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MT07 서비스매뉴얼
MT07 서비스매뉴얼
MT07 서비스매뉴얼
SERVICE MANUAL
MT-07 ABS
MTN660-AJ
MTN690-A
MTN690-AJ
MTN690-U
B4C-28197-E0
EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
• * If the contents of the manual are revised, the last digit of the manual number will be increased by one.
• Designs and specifications are subject to change without notice.
EAS30001
EAS20002
MTN660-AJ/MTN690-A/
MTN690-AJ/MTN690-U
SERVICE MANUAL
©2018 by Yamaha Motor Co., Ltd.
First edition, January 2018
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20004
CLUTCH CLUTCH
2
EAS20055 EAS30348 EAS30349
2 Wear limit
2.82 mm (0.111 in)
Friction plate 2 thickness Warpage limit
2.92–3.08 mm (0.115–0.121 in) 0.10 mm (0.004 in)
E
Wear limit
5
LT
LT
3 (10)
4 3
12 N•m (1.2 kgf•m, 8.9 lb •ft) EAS30351
T.R.
5-55 5-60
EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
Silicone fluid
S
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
APPENDIX 9
GENERAL INFORMATION
FEATURES...................................................................................................... 1-2
1
MULTI-FUNCTION METER UNIT ............................................................. 1-2
EAS20007
IDENTIFICATION
EAS30002
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.
1-1
FEATURES
EAS20008
TIP
FEATURES
• Except when accessing the brightness control
EAS30982 mode or when displaying the clock, the key
MULTI-FUNCTION METER UNIT must be turned to “ON” before you can use the
left and right set buttons to adjust the multi-
function meter.
• For the UK: To switch between kilometers and
miles, press the left set button for three sec-
onds.
Speedometer
The speedometer shows the vehicle’s traveling
1 2 speed.
1. Left set button
2. Right set button Tachometer
1 2 3 4 5
1 2
7 6
1. Tachometer
1. Fuel meter 2. Tachometer red zone
2. Clock
3. Transmission gear display The tachometer allows the rider to monitor the
4. Eco indicator “ECO” engine speed and keep it within the ideal power
5. Speedometer range.
ECA19660
6. Tachometer
NOTICE
7. Multi-function display
Do not operate the engine in the tachometer
The multi-function meter unit is equipped with red zone.
the following:
• speedometer
Clock
• tachometer
• clock 1
• fuel meter
• eco indicator
• transmission gear display
• multi-function display
EWA12423
WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the 1. Clock
risk of an accident. The clock uses a 12-hour time system. When
the main switch is not in the “ON” position, the
clock can be viewed for 10 seconds by pushing
the left set button.
1-2
FEATURES
[To set the clock] The eco indicator comes on when the vehicle is
1. Turn the key to “ON”. being operated in an environmentally friendly,
2. Push the left set button and right set button fuel-efficient manner. The indicator goes off
together for two seconds. The hour digits will when the vehicle is stopped.
start flashing. TIP
3. Use the right set button to set the hours. Consider the following tips to reduce fuel con-
4. Push the left set button, and the minute digits sumption:
will start flashing. • Avoid high engine speeds during acceleration.
5. Use the right set button to set the minutes. • Travel at a constant speed.
6. Push the left set button and then release it to • Select the transmission gear that is appropri-
start the clock. ate for the vehicle speed.
Fuel meter
Transmission gear display
1
1 2
1. Fuel meter
1. Transmission gear display
The fuel meter indicates the amount of fuel in the 2. Neutral indicator light “ ”
fuel tank. The segments of the fuel meter disap-
pear from “F” (full) towards “E” (Empty) as the The transmission gear display shows the select-
fuel level decreases. When the last segment of ed gear. The neutral position is indicated by “–”
the fuel meter starts flashing, refuel as soon as and by the neutral indicator light.
possible.
TIP Multi-function display
The fuel meter is equipped with a self-diagnosis 1
function. If a problem is detected in the fuel me-
ter electrical circuit, the fuel meter will flash re-
peatedly. If this occurs, check the electrical
circuit. Refer to “SIGNALING SYSTEM” on
page 8-21.
