL INJECTION SYSTEM Fault code No. P0112, P0113 [P0112] Intake air temperature sensor: ground short circuit detected. Item [P0113] Intake air temperature sensor: open or power short circuit detected. Br/W Br/W 1. Intake air temperature sensor 2. ECU 3. Sensor output lead 4.
  • Page 415
    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 416
    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 417
    Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service. Condition is “Detected”  Go to item 4.
  • Page 418
    FUEL INJECTION SYSTEM Fault code No. P0117, P0118 [P0117] Coolant temperature sensor: ground short circuit detected. Item [P0118] Coolant temperature sensor: open or power short circuit detected. [For P0118] Open circuit Between wire harness coupler (ECU side) and ECU coupler: green/white–green/white Between sub-wire harness coupler (coolant temperature sensor side) and coolant temperature sen- sor coupler: green/white–green/white If there is no continuity, replace the wire harness and/or sub-wire harness.
  • Page 419
    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 420
    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 421
    FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 422
    FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 423
    FUEL INJECTION SYSTEM Fault code No. P0122, P0123, P0222, P0223, P2135 [P0122] Throttle position sensor: ground short circuit detected. [P0123] Throttle position sensor: open or power short circuit detected. Item [P0222] Throttle position sensor: ground short circuit detected. [P0223] Throttle position sensor: open or power short circuit detected.
  • Page 424
    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 425
    1. and then check the condition of Execute the diagnostic mode. the fault code using the mal- function mode of the Yamaha (Code No. 01) When the throttle valves are diagnostic tool. Condition is “Recovered”  Go fully closed: A value of 11–21 is indicated.
  • Page 426
    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 427: Specifications

    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 428
    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 429
    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 430
    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 431
    Crank the engine, and then the wire harness. check the condition of the fault Between crankshaft position code using the malfunction sensor coupler and ECU cou- mode of the Yamaha diagnostic pler. tool. Condition is “Recovered”  Go gray–gray Between crankshaft position to item 7 and finish the service.
  • Page 432
    Diagnostic code No. 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 433
    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 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
    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 436
    Check the condition of the fault Replace if out of specification. code using the malfunction Refer to “CHECKING THE mode of the Yamaha diagnostic IGNITION COILS” on page tool. Condition is “Recovered”  Go 8-163. to item 7 and finish the service.
  • Page 437
    FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
  • Page 438
    (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 439
    FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
  • Page 440
    FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected  Con- Connection of ECU coupler.
  • Page 441
    (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 442
    FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
  • Page 443
    FUEL INJECTION SYSTEM Fault code No. P0500, P1500 Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Neutral switch: open or short circuit is detected. Clutch switch: open or short circuit is detected. Improperly connected  Con- Connection of ECU coupler.
  • Page 444
    (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 445
    FUEL INJECTION SYSTEM Fault code No. P0601, P0606 Fault code No. P0601, P0606 Internal malfunction in ECU. (When this malfunction is detected in Item the ECU, the fault code number might not appear on the tool dis- play.) Able/Unable to start engine Fail-safe system Able/Unable to drive vehicle Diagnostic code No.
  • Page 446
    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 3-11. After this adjustment is made, to item 7 and finish the service.
  • Page 447
    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 448
    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 449
    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 450
    (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 451
    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 452
    Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 453
    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 454
    ECU coupler. Check the condition of the fault black/red–black/red code using the malfunction Between relay unit coupler and mode of the Yamaha diagnostic sidestand switch coupler. tool. Condition is “Recovered”  Go blue/black–blue/black to item 7 and finish the service.
  • Page 455
    Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 456
    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 457
    FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit. 1. Lean angle sensor 2. ECU 3. Sensor input lead 4. Sensor output lead 5.
  • Page 458
    FUEL INJECTION SYSTEM Fault code No. P1604, P1605 [P1604] Lean angle sensor: ground short circuit detected. Item [P1605] Lean angle sensor: open or power short circuit. [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: yellow/green–yellow/green If there is no continuity, replace the wire harness. [For P1605] Open circuit Between lean angle sensor coupler and ECU coupler: black/blue–black/blue If there is no continuity, replace the wire harness.
  • Page 459
    “OFF”, and then back to page 8-165. “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 460
    Turn the main switch to “ON”, the wire harness. and then check the condition of the fault code using the mal- function mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 7 and finish the service.
  • Page 461
    FUEL INJECTION SYSTEM Fault code No. P1606, P1607 [P1606] Intake air pressure sensor 2: ground short circuit detected. Item [P1607] Intake air pressure sensor 2: open or power short circuit detected. [For P1607] Open circuit Between Intake air pressure sensor 2 coupler and ECU coupler: blue–blue If there is no continuity, replace the wire harness.
  • Page 462
    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 463
    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 464
    Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 465
    FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
  • Page 466
    FUEL INJECTION SYSTEM Fault code No. P2122, P2123, P2127, P2128, P2138 [P2122] Accelerator position sensor: open or ground short circuit detected. [P2123] Accelerator position sensor: power short circuit detected. Item [P2127] Accelerator position sensor: ground short circuit detected. [P2128] Accelerator position sensor: open or power short circuit detected.
  • Page 467
    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 468
    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 469
    FUEL INJECTION SYSTEM Fault code No. P2158 Front wheel sensor: no normal signals are received from the front Item wheel sensor. Locate the malfunction. If the ABS warning light is on, refer to “BASIC INSTRUC- TIONS FOR TROUBLESHOOT- ING” on page 8-124. If the ABS warning light is off, perform the following procedure.
  • Page 470
    (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 471
    Improperly installed sensor  Check the condition of the fault Reinstall or replace the sensor. code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 2.
  • Page 472
    FUEL PRESSURE” on page approximately 10 seconds. 7-11. Check the condition of the fault code using the malfunction mode of the Yamaha diagnostic tool. Condition is “Recovered”  Go to item 8 and finish the service. Condition is “Detected”  Go to item 6.
  • Page 473
    Disconnect the coupler and function mode of the Yamaha check the pins (bent or broken diagnostic tool. Condition is “Recovered”  Go terminals and locking condition of the pins).
  • Page 474
    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-103…
  • Page 475
    FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 20.Joint connector 21.Joint coupler 22.Relay unit 24.Fuel pump relay 28.ECU (Engine Control Unit) 69.Fuel pump 70.Handlebar switch (right) 72.Start/engine stop switch A. Wire harness D.
  • Page 476
    FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 477
    FUEL PUMP SYSTEM 8-106…
  • Page 478
    IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-107…
  • Page 479
    IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 8. Backup fuse 11.Ignition fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 26.Immobilizer unit 28.ECU (Engine Control Unit) 53.Meter assembly 54.Immobilizer system indicator light 58.Multi-function meter A. Wire harness D. Negative battery sub-wire harness 8-108…
  • Page 480
    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 481
    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 482
    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 483
    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 484
    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 8-157.
  • Page 485
    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 486
    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 487
    IMMOBILIZER SYSTEM 8-116…
  • Page 488
    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-117…
  • Page 489
    22.Relay unit 23.Starting circuit cut-off relay 28.ECU (Engine Control Unit) 46.Front wheel sensor 47.Rear wheel sensor 48.ABS ECU (electronic control unit) 52.Yamaha diagnostic tool coupler 53.Meter assembly 58.Multi-function meter 65.ABS warning light 70.Handlebar switch (right) 72.Start/engine stop switch 74.Front brake light switch 75.Rear brake light switch…
  • Page 490
    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30525 ABS COMPONENTS CHART 8-119…
  • Page 491
    ABS (ANTI-LOCK BRAKE SYSTEM) 1. Hydraulic unit assembly 2. Fuse box 3 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 2…
  • Page 492
    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART 8-121…
  • Page 493
    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 8-122…
  • Page 494
    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 8-127. For troubleshooting items other than the following items, follow the normal service method.
  • Page 495
    Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. 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 496
    • 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 497
    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 498
    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 499
    Removing the rider seat. Refer to “GENERAL CHASSIS (1)” on page 4-1. Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler. Details about the displayed fault codes are shown in the following chart. Refer to this chart and check the vehicle.
  • Page 500
    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 • Incorrect installation of the while the vehicle is traveling.) rear wheel •…
  • Page 501
    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) • Defective coupler between light circuit, or front or rear brake light switch circuit.) the signaling system…
  • Page 502
    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 503: Troubleshooting Details

    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 504
    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 505
    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 506
    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 • Check for continuity between the white terminal “1” Open or short circuit in the wire harness between the front wheel sensor and the and the white terminal “4”…
  • Page 507
    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 • Check for continuity between the white terminal “1” Open or short circuit in the wire harness between the rear wheel sensor and the and the white terminal “4”…
  • Page 508
    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 509
    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 510
    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 511
    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 512
    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 513
    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 514
    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 515
    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 516
    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 517
    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 518
    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 519
    ABS (ANTI-LOCK BRAKE SYSTEM) 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. • Malfunction in the ABS warning light circuit in the hydraulic unit assembly. 8-148…
  • Page 520
    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-149…
  • Page 521
    ELECTRICAL COMPONENTS 1. Main switch/Immobilizer unit 2. Clutch switch 3. Front brake light switch 4. Hydraulic unit assembly 5. Battery 6. Fuse box 3 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 522
    ELECTRICAL COMPONENTS 8-151…
  • Page 523
    ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. ECU (Engine Control Unit) 3. Fuel pump 4. Lean angle sensor 5. Radiator fan motor relay 6. Turn signal/hazard relay 7. Relay unit 8. Stator coil 9. Crankshaft position sensor 10.Coolant temperature sensor 11.Throttle servo motor 12.Accelerator position sensor 13.Throttle position sensor…
  • Page 524
    ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Br/W B/Y W/R B W/G Br B/R B/L B/L Br/W 8-153…
  • Page 525
    ELECTRICAL COMPONENTS 1. Dimmer/pass switch 2. Turn signal switch 3. Horn switch 4. Select switch 5. Menu 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 8-154…
  • Page 526
    ELECTRICAL COMPONENTS Check each switch for continuity with the digital curcuit 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 527
    ELECTRICAL COMPONENTS EAS30550 CHECKING THE BULBS AND BULB Digital circuit tester (CD732) 90890-03243 SOCKETS Model 88 Multimeter with tachom- Check each bulb and bulb socket for damage or eter wear, proper connections, and also for continuity YU-A1927 between the terminals. Damage/wear …
  • Page 528
    ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Amperage Fuses Q’ty rating EAS30551 CHECKING THE FUSES Main 50 A The following procedure applies to all of the fus- Headlight 7.5 A Signaling system 7.5 A ECA13680 NOTICE Ignition 15 A To avoid a short circuit, always set the main switch to “OFF”…
  • Page 529
    ELECTRICAL COMPONENTS be charged according to the appropriate Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-8. charging method. If the battery is over- charged, the electrolyte level will drop con- 4. Check: • Engine idling speed siderably. Therefore, take special care when charging the battery.
  • Page 530
    ELECTRICAL COMPONENTS tery overheating and battery plate damage. nected). • No charging is necessary when the open-cir- • If it is impossible to regulate the charging current on the battery charger, be careful cuit voltage equals or exceeds 12.8 V. not to overcharge the battery.
  • Page 531
    ELECTRICAL COMPONENTS charging. tery. Voltage should be measured 30 minutes after If the current is lower than the standard charging the engine is stopped. current written on the battery, this type of battery charger cannot charge the VRLA (Valve Regu- b.
  • Page 532
    ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) 10.Install: • Rider seat/Passenger seat Refer to “GENERAL CHASSIS (1)” on page 4-1. EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester. If the continuity reading is incor- rect, replace the relay.
  • Page 533
    ELECTRICAL COMPONENTS Radiator fan motor relay b. Turn the main switch to “ON”. 1. Positive battery terminal c. Measure the turn signal/hazard relay input 2. Negative battery terminal voltage. 3. Positive tester probe ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Negative tester probe 2. Check: •…
  • Page 534
    ELECTRICAL COMPONENTS EAS30795 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification  Replace. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the relay unit coupler from the The digital circuit tester readings are shown in wire harness.
  • Page 535
    ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the ignition coil from the spark plug. b. Connect the ignition checker “1” as shown. c.
  • Page 536
    ELECTRICAL COMPONENTS Digital circuit tester (CD732) Digital circuit tester (CD732) 90890-03243 90890-03243 Model 88 Multimeter with tachom- Model 88 Multimeter with tachom- eter eter YU-A1927 YU-A1927 Test harness– lean angle sensor (6P) • Positive tester probe 90890-03209 gray “1” Test harness– lean angle sensor •…
  • Page 537
    ELECTRICAL COMPONENTS fluid is in the vicinity. b. Measure the stator coil resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Check the starter motor operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30680 CHECKING THE RECTIFIER/REGULATOR EAS30566 1. Check: CHECKING THE STATOR COIL • Rectifier/regulator input voltage 1. Disconnect: Out of specification  Correct the stator coil •…
  • Page 538
    ELECTRICAL COMPONENTS EAS30569 CHECKING THE HORN 1. Check: • Horn resistance Out of specification  Replace. Horn Coil resistance 1.07–1.11  ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the horn leads from the horn ter- c. Start the engine and let it run at approximate- minals.
  • Page 539
    ELECTRICAL COMPONENTS 4. Check: Oil level switch • Fuel sender resistance Oil level switch resistance (maxi- Out of specification  Replace the fuel pump mum level position) assembly. 484.0–536.0  Oil level switch resistance (mini- Sender unit resistance (full) mum level position) 9.0–11.0 …
  • Page 540
    ELECTRICAL COMPONENTS 1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Fuel meter/fuel level warning light “1” a. Disconnect the radiator fan motor coupler (Turn the main switch to “ON”.) from the wire harness. Warning light comes on for a few seconds, b. Connect the battery (DC 12 V) as shown. then goes off …
  • Page 541
    ELECTRICAL COMPONENTS Digital circuit tester (CD732) Resistance 90890-03243 1.20–2.80 k Model 88 Multimeter with tachom- eter ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-A1927 a. Connect the digital circuit tester () to the throttle position sensor terminals as shown. b. Immerse the coolant temperature sensor “1” Digital circuit tester (CD732) in a container filled with coolant “2”.
  • Page 542
    ELECTRICAL COMPONENTS tance servo motor terminals “1” as shown. Out of specification  Replace the accelera- ECA17660 NOTICE tor position sensor. Do not use a 12 V battery to operate the throt- Resistance tle servo motor. 1.08–2.52 k Do not use old batteries to operate the throttle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…
  • Page 543
    ELECTRICAL COMPONENTS Digital circuit tester (CD732) Digital circuit tester (CD732) 90890-03243 90890-03243 Model 88 Multimeter with tachom- Model 88 Multimeter with tachom- eter eter YU-A1927 YU-A1927 Test harness S– pressure sensor (3P) • Positive tester probe  90890-03207 Air induction system solenoid terminal “1” Test harness S–…
  • Page 544
    ELECTRICAL COMPONENTS with special care. EAS31088 CHECKING THE GEAR POSITION SWITCH • Never subject the intake air temperature 1. Remove: sensor to strong shocks. If the intake air • Fuel tank temperature sensor is dropped, replace it. Refer to “FUEL TANK” on page 7-1. 2.
  • Page 545
    ELECTRICAL COMPONENTS EAS30681 Result CHECKING THE FUEL INJECTORS Neutral position The following procedure applies to all of the fuel Continuity injectors. Positive tester probe 1. Remove: sky blue “1” • Fuel injector Negative tester probe Refer to “THROTTLE BODIES” on page 7-5. Sensor terminal “a”…
  • Page 546
    ELECTRICAL COMPONENTS 8-175…

  • Page 547: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING………………9-1 GENERAL INFORMATION …………….9-1 STARTING FAILURES…………….9-1 INCORRECT ENGINE IDLING SPEED ………….9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ……9-2 FAULTY GEAR SHIFTING……………..9-2 SHIFT PEDAL DOES NOT MOVE ………….9-2 JUMPS OUT OF GEAR…………….9-2 FAULTY CLUTCH ………………9-2 OVERHEATING ………………9-2 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 548: 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 549
    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 550
    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 551
    TROUBLESHOOTING • Incorrect connection • Faulty tail/brake light assembly Turn signal does not come on • Faulty turn signal switch • Faulty turn signal/hazard relay • Burnt-out turn signal bulb • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit •…
  • Page 552
    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 8-33. Fault Probable cause of Fail-safe system Item Vehicle symptom code No.
  • Page 553
    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 554
    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 555
    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 556
    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 557
    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 • Hose of intake air sensor 1 or intake air start.
  • Page 558
    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 559
    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 560
    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 561
    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 562
    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 563
    • 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 564
    Check that injector #3 is The “check” indicator on the actuated five times by listen- Yamaha diagnostic tool ing for the operating sound. screen come on each time the injector is actuated. Air induction system solenoid Actuates the air induction…
  • Page 565
    EVENT CODE TABLE EAS20164 EVENT CODE TABLE Item Symptom Possible causes Note Intake air pres- Brief abnormality Same as for fault code Perform the checks and sure sensor 1 detected in the intake number P0107 and maintenance jobs for fault air pressure sensor 1 P0108 code number P0107 and…
  • Page 566
    EVENT CODE TABLE Item Symptom Possible causes Note During idling, the Idling engine speed is • Implement diagnosis (Stuck at the adjustment is main- slow mode (diagnostic code • Clogged throttle body upper limit for tained at the upper number 67), and check •…
  • Page 567
    EVENT CODE TABLE EAS32023 TROUBLESHOOTING DETAILS (EVENT CODE) Event code No. 30 Event code No. Item Latch up detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Tool display • 0.4–1.4 (upright) •…
  • Page 568
    EVENT CODE TABLE Event code No. 70 If another error code is displayed at the same time, check the other error code first and repair it. Event code No. Engine forcibly stops when the vehicle is left idling for a long period Item of time.

  • Page 569: Wiring Diagram

    49. Throttle servo motor A. Wire harness 50. Accelerator position sensor B. Sub-wire harness (Injector #2) 51. Throttle position sensor C. Sub-wire harness (Coolant 52. Yamaha diagnostic tool cou- temperature sensor) pler D. Negative battery sub-wire har- 53. Meter assembly ness 54.

  • Page 570
    EAS30613 COLOR CODE Black Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue Violet White Yellow Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Red Green/White Green/Yellow Gy/G Gray/Green Gy/R Gray/Red Blue/Black…
  • Page 573
    MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO…
  • Page 574
    MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 MT09TRA/MT09TRAH 2017 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO…

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Yamaha TRACER MT09TRA Service Manual

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Summary of Contents for Yamaha TRACER MT09TRA

  • Page 1
    2015 SERVICE MANUAL MT09TRA MT09TRAF 2PP-28197-E0…
  • Page 3
    EAS20002 MT09TRA/MT09TRAF SERVICE MANUAL ©2014 by Yamaha Motor Co., Ltd. First edition, June 2014 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: How To Use This Manual

    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

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

  • Page 9: General Information

    VEHICLE IDENTIFICATION NUMBER …………1-1 MODEL LABEL……………….1-1 FEATURES …………………..1-2 OUTLINE OF THE FI SYSTEM…………..1-2 FI SYSTEM………………..1-3 YCC-T (Yamaha Chip Controlled Throttle)……….1-4 OUTLINE OF THE ABS…………….1-5 ABS COMPONENT FUNCTIONS …………1-10 ABS OPERATION ………………1-15 ABS WARNING LIGHT AND OPERATION……….1-18 OUTLINE OF THE TCS (Traction Control System)……..1-19 MULTI-FUNCTION METER UNIT …………1-23…

  • 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 battery box under the passenger seat. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 12: Fi System

    FEATURES EAS30617 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remain open.

  • Page 13: Ycc-T (Yamaha Chip Controlled Throttle)

    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 14: Outline Of The Abs

    EAS30683 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle.

  • Page 15
    4. Rear wheel sensor 5. Rear wheel sensor rotor The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake.
  • Page 16
    FEATURES continues to travel. • Side force: The force on the tires which supports the vehicle when cornering. • Slip ratio: When the brakes are applied, slipping occurs between the tires and the road surface. This causes a difference between the wheel speed and the chassis speed. Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula.
  • Page 17
    FEATURES Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values.
  • Page 18
    Slip ratio (%) b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.

  • Page 19: Abs Component Functions

    FEATURES ABS block diagram 8. ABS ECU 1. Rear brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10.Rear brake caliper 3. Front brake master cylinder 11.Rear wheel sensor 4. Inlet solenoid valve 12.ABS warning light 5. ABS motor 13.Front brake caliper 6.

  • Page 20
    FEATURES 6. Wheel sensor rotor 3. At low speed 7. Voltage 4. At high speed 5. Wheel sensor 8. Time ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function check is properly completed at a speed of about 6 to 10 km/h [3.8 to 6.3 mi/h]).
  • Page 21
    FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
  • Page 22
    FEATURES 3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic pressure difference between the brake fluid in the upper brake lines (brake master cylinder side) and the brake fluid in the lower brake lines (brake caliper side).
  • Page 23
    FEATURES 15.ABS ECU 1. Battery 16.ABS motor relay 2. AC magneto 17.Solenoid relay 3. Rectifier/regulator 18.Front brake outlet solenoid 4. Main fuse 19.Front brake inlet solenoid 5. ABS motor fuse 20.Rear brake outlet solenoid 6. ABS solenoid fuse 21.Rear brake inlet solenoid 7.

  • Page 24: Abs Operation

    FEATURES 5. Self-diagnosis (when riding) 1. Software operation flow 6. Receive signals 2. Main switch “ON” 7. Control operation 3. Initialize 8. Depressurize/pressurize 4. Self-diagnosis (when static) EAS30710 ABS OPERATION The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de- scribes the system for the front wheel only.

  • Page 25
    FEATURES 8. Brake caliper 1. Brake master cylinder 9. Wheel sensor 2. Brake light switch 10.ABS ECU 3. ABS motor 11.ABS warning light 4. Hydraulic pump 12.Brake fluid pressure 5. Buffer chamber 13.Time 6. Outlet solenoid valve 7. Inlet solenoid valve Emergency braking (ABS activated) 1.
  • Page 26
    FEATURES 8. Brake caliper 1. Brake master cylinder 2. Brake light switch 9. Wheel sensor 10.ABS ECU 3. ABS motor 11.ABS warning light 4. Hydraulic pump 12.Brake fluid pressure 5. Buffer chamber 13.Time 6. Outlet solenoid valve 7. Inlet solenoid valve 2.

  • Page 27: Abs Warning Light And Operation

    FEATURES 8. Brake caliper 1. Brake master cylinder 2. Brake light switch 9. Wheel sensor 10.ABS ECU 3. ABS motor 11.ABS warning light 4. Hydraulic pump 12.Brake fluid pressure 5. Buffer chamber 13.Time 6. Outlet solenoid valve 7. Inlet solenoid valve EAS30712 ABS WARNING LIGHT AND OPERATION ABS warning light…

  • Page 28: Outline Of The Tcs (Traction Control System)

    FEATURES ABS function EWA16521 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is close to the limit.

