Page 1 2014 SERVICE MANUAL FJR1300AE FJR1300AEE 2PD-28197-E0...
Page 2 EAS20040 FJR1300AE/FJR1300AEE 2014 SERVICE MANUAL ©2013 by Yamaha Motor Co., Ltd. First edition, July 2013 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 3 EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha 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 4 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5 EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
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 CRUISE CONTROL SYSTEM........1-6 OUTLINE OF THE UNIFIED BRAKE SYSTEM ........1-13 OUTLINE OF THE ABS................1-15 ABS COMPONENT FUNCTIONS ............1-19 ABS OPERATION ...................1-25...
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES ET2C01025 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 ET3P61042 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 remains 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 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 15: Outline Of The Cruise Control System
FEATURES EAS1MC1087 OUTLINE OF THE CRUISE CONTROL SYSTEM This model is equipped with a cruise control system designed to maintain a set cruising speed. Be- cause the vehicle is equipped with the YCC-T system, the cruise control system can be controlled elec- tronically.
Page 16 FEATURES EWA1MC1006 WARNING • Improper use of the cruise control 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. •...
Page 17 FEATURES Deactivating the cruise control system Perform one of the following operations to cancel the set cruising speed. The cruise control setting in- dicator light “SET” will go off. • Turn the throttle grip past the closed position in the deceleration direction. •...
Page 18 FEATURES Operation chart A. Operation d. Currently set cruising speed increases B. Indication e. Currently set cruising speed decreases C. Speed f. New cruising speed is set D. 180 km/h (112 mph) g. Currently set cruising speed is canceled E. 50 km/h (31 mph) h.
Page 19 Because the automatic deactivation of the cruise control system is stored in the memory of the ECU, the deactivation can be checked using the Yamaha diagnostic tool. In some cases, the cruise control system may not be able to maintain the set cruising speed when the vehicle is traveling uphill or downhill.
Page 20 FEATURES Meter displays during cruise control system operation A. Cruise control system is activated (cruising b. 4 seconds elapse (during this time, input from speed is set) the cruise control power switch “ ” will not be received) B. Cruise control system is turned off (cruise control system indicator light “...
Page 21 FEATURES ECA1MC1006 NOTICE If the display indicates a fault code, the vehicle should be checked as soon as possible in order to avoid engine damage. • If the cruise control system turned off because a malfunction was detected by the FI self-diagnosis, the cruise control power switch “...
Page 22: Outline Of The Unified Brake System
OUTLINE OF THE UNIFIED BRAKE SYSTEM The Yamaha unified brake system is a system that operates one set of pistons in the front brakes to- gether with the rear brake when the brake pedal is depressed. Compared to conventional brake sys- tems, the ability to slow the vehicle using the simple operation of the brake pedal is improved.
Page 23 FEATURES Brake pedal input force and braking force at each wheel a. Brake force e. Proportioning valve operation b. Brake pedal force f. Metering valve operation c. Rear brake force d. Front brake force (unified brake system) Metering valve This valve prevents the brake fluid pressure that is transmitted to the right front brake caliper from in- creasing until the pressure exceeds a set level.
Page 24: Outline Of The Abs
8. Rear wheel sensor 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. However, part of the front brake is operated together with rear brake.
Page 25 FEATURES When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis travels forward by its inertia even though the wheel speed is reduced. • Brake force: The force applied by braking to reduce the wheel speed. •...
Page 26 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 27 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 28: Abs Component Functions
FEATURES ABS block diagram 1. Rear brake master cylinder 10. Proportioning valve 2. Hydraulic unit assembly 11. Rear brake caliper 3. Front brake master cylinder 12. Rear wheel sensor 4. Inlet solenoid valve 13. Metering valve 5. ABS motor 14. ABS warning light 6.
Page 29 FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor 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 during the ABS self-diagnosis to check the electrical circuit of the light.
Page 30 FEATURES GEAR A.TEMP ˚C C.TEMP ˚C TIME TRIP 0:06 • 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 accord- ing to signals transmitted from the ABS ECU.
Page 31 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 cylin- der side) and the brake fluid in the lower brake lines (brake caliper side).
Page 32 FEATURES • ABS ECU The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 20 21 24 25 1.
Page 33 FEATURES ABS control operation The ABS control operation performed in the ABS ECU is divided into the following two parts. • Hydraulic control • Self-diagnosis When a malfunction is detected in the ABS, a fault code is stored in the memory of the ABS ECU for easy problem identification and troubleshooting.
Page 34: Abs Operation
FEATURES ET3P61052 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, excluding the unified brake system. Normal braking (ABS not activated) When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.
Page 35 FEATURES Emergency braking (ABS activated) 1. Depressurizing phase When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line from the brake master cylinder.
Page 36 FEATURES 2. Pressurizing phase The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the brake caliper.
Page 37: Abs Self-Diagnosis Function
FEATURES ET3P61053 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. It is located in the multi-function meter center display. GEAR A.TEMP ˚C C.TEMP ˚C TIME TRIP 0:06 Instances when the ABS warning light comes on 1.
Page 38 FEATURES 2. The ABS warning light comes on while the “ ” side of the start/engine stop switch is being pushed. When the engine is being started, the ABS warning light comes on while the “ ” side of the start/en- gine stop switch is being pushed.
Page 39 FEATURES a. ABS warning light d. Unstable ABS ECU input b. Comes on c. Goes off 5. The ABS warning light “1” flashes and a fault code “2” is indicated on the multi-function meter right display when the test coupler adapter “3” is connected to the ABS test coupler “4” for troubleshooting the ABS.
Page 40: Abs Warning Light And Operation
FEATURES ET3P61054 ABS WARNING LIGHT AND OPERATION ABS and UBS function EWA1MC1024 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.
Page 41: Outline Of The Tcs (Traction Control System)
FEATURES EAS1MC1082 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 42 FEATURES 1. Front wheel sensor D. Actuator control 2. Rear wheel sensor E. Fuel cut-off 3. ABS ECU (electronic control unit) F. Ignition timing (retarded) 4. “TCS” button G. Traction control system indicator/warning light (flashes) 5. ECU (engine control unit) H.
Page 43 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. ECA1MC1014 NOTICE Use only the specified tires. Using different sized tires will prevent the traction control system from controlling tire rotation accurately.
Page 44: Multi-Function Meter Unit
FEATURES • a clock EAS1MC1030 MULTI-FUNCTION METER UNIT • a fuel meter • a transmission gear display 9 10 • a drive mode display (which shows the select- ed drive mode) • a function display (which shows the selected function) GEAR •...
Page 45 FEATURES Fuel meter • Select the transmission gear that is appropri- ate for the vehicle speed. Transmission gear display GEAR A.TEMP GEAR C.TEMP A.TEMP ˚C C.TEMP ˚C 1. Fuel meter TIME TRIP 0:06 The fuel meter indicates the amount of fuel in the fuel tank.
Page 46 FEATURES Setting Display High To increase the grip warmer temperature, push the “ ” side of the select switch. To decrease the grip warmer temperature, push the “ ” side of the select switch. ECA1MC1008 NOTICE • Be sure to wear gloves when using the grip 1.
Page 47 FEATURES TRIP-F → Display-1 → Display-2 → Odometer display: Display-3 → TRIP-F To reset a tripmeter, push the select switch to select the information display that contains the tripmeter. Push the “RESET” button briefly so that the tripmeter flashes, and then push the “RESET”...
Page 48 FEATURES Ambient temperature display: The selected information display cannot be switched while the message “Hi” is flashing. ECA1MC1009 A.TEMP ˚C NOTICE Do not continue to operate the engine if it is overheating. Average fuel consumption display: This display shows the ambient temperature from –9 °C to 50 °C in 1 °C increments.
Page 49 FEATURES The instantaneous fuel consumption display Display Description modes “km/L”, “L/100km” or “MPG” (for the UK This function allows you to only) show the fuel consumption under the cur- check and reset the “OIL” oil rent riding conditions. change interval (distance •...
Page 50 FEATURES Adjusting the temperature levels of the grip 4. Use the select switch to highlight “Middle” or warmer settings “Low”, and then change the setting using the 1. Use the select switch to highlight “Grip same procedure that was used for the high Warmer”.
Page 51 FEATURES Checking and resetting TIME-2 and TIME-3 2. Push the menu switch “MENU”. The unit set- 1. Use the select switch to highlight “Time Trip”. ting display will be shown and “km or mile” (for the UK only) or “km/L or L/100km” (ex- cept for the UK) will flash in the display.
Page 52 FEATURES 5. Use the select switch to select “km/L or 3. Use the select switch to highlight the item to L/100km”. change, and then push the menu switch 6. Push the menu switch “MENU”, use the se- “MENU”. lect switch to select “L/100km” or “km/L”, and then push the menu switch “MENU”...
Page 53 FEATURES Adjusting the meter panel brightness 4. Push the menu switch “MENU”, and the 1. Use the select switch to highlight “Bright- minute digits start flashing. ness”. 5. Use the select switch to set the minutes. 6. Push the menu switch “MENU” to return to the setting mode menu.
Page 54 FEATURES If the information display indicates any fault codes, note the code number, and then check the fuel injection system. (Refer to “FUEL IN- JECTION SYSTEM” on page 8-33.) The self-diagnosis device also detects problems in the immobilizer system circuits. If a problem is detected in the immobilizer sys- tem circuits, the immobilizer system indicator light will flash and the information display will in-...
Page 55: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 56: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 EAS1MC1085 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.
Page 57: Basic Service Information
BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with 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 58: Electrical System
BASIC SERVICE INFORMATION ECA16760 EAS30402 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
Page 59 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA16630 ECA14371 NOTICE NOTICE...
Page 60 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
Page 61 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 kΩ...
Page 62: Special Tools
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of 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 63 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-20, 4-91 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-25 90890-01426 YU-38411 Oil pressure gauge set 3-26 90890-03120 Oil pressure adapter B 3-26 90890-03124 Hexagon wrench (41) 4-32, 4-34 90890-01525 YM-01525...
Page 64 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver attachment 4-85 90890-01503 Rod puller 4-86 90890-01437 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Rod puller attachment (M10) 4-86 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring gear fix bolt (M14) 4-113 90890-01524...
Page 65 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Bearing retainer wrench 4-116, 4-119 90890-04050 Pinion bearing retainer & remover YM-04050 Fork seal driver weight 4-121 90890-01184 Replacement hammer YM-A9409-7 Fork seal driver attachment 4-121 90890-01186 Replacement 27 mm YM-A9409-1 Oil seal installing tool 4-121 90890-01512 YM-01512...
Page 66 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-18, 5-33, 90890-85505 5-36, 5-81, (Three Bond No.1215®) 6-13 Valve spring compressor 5-24, 5-29 90890-04019 YM-04019 Valve spring compressor attachment 5-24, 5-29 90890-04114 Valve spring compressor adapter 19.5 mm YM-04114 Valve guide remover (ø5)
Page 67 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-48, 5-51 90890-04086 YM-91042 Thickness gauge 5-49 90890-03180 Feeler gauge set YU-26900-9 Bearing retainer wrench 5-68, 5-70 90890-04137 Middle drive shaft bearing retainer wrench YM-04137 Damper spring compressor 5-68, 5-69 90890-04090 Middle drive gear damper spring com- pressor...
Page 68 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-85 90890-01304 Piston pin puller YU-01304 YU-01304 Piston ring compressor 5-90 90890-05158 YM-08037 Slide hammer bolt 5-101 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-101 90890-01084 YU-01083-3 YU-01083-3 Radiator cap tester 90890-01325...
Page 69 Middle drive bearing installer 40 & 50 mm YM-04058 Pressure gauge 7-9, 7-10 90890-03153 YU-03153 Fuel injector pressure adapter 90890-03210 YU-03210 Fuel pressure adapter 7-10 90890-03176 YM-03176 Yamaha diagnostic tool 8-39 90890-03215 Ignition checker 8-204 90890-06754 Spark checker YM-34487 1-60...
Page 70 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Test harness– lean angle sensor (6P) 8-205 90890-03209 YU-03209 Digital circuit tester 8-206, 8-212 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Test harness– speed sensor (3P) 8-211 90890-03208 YU-03208 Test harness S– pressure sensor (3P) 8-212 90890-03207 YU-03207...
Page 71: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-10 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........2-28 ENGINE....................2-28 CHASSIS....................2-30 LUBRICATION SYSTEM CHART AND DIAGRAMS........
Page 72: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 2PD1 (Europe except (F)) 2PD2 (B) (F) 2PD6 (AUS) Dimensions Overall length 2230 mm (87.8 in) Overall width 750 mm (29.5 in) Overall height 1325/1455 mm (52.2/57.3 in) Seat height 805/825 mm (31.7/32.5 in) Wheelbase 1545 mm (60.8 in) Ground clearance...
Page 73: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 1298.0 cm³ Cylinder arrangement Inline 4-cylinder Bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) Compression ratio 10.80 : 1 Standard compression pressure (at sea level) 1600 kPa/400 r/min (16.0 kgf/cm²/400 r/min, 227.6 psi/400 r/min) Minimum-maximum...
Page 74 ENGINE SPECIFICATIONS Relief valve operating pressure 480.0–560.0 kPa (4.80–5.60 kgf/cm², 69.6–81.2 psi) Cooling system Radiator capacity (including all routes) 2.60 L (2.75 US qt, 2.29 Imp.qt) Radiator capacity 0.65 L (0.69 US qt, 0.57 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt) Radiator cap opening pressure...
Page 75 ENGINE SPECIFICATIONS Limit 24.897 mm (0.9802 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.22 mm (0.0059–0.0087 in) Exhaust 0.18–0.25 mm (0.0071–0.0098 in) Valve dimensions Valve head diameter A (intake) 29.90–30.10 mm (1.1772–1.1850 in) Valve head diameter A (exhaust) 25.90–26.10 mm (1.0197–1.0276 in)
Page 76 ENGINE SPECIFICATIONS Limit 0.105 mm (0.0041 in) Valve stem runout 0.010 mm (0.0004 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve spring Free length (intake) 39.73 mm (1.56 in) Limit 37.74 mm (1.49 in) Free length (exhaust)
Page 77 ENGINE SPECIFICATIONS Height H 5.0 mm (0.20 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 19.004–19.015 mm (0.7482–0.7486 in) Limit 19.045 mm (0.7498 in) Piston pin outside diameter 18.991–19.000 mm (0.7477–0.7480 in) Limit 18.971 mm (0.7469 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.00016–0.00094 in)
Page 78 ENGINE SPECIFICATIONS Crankshaft Width A 61.60–63.20 mm (2.425–2.488 in) Width B 325.10–326.30 mm (12.80–12.85 in) Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in) Journal oil clearance 0.027–0.045 mm (0.0011–0.0018 in) Bearing color code 2.Black 3.Brown 4.Green 5.Yellow 6.Pink 7.Red 8.White Balancer...
Page 79 ENGINE SPECIFICATIONS Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.100 mm (0.0039 in) Air filter Air filter element Dry element Fuel pump Pump type Electrical Maximum consumption amperage 6.0 A Fuel injector Model/quantity 0990/4 12.0 Ω...
Page 80 ENGINE SPECIFICATIONS Shaft drive Middle gear backlash 0.10–0.20 mm (0.0039–0.0079 in) Ring-gear-to-stopper-bolt clearance 0.30–0.60 mm (0.0118–0.0236 in) Ring-gear-to-thrust-washer clearance 0.20 mm (0.0079 in) Final gear backlash 0.22–0.45 mm (0.0087–0.0177 in)
Page 81: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 26.00° Trail 109.0 mm (4.29 in) Front wheel Wheel type Cast wheel 17M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 135.0 mm (5.31 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 82 CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter × thickness 320.0 × 4.5 mm (12.60 × 0.18 in) Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 5.5 mm (0.22 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer)
Page 83 CHASSIS SPECIFICATIONS Optional spring available Recommended oil Suspension oil M1 or equivalent Quantity (left) 580.0 cm³ (19.61 US oz, 20.46 Imp.oz) Quantity (right) 570.0 cm³ (19.27 US oz, 20.10 Imp.oz) Level 123 mm (4.8 in) Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel...
Page 84: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0°/1050 r/min Engine control unit Model/manufacturer TBDFL1/DENSO (Europe except (F)) (AUS) TBDFL2/DENSO (B) (F) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω...
Page 85 ELECTRICAL SPECIFICATIONS Engine trouble warning light ABS warning light Cruise control system indicator light Cruise control setting indicator light Immobilizer system indicator light Traction control system indicator/warning light Suspension warning light Electric starting system System type Constant mesh Starter motor Power output 0.80 kW 0.024–0.030 Ω...
Page 86 ELECTRICAL SPECIFICATIONS 1.17–1.43 Ω Grip warmer resistance (R) Fuses Main fuse 50.0 A Cooling system fuse 30.0 A Headlight fuse 25.0 A Brake light fuse 1.0 A Signaling system fuse 10.0 A Ignition fuse 20.0 A 10.0 A × 2 Radiator fan fuse Auxiliary DC jack fuse 3.0 A...
Page 87: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 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 88: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head bolt See TIP. Cylinder head bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Cylinder head cover plate bolt...
Page 89 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pan bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pump drive chain guide bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil pump housing cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Oil level switch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Throttle cable holder bolt...
Page 90 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Upper crankcase damper bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Damper cover bolt (clutch cover) 12 Nm (1.2 m·kg, 8.7 ft·lb) Stator coil assembly lead holder 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt Main gallery bolt 8 Nm (0.8 m·kg, 5.8 ft·lb)
Page 91 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Radiator cover bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Radiator bracket bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Coolant reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Coolant reservoir bracket bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Cylinder head bolt Tighten the cylinder head bolts to 25 Nm (2.5 m·kg, 18 ft·lb) in the proper tightening sequence, loosen...
Page 92 TIGHTENING TORQUES Crankcase tightening sequence: Middle gear case cover bolt Apply locking agent (LOCTITE®) only to the threads of the 2 upper middle gear case cover bolts, and then tighten all of the bolts to 12 Nm (1.2 m·kg, 8.7 ft·lb). 2-21...
Page 93: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (right front 49 Nm (4.9 m·kg, 35 ft·lb) lower side) Engine mounting bolt (right front 49 Nm (4.9 m·kg, 35 ft·lb) upper side) Engine mounting bolt (left front 49 Nm (4.9 m·kg, 35 ft·lb) lower side) Engine mounting bolt (left front...
Page 94 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear shock absorber assembly 5 Nm (0.5 m·kg, 3.6 ft·lb) preload adjusting pump bolt Rear shock absorber assembly preload adjusting pump bracket 7 Nm (0.7 m·kg, 5.1 ft·lb) bolt Rear shock absorber assembly 4 Nm (0.4 m·kg, 2.9 ft·lb) DC motor bolt Rear shock absorber assembly...
Page 95 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Center rear cowling bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel pump bolt 4 Nm (0.4 m·kg, 2.9 ft·lb) Front fuel tank bracket and frame 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt Fuel tank and front fuel tank 16 Nm (1.6 m·kg, 11 ft·lb)
Page 96 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Brake pipe/joint assembly bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Front brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) Front brake hose holder bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Front brake hose joint bolt See TIP.