Eco indicator
1 1. Multi-function display
The multi-function display is equipped with the
following:
• odometer
• two tripmeters
• fuel reserve tripmeter
• instantaneous fuel consumption
• average fuel consumption
• coolant temperature
1. Eco indicator “ECO”
• air temperature
• brightness control mode
1-3
FEATURES
Push the left set button to change the display be- TRIP F km/L or L/100 km AVE_ _._ km/L or
tween the odometer “ODO”, tripmeters “TRIP 1” AVE_ _._ L/100 km _ _ C Air_ _ C
and “TRIP 2”, instantaneous fuel consumption ODO TRIP 1 TRIP 2 TRIP F
“km/L” or “L/100 km”, average fuel consumption For the UK:
“AVE_ _._ km/L” or “AVE_ _._ L/100 km”, cool- TRIP F km/L, L/100 km or MPG AVE_ _._
ant temperature “_ _ C”, and air temperature km/L, AVE_ _._ L/100 km or AVE_ _._ MPG
“Air_ _ C” in the following order: _ _ C Air_ _ C ODO TRIP 1 TRIP 2
ODO TRIP 1 TRIP 2 km/L or L/100 km TRIP F
AVE_ _._ km/L or AVE_ _._ L/100 km _ _ TIP
C Air_ _ C ODO • Push the right set button to change the display
in the reverse order.
For the UK: • You can manually reset the fuel reserve trip-
Push the left set button to change the display be- meter, or after refueling and traveling 5 km (3
tween the odometer “ODO”, tripmeters “TRIP 1” mi) it will reset automatically and disappear
and “TRIP 2”, instantaneous fuel consumption from the display.
“km/L”, “L/100 km” or “MPG”, average fuel con-
sumption “AVE_ _._ km/L”, “AVE_ _._ L/100 km”
or “AVE_ _._ MPG”, coolant temperature “_ _ Instantaneous fuel consumption
C”, and air temperature “Air_ _ C” in the follow- 1
ing order:
ODO TRIP 1 TRIP 2 km/L, L/100 km or
MPG AVE_ _._ km/L, AVE_ _._ L/100 km or
AVE_ _._ MPG _ _ C Air_ _ C ODO
TIP
• Push the right set button to change the display
in the reverse order.
• The fuel reserve tripmeter comes on automati-
cally, while the brightness control mode is ac- 1. Instantaneous fuel consumption display
cessed separately.
This function calculates the fuel consumption
under current riding conditions.
Odometer and tripmeters The instantaneous fuel consumption can be set
The odometer shows the total distance traveled to either “km/L”, “L/100 km” or “MPG” (for the
by the vehicle. UK).
The tripmeters show the distance traveled since • “km/L”: The distance that can be traveled on
they were last reset. 1.0 L of fuel under the current riding conditions
To reset a tripmeter, use the left set button to is shown.
display the tripmeter you want to reset, and then • “L/100 km”: The amount of fuel necessary to
push the right set button for one second. travel 100 km under the current riding condi-
TIP tions is shown.
• The odometer will lock at 999999. • “MPG” (for the UK): The distance that can be
• The tripmeters will lock at 9999.9 but can be traveled on 1.0 Imp.gal of fuel under the cur-
manually reset. rent riding conditions is shown.
To switch the instantaneous fuel consumption
settings, push and hold the left set button until
Fuel reserve tripmeter
the display changes.
When the fuel level becomes low, the last seg-
ment of the fuel meter will start flashing. The fuel TIP
reserve tripmeter “TRIP F” will automatically ap- If traveling at speeds under 20 km/h (12 mi/h), “_
pear and start counting the distance traveled _._” is displayed.
from that point. In this case, push the left set but-
ton to switch the display in the following order:
1-4
FEATURES
Air temperature
1
Coolant temperature
1
1-5
FEATURES
1-6
SPECIAL TOOLS
EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB 3-4, 3-9, 4-64,
90890-03256 4-65, 5-9,
7-13, 7-13,
7-14, 7-14,
8-36, 8-116,
8-141, 8-145
Yamaha diagnostic tool (A/I) 3-4, 3-9, 4-64,
90890-03262 4-65, 5-9,
7-13, 7-13,
7-14, 7-14,
8-36, 8-116,
8-141, 8-145
Thickness gauge 3-6, 4-22, 4-31,
90890-03180 5-60
Feeler gauge set
YU-26900-9
YM-A8998
YU-44456
1-7
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Carburetor angle driver 2 3-10
90890-03173
YM-A9409-7/YM-A5142-4
1-8
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Fork seal driver attachment (ø41) 4-79, 4-79