  • Page 29
    FEATURES TCS (Traction control system) layout 8, 9 6. Rear wheel sensor 1. “TCS” button 7. Front wheel sensor 2. Traction control system indicator/warning light 8. Ignition coil 3. ECU (engine control unit) 9. Spark plug 4. Throttle servo motor 10.Fuel injector 5.
  • Page 30
    FEATURES C. Exceeds preset value 1. Front wheel sensor D. Actuator control 2. Rear wheel sensor E. Fuel cut-off 3. ABS ECU F. Ignition timing (retarded) 4. “TCS” button G. Traction control system indicator/warning 5. ECU (engine control unit) light (flashes) A.
  • Page 31
    FEATURES Turn the traction control system off to help free the rear wheel if the motorcycle gets stuck in mud, sand, or other soft surfaces. ECA19650 NOTICE Use only the specified tires. Using different sized tires will prevent the traction control system from controlling tire rotation accurately.

  • Page 32: Multi-Function Meter Unit

    FEATURES The multi-function meter unit is equipped with EAS30982 MULTI-FUNCTION METER UNIT the following: • a speedometer 5 6 7 • a tachometer • a clock • a fuel meter GEAR • an eco indicator A.TEMP °C C.TEMP °C • a transmission gear display TIME TRIP 0:00 •…

  • Page 33
    FEATURES itor the engine speed and keep it within the ideal level. power range. When the key is turned to “ON”, the tachometer This fuel meter is equipped with a self-diagnosis will sweep across the r/min range and then re- system.
  • Page 34
    FEATURES Odometer display: by the transmission gear display “ ”. Drive mode display Tripmeter displays: 1. Drive mode display This display indicates which drive mode has been selected: “STD”, “A” or “B”. For more de- TRIP-1 tails on the modes and on how to select them, refer to “D-mode (drive mode)”…
  • Page 35
    FEATURES In that case, pushing the select switch switch- • –9 C will be displayed even if the ambient tem- es the display between the various informa- perature falls below –9 C. tion displays in the following order; • The accuracy of the temperature reading may TRIP-F …
  • Page 36
    FEATURES Setting mode The average fuel consumption display modes “km/L”, “L/100km” or “MPG” (for the UK only) show the average fuel consumption since the display was last reset. • The “km/L” display shows the average dis- tance that can be traveled on 1.0 L of fuel. MENU •…
  • Page 37
    FEATURES This function allows you to “Display” change the items shown in 3 MENU information displays. Maintenance This function allows you to Time Trip adjust the brightness of the Unit “Brightness” multi-function meter unit panel Display to suit the rider’s preference. Brightness This function allows you to set Clock…
  • Page 38
    FEATURES Unit MENU Maintenance Time Trip km or mile Unit Display km/L or L/100km Brightness km/L Clock All Reset 2. Push the menu switch “MENU”, use the se- • For the UK: Continue with the following steps. lect switch to highlight the display to change, •…
  • Page 39
    FEATURES Setting the clock the previous display. 1. Use the select switch to highlight “Clock”. Display-1 MENU Maintenance Time Trip Unit C.TEMP Display Brightness TIME TRIP Clock All Reset 6. Use the select switch to highlight “ ”, and then push the menu switch “MENU” to return 2.

  • Page 40: D-Mode (Drive Mode)

    FEATURES than one immobilizer key on the same key ring! Immobilizer system keys may cause signal inter- All Reset ference, which may prevent the engine from starting. 2. If the engine starts, turn it off, and try starting the engine with the standard keys. 3.

  • Page 41
    FEATURES Mode “B” Mode “B” offers response that is somewhat less sharp compared to mode “STD” for riding situa- tions that require especially sensitive throttle op- eration. 1-32…

  • Page 42: 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 43: Circlips

    IMPORTANT INFORMATION When installing oil seals, lubricate the oil seal contact the parts. lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. ECA13300 NOTICE Do not spin the bearing with compressed air because this will damage the bearing surfac- EAS30011 CIRCLIPS Before reassembly, check all circlips carefully…

  • Page 44: 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 45: 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 46
    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 47
    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 48
    BASIC SERVICE INFORMATION • 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 (68 F). If the measuring temperature is not 20 C (68 F), the specified measuring condi- 4.

  • Page 49: 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 50
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Flywheel puller 5-32 90890-01362 Heavy duty puller YU-33270-B Steering nut wrench 3-20, 4-89 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-80, 4-82 90890-01582 Damper rod holder YM-01582 Oil filter wrench 3-25 90890-01426 Oil filter wrench…
  • Page 51
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller 4-83, 4-84, 4-85 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Fork spring compressor 4-79, 4-84, 4-85 90890-01441 Fork spring compressor YM-01441 Fork seal driver 4-82, 4-83 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442 Pivot shaft wrench adapter 5-7, 5-8…
  • Page 52
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave holder 5-32, 5-33 90890-01701 Primary clutch holder YS-01880-A Compression gauge 90890-03081 90890-03081 Engine compression tester YU-33223 YU-33223 Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Pocket tester 1-39, 8-129, 90890-03112 8-130, 8-131, Analog pocket tester 8-135, 8-136, YU-03112-C 8-137, 8-138,…
  • Page 53
    8-139 90890-03209 Test harness– lean angle sensor (6P) YU-03209 Fuel injector pressure adapter 7-10 90890-03210 Fuel injector pressure adapter YU-03210 Yamaha diagnostic tool 4-65, 4-66, 8-37, 90890-03231 8-101, 8-122 Valve spring compressor 5-23, 5-28 90890-04019 Valve spring compressor YM-04019 1-44…
  • Page 54
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 6-11 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Mechanical seal installer 6-11 90890-04078 Water pump seal installer YM-33221-A Universal clutch holder 5-42, 5-45 90890-04086 Universal clutch holder YM-91042 Valve lapper…
  • Page 55
    YM-04118 Extension 90890-04136 Piston installing tool 5-68 90890-04161 Piston installing tool YM-04161 Camshaft wrench 5-12, 5-15 90890-04162 Camshaft wrench YM-04162 Ignition checker 8-138 90890-06754 Oppama pet–4000 spark checker YM-34487 Yamaha bond No. 1215 5-34, 5-57 90890-85505 (Three bond No.1215®) 1-46…
  • Page 56
    SPECIAL TOOLS 1-47…

  • Page 57: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS…………….2-1 ENGINE SPECIFICATIONS …………….2-2 CHASSIS SPECIFICATIONS …………….2-7 ELECTRICAL SPECIFICATIONS …………..2-10 TIGHTENING TORQUES …………….2-13 GENERAL TIGHTENING TORQUE SPECIFICATIONS……2-13 ENGINE TIGHTENING TORQUES…………2-14 CHASSIS TIGHTENING TORQUES…………2-18 LUBRICATION POINTS AND LUBRICANT TYPES……..2-22 ENGINE………………..2-22 CHASSIS………………..2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS ……..2-25 ENGINE OIL LUBRICATION CHART …………2-25 LUBRICATION DIAGRAMS …………..2-27 COOLING SYSTEM DIAGRAMS …………..2-37 CABLE ROUTING ………………2-41…

  • Page 58: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model MT09TRA 2SC1 (AUT)(BEL)(CHE)(CYP)(CZE) (DEU)(DNK)(ESP)(FIN)(GBR)(GRC)(HUN) (IRL)(ITA)(NLD)(NOR)(POL)(PRT)(SVK)(SVN) (SWE)(TUR) MT09TRA 2SC2 (BEL)(FRA) MT09TRA 2SC3 (RUS) MT09TRA 2SC9 (AUT)(BEL)(CHE)(CYP)(CZE) (DEU)(DNK)(ESP)(FIN)(GBR)(GRC)(HUN) (IRL)(ITA)(NLD)(NOR)(POL)(PRT)(SVK)(SVN) (SWE)(TUR)(ZAF) MT09TRA 2SCA (BEL)(FRA) MT09TRA 2SCB (RUS) MT09TRAF 2SC4 Dimensions Overall length 2160 mm (85.0 in) Overall width 950 mm (37.4 in) Overall height…

  • Page 59: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 847 cm³ Cylinder arrangement Inline 3-cylinder Bore  stroke 78.0  59.1 mm (3.07  2.33 in) Compression ratio 11.5 : 1 Standard compression pressure (at sea level) 1530 kPa/680 r/min (15.3 kgf/cm²/680 r/min, 217.6 psi/680 r/min) Minimum–maximum…

  • Page 60
    ENGINE SPECIFICATIONS Relief valve operating pressure 670.0–810.0 kPa (6.70–8.10 kgf/cm², 97.2–117.5 psi) Cooling system Coolant quantity Radiator (including all routes) 1.93 L (2.04 US qt, 1.70 Imp.qt) Coolant reservoir (up to the maximum level 0.25 L (0.26 US qt, 0.22 Imp.qt) mark) Radiator cap opening pressure 93.3–122.7 kPa (0.93–1.23 kgf/cm², 13.5–17.8…
  • Page 61
    ENGINE SPECIFICATIONS Limit 1.8 mm (0.07 in) Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) Limit 4.445 mm (0.1750 in) Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in) Limit 4.430 mm (0.1744 in) Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in) Limit 4.542 mm (0.1788 in) Valve guide inside diameter (exhaust)
  • Page 62
    ENGINE SPECIFICATIONS Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type Taper End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.80 mm (0.0315 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.115 mm (0.0045 in) Oil ring…
  • Page 63
    ENGINE SPECIFICATIONS 1.381 (29/21) 1.190 (25/21) 1.037 (28/27) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.050 mm (0.0020 in) Shift fork thickness 5.76–5.89 mm (0.2268–0.2319 in)

  • Page 64: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 24.00  Caster angle Trail 100 mm (3.9 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 137 mm (5.4 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)

  • Page 65
    CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 15.00 mm (0.59 in) Caliper cylinder inside diameter 30.23 mm (1.19 in) Caliper cylinder inside diameter 27.00 mm (1.06 in)
  • Page 66
    CHASSIS SPECIFICATIONS Standard 7 click(s) out* Maximum 1 click(s) out* *With the adjusting screw fully turned in Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 60.0 mm (2.36 in) Spring installed length 179.8 mm (7.08 in) Spring rate K1 99.96 N/mm (10.19 kgf/mm, 570.77 lbf/in)

  • Page 67: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system 5.0 1200 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer MT09TRA TBDFN6/DENSO (AUT)(BEL)(CHE) (CYP)(CZE)(DEU)(DNK)(ESP)(FIN)(GBR) (GRC)(HUN)(IRL)(ITA)(NLD)(NOR)(POL) (PRT)(RUS)(SVK)(SVN)(SWE)(TUR)(ZAF) MT09TRA TBDFN7/DENSO (BEL)(FRA) MT09TRAF TBDFN6/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 …

  • Page 68
    ELECTRICAL SPECIFICATIONS ABS warning light Immobilizer system indicator light Traction control system indicator/warning light Electric starting system System type Constant mesh 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)
  • Page 69
    ELECTRICAL SPECIFICATIONS ABS solenoid fuse 15.0 A Auxiliary fuse 1 2.0 A Auxiliary fuse 2 2.0 A Terminal fuse 1 2.0 A Terminal fuse 2 2.0 A Backup fuse 7.5 A Electronic throttle valve fuse 7.5 A Spare fuse 30.0 A Spare fuse 20.0 A Spare fuse…

  • Page 70: 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 71: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Cylinder head bolt See TIP. Cylinder head bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Intake camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Exhaust camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Camshaft cap bolt…

  • Page 72
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Air filter case joint clamp screw 2.8 Nm (0.28 m·kgf, 2.0 ft·lbf) Fuel injector adapter bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Air filter case bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler bolt…
  • Page 73
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Starter motor lead nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Shift rod locknut (front) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Shift rod locknut (rear) 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Left thread Shift rod joint bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Centerstand bracket bolt…
  • Page 74
    TIGHTENING TORQUES Connecting rod bolt 1. Tighten the bolts to 20 Nm (2.0 m·kgf, 14 ft·lbf) 2. Tighten the bolts further to reach the specified angle 175–185. Crankcase bolt (main journal) 1. Lubricate the bolt threads and both sides of the washers with engine oil. 2.

  • Page 75: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front upper 45 Nm (4.5 m·kgf, 33 ft·lbf) and front lower side) Engine mounting nut (rear upper 45 Nm (4.5 m·kgf, 33 ft·lbf) side) Engine mounting nut (rear lower 45 Nm (4.5 m·kgf, 33 ft·lbf) side)

  • Page 76
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake master cylinder reservoir 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) cap screw Clutch lever holder pinch bolt 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Horn bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front fender bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Meter assembly screw…
  • Page 77
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Sidestand switch bolt 4.3 Nm (0.43 m·kgf, 3.1 ft·lbf) Battery box bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Mudguard assembly nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rectifier/regulator bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Hydraulic unit and Hydraulic unit 7 Nm (0.7 m·kgf, 5.1 ft·lbf) bracket…
  • Page 78
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Handguard bracket nut (right) 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Grab bar bolt (front) 25 Nm (2.5 m·kgf, 18 ft·lbf) Grab bar bolt (rear) 32 Nm (3.2 m·kgf, 23 ft·lbf) Rear side cover bolt 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Rear side cover and Stay 26 Nm (2.6 m·kgf, 19 ft·lbf)

  • Page 79: 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 80: 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 81
    LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Shift pedal pivoting parts Passenger footrest ball and metal-to-metal moving parts Shift shaft joint rod moving parts Front wheel oil seal (left and right) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Brake caliper piston seal Master cylinder inside…

  • Page 82: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-25…

  • Page 83
    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 84: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS 2-27…

  • Page 85
    LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil filter cartridge union bolt 3. Oil filter cartridge 4. Crankshaft 2-28…
  • Page 86
    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29…
  • Page 87
    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 A. MT09TRA for Europe: RN29F0011886 and after MT09TRAG for Oceania: RN29K 0000556 and after…
  • Page 88
    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31…
  • Page 89
    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 2-32…
  • Page 90
    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33…
  • Page 91
    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 2-34…
  • Page 92
    LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35…
  • Page 93
    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 94: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-37…

  • Page 95
    COOLING SYSTEM DIAGRAMS 1. Water pump 2. Thermostat 3. Radiator 2-38…
  • Page 96
    COOLING SYSTEM DIAGRAMS 2-39…
  • Page 97
    COOLING SYSTEM DIAGRAMS 1. Water jacket 2. Thermostat 3. Radiator 4. Water pump 5. Oil cooler 6. Coolant reservoir 2-40…

  • Page 98: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (top view) 2-41…

  • Page 99
    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 100
    CABLE ROUTING Handlebar (front view) 2-43…
  • Page 101
    CABLE ROUTING 1. Throttle cable 2. Clutch cable 3. Handlebar switch lead (left) 4. Main switch lead/Immobilizer lead 5. Steering stopper 6. Horn lead 7. Handlebar switch lead (right) 8. Front brake hose A. Fasten the right handlebar switch lead onto the handlebar with the clamp.
  • Page 102
    CABLE ROUTING Radiator (front side view and right side view) 2-45…
  • Page 103
    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 104
    CABLE ROUTING Fuel tank (left and bottom view) 2-47…
  • Page 105
    CABLE ROUTING 1. Frame 2. Fuel tank 3. Fuel pump 4. Fuel tank drain hose 5. Fuel tank breather hose 6. Clip 7. Fuel hose assembly A. Insert the fuel tank drain hose up to the sec- tion where the fuel tank pipe increases in diameter.
  • Page 106
    CABLE ROUTING Air filter case and throttle body (top view and left side view) 2-49…
  • Page 107
    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 108
    CABLE ROUTING Air cut-off valve (left side view) 2-51…
  • Page 109
    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 110
    CABLE ROUTING Frame and engine (right side view) 2-53…
  • Page 111
    CABLE ROUTING 1. Clamp 2. Rear brake light switch lead 3. O sensor coupler 4. Radiator fan motor coupler 5. Handlebar switch coupler (right) 6. Inner panel 7. Front right turn signal light coupler 8. Fuse box 1 9. Bracket 10.Fuse box 2 11.Coupler cover 12.O…
  • Page 112
    CABLE ROUTING Frame and engine (right side view) 2-55…
  • Page 113
    CABLE ROUTING I. Fasten the auxiliary light lead and auxiliary 1. Guide DC jack lead with the clamp and then insert 2. Wire harness the clamp into the hole in the headlight stay. 3. Pipe (headlight stay) J. Fasten the main switch lead to the coupler 4.
  • Page 114
    CABLE ROUTING Frame and engine (left side view) 2-57…
  • Page 115
    CABLE ROUTING O. It does not matter whether the oil level switch 1. Air induction system hose (air filter case to air lead or the sidestand switch lead is on top. cut-off valve) P. It does not matter whether the fuel tank drain 2.
  • Page 116
    CABLE ROUTING Frame (top view) 2-59…
  • Page 117
    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 118
    CABLE ROUTING Frame (top view) 2-61…
  • Page 119
    CABLE ROUTING 1. Stator coil assembly lead 2. Oil level switch coupler 3. Rear brake light switch coupler 4. Sidestand switch coupler 5. Gear position switch coupler 1 6. Gear position switch coupler 2 7. Negative battery lead coupler 8. Lean angle sensor 9.
  • Page 120
    CABLE ROUTING Frame (top view) 2-63…
  • Page 121
    The order of the leads does not matter. L. Route the Yamaha diagnostic tool coupler lead at the bottom of the battery box. M. Insert the Yamaha diagnostic tool coupler to the battery box. 2-64…
  • Page 122
    CABLE ROUTING Front brake (right side view and left side view) 2-65…
  • Page 123
    CABLE ROUTING P. Install the clamp so that the front wheel sen- 1. Front brake hose sor lead is on the right side of the vehicle. 2. Front wheel sensor lead 3. Clamp 4. Front wheel sensor protector 5. Brake caliper (right) 6.
  • Page 124
    CABLE ROUTING Rear brake 2-67…
  • Page 125
    CABLE ROUTING 1. Brake fluid reservoir 2. Rear frame 3. Rear frame (welded portion) 4. Rear brake master cylinder 5. Rear wheel sensor 6. Rear wheel sensor lead 7. Rear brake caliper 8. Rear brake hose 9. Clamp 10.Brake fluid reservoir hose 11.Swingarm assembly A.
  • Page 126
    CABLE ROUTING Hydraulic unit (top view and left side view) 2-69…
  • Page 127
    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 128
    CABLE ROUTING 2-71…

  • Page 129: 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 ADJUSTING THE EXHAUST GAS VOLUME ……….3-10…

  • Page 130
    CHANGING THE ENGINE OIL …………..3-25 MEASURING THE ENGINE OIL PRESSURE ………3-26 CHECKING THE COOLANT LEVEL…………3-27 CHECKING THE COOLING SYSTEM ………….3-27 CHANGING THE COOLANT…………..3-27 CHECKING THE FRONT BRAKE LIGHT SWITCH ………3-29 ADJUSTING THE REAR BRAKE LIGHT SWITCH ……..3-29 CHECKING AND LUBRICATING THE CABLES ……..3-29 CHECKING THE THROTTLE GRIP…………3-30 CHECKING AND CHARGING THE BATTERY……..3-30 CHECKING THE FUSES ……………..3-30…

  • Page 131: 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 132
    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) 6 * Brake fluid • Replace. Every 2 years • Check runout and for dam- 7 * Wheels …
  • Page 133
    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) Moving parts and • Lubricate.      cables •…

  • Page 134: Checking The Fuel Line

    PERIODIC MAINTENANCE 4-6. EAS30619 CHECKING THE FUEL LINE The following procedure applies to all of the fuel, EAS30620 CHECKING THE SPARK PLUGS drain and breather hoses. The following procedure applies to all of the 1. Remove: spark plugs. • Fuel tank front cover/Front side panel/Front 1.

  • Page 135: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE Refer to “GENERAL CHASSIS (2)” on page Spark plug gap 4-6. 0.8–0.9 mm (0.031–0.035 in) • Passenger seat/Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-13.

  • Page 136
    PERIODIC MAINTENANCE d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as specified in the following table. TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
  • Page 137
    PERIODIC MAINTENANCE prevent the valve pad from falling into the the following table, and then select the suit- crankcase. able valve pad. • Make a note of the position of each valve lifter Last digit Rounded value “1” and valve pad “2” so that they can be in- 0, 1, 2 stalled in the correct place.

  • Page 138: Checking The Engine Idling Speed

    “02”  Clean the throttle bodies. Refer to “CHECKING AND CLEANING THE THROTTLE BODIES” on page 7-7. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the Yamaha diagnostic tool. 4. Install: Use the diagnostic code number “67”. • Vacuum gauge “1” Refer to “SELF-DIAGNOSTIC FUNCTION Vacuum gauge AND DIAGNOSTIC CODE TABLE”…

  • Page 139
    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 140: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE 4-6. 5. Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE SELECT GRIP” on page 3-30. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) EAS30798 CHECKING THE THROTTLE BODY JOINTS 1. Remove: 4. Press the “TCS” button “1” to select the CO •…

  • Page 141: Checking The Air Induction System

    PERIODIC MAINTENANCE pressing the “TCS” button or “RESET” but- ton. DATA 3. Install: • Air filter case Refer to “GENERAL CHASSIS (3)” on page 4-13. The CO adjustment volume appears on the multi-function meter right display. EAS30628 REPLACING THE AIR FILTER ELEMENT •…

  • Page 142: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE are riding in unusually wet or dusty areas. 2. Adjust: • Clutch lever free play 4. Install: • Air filter element ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Air filter case cover Handlebar side • ECU (engine control unit) a. Turn the adjusting bolt “1” in direction “a” or “b”…

  • Page 143: Checking The Brake Operation

    PERIODIC MAINTENANCE Clutch cable locknut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly  Check the brake system. A. Front brake Refer to “FRONT BRAKE” on page 4-35 and B.

  • Page 144: Checking The Front Brake Pads

    PERIODIC MAINTENANCE • While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in the desired position. • Be sure to align the setting on the adjusting dial with the arrow mark “2” on the brake lever hold- Position #1 Distance “a”…

  • Page 145: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow.

  • Page 146: Checking The Front Brake Hoses

    PERIODIC MAINTENANCE e. Slowly apply the brake several times. 4. Check: f. Fully squeeze the brake lever or fully depress • Brake hose Brake fluid leakage  Replace the damaged the brake pedal and hold it in position. g. Loosen the bleed screw. hose.

  • Page 147
    Front en if a tire combination other than one 250 kPa (2.50 kgf/cm², 36 psi) Rear approved by Yamaha is used on this vehicle. 290 kPa (2.90 kgf/cm², 42 psi) Maximum load Front tire 180 kg (397 lb)

  • Page 148: Checking The Wheel Bearings

    PERIODIC MAINTENANCE • Install the tire with the mark pointing in the di- the drive chain slack within the specified lim- rection of wheel rotation. its. • Align the mark “2” with the valve installation 1. Stand the vehicle on a level surface. point.

  • Page 149: Lubricating The Drive Chain

    PERIODIC MAINTENANCE 5. Adjust: and thoroughly lubricate it with engine oil or • Drive chain slack chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ chain since they may contain solvents that could a.