Page 97 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Coupling gear nut 110 Nm (11.0 m·kg, 80 ft·lb) Stake Ring gear bearing housing bolt 40 Nm (4.0 m·kg, 29 ft·lb) Ring gear bearing housing nut 23 Nm (2.3 m·kg, 17 ft·lb) Final gear case stud bolt 9 Nm (0.9 m·kg, 6.5 ft·lb) Ring gear bearing housing stop-...
Page 98 TIGHTENING TORQUES 4. In the order pinch bolt “4” → pinch bolt “3” → pinch bolt “4”, tighten each bolt to 21 Nm (2.1 m·kg, 15 ft·lb) without performing temporary tightening. 2-27...
Page 99: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Balancer dampers, weights, gears and shafts Valve stems and stem end (intake and exhaust) Valve lifter surfaces Water pump impeller shaft...
Page 100 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Cylinder head cover mating surface Three Bond 1541C® Yamaha bond No.1215 Cylinder head cover gasket (Three Bond No.1215®) Yamaha bond No.1215 Crankcase mating surface (Three Bond No.1215®) Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond No.1215®)
Page 101: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing cover lip Lower bearing dust seal lip Front wheel oil seal lip Rear wheel oil seal lip Rear wheel drive hub mating surface Rear brake pedal pivoting point Footrest assembly pivoting point Passenger footrest pivoting point Shift pedal pivoting point...
Page 102: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31...
Page 103 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve assembly 4. Oil filter cartridge 5. Oil cooler 6. Main gallery 7. Front balancer shaft 8. Rear balancer shaft 9. Oil nozzle 10. Intake camshaft 11. Exhaust camshaft 12.
Page 104: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33...
Page 105 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 4. Oil check bolt 5. Main gallery bolt 6. Crankshaft 7. Oil nozzle 2-34...
Page 106 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 107 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil delivery pipe 1 2-36...
Page 108 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 109 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil check bolt 2. Crankshaft 3. Oil cooler 4. Oil strainer 5. Oil delivery pipe 3 6. Oil pump 2-38...
Page 110 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
Page 111 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Rear balancer 2. Oil delivery pipe 2 3. Engine oil drain bolt 4. Oil level switch 5. Crankshaft 6. Front balancer 7. Crank pin 8. Oil delivery pipe 3 9. Relief valve assembly 2-40...
Page 112 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
Page 113 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil delivery pipe 2 3. Oil cooler 4. Engine oil drain bolt 5. Oil level switch 6. Oil filter cartridge 7. Oil delivery pipe 3 8. Oil pan 9. Oil pump 2-42...
Page 114: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-43...
Page 115 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 1 3. Oil cooler outlet hose 4. Radiator 5. Coolant reservoir breather hose 6. Thermostat inlet pipe 2 7. Coolant reservoir hose 8. Radiator inlet hose 9. Thermostat inlet hose 2 10.
Page 116 COOLING SYSTEM DIAGRAMS 2-45...
Page 117 COOLING SYSTEM DIAGRAMS 1. Thermostat inlet pipe 1 2. Thermostat inlet hose 2 3. Radiator inlet hose 4. Radiator 5. Radiator outlet hose 6. Oil cooler outlet hose 7. Water jacket joint inlet hose 8. Water pump outlet pipe 9. Water pump outlet hose 10.
Page 118: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (front view) 2-47...
Page 119 CABLE ROUTING 1. Right grip warmer lead 2. Coupler rubber cover 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4. Right handlebar switch lead 5. Front brake light switch lead 6. Clutch hose 7. Left handlebar switch lead 8.
Page 120 CABLE ROUTING Radiator and battery (right side view) 2-49...
Page 121 8. Radiator fan motor relay 9. Starter relay coupler 10. Front right turn signal light coupler 11. ABS test coupler lead 12. Yamaha diagnostic tool connector 13. Right radiator fan motor coupler 14. Negative battery lead 15. O sensor lead 16.
Page 122 CABLE ROUTING Rear brake hose (right side view) 5 6 7 8 9 10 11 1 12 13 2-51...
Page 123 CABLE ROUTING 1. Rear wheel sensor lead 2. Brake hose (rear brake master cylinder to brake pipe/middle joint assembly) 3. Rear brake fluid reservoir hose 4. Rear brake fluid reservoir 5. Brake pipe (hydraulic unit to metering valve) 6. Hydraulic unit assembly 7.
Page 124 CABLE ROUTING Horn and radiator (left side view) 2-53...
Page 125 CABLE ROUTING 1. Radiator inlet hose 2. Left radiator fan motor 3. Radiator 4. Coolant reservoir breather hose 5. Horn 6. Left radiator fan motor coupler 7. Left radiator fan motor lead 8. Coolant reservoir hose A. After connecting the left radiator fan motor coupler, position the coupler between the left side cowling and the left lower inner panel.
Page 126 CABLE ROUTING Front brake hose and engine (left side view) 2-55...
Page 127 CABLE ROUTING 1. Clutch hose P. Fasten the grommet on the front wheel sensor lead with the holder. 2. AC magneto lead Q. Fasten the grommet on the brake hose (brake 3. Rectifier/regulator lead pipe/upper joint assembly to left front brake caliper) 4.
Page 128 CABLE ROUTING Rear fender (left side view) 1 2 3 2-57...
Page 129 CABLE ROUTING 1. Wire harness 2. License plate light connectors 3. Tail/brake light assembly coupler 4. Tail/brake light 5. Rear turn signal light 6. Tail/brake light assembly lead 7. License plate light lead 8. Seat lock cable 9. Preload adjusting pump hose 10.
Page 130 CABLE ROUTING Throttle bodies (top view) 5 6 7 2-59...
Page 131 CABLE ROUTING 1. Ignition coil #1 coupler E. Install the immobilizer unit coupler holder so that the end with the bolt is facing forward. 2. Clutch hose F. Install the positive battery lead terminal so that it is 3. Front wheel sensor lead not positioned to the outside of the starter relay.
Page 132 CABLE ROUTING Rear fender (top view) 2-61...
Page 133 6. Tail/brake light assembly lead 7. Seat lock cable 8. SCU lead A. Route the Yamaha diagnostic tool lead to the rear of the positioning ribs and under the band that is used to secure the SCU (suspension control unit).
Page 134 CABLE ROUTING Front cowling assembly and electrical components board 17 18 26 V 2-63...
Page 135 CABLE ROUTING 1. Right headlight lead O. Insert the projection on left handlebar switch coupler completely into the hole in the electrical 2. Right auxiliary light lead components board. 3. Relay unit lead P. Route the air temperature sensor lead under the 4.
Page 136 CABLE ROUTING Hydraulic unit assembly (top and side view) 2-65...
Page 137 CABLE ROUTING 1. Hydraulic unit assembly 2. Brake pipe/middle joint assembly 3. Brake pipe (hydraulic unit to metering valve) 4. Brake pipe (hydraulic unit to proportioning valve) 5. Brake pipe/upper joint assembly 6. Brake pipe/lower joint assembly 7. Brake pipe (proportioning valve to rear brake hose) 8.
Page 138 CABLE ROUTING 2-67...
Page 139: 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 ..........3-7 SYNCHRONIZING THE THROTTLE BODIES..........
Page 140 CHECKING THE COOLANT LEVEL............3-27 CHECKING THE COOLING SYSTEM ............3-27 CHANGING THE COOLANT..............3-28 CHECKING THE FINAL GEAR OIL LEVEL ..........3-29 CHANGING THE FINAL GEAR OIL............3-30 CHECKING THE BRAKE LIGHT SWITCHES.........3-30 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-30 CHECKING AND LUBRICATING THE CABLES ........3-31 CHECKING THE THROTTLE GRIP OPERATION .........3-31 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......
Page 142: 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 143 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 √ √ √ √ √ √...
Page 144 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 145: Checking The Fuel Line
PERIODIC MAINTENANCE EAS21030 ECA13320 CHECKING THE FUEL LINE NOTICE 1. Remove: Before removing the spark plugs, blow away • Rider seat any dirt accumulated in the spark plug wells Refer to “GENERAL CHASSIS” on page 4-1. with compressed air to prevent it from falling •...
Page 146: Adjusting The Valve Clearance
PERIODIC MAINTENANCE 10.Install: Valve clearance (cold) • T-bar Intake Refer to “GENERAL CHASSIS” on page 4-1. 0.15–0.22 mm (0.0059–0.0087 in) • Fuel tank Exhaust Refer to “FUEL TANK” on page 7-1. 0.18–0.25 mm (0.0071–0.0098 in) • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. ▼...
Page 147 PERIODIC MAINTENANCE • Measure the valve clearance in the following ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve lifter “1” and the valve pad sequence. “2” with the valve lapper “3”. Valve clearance measuring sequence Valve lapper Cylinder #1 →...
Page 148: Checking The Engine Idling Speed
PERIODIC MAINTENANCE If the valve pad is marked “155”, the pad thickness is 1.55 mm (0.061 in). g. Install the exhaust and intake camshafts, tim- ing chain and camshaft caps. d. Calculate the sum of the values obtained in Camshaft cap bolt steps (b) and (c) to determine the required 10 Nm (1.0 m·kg, 7.2 ft·lb) valve pad thickness and the valve pad num-...
Page 149: Synchronizing The Throttle Bodies
▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU)” on page 9-5. b. Check the ISC (idle speed control) leaning value.
Page 150: Checking The Exhaust System
PERIODIC MAINTENANCE 2. Adjust: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Throttle body synchronization 3. Stop the engine and remove the measuring ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 151: Adjusting The Exhaust Gas Volume
PERIODIC MAINTENANCE 1. Turn the main switch to “OFF”. Exhaust pipe assembly nut 2. Simultaneously press and hold the “TCS” 20 Nm (2.0 m·kg, 14 ft·lb) button “1” and “RESET” button “2”, turn the Exhaust pipe assembly bolt main switch to “ON”, and continue to press 17 Nm (1.7 m·kg, 12 ft·lb) the buttons for 8 seconds or more.
Page 152: Checking The Air Induction System
PERIODIC MAINTENANCE 2. Check: • Crankcase breather hose “1” The selected cylinder number appears on the Cracks/damage → Replace. multi-function meter right display. Loose connection → Connect properly. • To decrease the selected cylinder number, ECA13450 press the “RESET” button. NOTICE •...
Page 153: Adjusting The Clutch Lever
PERIODIC MAINTENANCE EC3P61043 EAS20890 CHECKING THE CLUTCH FLUID LEVEL NOTICE 1. Stand the vehicle on a level surface. Never operate the engine without the air filter element installed. Unfiltered air will cause Place the vehicle on the centerstand. rapid wear of engine parts and may damage the engine.
Page 154: Bleeding The Hydraulic Clutch System
PERIODIC MAINTENANCE EAS20900 BLEEDING THE HYDRAULIC CLUTCH Loosening the bleed screw will release the pres- SYSTEM sure and cause the clutch lever to contact the EWA13000 WARNING handlebar grip. Bleed the hydraulic clutch system whenever: h. Tighten the bleed screw and then release the •...
Page 155: Checking The Brake Fluid Level
PERIODIC MAINTENANCE EWA13050 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will consid- erably reduce braking performance.
Page 156: Bleeding The Hydraulic Brake System (Abs)
PERIODIC MAINTENANCE EAS22780 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. EC3P61012 NOTICE • Bleed the brake system in the following or- der. • 1st step: Front brake calipers •...
Page 157: Checking The Front Brake Pads
PERIODIC MAINTENANCE Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-70. EC3P61029 NOTICE Make sure that the main switch is turned to “OFF” before checking the operation of the hydraulic unit. k. After operating the ABS, repeat steps (e) to (i), and then fill the brake master cylinder res- ervoir or brake fluid reservoir to the proper level with the specified brake fluid.
Page 158: Checking The Rear Brake Pads
PERIODIC MAINTENANCE EAS21280 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose holders. 1. Check: • Brake hoses Cracks/damage/wear → Replace. 2. Check: • Brake hose holders Loose → Tighten the holder bolts. 3.
Page 159 PERIODIC MAINTENANCE EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed.
Page 160: Checking The Wheel Bearings
• Swingarm vertical movement cerning handling characteristics can be giv- Refer to “REMOVING THE SWINGARM” on en if a tire combination other than one page 4-105. approved by Yamaha is used on this vehicle. EAS1MC1039 LUBRICATING THE SWINGARM PIVOT Front tire 1. Lubricate: Size •...
Page 161: Lubricating The Steering Head
PERIODIC MAINTENANCE f. Install the upper ring nut “2”. g. Finger tighten the upper ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h.
Page 162: Checking The Sidestand
PERIODIC MAINTENANCE 3. Hold the vehicle upright and apply the front Recommended lubricant brake. Lithium-soap-based grease 4. Check: • Front fork operation EAS1MC1042 Push down hard on the handlebar several CHECKING THE SIDESTAND times and check if the front fork rebounds 1.
Page 163: Checking The Rear Suspension
PERIODIC MAINTENANCE b. Push the menu switch “MENU” “1” to switch the function display “2” to the damping force GEAR GEAR adjusting function “3”. HARD GEAR HARD ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 164 PERIODIC MAINTENANCE • The suspension will still operate as normal, only the preload adjusting function cannot be For solo riding and luggage used. • To reset the electronically adjustable suspen- sion system warning light, wait approximately 6 minutes and then turn the key to “OFF” or immediately turn the key to “OFF”...
Page 165: Lubricating The Rear Suspension
PERIODIC MAINTENANCE GEAR GEAR HARD • If the preload is adjusted repeatedly, the pre- Recommended brand load setting pictogram will flash 4 times and YAMALUBE the preload cannot be adjusted. Wait approx- Type imately 6 minutes for the preload adjusting SAE 10W-40, 10W-50, 15W-40, function motor to cool down, and then try ad- 20W-40 or 20W-50...
Page 166: Changing The Engine Oil
PERIODIC MAINTENANCE EAS20780 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • Engine oil filler cap “1” •...
Page 167: Measuring The Engine Oil Pressure
PERIODIC MAINTENANCE b. Slightly loosen the engine oil check bolt “1”. 4. Remove: • Main gallery bolt EWA12980 WARNING The engine, muffler and engine oil are ex- tremely hot. 5. Install: • Oil pressure gauge set “1” • Oil pressure adapter B “2” Oil pressure gauge set 90890-03120 c.
Page 168: Checking The Coolant Level
PERIODIC MAINTENANCE 8. Install: EAS21120 CHECKING THE COOLING SYSTEM • Right side cowling 1. Remove: Refer to “GENERAL CHASSIS” on page 4-1. • Side cowlings Refer to “GENERAL CHASSIS” on page 4-1. EAS21110 CHECKING THE COOLANT LEVEL • Exhaust pipe assembly 1.
Page 169: Changing The Coolant
PERIODIC MAINTENANCE Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move.
Page 170: Checking The Final Gear Oil Level
PERIODIC MAINTENANCE 11.Fill: • Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion in- hibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) 14.Install: Radiator capacity (including all • Coolant reservoir cap routes) 15.Start the engine, warm it up for several min- 2.60 L (2.75 US qt, 2.29 Imp.qt)
Page 171: Changing The Final Gear Oil
PERIODIC MAINTENANCE EAS1MC1046 CHECKING THE BRAKE LIGHT SWITCHES Type 1. Check: Shaft drive gear oil (Part No.: • Front brake light switch operation 9079E-SH002-00) • Rear brake light switch operation 4. Install: When operating the brake lever and brake • Final gear oil filler bolt pedal, confirm that the brake light turns on.
Page 172: Checking And Lubricating The Cables
▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “82”. With the engine stopped, turn the throttle grip Refer to “SELF-DIAGNOSTIC FUNCTION slowly and release it. Make sure that the throttle AND DIAGNOSTIC CODE TABLE (ECU)”...
Page 173: Checking The Switches, Lights And Signals
PERIODIC MAINTENANCE Direction “a” Throttle grip free play is increased. Direction “b” Throttle grip free play is decreased. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Adjust: • Headlight beam (horizontally) ▼...
Page 174 PERIODIC MAINTENANCE When removing the right headlight bulb cover, it If the ABS test coupler and main fuse holder are is necessary to remove the ABS test coupler “3” removed, it is necessary to install them. and main fuse holder “4”. 9.
Page 175: Chassis
CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE CENTER REAR COWLING.......... 4-2 INSTALLING THE CENTER REAR COWLING ........4-2 REMOVING THE REAR COWLINGS ............4-2 INSTALLING THE REAR COWLINGS............4-2 REMOVING THE SIDE COVERS ............. 4-3 INSTALLING THE SIDE COVERS............4-3 INSTALLING THE SEATS................. 4-3 ADJUSTING THE SIDE PANELS .............
Page 176 FRONT BRAKE ..................... 4-37 INTRODUCTION ..................4-42 CHECKING THE FRONT BRAKE DISCS..........4-42 REPLACING THE FRONT BRAKE PADS ..........4-43 REMOVING THE FRONT BRAKE CALIPERS ........4-44 DISASSEMBLING THE FRONT BRAKE CALIPERS......4-44 CHECKING THE FRONT BRAKE CALIPERS ........4-45 ASSEMBLING THE FRONT BRAKE CALIPERS........4-45 INSTALLING THE FRONT BRAKE CALIPERS ........
Page 177 STEERING HEAD..................4-89 REMOVING THE LOWER BRACKET.............4-91 CHECKING THE STEERING HEAD ............4-91 INSTALLING THE STEERING HEAD .............4-91 REAR SHOCK ABSORBER ASSEMBLY ............4-93 REMOVING THE REAR FENDER ASSEMBLY........4-98 HANDLING THE REAR SHOCK ABSORBER ........4-98 DISPOSING OF A REAR SHOCK ABSORBER ........4-99 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....
Page 178: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and covers 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 21 Nm (2.1 m kg, 15 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 179: Removing The Center Rear Cowling
GENERAL CHASSIS EAS1MC1049 REMOVING THE CENTER REAR COWLING 1. Remove: • Center rear cowling “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Unhook the projections on the center rear cowling from the rear fender.
Page 180: Removing The Side Covers
GENERAL CHASSIS b. Make sure that the grommet on the tail/brake EAS1MC1055 INSTALLING THE SEATS light assembly fits into the slot in the rear 1. Install: cowling. • Rider seat height position adjuster • Rider seat The rider seat height can be adjusted to one of two positions to suit the rider’s preference.
Page 181 GENERAL CHASSIS 2. Install: • Passenger seat “1” Insert the projections “a” on the rear of the pas- senger seat into the seat holders “b” as shown, and then push the front of the seat down to lock it in place. ▲...
Page 182 GENERAL CHASSIS Removing the side cowlings Order Job/Parts to remove Q’ty Remarks Open the accessory box lid. Headlight beam adjusting knob Front cowling inner panel Right upper inner panel Right lower inner panel Right side panel Right side cowling Front right turn signal light coupler Disconnect.
Page 183 GENERAL CHASSIS Removing the side cowlings Order Job/Parts to remove Q’ty Remarks Accessory box Accessory box solenoid Auxiliary DC jack Left upper inner panel 2 For installation, reverse the removal proce- dure.