90890-01381
Replacement 41 mm
YM-A5142-2
YU-33223
1-9
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Valve guide installer (ø4.5) 5-41
90890-04117
Valve guide installer (4.5 mm)
YM-04117
1-10
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Piston pin puller set 5-82
90890-01304
Piston pin puller
YU-01304
YU-01304
YU-24460-A
YU-33984
1-11
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Middle driven shaft bearing driver 6-13
90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
1-12
SPECIAL TOOLS
1-13
SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model B1M1 (MTN660-AJ)
B4C1 (MTN690-A)
B4C5 (MTN690-AJ)
B8M1 (MTN690-U)
Dimensions
Overall length 2085 mm (82.1 in)
Overall width 745 mm (29.3 in)
Overall height 1090 mm (42.9 in)
Wheelbase 1400 mm (55.1 in)
Ground clearance 140 mm (5.51 in)
Minimum turning radius 2.7 m (8.86 ft)
Weight
Curb weight 183 kg (403 lb)
Loading
Maximum load 172 kg (379 lb)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EAS20014
ENGINE SPECIFICATIONS
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 655 cm³ (MTN660-AJ)
689 cm³ (MTN690-A, MTN690-AJ, MTN690-U)
Cylinder arrangement Inline
Number of cylinders 2-cylinder
Bore stroke 78.0 68.6 mm (3.07 2.70 in) (MTN660-AJ)
80.0 68.6 mm (3.15 2.70 in) (MTN690-A,
MTN690-AJ, MTN690-U)
Compression ratio 11.0 : 1 (MTN660-AJ)
11.5 : 1 (MTN690-A, MTN690-AJ, MTN690-U)
Compression pressure 643–828 kPa/495 r/min (6.4–8.3 kgf/cm²/495 r/
min, 91.6–117.9 psi/495 r/min) (MTN660-AJ)
765–985 kPa/355 r/min (7.7–9.9 kgf/cm²/355 r/
min, 108.9–140.2 psi/355 r/min) (MTN690-A,
MTN690-AJ, MTN690-U)
Compression pressure (#2 cylinder) 626–806 kPa/495 r/min (6.3–8.1 kgf/cm²/495 r/
min, 89.1–114.7 psi/495 r/min) (MTN660-AJ)
687–884 kPa/355 r/min (6.9–8.8 kgf/cm²/355 r/
min, 97.8–125.8 psi/355 r/min) (MTN690-A,
MTN690-AJ, MTN690-U)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol [E10] ac-
ceptable)
Fuel tank capacity 14 L (3.7 US gal, 3.1 Imp.gal)
Fuel reserve amount 2.7 L (0.71 US gal, 0.59 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 2.30 L (2.43 US qt, 2.02 Imp.qt)
With oil filter removal 2.60 L (2.75 US qt, 2.29 Imp.qt)
Quantity (disassembled) 3.00 L (3.17 US qt, 2.64 Imp.qt)
Oil filter
Oil filter type Cartridge
2-2
ENGINE SPECIFICATIONS
Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.03–0.08 mm (0.0012–0.0032 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09–0.15 mm (0.0035–0.0059 in)
Limit 0.22 mm (0.0087 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.03–0.08 mm (0.0012–0.0032 in)
Limit 0.15 mm (0.0059 in)
Oil pressure 280.0 kPa/5000 r/min (2.80 kgf/cm²/5000 r/min,
40.6 psi/5000 r/min)
Relief valve operating pressure 720.0 kPa (7.20 kgf/cm², 104.4 psi)
Cooling system
Coolant quantity
Radiator (including all routes) 1.60 L (1.69 US qt, 1.41 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator cap valve opening pressure 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9
psi)
Thermostat
Valve opening temperature 80.0–84.0 C (176.00–183.20 F)
Valve full open temperature 95.0 C (203.00 F)
Valve lift (full open) 8.0 mm (0.31 in)
Spark plug(s)
Manufacturer/model NGK/LMAR8A-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Camshaft
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in)
Camshaft journal diameter 21.959–21.972 mm (0.8645–0.8650 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) 35.610–35.710 mm (1.4020–1.4059 in)
Limit 35.510 mm (1.3980 in)
Lobe height (Exhaust) 35.710–35.810 mm (1.4059–1.4098 in)
Limit 35.610 mm (1.4020 in)
2-3
ENGINE SPECIFICATIONS
Valve spring
Free length (intake) 40.30 mm (1.59 in)
Limit 38.29 mm (1.51 in)
Free length (exhaust) 41.39 mm (1.63 in)
Limit 39.32 mm (1.55 in) (MTN690-A, MTN690-AJ,
MTN690-U)
39.92 mm (1.57 in) (MTN660-AJ)
Cylinder
Bore 78.000–78.010 mm (3.0709–3.0713 in)
(MTN660-AJ)
80.000–80.010 mm (3.1496–3.1500 in)
(MTN690-A, MTN690-AJ, MTN690-U)
Wear limit 78.060 mm (3.0732 in) (MTN660-AJ)
80.060 mm (3.1520 in) (MTN690-A, MTN690-
AJ, MTN690-U)
Piston