  • Page 150: Lubricating The Steering Head

    PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Steering nut wrench 5. Install: 90890-01403 • Upper bracket Exhaust flange nut wrench Refer to “HANDLEBAR” on page 4-69. YU-A9472 EAS30646 LUBRICATING THE STEERING HEAD Lower ring nut (initial tightening 1. Lubricate: torque) • Upper bearing 52 Nm (5.2 m·kgf, 38 ft·lbf) •…

  • Page 151: Adjusting The Shift Pedal

    PERIODIC MAINTENANCE Rough movement  Repair or replace. EAS30851 ADJUSTING THE SHIFT PEDAL EAS30651 LUBRICATING THE SIDESTAND The shift pedal position is determined by the in- Lubricate the pivoting point, metal-to-metal mov- stalled shift rod length. ing parts and spring contact point of the sides- 1.

  • Page 152: Adjusting The Front Fork Legs

    PERIODIC MAINTENANCE A. Left side EAS30806 ADJUSTING THE FRONT FORK LEGS B. Right side The following procedure applies to both of the front fork legs. The spring preload setting is determined by EWA13120 measuring the distance “c” shown in the illustra- WARNING tion.

  • Page 153: 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 adjusting posi- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…

  • Page 154: Checking The Connecting Arm And Relay Arm

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

  • Page 155: Changing The Engine Oil

    PERIODIC MAINTENANCE minutes until the oil has settled. filter wrench “2”. Oil filter wrench EAS30657 90890-01426 CHANGING THE ENGINE OIL Oil filter wrench 1. Start the engine, warm it up for several min- YU-38411 utes, and then turn it off. 2.

  • Page 156: Engine

    PERIODIC MAINTENANCE tremely hot. Engine oil quantity Quantity (disassembled) 3.40 L (3.59 US qt, 2.99 Imp.qt) Without oil filter cartridge re- placement 2.40 L (2.54 US qt, 2.11 Imp.qt) With oil filter cartridge replace- ment 2.70 L (2.85 US qt, 2.38 Imp.qt) 8.

  • Page 157: Checking The Coolant Level

    PERIODIC MAINTENANCE • Oil cooler outlet hose “6” Main gallery bolt • Water jacket joint “7” 8 Nm (0.8 m·kgf, 5.8 ft·lbf) • Water pump inlet hose “8” Cracks/damage  Replace. EAS30811 Refer to “RADIATOR” on page 6-1, “OIL CHECKING THE COOLANT LEVEL COOLER”…

  • Page 158: Cooling System

    PERIODIC MAINTENANCE 6. Drain: • Coolant (from the engine and radiator) 7. Install: • Water pump drain bolt • Copper washer Water pump drain bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 8. Install: • Collars 2. Remove: • Coolant reservoir •…

  • Page 159: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE and if necessary, correct the antifreeze EAS30659 ADJUSTING THE REAR BRAKE LIGHT concentration of the coolant. SWITCH • Use only distilled water. However, if dis- tilled water is not available, soft water may The rear brake light switch is operated by move- be used.

  • Page 160: Checking The Throttle Grip

    PERIODIC MAINTENANCE tle body synchronization should be adjusted Recommended lubricant properly. Engine oil or a suitable cable lu- bricant ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slide back the rubber cover “1”. b. Loosen the locknut “2”. Hold the cable end upright and pour a few drops c.

  • Page 161
    PERIODIC MAINTENANCE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screws “1” in direction “a” or “b”. Left headlight Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Right headlight Direction “a”…
  • Page 162
    PERIODIC MAINTENANCE 3-32…
  • Page 163
    CHASSIS GENERAL CHASSIS (1) ………………4-1 INSTALLING THE SEATS…………….4-4 GENERAL CHASSIS (2) ………………4-6 REMOVING THE FUEL TANK FRONT COVER……..4-10 INSTALLING THE FUEL TANK FRONT COVER ……..4-10 REMOVING THE FRONT SIDE COWLINGS ……….4-10 INSTALLING THE FRONT SIDE COWLINGS ………4-11 ADJUSTING THE WINDSHIELD HEIGHT……….4-12 GENERAL CHASSIS (3) …………….4-13 REMOVING THE FUEL TANK COVERS……….4-17 INSTALLING THE FUEL TANK COVERS ……….4-17…
  • Page 164
    ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ….4-45 INSTALLING THE FRONT BRAKE MASTER CYLINDER…….4-45 REAR BRAKE ………………..4-48 INTRODUCTION ………………4-54 CHECKING THE REAR BRAKE DISC………….4-54 REPLACING THE REAR BRAKE PADS……….4-54 REMOVING THE REAR BRAKE CALIPER ……….4-55 DISASSEMBLING THE REAR BRAKE CALIPER ……..4-56 CHECKING THE REAR BRAKE CALIPER……….4-56 ASSEMBLING THE REAR BRAKE CALIPER ………4-57 INSTALLING THE REAR BRAKE CALIPER……….4-57…
  • Page 165
    INSTALLING THE RELAY ARM……………4-93 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ….4-93 SWINGARM………………..4-95 REMOVING THE SWINGARM…………..4-96 CHECKING THE SWINGARM …………..4-96 INSTALLING THE SWINGARM ……………4-97 CHAIN DRIVE………………..4-98 REMOVING THE DRIVE CHAIN…………..4-99 CHECKING THE DRIVE CHAIN …………..4-99 CHECKING THE DRIVE SPROCKET…………4-100 CHECKING THE REAR WHEEL SPROCKET……..4-100 CHECKING THE REAR WHEEL DRIVE HUB ……..4-100 INSTALLING THE DRIVE CHAIN …………4-101…

  • Page 166: General Chassis (1)

    GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 2.2 Nm (0.22 m kgf, 1.6 ft lbf) 25 Nm (2.5 m kgf, 18 ft lbf) 32 Nm (3.2 m kgf, 23 ft lbf) • • • • •…

  • Page 167
    GENERAL CHASSIS (1) Removing the rear side covers 26 Nm (2.6 m kgf, 19 ft lbf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft lbf) • • 26 Nm (2.6 m kgf, 19 ft lbf) •…
  • Page 168
    GENERAL CHASSIS (1) Removing the tail/brake light and mudguard assembly 7 Nm (0.7 m kgf, 5.1 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 Passenger seat/Rider seat 4-1.

  • Page 169: Installing The Seats

    GENERAL CHASSIS (1) EAS30125 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ INSTALLING THE SEATS To install the rider seat in the low position 1. Install: a. Insert the projection “a” on the rider seat • Rider seat height position adjuster “1” height position adjuster into the grommet “b”. •…

  • Page 170: General Chassis (2)

    GENERAL CHASSIS (1)

  • Page 171
    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the fuel tank front cover, front side panels and front side cowlings 1.5 Nm (0.15 m kgf, 1.1 ft lbf) 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • • • 4.0 Nm (0.40 m kgf, 2.9 ft lbf)
  • Page 172
    GENERAL CHASSIS (2) Removing the headlight assembly and meter assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft lbf)
  • Page 173
    GENERAL CHASSIS (2) Disassembling the headlight assembly Order Job/Parts to remove Q’ty Remarks Headlight top cover (left) Headlight top cover (right) Headlight side cover (left) Headlight side cover (right) Center cover Headlight control unit coupler Disconnect. Headlight control unit…
  • Page 174
    GENERAL CHASSIS (2) Removing the headlight stay 33 Nm (3.3 m kgf, 24 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)” on page cowling 4-6. Refer to “GENERAL CHASSIS (2)” on page Headlight assembly 4-6.

  • Page 175: Removing The Fuel Tank Front Cover

    GENERAL CHASSIS (2) EAS31379 REMOVING THE FUEL TANK FRONT COVER Fuel tank front cover bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) 1. Remove: • Fuel tank front cover “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the quick fastener screws “2” and fuel tank front cover bolts “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲…

  • Page 176: Installing The Front Side Cowlings

    GENERAL CHASSIS (2) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS31382 INSTALLING THE FRONT SIDE COWLINGS 1. Install: • Front side cowling (left) “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert the slot “a” into the projection “b”, and then install the front side cowling as shown in the illustration. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲…

  • Page 177: Adjusting The Windshield Height

    GENERAL CHASSIS (2) 2. Install: EAS31383 ADJUSTING THE WINDSHIELD HEIGHT • Front side cowling (right) “1” 1. Adjust: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Windshield height position a. Insert the slot “a” into the projection “b”, and ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ then install the front side cowling as shown in a.

  • Page 178
    GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the fuel tank covers and fuel tank protector 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • 4.0 Nm (0.40 m kgf, 2.9 ft lbf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side…
  • Page 179
    GENERAL CHASSIS (3) Removing the electrical components tray (left) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)” on page cowling 4-6.
  • Page 180
    GENERAL CHASSIS (3) Removing the electrical components tray (right) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…
  • Page 181
    GENERAL CHASSIS (3) 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 182: Removing The Fuel Tank Covers

    GENERAL CHASSIS (3) then install the fuel tank cover as shown in EAS31384 REMOVING THE FUEL TANK COVERS the illustration. 1. Remove: • Fuel tank front cover • Front side panel • Front side cowling 2. Remove: • Passenger seat •…

  • Page 183
    GENERAL CHASSIS (3) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Install: • Rider seat • Passenger seat 4. Install: • Front side cowling • Front side panel • Fuel tank front cover 4-18…

  • Page 184: Front Wheel

    FRONT WHEEL EAS20028 FRONT WHEEL Removing the front wheel and brake discs 35 Nm (3.5 m kgf, 25 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •…

  • Page 185
    FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front wheel sensor rotor Oil seal Wheel bearing Spacer 4-20…

  • Page 186: Removing The Front Wheel

    FRONT WHEEL tor, wipe it off immediately. EAS30145 REMOVING THE FRONT WHEEL 1. Remove: ECA21380 • Oil seals NOTICE • Wheel bearings Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ from the front wheel sensor “1”, otherwise a.

  • Page 187: Assembling The Front Wheel

    FRONT WHEEL EAS30151 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 188: Maintenance Of The Front Wheel Sensor And Sensor Rotor

    FRONT WHEEL • 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  Replace. 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Iron powder/dust …

  • Page 189: 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 190: Installing The Front Wheel (Disc Brake)

    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 191
    FRONT WHEEL Distance “a” (between the front Check that wheel axle end “a” is flush with front wheel sensor rotor and front folk surface “b” and then tighten the wheel axle wheel sensor) pinch bolt. If end “a” is not flush with surface “b”, 0.9–1.5 mm (0.04–0.06 in) align the ends manually or with a plastic ham- mer.

  • Page 192: 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 193
    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 194
    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 4-29…

  • Page 195: Removing The Rear Wheel

    REAR WHEEL EAS30156 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 196: 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 4-21. 2. Check: • Tire • Rear wheel Damage/wear  Replace. b. Correct Refer to “CHECKING THE TIRES” on page 1.

  • Page 197: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

    REAR WHEEL • Oil seal EAS30165 INSTALLING THE REAR WHEEL (DISC Refer to “ASSEMBLING THE FRONT BRAKE) WHEEL” on page 4-22. 1. Install: • Rear brake disc EAS30167 MAINTENANCE OF THE REAR WHEEL Rear brake disc bolt SENSOR AND SENSOR ROTOR 30 Nm (3.0 m·kgf, 22 ft·lbf) ECA21060 LOCTITE®…

  • Page 198
    REAR WHEEL 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 the rear wheel sensor rotor and rear wheel sensor. Foreign materials cause damage to the rear wheel sensor rotor and rear wheel A.
  • Page 199
    REAR WHEEL Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 4-34…

  • Page 200: Front Brake

    FRONT BRAKE EAS20030 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

  • Page 201
    FRONT BRAKE Removing the front brake master cylinder 1.0 Nm (0.10 m kgf, 0.72 ft lbf) • • 1.5 Nm (0.15 m kgf, 1.1 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf) • • 17 Nm (1.7 m kgf, 12 ft lbf) •…
  • Page 202
    FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body 4-37…
  • Page 203
    FRONT BRAKE Removing the front brake calipers 35 Nm (3.5 m kgf, 25 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 204
    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 205: 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 206: Replacing The Front Brake Pads

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

  • Page 207: 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 208: 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 209: 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: Specified brake fluid • Brake pads DOT 4 • Brake pad spring • Brake pad pin • Brake pad clips EAS30175 INSTALLING THE FRONT BRAKE CALIPERS •…

  • Page 210: 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 211
    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 212
    FRONT BRAKE BRAKE SYSTEM (ABS)” on page 3-15. 4-47…

  • Page 213: 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 4-48…

  • Page 214
    REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 110 Nm (11 m kgf, 80 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •…
  • Page 215
    REAR BRAKE Removing the rear brake master cylinder 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 110 Nm (11 m kgf, 80 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •…
  • Page 216
    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 4-51…
  • Page 217
    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 3-15. Brake hose union bolt Brake hose gasket Brake hose Rear brake caliper 4-52…
  • Page 218
    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 4-53…

  • Page 219: 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 220: Removing The Rear Brake Caliper

    REAR BRAKE ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always install new brake pads, brake pad insu- 3. Lubricate: lators, brake pad shims, and brake pad spring as • Rear brake caliper bolts a set. Recommended lubricant ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Silicone grease a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.

  • Page 221: Disassembling The Rear Brake Caliper

    REAR BRAKE the brake fluid from the entire brake system. 1. Remove: • Brake hose union bolt “1” • 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.

  • Page 222: Assembling The Rear Brake Caliper

    REAR BRAKE 2. Check: EWA13531 WARNING • Rear brake caliper bracket “1” Proper brake hose routing is essential to in- Cracks/damage  Replace. sure safe vehicle operation. Refer to “REAR WHEEL” on page 4-27. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a”…

  • Page 223: 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 224: 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 225: 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) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) •…

  • Page 226
    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) • • • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •…

  • Page 227: Abs Components Chart

    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30728 ABS COMPONENTS CHART 1. Hydraulic unit assembly 2. Fuse box 3 3. ABS test 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 228: 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 229
    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 230: 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 the diagnosis mode screen. • For the brake line routing confirmation, use the 7. Select code No. 2, “Brake line routing confir- diagnosis mode of the Yamaha diagnostic tool.

  • Page 231
    Securely support the vehicle so that there is no danger of it falling over. • For the ABS reaction-force confirmation, use the diagnosis mode of the Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool.
  • Page 232
    • “ON” and “OFF” on the tool screen indicate when the brakes are being applied and re- leased respectively. 6. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 7. Select code No. 1, “ABS reaction-force con- firmation”.

  • Page 233: Checking The Abs Warning Light

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

  • Page 234: Handlebar

    HANDLEBAR EAS20033 HANDLEBAR Removing the handlebar 1/2 17 Nm (1.7 m kgf, 12 ft lbf) • • 17 Nm (1.7 m kgf, 12 ft lbf) • • 4.3 Nm (0.43 m kgf, 3.1 ft lbf) • • 17 Nm (1.7 m kgf, 12 ft lbf) •…

  • Page 235
    HANDLEBAR Removing the handlebar 2/2 3.8 Nm (0.38 m kgf, 2.8 ft lbf) • • 26 Nm (2.6 m kgf, 19 ft lbf) • • 22 Nm (2.2 m kgf, 16 ft lbf) • • 11 Nm (1.1 m kgf, 8.0 ft lbf) •…

  • Page 236: Adjusting The Handlebar Position

    HANDLEBAR holders “1”. EAS31396 ADJUSTING THE HANDLEBAR POSITION 1. Check: Upper handlebar holder bolt 22 Nm (2.2 m·kgf, 16 ft·lbf) • Handlebar position ECA19130 The handlebar position can be adjusted in two NOTICE positions to suit the rider’s preference. • First, tighten the bolts on the front side of the upper handlebar holder, and then on the rear side.

  • Page 237: 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 and the handlebar grip, and gradually push the EAS30205 INSTALLING THE HANDLEBAR…

  • Page 238
    HANDLEBAR • 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: • Throttle grip “1” • Throttle cables Align the center of slit on the clutch lever holder •…

  • Page 239: Installing The Rearview Mirrors And Handguards

    HANDLEBAR EWA13700 WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP” on page 3-30. b. Tighten the handguard bracket bolts “3” to Throttle grip free play specification.

  • Page 240
    HANDLEBAR b. Tighten the handguard bracket bolts “3” to specification. Handguard bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) c. Tighten the rearview mirror locknut “4” to specification. Rearview mirror locknut 17 Nm (1.7 m·kgf, 12 ft·lbf) d. Tighten the handguard bolt “5” to specifica- tion.

  • Page 241: Front Fork

    FRONT FORK EAS20034 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kgf, 19 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) 23 Nm (2.3 m kgf, 17 ft Ibf) • • • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf)

  • Page 242
    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 243
    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 244: 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 245: Checking The Front Fork Legs

    FRONT FORK (with a flat-head screwdriver) Damper rod holder ECA19100 90890-01582 NOTICE Damper rod holder Do not scratch the outer tube. YM-01582 4. Remove: • Outer tube EAS30208 CHECKING THE FRONT FORK LEGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Hold the front fork leg horizontally. The following procedure applies to both of the b.

  • Page 246: 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 247
    FRONT FORK damper rod holder “1”, tighten the damper rod assembly bolt. Damper rod holder 90890-01582 Damper rod holder YM-01582 5. Install: • Outer tube (to the inner tube) 6. Install: • Outer tube bushing “1” • Washer “2” (with the fork seal driver “3”) Fork seal driver 3.
  • Page 248
    FRONT FORK 8. Install: • Oil seal clip “1” Adjust the oil seal clip so that it fits into the outer tube’s groove. 11.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil 9.
  • Page 249
    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 250
    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 251: Installing The Front Fork Legs

    FRONT FORK ment. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ j. Position the locknut “3” as specified “b”. 17.Install: • Cap bolt Distance “b” (to the outer tube) 12 mm (0.47 in) • Temporarily tighten the cap bolt. • When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts.

  • Page 252: Steering Head

    STEERING HEAD EAS20035 STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •…

  • Page 253
    STEERING HEAD Removing the lower bracket 110 Nm (11 m kgf, 80 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 52 Nm (5.2 m kgf, 38 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •…

  • Page 254: 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 255: Installing The Steering Head

    STEERING HEAD ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage  Replace. EAS30216 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” •…

  • Page 256: 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 Ibf) • • 61 Nm (6.1 m kgf, 44 ft Ibf) • • 44 Nm (4.4 m kgf, 32 ft Ibf) •…

  • Page 257: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS30826 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 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 258: Installing The Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY 2. Check: • Bearings • Oil seals Damage/pitting  Replace. 3. Check: • Collars Damage/scratches  Replace. EAS30222 INSTALLING THE RELAY ARM 1. Lubricate: • Collars 3. Relay arm • Oil seals 4. Connecting arm 5. Rear shock absorber assembly Recommended lubricant Lithium-soap-based grease A.

  • Page 259
    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) 4-94…

  • Page 260: Swingarm

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

  • Page 261: 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 the centerstand so that the rear wheel is elevated. 2.

  • Page 262: Installing The Swingarm

    SWINGARM • Collars “3” Damage/scratches  Replace. • Bearings “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 263: 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 264: 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 265: Checking The Drive Sprocket

    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 266: Installing The Drive Chain

    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 267
    CHAIN DRIVE 5. Adjust: • Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” on page 3-18. Drive chain slack 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 268
    CHAIN DRIVE 4-103…
  • Page 269
    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……..5-14 INSTALLING THE CAMSHAFTS ………….5-14 CYLINDER HEAD……………….5-19 REMOVING THE CYLINDER HEAD…………5-20…
  • Page 270
    CHECKING THE CLUTCH HOUSING ………….5-44 CHECKING THE CLUTCH BOSS…………5-44 CHECKING THE PRESSURE PLATE ………….5-44 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…………..5-45 SHIFT SHAFT………………..5-48 CHECKING THE SHIFT SHAFT …………..5-49 CHECKING THE STOPPER LEVER …………5-49 INSTALLING THE SHIFT SHAFT …………5-49 OIL PUMP…………………..5-50…
  • Page 271
    CHECKING THE SHIFT DRUM ASSEMBLY………..5-81 CHECKING THE TRANSMISSION …………5-81 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE …….5-81 INSTALLING THE TRANSMISSION …………5-82…

  • Page 272: Engine Inspection

    ENGINE INSPECTION EAS20041 ENGINE INSPECTION Compression gauge 90890-03081 Engine compression tester EAS30249 MEASURE THE COMPRESSION PRESSURE YU-33223 The following procedure applies to all of the cyl- Extension inders. 90890-04136 Insufficient compression pressure will result in a loss of performance. 1. Measure: •…

  • Page 273
    ENGINE INSPECTION gine oil into the spark plug bore and measure again. Refer to the following table. 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 …

  • Page 274: Engine Removal

    ENGINE REMOVAL EAS20042 ENGINE REMOVAL Removing the muffler and exhaust pipe 20 Nm (2.0 m kgf, 14 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •…

  • Page 275
    ENGINE REMOVAL Disconnecting the leads and hoses 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 Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…
  • Page 276
    ENGINE REMOVAL Disconnecting the leads and hoses 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 Gear position switch coupler Disconnect. Crankshaft position sensor coupler Disconnect.
  • Page 277
    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 278: 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 YM-01485 EAS30251 INSTALLING THE ENGINE 1. Install: •…

  • Page 279
    ENGINE REMOVAL 7. Tighten: Centerstand bracket bolt • Engine mounting adjust bolt (rear) “2” 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • 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.