Page 184: Adjusting The Side Panels
GENERAL CHASSIS EAS1MC1056 ADJUSTING THE SIDE PANELS The following procedure applies to both of the side panels. 1. Adjust: • Side panel position The side panel “1” can be opened 20 mm (0.79 in) for added ventilation to suit the riding condi- tions.
Page 185: Installing The Front Cowling Inner Panel
GENERAL CHASSIS 2. Remove: EAS1MC1060 INSTALLING THE FRONT COWLING INNER • Front cowling inner panel “1” PANEL ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Unhook the tabs “a” on the top of the front 1.
Page 186: Removing The Side Cowlings
GENERAL CHASSIS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the front left turn signal light coupler, auxiliary DC jack coupler, and accessory box solenoid coupler, and then fasten the front left turn signal light lead “a”, auxiliary DC jack lead “b”, and accessory box solenoid lead “c”...
Page 187 GENERAL CHASSIS Removing the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Side cowlings Refer to “Removing the side cowlings”. Windshield bracket outer cover Windshield Windshield bracket Windshield bracket inner cover...
Page 188 GENERAL CHASSIS Removing the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Headlight assembly For installation, reverse the removal proce- dure. 4-11...
Page 189: Removing The Windshield Bracket Covers
GENERAL CHASSIS EAS1MC1061 REMOVING THE WINDSHIELD BRACKET COVERS The following procedure applies to both of the windshield bracket covers. 1. Remove: • Windshield bracket outer cover “1” Slide the windshield bracket outer cover upward, and then remove it. EAS1MC1062 REMOVING THE CENTER COVERS 1.
Page 190: Installing The Front Cowling Assembly
GENERAL CHASSIS Face the projection “a” on the headlight beam adjusting knob joint forward. 2. Install: • Center cover assembly “1” Fit the projections on the lower center cover into the holes in the front cowling. EAS1MC1031 INSTALLING THE FRONT COWLING ASSEMBLY 1.
Page 191 GENERAL CHASSIS Removing the meter assembly and electrical components board 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Side cowlings Refer to “Removing the side cowlings”. Refer to “Removing the front cowling assem- Front cowling assembly bly”.
Page 192 GENERAL CHASSIS Removing the windshield drive unit 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 32 Nm (3.2 m kg, 23 ft •...
Page 193: Installing The Windshield Drive Unit
GENERAL CHASSIS EAS1MC1079 INSTALLING THE WINDSHIELD DRIVE UNIT 1. Check: • Windshield drive unit operation After installing the windshield drive unit to the windshield drive unit bracket, check the opera- tion of the drive unit. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼...
Page 194 GENERAL CHASSIS Removing the electrical components tray 1/2 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Right side cowling Refer to “Removing the side cowlings”. Negative battery lead Disconnect.
Page 195 GENERAL CHASSIS Removing the electrical components tray 2/2 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 196 GENERAL CHASSIS Removing the T-bar 37 Nm (3.7 m kg, 27 ft • • 37 Nm (3.7 m kg, 27 ft • • Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “Removing the seats and covers”. Fuel tank Refer to “FUEL TANK”...
Page 197 Air shroud Air duct Air filter case cover Air filter element Owner’s tool kit SCU (suspension control unit) Yamaha diagnostic tool coupler Rear lower fuel tank bracket Storage compartment Crankcase breather hose Disconnect. Air induction system hose (air filter case joint Disconnect.
Page 198 GENERAL CHASSIS Removing the air filter case 7 Nm (0.7 m kg, 5.1 ft • • 8 Nm (0.8 m kg, 5.8 ft • • (11) 8 Nm (0.8 m kg, 5.8 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
Page 199: Front Wheel
FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel, brake discs, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 6 Nm (0.6 m kg, 4.3 ft •...
Page 200 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Front wheel sensor rotor Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-23...
Page 201: Removing The Front Wheel
FRONT WHEEL ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS21900 REMOVING THE FRONT WHEEL a. Clean the surface of the front wheel hub. ECA1MC1028 b. Remove the oil seals “1” with a flathead NOTICE screwdriver.
Page 202: Maintenance Of The Front Wheel Sensor And Sensor Rotor
FRONT WHEEL 2. Check: • The front wheel sensor cannot be disas- • Tire sembled. Do not attempt to disassemble it. • Front wheel If faulty, replace with a new one. Damage/wear → Replace. • Keep magnets (including magnetic pick-up Refer to “CHECKING THE TIRES”...
Page 203: Assembling The Front Wheel
FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL Wheel sensor rotor deflection ECA3P6D003 limit NOTICE 0.14 mm (0.0055 in) • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼...
Page 204: Adjusting The Front Wheel Static Balance
FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Install: c. Turn the front wheel 90° so that the “X ”...
Page 205: Installing The Front Wheel (Front Brake Discs)
FRONT WHEEL c. If the heavy spot does not stay in that posi- 2. Check: tion, install a heavier weight. • Front brake discs d. Repeat steps (b) and (c) until the front wheel Refer to “CHECKING THE FRONT BRAKE is balanced.
Page 206 FRONT WHEEL EC3P61022 NOTICE Distance “a” (between the wheel sensor rotor and wheel sensor Before tightening the wheel axle bolt, push housing) down hard on the handlebars several times 28.82–29.66 mm (1.135–1.168 in) and check if the front fork rebounds smooth- ▼...
Page 207: Rear Wheel
REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel, brake disc, wheel sensor, and sensor housing 7 Nm (0.7 m kg, 5.1 ft • • 125 Nm (12.5 m kg, 90 ft • • 30 Nm (3.0 m kg, 22 ft •...
Page 208 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Dust cover Rear wheel drive hub Dust seal Wheel bearing Rear wheel drive hub damper Oil seal Bearing retainer Left-hand threads Rear wheel sensor rotor Wheel bearing Spacer Spacer Bearing For assembly, reverse the disassembly pro-...
Page 209: Removing The Rear Wheel
REAR WHEEL EAS22050 ET3P6D002 REMOVING THE REAR WHEEL DISASSEMBLING THE REAR WHEEL ECA1MC1029 ECA3P6D003 NOTICE NOTICE Keep magnets (including magnetic pick-up • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the from the wheel sensor rotor.
Page 210: Checking The Rear Wheel
REAR WHEEL EAS22200 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ECA3P6D008 NOTICE • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. •...
Page 211: Adjusting The Rear Wheel Static Balance
REAR WHEEL Hexagon wrench (41) 90890-01525 YM-01525 Bearing retainer 80 Nm (8.0 m·kg, 58 ft·lb) LOCTITE® ECA3P6D009 NOTICE 2. Rear wheel The bearing retainer has left-handed 2. Install: threads. To tighten the retainer, turn it coun- terclockwise. • Wheel bearings ▼...
Page 212: Installing The Rear Wheel (Rear Brake Disc)
REAR WHEEL EAS22170 ECA14470 INSTALLING THE REAR WHEEL (REAR NOTICE BRAKE DISC) Make sure there are no foreign materials in 1. Install: the wheel hub. Foreign materials cause dam- • Rear brake disc age to the inner sensor rotor and wheel sen- sor.
Page 213 REAR WHEEL Distance “a” (between the wheel sensor rotor and wheel sensor housing) 28.84–29.64 mm (1.135–1.167 in) 7. Install: • Rear wheel sensor Rear wheel sensor bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) ECA1MC1030 NOTICE To route the rear wheel sensor lead, refer to “CABLE ROUTING”...
Page 214: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft •...
Page 215 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”...
Page 216 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder push rod Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-39...
Page 217 FRONT BRAKE Removing the front brake calipers 40 Nm (4.0 m kg, 29 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 218 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • 6 Nm (0.6 m kg, 4.3 ft • • 17 Nm (1.7 m kg, 12 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 219: Introduction
FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.
Page 220: Replacing The Front Brake Pads
FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pads steps until the brake disc deflection is within • Brake pad springs specification. f. If the brake disc deflection cannot be brought Always install new brake pads and new brake within specification, replace the brake disc.
Page 221: Removing The Front Brake Calipers
FRONT BRAKE 3. Install: • Copper washers • Brake pad bolts • Brake hose (brake pipe/upper joint assembly • Brake caliper to right front brake caliper) “3” • Brake hose (metering valve to right front Brake pad bolt brake caliper) “4” 17 Nm (1.7 m·kg, 12 ft·lb) Brake caliper bolt Put the end of the brake hoses into a container...
Page 222: Checking The Front Brake Calipers
FRONT BRAKE EWA13560 EAS22410 ASSEMBLING THE FRONT BRAKE WARNING CALIPERS • Cover the brake caliper pistons with a rag. EWA3P6D002 Be careful not to get injured when the pis- WARNING tons are expelled from the brake caliper. • Before installation, all internal brake com- •...
Page 223: Removing The Front Brake Master Cylinder
FRONT BRAKE ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-15. 6. Check: 2.
Page 224: Checking The Front Brake Master Cylinder
FRONT BRAKE • Copper washers “2” EAS22530 INSTALLING THE FRONT BRAKE MASTER • Brake hose (front brake master cylinder to CYLINDER brake pipe/lower joint assembly) “3” 1. Install: • Brake master cylinder “1” To collect any remaining brake fluid, place a •...
Page 225 FRONT BRAKE 3. Fill: • Brake master cylinder reservoir • Brake fluid reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT 4 EW3P61008 WARNING A. Front brake • Use only the designated brake fluid. Other B.
Page 226: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Brake pad shim Rear brake pad Brake pad spring For installation, reverse the removal proce- dure. 4-49...
Page 227 REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 228 REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 18 Nm (1.8 m kg, 13 ft • • 28 Nm (2.8 m kg, 20 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 229 REAR BRAKE Disassembling the rear brake master cylinder 16 Nm (1.6 m kg, 11 ft • • Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder push rod Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
Page 230 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 Copper washer Brake hose (proportioning valve to rear brake caliper) Rear brake caliper bolt Loosen.
Page 231 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Brake pad shim Rear brake pad Brake pad spring Rear brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 232: Introduction
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 233: Removing The Rear Brake Caliper
REAR BRAKE Recommended lubricant Always install new brake pads, brake pad shims, Silicone grease and brake pad springs as a set. ECA3P6D017 ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ NOTICE a.
Page 234: Disassembling The Rear Brake Caliper
REAR BRAKE EAS22640 CHECKING THE REAR BRAKE CALIPER Recommended brake component replace- ment schedule Brake pads If necessary Piston dust seal Every two years Piston seal Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake EAS22600 DISASSEMBLING THE REAR BRAKE...
Page 235: Installing The Rear Brake Caliper
REAR BRAKE • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal.
Page 236: Removing The Rear Brake Master Cylinder
REAR BRAKE 4. Remove: • Rear brake caliper bolts • Rear brake caliper 5. Install: • Brake pad springs • Rear brake pads • Brake pad shims • Rear brake caliper bolts • Rear brake caliper Refer to “REPLACING THE REAR BRAKE PADS”...
Page 237: Assembling The Rear Brake Master Cylinder
REAR BRAKE 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake fluid reservoir Cracks/damage → Replace. • Brake fluid reservoir diaphragm Cracks/damage → Replace. 4. Check: • Brake hose Cracks/damage/wear → Replace. 2. Install: • Rear brake light switch “1” EAS22730 ASSEMBLING THE REAR BRAKE MASTER CYLINDER...
Page 238 REAR BRAKE 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-15. 5. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 239: Abs (Anti-Lock Brake System)
ABS (ANTI-LOCK BRAKE SYSTEM) EAS22760 ABS (ANTI-LOCK BRAKE SYSTEM) ET3P61060 ABS COMPONENTS CHART 12,13 1. Brake hose (metering valve to right front brake caliper) 2. Brake hose (brake pipe/upper joint assembly to front brake calipers) 3. Brake hose (front brake master cylinder to brake pipe/lower joint assembly) 4.
Page 240 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the metering valve, proportioning valve, and brake pipes 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 16 Nm (1.6 m kg, 11 ft • • 16 Nm (1.6 m kg, 11 ft 7 Nm (0.7 m...
Page 241 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the metering valve, proportioning valve, and brake pipes 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 16 Nm (1.6 m kg, 11 ft • • 16 Nm (1.6 m kg, 11 ft 7 Nm (0.7 m...
Page 242 ABS (ANTI-LOCK BRAKE SYSTEM) Removing the hydraulic unit assembly 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 243: Removing The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) 3. Slide the rear fender assembly “1” down. ET3P6D003 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA3P6D018 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is already in the system.
Page 244: Checking The Hydraulic Unit Assembly
ABS (ANTI-LOCK BRAKE SYSTEM) • When using a bolt, do not tighten the bolt until ET3P6D005 INSTALLING THE HYDRAULIC UNIT the bolt head touches the hydraulic unit. Other- ASSEMBLY wise, the brake pipe seating surface could be 1. Install: deformed. •...
Page 245 ABS (ANTI-LOCK BRAKE SYSTEM) 7. Install: ECA3P6D022 NOTICE • Proportioning valve “1” If the brake pipe flare nut does not turn easi- • Brake pipe (hydraulic unit to proportioning ly, replace the hydraulic unit, brake pipes, valve) “2” and related parts as a set. Proportioning valve bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) First tighten the brake pipe/joint assembly flare...
Page 246 ABS (ANTI-LOCK BRAKE SYSTEM) ECA3P6D022 NOTICE Brake pipe flare nut 16 Nm (1.6 m·kg, 11 ft·lb) If the brake pipe flare nut does not turn easi- Metering valve bolt ly, replace the hydraulic unit, brake pipes, 7 Nm (0.7 m·kg, 5.1 ft·lb) and related parts as a set.
Page 247: Hydraulic Unit Operation Tests
ABS (ANTI-LOCK BRAKE SYSTEM) 1. Place the vehicle on the centerstand. ECA13540 NOTICE 2. Turn the main switch to “OFF”. Brake fluid may damage painted surfaces 3. Remove: and plastic parts. Therefore, always clean up • Right upper inner panel any spilt brake fluid immediately.
Page 248 ABS (ANTI-LOCK BRAKE SYSTEM) 6. Turn the main switch to “ON” while operating the brake lever and the brake pedal simulta- neously. • This check cannot be performed unless both the brake lever and the brake pedal are oper- ated simultaneously when the main switch is turned to “ON”.
Page 249 ABS (ANTI-LOCK BRAKE SYSTEM) e. Retract the sidestand. 6. Extend the sidestand. 7. Turn the main switch to “ON”. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 8. Push the “ ” side of the start/engine stop 3.
Page 250: Checking The Abs Warning Light
ABS (ANTI-LOCK BRAKE SYSTEM) 11.After the pulsating action has stopped in the 13.Turn the main switch to “OFF”. brake lever, it is generated in the brake pedal 14.Remove the test coupler adapter from the “1” 0.5 second later and continues for approx- ABS test coupler.
Page 251: Handlebars
HANDLEBARS EAS22850 HANDLEBARS Removing the left handlebar 65 Nm (6.5 m kg, 47 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Clutch master cylinder holder Clutch master cylinder assembly Left handlebar...
Page 252 HANDLEBARS Removing the right handlebar 23 Nm (2.3 m kg, 17 ft • • 65 Nm (6.5 m kg, 47 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Front brake master cylinder holder Front brake master cylinder assembly Grip end Throttle cable housing...
Page 253: Adjusting The Handlebar Position
HANDLEBARS EAS1MC1065 ADJUSTING THE HANDLEBAR POSITION 1. Check: • Handlebar position The handlebar position can be adjusted to one of three positions to suit the rider’s preference. a. Front position b. Standard position c. Rear position e. Install the handlebar bolts “3” and nuts “2” temporarily.
Page 254: Checking The Handlebars
HANDLEBARS ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS22890 CHECKING THE HANDLEBARS 3. Install: 1. Check: • Right handlebar switch “1” • Left handlebar • Right handlebar Align the projection “a” on the right handlebar Bends/cracks/damage →...
Page 255 HANDLEBARS • When installing the throttle cable housing, align the projection “a” on the housing with the hole “b” in the right handlebar and be sure not to pinch the right grip warmer lead. • There should be 1–3 mm (0.04–0.12 in) of clearance “c”...
Page 256 HANDLEBARS 10.Install: • Clutch master cylinder assembly • Clutch master cylinder holder “1” Clutch master cylinder holder bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) • Install the clutch master cylinder holder with the “UP” mark facing up. • Align the mating surfaces of the clutch master cylinder holder with the punch mark “a”...
Page 257: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
Page 258 FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt (with front fork stepping motor) O-ring Locknut...
Page 259: Removing The Front Fork Legs
FRONT FORK EAS22960 ECA2PD1004 REMOVING THE FRONT FORK LEGS NOTICE The following procedure applies to both of the Because the left and right damper rod as- front fork legs. semblies are different, be sure to install them 1. Stand the vehicle on a level surface. in the correct positions.
Page 260: Checking The Front Fork Legs
FRONT FORK Stroke the damper rod “1” several times while draining the fork oil. A. Left side B. Right side EAS23010 CHECKING THE FRONT FORK LEGS 3. Remove: The following procedure applies to both of the • Dust seal front fork legs. •...
Page 261: Assembling The Front Fork Legs
FRONT FORK 3. Check: • Damper rod assembly The left side (for the compression) damper rod Damage/wear → Replace. assembly has the holes “a” of oil path, unlike the Obstruction → Blow out all of the oil passag- right side. es with compressed air.
Page 262 FRONT FORK 3. Lubricate: 5. Install: • Inner tube outer surface • Outer tube (onto the inner tube) Recommended oil 6. Install: Suspension oil 01 or equivalent • Oil seal “1” (with the fork seal driver “2”) 4. Install: • Dust seal “1” Fork seal driver 90890-01502 •...
Page 263 FRONT FORK Fork seal driver Recommended oil 90890-01502 Suspension oil M1 or equiva- Fork seal driver (48) lent YM-A0948 Quantity (left) 580.0 cm³ (19.61 US oz, 20.46 Imp.oz) Quantity (right) 570.0 cm³ (19.27 US oz, 20.10 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
Page 264 FRONT FORK d. Reinstall the rod puller and rod puller attach- ment. e. Press down in the spacer with the fork spring compressor “1”. f. Pull up the rod puller and install the rod holder “2” between the locknut “3” and the spacer “4”.
Page 265: Installing The Front Fork Legs
FRONT FORK EWA2PD1002 WARNING The fork spring is compressed. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
Page 266: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 7 Nm (0.7 m kg, 5.1 ft • • 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft •...
Page 267 STEERING HEAD Removing the lower bracket 7 Nm (0.7 m kg, 5.1 ft • • 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft •...
Page 268: Removing The Lower Bracket
STEERING HEAD b. Remove the bearing race from the lower EAS23110 REMOVING THE LOWER BRACKET bracket “3” with a floor chisel “4” and ham- 1. Stand the vehicle on a level surface. mer. EWA13120 c. Install new bearing races. WARNING ECA14270 Securely support the vehicle so that there is NOTICE...