Diameter 77.970–77.985 mm (3.0697–3.0703 in)
(MTN660-AJ)
79.970–79.985 mm (3.1484–3.1490 in)
(MTN690-A, MTN690-AJ, MTN690-U)
Measuring point (from piston skirt bottom) 8.0 mm (0.31 in)
Piston-to-cylinder clearance 0.015–0.040 mm (0.0006–0.0016 in)
Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in)
Limit 18.045 mm (0.7104 in)
Piston pin outside diameter 17.990–17.995 mm (0.7083–0.7085 in)
Limit 17.970 mm (0.7075 in)
Piston-pin-to-piston-pin-bore clearance 0.009–0.025 mm (0.0004–0.0010 in)
2-4
ENGINE SPECIFICATIONS
Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 0.80 mm (0.0315 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)
Connecting rod
Oil clearance 0.027–0.051 mm (0.0011–0.0020 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.018–0.042 mm (0.0007–0.0017 in)
Bearing color code
Model identification color Pink
Code -1 Purple
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Balancer
Balancer shaft runout limit 0.030 mm (0.0012 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Balancer shaft journal to balancer shaft
bearing clearance 0.020–0.054 mm (0.0008–0.0021 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 5.0–10.0 mm (0.20–0.39 in)
Friction plate 1 thickness 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 5 pcs
Wear limit 2.82 mm (0.111 in)
Friction plate 2 thickness 2.90–3.10 mm (0.114–0.122 in)
Plate quantity 2 pcs
Wear limit 2.80 mm (0.110 in)
2-5
ENGINE SPECIFICATIONS
Drivetrain
Primary reduction ratio 1.925 (77/40)
Transmission type Constant mesh 6-speed
Gear ratio
1st 2.846 (37/13)
2nd 2.125 (34/16)
3rd 1.632 (31/19)
4th 1.300 (26/20)
5th 1.091 (24/22)
6th 0.964 (27/28)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 2.688 (43/16)
Final drive Chain
Shifting mechanism
Installed shift rod length 217.5–219.5 mm (8.56–8.64 in)
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
Maximum consumption amperage 3.3 A
Fuel injector
Resistance 12.0
Throttle body
ID mark 1WS1 00 (MTN690-AJ)
1WS1 10 (MTN690-A, MTN690-U)
1WS1 30 (MTN660-AJ)
Idling condition
Engine idling speed 1250–1450 r/min
O2 feedback control Active
Coolant temperature 85–105 C (185–221 F)
Difference in vacuum pressure between the
cylinders 0 kPa–1.3 kPa (0 mmHg–10 mmHg, 0 inHg–0.4
inHg)
CO% 0.0–2.0 %
Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-6
CHASSIS SPECIFICATIONS
EAS20015
CHASSIS SPECIFICATIONS
Chassis
Frame type Diamond
Caster angle 24.8
Trail 90 mm (3.5 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/C x MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C x MT5.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size 120/70 ZR 17M/C(58W)
Manufacturer/model MICHELIN/PILOT ROAD 4
Manufacturer/model BRIDGESTONE/BT023F F
Rear tire
Type Tubeless
Size 180/55 ZR 17M/C(73W)
Manufacturer/model MICHELIN/PILOT ROAD 4
Manufacturer/model BRIDGESTONE/BT023R M
Front brake
Type Hydraulic dual disc brake
Disc outside diameter thickness 282.0 4.5 mm (11.10 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on
wheel) 0.10 mm (0.0039 in)
Brake pad lining thickness limit 0.5 mm (0.02 in)
Master cylinder inside diameter 15.00 mm (0.59 in)
Caliper cylinder inside diameter (Left) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Caliper cylinder inside diameter (Right) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Specified brake fluid DOT 4
2-7
CHASSIS SPECIFICATIONS
Rear brake
Type Hydraulic single disc brake
Disc outside diameter thickness 245.0 5.0 mm (9.65 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on
wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 1.0 mm (0.04 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 38.18 mm (1.50 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 130 mm (5.1 in)
Fork spring free length 345.4 mm (13.60 in)
Limit 338.4 mm (13.33 in)
Recommended oil Yamaha Suspension Oil G10
Quantity (left) 405.0 cm³ (13.69 US oz, 14.28 Imp.oz)
Quantity (right) 405.0 cm³ (13.69 US oz, 14.28 Imp.oz)
Level (left) 160 mm (6.3 in)
Level (right) 160 mm (6.3 in)
Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 130 mm (5.1 in)
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Cam position
Adjustment value (Soft) 1
Adjustment value (STD) 4
Adjustment value (Hard) 7
Rebound damping
Adjusting system Mechanical adjustable type
Unit for adjustment Turn
Adjustment value from the start position
(Soft) 3
Adjustment value from the start position
(STD) 1.5
Adjustment value from the start position
(Hard) 0
2-8
CHASSIS SPECIFICATIONS
Drive chain
Size 525VZ
Chain type Sealed type
Number of links 108
Drive chain slack 51.0–56.0 mm (2.01–2.20 in)
Drive chain slack (Maintenance stand) 56.0–61.0 mm (2.20–2.40 in)
Limit 58.0 mm (2.28 in)
15-link length limit 239.3 mm (9.42 in)
2-9
ELECTRICAL SPECIFICATIONS
EAS20016
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 /1350 r/min
Ignition coil
Primary coil resistance 1.19–1.61
Secondary coil resistance 8.50–11.50 k
Charging system
Charging system AC magneto
Standard output 14.0 V, 29.3 A at 5000 r/min
Stator coil resistance 0.128–0.192
Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.3–14.7 V
Rectifier capacity (DC) 50.0 A
Battery
Model YTZ10S
Voltage, capacity 12 V, 8.6 Ah (10 HR)
Headlight
Bulb type Halogen bulb
Bulb wattage
Headlight H4, 60.0 W/55.0 W
Brake/tail light LED
Front turn signal light 10.0 W
Rear turn signal light 10.0 W
Auxiliary light 5.0 W
License plate light 5.0 W
Meter lighting LED
2-10
ELECTRICAL SPECIFICATIONS
Indicator light
Neutral indicator light LED
Oil pressure warning light LED
High beam indicator light LED
Turn signal indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
ABS warning light LED
Immobilizer system indicator light LED
Starter motor
Power output 0.50 kW
Armature coil resistance 0.016–0.024
Brush overall length limit 6.5 mm (0.26 in)
Mica undercut (depth) 0.70 mm (0.03 in)
Fuse(s)
Main fuse 30.0 A
Headlight fuse 15.0 A
Signaling system fuse 10.0 A
Ignition fuse 10.0 A
Parking lighting fuse 7.5 A
Radiator fan motor fuse 10.0 A
ABS control unit fuse 7.5 A
ABS motor fuse 30.0 A
ABS solenoid fuse 20.0 A
Auxiliary fuse 2.0 A
Backup 1 fuse 7.5 A
Backup 2 fuse 10.0 A
2-11
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30016
EAS30017
2-12
TIGHTENING TORQUES
Thread
Item Q’ty Tightening torque Remarks
size
Cap nut M25 1 See TIP.
Stake
Drive sprocket nut M22 1 95 N·m (9.5 kgf·m, 70 lb·ft)
E
TIP
Cap nut
1. First, tighten the cap nut to approximately 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then
loosen the cap nut completely.
2. Retighten the cap nut to 18 N·m (1.8 kgf·m, 13 lb·ft) with a torque wrench.
2-13
TIGHTENING TORQUES
2-14
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
X I J 3 10
9 12
W
5 6 K
C
13
2 1
K 9
K 7
L
V
1 A
2
H 11 3
4 B
10
5
G
9 6 3
S
9
T F C
5
2
8
1
7
E D
3
C
M
R
Q
U
O
2-15
CABLE ROUTING
1. Throttle cable (accelerator cable) S. Route the handlebar switch lead (right han-
2. Throttle cable (decelerator cable) dlebar switch) to the inside of the throttle
cables.
3. Clutch cable
T. Route the brake hose (front brake master
4. Clutch switch lead cylinder to hydraulic unit) to the rear of the
5. Handlebar switch lead (left) bracket.
6. Handlebar switch coupler (left) U. Connect the headlight coupler.
7. Front wheel sensor lead V. Clamp the handlebar switch lead (right) at
8. Headlight coupler the end of the master cylinder.
9. Handlebar switch coupler (right) W. Place the handlebar switch lead (right) on
the rear side of the vehicle.
10. Wire harness end cap
X. Face the fastening portion of the plastic
11. Front brake light switch connector band toward the vehicle top and point the
12. Main switch lead end of plastic band toward the vehicle
13. Brake hose front.
2-16
CABLE ROUTING
C
15 M
B 3
A
1 2
K 4 D
14
5 E
13
1 2 16
12
J 11
I
V 17
18
19
10 H G 9 8 F 7
20
S P
O
Q
T
R
1
2
21 2 N
U
2-17
CABLE ROUTING
1. Fuel tank breather hose (blue paint mark) O. Less than 10 mm (0.39 in). Fasten the
2. Fuel tank overflow hose (white paint mark) hose protector of each hose with the
holder.