  • Page 280: 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 Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…

  • Page 281
    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 282: 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 283: Checking The Camshafts

    CAMSHAFTS Camshaft wrench 90890-04162 Camshaft wrench YM-04162 EAS30257 CHECKING THE CAMSHAFTS 1. Check: • Camshaft lobes Blue discoloration/pitting/scratches  Re- place the camshaft. 3. Measure: 2. Measure: • Camshaft runout • Camshaft lobe dimensions “a” and “b” Out of specification  Replace. Out of specification …

  • Page 284: Checking The Timing Chain And Camshaft Sprocket

    CAMSHAFTS c. Install the dowel pins and camshaft caps. EAS30258 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET • Tighten the camshaft cap bolts in stages and in 1. Check: a crisscross pattern, working from the inner • Timing chain caps out. Damage/stiffness …

  • Page 285: Checking The Timing Chain Tensioner

    CAMSHAFTS EAS30269 INSTALLING THE CAMSHAFTS 1. Remove: • Timing mark accessing bolt “1” • Crankshaft end cover “2” EAS30266 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • Timing chain tensioner Cracks/damage/rough movement  Re- 2. Align: place. • Mark “a” on the generator rotor ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…

  • Page 286
    CAMSHAFTS Camshaft wrench 90890-04162 Camshaft wrench YM-04162 5. Install: • Camshaft cap • Intake camshaft cap • Exhaust camshaft cap • Make sure each camshaft cap is installed in its original place. Refer to the identification marks as follows: “IL”: Intake left side camshaft cap mark “EL”: Exhaust left side camshaft cap mark •…
  • Page 287
    CAMSHAFTS 7. Tighten: 9. Install: • Camshaft cap bolts “1” • Timing chain tensioner • Timing chain tensioner gasket Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a few drops of engine oil to the inside “a”…
  • Page 288
    CAMSHAFTS d. Install the timing chain tensioner gasket “3”, h. Install the timing chain tensioner cap bolt and the timing chain tensioner “4”, and the timing gasket, and then tighten the timing chain ten- sioner cap bolt to the specified torque. chain tensioner bolts “5”…
  • Page 289
    CAMSHAFTS 12.Measure: • Valve clearance Out of specification  Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-5. 13.Install: • Timing mark accessing bolt “1” Timing mark accessing bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) 15.Install: • Crankshaft end cover “2” •…

  • Page 290: 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 291: 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 292: 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 293
    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 294: 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 295
    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 296: 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 297: 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 298: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Measure: EAS30287 CHECKING THE VALVE LIFTERS • Compressed valve spring force “a” The following procedure applies to all of the Out of specification  Replace the valve valve lifters. spring. 1. Check: • Valve lifter Damage/scratches …

  • Page 299
    VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapter 22 mm YM-04108 3. Install: • Valve spring seat “1” • Valve stem seal “2” • Valve “3” •…
  • Page 300
    VALVES AND VALVE SPRINGS • Valve lifter • The valve lifter must move smoothly when ro- tated with a finger. • Each valve lifter and valve pad must be rein- stalled in its original position. 5-29…

  • Page 301: 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) •…

  • Page 302
    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) •…

  • Page 303: 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 304: 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 305
    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 306: Electric Starter

    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 Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…

  • Page 307
    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 5-36…

  • Page 308: Checking The Starter Motor

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

  • Page 309: 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 310: Clutch

    CLUTCH EAS20055 CLUTCH Removing the clutch cover 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •…

  • Page 311
    CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Bearing 5-40…
  • Page 312
    CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump driven sprocket Refer to “OIL PUMP” on page 5-50. Compression spring Pressure plate Pull rod…

  • Page 313: Removing The Clutch

    CLUTCH EAS30346 REMOVING THE CLUTCH 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 314: Checking The Friction Plates

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

  • Page 315: Checking The Clutch Housing

    CLUTCH set. 2. Measure: • Clutch spring free length “a” Out of specification  Replace the clutch springs as a set. Clutch spring free length 52.50 mm (2.07 in) Limit 49.88 mm (1.96 in) 3. Check: • Bearing Damage/wear  Replace the bearing and clutch housing.

  • Page 316: Checking The Primary Drive Gear

    CLUTCH EAS30356 CHECKING THE PRIMARY DRIVE GEAR Install the oil pump drive chain onto the oil pump 1. Check: drive sprocket “a”. • Primary drive gear Damage/wear  Replace the crankshaft and clutch housing as a set. Excessive noise during operation  Replace the crankshaft and clutch housing as a set.

  • Page 317
    CLUTCH Oil pump driven sprocket bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) LOCTITE® • Tighten the clutch spring bolts in stages and in a crisscross pattern. • Apply lithium-soap-based grease onto the pull rod. • Position the pull rod so that the teeth “a” face towards the hole “b”.
  • Page 318
    CLUTCH pull lever aligns with the mark “b” on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged. 7. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY”…
  • Page 319
    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 5-39. Shift arm Refer to “CHAIN DRIVE” on page 4-98. Circlip Washer Shift shaft…

  • Page 320: 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 321: 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 322
    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 323: 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- 0.20 mm (0.0079 in) ING” on page 5-44. Outer-rotor-to-oil-pump-housing 2. Check: clearance •…

  • Page 324: Checking The Relief Valve

    OIL PUMP 3. Check: EAS30338 CHECKING THE RELIEF VALVE • Oil pump operation 1. Check: Refer to “CHECKING THE OIL PUMP” on • Relief valve “1” page 5-52. • Spring “2” Damage/wear  Replace the oil pump as- EAS30343 INSTALLING THE OIL PUMP sembly.

  • Page 325: 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) • • 43 Nm (4.3 m kgf, 31 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft lbf)

  • Page 326: Removing The Oil Pan

    OIL PAN EAS31068 EAS31070 REMOVING THE OIL PAN INSTALLING THE OIL PAN 1. Remove: 1. Install: • Oil level switch “1” • Gasket • Oil pan “2” • Oil pan “1” • Oil pan gasket Oil pan bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern.

  • Page 327: 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 328: 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 329
    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 330
    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 5-59…
  • Page 331
    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 5-56. Connecting rod cap Big end lower bearing Piston pin clip…

  • Page 332: 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 333: Checking The Piston Rings

    CONNECTING RODS AND PISTONS d. If out of specification, replace the piston and piston rings as a set. Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. e. Calculate the piston-to-cylinder clearance with the following formula. Then, find the average of the measurements.

  • Page 334: Checking The Piston Pin

    CONNECTING RODS AND PISTONS Piston pin outside diameter Use the piston crown to level the piston ring near 16.990–16.995 mm (0.6689– bottom of cylinder “a”, where cylinder wear is 0.6691 in) lowest. Limit 16.970 mm (0.6681 in) 3. Measure: • Piston ring end gap Out of specification …

  • Page 335
    CONNECTING RODS AND PISTONS Out of specification  Replace the big end plastic-region tightening angle method. Al- bearings. ways install new bolts. Oil clearance • Clean the connecting rod bolts and lubricate 0.027–0.051 mm (0.0011–0.0020 the bolt threads and seats with molybdenum disulfide oil.
  • Page 336
    CONNECTING RODS AND PISTONS big end bearing kept in the current condition. • Do not move the connecting rod or crankshaft until the clearance measurement has been completed. • Make sure that the projection “a” on the con- necting rod cap faces the same direction as the “Y”…

  • Page 337: Installing The Connecting Rod And Piston

    CONNECTING RODS AND PISTONS 2. Select: EAS30751 INSTALLING THE CONNECTING ROD AND • Big end bearings (P –P PISTON The following procedure applies to all of the con- • The numbers “A” stamped into the crankshaft necting rods and pistons. web and the numbers “1”…

  • Page 338
    CONNECTING RODS AND PISTONS the bolt threads and seats with molybdenum disulfide oil. c. After installing the big end bearing, assemble the connecting rod and connecting rod cap without installing them onto the crankshaft. d. Tighten the connecting rod bolt while check- ing that the sections shown “a”…
  • Page 339
    CONNECTING RODS AND PISTONS 6. Offset: • Piston ring end gaps 90˚ 90˚ 9. Install: 45˚ • Connecting rod caps • Connecting rod bolts a. Top ring b. 2nd ring • Make sure the “Y” marks “a” on the connecting c.
  • Page 340
    CONNECTING RODS AND PISTONS Connecting rod bolt (1st) 20 Nm (2.0 m·kgf, 14 ft·lbf) b. Put a mark “1” on the corner of the connecting rod bolt “2” and the connecting rod cap “3”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Tighten the connecting rod bolts further to reach the specified angle 175–185.

  • Page 341: 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 5-56. Refer to “REMOVING THE CONNECTING Connecting rod RODS AND PISTONS” on page 5-61. Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing…

  • Page 342: 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 343
    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 344: 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 345: Installing The Crankshaft

    CRANKSHAFT AND BALANCER SHAFT e. Install the balancer shaft journal lower bear- for all of the bearings. ings “1” into the lower crankcase and assem- For example, if the crankcase “J ” and bal- ble the crankcase halves. ancer shaft web “J ”…

  • Page 346: Installing The Balancer Assembly

    CRANKSHAFT AND BALANCER SHAFT crankcase. • Be sure to install each crankshaft journal bear- ings in its original place. EAS31172 INSTALLING THE BALANCER ASSEMBLY 1. Install: • Balancer shaft journal upper bearings (into the upper crankcase) • Balancer shaft journal lower bearings (into the lower crankcase) •…

  • Page 347: 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 348
    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 5-77…
  • Page 349
    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 350
    TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Collar Bearing Circlip Drive axle 5-79…

  • Page 351: 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 352
    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 353
    TRANSMISSION 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 354
    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 355
    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 356: Radiator

    RADIATOR EAS20063 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 9 Nm (0.9 m…

  • Page 357: 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 358
    RADIATOR pressure. c. Measure the indicated pressure with the gauge. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Measure: • Radiator cap opening pressure Below the specified pressure  Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-2.

  • Page 359: 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 360: 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 3-27. • Oil cooler inlet hose •…

  • Page 361: 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 3-27.

  • Page 362: 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 3-27.

  • Page 363: 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 3-27. Water pump inlet hose Disconnect. Water pump assembly…

  • Page 364
    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 365: 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) •…

  • Page 366
    WATER PUMP 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. touches the water pump housing.

  • Page 367: Fuel System

    FUEL SYSTEM FUEL TANK ………………….7-1 REMOVING THE FUEL TANK …………..7-2 REMOVING THE FUEL PUMP …………..7-2 CHECKING THE FUEL PUMP BODY…………7-2 CHECKING THE FUEL PUMP OPERATION……….7-2 INSTALLING THE FUEL PUMP…………..7-2 INSTALLING THE FUEL TANK…………..7-3 THROTTLE BODIES ………………7-4 CHECKING THE INJECTORS (BEFORE REMOVING) ……7-7 REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ……..7-7 REMOVING THE INJECTORS …………..7-7 CHECKING THE INJECTORS …………..7-7…

  • Page 368: Fuel Tank

    FUEL TANK EAS20067 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •…

  • Page 369: Removing The Fuel Tank

    FUEL TANK 4. Remove: EAS30450 REMOVING THE FUEL TANK • Fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. Do not set the fuel tank down so that the instal- 2. Remove: lation surface of the fuel pump is directly under •…

  • Page 370: Installing The Fuel Tank

    FUEL TANK ening sequence as shown. A. Forward EAS30457 INSTALLING THE FUEL TANK 1. Connect: • Fuel hose (fuel tank side) ECA17500 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be properly installed.

  • Page 371
    THROTTLE BODIES EAS20070 THROTTLE BODIES Removing the throttle bodies 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…
  • Page 372
    THROTTLE BODIES Removing the sensors 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Negative pressure hose Hose joint Intake air pressure sensor 2 Intake air pressure sensor 1 Throttle position sensor Accelerator position sensor…
  • Page 373
    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 7-4. Fuel rail Injector Injector coupler…

  • Page 374: Throttle Bodies

    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 375
    • 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 376: Replacing The Throttle Bodies

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

  • Page 377: Checking The Fuel Pressure

    THROTTLE BODIES the fuel rail joint “2”, and then connect an air side cowling compressor “3” to the adapter. Refer to “GENERAL CHASSIS (2)” on page b. Connect the pressure gauge “4” to the injec- 4-6. tor pressure adapter “1”. •…

  • Page 378: Installing The Fuel Hose (Fuel Rail Side)

    THROTTLE BODIES or equivalent coverings. d. Start the engine. e. Measure the fuel pressure. EAS30485 ADJUSTING THE THROTTLE POSITION Faulty  Replace the fuel pump. SENSOR Fuel line pressure at idling EWA16690 300–390 kPa (3.0–3.9 kgf/cm², WARNING 43.5–56.6 psi) • Handle the throttle position sensor with special care.

  • Page 379: Adjusting The Accelerator Position Sensor

    THROTTLE BODIES SELECT ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ g. Press the “TCS” button “1” to select the diag- nostic mode “DIAG” “3” or the CO adjustment EAS30486 mode “CO”. ADJUSTING THE ACCELERATOR POSITION SENSOR EWA16700 WARNING • Handle the accelerator position sensor with DIAG special care.

  • Page 380
    THROTTLE BODIES display. Accelerator position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) SELECT h. Press the “TCS” button “1” to select the diag- nostic mode “DIAG” “3” or the CO adjustment mode “CO”. n. Turn the throttle grip to the fully open position. o.
  • Page 381
    THROTTLE BODIES 7-14…

  • Page 382: Air Induction System

    AIR INDUCTION SYSTEM EAS20071 AIR INDUCTION SYSTEM 7-15…

  • Page 383
    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 384
    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 Fuel tank front cover/Front side panel/Front side Refer to “GENERAL CHASSIS (2)”…
  • Page 385
    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 Reed valve assembly 2 Reed valve plate 7-18…

  • Page 386: 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 387
    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 388
    AIR INDUCTION SYSTEM 7-21…

  • Page 389: Electrical System

    CIRCUIT DIAGRAM ……………..8-27 TROUBLESHOOTING …………….8-29 FUEL INJECTION SYSTEM…………….8-31 CIRCUIT DIAGRAM ……………..8-31 ECU SELF-DIAGNOSTIC FUNCTION………….8-33 TROUBLESHOOTING METHOD………….8-35 DIAGNOSTIC MODE …………….8-36 YAMAHA DIAGNOSTIC TOOL …………..8-37 TROUBLESHOOTING DETAILS ………….8-38 FUEL PUMP SYSTEM………………8-77 CIRCUIT DIAGRAM ……………..8-77 TROUBLESHOOTING …………….8-79 IMMOBILIZER SYSTEM……………..8-81 CIRCUIT DIAGRAM ……………..8-81 GENERAL INFORMATION …………..8-83 PARTS REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS………………8-83…

  • Page 390
    ABS (ANTI-LOCK BRAKE SYSTEM)…………8-91 CIRCUIT DIAGRAM ……………..8-91 ABS COMPONENTS CHART …………..8-93 ABS COUPLER LOCATION CHART …………8-95 MAINTENANCE OF THE ABS ECU …………8-97 ABS TROUBLESHOOTING OUTLINE………….8-97 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ……8-98 BASIC PROCESS FOR TROUBLESHOOTING ……..8-99 [A] CHECKING THE ABS WARNING LIGHT………8-100 [A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON….8-100 [A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON …………..8-100…

  • Page 392: Ignition System

    IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM…

  • Page 393
    IGNITION SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 20.Joint connector 21.Joint coupler 22.Relay unit 25.Sidestand switch 27.ECU (engine control unit) 28.Ignition coil #1 29.Ignition coil #2 30.Ignition coil #3 31.Spark plug 39.Crankshaft position sensor 44.Lean angle sensor 66.Gear position switch…

  • Page 394: 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 395: Troubleshooting

    IGNITION SYSTEM EAS30492 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5.

  • Page 396
    IGNITION SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-147. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-127. OK…
  • Page 397
    IGNITION SYSTEM…

  • Page 398: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM…

  • Page 399
    ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 18.Starter relay 19.Starter motor 20.Joint connector 21.Joint coupler 22.Relay unit 23.Starting circuit cut-off relay 25.Sidestand switch 66.Gear position switch 69.Handlebar switch (right) 71.Start/engine stop switch 76.Handlebar switch (left) 77.Clutch switch…

  • Page 400: 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 401
    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 402: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS30495 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6.

  • Page 403
    ELECTRIC STARTING SYSTEM 9. Check the gear position switch. Refer to “CHECKING THE GEAR Replace the gear position switch. POSITION SWITCH” on page NG 8-147. OK 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. NG SWITCHES” on page 8-127. OK…

  • Page 404: Charging System

    CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS30496 CIRCUIT DIAGRAM 8-13…

  • Page 405
    CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 15.Battery 16.Engine ground 8-14…

  • Page 406: Troubleshooting

    CHARGING SYSTEM EAS30497 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Passenger seat/Rider seat 2. Rear side cover (left)/Lower tail cover 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUSES” NG…

  • Page 407
    CHARGING SYSTEM 8-16…

  • Page 408: Lighting System

    LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS30498 CIRCUIT DIAGRAM 8-17…

  • Page 409
    LIGHTING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 27.ECU (engine control unit) 52.Meter assembly 55.Meter light 61.High beam indicator light 76.Handlebar switch (left) 83.Dimmer/pass switch 88.Headlight control unit 89.Headlight (high beam) 90.Headlight (low beam) 91.Auxiliary light (right)

  • Page 410: 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. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3.

  • Page 411
    LIGHTING SYSTEM 8-20…

  • Page 412: Signaling System

    SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS30500 CIRCUIT DIAGRAM 8-21…

  • Page 413
    SIGNALING SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 13.Signaling system fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 22.Relay unit 27.ECU (engine control unit) 41.Coolant temperature sensor 46.Rear wheel sensor 47.ABS ECU (electronic control unit) 52.Meter assembly 54.Neutral indicator light 56.Tachometer 57.Multi-function meter 58.Oil level warning light…

  • Page 414: 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. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2.

  • Page 415
    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 416
    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 417
    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 (en- gine control unit)” on page 8-132. The speedometer fails to operate.

  • Page 418: Cooling System

    COOLING SYSTEM EAS20077 COOLING SYSTEM EAS30502 CIRCUIT DIAGRAM 8-27…

  • Page 419
    COOLING SYSTEM 3. Main switch 4. Main fuse 9. Radiator fan motor fuse 11.Ignition fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 27.ECU (engine control unit) 41.Coolant temperature sensor 95.Radiator fan motor relay 96.Radiator fan motor 8-28…

  • Page 420: Troubleshooting

    COOLING SYSTEM EAS30503 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 5. Air filter case 6. Throttle bodies 1. Check the fuses. (Main, ignition and radiator fan) Replace the fuse(s).

  • Page 421
    COOLING SYSTEM 8-30…

  • Page 422: Fuel Injection System

    FUEL INJECTION SYSTEM EAS20078 FUEL INJECTION SYSTEM EAS30504 CIRCUIT DIAGRAM 8-31…

  • Page 423
    44.Lean angle sensor 46.Rear wheel sensor 47.ABS ECU (electronic control unit) 48.Throttle servo motor 49.Accelerator position sensor 50.Throttle position sensor 51.Yamaha diagnostic tool coupler 52.Meter assembly 57.Multi-function meter 59.Engine trouble warning light 66.Gear position switch 68.Fuel pump 69.Handlebar switch (right) 70.Drive mode switch…

  • Page 424: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS30505 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 425
    FUEL INJECTION SYSTEM ECU detects an abnormal signal from a sensor If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.

  • Page 426: Troubleshooting Method

    FUEL INJECTION SYSTEM The engine operation is not normal, but the EAS30506 TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the engine trouble warning light comes on. 1. Check the operation of the following sensors 1.

  • Page 427: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS30507 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “TCS” button “1” and “RESET” button “2”, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.

  • Page 428: Yamaha Diagnostic Tool

    9. Connect the wire harness coupler to the fuel pump. 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 90890-03231…

  • Page 429: Troubleshooting Details

    However, the diagnostic tool cannot be used to freely change the basic vehicle functions, such as ad- justing the ignition timing. Connecting the Yamaha diagnostic tool Remove the protective cap “1”, and then connect the Yamaha diagnostic tool “2” to the coupler. Lg/L Lg/W L Br When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation.