Page 269 STEERING HEAD • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-19. 3. Install: • Upper bracket • Steering stem nut Temporarily tighten the steering stem nut. 4. Install: • Front fork legs Refer to “FRONT FORK” on page 4-80. Temporarily tighten the upper and lower bracket pinch bolts.
Page 270: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear fender assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rear cowlings/Side covers/Air shroud 4-1.
Page 271 REAR SHOCK ABSORBER ASSEMBLY Removing the rear fender assembly 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Seat lock cable assembly For installation, reverse the removal proce- dure.
Page 272 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kg, 5.1 ft 64 Nm (6.4 m kg, 46 ft • • • • 11 9 10 10 40 Nm (4.0 m kg, 29 ft • •...
Page 273 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kg, 5.1 ft 64 Nm (6.4 m kg, 46 ft • • • • 11 9 10 10 40 Nm (4.0 m kg, 29 ft • •...
Page 274 REAR SHOCK ABSORBER ASSEMBLY Removing the stepping motor and DC motor 0.7 Nm (0.07 m kg, 0.51 ft • • 0.7 Nm (0.07 m kg, 0.51 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
Page 275: Removing The Rear Fender Assembly
REAR SHOCK ABSORBER ASSEMBLY then pull the couplers out through the holes in EAS2PD1004 REMOVING THE REAR FENDER ASSEMBLY the DC motor upper cover and rear fender as- 1. Remove the rear fender bolts “1” and quick sembly. fasteners “2”. Move the rear shock absorber assembly, and then pull the couplers out through the holes in the DC motor upper cover and rear fender as-...
Page 276: Disposing Of A Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY • Spacer “2” EAS23190 DISPOSING OF A REAR SHOCK ABSORBER • Rear shock absorber assembly 1. Gas pressure must be released before dis- posing of a rear shock absorber. To release Partially pull out the rear shock absorber assem- the gas pressure, drill a 2–3 mm (0.08–0.12 bly upper bolt, slide the spacer “2”...
Page 277: Replacing The Stepping Motor
REAR SHOCK ABSORBER ASSEMBLY 3. Check: • Spacers • Make sure that the warning label on the rear Damage/scratches → Replace. shock absorber assembly faces to the right. • When installing the rear shock absorber as- EAS2PD1005 REPLACING THE STEPPING MOTOR sembly, lift up the swingarm.
Page 278: Installing The Rear Fender Assembly
REAR SHOCK ABSORBER ASSEMBLY Installed depth “a” 4.0 mm (0.16 in) Installed depth “b” 1.0 mm (0.04 in) Installed depth “c” 3.5–4.5 mm (0.14–0.18 in) Installed depth “d” 0.5 mm (0.02 in) Installed depth “e” 4.5 mm (0.18 in) EAS2PD1007 INSTALLING THE REAR FENDER ASSEMBLY •...
Page 279 REAR SHOCK ABSORBER ASSEMBLY 4. Place the DC motor upper cover “1” in its orig- inal position, and then install the quick fasten- er “2”. 5. Install the rear fender bolts “1” and quick fas- teners “2”. 4-102...
Page 280: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm 23 Nm (2.3 m kg, 17 ft • • 125 Nm (12.5 m kg, 90 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft •...
Page 281 SWINGARM Removing the swingarm 23 Nm (2.3 m kg, 17 ft • • 125 Nm (12.5 m kg, 90 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft • • 28 Nm (2.8 m kg, 20 ft •...
Page 282: Removing The Swingarm
SWINGARM EAS23350 EAS23360 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: • Swingarm EWA13120 WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is 2. Check: no danger of it falling over. •...
Page 283 SWINGARM 3. Swingarm 4. Connecting arm A. Left side B. Right side 3. Tighten: • Pivot shaft Pivot shaft 23 Nm (2.3 m·kg, 17 ft·lb) • Pivot shaft nut Pivot shaft nut 115 Nm (11.5 m·kg, 85 ft·lb) • Pivot shaft self-lock nut Pivot shaft self-lock nut 125 Nm (12.5 m·kg, 90 ft·lb) 4-106...
Page 284: Shaft Drive
SHAFT DRIVE EAS23550 SHAFT DRIVE Removing the final drive assembly Order Job/Parts to remove Q’ty Remarks Drain. Final gear oil Refer to “CHANGING THE FINAL GEAR OIL” on page 3-30. Rear wheel Refer to “REAR WHEEL” on page 4-30. Final drive assembly For installation, reverse the removal proce- dure.
Page 285 SHAFT DRIVE Removing the universal joint 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft •...
Page 286 SHAFT DRIVE Disassembling the final drive assembly Order Job/Parts to remove Q’ty Remarks Circlip Oil seal Drive shaft Spring Ring gear bearing housing Dust cover Oil seal Stopper bolt Left-hand threads Refer to “ADJUSTING THE RING-GEAR- Stopper bolt shim TO-STOPPER-BOLT CLEARANCE” on page 4-115.
Page 287 SHAFT DRIVE Disassembling the final drive assembly Order Job/Parts to remove Q’ty Remarks Coupling gear nut Coupling gear Bearing retainer Left-hand threads Oil seal Final drive pinion gear Bearing Refer to “ALIGNING THE FINAL DRIVE Final drive pinion gear shim PINION GEAR AND RING GEAR”...
Page 288: Troubleshooting
SHAFT DRIVE EAS23560 TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sus- B. Improper gear backlash tained speeds (not to be confused with en- C. Damaged gear teeth gine surging or transmission-related D.
Page 289 SHAFT DRIVE Troubleshooting chart When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section ex- ist, check the following points. YES → 1. Place the vehicle on a suitable stand so that the front wheel is ele- •...
Page 290: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks
SHAFT DRIVE EAS23570 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 1. Drain: • Final gear oil (from the final gear case) Refer to “CHANGING THE FINAL GEAR OIL” on page 3-30. 2. Check: •...
Page 291: Adjusting The Final Gear Backlash
SHAFT DRIVE EAS23590 ADJUSTING THE FINAL GEAR BACKLASH 1. Remove: • Ring gear bearing housing bolts “1” • Ring gear bearing housing nuts “2” Working in a crisscross pattern, loosen each bolt and nut 1/4 of a turn. After all of the bolts and nuts are fully loosened, remove them.
Page 292: Measuring The Ring-Gear-To-Stopper-Bolt Clearance
SHAFT DRIVE EAS23610 ADJUSTING THE RING-GEAR-TO- Ring gear shims STOPPER-BOLT CLEARANCE Thickness (mm) 1. Remove: 0.25 0.30 0.40 0.50 • Ring gear “1” • Stopper bolt “2” Thrust washers • Stopper bolt shim(s) “3” Thickness (mm) • Ring gear bearing housing “4” 1.2 1.4 1.6 1.8 2.0 ▲...
Page 293: Disassembling The Final Drive Assembly
SHAFT DRIVE Ring-gear-to-stopper-bolt clear- Bearing retainer wrench ance 90890-04050 0.30–0.60 mm (0.0118–0.0236 in) Pinion bearing retainer & remov- YM-04050 If the ring-gear-to-stopper-bolt clearance is out ECA14330 of specification, repeat the above procedure. NOTICE The bearing retainer has left-hand threads. EAS23620 To loosen the bearing retainer, turn it clock- DISASSEMBLING THE FINAL DRIVE wise.
Page 294: Aligning The Final Drive Pinion Gear And Ring Gear
SHAFT DRIVE The bearing can be reused, but Yamaha recom- mends installing a new one. 3. Remove: • Bearing “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Heat the final gear case to approximately 150 °C (302 °F).
Page 295 SHAFT DRIVE Final drive pinion gear shims Thickness (mm) 0.30 0.40 0.50 Since the final drive pinion gear shims are only available in 0.10 mm increments, round off to the hundredths digit. Hundredth Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 In the example above, the calculated final drive pinion gear shim thickness is 0.51 mm.
Page 296 SHAFT DRIVE Ring gear bearing thickness 13.00 mm (0.51 in) Example: If the final gear case is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “+ 05”, and “f” is 13.00: 45.51 + 3.35 - 35.45 - 13 0.41 3.
Page 297: Checking The Drive Shaft
SHAFT DRIVE 6. Adjust: Thrust washers • Final gear backlash Thickness (mm) Refer to “MEASURING THE FINAL GEAR 1.2 1.4 1.6 1.8 2.0 BACKLASH” on page 4-113 and “ADJUST- ING THE FINAL GEAR BACKLASH” on i. Repeat the measurement steps until the ring- page 4-114.
Page 298 SHAFT DRIVE Fork seal driver weight 90890-01184 Replacement hammer YM-A9409-7 Fork seal driver attachment 90890-01186 Replacement 27 mm YM-A9409-1 6. Install: • Universal joint • Final drive assembly Align the drive shaft splines with the driven yoke of the universal joint. 7.
Page 299 SHAFT DRIVE 9. Install: • Shift arm “1” Align the punch mark “a” in the shift shaft with the slot in the shift arm. 10.Install: • Rear wheel Refer to “REAR WHEEL” on page 4-30. 11.Fill: • Final gear case Refer to “CHECKING THE FINAL GEAR OIL LEVEL”...
Page 300 SHAFT DRIVE 4-123...
Page 301 ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 REMOVING THE ENGINE ................ 5-8 INSTALLING THE ENGINE............... 5-8 CAMSHAFTS....................5-11 REMOVING THE CAMSHAFTS..............5-13 CHECKING THE CAMSHAFTS ..............5-14 CHECKING THE CAMSHAFT SPROCKETS .........5-15 CHECKING THE TIMING CHAIN GUIDES..........5-15 CHECKING THE TIMING CHAIN TENSIONER........
Page 302 CLUTCH ......................5-42 REMOVING THE CLUTCH ..............5-48 CHECKING THE FRICTION PLATES.............5-49 CHECKING THE CLUTCH PLATES ............5-49 CHECKING THE CLUTCH SPRING PLATE...........5-49 CHECKING THE CLUTCH HOUSING ............5-50 CHECKING THE CLUTCH BOSS............5-50 CHECKING THE PRESSURE PLATE ............5-50 CHECKING THE CLUTCH PUSH RODS ..........5-50 CHECKING THE PRIMARY DRIVEN GEAR ..........5-50 INSTALLING THE CLUTCH..............
Page 303 CRANKCASE ....................5-76 DISASSEMBLING THE CRANKCASE............5-80 CHECKING THE CRANKCASE ..............5-80 CHECKING THE OIL DELIVERY PIPES ..........5-80 CHECKING THE BEARINGS AND OIL SEAL ........5-80 CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN..5-80 ASSEMBLING THE CRANKCASE............5-80 INSTALLING THE OIL PUMP DRIVE SPROCKET ........5-83 CONNECTING RODS AND PISTONS ............
Page 304: Engine Inspection
ENGINE INSPECTION EAS1MC1068 ENGINE INSPECTION EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 8. Measure: 1. Measure: • Compression pressure Out of specification → Refer to steps (c) and •...
Page 305 ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Repair. Pistons, valves, cylin- der head gasket or Same as without oil piston ring(s) possi- bly defective → Re- pair.
Page 306: Engine Removal
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust pipe assembly and muffler 17 Nm (1.7 m kg, 12 ft • • 25 Nm (2.5 m kg, 18 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 5 Nm (0.5 m kg, 3.6 ft •...
Page 307 ENGINE REMOVAL Disconnecting the leads and hose 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Front fender Refer to “FRONT WHEEL” on page 4-22. Refer to “GENERAL CHASSIS”...
Page 308 ENGINE REMOVAL Disconnecting the leads and hose 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil level switch coupler Disconnect. Crankshaft position sensor coupler Disconnect.
Page 309 ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kg, 5.8 ft 45 Nm (4.5 m kg, 32 ft • • 49 Nm (4.9 m kg, 35 ft • • • • 45 Nm (4.5 m kg, 32 ft • •...
Page 310: Engine
ENGINE REMOVAL Removing the engine 8 Nm (0.8 m kg, 5.8 ft 45 Nm (4.5 m kg, 32 ft • • 49 Nm (4.9 m kg, 35 ft • • • • 45 Nm (4.5 m kg, 32 ft • •...
Page 311: Removing The Engine
ENGINE REMOVAL EAS1MC1066 REMOVING THE ENGINE 1. Loosen: • Spacer bolt Loosen the spacer bolt with the pivot shaft wrench “1” and pivot shaft wrench adapter “2”. Pivot shaft wrench 90890-01471 Frame spanner socket YM-01471 Pivot shaft wrench adapter 90890-01476 3.
Page 312 ENGINE REMOVAL 11.Tighten: Pivot shaft wrench • Engine bracket and engine bolts (top) “13” 90890-01471 (temporarily tighten) Frame spanner socket • Engine bracket bolts (top) “14” YM-01471 (temporarily tighten) Pivot shaft wrench adapter 90890-01476 When temporarily tightened, the bolts “13” and 6.
Page 313 ENGINE REMOVAL • Engine bracket and frame bolt (left rear side) “2” • Engine bracket and engine bolts (left rear side) “3” Do not fully tighten the bolts. 14.Tighten: • Engine bracket and frame bolt (left rear side) “2” Engine bracket and frame bolt (left rear side) 32 Nm (3.2 m·kg, 23 ft·lb) 15.Tighten:...
Page 314: Camshafts
CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 10 Nm (1.0 m kg, 7.2 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 315 CAMSHAFTS Removing the camshafts Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-35. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft Exhaust camshaft Intake camshaft sprocket...
Page 316: Removing The Camshafts
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “T” mark on the pickup rotor (with the crankcase mating surface) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the crankshaft clockwise. b.
Page 317: Checking The Camshafts
CAMSHAFTS 3. Measure: EAS23850 CHECKING THE CAMSHAFTS • Camshaft runout 1. Check: Out of specification → Replace. • Camshaft lobes Blue discoloration/pitting/scratches → Re- Camshaft runout limit place the camshaft. 0.030 mm (0.0012 in) 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →...
Page 318: Checking The Camshaft Sprockets
CAMSHAFTS • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®. Camshaft cap bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) a.
Page 319: Installing The Camshafts
CAMSHAFTS 2. Install: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Timing chain “1” EAS24010 INSTALLING THE CAMSHAFTS • Exhaust camshaft “2” 1. Install: • Intake camshaft “3” • Exhaust camshaft sprocket (with the camshaft sprockets) •...
Page 320 CAMSHAFTS ECA13730 NOTICE The camshaft cap bolts must be tightened evenly or damage to the cylinder head, cam- shaft caps, and camshafts will result. Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
Page 321 • Apply Three Bond 1514C® “1” onto the mating Timing chain tensioner cap bolt surfaces of the cylinder head cover and cylin- 6 Nm (0.6 m·kg, 4.3 ft·lb) der head cover gasket. • Apply Yamaha bond No.1215 “2” onto the mat- ▲ ▲▲▲ ▲ ▲▲▲ ▲...
Page 322 CAMSHAFTS 11.Install: • Cylinder head cover plate “1” Be sure the “UP” mark “a” is facing up. 5-19...
Page 323: Cylinder Head
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head (10) 25 Nm (2.5 m kg, 18 ft • • 2nd 25 Nm (2.5 m kg, 18 ft • • Final Specified angle 175–185˚ 12 Nm (1.2 m kg, 8.7 ft •...
Page 324: Removing The Cylinder Head
CYLINDER HEAD ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS24120 REMOVING THE CYLINDER HEAD a. Place a straightedge “1” and a thickness 1. Remove: gauge “2” across the cylinder head. •...
Page 325 CYLINDER HEAD Cylinder head bolt (M10) 25 Nm (2.5 m·kg, 18 ft·lb) e. Tighten the cylinder head bolts further to reach the specified angle 175–185° in the proper tightening sequence as shown. Cylinder head bolt (M10) Final Specified angle 175–185° ▲...
Page 326 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-20. Valve lifter Valve pad Valve cotter Upper spring seat Intake valve spring Exhaust valve spring Intake valve Exhaust valve...
Page 327: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24280 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 328 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...
Page 329: Checking The Valve Seats
VALVES AND VALVE SPRINGS Valve guide remover (ø5) Valve stem runout 90890-04097 0.010 mm (0.0004 in) Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 90890-04099 Valve guide reamer (5.0 mm) YM-04099 ▲...
Page 330: Checking The Valve Springs
VALVES AND VALVE SPRINGS For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.
Page 331: Checking The Valve Lifters
VALVES AND VALVE SPRINGS 1. Measure: 3. Measure: • Valve spring free length “a” • Valve spring tilt “a” Out of specification → Replace the valve Out of specification → Replace the valve spring. spring. Free length (intake) Spring tilt (intake) 39.73 mm (1.56 in) 2.5°/1.7 mm (2.5°/0.067 in) Limit...
Page 332 VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- ment 90890-04114 Valve spring compressor adapt- er 19.5 mm YM-04114 3. Install: • Lower spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” •...
Page 333 GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-25.
Page 334: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH Removing the stator coil assembly Order Job/Parts to remove Q’ty Remarks Stator coil assembly lead holder Stator coil assembly For installation, reverse the removal proce- dure. 5-31...
Page 335: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS24490 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 EAS24560 REMOVING THE STARTER CLUTCH 90890-01701 1.
Page 336: Installing The Starter Clutch
Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) EAS24500 INSTALLING THE GENERATOR 1. Install: • Woodruff key • Generator rotor...
Page 337 GENERATOR AND STARTER CLUTCH 4. Install: • Generator cover gasket • Generator cover Generator cover bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Tighten the generator cover bolts in stages and in a crisscross pattern. 5-34...
Page 338: Pickup Rotor
PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 12 Nm (1.2 m kg, 8.7 ft • • 65 Nm (6.5 m kg, 47 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 339: Removing The Pickup Rotor
When installing the pickup rotor, align the groove “a” in the crankshaft sprocket with the projection “b” in the pickup rotor. 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5-36...
Page 340 PICKUP ROTOR 4. Measure: • Gap (between the crankshaft position sensor “1” and pickup rotor “2”) “a” Out of specification → Reinstall or replace. Gap (between the crankshaft po- sition sensor and pickup rotor) 0.5 mm (0.02 in) 5. Install: •...
Page 341: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Starter motor lead Disconnect. Starter motor assembly For installation, reverse the removal proce- dure. 5-38...
Page 342 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Brush Brush seat (along with brushes) Washer Lock washer Oil seal Bearing Starter motor rear cover Collar O-ring Starter motor yoke Armature assembly For assembly, reverse the disassembly pro- cedure.
Page 343: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “1” Armature coil Out of specification → Replace the starter Commutator resistance “1”...
Page 344: Assembling The Starter Motor
ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush seat “1” Align the slot “a” on the brush seat with the tab “b”...
Page 345: Clutch
CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • (10) 12 Nm (1.2 m kg, 8.7 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 346 CLUTCH Removing the clutch 90 Nm (9.0 m kg, 65 ft • • 20 19 17 16 15 14 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,15 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty...
Page 347 CLUTCH Removing the clutch 90 Nm (9.0 m kg, 65 ft • • 20 19 17 16 15 14 10 Nm (1.0 m kg, 7.2 ft • • 11 10 9,15 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty...