3. Headlight coupler
P. To fuel tank
4. Front turn signal light lead
Q. When fastening the fuel tank breather hose
5. Clutch cable with the holder, make sure that the paint
6. Oil pressure switch lead mark on the hose is positioned 0–10 mm
7. Oil pressure switch from the holder.
8. O2 sensor R. When installing the hoses, silicone water
or soapy water may be applied to the
9. O2 sensor lead inside of the hoses.
10. Rear brake light switch lead
S. Point the end of hose clamp upward.
11. O2 sensor coupler T. Point the end of hose clamp inward.
12. Rear brake light switch coupler U. Point the end of hose clamp downward.
13. Oil pressure switch connector
V. Place the wire sub-lead coupler closer to
14. Rear wheel sensor coupler the vehicle inside than to the bracket.
15. Meter coupler
16. Cylinder head breather hose
17. Hose air 3
18. Hose air 1
19. Wire sub lead
20. Canister purge hose (hose joint to canis-
ter)
21. Fuel tank breather hose
2-18
CABLE ROUTING
22
11
13 Q 14 R
C
19 15 S
23 P 16
18
X W
17 O
1 A
N 21
D
M 12 2
20
L 3
C 11 4
K 9
10
J
I
5
H
9
T
U
8
7
9
G 7 F 6 E
V
2-19
CABLE ROUTING
1. Main switch lead J. Fasten the stator coil lead, horn lead, and
2. Fuel pump coupler coolant reservoir hose with the holder at
the location shown in the illustration. Make
3. Throttle cable (decelerator cable) sure that there is no slack in the stator coil
4. Throttle cable (accelerator cable) lead, horn lead, and coolant reservoir
5. Throttle body assembly hose.
6. Oil cooler inlet hose K. Route the stator coil lead to the inside of
the radiator inlet hose, and then connect
7. Coolant reservoir hose
the stator coil coupler to the rectifier/regu-
8. Horn lead lator.
9. Stator coil lead L. Clamp the turn signal light lead at 5 mm
10. Radiator inlet hose (0.20 in) from the left end of the coupler.
11. Front turn signal light lead The clamp can be moved within the range
of 0–15 mm (0.59 in) from the left end of
12. Clutch cable turn signal light lead coupler.
13. Stator coil coupler M. Route the clutch cable through the hole in
14. Rectifier/regulator coupler the cover.
15. Joint coupler N. Slack in the main switch lead must be posi-
16. Auxiliary DC outlet coupler tioned closer to the inside of the vehicle
than to the wire harness.
17. Rectifier/regulator bracket
O. Connect the crankshaft position sensor
18. Crankshaft position sensor coupler lead to the coupler.
19. Radiator fan motor coupler P. Connect the coupler, and then insert the
20. Ignition coil #1 coupler projection on the coupler into the hole in
21. Ignition coil #2 coupler the rectifier/regulator bracket.
22. Frame Q. Connect the stator coil coupler to the recti-
fier/regulator.
23. Center line
R. Connect the rectifier/regulator coupler to
A. Route the main switch lead under the lower the rectifier/regulator.
handlebar holder. S. Secure the joint coupler to the cover.
B. Fasten the main switch lead at the tape T. Onward
with a plastic locking tie. Face the buckle of U. Front side
the plastic locking tie forward with the end
pointing downward. V. Face the catch of the holder inward.
C. To the front turn signal light lead W. Cut the end of plastic band. The cut length
must be less than 3 mm (0.12 in).
D. Make sure that the throttle cables do not
twist between the throttle body assembly X. Place the fastening portion of the plastic
and the cable guide of the frame. band below the center line shown in the
illustration.
E. 5–10 mm (0.20–0.39 in)
F. Fasten the stator coil lead to the oil cooler
inlet hose with a plastic locking tie. Make
sure to route the stator coil lead to the out-
side of the oil cooler inlet hose. Align the
plastic locking tie with the blue tape on the
stator coil lead. Face the buckle of the
plastic locking tie rearward, and then cut
off the excess end of the tie to 2 mm (0.08
in) or less.
G. Fasten the stator coil lead and coolant res-
ervoir hose with the holder at the location
shown in the illustration. Make sure that
there is no slack in the stator coil lead.
H. Secure the holder by inserting the projec-
tion on the holder into the hole in the radia-
tor fan motor bracket, and then fasten the
stator coil lead, horn lead, and coolant res-
ervoir hose with the holder. Make sure that
the coolant reservoir hose and leads do
not cross between the oil cooler inlet hose
and this holder.
I. Fasten the stator coil lead, horn lead, and
coolant reservoir hose with the holder.