  • Page 430
    FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received from Item the crankshaft position sensor. Improperly connected  Con- Connection of crankshaft posi- Crank the engine. tion sensor coupler. nect the coupler securely or Fault code number is not dis- played …
  • Page 431
    FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 1: open or short circuit detected. Meter display Displays the intake air pressure. Procedure Operate the throttle while pushing the “ ” side of the start/engine stop switch. (If the display value changes, the performance is OK.) Item Probable cause of Maintenance job…
  • Page 432
    FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 1: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”. sensor 1. (Code No. 03) Fault code number is not dis- played …
  • Page 433
    FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 1: hose system malfunction (clogged or Item detached hose). Defective intake air pressure Execute the diagnostic mode. sensor 1. (Code No. 03) When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indicated.
  • Page 434
    FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Improperly connected  Con- Connection of throttle position Turn the main switch to “ON”. sensor coupler. nect the coupler securely or Fault code number is not dis- played …
  • Page 435
    FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)” on page 8-132. Fault code No. Sidestand switch: a break or disconnection of the black/red lead of Item the ECU is detected.
  • Page 436
    FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red lead of Item the ECU is detected. Defective sidestand switch. Execute the diagnostic mode. Turn the main switch to “ON”, (Code No. 20) and then extend and retract the Shift the transmission into gear.
  • Page 437
    FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 1 or intake air pressure sensor 2: when Item the main switch is turned to “ON”, the intake air pressure sensor 1 voltage and intake air pressure sensor 2 voltage differ greatly. Defective intake air pressure Execute the diagnostic mode.
  • Page 438
    FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Open or short circuit  Replace Wire harness continuity. Turn the main switch to “ON”. the wire harness. Fault code number is not dis- played  Service is finished. Between coolant temperature sensor coupler and ECU cou- Fault code number is displayed…
  • Page 439
    FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected  Con- Connection of wire harness Turn the main switch to “ON”. ECU coupler. nect the coupler securely or Fault code number is not dis- played …
  • Page 440
    FUEL INJECTION SYSTEM Fault code No. Item sensor: no normal signals are received from the O sensor. sensor. Improperly installed sensor  Installed condition of O Start the engine, warm it up, Reinstall or replace the sensor. and then race it, or execute the diagnostic mode.
  • Page 441
    FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 2: open or short circuit detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No. Meter display Displays the intake air pressure. Procedure Operate the throttle while pushing the “ ”…
  • Page 442
    FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor 2: open or short circuit detected. Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”. sensor 2. (Code No. 04) Fault code number is not dis- played …
  • Page 443
    FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor 2: hose system malfunction (clogged or Item detached hose). Clogged or detached hose  Condition of intake air pressure Start the engine and let it idle for sensor 2 hose. Repair or replace the sensor approximately 5 seconds.
  • Page 444
    FUEL INJECTION SYSTEM Fault code No. Item Latch up detected. The vehicle has overturned. Raise the vehicle upright. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”. Fault code number is not dis- played  Service is finished. Fault code number is displayed …
  • Page 445
    FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#1 ignition coil. Improperly connected  Con- Connection of wire harness Start the engine and let it idle for ECU coupler.
  • Page 446
    FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#2 ignition coil. Improperly connected  Con- Connection of cylinder-#2 igni- Start the engine and let it idle for tion coil coupler.
  • Page 447
    FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the pri- Item mary lead of the cylinder-#3 ignition coil. Item Probable cause of Maintenance job Confirmation of service com- malfunction and check pletion Improperly connected  Con- Connection of cylinder-#3 igni- Start the engine and let it idle for tion coil coupler.
  • Page 448
    FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Actuation Actuates injector #1 five times at one-second intervals. Illuminates the engine trouble warning light. Procedure Check that injector #1 is actuated five times by listening for the operating sound.
  • Page 449
    FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Open or short circuit  Replace Wire harness continuity. Execute the diagnostic mode. the wire harness. (Code Nos. 36, 37, 38) No operating sound  Go to Between injector coupler and ECU coupler.
  • Page 450
    FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Open or short circuit  Replace Wire harness continuity. Turn the main switch to “ON”, the wire harness. then to “OFF”, and then back to Between lean angle sensor cou- “ON”.
  • Page 451
    FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
  • Page 452
    FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction in ECU. Replace the ECU.
  • Page 453
    FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Value does not increase  Go Locate the malfunction.
  • Page 454
    FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Defective relay unit. Check the relay unit.
  • Page 455
    FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
  • Page 456
    FUEL INJECTION SYSTEM Fault code No. A Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected  Con- Connection of clutch switch cou- Execute the diagnostic mode.
  • Page 457
    FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Defective clutch switch. Check the clutch switch.
  • Page 458
    FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel injector Item and fuel pump. Improperly connected  Con- Connection of relay unit coupler. Start the engine and let it idle for Check the locking condition of nect the coupler securely or approximately 5 seconds.
  • Page 459
    FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. Meter display EEPROM fault code display • 00 (no history) • 01–03: Cylinder fault code number (history exists) If more than one cylinder is defective, the display switches every two seconds to show the cylinder fault code numbers of all defective cylin- ders in a repeating cycle.
  • Page 460
    FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading or Item writing on EEPROM. “11” is indicated in diagnostic Turn the main switch to “OFF”. Turn the main switch to “ON”. mode (code No. 60). EEPROM Fault code number is not dis- played …
  • Page 461
    FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Fail-safe system Able/Unable to start engine Able/Unable to drive vehicle Diagnostic code No. 14, 15 Meter display Accelerator position sensor signal 1 • 12–22 (fully closed position) •…
  • Page 462
    FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Defective accelerator position Check accelerator position sen- Turn the main switch to “ON”. sensor. sor signal 1. Fault code number is not dis- played  Service is finished. Execute the diagnostic mode.
  • Page 463
    FUEL INJECTION SYSTEM Fault code No. Item YCC-T drive system: malfunction detected. Abnormality  Replace the Check the electronic throttle Turn the main switch to “ON”. valve fuse. electronic throttle valve fuse. Fault code number is not dis- played  Service is finished. Fault code number is displayed …
  • Page 464
    FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the front Item wheel sensor. Locate the malfunction. If the ABS warning light is on, refer to “BASIC INSTRUC- TIONS FOR TROUBLESHOOT- ING” on page 8-98. If the ABS warning light is off, perform the following procedure.
  • Page 465
    The fault code can also be deleted by activating the diag- nostic mode and selecting diag- nostic code number “63”. 89 (Yamaha diagnostic tool) Fault code No. Err (multi-function meter display) Multi-function meter: signals cannot be transmitted between the Item ECU and the multi-function meter.
  • Page 466
    FUEL INJECTION SYSTEM 89 (Yamaha diagnostic tool) Fault code No. Err (multi-function meter display) Multi-function meter: signals cannot be transmitted between the Item ECU and the multi-function meter. Improperly connected  Con- Connection of wire harness Turn the main switch to “ON”.
  • Page 467
    FUEL INJECTION SYSTEM 8-76…
  • Page 468
    FUEL PUMP SYSTEM EAS20081 FUEL PUMP SYSTEM EAS30513 CIRCUIT DIAGRAM 8-77…
  • Page 469
    FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 11.Ignition fuse 15.Battery 16.Engine ground 17.Fuel injection system fuse 20.Joint connector 21.Joint coupler 22.Relay unit 24.Fuel pump relay 27.ECU (engine control unit) 68.Fuel pump 69.Handlebar switch (right) 71.Start/engine stop switch 8-78…
  • Page 470
    FUEL PUMP SYSTEM EAS30514 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Fuel tank front cover/Front side panel/Front side cowling 2. Passenger seat/Rider seat 3. Fuel tank cover 4. Fuel tank 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 471
    FUEL PUMP SYSTEM 8-80…
  • Page 472
    IMMOBILIZER SYSTEM EAS20084 IMMOBILIZER SYSTEM EAS30519 CIRCUIT DIAGRAM 8-81…
  • Page 473
    IMMOBILIZER SYSTEM 3. Main switch 4. Main fuse 8. Backup fuse 11.Ignition fuse 15.Battery 16.Engine ground 20.Joint connector 21.Joint coupler 26.Immobilizer unit 27.ECU (engine control unit) 52.Meter assembly 53.Immobilizer system indicator light 57.Multi-function meter 8-82…
  • Page 474
    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 475
    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 476
    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 477
    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 478
    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 8-131.
  • Page 479
    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 480
    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 481
    IMMOBILIZER SYSTEM 8-90…
  • Page 482
    ABS (ANTI-LOCK BRAKE SYSTEM) EAS20085 ABS (ANTI-LOCK BRAKE SYSTEM) EAS30843 CIRCUIT DIAGRAM 8-91…
  • Page 483
    22.Relay unit 23.Starting circuit cut-off relay 27.ECU (engine control unit) 45.Front wheel sensor 46.Rear wheel sensor 47.ABS ECU (electronic control unit) 51.Yamaha diagnostic tool coupler 52.Meter assembly 57.Multi-function meter 64.ABS warning light 69.Handlebar switch (right) 71.Start/engine stop switch 73.Front brake light switch 74.Rear brake light switch…
  • Page 484
    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30525 ABS COMPONENTS CHART 8-93…
  • Page 485
    ABS (ANTI-LOCK BRAKE SYSTEM) 1. Hydraulic unit assembly 2. Fuse box 3 3. ABS test 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 2 8-94…
  • Page 486
    ABS (ANTI-LOCK BRAKE SYSTEM) EAS30844 ABS COUPLER LOCATION CHART 8-95…
  • Page 487
    ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. Rear wheel sensor coupler 3. ABS ECU coupler 4. ABS test coupler 5. Front wheel sensor coupler 8-96…
  • Page 488
    Previous malfunctions can be checked since the ABS ECU also stores the mal- function history. 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-…
  • Page 489
    Since all malfunctions are recorded after they are detected, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the ABS ECU has entered the self-diagnosis mode.
  • Page 490
    • 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 491
    EAS31162 [A-3] THE ABS WARNING LIGHT COMES ON Connect the Yamaha diagnostic tool to the ABS test coupler and execute functional diagnosis. (For in- formation about how to execute functional diagnosis, refer to the operation manual that is included with the tool.)
  • Page 492
    ABS test coupler. (CANL) EAS31165 [B-1] MALFUNCTION ARE CURRENTLY DETECTED When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed on the computer screen. • A fault code is displayed. [B-2] •…
  • Page 493
    Once all the work is complete, delete the fault codes. [B-3] • When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function me- ter and indicators will be different from the normal operation.
  • Page 494
    ABS (ANTI-LOCK BRAKE SYSTEM) B. Recovered malfunction A. Detected malfunction 4. ECU The types of the control units are displayed. (e.g., FI, ABS) 5. Item The item names of the detected malfunction are displayed. 6. Condition The current conditions are displayed. (Detected/Recovered) 7.
  • Page 495
    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered mal pulse period) not received properly. (The around the front wheel sen- pulse period is abnormal • Incorrect installation of the while the vehicle is traveling.) front wheel •…
  • Page 496
    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered pulses) not received properly. (Miss- around the rear wheel sen- ing pulses are detected in • Incorrect installation of the the signal while the vehicle is traveling.) rear wheel…
  • Page 497
    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the tent wheel speed pulses or sensor are received inter- front wheel sensor • Incorrect rotation of the incorrect depressurization) mittently while the vehicle is traveling.
  • Page 498
    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code Item Symptom Check point Hydraulic unit assembly Abnormality is detected in • Defective battery • Defective coupler between (defective ABS solenoid and the solenoid or motor power ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau- cuits) unit assembly.
  • Page 499
    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (intermittent pulses or no pulses) Front wheel sensor signal is not received properly. (Pulses are not Symptom received or are received intermittently while the vehicle is travel- ing.) Order Item/components and probable cause Check or maintenance job Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed…
  • Page 500
    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Front wheel sensor (abnormal pulse period) Front wheel sensor signal is not received properly. (The pulse Symptom period is abnormal while the vehicle is traveling.) Order Item/components and probable cause Check or maintenance job Incorrect installation of the front wheel Check the components for looseness, distortion, and bends.
  • Page 501
    ABS (ANTI-LOCK BRAKE SYSTEM) • If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record- ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re- corded.
  • Page 502
    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 • Check the coupler for any pins that may be pulled out. Defective coupler between the rear wheel •…
  • Page 503
    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 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor wheel sensor…
  • Page 504
    ABS (ANTI-LOCK BRAKE SYSTEM) If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault code No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code No.
  • Page 505
    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 506
    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 507
    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 508
    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 Incorrect installation of the front wheel Check the components for looseness, distortion, and bends.
  • Page 509
    ABS (ANTI-LOCK BRAKE SYSTEM) 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. 52) •…
  • Page 510
    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Hydraulic unit assembly (defective ABS solenoid and ABS motor Item power supply circuits) Abnormality is detected in the solenoid or motor power supply cir- Symptom cuit in the hydraulic unit assembly. Order Item/components and probable cause Check or maintenance job Defective battery Recharge or replace the battery.
  • Page 511
    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 •…
  • Page 512
    ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Item Rear wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the rear wheel sensor Symptom is too low. Order Item/components and probable cause Check or maintenance job •…
  • Page 513
    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 514
    ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 8-123…
  • Page 515
    ELECTRICAL COMPONENTS 1. Main switch/Immobilizer unit 2. Clutch switch 3. Front brake light switch 4. Hydraulic unit assembly 5. Battery 6. Fuse box 3 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 516
    ELECTRICAL COMPONENTS 8-125…
  • Page 517
    ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. ECU (engine control unit) 3. Fuel pump 4. Lean angle sensor 5. Radiator fan motor relay 6. Turn signal/hazard relay 7. Relay unit 8. Stator coil 9. Crankshaft position sensor 10.Coolant temperature sensor 11.Throttle servo motor 12.Accelerator position sensor 13.Throttle position sensor…
  • Page 518
    ELECTRICAL COMPONENTS EAS30549 CHECKING THE SWITCHES Br/W B/Y W/R B W/G Br B/R B/L B/L Br/W 8-127…
  • Page 519
    ELECTRICAL COMPONENTS 1. Dimmer/pass switch 2. Turn signal switch 3. Horn switch 4. Select switch 5. Menu 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 8-128…
  • Page 520
    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 521
    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 522
    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 523
    ELECTRICAL COMPONENTS 4. Install: ECA13661 NOTICE • Rider seat/Passenger seat • This is a VRLA (Valve Regulated Lead Acid) Refer to “GENERAL CHASSIS (1)” on page battery. Never remove the sealing caps be- 4-1. cause the balance between cells will not be EAS31006 maintained and battery performance will REPLACING THE ECU (engine control unit)
  • Page 524
    ELECTRICAL COMPONENTS ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a pocket tester to the battery termi- 5. Charge: nals. • Battery (refer to the appropriate charging method) • Positive tester probe  positive battery terminal EWA13300 • Negative tester probe  WARNING negative battery terminal Do not quick charge a battery.
  • Page 525
    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 526
    ELECTRICAL COMPONENTS Starter relay 8. Check: 1. Positive battery terminal • Battery terminals 2. Negative battery terminal Dirt  Clean with a wire brush. 3. Positive tester probe Loose connection  Connect properly. 4. Negative tester probe 9. Lubricate: • Battery terminals Relay operation Recommended lubricant Continuity…
  • Page 527
    ELECTRICAL COMPONENTS Relay unit (fuel pump relay) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (DC 20 V) to the turn signal/hazard relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe blue/red “1” • Negative tester probe Ground 1.
  • Page 528
    ELECTRICAL COMPONENTS Continuity Positive tester probe sky blue “1” Negative tester probe black/yellow “2” No continuity Positive tester probe black/yellow “2” Negative tester probe sky blue “1” Continuity b. Turn the main switch to “ON”. Positive tester probe c. Measure the turn signal/hazard relay output sky blue “1”…
  • Page 529
    ELECTRICAL COMPONENTS unit terminal as shown. nition coil as shown. c. Check the relay unit (diode) for continuity. Pocket tester d. Check the relay unit (diode) for no continuity. 90890-03112 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Analog pocket tester YU-03112-C EAS30558 CHECKING THE IGNITION COILS The following procedure applies to all of the igni- •…
  • Page 530
    ELECTRICAL COMPONENTS b. Measure the crankshaft position sensor re- 2. Ignition coil sistance. c. Turn the main switch to “ON”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the “ ” side of EAS30561 the start/engine stop switch and gradually in- CHECKING THE LEAN ANGLE SENSOR crease the spark gap until a misfire occurs.
  • Page 531
    ELECTRICAL COMPONENTS EAS30566 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification  Replace the stator coil. Stator coil resistance 0.152–0.228  (W-W) c. Set the main switch to “ON”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼…
  • Page 532
    ELECTRICAL COMPONENTS on page 8-140. b. Connect the pocket tester (DC 20 V) to the battery as shown. Rectifier/regulator input voltage above 14 V at 5000 r/min Pocket tester 90890-03112 Analog pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C a. Set the engine tachometer to the ignition coil of cylinder #1.
  • Page 533
    ELECTRICAL COMPONENTS c. Measure the horn resistance. b. Measure the oil level switch resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Horn sound EAS30573 CHECKING THE FUEL SENDER Faulty sound  Replace. 1. Disconnect: • Fuel pump coupler EAS30846 CHECKING THE ENGINE OIL LEVEL (from the fuel pump) SWITCH 2.
  • Page 534
    ELECTRICAL COMPONENTS EAS30575 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis de- vice for the oil level detection circuit. 1. Check: • Oil level warning light “1” (Turn the main switch to “ON”.) Warning light comes on for a few seconds, then goes off …
  • Page 535
    ELECTRICAL COMPONENTS EAS30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: • Coolant temperature sensor Refer to “CYLINDER HEAD” on page 5-19. EWA14130 WARNING • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- ature sensor is dropped, replace it.
  • Page 536
    ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Resistance a. Connect the pocket tester (  1 k) to the 1.08–2.52 k throttle position sensor terminals as shown. Pocket tester ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester (  1 k) to the ac- 90890-03112 Analog pocket tester celerator position sensor terminals as shown.
  • Page 537
    ELECTRICAL COMPONENTS tle servo motor. • Positive tester probe  Air induction system solenoid terminal “1” • Negative tester probe  Do not use old batteries to operate the throttle Air induction system solenoid terminal “2” servo motor. c. Measure the air induction system solenoid re- sistance.
  • Page 538
    ELECTRICAL COMPONENTS • Positive tester probe Intake air temperature sensor re- pink (wire harness color) (intake air pressure sistance sensor 1) 5400–6600 @0 C (32 F) pink/white (wire harness color) (intake air pres- Intake air temperature sensor re- sure sensor 2) •…
  • Page 539
    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C Result Neutral position Continuity Positive tester probe sky blue “1” EAS30681 Negative tester probe CHECKING THE FUEL INJECTORS Sensor terminal “a” The following procedure applies to all of the fuel 1st position injectors.
  • Page 540
    ELECTRICAL COMPONENTS 8-149…

  • Page 541: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING………………9-1 GENERAL INFORMATION …………….9-1 STARTING FAILURES…………….9-1 INCORRECT ENGINE IDLING SPEED ………….9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ……9-2 FAULTY GEAR SHIFTING……………..9-2 SHIFT PEDAL DOES NOT MOVE ………….9-2 JUMPS OUT OF GEAR…………….9-2 FAULTY CLUTCH ………………9-2 OVERHEATING ………………9-2 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 542: 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 543: 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 544: 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 545: Troubleshooting At The Abs Warning Light

    TROUBLESHOOTING • Incorrect connection • Faulty tail/brake light assembly Turn signal does not come on • Faulty turn signal switch • Faulty turn signal/hazard relay • Burnt-out turn signal bulb • Incorrect connection • Damaged or faulty wire harness • Improperly grounded circuit •…

  • Page 546: Self-Diagnostic Function And Diagnostic Code Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS20116 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS31118 SELF-DIAGNOSTIC FUNCTION TABLE • The fault code numbers 51–56 cannot be displayed on the meter. The pattern of the immobilizer sys- tem indicator light flashing shows the fault code. •…

  • Page 547: Communication Error With The Meter

    Front wheel sensor: no normal signals are received from the front wheel sensor. Engine idling stop EAS31119 COMMUNICATION ERROR WITH THE METER Fault code No. Item 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmitted between the ECU and Err (multi-function meter dis- the multi-function meter. play) EAS31120…

  • Page 548
    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Rear wheel vehicle speed Rear wheel speed pulse Check that the number pulses 0–999 increases when the rear wheel is rotated. The number is cumulative and does not reset each time the wheel is stopped.
  • Page 549
    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. gear position switch and Operate the transmission, clutch switch clutch lever, and sidestand. • Transmission is in neutral • Transmission is in gear or the clutch lever released •…

  • Page 550: Diagnostic Code: Actuator Operation Table

    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Meter display Procedure code No. Malfunction code reinstate- ment (for fault code No. 24, 42 only) • No malfunction code — • Malfunction code exists Fault code 24, 42 To reinstate, set the •…

  • Page 551
    SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Actuation Procedure code No. Injector #3 Actuates the injector #3 five Check that injector #3 is times at one-second inter- actuated five times by listen- vals. ing for the operating sound. Illuminates the engine trou- ble warning light.

  • Page 552: Event Code Table

    EVENT CODE TABLE EAS20164 EVENT CODE TABLE The event code numbers listed below cannot be displayed on the meter. To display the event code numbers, use the Yamaha diagnostic tool. Item Symptom Possible causes Note Intake air pres- Brief abnormality…

  • Page 553
    EVENT CODE TABLE Item Symptom Possible causes Note During idling, the Idling engine speed is – Implement diagnosis (Stuck at the adjustment is main- slow mode D67, and check upper limit for tained at the upper – Clogged throttle body the ISC maintenance adjustment) limit…
  • Page 554
    EVENT CODE TABLE 9-13…

  • Page 555: Wiring Diagram

    Yellow/Red 49. Accelerator position sensor B. Sub-wire harness (Injector #2) Yellow/White 50. Throttle position sensor C. Sub-wire harness (Coolant 51. Yamaha diagnostic tool cou- temperature sensor) pler D. Negative battery sub-wire har- 52. Meter assembly ness 53. Immobilizer system indicator light 54.

  • Page 559
    MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO…
  • Page 560
    MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 MT09TRA/MT09TRAF 2015 SCHÉMA DE CÂBLAGE SCHEMA ELETTRICO WIRING DIAGRAM SCHALTPLAN DIAGRAMA ELÉCTRICO…

Источник
инструкцияYamaha Tracer 900 GT (2018)

DIC183

MTT850D

OWNER’S MANUAL

Read this manual carefully before operating this vehicle.

B1J-28199-E0

[English (E)]

Посмотреть инструкция для Yamaha Tracer 900 GT (2018) бесплатно. Руководство относится к категории мотоциклы, 6 человек(а) дали ему среднюю оценку 9.4. Руководство доступно на следующих языках: английский. У вас есть вопрос о Yamaha Tracer 900 GT (2018) или вам нужна помощь? Задайте свой вопрос здесь

  • Introduction
  • Important manual information
  • Table of contents
  • Safety information
  • Description
  • Instrument and control functions
  • For your safety – pre-operation checks
  • Operation and important riding points
  • Periodic maintenance and adjustment
  • Motorcycle care and storage
  • Specifications
  • Consumer information
  • Index

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View, print and download for free: YAMAHA TRACER 900 2021 User Guide, 118 Pages, PDF Size: 4.38 MB. Search in YAMAHA TRACER 900 2021 User Guide online. CarManualsOnline.info is the largest online database of car user manuals. YAMAHA TRACER 900 2021 User Guide PDF Download. Safety information
1-4
1
tents, can create unstable han-
dling or a slow steering re-
sponse.
 This vehicle is not desi gne d to
pull a trailer or to be at

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Источник

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Manual Yamaha Tracer 900 GT (2019) Motorcycle

Источник
manualYamaha Tracer 900 (2021)

DIC183

MTT890 (Tracer 9)

1

2

3

4

5

6

7

8

9

10

11

B5U-28199-E0

Read this manual carefully
before operating this vehicle.
MOTORCYCLE
OWNER’S MANUAL

Specifications

Consumer information

Motorcycle care and storage

Periodic maintenance and adjustment

For your safety – pre-operation checks

Instrument and control functions

Special features

Description

Safety information

Operation and important riding points

Index

[English (E)]

Источник

View a manual of the Yamaha Tracer 900 GT (2018) below. All manuals on ManualsCat.com can be viewed completely free of charge. By using the ‘Select a language’ button, you can choose the language of the manual you want to view.