Page 348 CLUTCH Removing the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-13. Clutch master cylinder reservoir cap Clutch master cylinder reservoir diaphragm holder Clutch master cylinder reservoir diaphragm Clutch lever Clutch master cylinder push rod pin Clutch hose union bolt...
Page 349 CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Dust boot Circlip Washer Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. 5-46...
Page 350 CLUTCH Removing the clutch release cylinder Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-13. Clutch hose union bolt Copper washer Clutch hose Disconnect. Clutch release cylinder Dowel pin Plate For installation, reverse the removal proce- dure.
Page 351: Removing The Clutch
CLUTCH EAS25080 REMOVING THE CLUTCH There is a built-in damper between the clutch 1. Remove: boss and the clutch plate. It is not necessary to • Clutch cover “1” remove the wire circlip “4” and disassemble the built-in damper unless there is serious clutch Loosen each bolt 1/4 of a turn at a time, in stag- chattering.
Page 352: Checking The Friction Plates
CLUTCH 1. Check: EAS25100 CHECKING THE FRICTION PLATES • Clutch plate The following procedure applies to all of the fric- Damage → Replace the clutch plates as a tion plates. set. 1. Check: 2. Measure: • Friction plate • Clutch plate warpage Damage/wear →...
Page 353: Checking The Clutch Housing
CLUTCH EAS25170 EAS25150 CHECKING THE PRESSURE PLATE CHECKING THE CLUTCH HOUSING 1. Check: 1. Check: • Pressure plate • Clutch housing dogs Cracks/damage → Replace. Damage/pitting/wear → Deburr the clutch • Bearing housing dogs or replace the clutch housing. Damage/wear → Replace. Pitting on the clutch housing dogs will cause er- EAS25190 CHECKING THE CLUTCH PUSH RODS...
Page 354: Installing The Clutch
CLUTCH 3. Install: EAS25250 INSTALLING THE CLUTCH • Clutch boss assembly “1” 1. Install: • Clutch housing “1” • If the wire circlip “2” has been removed, care- fully install a new one. • Make sure that the projections “a” in the clutch •...
Page 355: Disassembling The Clutch Master Cylinder
CLUTCH • Clutch plates • Never disassemble clutch components un- (with the recommended lubricant) less absolutely necessary. • If any connection on the hydraulic clutch Recommended lubricant system is disconnected, the entire clutch Engine oil system must be disassembled, drained, cleaned, properly filled, and bled after reas- 7.
Page 356: Assembling The Clutch Master Cylinder
CLUTCH • First, tighten the upper bolt, then the lower Recommended clutch component replace- bolt. ment schedule Every two years and Clutch fluid whenever the clutch is disassembled 1. Check: • Clutch master cylinder body Cracks/damage → Replace the clutch mas- ter cylinder.
Page 357: Removing The Clutch Release Cylinder
CLUTCH 6. Check: Specified brake and clutch fluid • Clutch lever operation DOT 4 Soft or spongy feeling → Bleed the clutch system. EWA1MC1009 Refer to “BLEEDING THE HYDRAULIC WARNING CLUTCH SYSTEM” on page 3-13. • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to ET3P61024 REMOVING THE CLUTCH RELEASE...
Page 358: Installing The Clutch Release Cylinder
CLUTCH • When refilling, be careful that water does EAS25350 INSTALLING THE CLUTCH RELEASE not enter the clutch master cylinder reser- CYLINDER voir. Water will significantly lower the boil- 1. Check: ing point of the clutch fluid and could cause •...
Page 359: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-42. Oil baffle plate 1 Shift arm Circlip Shift shaft Shift shaft spring Spacer Stopper lever spring Stopper lever Circlip Collar...
Page 360: Checking The Shift Shaft
SHIFT SHAFT 3. Install: EAS25420 CHECKING THE SHIFT SHAFT • Shift arm “1” 1. Check: • Shift shaft Shift arm pinch bolt Bends/damage/wear → Replace. 10 Nm (1.0 m·kg, 7.2 ft·lb) • Shift shaft spring Damage/wear → Replace. Align the punch mark “a” in the shift shaft with EAS25430 CHECKING THE STOPPER LEVER the slot in the shift arm.
Page 361 SHIFT SHAFT c. Tighten both locknuts to specification. Shift rod locknut 7 Nm (0.7 m·kg, 5.1 ft·lb) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5-58...
Page 362: Oil Pump
OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-25. Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Exhaust pipe assembly Refer to “ENGINE REMOVAL”...
Page 363 OIL PUMP Removing the oil pan and oil pump Order Job/Parts to remove Q’ty Remarks Relief valve assembly sensor lead bracket For installation, reverse the removal proce- dure. 5-60...
Page 364 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump driven sprocket Oil pump housing For assembly, reverse the disassembly pro- cedure. 5-61...
Page 365: Checking The Oil Pump
OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven sprocket Less than 0.12 mm (0.0047 in) Limit • Oil pump housing 0.20 mm (0.0079 in) • Oil pump housing cover Cracks/damage/wear → Replace the defec- Outer-rotor-to-oil-pump-housing clearance tive part(s).
Page 366: Checking The Oil Strainer
OIL PUMP 1. Check: • Oil pan • Oil delivery pipes Oil pan bolt Damage → Replace. 12 Nm (1.2 m·kg, 8.7 ft·lb) Obstruction → Wash and blow out with com- pressed air. EAS24990 Tighten the oil pan bolts in stages and in a criss- CHECKING THE OIL STRAINER cross pattern.
Page 367: Middle Gear
MIDDLE GEAR EAS25710 MIDDLE GEAR Removing the middle gear 160 Nm (16.0 m kg, 115 ft • • 110 Nm (11.0 m kg, 80 ft • • Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-3. Oil pan/Oil pump Refer to “OIL PUMP”...
Page 368 MIDDLE GEAR Removing the middle gear 160 Nm (16.0 m kg, 115 ft • • 110 Nm (11.0 m kg, 80 ft • • Order Job/Parts to remove Q’ty Remarks Middle drive shaft assembly Spacer Middle driven gear Bearing retainer Bearing Refer to “ALIGNING THE MIDDLE GEAR”...
Page 369 MIDDLE GEAR Disassembling the middle drive shaft assembly Order Job/Parts to remove Q’ty Remarks Spring retainer Spring seat Damper spring Damper driven cam Damper drive cam Middle drive shaft For assembly, reverse the disassembly pro- cedure. 5-66...
Page 370 MIDDLE GEAR Disassembling the middle driven shaft assembly 110 Nm (11.0 m kg, 80 ft • • 180 Nm (18.0 m kg, 130 ft • • Order Job/Parts to remove Q’ty Remarks Oil seal Middle driven pinion gear nut Middle driven shaft Middle driven pinion gear Bearing retainer Bearing...
Page 371: Removing The Middle Drive Shaft Assembly
MIDDLE GEAR EAS25730 REMOVING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: • Middle drive pinion gear nut “1” • Lock washer “2” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a.
Page 372: Checking The Middle Drive Shaft Assembly
MIDDLE GEAR 4. Check: • Bearings Damage/pitting → Replace. EAS25790 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Check: • Middle driven pinion gear Galling/pitting/wear → Replace. 2. Check: c. Remove the middle driven pinion gear nut. • Bearings Damage/pitting → Replace. ▲...
Page 373: Installing The Middle Drive Shaft Assembly
MIDDLE GEAR c. Tighten the bearing retainer to specification. Bearing retainer 110 Nm (11.0 m·kg, 80 ft·lb) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS25860 INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1.
Page 374: Installing The Middle Driven Shaft Assembly
MIDDLE GEAR • Middle drive pinion gear nut “2” • Middle driven shaft end cover ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ • Middle driven shaft bearing housing bolts a.
Page 375: Measuring The Middle Gear Backlash
MIDDLE GEAR EAS25880 EAS25900 MEASURING THE MIDDLE GEAR ADJUSTING THE MIDDLE GEAR BACKLASH BACKLASH 1. Loosen: 1. Measure: • Middle driven shaft bearing housing bolts • Middle gear backlash 2. Remove: Out of specification → Refer to “ADJUSTING • Middle driven pinion gear shim(s) THE MIDDLE GEAR BACKLASH”...
Page 376: Aligning The Middle Gear
MIDDLE GEAR Middle driven shaft bearing hous- While carefully tightening the middle driven shaft ing bolt bearing housing bolts in stages and in a criss- 25 Nm (2.5 m·kg, 18 ft·lb) cross pattern, turn the middle driven shaft back LOCTITE® and forth until the dial gauge reads 0.10–0.20 mm (0.0039–0.0079 in).
Page 377 MIDDLE GEAR ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ “d” = a numeral on the middle driven pinion a. Position the middle gears with the appropri- gear, to be divided by 100 and either added ate shim(s) that has had its respective thick- to or subtracted from “34”...
Page 378 MIDDLE GEAR Middle driven pinion gear shim Thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 5-75...
Page 379: Crankcase
CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft (10) • • 24 Nm (2.4 m kg, 17 ft •...
Page 380 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft 20 Nm (2.0 m kg, 14 ft • • • • 2nd 20 Nm (2.0 m kg, 14 ft • • (10) 24 Nm (2.4 m kg, 17 ft •...
Page 381 CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 382 CRANKCASE Removing the oil baffle plate and bearings 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 383: Disassembling The Crankcase
CRANKCASE EAS25550 EAS25580 DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE 1. Place the engine upside down. 1. Thoroughly wash the crankcase halves in a 2. Remove: mild solvent. • Crankcase bolts 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3.
Page 384 Engine oil 2. Apply: • Sealant (onto the crankcase mating surfaces and oil baffle plate 2) 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.
Page 385 CRANKCASE Crankcase bolt “1”–“10” • Lubricate the bolts “1”–“10” thread and wash- ers with engine oil. 20 Nm (2.0 m·kg, 14 ft·lb) • Lubricate the bolts “11”–“31” thread part and mating surface with engine oil. b. Loosen and retighten the crankcase bolts in •...
Page 386: Installing The Oil Pump Drive Sprocket
CRANKCASE 13 21 19 22 EAS2PD1001 INSTALLING THE OIL PUMP DRIVE SPROCKET 1. Install: • Conical spring washer “1” • Collar “2” • Oil pump drive sprocket “3” • Oil pump drive chain Make sure that the white paint mark on the con- ical spring washer is facing outward as shown in the illustration.
Page 387 CONNECTING RODS AND PISTONS ET3P61027 CONNECTING RODS AND PISTONS Removing the connecting rods and pistons Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-76. Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing...
Page 388: Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS26030 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” Identify the position of each connecting rod so that it can be reinstalled in its original place. 2.
Page 389: Checking The Piston Rings
CONNECTING RODS AND PISTONS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measurements.
Page 390: Checking The Piston Pin
CONNECTING RODS AND PISTONS Piston ring Piston ring Top ring Top ring Ring side clearance End gap (installed) 0.030–0.070 mm (0.0012– 0.20–0.30 mm (0.0079–0.0118 0.0028 in) Limit Limit 0.120 mm (0.0047 in) 0.55 mm (0.0217 in) 2nd ring 2nd ring Ring side clearance End gap (installed) 0.020–0.060 mm (0.0008–...
Page 391: Checking The Connecting Rods
CONNECTING RODS AND PISTONS b. Install the big end upper bearing into the con- Piston pin bore inside diameter necting rod and the big end lower bearing into 19.004–19.015 mm (0.7482– the connecting rod cap. 0.7486 in) Limit Align the projections “a” on the big end bearings 19.045 mm (0.7498 in) with the notches “b”...
Page 392: Installing The Connecting Rods And Pistons
CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Refer to “INSTALLING THE CONNECTING RODS AND PISTONS” on page 5-89. f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS” on page 5-85. g.
Page 393 CONNECTING RODS AND PISTONS 4. Lubricate: • Piston • Apply engine oil onto the piston pin. • Piston rings • Make sure that the “Y” mark “a” on the connect- • Cylinder ing rod is facing to the left when the punch (with the recommended lubricant) mark “b”...
Page 394 CONNECTING RODS AND PISTONS c. Tighten the connecting rod nuts further to reach the specified angle 115–125°. Connecting rod nut (final) Specified angle 115–125° EWA13400 WARNING If the connecting rod nut is tightened more than the specified angle, do not loosen the nut and then retighten it.
Page 395: Crankshaft
CRANKSHAFT EAS25950 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-76. Front balancer weight Refer to “BALANCERS” on page 5-105. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-84. Crankshaft Crankshaft journal upper bearing Crankshaft journal lower bearing...
Page 396: Removing The Crankshaft Journal Bearings
CRANKSHAFT EAS26040 REMOVING THE CRANKSHAFT JOURNAL Journal oil clearance BEARINGS 0.027–0.045 mm (0.0011–0.0018 1. Remove: • Crankshaft journal upper bearings ECA13920 (from the upper crankcase) NOTICE • Crankshaft journal lower bearings Do not interchange the crankshaft journal (from the lower crankcase) bearings.
Page 397: Installing The Crankshaft
CRANKSHAFT e. Install the crankshaft journal lower bearings • If J –J are the same, use the same size for all “3” into the lower crankcase and assemble of the bearings. the crankcase halves. • Align the projections “c” of the crankshaft jour- nal lower bearings with the notches “d”...
Page 398 CRANKSHAFT • Align the projections “a” on the crankshaft jour- nal bearings “1” with the notches “b” in the crankcases. • Be sure to install each crankshaft journal bear- ing in its original place. 5-95...
Page 399: Transmission
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-76. Stopper lever Refer to “SHIFT SHAFT” on page 5-56. Drive axle assembly Bearing Washer Bearing Shift drum retainer Long shift fork guide bar...
Page 400 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Main axle assembly For installation, reverse the removal proce- dure. 5-97...
Page 401 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 5th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear 4th pinion gear Collar Main axle/1st pinion gear Bearing Washer Main axle bearing housing...
Page 402 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Middle drive gear Washer 2nd wheel gear Collar Washer 5th wheel gear Circlip Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 4th wheel gear Washer 1st wheel gear Bearing...
Page 403 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-100...
Page 404: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly Remove the main axle assembly with the slide hammer bolts “1” and weight. Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm 3. Check: YU-01083-1 • Shift fork movement Weight (along the shift fork guide bar) 90890-01084...
Page 405: Assembling The Main Axle And Drive Axle
TRANSMISSION Incorrect → Reassemble the transmission Main axle runout limit axle assemblies. 0.08 mm (0.0032 in) 5. Check: • Transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • Circlips Bends/damage/looseness → Replace. ET3P61030 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1.
Page 406: Installing The Transmission
TRANSMISSION • Be sure to align the projection on the toothed lock washer that is between the alignment • When installing the main axle assembly, use a marks “b” with the alignment mark “c” on the re- pin “2” to align the bearing housing hole with tainer.
Page 407 TRANSMISSION 4. Install: • Drive axle assembly • The bearing pin “1” must face towards the rear of the upper crankcase. • Make sure the bearing circlip “2” is inserted into the groove in the upper crankcase. 5. Check: • Transmission Rough movement →...
Page 408 BALANCERS ET3P61031 BALANCERS Removing the front balancer Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-76. Front balancer lever Front balancer shaft Washer Bearing Front balancer gear Damper Front balancer weight For installation, reverse the removal proce- dure.
Page 409 BALANCERS Removing the rear balancer Order Job/Parts to remove Q’ty Remarks Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-35. Clutch cover Refer to “CLUTCH” on page 5-42. Rear balancer cover Rear balancer cover gasket Rear balancer lever Rear balancer shaft...
Page 410: Balancers
BALANCERS 2. Align: EAS26120 CHECKING THE BALANCERS • “T” mark on the pickup rotor 1. Check: (with the crankcase mating surface) • Front balancer gear ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 411: Installing The Rear Balancer
BALANCERS • Front balancer shaft pinch bolt “2” Front balancer lever bolt 14 Nm (1.4 m·kg, 10 ft·lb) Front balancer shaft pinch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Make sure that the balancer shaft does not ro- tate. ▲ ▲▲▲...
Page 412 BALANCERS b. Align the balancer gear punch mark “c” with the primary driven gear point “d” as shown. • Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor- rectly. • Make sure that the balancer gear punch mark “c”...
Page 413 BALANCERS • Rear balancer shaft pinch bolt “2” Rear balancer lever bolt 14 Nm (1.4 m·kg, 10 ft·lb) Rear balancer shaft pinch bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Make sure that the balancer shaft does not ro- tate. ▲ ▲▲▲...
Page 414 BALANCERS 5-111...
Page 415: Cooling System
COOLING SYSTEM RADIATOR ...................... 6-1 REMOVING THE RADIATOR ..............6-3 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-4 CHECKING THE OIL COOLER ..............6-5 INSTALLING THE OIL COOLER .............. 6-5 THERMOSTAT ....................6-6 CHECKING THE THERMOSTAT.............. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP....................6-10 DISASSEMBLING THE WATER PUMP..........
Page 416: Radiator
RADIATOR EAS26380 RADIATOR Removing the radiator 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 12 Nm (1.2 m kg, 8.7 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 417 RADIATOR Removing the radiator 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 12 Nm (1.2 m kg, 8.7 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m...
Page 418: Removing The Radiator
RADIATOR EAS1MC1032 REMOVING THE RADIATOR Radiator cap tester 1. Pull the top of electrical components tray “1” 90890-01325 slightly outward as shown in the illustration Mityvac cooling system tester kit YU-24460-A and then remove the radiator bolt “2”. Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984...
Page 419: Oil Cooler
OIL COOLER EAS26410 OIL COOLER Removing the oil cooler Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-25. Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-28. Radiator Refer to “RADIATOR” on page 6-1. Exhaust pipe assembly Refer to “ENGINE REMOVAL”...
Page 420: Checking The Oil Cooler
OIL COOLER EAS26420 CHECKING THE OIL COOLER 1. Check: • Oil cooler Cracks/damage → Replace. 2. Check: • Oil cooler inlet hose • Oil cooler outlet hose • Water pump outlet hose • Water pump outlet pipe • Water jacket joint inlet hose Cracks/damage/wear →...
Page 421: Thermostat
THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat assembly 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 422 THERMOSTAT Removing the thermostat assembly 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
Page 423: Checking The Thermostat
THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat housing 1. Check: Cracks/damage → Replace. • Thermostat 3. Check: Does not open at 69.0–73.0 °C (156.20– • Thermostat hoses 163.40 °F) → Replace. • Thermostat pipes • Radiator inlet hose •...
Page 424 THERMOSTAT 5. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.
Page 425: Water Pump
WATER PUMP EAS26500 WATER PUMP Removing the water pump 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Right side cowling 4-1.
Page 426 WATER PUMP Disassembling the water pump Order Job/Parts to remove Q’ty Remarks Water pump housing cover O-ring Circlip Impeller shaft Mechanical seal (impeller side) Mechanical seal (housing side) Oil seal Bearing Water pump housing For assembly, reverse the disassembly pro- cedure.
Page 427: Disassembling The Water Pump
WATER PUMP EAS26510 EAS26540 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Mechanical seal (impeller side) “1” • Water pump housing cover (from the impeller, with a thin, flat-head • Water pump housing screwdriver) • Impeller shaft Cracks/damage/wear →...