2-20
CABLE ROUTING
11 12 13 17 N
17
14 18 M 18 M
15
20
J
K
L 16
21 21
N
20 19
∼
20
25 2 3 4
10 I 1 A
6 5
23
22
H B
P 1
24 Q
7
G
C
1
7
8
20 8 8
F 7
24 R
19
E D
2-21
CABLE ROUTING
1. Starter motor lead K. The gear position switch lead and coolant
2. Tail/brake light coupler temperature sensor lead may be posi-
tioned and routed in any order. Make sure
3. License plate light coupler that the leads is not twisted.
4. Yamaha diagnostic tool coupler L. Route the coolant temperature sensor lead
5. Rear turn signal light coupler (left) to the front of the gear position switch lead.
6. Rear turn signal light coupler (right) M. Insert the projection on the coupler into the
7. Engine ground lead hole in the bracket.
8. Sidestand switch lead N. With canister model
9. Sidestand switch coupler O. Point the ends of the hose clamp inward.
10. Terminal cover P. Do not pinch the sidestand switch lead
between the engine ground lead and the
11. Injector #1 coupler frame.
12. ISC (Idle Speed Control) unit coupler Q. Insert the projection on the holder into the
13. Injector #2 coupler hole in the frame from the bottom of the
14. Throttle position sensor coupler frame. The catch of the holder may be fac-
15. Throttle position sensor ing in any direction.
16. Coolant temperature sensor lead R. Fit the starter motor lead between the bot-
tom of the battery box and the rib on the
17. Gear position switch lead battery box.
18. Gear position switch coupler
19. Fuel tank breather hose (blue paint mark)
20. Fuel tank overflow hose (white paint mark)
21. Coolant temperature sensor coupler
22. Battery box
23. Battery
24. Frame
25. Canister breather hose
2-22
CABLE ROUTING
3 4 5 6 7 8
O N 9 10 11 12
2
A
1
13
5
C
D
P
E
M
22
F
23 21
R 20
X 29
24 19 U L
W 28 19 Y
30
22 19
T G
15
V
K
23
H
27 25
26
14
22 23 19 15
14 I
25 16 J
27 28 16
AA
27 Z 17
18
22
26
2-23
CABLE ROUTING
2-24
CABLE ROUTING
1 2 3
4
12
13
4
5
13
B 5
14 C
13 7
6
D
8
13
9
14
10
11
13 E
A
13
2-25
CABLE ROUTING
1. Battery band
2. Wire harness
3. Positive battery lead
4. Negative battery lead
5. Fuse box 1
6. Fuse box 2
7. Lean angle sensor
8. Rear turn signal light lead (left turn signal
light)
9. Rear turn signal light lead (right turn signal
light)
10. License plate light lead
11. Tail/brake light assembly lead
12. Battery
13. Battery box
14. Seat lock cable
2-26
CABLE ROUTING
8 9
C
B 1
4
3
2
6 2 3
A
6 2 3
D D
6 10 2
11
2
6 3
12
D
12
10 11
13 6
E
2-27
CABLE ROUTING
2-28
CABLE ROUTING
F K
4
3 G H
3
5
I
E 4
7 J 6
3
4
3
D 4
C
2
D
1 B
A L
5 1
6
4
E 3
1
4 M
2-29
CABLE ROUTING
2-30
CABLE ROUTING
F
4
G
G
3
2
1
B
1
3 C
2
D D
2-31
CABLE ROUTING
2-32
CABLE ROUTING
A
2
1
2-33
CABLE ROUTING
2-34
CABLE ROUTING
B C 4 B A 3
2
2-35
CABLE ROUTING
1. Fuel tank
2. Fuel hose
3. Fuel tank breather hose
4. Fuel tank overflow hose
2-36
CABLE ROUTING
2-37
CABLE ROUTING
2-38
CABLE ROUTING
1 2 3 A
4 B C
5
7
E
F
8 G
2-39
CABLE ROUTING
2-40
CABLE ROUTING
2 A B 3 4
2-41
CABLE ROUTING
1. Radiator
2. Radiator cap
3. Coolant reservoir hose
4. Radiator inlet hose
5. Coolant reservoir
6. Radiator outlet hose
2-42
CABLE ROUTING
F
E 1
G
11
10 H
A 1 2 B
4
8
4
4
5
I 5 10
5
6
6
2-43
CABLE ROUTING
2-44
CABLE ROUTING
A B 2
C
8
2-45
CABLE ROUTING
2-46
CABLE ROUTING
2-47
PERIODIC CHECKS AND ADJUSTMENTS
EAS20022
PERIODIC MAINTENANCE
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS30614
ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
No. ITEM JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check fuel hoses for cracks or
1 * Fuel line damage.
• Replace if necessary.
• Check condition.
• Adjust gap and clean.
2 * Spark plugs
• Replace.
3 * Valve clearance • Check and adjust. Every 40000 km (24000 mi)
• Check engine idle speed.