Page: 1

DIC183
MTT850D
OWNER’S MANUAL
Read this manual carefully before operating this vehicle.
B1J-28199-E0
[English (E)]

Page: 2

EAU81560
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
EAU81570
Declaration of Conformity:
Hereby, YAMAHA MOTOR ELECTRONICS Co., Ltd declares that the radio equipment type, IMMOBILIZER, 1RC-00 is in
compliance with Directive 2014/53/EU.
The full text of the EU declaration of conformity is available at the following internet address:
https://global.yamaha-motor.com/eu_doc/
Frequency band: 134.2 kHz
The maximum radio frequency power: 49.0 [dBμV/m]
Manufacturer:
YAMAHA MOTOR ELECTRONICS Co., Ltd
1450-6 Mori, Mori-machi, Shuchi-Gun, Shizuoka, 437-0292 Japan
Importer:
YAMAHA MOTOR EUROPE N.V.
Koolhovenlaan 101, 1119 NC Schiphol-Rijk, 1117 ZN, Schiphol, the Netherlands
UB1JE0E0.book Page 1 Tuesday, February 13, 2018 9:12 AM

Page: 3

Introduction
EAU10103
Welcome to the Yamaha world of motorcycling!
As the owner of the MTT850D, you are benefiting from Yamaha’s vast experience and newest technology regarding the
design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
Please take the time to read this manual thoroughly, so as to enjoy all advantages of your MTT850D. The Owner’s Manual
does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself
and others from trouble and injury.
In addition, the many tips given in this manual will help keep your motorcycle in the best possible condition. If you have any
further questions, do not hesitate to contact your Yamaha dealer.
The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!
Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most cur-
rent product information available at the time of printing, there may be minor discrepancies between your motorcycle and
this manual. If there is any question concerning this manual, please consult a Yamaha dealer.
WARNING
EWA10032
Please read this manual carefully and completely before operating this motorcycle.
UB1JE0E0.book Page 1 Tuesday, February 13, 2018 9:12 AM

Page: 4

Important manual information
EAU10134
Particularly important information is distinguished in this manual by the following notations:
*Product and specifications are subject to change without notice.
This is the safety alert symbol. It is used to alert you to potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury
or death.
A WARNING indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the
vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
WARNING
NOTICE
TIP
UB1JE0E0.book Page 1 Tuesday, February 13, 2018 9:12 AM

Page: 5

Important manual information
EAU10201
MTT850D
OWNER’S MANUAL
©2018 by Yamaha Motor Co., Ltd.
1st edition, January 2018
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
UB1JE0E0.book Page 2 Tuesday, February 13, 2018 9:12 AM

Page: 6

Table of contents
Safety information………………………. 1-1
Description ………………………………… 2-1
Left view ………………………………….. 2-1
Right view………………………………… 2-2
Controls and instruments…………… 2-3
Instrument and control functions… 3-1
Immobilizer system……………………. 3-1
Main switch/steering lock…………… 3-2
Handlebar switches…………………… 3-3
Indicator lights and warning
lights…………………………………….. 3-5
Cruise control system………………… 3-8
Display…………………………………… 3-11
MENU screen …………………………. 3-15
D-mode (drive mode)……………….. 3-25
Clutch lever ……………………………. 3-25
Shift pedal ……………………………… 3-26
Quick shift system…………………… 3-26
Brake lever……………………………… 3-26
Brake pedal ……………………………. 3-27
ABS ………………………………………. 3-27
Traction control system……………. 3-28
Fuel tank cap………………………….. 3-30
Fuel……………………………………….. 3-31
Fuel tank overflow hose …………… 3-33
Catalytic converter ………………….. 3-33
Seats …………………………………….. 3-34
Adjusting the rider seat height…… 3-35
Helmet holder…………………………. 3-37
Storage compartment……………….3-38
Windshield ……………………………..3-38
Adjusting the headlight beams …..3-38
Handlebar position …………………..3-39
Adjusting the front fork ……………..3-39
Adjusting the shock absorber
assembly………………………………3-41
Auxiliary DC jack………………………3-43
Auxiliary DC connector ……………..3-44
Sidestand………………………………..3-44
Ignition circuit cut-off system …….3-45
For your safety – pre-operation
checks ………………………………………..4-1
Operation and important riding
points………………………………………….5-1
Starting the engine……………………..5-1
Shifting……………………………………..5-2
Tips for reducing fuel
consumption…………………………..5-3
Engine break-in………………………….5-3
Parking……………………………………..5-4
Periodic maintenance and
adjustment ………………………………….6-1
Tool kit ……………………………………..6-2
Periodic maintenance charts ……….6-3
Periodic maintenance chart for the
emission control system…………..6-3
General maintenance and
lubrication chart …………………….. 6-5
Removing and installing the
panel…………………………………….. 6-9
Checking the spark plugs…………. 6-10
Canister …………………………………. 6-11
Engine oil ……………………………….. 6-11
Coolant ………………………………….. 6-13
Air filter element………………………. 6-15
Checking the engine idling
speed …………………………………. 6-15
Checking the throttle grip free
play…………………………………….. 6-15
Valve clearance……………………….. 6-16
Tires………………………………………. 6-16
Cast wheels ……………………………. 6-18
Adjusting the clutch lever free
play…………………………………….. 6-19
Checking the brake lever free
play…………………………………….. 6-19
Brake light switches ………………… 6-20
Checking the front and rear
brake pads ………………………….. 6-20
Checking the brake fluid level …… 6-21
Changing the brake fluid ………….. 6-22
Drive chain slack……………………… 6-23
Cleaning and lubricating the
drive chain…………………………… 6-24
Checking and lubricating the
cables…………………………………. 6-25
UB1JE0E0.book Page 1 Tuesday, February 13, 2018 9:12 AM

Page: 7

Table of contents
Checking and lubricating the
throttle grip and cable…………….6-25
Checking and lubricating the
brake and shift pedals ……………6-26
Checking and lubricating the
brake and clutch levers…………..6-26
Checking and lubricating the
centerstand and sidestand ……..6-27
Lubricating the swingarm pivots …6-28
Checking the front fork………………6-28
Checking the steering ……………….6-29
Checking the wheel bearings……..6-29
Battery…………………………………….6-29
Replacing the fuses…………………..6-31
Headlights ……………………………….6-33
Auxiliary lights ………………………….6-33
Brake/tail light ………………………….6-33
Replacing a turn signal light
bulb……………………………………..6-34
Replacing the license plate light
bulb……………………………………..6-34
Troubleshooting ……………………….6-35
Troubleshooting charts ……………..6-36
Motorcycle care and storage ……….7-1
Matte color caution …………………….7-1
Care………………………………………….7-1
Storage……………………………………..7-4
Specifications…………………………….. 8-1
Consumer information………………… 9-1
Identification numbers ……………….. 9-1
Diagnostic connector…………………. 9-2
Vehicle data recording……………….. 9-2
Index………………………………………… 10-1
UB1JE0E0.book Page 2 Tuesday, February 13, 2018 9:12 AM

Page: 8

1-1
1
Safety information
EAU1028C
Be a Responsible Owner
As the vehicle’s owner, you are re-
sponsible for the safe and proper oper-
ation of your motorcycle.
Motorcycles are single-track vehicles.
Their safe use and operation are de-
pendent upon the use of proper riding
techniques as well as the expertise of
the operator. Every operator should
know the following requirements be-
fore riding this motorcycle.
He or she should:
 Obtain thorough instructions from
a competent source on all aspects
of motorcycle operation.
 Observe the warnings and mainte-
nance requirements in this Own-
er’s Manual.
 Obtain qualified training in safe
and proper riding techniques.
 Obtain professional technical ser-
vice as indicated in this Owner’s
Manual and/or when made neces-
sary by mechanical conditions.
 Never operate a motorcycle with-
out proper training or instruction.
Take a training course. Beginners
should receive training from a cer-
tified instructor. Contact an autho-
rized motorcycle dealer to find out
about the training courses nearest
you.
Safe Riding
Perform the pre-operation checks
each time you use the vehicle to make
sure it is in safe operating condition.
Failure to inspect or maintain the vehi-
cle properly increases the possibility of
an accident or equipment damage.
See page 4-1 for a list of pre-operation
checks.
 This motorcycle is designed to
carry the operator and a passen-
ger.
 The failure of motorists to detect
and recognize motorcycles in traf-
fic is the predominating cause of
automobile/motorcycle accidents.
Many accidents have been
caused by an automobile driver
who did not see the motorcycle.
Making yourself conspicuous ap-
pears to be very effective in reduc-
ing the chance of this type of
accident.
Therefore:
• Wear a brightly colored jacket.
• Use extra caution when you are
approaching and passing
through intersections, since in-
tersections are the most likely
places for motorcycle accidents
to occur.
• Ride where other motorists can
see you. Avoid riding in another
motorist’s blind spot.
• Never maintain a motorcycle
without proper knowledge.
Contact an authorized motorcy-
cle dealer to inform you on ba-
sic motorcycle maintenance.
Certain maintenance can only
be carried out by certified staff.
UB1JE0E0.book Page 1 Tuesday, February 13, 2018 9:12 AM

Page: 9

Safety information
1-2
1
 Many accidents involve inexperi-
enced operators. In fact, many op-
erators who have been involved in
accidents do not even have a cur-
rent motorcycle license.
• Make sure that you are qualified
and that you only lend your mo-
torcycle to other qualified oper-
ators.
• Know your skills and limits.
Staying within your limits may
help you to avoid an accident.
• We recommend that you prac-
tice riding your motorcycle
where there is no traffic until you
have become thoroughly famil-
iar with the motorcycle and all of
its controls.
 Many accidents have been
caused by error of the motorcycle
operator. A typical error made by
the operator is veering wide on a
turn due to excessive speed or un-
dercornering (insufficient lean an-
gle for the speed).
• Always obey the speed limit and
never travel faster than warrant-
ed by road and traffic condi-
tions.
• Always signal before turning or
changing lanes. Make sure that
other motorists can see you.
 The posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handlebar and
both feet on the operator foot-
rests during operation to main-
tain control of the motorcycle.
• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger footrests.
Never carry a passenger unless
he or she can firmly place both
feet on the passenger footrests.
 Never ride under the influence of
alcohol or other drugs.
 This motorcycle is designed for
on-road use only. It is not suitable
for off-road use.
Protective Apparel
The majority of fatalities from motorcy-
cle accidents are the result of head in-
juries. The use of a safety helmet is the
single most critical factor in the pre-
vention or reduction of head injuries.
 Always wear an approved helmet.
 Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impairment
of vision that could delay seeing a
hazard.
 The use of a jacket, heavy boots,
trousers, gloves, etc., is effective
in preventing or reducing abra-
sions or lacerations.
 Never wear loose-fitting clothes,
otherwise they could catch on the
control levers, footrests, or wheels
and cause injury or an accident.
 Always wear protective clothing
that covers your legs, ankles, and
feet. The engine or exhaust sys-
tem become very hot during or af-
ter operation and can cause
burns.
 A passenger should also observe
the above precautions.
UB1JE0E0.book Page 2 Tuesday, February 13, 2018 9:12 AM

Page: 10

Safety information
1-3
1
Avoid Carbon Monoxide Poisoning
All engine exhaust contains carbon
monoxide, a deadly gas. Breathing
carbon monoxide can cause head-
aches, dizziness, drowsiness, nausea,
confusion, and eventually death.
Carbon Monoxide is a colorless, odor-
less, tasteless gas which may be pres-
ent even if you do not see or smell any
engine exhaust. Deadly levels of car-
bon monoxide can collect rapidly and
you can quickly be overcome and un-
able to save yourself. Also, deadly lev-
els of carbon monoxide can linger for
hours or days in enclosed or poorly
ventilated areas. If you experience any
symptoms of carbon monoxide poi-
soning, leave the area immediately, get
fresh air, and SEEK MEDICAL TREAT-
MENT.
 Do not run engine indoors. Even if
you try to ventilate engine exhaust
with fans or open windows and
doors, carbon monoxide can rap-
idly reach dangerous levels.
 Do not run engine in poorly venti-
lated or partially enclosed areas
such as barns, garages, or car-
ports.
 Do not run engine outdoors where
engine exhaust can be drawn into
a building through openings such
as windows and doors.
Loading
Adding accessories or cargo to your
motorcycle can adversely affect stabil-
ity and handling if the weight distribu-
tion of the motorcycle is changed. To
avoid the possibility of an accident, use
extreme caution when adding cargo or
accessories to your motorcycle. Use
extra care when riding a motorcycle
that has added cargo or accessories.
Here, along with the information about
accessories below, are some general
guidelines to follow if loading cargo to
your motorcycle:
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
Operation of an overloaded vehicle
could cause an accident.
When loading within this weight limit,
keep the following in mind:
 Cargo and accessory weight
should be kept as low and close to
the motorcycle as possible. Se-
curely pack your heaviest items as
close to the center of the vehicle
as possible and make sure to dis-
tribute the weight as evenly as
possible on both sides of the mo-
torcycle to minimize imbalance or
instability.
 Shifting weights can create a sud-
den imbalance. Make sure that
accessories and cargo are se-
curely attached to the motorcycle
before riding. Check accessory
mounts and cargo restraints fre-
quently.
• Properly adjust the suspension
for your load (suspension-ad-
justable models only), and
check the condition and pres-
sure of your tires.
• Never attach any large or heavy
items to the handlebar, front
fork, or front fender. These
items, including such cargo as
sleeping bags, duffel bags, or
Maximum load:
179 kg (395 lb)
UB1JE0E0.book Page 3 Tuesday, February 13, 2018 9:12 AM

Page: 11

Safety information
1-4
1
tents, can create unstable han-
dling or a slow steering re-
sponse.
 This vehicle is not designed to
pull a trailer or to be attached to
a sidecar.
Genuine Yamaha Accessories
Choosing accessories for your vehicle
is an important decision. Genuine
Yamaha accessories, which are avail-
able only from a Yamaha dealer, have
been designed, tested, and approved
by Yamaha for use on your vehicle.
Many companies with no connection
to Yamaha manufacture parts and ac-
cessories or offer other modifications
for Yamaha vehicles. Yamaha is not in
a position to test the products that
these aftermarket companies produce.
Therefore, Yamaha can neither en-
dorse nor recommend the use of ac-
cessories not sold by Yamaha or
modifications not specifically recom-
mended by Yamaha, even if sold and
installed by a Yamaha dealer.
Aftermarket Parts, Accessories, and
Modifications
While you may find aftermarket prod-
ucts similar in design and quality to
genuine Yamaha accessories, recog-
nize that some aftermarket accesso-
ries or modifications are not suitable
because of potential safety hazards to
you or others. Installing aftermarket
products or having other modifications
performed to your vehicle that change
any of the vehicle’s design or operation
characteristics can put you and others
at greater risk of serious injury or
death. You are responsible for injuries
related to changes in the vehicle.
Keep the following guidelines in mind,
as well as those provided under “Load-
ing” when mounting accessories.
 Never install accessories or carry
cargo that would impair the per-
formance of your motorcycle.
Carefully inspect the accessory
before using it to make sure that it
does not in any way reduce
ground clearance or cornering
clearance, limit suspension travel,
steering travel or control opera-
tion, or obscure lights or reflec-
tors.
• Accessories fitted to the han-
dlebar or the front fork area can
create instability due to improp-
er weight distribution or aerody-
namic changes. If accessories
are added to the handlebar or
front fork area, they must be as
lightweight as possible and
should be kept to a minimum.
• Bulky or large accessories may
seriously affect the stability of
the motorcycle due to aerody-
namic effects. Wind may at-
tempt to lift the motorcycle, or
the motorcycle may become
unstable in cross winds. These
accessories may also cause in-
stability when passing or being
passed by large vehicles.
• Certain accessories can dis-
place the operator from his or
her normal riding position. This
improper position limits the
freedom of movement of the
UB1JE0E0.book Page 4 Tuesday, February 13, 2018 9:12 AM

Page: 12

Safety information
1-5
1
operator and may limit control
ability, therefore, such accesso-
ries are not recommended.
 Use caution when adding electri-
cal accessories. If electrical ac-
cessories exceed the capacity of
the motorcycle’s electrical sys-
tem, an electric failure could re-
sult, which could cause a
dangerous loss of lights or engine
power.
Aftermarket Tires and Rims
The tires and rims that came with your
motorcycle were designed to match
the performance capabilities and to
provide the best combination of han-
dling, braking, and comfort. Other
tires, rims, sizes, and combinations
may not be appropriate. See page 6-16
for tire specifications and for informa-
tion on servicing and replacing your
tires.
Transporting the Motorcycle
Be sure to observe following instruc-
tions before transporting the motorcy-
cle in another vehicle.
 Remove all loose items from the
motorcycle.
 Check that the fuel cock (if
equipped) is in the off position and
that there are no fuel leaks.
 Shift the transmission into gear
(for models with a manual trans-
mission).
 Secure the motorcycle with tie-
downs or suitable straps that are
attached to solid parts of the mo-
torcycle, such as the frame or up-
per front fork triple clamp (and not,
for example, to rubber-mounted
handlebars or turn signals, or
parts that could break). Choose
the location for the straps carefully
so the straps will not rub against
painted surfaces during transport.
 The suspension should be com-
pressed somewhat by the tie-
downs, if possible, so that the mo-
torcycle will not bounce exces-
sively during transport.
UB1JE0E0.book Page 5 Tuesday, February 13, 2018 9:12 AM