Page 428: Installing The Water Pump
Middle driven shaft bearing driv- Impeller shaft tilt limit 90890-04058 0.15 mm (0.006 in) Middle drive bearing installer 40 & 50 mm YM-04058 Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 1. Straightedge 2. Impeller 5. Install: • Impeller “1”...
Page 429 WATER PUMP 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-28. 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure →...
Page 430 WATER PUMP 6-15...
Page 431: 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 INSTALLING THE FUEL PUMP..............7-2 INSTALLING THE FUEL TANK..............7-2 THROTTLE BODIES ..................7-4 CHECKING THE INJECTORS (BEFORE REMOVING) ......7-7 REMOVING THE INJECTORS ..............7-7 CHECKING THE INJECTORS ..............7-7 CHECKING AND CLEANING THE THROTTLE BODIES......7-7 CHECKING THE THROTTLE BODY JOINTS ..........
Page 432: Fuel Tank
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 10 Nm (1.0 m kg, 7.2 ft 4 Nm (0.4 m kg, 2.9 ft • • 16 Nm (1.6 m kg, 11 ft • • • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 433: Removing The Fuel Tank
FUEL TANK EAS26630 EAS26670 REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body Obstruction → Clean. 2. Remove: Cracks/damage →...
Page 434 FUEL TANK 2. Install: • Fuel hose (fuel pump side) • Fuel hose holder EC3P61008 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holder is in the correct position, other- wise the fuel hose will not be properly in- stalled.
Page 435: Throttle Bodies
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 436 THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Throttle body joint For installation, reverse the removal proce- dure.
Page 437 THROTTLE BODIES Removing the injectors 3.5 Nm (0.35 m kg, 2.5 ft 3.5 Nm (0.35 m kg, 2.5 ft • • • • 5 Nm (0.5 m kg, 3.6 ft • • 5 Nm (0.5 m kg, 3.6 ft • •...
Page 438: Checking The Injectors (Before Removing)
Obstruction → Replace and check the fuel pump/fuel supply system. Recommended cleaning solvent Deposit → Replace. Yamaha Oil & Brake Cleaner Damage → Replace. 2. Check: • Injector resistance Refer to “CHECKING THE FUEL INJEC- TORS” on page 8-213.
Page 439 THROTTLE BODIES • Do not allow any cleaning solvent to enter the opening for the injectors. • Do not apply any cleaning solvent to the por- tions of the throttle valve shafts between the throttle bodies. e. Remove the carbon deposits from the inside of each throttle body in a downward direction, from the air filter case side of the throttle body to the engine side.
Page 440: Checking The Throttle Body Joints
THROTTLE BODIES Refer to “SYNCHRONIZING THE THROT- • If installing the original fuel rail and screws, TLE BODIES” on page 3-8. remove the white paint marks using a cleaning solvent. Otherwise, paint chips on EAS21010 the screw seats could prevent the screws CHECKING THE THROTTLE BODY JOINTS from being tightened.
Page 441: Checking The Fuel Pressure
THROTTLE BODIES b. Disconnect the fuel hose “2” from the fuel rail. c. Close the valve on the injector pressure EWA1MC1018 adapter. WARNING d. Apply air pressure with the air compressor. Cover fuel hose connections with a cloth e. Open the valve on the injector pressure when disconnecting them.
Page 442: Adjusting The Throttle Position Sensor
THROTTLE BODIES e. Measure the fuel line pressure. All displays on the multi-function meter right dis- Fuel line pressure at idling play disappear and “DIAG” appears. 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi) f. Simultaneously press the “TCS” button “1” and “RESET” button “2” for 2 seconds or Faulty →...
Page 443 THROTTLE BODIES 1. Check: • Accelerator position sensor The diagnostic code number “01” appears on Refer to “CHECKING THE ACCELERATOR the multi-function meter right display. POSITION SENSOR” on page 8-210. h. Diagnostic code number “14” is selected. 2. Adjust: i. Turn the throttle grip to the fully closed posi- •...
Page 444: Air Induction System
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-13...
Page 445 AIR INDUCTION SYSTEM 1. Reed valve assembly 2. Air induction system hose (3-way joint to reed valve cover) 3. Air induction system hose (air cut-off valve to 3-way joint) 4. Air induction system hose (3-way joint to air cut-off valve) 5.
Page 446 AIR INDUCTION SYSTEM Removing the air cut-off valve Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/T-bar 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air induction system solenoid coupler Disconnect. Air induction system hose (air filter case joint assembly to 3-way joint) Air induction system hose (3-way joint to hose plug)
Page 447 AIR INDUCTION SYSTEM Removing the reed valves 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/T-bar 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Air induction system hoses (3-way joint to reed Refer to “Removing the air cut-off valve”.
Page 448: Checking The Air Induction System
AIR INDUCTION SYSTEM • 3-way joint EAS27060 CHECKING THE AIR INDUCTION SYSTEM Cracks/damage → Replace. 2. Check: Air injection • Reed valve The air induction system burns unburned ex- • Reed valve stopper haust gases by injecting fresh air (secondary air) •...
Page 449: Electrical System
FUEL INJECTION SYSTEM................8-33 CIRCUIT DIAGRAM ................8-33 ECU SELF-DIAGNOSTIC FUNCTION............8-35 TROUBLESHOOTING METHOD (ECU)..........8-36 DIAGNOSTIC MODE (ECU) ..............8-38 YAMAHA DIAGNOSTIC TOOL ...............8-39 TROUBLESHOOTING DETAILS (ECU) ..........8-41 CRUISE CONTROL SYSTEM ............... 8-89 CIRCUIT DIAGRAM ................8-89 CRUISE CONTROL CIRCUIT OPERATION...........8-91 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ......
Page 450 FUEL PUMP SYSTEM.................8-107 CIRCUIT DIAGRAM ................8-107 TROUBLESHOOTING ................8-109 WINDSHIELD DRIVE SYSTEM..............8-111 CIRCUIT DIAGRAM ................8-111 TROUBLESHOOTING ................8-113 ACCESSORY BOX SYSTEM..............8-115 CIRCUIT DIAGRAM ................8-115 TROUBLESHOOTING ................8-117 IMMOBILIZER SYSTEM................8-119 CIRCUIT DIAGRAM ................8-119 GENERAL INFORMATION ..............8-121 PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS.................8-121 TROUBLESHOOTING ................8-125 SELF-DIAGNOSIS FAULT CODE INDICATION........8-126 ABS (ANTI-LOCK BRAKE SYSTEM)............8-129 CIRCUIT DIAGRAM ................8-129...
Page 451 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM....8-169 CIRCUIT DIAGRAM ................8-169 MAINTENANCE OF THE SCU (suspension control unit) .....8-171 SCU (suspension control unit) SELF-DIAGNOSTIC FUNCTION..8-171 TROUBLESHOOTING METHOD (SCU)..........8-172 BASIC INSTRUCTIONS FOR DIAGNOSTIC FUNCTION ....8-173 TROUBLESHOOTING DETAILS (SCU) ..........8-173 ELECTRICAL COMPONENTS..............8-187 CHECKING THE SWITCHES ...............8-191 CHECKING THE BULBS AND BULB SOCKETS .........8-194 CHECKING THE FUSES ..............8-195 REPLACING THE ECU (engine control unit) ........8-196...
Page 452 IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 453 IGNITION SYSTEM 2. Main switch 5. Joint coupler 10.Ignition fuse 17.Fuel injection system fuse 26.Main fuse 27.Battery 28.Engine ground 33.Relay unit 36.Sidestand switch 42.Right handlebar switch 44.Start/engine stop switch 46.Gear position switch 97.Crankshaft position sensor 101.Lean angle sensor 109.ECU (engine control unit) 110.Ignition coil #1 111.Ignition coil #2 112.Ignition coil #3...
Page 454 IGNITION SYSTEM ET3P61002 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 455 IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar 5. Storage compartment 6. Side covers 7.
Page 456 IGNITION SYSTEM NG → 8. Check the start/engine stop switch. • The start/engine stop switch is faulty. Refer to “CHECKING THE • Replace the right handlebar switch. SWITCHES” on page 8-191. OK ↓ NG → 9. Check the gear position switch. Refer to “CHECKING THE Replace the gear position switch.
Page 457 IGNITION SYSTEM...
Page 458 ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 459 ELECTRIC STARTING SYSTEM 2. Main switch 5. Joint coupler 10.Ignition fuse 26.Main fuse 27.Battery 28.Engine ground 30.Starter relay 31.Starter motor 33.Relay unit 34.Starting circuit cut-off relay 36.Sidestand switch 37.Clutch switch 42.Right handlebar switch 44.Start/engine stop switch 46.Gear position switch A. Wire harness B.
Page 460 ELECTRIC STARTING SYSTEM EAS27180 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 461 ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar 5. Throttle bodies NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
Page 462 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch/immobilizer unit. SWITCHES” on page 8-191. OK ↓ NG → 9. Check the gear position switch. Refer to “CHECKING THE Replace the gear position switch. SWITCHES”...
Page 463 ELECTRIC STARTING SYSTEM 8-12...
Page 464 CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13...
Page 465 CHARGING SYSTEM 3. AC magneto 4. Rectifier/regulator 26.Main fuse 27.Battery 28.Engine ground A. Wire harness B. Negative battery sub-wire harness 8-14...
Page 466 CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Side cowlings NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 467 CHARGING SYSTEM 8-16...
Page 468 LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
Page 469 LIGHTING SYSTEM 2. Main switch 5. Joint coupler 8. Hazard lighting fuse 10.Ignition fuse 17.Fuel injection system fuse 18.Backup fuse 20.Headlight fuse 22.Headlight relay (on/off) 26.Main fuse 27.Battery 28.Engine ground 49.Left handlebar switch 52.Dimmer/pass switch 57.Headlight relay (dimmer) 58.Tail/brake light assembly 59.Tail/brake light 62.License plate light 63.Headlight assembly...
Page 470 LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary lights or meter light. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4.
Page 471 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-17. OK ↓ Replace the ECU, meter assembly, or headlight assembly. Refer to “RE- PLACING THE ECU (engine control unit)”...
Page 472 SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
Page 473 SIGNALING SYSTEM 2. Main switch 5. Joint coupler 8. Hazard lighting fuse 9. ABS ECU fuse 10.Ignition fuse 12.Signaling system fuse 17.Fuel injection system fuse 18.Backup fuse 21.Horn 26.Main fuse 27.Battery 28.Engine ground 33.Relay unit 38.Brake light fuse 39.Rear brake light switch 41.Front brake light switch 42.Right handlebar switch 45.Hazard switch...
Page 474 SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
Page 475 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the horn. The tail/brake light fails to come on. NG → 1.
Page 476 SIGNALING SYSTEM The turn signal light, turn signal indicator light or both fail to blink. NG → 1. Check the rear turn signal light bulbs and sockets. Replace the rear turn signal light bulb, Refer to “CHECKING THE BULBS socket or both. AND BULB SOCKETS”...
Page 477 SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-21. OK ↓ Replace the meter assembly. The oil level warning light fails to come on. NG →...
Page 478 SIGNALING SYSTEM NG → 2. Check the entire speed sensor wir- Properly connect or replace the wire har- ing. ness. Refer to TIP. OK ↓ Replace the hydraulic unit assembly, ECU or meter assembly. Replace the wire harness if there is an open or short circuit. •...
Page 479 SIGNALING SYSTEM 8-28...
Page 480 COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-29...
Page 481 COOLING SYSTEM 2. Main switch 5. Joint coupler 10.Ignition fuse 13.Right radiator fan motor fuse 14.Left radiator fan motor fuse 17.Fuel injection system fuse 23.Radiator fan motor relay 24.Left radiator fan motor 25.Right radiator fan motor 26.Main fuse 27.Battery 28.Engine ground 29.Cooling system fuse 108.Coolant temperature sensor 109.ECU (engine control unit)
Page 482 COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Fuel tank 3. T-bar NG → 1. Check the fuses. (Main, ignition, cooling system, fuel injection system, left radiator fan Replace the fuse(s).
Page 483 COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-29. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-196.
Page 484 FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-33...
Page 485 85.Engine trouble warning light 95.Fuel pump 97.Crankshaft position sensor 98.Intake air pressure sensor 99.Atmospheric pressure sensor 100.Cylinder identification sensor 101.Lean angle sensor 102.Yamaha diagnostic tool coupler 104.O sensor 105.Throttle position sensor 106.Accelerator position sensor 107.Air temperature sensor 108.Coolant temperature sensor 109.ECU (engine control unit)
Page 486 FUEL INJECTION SYSTEM EAS27351 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the 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 487 FUEL INJECTION SYSTEM 2. Check and repair the probable cause of the EAS2PD1008 TROUBLESHOOTING METHOD (ECU) malfunction. Fault code No. No fault code No. • If there is a malfunction in the fuel injection sys- tem, the windshield adjusting function “1” will Check and repair.
Page 488 FUEL INJECTION SYSTEM The engine operation is not normal, but the engine trouble warning light does not come 1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “TROUBLESHOOTING DETAILS (ECU)” on page 8-41. 01: Throttle position sensor signal 1 (throttle angle) 13: Throttle position sensor signal 2 (throttle...
Page 489 FUEL INJECTION SYSTEM EAS2PD1009 DIAGNOSTIC MODE (ECU) Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the wire harness coupler from the fuel pump. (except for electronically adjustable sus- pension system) 3. Shift the transmission into gear and extend the sidestand. ECA2PD1019 NOTICE If the “...
Page 490 EAS1MC1036 YAMAHA DIAGNOSTIC TOOL This model uses the Yamaha diagnostic tool to identify malfunctions. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Yamaha diagnostic tool 90890-03215 Features of the Yamaha diagnostic tool You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth- ods.
Page 491 Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”. 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 492 FUEL INJECTION SYSTEM EAS2PD1017 TROUBLESHOOTING DETAILS (ECU) This section describes the measures per fault code number displayed on the multi-function meter right display. Check and service the items or components that are the probable cause of the malfunction fol- lowing the order given. After the check and service of the malfunctioning part have been completed, reset the multi-function meter right display according to the “Confirmation of service completion”.
Page 493 FUEL INJECTION SYSTEM Fault code No. Cylinder identification sensor: no normal signals are received Item from the cylinder identification sensor. Installed condition of cylinder Improperly installed sensor Crank the engine. → Reinstall or replace the identification sensor. Fault code number is not dis- played →...
Page 494 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Open or short circuit → Re- Wire harness continuity. Crank the engine. place the wire harness. Fault code number is not dis- played →...
Page 495 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Improperly connected → Connection of intake air Turn the main switch to “ON”. pressure sensor coupler. Connect the coupler secure- Fault code number is not dis- played →...
Page 496 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Defective intake air pressure Execute the diagnostic Turn the main switch to “ON”. sensor. mode. (Code No. 03) Fault code number is not dis- played →...
Page 497 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Condition of intake air pres- Clogged or detached hose Start the engine and let it idle → Repair or replace the sen- sure sensor hose.
Page 498 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor signal 2 Meter display • 9–23 (fully closed position) • 94–108 (fully open position) • Check with throttle valves fully closed. Procedure •...
Page 499 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Defective throttle position Check throttle 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 500 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red Item lead of the ECU is detected. Improperly connected → Connection of sidestand Turn the main switch to “ON”, switch coupler. Connect the coupler secure- and then extend and retract Check the locking condition ly or replace the wire har-...
Page 501 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the intake air pres- Item sure sensor voltage and atmospheric pressure sensor voltage differ greatly. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 502 FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the intake air pres- Item sure sensor voltage and atmospheric pressure sensor voltage differ greatly. Defective atmospheric pres- Execute the diagnostic Turn the main switch to “ON”.
Page 503 FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Improperly connected → Connection of ECU coupler. Turn the main switch to “ON”. Check the locking condition Connect the coupler secure- Fault code number is not dis- played →...
Page 504 FUEL INJECTION SYSTEM Fault code No. Item Air temperature sensor: open or short circuit detected. Meter display Displays the air temperature. Compare the actually measured air temperature with the meter Procedure display value. Probable cause of mal- Confirmation of service Item Maintenance job function and check...
Page 505 FUEL INJECTION SYSTEM Fault code No. Item Air temperature sensor: open or short circuit detected. Defective air temperature Execute the diagnostic Turn the main switch to “ON”. sensor. mode. (Code No. 05) Fault code number is not dis- played → Service is finished. When engine is cold: Displayed temperature is Fault code number is dis-...
Page 506 FUEL INJECTION SYSTEM Fault code No. Item Atmospheric pressure sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness. Fault code number is not dis- played →...
Page 507 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Probable cause of mal- Confirmation of service Item Maintenance job...
Page 508 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Check fuel pressure. Refer to “CHECKING THE Start the engine, warm it up, FUEL PRESSURE” on page and then race it, or execute 7-10.
Page 509 FUEL INJECTION SYSTEM Fault code No. Item Latch up detected. Defective lean angle sensor. Execute the diagnostic Turn the main switch to “ON”, mode. (Code No. 08) then to “OFF”, and then back Replace if defective. to “ON”. Refer to “CHECKING THE Fault code number is not dis- played →...
Page 510 FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#1 ignition coil. Installed condition of cylin- Improperly installed ignition Start the engine and let it idle coil → Reinstall or replace der-#1 ignition coil.
Page 511 FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#2 ignition coil. Improperly connected → Connection of ECU coupler. Start the engine and let it idle Check the locking condition Connect the coupler secure- for approximately 5 seconds.
Page 512 FUEL INJECTION SYSTEM Fault code No. Cylinder-#3 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#3 ignition coil. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Improperly connected → Connection of cylinder-#3 ig- Start the engine and let it idle nition coil coupler.
Page 513 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#4 ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 514 FUEL INJECTION SYSTEM Fault code No. Cylinder-#4 ignition coil: open or short circuit detected in the Item primary lead of the cylinder-#4 ignition coil. Malfunction in ECU. Execute the diagnostic mode. (Code No. 33) No spark → Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)”...
Page 515 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Improperly connected → Connection of injector #1, Execute the diagnostic #2, #3, and/or injector #4 Connect the coupler secure- mode. (Code Nos. 36, 37, coupler. ly or replace the wire har- 38, 39) No operating sound →...
Page 516 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. Lean angle sensor output voltage Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Remove the lean angle sensor and incline it more than 65 de- Procedure grees.
Page 517 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. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 518 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. Improperly connected → Connection of ABS ECU Execute the diagnostic coupler.
Page 519 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. Delete the fault code. Turn the main switch to “ON”, and then rotate the rear wheel by hand.
Page 520 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. Improperly connected → Connection of neutral switch Execute the diagnostic coupler.
Page 521 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 gear position Check the gear position Execute the diagnostic switch (neutral circuit).
Page 522 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 523 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. Improperly connected → Connection of clutch switch Execute the diagnostic coupler.
Page 524 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 525 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. 09, 50 Fuel system voltage (battery voltage) Meter display Approximately 12.0 Set the start/engine stop switch to “...
Page 526 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Open or short circuit → Re- Wire harness continuity. Start the engine and let it idle place the wire harness. for approximately 30 sec- Between relay unit coupler onds.
Page 527 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading Item or writing on EEPROM. EEPROM fault code display • 00 (no history) • 01–04: Cylinder fault code number (history exists) If more than one cylinder is defective, the display switches every Meter display two seconds to show the cylinder fault code numbers of all defec- tive cylinders in a repeating cycle.
Page 528 FUEL INJECTION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading Item or writing on EEPROM. “03” is indicated in diagnostic Change the CO concentra- Turn the main switch to “ON”. mode (code No. 60). EEP- tion of cylinder #3, and re- Fault code number is not dis- played →...
Page 529 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Malfunction in charging sys- Check the charging system. Start the engine and let it idle tem.
Page 530 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Accelerator position sensor signal 2 Meter display • 10–24 (fully closed position) • 97–109 (fully open position) • Check with throttle grip in fully closed position. Procedure •...
Page 531 FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Defective accelerator posi- Check accelerator position Turn the main switch to “ON”. tion sensor. sensor signal 1. Fault code number is not dis- played → Service is finished. Execute the diagnostic mode.
Page 532 FUEL INJECTION SYSTEM Fault code No. Item YCC-T drive system: malfunction detected. Improperly connected → Connection of throttle servo Turn the main switch to “ON”. motor coupler. Connect the coupler secure- Fault code number is not dis- played → Service is finished. Check the locking condition ly or replace the wire har- of the coupler.
Page 533 FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item front wheel sensor. Front wheel speed pulse Meter display 0–999 Check that the number increases when the front wheel is rotated. Procedure The number is cumulative and does not reset each time the wheel is stopped.
Page 534 FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item front wheel sensor. Improperly connected → Connection of ECU coupler. Execute the diagnostic Check the locking condition Connect the coupler secure- mode. (Code No. 16) of the coupler.
Page 535 The fault code can also be deleted by activating the di- agnostic mode and selecting diagnostic code number “63”. Fault code No. 89 (Yamaha diagnostic tool) Multi-function meter: signals cannot be transmitted between Item the ECU and the multi-function meter. Able to start engine...
Page 536 FUEL INJECTION SYSTEM Fault code No. Err (multi-function meter center display) Abnormal meter assembly communication (meter assembly Item cannot receive CAN communication data). Locate the malfunction. Check the engine trouble — warning light and electroni- cally adjustable suspension system warning light. •...
Page 537 FUEL INJECTION SYSTEM Fault code No. Err (multi-function meter center display) Abnormal ECU communication (CAN communication from the Item meter assembly). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Probable cause of mal- Confirmation of service Item...
Page 538 FUEL INJECTION SYSTEM Fault code No. Err (multi-function meter center display) Abnormal SCU communication (CAN communication from the Item meter assembly). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display — Procedure — Probable cause of mal- Confirmation of service Item...
Page 539 FUEL INJECTION SYSTEM 8-88...
Page 540 CRUISE CONTROL SYSTEM EAS1MC1010 CRUISE CONTROL SYSTEM EAS1MC1011 CIRCUIT DIAGRAM 8-89...
Page 541 CRUISE CONTROL SYSTEM 2. Main switch 5. Joint coupler 10.Ignition fuse 12.Signaling system fuse 17.Fuel injection system fuse 18.Backup fuse 26.Main fuse 27.Battery 28.Engine ground 32.Cruise control system fuse 37.Clutch switch 38.Brake light fuse 39.Rear brake light switch 40.Grip cancel switch 41.Front brake light switch 47.Brake switch relay 48.Brake light relay...
Page 542 CRUISE CONTROL SYSTEM EAS1MC1012 CRUISE CONTROL CIRCUIT OPERATION 8-91...
Page 543 CRUISE CONTROL SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Backup fuse 5. Fuel injection system fuse 6. Signaling system fuse 7. Brake light fuse 8. Ignition fuse 9. Cruise control system fuse 10.Cruise control power switch 11.Cruise control setting switch 12.Clutch switch 13.Front brake light switch 14.Rear brake light switch...
Page 544 [A] Malfunction check using the cruise control system indicator light. [B] Use the diagnostic mode or Yamaha diagnostic tool to determine the cause of the malfunction for the stored fault code from the condition and place where the malfunction occurred.
Page 545 CRUISE CONTROL SYSTEM EAS1MC1015 BASIC PROCESS FOR TROUBLESHOOTING Push the cruise control Fails to come on The cruise control power switch is • power switch, and check defective. the cruise control system • The cruise control system fuse is indicator light. Flashes blown.
Page 546 CRUISE CONTROL SYSTEM EWA1MC1005 WARNING When maintenance or checks have been performed on components related to the cruise control system, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[C-2] FINAL CHECK” on page 8-104.) EAS1MC1016 [A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT Turn the main switch to “ON”, and then push the cruise control power switch.
Page 547 CRUISE CONTROL SYSTEM Fault code No. A Front brake light switch: open or short circuit is detected. Item B Rear brake light switch: open or short circuit is detected. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Locate the malfunction.
Page 548 CRUISE CONTROL SYSTEM Fault code No. A Front brake light switch: open or short circuit is detected. Item B Rear brake light switch: open or short circuit is detected. Abnormality → Replace the Check the fuse. (Main, sig- Turn the main switch to “ON”. naling system, brake light) fuse.
Page 549 CRUISE CONTROL SYSTEM Fault code No. A Front brake light switch: open or short circuit is detected. Item B Rear brake light switch: open or short circuit is detected. “ON” (when the brakes are applied) Meter display “OFF” (when the brakes are not applied) Procedure Operate the brake pedal.
Page 550 CRUISE CONTROL SYSTEM Fault code No. A Front brake light switch: open or short circuit is detected. Item B Rear brake light switch: open or short circuit is detected. Abnormality → Replace the Check the fuse. (Main, sig- Turn the main switch to “ON”. naling system, brake light) fuse.
Page 551 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is detected. Item Cruise control setting switch “SET–”: open or short circuit is de- tected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 552 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is detected. Item Cruise control setting switch “SET–”: open or short circuit is de- tected. Improperly connected → Connection of ECU coupler. Turn the main switch to “ON”. Check the locking condition Connect the coupler secure- Push and release the...
Page 553 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is detected. Item Cruise control setting switch “SET–”: open or short circuit is de- tected. Malfunction in ECU. Replace the ECU. Refer to “REPLACING THE ECU (engine control unit)”...
Page 554 CRUISE CONTROL SYSTEM Fault code No. Cruise control setting switch “RES+”: open or short circuit is de- tected. Item Cruise control setting switch “SET–”: open or short circuit is detected. Improperly connected → Connection of main switch Turn the main switch to “ON”. coupler.
Page 555 Refer to “OUTLINE OF THE CRUISE CONTROL SYSTEM” on page 1-6. If you do not have a Yamaha diagnostic tool, the automatic deactivation history cannot be checked. Therefore, explain the automatic deactivation function of the cruise control system to the customer and explain that this is not a malfunction.
Page 556 CRUISE CONTROL SYSTEM 2. Check the rear brake light switches. Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” on page 3-30. 3. Execute the diagnostic mode (code Nos. 82 and 83) to check the operation of the front brake light switch, rear brake light switch, clutch switch, and grip cancel switch.
Page 557 CRUISE CONTROL SYSTEM 8-106...
Page 558 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-107...
Page 559 FUEL PUMP SYSTEM 2. Main switch 5. Joint coupler 10.Ignition fuse 17.Fuel injection system fuse 26.Main fuse 27.Battery 28.Engine ground 33.Relay unit 35.Fuel pump relay 42.Right handlebar switch 44.Start/engine stop switch 95.Fuel pump 109.ECU (engine control unit) A. Wire harness B.
Page 560 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Side cowlings 2. Front cowling assembly 3. Fuel tank 4. T-bar NG → 1. Check the fuses. (Main, ignition, and fuel injection system) Replace the fuse(s).
Page 561 FUEL PUMP SYSTEM NG → 7. Check the entire fuel pump system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 8-107. OK ↓ Replace the ECU. Refer to “REPLAC- ING THE ECU (engine control unit)” on page 8-196.
Page 562 WINDSHIELD DRIVE SYSTEM EAS27610 WINDSHIELD DRIVE SYSTEM EAS27620 CIRCUIT DIAGRAM 8-111...
Page 563 WINDSHIELD DRIVE SYSTEM 2. Main switch 5. Joint coupler 7. Windshield drive system fuse 10.Ignition fuse 12.Signaling system fuse 18.Backup fuse 26.Main fuse 27.Battery 28.Engine ground 49.Left handlebar switch 54.Menu switch 55.Select switch 70.Windshield drive unit 71.Windshield drive unit relay (down) 72.Windshield drive unit relay (up) 78.Meter assembly 79.Multi-function meter...
Page 564 WINDSHIELD DRIVE SYSTEM EAS27630 TROUBLESHOOTING The windshield fails to move. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Fuel tank 3. T-bar NG → 1. Check that there are no rocks or other foreign material in the wind- Remove the foreign material.
Page 565 WINDSHIELD DRIVE SYSTEM NG → 8. Check the windshield drive unit re- lay (up). Replace the windshield drive unit relay Refer to “CHECKING THE RE- (up). LAYS” on page 8-199. OK ↓ NG → 9. Check the windshield drive unit re- lay (down).
Page 566 ACCESSORY BOX SYSTEM ET3P61009 ACCESSORY BOX SYSTEM ET3P61010 CIRCUIT DIAGRAM 8-115...
Page 567 ACCESSORY BOX SYSTEM 2. Main switch 5. Joint coupler 12.Signaling system fuse 26.Main fuse 27.Battery 28.Engine ground 68.Accessory box solenoid A. Wire harness B. Negative battery sub-wire harness C. Accessory box solenoid sub-lead 8-116...
Page 568 ACCESSORY BOX SYSTEM ET3P61012 TROUBLESHOOTING The accessory box fails to operate. • Before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Left side cowling 3. Fuel tank 4. T-bar NG → 1. Check the fuses. (Main and signaling system) Replace the fuse(s).
Page 569 ACCESSORY BOX SYSTEM 8-118...
Page 570 IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-119...
Page 571 5. Joint coupler 10.Ignition fuse 17.Fuel injection system fuse 18.Backup fuse 26.Main fuse 27.Battery 28.Engine ground 78.Meter assembly 79.Multi-function meter 80.Immobilizer system indicator light 103.Yamaha diagnostic tool connector 109.ECU (engine control unit) A. Wire harness B. Negative battery sub-wire harness 8-120...
Page 572 IMMOBILIZER SYSTEM EAS27670 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 573 IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √...
Page 574 IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on d. LED off 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.
Page 575 IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” B. Immobilizer system indicator light stops flashing when the registration of the second b. Main switch “OFF” standard key is complete. c. LED on d. LED off e. Less than 5.0 s f.
Page 576 IMMOBILIZER SYSTEM EAS27700 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, fuel injection sys- tem, and backup) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
Page 577 IMMOBILIZER SYSTEM EAS27720 SELF-DIAGNOSIS FAULT CODE INDICATION When a system malfunction occurs, the fault code number is indicated in the multi-function meter right display and the immobilizer system indicator light flashes at the same time. The pattern of flashing also shows the fault code.
Page 578 IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Key code registra- Same standard key was UNIT tion malfunction. attempted to be regis- Register another tered two consecutive standard key. times. Unidentified code is Noise interference or 1. Check the wire received.
Page 579 IMMOBILIZER SYSTEM 8-128...
Page 580 ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM 8-129...
Page 581 ABS (ANTI-LOCK BRAKE SYSTEM) 2. Main switch 5. Joint coupler 9. ABS ECU fuse 10.Ignition fuse 12.Signaling system fuse 15.ABS motor fuse 16.ABS solenoid fuse 17.Fuel injection system fuse 18.Backup fuse 26.Main fuse 27.Battery 28.Engine ground 30.Starter relay 33.Relay unit 34.Starting circuit cut-off relay 38.Brake light fuse 39.Rear brake light switch...
Page 582 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 12,13 1. ABS test coupler 2. ABS warning light 3. ABS ECU fuse 4. ABS solenoid fuse 5. ABS motor fuse 6. Proportioning valve 7. Hydraulic unit assembly 8. Rear wheel sensor 9.
Page 583 ABS (ANTI-LOCK BRAKE SYSTEM) 8-132...
Page 584 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART Br/Y Br/W Br/B Br/W Br/B R/W W/L W/G W/R G/W L/R L/B G/B Sb/W Y G/R R/G R/G R/G Ch (Gy) W Gy Gy W W Gy W B G/W L/W W/Y L/B B/W Gy W W/L G/Y Sb Br/W...
Page 585 ABS (ANTI-LOCK BRAKE SYSTEM) 1. Meter assembly coupler 2. ABS test coupler 3. Rear wheel sensor coupler 4. ABS ECU coupler 5. Front wheel sensor coupler 8-134...
Page 586 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 MAINTENANCE OF THE ABS ECU If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air. Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damages → Replace the hydraulic unit assembly and the brake pipes that are connected to the assembly as a set.
Page 587 ABS (ANTI-LOCK BRAKE SYSTEM) The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned to “ON”. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.
Page 588 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING Fails to Does only the ABS warning [A-1] Turn the main switch to The ABS warning light(LED) is come on • light fail to come on? “ON”, and check the ABS defective.
Page 589 ABS (ANTI-LOCK BRAKE SYSTEM) EWA1MC1004 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. (Refer to “[C-3] FINAL CHECK” on page 8-164.) EAS27830 [A] CHECKING THE ABS WARNING LIGHT Turn the main switch to “ON”.
Page 590 ABS (ANTI-LOCK BRAKE SYSTEM) • If the T/C terminal is not short-circuited to the ground, check the internal circuit of the meter assem- bly. Turn the main switch to “OFF”. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main switch is turned to “ON”.
Page 591 ABS (ANTI-LOCK BRAKE SYSTEM) EAS1MC1005 [B-1] A FAULT CODE NUMBER IS NOT DISPLAYED IN THE MULTI-FUNCTION METER RIGHT DISPLAY 1. The ABS warning light remains on. A malfunction is detected. [B-2] 2. The ABS warning light flashes every 0.5 second for more than 6 seconds. A malfunction is not detected.
Page 592 ABS (ANTI-LOCK BRAKE SYSTEM) • If the ABS warning light does not come on, the ABS ECU is defective. Replace the hydraulic unit assembly. 7. The hydraulic unit assembly is defective. EAS1MC1029 [B-3] DIAGNOSIS USING THE FAULT CODES Connect the test coupler adapter to the ABS test coupler, and then turn the main switch to “ON”. Information for the fault codes from the ABS ECU is contained in the following table.
Page 593 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. Start switch signal is not received prop- • Wire harness ABS_22 erly (start switch circuit or start switch • Connection of the relay unit coupler and monitor circuit). ABS ECU coupler. •...
Page 594 ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. • Battery voltage ABS_51 • Battery terminal Power voltage is too high. ABS_52 • Refer to “CHARGING SYSTEM” on page 8-13. • Battery voltage • Connection of the ABS ECU coupler ABS_53 Power voltage is too low.
Page 595 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_11 Symptom Front wheel sensor signal is not received prop- ABS_25 erly. Order Item/components and probable Check or maintenance job cause Installed condition of wheel sensor. Check for looseness. Properly install or replace the wheel sensor if necessary.
Page 596 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_13 Symptom Incorrect signal from the front wheel sensor is ABS_26 detected. Order Item/components and probable Check or maintenance job cause Installed condition of wheel sensor. Check for looseness. Properly install or replace the wheel sensor if necessary.
Page 597 ABS (ANTI-LOCK BRAKE SYSTEM) Vehicle possibly ridden on uneven roads. Fault code No. ABS_15 Symptom No continuity in the front wheel sensor circuit. Order Item/components and probable Check or maintenance job cause Connections • Check the coupler for any pins that may be pulled •...
Page 598 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_15 Symptom No continuity in the front wheel sensor circuit. Order Item/components and probable Check or maintenance job cause Defective wheel sensor. If the above items were performed and no malfunc- tions were found, connect the ABS ECU coupler and front wheel sensor coupler, and then delete the fault codes.
Page 599 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_16 Symptom No continuity in the rear wheel sensor circuit. Order Item/components and probable Check or maintenance job cause Wire harness continuity. • Check for continuity between the gray terminal “1” and the gray terminal “3” and between the white terminal “2”...
Page 600 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_17 Symptom Missing pulses detected in the front wheel sen- ABS_45 sor signal. Order Item/components and probable Check or maintenance job cause Foreign material inside sensor hous- Check the interior of the sensor housing and the ing.
Page 601 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_22 Symptom Start switch signal is not received properly (start switch circuit or start switch monitor cir- cuit). Order Item/components and probable Check or maintenance job cause Connections • Check the coupler for any pins that may be pulled •...
Page 602 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_23 Symptom Brake light signal is not received properly when main switch is turned to “ON” (brake light cir- cuit, or front or rear brake light switch circuit). Order Item/components and probable Check or maintenance job cause Open or short circuit in wire harness.
Page 603 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_24 Symptom Brake light signal is not received properly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit). Order Item/components and probable Check or maintenance job cause Open or short circuit in wire harness.
Page 604 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_32 Symptom Hydraulic unit solenoid relay is short-circuited. Order Item/components and probable Check or maintenance job cause Short circuit in solenoid relay. Replace the hydraulic unit assembly. Hydraulic unit assembly internal mal- Replace the hydraulic unit assembly. function.
Page 605 Brake lines • Check the brake lines for kinks and deterioration. EWA3P6D005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines...
Page 606 ABS (ANTI-LOCK BRAKE SYSTEM) EWA3P6D006 WARNING The front brakes will not function properly if the connections are reversed. • Brake pipe/lower joint assembly “1” and brake pipe “2” inlet: from the front brake master cyl- inder • Brake pipe/upper joint assembly “3” and brake pipe “4” outlet: to the front brake calipers •...
Page 607 (particularly between the hydraulic unit and the rear brake caliper). EWA3P6D005 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit and from the hydraulic unit to the proportion- ing valve are correct.
Page 608 ABS (ANTI-LOCK BRAKE SYSTEM) • If the brake pipes (to the proportioning valve and the metering valve) are switched during assembly, the brakes will continue to operate as normal. However, the reduction of the hydraulic pressure for the rear brake and part of the right front brake will be reversed during the ABS operation when the final check on page “[C-3] FINAL CHECK”...
Page 609 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_51 Symptom Power voltage is too high. ABS_52 Order Item/components and probable Check or maintenance job cause Battery voltage Replace the battery. Refer to “CHECKING AND CHARGING THE BAT- TERY” on page 8-196. Disconnected battery terminal (fault Check the connection.
Page 610 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_54 Symptom Power voltage is too low. Order Item/components and probable Check or maintenance job cause Open or short circuit in wire harness. • Replace if there is an open or short circuit. •...
Page 611 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_63 Symptom Front wheel sensor power is abnormal. Order Item/components and probable Check or maintenance job cause Short circuit in front wheel sensor • Check that there is no short circuit between the lead.