Page: 13

Description
2-1
2
EAU10411
Left view
1 2 3 4,5
6
10
11 8 7
9
1. Windshield (page 3-38)
2. Battery (page 6-29)
3. Fuses (page 6-31)
4. Storage compartment (page 3-38)
5. Tool kit (page 6-2)
6. Seat lock (page 3-34)
7. Spring preload adjuster (page 3-41)
8. Rebound damping force adjuster (page 3-41)
9. Shift pedal (page 3-26)
10.Engine oil drain bolt (page 6-11)
11.Engine oil filter cartridge (page 6-11)
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Description
2-2
2
EAU10421
Right view
1 2 3,4,5 6 7
8
9
10
11
1. Rear brake fluid reservoir (page 6-21)
2. Fuel tank cap (page 3-30)
3. Rebound damping force adjuster (page 3-39)
4. Spring preload adjuster (page 3-39)
5. Compression damping force adjuster (page 3-39)
6. Headlight (page 6-33)
7. Fuses (page 6-31)
8. Coolant reservoir (page 6-13)
9. Engine oil level check window (page 6-11)
10.Engine oil filler cap (page 6-11)
11.Brake pedal (page 3-27)
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Description
2-3
2
EAU10431
Controls and instruments
1 2 7
8,9
9 10
6
5
3 4
1. Clutch lever (page 3-25)
2. Left handlebar switches (page 3-3)
3. Auxiliary DC jack (page 3-43)
4. Instrument panel (page 3-5, 3-11)
5. Front brake fluid reservoir (page 6-21)
6. Right handlebar switches (page 3-3)
7. Brake lever (page 3-26)
8. Throttle grip (page 6-15)
9. Grip warmer (page 3-14)
10.Main switch/steering lock (page 3-2)
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Instrument and control functions
3-1
3
EAU10979
Immobilizer system
This vehicle is equipped with an immo-
bilizer system to help prevent theft by
re-registering codes in the standard
keys. This system consists of the fol-
lowing:
 a code re-registering key
 two standard keys
 a transponder (in each key)
 an immobilizer unit (on the vehicle)
 an ECU (on the vehicle)
 a system indicator light (page 3-7)
About the keys
The key with the red bow is used to
register codes in each standard key.
Store the code re-registering key in a
safe place. When necessary, take the
vehicle along with all three keys to a
Yamaha dealer to have them re-regis-
tered.
Do not use the key with the red bow for
driving. It should only be used for re-
registering the standard keys. Always
use a standard key for driving.
TIP
 Keep the standard keys as well as
keys of other immobilizer systems
away from the code re-registering
key.
 Keep other immobilizer system
keys away from the main switch
as they may cause signal interfer-
ence.
NOTICE
ECA11823
DO NOT LOSE THE CODE RE-REG-
ISTERING KEY! CONTACT YOUR
DEALER IMMEDIATELY IF IT IS
LOST! If the code re-registering key
is lost, the existing standard keys
can still be used to start the vehicle.
However, registering a new stan-
dard key is impossible. If all keys
have been lost or damaged, the en-
tire immobilizer system must be re-
placed. Therefore, handle the keys
carefully.
 Do not submerse in water.
 Do not expose to high tempera-
tures.
 Do not place near magnets.
 Do not place near items that
transmit electrical signals.
 Do not handle roughly.
 Do not grind or alter.
 Do not disassemble.
 Do not put two keys of any im-
mobilizer system on the same
key ring.
1. Code re-registering key (red bow)
2. Standard keys (black bow)
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Instrument and control functions
3-2
3
EAU10474
Main switch/steering lock
The main switch/steering lock controls
the ignition and lighting systems, and is
used to lock the steering. The various
positions are described below.
TIP
Be sure to use the standard key (black
bow) for regular use of the vehicle. To
minimize the risk of losing the code re-
registering key (red bow), keep it in a
safe place and only use it for code re-
registering.
EAU84031
ON
All electrical circuits are supplied with
power and the vehicle lights are turned
on. The engine can be started. The key
cannot be removed.
TIP
 The headlight(s) will turn on when
the engine is started.
 To prevent battery drain, do not
leave the key in the on position
without the engine running.
EAU10662
OFF
All electrical systems are off. The key
can be removed.
WARNING
EWA10062
Never turn the key to “OFF” or
“LOCK” while the vehicle is moving.
Otherwise the electrical systems will
be switched off, which may result in
loss of control or an accident.
EAU1068B
LOCK
The steering is locked and all electrical
systems are off. The key can be re-
moved.
To lock the steering
1. Turn the handlebars all the way to
the left.
2. With the key in the “OFF” position,
push the key in and turn it to
“LOCK”.
3. Remove the key.
P
ON
OFF
LOCK
1. Push.
2. Turn.
1 2
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Instrument and control functions
3-3
3
TIP
If the steering will not lock, try turning
the handlebars back to the right slight-
ly.
To unlock the steering
From the “LOCK” position, push the
key in and turn it to “OFF”.
EAU59680
(Parking)
The hazard lights and turn signal lights
can be turned on, but all other electri-
cal systems are off. The key can be re-
moved.
The steering must be locked before the
key can be turned to “ ”.
NOTICE
ECA20760
Using the hazard or turn signal lights
for an extended length of time may
cause the battery to discharge.
EAU66055
Handlebar switches
Left
1. Push.
2. Turn.
1 2
1. Drive mode switch “MODE”
2. TCS switch “ / ”
3. Cruise control switches
4. Hazard switch “ ”
5. Horn switch “ ”
6. Turn signal switch “ / ”
7. Dimmer/Pass switch “ / /PASS”
2
3
4
5
1
7
6
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Instrument and control functions
3-4
3
Right
EAU73921
Dimmer/Pass switch “ / /PASS”
Set this switch to “ ” for the high
beam and to “ ” for the low beam.
To flash the high beam, push the pass
side “PASS” of the switch while the
headlights are on low beam.
EAU66040
Turn signal switch “ / ”
To signal a right-hand turn, push this
switch to “ ”. To signal a left-hand
turn, push this switch to “ ”. When
released, the switch returns to the cen-
ter position. To cancel the turn signal
lights, push the switch in after it has re-
turned to the center position.
EAU66030
Horn switch “ ”
Press this switch to sound the horn.
EAU84240
TCS switch “ / ”
See page 3-28 for an explanation of
the traction control system.
EAU66060
Stop/Run/Start switch “ / / ”
To crank the engine with the starter,
set this switch to “ ”, and then push
the switch down towards “ ”. See
page 5-1 for starting instructions prior
to starting the engine.
Set this switch to “ ” to stop the en-
gine in case of an emergency, such as
when the vehicle overturns or when the
throttle cable is stuck.
EAU66010
Hazard switch “ ”
With the key in the “ON” or “ ” posi-
tion, use this switch to turn on the haz-
ard lights (simultaneous flashing of all
turn signal lights).
The hazard lights are used in case of an
emergency or to warn other drivers
when your vehicle is stopped where it
might be a traffic hazard.
NOTICE
ECA10062
Do not use the hazard lights for an
extended length of time with the en-
gine not running, otherwise the bat-
tery may discharge.
EAU84250
Cruise control switches
See page 3-8 for an explanation of the
cruise control system.
EAU84260
Drive mode switch “MODE”
See page 3-25 for an explanation of
the drive mode.
EAU84271
Wheel switch “ ”
When the display is set to the main
screen, use the wheel switch to scroll
and reset the information display items
and to set the grip warmers.
When the display has been changed to
the MENU screen, use the wheel
switch to navigate the setting modules
and make setting changes.
Operate the wheel switch as follows.
Rotate up — rotate the wheel upward to
scroll up or increase a setting value.
1. Stop/Run/Start switch “ / / ”
2. Wheel switch “ ”
1
2
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Instrument and control functions
3-5
3
Rotate down — rotate the wheel down-
ward to scroll down or decrease a set-
ting value.
Short push — briefly press the switch
inward to make and confirm selec-
tions.
Long push — press the switch inward
for one second to reset an information
display item or to access and exit the
MENU screen.
TIP
 The MENU screen can be ac-
cessed by long pushing the wheel
switch except when the grip
warmer display is selected or the
fuel tripmeter (F-TRIP) is dis-
played.
 See page 3-11 for more informa-
tion on the main screen and its
functions.
 See page 3-15 for more informa-
tion on the MENU screen and how
to make setting changes.
EAU4939F
Indicator lights and warning
lights
EAU11032
Turn signal indicator lights “ ”
and “ ”
Each indicator light will flash when its
corresponding turn signal lights are
flashing.
EAU11061
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
EAU11081
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU58402
Cruise control indicator lights “ ”
and “SET”
These indicator lights come on when
the cruise control system is activated.
(See page 3-8.)
TIP
When the vehicle is turned on, these
lights should come on for a few sec-
onds and then go off. If the lights do
not come on, have a Yamaha dealer
check the vehicle.
EAU79310
Engine trouble warning light “ ”
This warning light comes on if a prob-
lem is detected in the engine. If this oc-
curs, have a Yamaha dealer check the
on-board diagnostic system.
1. Traction control system indicator light “ ”
2. Engine oil and Coolant warning light “ ”
3. Cruise control indicator lights “ ” “SET”
4. Shift indicator light
5. High beam indicator light “ ”
6. ABS warning light “ ”
7. Engine trouble warning light “ ”
8. Right turn signal indicator light “ ”
9. Left turn signal indicator light “ ”
10.Neutral indicator light “ ”
11.Immobilizer system indicator light “ ”
9 8
10 7 6
11
1 3 4 5
2
ABS
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Instrument and control functions
3-6
3
The electrical circuit of the warning
light can be checked by turning the ve-
hicle power on. The warning light
should come on for a few seconds,
and then go off.
If the warning light does not come on at
all, or if the warning light remains on,
have a Yamaha dealer check the vehi-
cle.
EAU69891
ABS warning light “ ”
In normal operation, this warning light
comes on when the key is turned to
“ON”, and goes off after traveling at a
speed of 10 km/h (6 mi/h) or higher.
If the ABS warning light:
 does not come on when the key is
turned to “ON”
 comes on or flashes while riding
 does not go off after traveling at a
speed of 10 km/h (6 mi/h) or high-
er
The ABS may not work correctly. If any
of the above occurs, have a Yamaha
dealer check the system as soon as
possible. (See page 3-27 for an expla-
nation of the ABS.)
WARNING
EWA16041
If the ABS warning light does not go
off after traveling at a speed of 10
km/h (6 mi/h) or higher, or if the
warning light comes on or flashes
while riding, the brake system re-
verts to conventional braking. If ei-
ther of the above occurs, or if the
warning light does not come on at
all, use extra caution to avoid possi-
ble wheel lock during emergency
braking. Have a Yamaha dealer
check the brake system and electri-
cal circuits as soon as possible.
EAU73272
Traction control system indicator
light “ ”
In normal operation, this indicator light
is off. When traction control has en-
gaged, this indicator light will flash for
a few seconds and then go off.
When the traction control system is
turned off, this indicator light will come
on.
If the traction control system becomes
disabled while riding, or if a problem is
detected in the traction control system,
this indicator light and the engine trou-
ble warning light will come on. (See
page 3-28 for an explanation of the
traction control system.)
EAU67432
Shift indicator light
This indicator light comes on when it is
time to shift to the next higher gear.
The engine speeds at which it comes
on or goes off can be adjusted. (See
page 3-18.)
As a self-check, the light will come on
briefly when the vehicle is first powered
on.
ABS
1. Traction control system indicator light “ ”
2. Engine trouble warning light “ ”
1 2
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Instrument and control functions
3-7
3
EAU73120
Immobilizer system indicator
light “ ”
When the key is turned to “OFF” and
30 seconds have passed, the indicator
light will flash steadily to indicate the
immobilizer system is enabled. After 24
hours have passed, the indicator light
will stop flashing, however the immobi-
lizer system is still enabled.
The electrical circuit of the indicator
light can be checked by turning the key
to “ON”. The indicator light should
come on for a few seconds, and then
go off.
If the indicator light does not come on
initially when the key is turned to “ON”,
if the indicator light remains on, or if the
indicator light flashes in a pattern (if a
problem is detected in the immobilizer
system, the immobilizer system indica-
tor light will flash in a pattern), have a
Yamaha dealer check the vehicle.
TIP
If the immobilizer system indicator light
flashes in the pattern, slowly 5 times
then quickly 2 times, this could be
caused by transponder interference. If
this occurs, try the following.
1. Make sure there are no other im-
mobilizer keys close to the main
switch. Other immobilizer system
keys may cause signal interfer-
ence and prevent the engine from
starting.
2. Use the code re-registering key to
start the engine.
3. If the engine starts, turn it off, and
try starting the engine with the
standard keys.
4. If one or both of the standard keys
do not start the engine, take the
vehicle and all 3 keys to a Yamaha
dealer to have the standard keys
re-registered.
EAU84281
Engine oil and Coolant warning
light “ ”
This warning light comes on if the en-
gine oil level is low or if the coolant
temperature is high. If this occurs, stop
the engine immediately.
When the vehicle is turned on, the
warning light should come on for a few
seconds, and then go off. If the warn-
ing light does not come on, have a
Yamaha dealer check the vehicle.
NOTICE
ECA26391
If the engine oil and coolant warning
light comes on while the engine is
running, stop the vehicle and engine
immediately.
 If the engine is overheating, the
coolant temperature warning
icon will come on. Let the en-
gine cool. Check the coolant
level (see page 6-37).
 If the engine oil level is low, the
engine oil warning icon will
come on. Check the oil level
(see page 6-11).
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Instrument and control functions
3-8
3
 If the warning light remains on
after letting the engine cool and
confirming the proper oil level,
have a Yamaha dealer check
the vehicle. Do not continue to
operate the vehicle!
EAU84290
Cruise control system
This model is equipped with a cruise
control system designed to maintain a
set cruising speed.
The cruise control system operates
only when riding in 4th, 5th or 6th gear
at speeds between about 50 km/h (31
mi/h) and 160 km/h (100 mi/h).
WARNING
EWA16341
 Improper use of the cruise con-
trol system may result in loss of
control, which could lead to an
accident. Do not activate the
cruise control system in heavy
traffic, poor weather conditions,
or among winding, slippery,
hilly, rough or gravel roads.
 When traveling uphill or down-
hill, the cruise control system
may not be able to maintain the
set cruising speed.
 To prevent accidentally activat-
ing the cruise control system,
turn it off when not in use. Make
sure that the cruise control sys-
tem indicator light “ ” is off.
1. Cruise control setting indicator light “SET”
2. Cruise control system indicator light “ ”
1. Cruise control setting switch “RES+/SET–”
2. Cruise control power switch “ ”
1 2
1
2
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Instrument and control functions
3-9
3
Activating and setting the cruise
control system
1. Push the cruise control power
switch “ ” located on the left
handlebar. The cruise control sys-
tem indicator light “ ” will come
on.
2. Push the “SET–” side of the cruise
control setting switch to activate
the cruise control system. Your
current traveling speed will be-
come the set cruising speed. The
cruise control setting indicator
light “SET” will come on.
Adjusting the set cruising speed
While the cruise control system is op-
erating, push the “RES+” side of the
cruise control setting switch to in-
crease the set cruising speed or the
“SET–” side to decrease the set speed.
TIP
Pushing the setting switch once will
change the speed in increments of ap-
proximately 2.0 km/h (1.2 mi/h). Hold-
ing the “RES+” or “SET–” side of the
cruise control setting switch down will
increase or decrease the speed contin-
uously until the switch is released.
You can also manually increase your
traveling speed using the throttle. After
you have accelerated, you can set a
new cruising speed by pushing the
“SET–” side of the setting switch. If you
do not set a new cruising speed, when
you return the throttle grip, the vehicle
will decelerate to the previously set
cruising speed.
Deactivating the cruise control sys-
tem
Perform one of the following opera-
tions to cancel the set cruising speed.
The “SET” indicator light will go off.
 Turn the throttle grip past the
closed position in the deceleration
direction.
1. Cruise control power switch “ ”
2. Cruise control system indicator light “ ”
2
1
1. Cruise control setting switch “RES+/SET–”
2. Cruise control setting indicator light “SET”
2
1
1. Deceleration direction
1
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Instrument and control functions
3-10
3
 Apply the front or rear brake.
 Disengage the clutch.
Push the power switch to turn off the
cruise control system. The “ ” indica-
tor light and the “SET” indicator light
will go off.
TIP
Traveling speed decreases as soon as
the cruise control system is deactivat-
ed; unless the throttle grip is turned.
Using the resume function
Push the “RES+” side of the cruise
control setting switch to reactivate the
cruise control system. The traveling
speed will return to the previously set
cruising speed. The “SET” indicator
light will come on.
WARNING
EWA16351
It is dangerous to use the resume
function when the previously set
cruising speed is too high for current
conditions.
TIP
Pushing the power switch while the
system is operating will turn the sys-
tem off completely and erase the previ-
ously set cruising speed. You will not
be able to use the resume function until
a new cruising speed has been set.
Automatic deactivation of the cruise
control system
The cruise control system for this mod-
el is electronically controlled and is
linked with the other control systems.
The cruise control system will auto-
matically become deactivated under
the following conditions:
 The cruise control system is not
able to maintain the set cruising
speed.
 Wheel slip or wheel spin is detect-
ed. (If the traction control system
has not been turned off, the trac-
tion control system will work.)
 The start/engine stop switch is set
to the “ ” position.
 The engine stalls.
 The sidestand is lowered.
When traveling with a set cruising
speed, if the cruise control system is
deactivated under the above condi-
tions, the “ ” indicator light will go off
and the “SET” indicator light will flash
for 4 seconds, and then go off.
When not traveling with a set cruising
speed, if the start/engine stop switch is
set to the “ ” position, the engine
stalls, or the sidestand is lowered, then
the “ ” indicator light will go off (the
“SET” indicator light will not flash).
If the cruise control system is automat-
ically deactivated, please stop and
confirm that your vehicle is in good op-
erating condition.
Before using the cruise control system
again, activate it using the power
switch.
TIP
In some cases, the cruise control sys-
tem may not be able to maintain the set
cruising speed when the vehicle is
traveling uphill or downhill.
 When the vehicle is traveling up-
hill, the actual traveling speed may
become lower than the set cruis-
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Instrument and control functions
3-11
3
ing speed. If this occurs, acceler-
ate to the desired traveling speed
using the throttle.
 When the vehicle is traveling
downhill, the actual traveling
speed may become higher than
the set cruising speed. If this oc-
curs, the setting switch cannot be
used to adjust the set cruising
speed. To reduce the traveling
speed, apply the brakes. When
the brakes are applied, the cruise
control system will become deac-
tivated.
EAU84301
Display
The following items can be found on
the display.
 Speedometer
 Tachometer
 Fuel meter
 Information display
 Transmission gear display
 Drive mode display
 TCS display
 Air temperature display
 Grip warmer display
 QS indicator
 Clock
 Revolution peak hold indicator
 Eco indicator
 Fuel level warning icon
 Engine oil warning icon
 Coolant temperature warning icon
TIP
This model uses a thin-film-transistor
liquid-crystal display (TFT LCD) for
good contrast and readability in vari-
ous lighting conditions. However, due
to the nature of this technology, it is
normal for a small number of pixels to
be inactive.
1. Tachometer
2. QS indicator
3. Speedometer
4. Revolution peak hold indicator
5. Clock
6. Fuel meter
7. Eco indicator “ECO”
8. Grip warmer display
9. Air temperature display
10.Transmission gear display
11.TCS display
12.Drive mode display
13.Information display
km
TRIP-2
TRIP-1
1234.5
1234.5
km
1 N 2
km/h
1000 r/min
QS 12:00
E
ECO
F
2
/
1
MODE-STD TCS 1 In °C 25
7
10
13 8
9
11
12
1 6
4
2 5
3
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Instrument and control functions
3-12
3
WARNING
EWA18210
Stop the vehicle before making any
setting changes. Changing settings
while riding can distract the opera-
tor and increase the risk of an acci-
dent.
Speedometer
The speedometer shows the vehicle’s
traveling speed.
TIP
The display can be set to miles or kilo-
meters. Use the “Unit” module on the
MENU screen.
Tachometer
The tachometer shows the engine
speed, as measured by the rotational
velocity of the crankshaft, in revolu-
tions per minute (r/min). When the ve-
hicle is first powered on, the
tachometer will sweep across the r/min
range and then return to zero.
TIP
The tachometer can be color-adjusted
and has a revolution peak hold indica-
tor which can be turned on or off.
NOTICE
ECA10032
Do not operate the engine in the ta-
chometer red zone.
Red zone: 11250 r/min and above
Fuel meter
The fuel meter indicates the amount of
fuel in the fuel tank. The display seg-
ments of the fuel meter disappear from
“F” (full) towards “E” (empty) as the fuel
level decreases.
When the last segment starts flashing
and the fuel level warning icon comes
on, refuel as soon as possible.
TIP
If all the fuel meter display segments
flash repeatedly, have a Yamaha deal-
er check the related circuits.
Clock
The clock uses a 12-hour time system.
Information display
This section of the main screen is used
to show additional riding related infor-
mation such as air and coolant temper-
ature readings, tripmeters, and fuel
consumption statistics. The informa-
tion display items can be set into four
groups via the MENU screen.
The information display items are:
A.TEMP: air temperature
C.TEMP: coolant temperature
TRIP-1: tripmeter 1
TRIP-2: tripmeter 2
F-TRIP: fuel tripmeter
ODO: odometer
FUEL CON: the amount of fuel con-
sumed
FUEL AVG: average fuel consumption
CRNT FUEL: current fuel consumption
TIP
 ODO will lock at 999999.
 TRIP-1 and TRIP-2 will reset and
continue counting after 9999.9
has been reached.
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Instrument and control functions
3-13
3
 When the fuel tank reserve level
has been reached, F-TRIP ap-
pears automatically and begins
recording distance traveled from
that point.
 After refueling and traveling some
distance, F-TRIP will automatically
disappear.
 See “Unit” on page 3-16 to
change the fuel consumption
units, set the clock, and switch
between miles and kilometers,
etc.
TRIP-1, TRIP-2, F-TRIP, FUEL CON,
and FUEL AVG items can be individu-
ally reset.
To reset information display items
1. Use the wheel switch to scroll
through the display items until the
item you want to reset appears.
2. Short push the wheel switch and
the item will flash for five seconds.
If both items are resettable items,
the top item will flash first. Scroll
down to select the bottom item.
3. While the item is flashing, press
and hold the wheel switch for one
second.
Transmission gear display
This shows which gear the transmis-
sion is in. This model has 6 gears and a
neutral position. The neutral position is
indicated by the neutral indicator
light “ ” and by the transmission gear
display “ ”.
Revolution peak hold indicator
This small bar momentarily appears
within the tachometer to mark the most
recent peak r/min speed of the engine.
TIP
The indicator comes on momentarily
only if the peak engine speed is 7000
r/min or higher.
QS indicator
When the key is turned to “ON”, the
quick shift system (page 3-26) turns on
and this indicator comes on.
TIP
If a problem is detected in the quick
shift system, this indicator will turn off
and the quick shift system will be un-
available. Have a Yamaha dealer check
the vehicle.
Eco indicator
This indicator comes on when the vehi-
cle is being operated in an environ-
mentally friendly, fuel-efficient manner.
The indicator goes off when the vehicle
is stopped.
TIP
Consider the following tips to reduce
fuel consumption:
 Avoid high engine speeds during
acceleration.
 Travel at a constant speed.
 Select the transmission gear that
is appropriate for the vehicle
speed.
Drive mode display
This display indicates which drive
mode has been selected: “STD”, “A” or
“B”. (See page 3-25.)
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Instrument and control functions
3-14
3
TCS display
This display indicates which traction
control system setting has been se-
lected: “1”, “2” or “OFF”. (See page
3-28.)
Air temperature display
This display indicates the air tempera-
ture from –9 °C to 50 °C in 1 °C incre-
ments.
TIP
 –9 °C will be displayed even if the
air temperature falls below –9 °C.
 50 °C will be displayed even if the
ambient temperature climbs
above 50 °C.
 The temperature displayed may
vary from the actual ambient tem-
perature.
Grip warmer display
The grip warmers can be used when
the engine is running. There are 4 grip
warmer settings.
To change the grip warmer setting
1. Select the grip warmer display.
2. Short push the wheel switch, and
then rotate the wheel switch up or
down to change the setting while
the display is flashing. Short push
the wheel switch to confirm the
setting.
TIP
Each grip warmer setting can be fine
tuned in “Grip Warmer Setting” (see
page 3-23).
NOTICE
ECA17932
 Be sure to wear gloves when
using the grip warmers.
 Do not use the grip warmers in
warm weather.
 If the handlebar grip or throttle
grip becomes worn or dam-
aged, stop using the grip warm-
ers and replace the grips.
Warning icons
Coolant temperature warning “ ”
This icon comes on if the coolant tem-
perature reaches 117 °C or higher.
Stop the vehicle and turn off the en-
gine. Allow the engine to cool.
NOTICE
ECA10022
Do not continue to operate the en-
gine if it is overheating.
Display Setting
Off
Low
Middle
High
1. Coolant temperature warning “ ”
2. Engine oil warning “ ”
3. Fuel level warning “ ”
1000 r/min
QS 12:00
2 3
1
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Instrument and control functions
3-15
3
Engine oil warning “ ”
This icon comes on when the engine oil
level is low. Stop the vehicle and cor-
rect the engine oil level.
When the vehicle is turned on, this icon
will come on for a few seconds, and
then go off.
If a malfunction is detected, the oil level
warning icon will flash repeatedly.
Have a Yamaha dealer check the vehi-
cle.
NOTICE
ECA26400
Do not continue to operate the en-
gine if the oil level is low.
Fuel level warning “ ”
This icon comes on when approxi-
mately 2.6 L (0.69 US gal, 0.57 Imp.gal)
of fuel remains in the tank.
If a malfunction is detected, the fuel
level warning icon will flash repeatedly.
Have a Yamaha dealer check the vehi-
cle.
EAU84311
MENU screen
The MENU screen contains the follow-
ing setting modules. Select a module
to make related setting changes. Al-
though some settings can be changed
or reset via the main screen, the MENU
screen offers access to all display and
control settings.
MENU access and operation
The following wheel switch operations
are common operations for accessing,