Page 612 ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. ABS_64 Symptom Rear wheel sensor power is abnormal. Order Item/components and probable Check or maintenance job cause Short circuit in rear wheel sensor • Check that there is no short circuit between the lead.
Page 613 ABS (ANTI-LOCK BRAKE SYSTEM) EAS1MC1007 5. Push the “ ” side of the start/engine stop [C-1] DELETING THE FAULT CODES switch “1” at least 10 times in 4 seconds to 1. Check: delete the fault codes. • Engine stop due to sidestand operation EWA1MC1021 WARNING •...
Page 614 ABS (ANTI-LOCK BRAKE SYSTEM) 5. Check: • ABS ECU voltage Lower than 12.8 V → Charge or replace the W B G/W L/W W/Y battery. L/B B/W Gy W W/L G/Y Sb Br/W Battery voltage Higher than 12.8 V R/B R/W ▼...
Page 615 ABS (ANTI-LOCK BRAKE SYSTEM) W B G/W L/W W/Y L/B B/W Gy W W/L G/Y Sb Br/W b. Shift the transmission into gear and extend the sidestand. c. Push the “ ” side of the start/engine stop switch. d. Measure the ABS ECU voltage. ▲...
Page 616 GRIP WARMER SYSTEM ET3P66016 GRIP WARMER SYSTEM ET3P66017 CIRCUIT DIAGRAM 8-165...
Page 617 GRIP WARMER SYSTEM 2. Main switch 5. Joint coupler 10.Ignition fuse 17.Fuel injection system fuse 18.Backup fuse 26.Main fuse 27.Battery 28.Engine ground 49.Left handlebar switch 54.Menu switch 55.Select switch 78.Meter assembly 79.Multi-function meter 85.Engine trouble warning light 109.ECU (engine control unit) 121.Left grip warmer 122.Right grip warmer A.
Page 618 GRIP WARMER SYSTEM ET3P66019 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Right upper inner panel 2. Lower center cover 3. Fuel tank 4. T-bar The grip warmers do not become warm at all. NG → 1. Check that the engine trouble warn- Perform the troubleshooting for fault code ing light is on and that “Err”...
Page 619 GRIP WARMER SYSTEM The grip warmers are abnormally hot while the engine is idling. NG → 1. Check that the temperature level of Adjust the temperature levels of the grip the low grip warmer setting is set to warmer settings. “1”.
Page 620 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM EAS2PD1010 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM EAS2PD1011 CIRCUIT DIAGRAM 8-169...
Page 621 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM 2. Main switch 5. Joint coupler 6. SCU fuse 10.Ignition fuse 17.Fuel injection system fuse 18.Backup fuse 26.Main fuse 27.Battery 28.Engine ground 73.SCU (suspension control unit) 74.Left front fork stepping motor 75.Right front fork stepping motor 76.Rear shock absorber assembly stepping motor 77.Rear shock absorber assembly DC motor...
Page 622 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM EAS2PD1012 MAINTENANCE OF THE SCU (suspension control unit) Checking the SCU (suspension control unit) 1. Check: • Terminals “1” of the SCU Cracks/damages → Replace the SCU. • Terminals “2” of the SCU couplers Connection defective, contaminated, come- off →...
Page 623 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM 3. Perform the reinstatement action for the elec- EAS2PD1014 TROUBLESHOOTING METHOD (SCU) tronically adjustable suspension system. Refer to “Confirmation of service completion” • If there is a malfunction in the electronically ad- in the appropriate table in “TROUBLE- justable suspension system, the damping SHOOTING DETAILS (SCU)”...
Page 624 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM EAS2PD1015 BASIC INSTRUCTIONS FOR DIAGNOSTIC FUNCTION For information about setting the diagnostic mode, refer to “DIAGNOSTIC MODE (ECU)” on page 8-38. EAS2PD1016 TROUBLESHOOTING DETAILS (SCU) This section describes the measures per fault code number displayed on the multi-function meter right display.
Page 625 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. EEPROM fault code number: an error is detected while reading Item from or writing on EEPROM. Locate the faulty data (pre- Turn the main switch to Execute the diagnostic load adjustment) in the SCU. “OFF”.
Page 626 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item SCU (suspension control unit): open or short circuit detected. When completed successfully: “00” is displayed in the multi-function meter right display and the electronically adjustable suspension system warning light goes off. The preload is adjusted to the solo-riding position. When not completed successfully: “F0”...
Page 627 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Signals cannot be transmitted between the SCU and the ECU and between the SCU and the meter assembly. (Fault code No. Item 89 is displayed in the multi-function meter right display only when abnormal ECU communication is detected.) Open or short circuit →...
Page 628 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Stepping motor: open or short circuit detected. Improperly connected → Connection of stepping mo- Turn the main switch to tor coupler. Connect the coupler secure- “OFF” and back to “ON”. Check the locking condition ly or replace the wire har- Fault code number is not dis- played →...
Page 629 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Stepping motor: open or short circuit detected. Open circuit → Replace. Wire harness and/or front Turn the main switch to fork stepping motor sub-lead • Between SCU coupler and “OFF” and back to “ON”. continuity.
Page 630 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Stepping motor: open or short circuit detected. Wire harness and/or front • SCU internal circuit (be- Turn the main switch to fork stepping motor sub-lead tween left front fork step- “OFF” and back to “ON”. continuity.
Page 631 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Stepping motor: open or short circuit detected. Malfunction in stepping mo- Stepping motor operation Turn the main switch to “ON”. tor. confirmation steps: Fault code number is not dis- played → Service is finished. a.
Page 632 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 633 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 634 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 635 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 636 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Preload adjusting motor (rear shock absorber assembly DC motor) is locked, rotary encoder signal is not received, encod- Item er signal is reversed, or motor rotates continuously at a low speed during the diagnostic mode (code No. 84 [preload home position adjustment]).
Page 637 ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM Fault code No. Item Defective preload adjusting motor (DC motor). Wire harness continuity. Refer to “REAR SHOCK AB- Execute the diagnostic SORBER ASSEMBLY” on mode. (Code No. 84) page 4-93. Start the engine, adjust the Short circuit → Replace the preload (solo riding →...
Page 638 ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-187...
Page 639 ELECTRICAL COMPONENTS 1. Windshield drive unit 2. Battery 3. Starter relay 4. Cooling system fuse 5. Front brake light switch 6. Clutch switch 7. Fuse box 3 8. Fuse box 1 9. Fuse box 2 10. SCU fuse 11. Cruise control system fuse 12.
Page 640 ELECTRICAL COMPONENTS 8-189...
Page 641 ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Accelerator position sensor 3. Throttle position sensor 4. Intake air pressure sensor 5. Atmospheric pressure sensor 6. Brake light relay 7. SCU (suspension control unit) 8. Brake switch relay 9. Hydraulic unit assembly 10.
Page 642 ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES W/G W/R O/W Y/B W/B W/Y R/Y Y G/L Br/L L/R Br/G G/L Y/B Br/L W/R B/W W/G R/B W/L B Y/B O/W Br/G W/L B/W L/B R/Y Y MENU PASS W/B L/R W/Y MODE G/W G/Y Y/B Y/W PULL...
Page 643 ELECTRICAL COMPONENTS 1. Start/engine stop switch 2. Hazard switch 3. Mode switch 4. Front brake light switch 5. Main switch 6. Rear brake light switch 7. Gear position switch 8. Sidestand switch 9. Clutch switch 10. Horn switch 11. Dimmer/pass switch 12.
Page 644 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 645 ELECTRICAL COMPONENTS EAS27990 EW3P61001 CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulbs get extremely hot, keep flammable products and your hands Do not check any of the lights that use LEDs. away from them until they have cooled down.
Page 646 ELECTRICAL COMPONENTS Checking the condition of the bulb sockets 3. Replace: The following procedure applies to all of the bulb • Blown fuse sockets. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 647 ELECTRICAL COMPONENTS may cause extensive damage to the electri- • Drink large quantities of water or milk fol- cal system, cause the lighting and ignition lowed with milk of magnesia, beaten egg or systems to malfunction and could possibly vegetable oil. Get immediate medical atten- cause a fire.
Page 648 ELECTRICAL COMPONENTS 4. Check: • Battery charge ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a pocket tester to the battery termi- nals. • Positive tester probe → positive battery terminal •...
Page 649 ELECTRICAL COMPONENTS • If the battery becomes hot to the touch at • Standard charging current is reached any time during the charging process, dis- Battery is good. connect the battery charger and let the bat- • Standard charging current is not reached tery cool before reconnecting it.
Page 650 ELECTRICAL COMPONENTS Starter relay 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 651 ELECTRICAL COMPONENTS Relay unit (fuel pump relay) Headlight relay (dimmer) First step: Br/W 1. Positive battery terminal 2. Negative battery terminal 1. Positive tester probe 3. Positive tester probe 2. Negative tester probe 4. Negative tester probe 3. Negative tester probe Result Result Continuity...
Page 652 ELECTRICAL COMPONENTS Brake switch relay 4. Negative tester probe Result No continuity (between “3” and “4”) Radiator fan motor relay Lg/B 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Br/B Result Continuity 1.
Page 653 ELECTRICAL COMPONENTS Second step: Second step: Br/G Br/G 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe 5.
Page 654 ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Continuity d. Check the relay unit (diode) for no continuity. Positive tester probe → sky blue ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
Page 655 ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester (Ω × 1k) to the ig- nition coil as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C •...
Page 656 ELECTRICAL COMPONENTS 65 65 B Gy b. Measure the crankshaft position sensor re- c. Turn the main switch to “ON”. sistance. d. Turn the lean angle sensor to 65°. e. Measure the lean angle sensor output volt- ▲ ▲▲▲ ▲ ▲▲▲ ▲...
Page 657 ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL Charging voltage 1. Disconnect: 14 V at 5000 r/min • Stator coil coupler (from the wire harness) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 658 ELECTRICAL COMPONENTS • Positive tester probe → Pocket tester green/white “1” 90890-03112 • Negative tester probe → Analog pocket tester black/white “2” YU-03112-C Minimum level position “A” • Positive tester probe → white “1” • Negative tester probe → body ground “2” Maximum level position “B”...
Page 659 ELECTRICAL COMPONENTS EAS28250 CHECKING THE RADIATOR FAN MOTORS The following procedure applies to both of the radiator fan motors. 1. Check: • Radiator fan motor Faulty/rough movement → Replace. GEAR ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 660 ELECTRICAL COMPONENTS 2. Check: EWA1MC1002 WARNING • Coolant temperature sensor resistance Out of specification → Replace. • Handle the throttle position sensor with special care. Coolant temperature sensor re- • Never subject the throttle position sensor sistance to strong shocks. If the throttle position 2.32–2.59 kΩ...
Page 661 ELECTRICAL COMPONENTS EAS29100 CHECKING THE ACCELERATOR POSITION When installing the accelerator position sensor, SENSOR adjust its angle properly. Refer to “ADJUSTING 1. Remove: THE ACCELERATOR POSITION SENSOR” on • Accelerator position sensor page 7-11. (from the throttle bodies) EWA1MC1003 WARNING EAS1MC1083 CHECKING THE THROTTLE SERVO MOTOR •...
Page 662 ELECTRICAL COMPONENTS ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ EAS28370 CHECKING THE AIR INDUCTION SYSTEM a. Connect the test harness– speed sensor (3P) SOLENOID “1” to the cylinder identification sensor cou- 1.
Page 663 ELECTRICAL COMPONENTS ECA1MC1005 ECA1MC1005 NOTICE NOTICE Pay attention to the installing direction of the Pay attention to the installing direction of the test harness S– pressure sensor (3P) cou- test harness S– pressure sensor (3P) cou- pler “a”. pler “a”. b.
Page 664 ELECTRICAL COMPONENTS Air temperature sensor resis- Result tance Neutral position 5.4–6.6 kΩ at 0 °C (32.0 °F) Continuity 290–390 Ω at 80.0 °C (176.0 °F) Positive tester probe → sky blue “1” Negative tester probe → ▼ ▼▼▼ ▼ ▼▼▼ ▼...
Page 665 ELECTRICAL COMPONENTS Resistance 12.0 Ω ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the fuel injector coupler from wire harness. b. Connect the pocket tester (Ω × 1) to the fuel injector terminals as shown.
Page 666 ELECTRICAL COMPONENTS c. Measure the accessory box solenoid resis- tance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ET3P66023 CHECKING THE GRIP WARMERS The following procedure applies to both of the grip warmers.
Page 667: 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 ..................9-3 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............
Page 668 TROUBLESHOOTING Electrical system EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.
Page 669 TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...
Page 670 TROUBLESHOOTING EAS28600 EAS28620 OVERHEATING POOR BRAKING PERFORMANCE • Worn brake pad Engine • Worn brake disc 1. Clogged coolant passages • Air in hydraulic brake system • Cylinder head and piston(s) • Leaking brake fluid • Heavy carbon buildup • Faulty brake caliper kit 2.
Page 671 TROUBLESHOOTING • Bent or damaged inner tube • Burnt-out tail/brake light bulb • Bent or damaged outer tube Tail/brake light bulb burnt out 3. Swingarm • Wrong tail/brake light bulb • Worn bearing or bushing • Faulty battery • Bent or damaged swingarm •...
Page 672 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) EAS2PD1002 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) • If there is a malfunction in the fuel injection system, the windshield adjusting function “1” will be dis- played in the function display, the engine trouble warning light “2” will come on, and a fault code num- ber “3”...
Page 673 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Fault Reference Item code No. pages Cylinder-#2 ignition coil: open or short circuit detected in the primary 8-59 lead of the cylinder-#2 ignition coil. Cylinder-#3 ignition coil: open or short circuit detected in the primary 8-60 lead of the cylinder-#3 ignition coil.
Page 674 Communication error with the meter Reference Fault code No. Item pages Multi-function meter: signals cannot be transmit- 89 (Yamaha diagnostic tool) ted between the ECU and the multi-function 8-84 meter. Abnormal meter assembly communication (meter assembly cannot receive CAN communication da- 8-84 ta).
Page 675 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Lean angle sensor Lean angle sensor output Remove the lean angle voltage sensor and incline it more than 65 degrees. • Upright 0.4–1.4 • Overturned 3.7–4.4 Fuel system voltage Approximately 12.0 Set the start/engine stop...
Page 676 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Gear position switch and Operate the transmission, clutch switch clutch lever, and side- stand. • Transmission is in neu- tral • Transmission is in gear or the clutch lever re- leased •...
Page 677 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. Malfunction history code — display • No history • History exists Fault codes 11–91 • (If more than one code number is detected, the display alternates every two seconds to show all the detected code num- bers.
Page 678 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Meter display Procedure code No. ISC (idle speed control) To erase the ISC (idle learning condition display ISC (idle speed control) speed control) learning ISC (idle speed control) learning data has been data, set the start/engine learning data erasure erased.
Page 679 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic code: actuator operation table Before using diagnostic code numbers “36”–“43”, disconnect the fuel pump coupler. Diagnostic Item Actuation Procedure code No. Cylinder-#1 ignition coil Actuates the cylinder-#1 Check that a spark is gen- ignition coil five times at erated five times.
Page 680 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (ECU) Diagnostic Item Actuation Procedure code No. Relay unit Actuates the relay unit five Check that the relay unit is times at one-second inter- actuated five times by lis- vals. tening for the operating Illuminates the engine sound.
Page 681 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) EAS2PD1003 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) • If there is a malfunction in the electronically adjustable suspension system, the damping force adjust- ing function “1” will be displayed in the function display, the electronically adjustable suspension sys- tem warning light “2”...
Page 682 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) Diagnostic code table Diagnostic Item Meter display Procedure code No. Monitor voltage Displays the monitor volt- Compare the actually age. measured battery voltage Approximately 12.0 with the meter display val- ue. (If the actually mea- sured battery voltage is low, recharge the battery.) Malfunction history code...
Page 683 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE (SCU) Diagnostic Item Meter display Procedure code No. Preload home position ad- Adjusts the preload home To adjust the preload justment position. home position, simulta- When completed success- neously press the “TCS” fully: button and “RESET” but- “00”...
Page 684 EVENT CODE TABLE EAS2PD1020 EVENT CODE TABLE Item Symptom Possible cause Remarks 192 Intake air pressure Brief abnormality de- Same as for fault Perform the checks sensor tected in intake air code number 13 and maintenance pressure sensor jobs for fault code number 13.
Page 685 EVENT CODE TABLE Item Symptom Possible cause Remarks 224 Ignition system Brief abnormality de- Same as for fault Perform the checks tected in primary lead code number 33 and maintenance of ignition coil jobs for fault code number 33. Same as for fault Perform the checks code number 34 and maintenance...
Page 686 EVENT CODE TABLE Item Symptom Possible cause Remarks 242 ISC (idle speed con- Correction value re- Low engine idling • Execute the diag- trol) mains at upper limit speed nostic mode (diag- (Correction value re- while the engine is • Clogged throttle nostic code number mains at upper limit) idling...
Page 687 EVENT CODE TABLE Item Symptom Possible cause Remarks 246 Cruise control system Automatic turning off The cruise control The automatic turn- of the cruise control system will automati- ing off of the cruise system detected cally turn off under control system does the following condi- not indicate a mal- tions:...
Page 688 47. Brake switch relay 100.Cylinder identification sensor 48. Brake light relay 101.Lean angle sensor 49. Left handlebar switch 102.Yamaha diagnostic tool cou- 50. Cruise control power switch pler 51. Cruise control setting switch 103.Yamaha diagnostic tool con- 52. Dimmer/pass switch nector 53.
Page 689 EAS28750 COLOR CODE Black Brown Chocolate Dark green Green Gray Blue Light green Orange Pink Sky blue White Yellow Black/Green Black/Blue Black/Red Black/White Black/Yellow Br/B Brown/Black Br/G Brown/Green Br/L Brown/Blue Br/R Brown/Red Br/W Brown/White Br/Y Brown/Yellow Green/Black Green/Blue Green/Red Green/White Green/Yellow Gy/R Gray/Red...
Page 693 FJR1300AE/FJR1300AEE 2014 FJR1300AE/FJR1300AEE 2014 FJR1300AE/FJR1300AEE 2014 FJR1300AE/FJR1300AEE 2014 FJR1300AE/FJR1300AEE 2014 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO R/G B Y/L G/B R/W B Br Br/W R/B R/B R/B L/W L/W Br/L Br/L Br/L Br/L Br/L Br/R Br/R L/W L/W B/L B/L B/L B/L B/L B/L B/L...
Page 694 FJR1300AE/FJR1300AEE 2014 FJR1300AE/FJR1300AEE 2014 FJR1300AE/FJR1300AEE 2014 FJR1300AE/FJR1300AEE 2014 FJR1300AE/FJR1300AEE 2014 SCHÉMA DE CÂBLAGE WIRING DIAGRAM SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO D D D D E E E E (Gy) (Gy) (Gy) (Gy) PULL (Gy) (Gy) (Gy) PRESS PULL MODE (Gy) (Gy) MENU PASS...

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Fjr 1300 aee 2014

Yamaha FJR 1300 AE 2014 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

Engine

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Troubleshooting

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