selecting, and moving within the
MENU screen and its modules.
Long push — press and hold the wheel
switch for one second to access the
MENU screen or exit MENU entirely.
Select — rotate the wheel switch up or
down to highlight the desired module
or setting item and then short push the
wheel switch (briefly press the wheel
switch inward) to confirm the selection.
Triangle mark — certain setting
screens have an upward pointing trian-
gle mark item. Select the triangle mark
to exit that screen and move back one
screen (or long push the wheel switch
to exit MENU entirely).
Module Description
View and reset three main-
tenance item intervals.
Set fuel consumption
units.
Set background color.
Turn the shift indicator
on/off and adjust tachom-
eter settings.
Set the multi-function dis-
play window items.
Adjust screen brightness.
12:00
MENU
km/h
Brightness
Display Setting
Shift Indicator
Wallpaper
Unit
Maintenance
Maintenance
Maintenance
Unit
Wallpaper
Shift Indicator
Display Setting
Brightness
Set the low, middle, and
high settings to 10 tem-
perature levels.
Adjust the clock.
Return all settings to fac-
tory default settings.
Grip Warmer
Setting
Clock
All Reset
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Instrument and control functions
3-16
3
TIP
 The MENU screen can be ac-
cessed by long pushing the wheel
switch, except when the grip
warmer display is selected or the
fuel tripmeter (F-TRIP) is dis-
played.
 Should vehicle motion be detect-
ed, the screen will automatically
exit MENU and change to the
main screen.
“Maintenance”
This module allows you to record dis-
tance traveled between engine oil
changes (use the OIL item), and for two
other items of your choice (use INTER-
VAL 1 and INTERVAL 2).
To reset a maintenance item
1. From the MENU screen, select
“Maintenance”.
2. Select the item you want to reset.
3. Long push the wheel switch to re-
set the item.
TIP
Maintenance item names cannot be
changed.
“Unit”
This module allows you to switch the
display between kilometers and miles.
When using kilometers, the fuel con-
sumption units can be changed be-
tween km/L or L/100km. When using
miles, MPG will be available.
To set the distance or fuel consump-
tion units
1. From the MENU screen, select
“Unit”.
12:00
MENU
km/h
Brightness
Display Setting
Shift Indicator
Wallpaper
Unit
Maintenance
Maintenance
INTERVAL 2
OIL
INTERVAL 1 123456 km
123456 km
123456 km
Maintenance
km/h GPS 12:00
INTERVAL 2
OIL
INTERVAL 1
0 km
123456 km
123456 km
Maintenance
km/h GPS 12:00
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Instrument and control functions
3-17
3
2. Select the distance or consump-
tion unit item you want to adjust.
TIP
When “km” is selected, “km/L” or
“L/100km” can be set as the fuel con-
sumption units. To set the fuel con-
sumption units, proceed as follows. If
“mile” is selected, skip step 3.
3. Select the units you want to use.
4. Select the triangle symbol to exit.
“Wallpaper”
This module allows you to set the main
screen background color to black or
white for both the day and night set-
tings. A photo sensor equipped in the
instrument panel detects lighting con-
ditions and will automatically change
the display between its day and night
settings. The photo sensor also con-
trols a subtle automatic brightness ad-
justment function within both the day
and night modes to suit ambient light
conditions.
To set the wallpaper
1. From the MENU screen, select
“Wallpaper”.
2. Select the mode you want to ad-
just (select DAY for daytime dis-
play settings or NIGHT for
nighttime display settings).
12:00
MENU
km/h
Brightness
Display Setting
Shift Indicator
Wallpaper
Unit
Maintenance
Unit
km/L or L/100km
km or mile km
km/L
Unit
km/h GPS 12:00
km/L or L/100km
km or mile km
km/L
Unit
km/h GPS 12:00
1. Photo sensor
1
12:00
MENU
km/h
Brightness
Display Setting
Shift Indicator
Wallpaper
Unit
Maintenance
Wallpaper
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Instrument and control functions
3-18
3
3. Select the background color (se-
lect BLACK for a black back-
ground or WHITE for a white
background).
4. Select the triangle symbol to exit.
5. To set another background color,
repeat from step 2 or select the tri-
angle symbol to exit this module.
“Shift indicator”
The shift indicator module contains the
following items.
To make setting changes
1. Select “Shift IND Setting”.
2. Select “IND Mode”.
3. Select “ON” to have the indicator
light steadily, “OFF” to turn the in-
dicator off, or “Flash” to have the
shift indicator flash when the indi-
cator start threshold has been
reached.
12:00
Wallpaper
km/h
DAY
NIGHT
STREET MODE (day)
WHITE
Wallpaper
km/h GPS 12:00
BLACK
Display Description
Set the shift indicator pat-
tern to “ON”, “Flash”, or
“OFF” and adjust at what
r/min the indicator will
come on and go off.
Adjust the brightness of
the shift indicator.
Set the tachometer color
display to “ON” or “OFF”
and adjust at what r/min
the tachometer will be
green and orange.
Set the tachometer revolu-
tion peak hold indicator to
“ON” or “OFF”.
Shift IND
Setting
Shift IND
Brightness
Tach IND
Setting
Peak Rev IND
Setting
12:00
MENU
km/h
Brightness
Display Setting
Shift Indicator
Wallpaper
Unit
Maintenance
Shift Indicator
12:00
Shift Indicator
km/h
Tach IND Setting
Shift IND Setting
Peak Rev IND Setting
Shift IND Brightness
1000 r/min
12:00
Shift IND Setting
IND Mode
IND Start
IND Stop
ON
6000 r/min
12000 r/min
km/h Shift Indicator
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Instrument and control functions
3-19
3
4. Select “IND Start”.
5. Rotate the wheel switch to adjust
the r/min at which the shift indica-
tor light will come on. “IND Start”
operational range is 5000–12800
r/min.
6. Select “IND Stop” then rotate the
wheel switch to adjust the r/min at
which the shift indicator will go off.
“IND Stop” operational range is
5500–13000 r/min.
TIP
The blue area on the tachometer indi-
cates the currently set operational
range of the shift indicator light.
“Shift IND Brightness”
The shift indicator light has six bright-
ness levels.
Select “Shift IND Brightness”, then use
the wheel switch to adjust the setting.
Short push the wheel switch to confirm
the setting and exit.
“Tach IND Setting”
This module allows you to turn the ta-
chometer color display on or off. When
turned off, the tachometer will display
all r/min levels below the red zone in
1000 r/min
12:00
Shift IND Setting
IND Mode
IND Start
IND Stop
ON
6000 r/min
12000 r/min
km/h Shift Indicator
1000 r/min
12:00
Shift IND Setting
IND Mode
IND Start
IND Stop
ON
7000 r/min
12000 r/min
km/h Shift Indicator
1000 r/min
12:00
Shift IND Setting
IND Mode
IND Start
IND Stop
ON
8000 r/min
13000 r/min
km/h Shift Indicator 12:00
Shift Indicator
km/h
Tach IND Setting
Shift IND Setting
Peak Rev IND Setting
Shift IND Brightness
12:00
Shift Indicator
km/h
Shift IND Brightness
3
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Instrument and control functions
3-20
3
black or white (depending on wallpa-
per settings). When turned on, the mid
and mid-to-high r/min zones can be
set to come on in green and then or-
ange colors.
1. Select “Tach IND Setting”.
2. Select “IND Mode”.
3. Select ON to turn the tachometer
color display mode on (or select
OFF to turn this function off).
4. Select “Tach IND 1st” to set the
green zone starting r/min.
5. Set the starting r/min by rotating
and then short pushing the wheel
switch. All r/min above this value
up to the “Tach IND 2nd” setting
value (or the red zone), will be dis-
played in green.
TIP
Green bar start setting range: 5000–
11300 r/min.
6. Select “Tach IND 2nd”.
12:00
Shift Indicator
km/h
Tach IND Setting
Shift IND Setting
Peak Rev IND Setting
Shift IND Brightness
1000 r/min
12:00
km/h Shift Indicator
Tach IND Setting
IND Mode ON
5000 r/min
8000 r/min
Tach IND 1st
Tach IND 2nd
1000 r/min
12:00
km/h Shift Indicator
Tach IND Setting
IND Mode ON
5000 r/min
8000 r/min
Tach IND 1st
Tach IND 2nd
1000 r/min
12:00
km/h Shift Indicator
Tach IND Setting
IND Mode ON
5000 r/min
8000 r/min
Tach IND 1st
Tach IND 2nd
1000 r/min
12:00
km/h Shift Indicator
Tach IND Setting
IND Mode ON
5000 r/min
8000 r/min
Tach IND 1st
Tach IND 2nd
1000 r/min
12:00
km/h Shift Indicator
Tach IND Setting
IND Mode ON
5000 r/min
8000 r/min
Tach IND 1st
Tach IND 2nd
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Instrument and control functions
3-21
3
7. Set the orange color starting r/min
by rotating and then short pushing
the wheel switch. All r/min above
this figure until the red zone, will
be displayed in orange.
TIP
Orange bar start setting range: 5000–
11300 r/min.
8. Select the triangle symbol to exit.
“Peak Rev IND Setting”
This module allows you to turn the rev-
olution peak hold indicator on or off.
1. Select “Peak Rev IND Setting”.
2. Select “IND Mode” and then se-
lect ON (to turn on the indicator) or
OFF (to turn off the indicator).
3. Select the triangle symbol to exit.
“Display Setting”
This module allows you to set how the
information display items (like TRIP-1,
ODO, C. TEMP, etc.) are grouped on
the main screen. There are four display
groups.
To set the display groups
1. From the MENU screen, select
“Display Setting”.
1000 r/min
12:00
km/h Shift Indicator
Tach IND Setting
IND Mode ON
5000 r/min
8000 r/min
Tach IND 1st
Tach IND 2nd
1000 r/min
12:00
km/h Shift Indicator
Tach IND Setting
IND Mode ON
5000 r/min
8000 r/min
Tach IND 1st
Tach IND 2nd
12:00
Shift Indicator
km/h
Tach IND Setting
Shift IND Setting
Peak Rev IND Setting
Shift IND Brightness
Peak Rev IND Setting
IND Mode ON
Shift Indicator
km/h GPS 12:00
1. Information display
km
TRIP-2
TRIP-1
1234.5
1234.5
km
1 N 2
km/h
1000 r/min
QS 12:00
E
ECO
F
2
/
1
MODE-STD TCS 1 In °C 25
1
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Instrument and control functions
3-22
3
2. DISPLAY-1, DISPLAY-2, DIS-
PLAY-3 and DISPLAY-4 are dis-
played.
3. For example, let’s select DIS-
PLAY-1. 1-1 and 1-2 are dis-
played.
4. Select 1-1.
5. Select the desired information dis-
play item with the wheel switch.
 A.TEMP: air temperature
 C.TEMP: coolant tempera-
ture
 TRIP-1: tripmeter 1
 TRIP-2: tripmeter 2
 ODO: odometer
 FUEL CON: the amount of
fuel consumed
 FUEL AVG: average fuel con-
sumption
 CRNT FUEL: current fuel con-
sumption
6. Select 1-2 to set the remaining
DISPLAY-1 group item.
7. Select the triangle symbol to exit.
To set the other display groups,
repeat from step 3.
“Brightness”
This module allows you to adjust the
general brightness level of the display
screen.
To set the brightness
1. From the MENU screen, select
“Brightness”.
12:00
MENU
km/h
Brightness
Display Setting
Shift Indicator
Wallpaper
Unit
Maintenance
Display Setting
DISPLAY-1
1 — 1 A.TEMP
1 — 2 C.TEMP
Display Setting
km/h GPS 12:00
DISPLAY-1
1 — 1 A.TEMP
1 — 2 C.TEMP
Display Setting
km/h GPS 12:00
DISPLAY-1
1 — 1 A.TEMP
1 — 2 C.TEMP
Display Setting
km/h GPS 12:00
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Instrument and control functions
3-23
3
2. Select the desired brightness level
by rotating the wheel switch, and
then short push the wheel switch
to fix the setting.
“Grip Warmer Setting”
This module allows you to set the low,
middle, and high settings to 10 tem-
perature levels.
To set the grip warmer temperature
levels
1. From the MENU screen, select
“Grip Warmer Setting”.
2. Select “LO”, “MIDDLE”, or
“HIGH”.
3. Set the temperature level.
4. To set the temperature level for
another grip warmer setting, re-
peat from step 2 or select the tri-
angle symbol to exit this module.
“Clock”
This module allows you to set the
clock.
To set the clock
1. From the MENU screen, select
“Clock”.
12:00
MENU
km/h
Brightness
Display Setting
Shift Indicator
Wallpaper
Unit
Maintenance
Brightness
12:00
km/h Brightness
2
12:00
MENU
km/h
All Reset
Clock
Grip Warmer Setting
Brightness
Display Setting
Shift Indicator
Grip Warmer Setting
HIGH
LO
MIDDLE Level 5
Level 1
Level 10
km/h GPS 12:00
Grip Warmer Setting
HIGH
LO
MIDDLE
km/h GPS 12:00
Level 5
Level 1
Level 10
Grip Warmer Setting
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Instrument and control functions
3-24
3
2. When “Clock” is selected, the
hours figure will be highlighted.
3. Set the hour by rotating and then
short push the wheel switch.
4. The minutes figure will become
highlighted.
5. Set the minutes figure by rotating
and then short push the wheel
switch.
6. Short push the wheel switch again
to exit and go back to the MENU
screen.
“All Reset”
This module contains the all reset func-
tion which resets everything, except
the odometer and clock, to its factory
preset or default setting.
Select YES to reset all items. After se-
lecting YES, all items will be reset and
the display will automatically return to
the MENU screen.
12:00
MENU
km/h
All Reset
Clock
Grip Warmer Setting
Brightness
Display Setting
Shift Indicator
Clock
12:00
Clock
km/h
11 34
:
12:00
Clock
km/h
12 34
:
12:00
Clock
km/h
12 34
:
12:00
Clock
km/h
12 58
:
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Instrument and control functions
3-25
3
EAU84420
D-mode (drive mode)
D-mode is an electronically controlled
engine performance system with three
mode selections: “STD”, “A”, and “B”.
Push the drive mode switch “MODE”
to switch between modes. (See page
3-4.)
TIP
Before using D-mode, make sure you
understand its operation along with the
operation of the drive mode switch.
Mode “STD”
Mode “STD” is suitable for various rid-
ing conditions.
This mode allows the rider to enjoy
smooth and sporty drivability from the
low-speed range to the high-speed
range.
Mode “A”
Mode “A” offers a sportier engine re-
sponse in the low- to mid-speed range
compared to mode “STD”.
Mode “B”
Mode “B” offers response that is
somewhat less sharp compared to
mode “STD” for riding situations that
require especially sensitive throttle op-
eration.
EAU12822
Clutch lever
The clutch lever is located on the left
side of the handlebar. To disengage
the clutch, pull the lever toward the
handlebar grip. To engage the clutch,
release the lever. The lever should be
pulled rapidly and released slowly for
smooth clutch operation.
The clutch lever is equipped with a
clutch switch, which is part of the igni-
tion circuit cut-off system. (See page
3-45.)
1. Drive mode switch “MODE”
1
1. Clutch lever
1
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Instrument and control functions
3-26
3
EAU84320
Shift pedal
The shift pedal is located on the left
side of the motorcycle and is used in
combination with the clutch lever when
shifting the gears of the 6-speed con-
stant-mesh transmission.
When the quick shift system is turned
on, the shift switch senses shift pedal
movement and allows for upshifting
without operating the clutch lever. (See
page 3-26.)
EAU84330
Quick shift system
The quick shift system (QS) allows for
full-throttle, clutch lever-less, electron-
ically-assisted upshifts. When the shift
switch detects motion in the shift pedal
(page 3-26), engine power and drive
torque are momentarily adjusted to al-
low the upshift to occur.
TIP
 The quick shift system operates
when traveling at least 20 km/h (12
mi/h) with an engine speed of
2300 r/min or higher, and only
when accelerating.
 It does not operate when the
clutch lever is pulled.
EAU26826
Brake lever
The brake lever is located on the right
side of the handlebar. To apply the
front brake, pull the lever toward the
throttle grip.
The brake lever is equipped with a
brake lever position adjusting dial. To
adjust the distance between the brake
lever and the throttle grip, slightly pull
the brake lever away from the throttle
grip and rotate the adjusting dial. Make
sure the setting number on the adjust-
ing dial aligns with the match mark on
the brake lever.
1. Shift pedal
2. Shift switch
1
2
1. Brake lever
2. Distance
3. Brake lever position adjusting dial
4. Match mark
2
3 4
1
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Instrument and control functions
3-27
3
EAU12944
Brake pedal
The brake pedal is located on the right
side of the motorcycle. To apply the
rear brake, press down on the brake
pedal.
EAU63040
ABS
The Yamaha ABS (Anti-lock Brake
System) features a dual electronic con-
trol system, which acts on the front and
rear brakes independently.
Operate the brakes with ABS as you
would conventional brakes. If the ABS
is activated, a pulsating sensation may
be felt at the brake lever or brake ped-
al. In this situation, continue to apply
the brakes and let the ABS work; do
not “pump” the brakes as this will re-
duce braking effectiveness.
WARNING
EWA16051
Always keep a sufficient distance
from the vehicle ahead to match the
riding speed even with ABS.
 The ABS performs best with
long braking distances.
 On certain surfaces, such as
rough or gravel roads, the brak-
ing distance may be longer with
the ABS than without.
The ABS is monitored by an ECU,
which will revert the system to conven-
tional braking if a malfunction occurs.
TIP
 The ABS performs a self-diagno-
sis test each time the vehicle first
starts off after the key is turned to
“ON” and the vehicle has traveled
at a speed of 10 km/h (6 mi/h) or
higher. During this test, a “click-
ing” noise can be heard from the
hydraulic control unit, and if the
brake lever or brake pedal is even
slightly applied, a vibration can be
felt at the lever and pedal, but
these do not indicate a malfunc-
tion.
 This ABS has a test mode which
allows the owner to experience
the pulsation at the brake lever or
brake pedal when the ABS is op-
erating. However, special tools are
required, so please consult your
Yamaha dealer.
NOTICE
ECA20100
Be careful not to damage the wheel
sensor or wheel sensor rotor; other-
wise, improper performance of the
ABS will result.
1. Brake pedal
1
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Instrument and control functions
3-28
3
EAU84341
Traction control system
The traction control system (TCS)
helps maintain traction when acceler-
ating on slippery surfaces, such as un-
paved 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.
WARNING
EWA15433
The traction control system is not a
substitute for riding appropriately
for the conditions. Traction control
cannot prevent loss of traction due
to excessive speed when entering
turns, when accelerating hard at a
sharp lean angle, or while braking,
and cannot prevent front wheel slip-
ping. As with any vehicle, approach
surfaces that may be slippery with
caution and avoid especially slip-
pery surfaces.
The “ ” indicator light flashes when
traction control has engaged. You may
notice slight changes in engine and ex-
haust sounds when the system has en-
gaged.
1. Front wheel sensor
2. Front wheel sensor rotor
1. Rear wheel sensor
2. Rear wheel sensor rotor
1
2
1
2
1. TCS switch “ / ”
1. Traction control system indicator light “ ”
2. TCS display
1
km
TRIP-2
TRIP-1
1234.5
1234.5
km
1 N 2
km/h
1000 r/min
QS 12:00
E
ECO
F
2
/
1
MODE-STD TCS 1 In °C 25
1 2
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Instrument and control functions
3-29
3
When the traction control system has
been set to “OFF”, the “ ” indicator
light will come on.
The TCS display indicates the current
TCS setting. There are three settings.
TCS “OFF”
TCS “OFF” turns the traction control
system off.
TCS “1”
TCS “1” minimizes traction control
system assist.
TCS “2”
TCS “2” maximizes traction control as-
sist; wheel spin is most strongly con-
trolled.
TIP
 When the vehicle is turned on,
traction control is turned on and
set to “1” or “2” (whichever was
last selected).
 Turn the traction control system
off to help free the rear wheel if the
vehicle gets stuck in mud, sand, or
other soft surfaces.
NOTICE
ECA16801
Use only the specified tires. (See
page 6-16.) Using different sized
tires will prevent the traction control
system from controlling tire rotation
accurately.
Setting the traction control system
WARNING
EWA15441
Be sure to stop the vehicle before
making any setting changes to the
traction control system. Changing
settings while riding can distract the
operator and increase the risk of an
accident.
TCS settings can be changed only
when the vehicle is stopped and the
throttle closed.
 Push the TCS switch “ ” to
change the TCS setting to TCS
“1” and push the TCS switch “ ”
to change the TCS setting to TCS
“2”.
 Push the TCS switch “ ” for two
seconds to turn the traction con-
trol system off.
 Push the TCS switch “ ” to turn
traction control back on (TCS will
return to the previous setting).
Resetting the traction control sys-
tem
The traction control system will auto-
matically disable when:
 the front wheel or rear wheel
comes off the ground while riding.
 excessive rear wheel spin is de-
tected while riding.
 either wheel is rotated with the key
turned to “ON” (such as when per-
forming maintenance).
If the traction control system is dis-
abled, both the “ ” indicator light and
the “ ” warning light will come on.
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Instrument and control functions
3-30
3
Should this occur, try resetting the sys-
tem as follows.
1. Stop the vehicle and turn the key
to “OFF”.
2. Wait a few seconds and then turn
the key back to “ON”.
3. The “ ” indicator light should
turn off and the system be en-
abled.
TIP
If the “ ” indicator light remains on af-
ter resetting, the vehicle may still be
ridden; however, have a Yamaha deal-
er check the vehicle as soon as possi-
ble.
4. Have a Yamaha dealer check the
vehicle and turn off the “ ”
warning light.
EAU13076
Fuel tank cap
To open the fuel tank cap
Open the fuel tank cap lock cover, in-
sert the key into the lock, and then turn
it 1/4 turn clockwise. The lock will be
released and the fuel tank cap can be
opened.
To close the fuel tank cap
With the key still inserted in the lock,
push down the fuel tank cap. Turn the
key 1/4 turn counterclockwise, remove
it, and then close the lock cover.
1. Traction control system indicator light “ ”
2. TCS display
3. Engine trouble warning light “ ”
km
TRIP-2
TRIP-1
1234.5
1234.5
km
1 N 2
km/h
1000 r/min
QS 12:00
E
ECO
F
2
/
1
MODE-STD TCS 1 In °C 25
3
1 2
1. Fuel tank cap lock cover
2. Unlock.
1
2
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Instrument and control functions
3-31
3
TIP
The fuel tank cap cannot be closed un-
less the key is in the lock. In addition,
the key cannot be removed if the cap is
not properly closed and locked.
WARNING
EWA11092
Make sure that the fuel tank cap is
properly closed after filling fuel.
Leaking fuel is a fire hazard.
EAU13222
Fuel
Make sure there is sufficient gasoline in
the tank.
WARNING
EWA10882
Gasoline and gasoline vapors are
extremely flammable. To avoid fires
and explosions and to reduce the
risk of injury when refueling, follow
these instructions.
1. Before refueling, turn off the en-
gine and be sure that no one is sit-
ting on the vehicle. Never refuel
while smoking, or while in the vi-
cinity of sparks, open flames, or
other sources of ignition such as
the pilot lights of water heaters
and clothes dryers.
2. Do not overfill the fuel tank. When
refueling, be sure to insert the
pump nozzle into the fuel tank filler
hole. Stop filling when the fuel
reaches the bottom of the filler
tube. Because fuel expands when
it heats up, heat from the engine or
the sun can cause fuel to spill out
of the fuel tank.
3. Wipe up any spilled fuel immedi-
ately. NOTICE: Immediately
wipe off spilled fuel with a clean,
dry, soft cloth, since fuel may
deteriorate painted surfaces or
plastic parts.[ECA10072]
4. Be sure to securely close the fuel
tank cap.
WARNING
EWA15152
Gasoline is poisonous and can
cause injury or death. Handle gaso-
line with care. Never siphon gasoline
by mouth. If you should swallow
some gasoline or inhale a lot of gas-
oline vapor, or get some gasoline in
your eyes, see your doctor immedi-
1. Fuel tank filler tube
2. Maximum fuel level
1 2
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Instrument and control functions
3-32
3
ately. If gasoline spills on your skin,
wash with soap and water. If gaso-
line spills on your clothing, change
your clothes.
EAU75300
NOTICE
ECA11401
Use only unleaded gasoline. The use
of leaded gasoline will cause severe
damage to internal engine parts,
such as the valves and piston rings,
as well as to the exhaust system.
TIP
 This mark identifies the recom-
mended fuel for this vehicle as
specified by European regulation
(EN228).
 Check that gasoline nozzle has
the same identifier when fueling.
Your Yamaha engine has been de-
signed to use premium unleaded gas-
oline with a research octane number of
95 or higher. If knocking (or pinging)
occurs, use a gasoline of a different
brand. Use of unleaded fuel will extend
spark plug life and reduce mainte-
nance costs.
Gasohol
There are two types of gasohol: gaso-
hol containing ethanol and that con-
taining methanol. Gasohol containing
ethanol can be used if the ethanol con-
tent does not exceed 10% (E10). Gas-
ohol containing methanol is not
recommended by Yamaha because it
can cause damage to the fuel system
or vehicle performance problems.
Recommended fuel:
Premium unleaded gasoline (Gaso-
hol [E10] acceptable)
Fuel tank capacity:
18 L (4.8 US gal, 4.0 Imp.gal)
Fuel reserve amount:
2.6 L (0.69 US gal, 0.57 Imp.gal)
E10
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Instrument and control functions
3-33
3
EAU72972
Fuel tank overflow hose
Before operating the vehicle:
 Check the overflow hose connec-
tion and for damage.
 Confirm the overflow hose is not
blocked and is routed through the
clamp.
TIP
See page 6-11 for canister information.
EAU13434
Catalytic converter
This model is equipped with a catalytic
converter in the exhaust system.
WARNING
EWA10863
The exhaust system is hot after op-
eration. To prevent a fire hazard or
burns:
 Do not park the vehicle near
possible fire hazards such as
grass or other materials that
easily burn.
 Park the vehicle in a place
where pedestrians or children
are not likely to touch the hot
exhaust system.
 Make sure that the exhaust sys-
tem has cooled down before
doing any maintenance work.
 Do not allow the engine to idle
more than a few minutes. Long
idling can cause a build-up of
heat.
NOTICE
ECA10702
Use only unleaded gasoline. The use
of leaded gasoline will cause unre-
pairable damage to the catalytic
converter.
1. Fuel tank overflow hose
2. Clamp
2
1
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Instrument and control functions
3-34
3
EAU65800
Seats
Passenger seat
To remove the passenger seat
1. Insert the key into the seat lock,
and then turn it counterclockwise.
2. Lift the front of the passenger seat
and pull it forward.
To install the passenger seat
1. Insert the projections on the rear
of the passenger seat into the seat
holders as shown, and then push
the front of the seat down to lock
it in place.
2. Remove the key.
Rider seat
To remove the rider seat
1. Remove the passenger seat.
2. Remove the cap, then push the
rider seat lock lever, located under
the back of the rider seat, to the
left as shown, and then pull the
seat off.
To install the rider seat
1. Install the cap with the arrow mark
facing forward.
2. Insert the projection on the front of
the rider seat into the seat holder
as shown, and then push the rear
of the seat down to lock it in place.
1. Seat lock
2. Unlock.
1
2
1. Projection
2. Seat holder
2
1
1. Cap
2. Rider seat lock lever
2
1
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Instrument and control functions
3-35
3
3. Install the passenger seat.
TIP
 Make sure that the seats are prop-
erly secured before riding.
 The rider seat height can be ad-
justed to change the riding posi-
tion. (See the following section.)
EAU63050
Adjusting the rider seat height
The rider seat height can be adjusted
to one of two positions to suit the rid-
er’s preference.
The rider seat height was adjusted to
the lower position at delivery.
To change the rider seat height to
the high position
1. Remove the passenger seat and
rider seat. (See page 3-34.)
2. Remove the rider seat height posi-
tion adjuster by pulling it upward.
3. Install the rider seat height posi-
tion adjuster by inserting the front
projections into the grommets.
1. Projection
2. Seat holder
2
1
1. Low position
2. High position
2 1
1. Rider seat height position adjuster
1. Rider seat height position adjuster
2. Projection
3. Grommet
1
1
2
3
3
UB1JE0E0.book Page 35 Tuesday, February 13, 2018 9:12 AM

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