4 * Fuel injection • Check and adjust synchroni-
zation.
• Check for leakage.
5 * Exhaust system • Tighten if necessary.
• Replace gaskets if necessary.
Evaporative emis- • Check control system for
6 * sion control sys- damage.
tem • Replace if necessary.
EAS30615
ODOMETER READING
No. ITEM CHECK OR MAINTENANCE ANNUAL
JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
3-1
PERIODIC MAINTENANCE
ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
No. ITEM
JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check operation.
4 Clutch
• Adjust.
• Check operation, fluid level,
and for fluid leakage.
5 * Front brake
• Replace brake pads if neces-
sary.
• Check operation, fluid level,
6 * Rear brake and for fluid leakage.
• Replace brake pads if neces-
sary.
• Check for cracks or damage.
7 * Brake hoses
• Replace. Every 4 years
8 * Brake fluid • Change. Every 2 years
• Check runout and for damage.
9 * Wheels • Replace if necessary.
3-2
PERIODIC MAINTENANCE
ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
No. ITEM
JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Change (warm engine before
25 Engine oil draining).
• Check oil level and vehicle for
oil leakage.
TIP
• Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty ar-
eas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
PERIODIC MAINTENANCE
EAS32024
5. Install:
CHECKING THE VEHICLE USING THE
• Storage compartment cover
YAMAHA DIAGNOSTIC TOOL
• Passenger seat
Use the Yamaha diagnostic tool and check the
Refer to “GENERAL CHASSIS (1)” on
vehicle according to the following procedure.
page 4-1.
1. Remove:
• Passenger seat EAS30619
3-4
PERIODIC MAINTENANCE
3. Check:
• Spark plug type
Incorrect Change.
Manufacturer/model
1 NGK/LMAR8A-9
2 4. Check:
• Electrode “1”
3
Damage/wear Replace the spark plug.
3. Install: • Insulator “2”
• Rear fuel tank bracket bolt Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
Rear fuel tank bracket bolt 5. Clean:
10 N·m (1.0 kgf·m, 7.4 lb·ft) • Spark plug
T.
R.
• Fuel tank
TIP
Refer to “FUEL TANK” on page 7-1.
2. Remove: Before installing the spark plug, clean the spark
• Ignition coil plug and gasket surface.
• Spark plug 8. Install:
ECA13320
NOTICE
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
Before removing the spark plugs, blow away
• Fuel tank center cover (fuel tank side covers)
any dirt accumulated in the spark plug wells
• Air scoop (right)
with compressed air to prevent it from falling
• Air scoop (left)
into the cylinders.
Refer to “GENERAL CHASSIS (4)” on
page 4-9.
3-5
PERIODIC MAINTENANCE
TIP
1
2 • If the valve clearance is incorrect, record the
measured reading.
• Measure the valve clearance in the following
sequence.
3-6
PERIODIC MAINTENANCE
#2 #1 Valve lapper
90890-04101
Valve lapping tool
YM-A8998
TIP
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
A
crankcase.
A. Front • Make a note of the position of each valve lifter
“1” and valve pad “2” so that they can be in-
d. To measure the valve clearances of cylin-
stalled in the correct place.
der #2 turn the crankshaft 270 counter-
clockwise.
158
3-7
PERIODIC MAINTENANCE
T.
R.
7, 8, 9 10 Intake camshaft cap bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
TIP TIP
Refer to the following table for the available • Refer to “CAMSHAFTS” on page 5-20.
valve pads. • Lubricate the camshaft lobes and camshaft
journals with molybdenum disulfide oil.
Valve pad range No. 150–240 • First, install the exhaust camshaft.
Valve pad thickness 1.50–2.40 mm • Align the camshafts sprocket marks with the
(0.0590–0.0944 in) cylinder head edge.
Available valve pads 25 thicknesses in • Turn the crankshaft counterclockwise several
0.05 mm (0.0020 in) full turns to seat the parts.
increments
h. Measure the valve clearance again.
i. If the valve clearance is still out of specifica-
Example:
tion, repeat all of the valve clearance ad-
Valve pad number = 163
justment steps until the specified clearance
Rounded value = 165
is obtained.
New valve pad number = 165
f. Install the new valve pad “1” and the valve 8. Install:
lifter “2”. • All removed parts
TIP TIP
• Lubricate the valve pad with molybdenum di- For installation, reverse the removal procedure.
sulfide oil.
• Lubricate the valve lifter with engine oil. EAS31017
• Install the valve lifter and the valve pad in the CHECKING THE ENGINE IDLING SPEED
correct place. TIP
• The valve lifter must turn smoothly when rotat- Prior to checking the engine idling speed, the
ed by hand. throttle body synchronization should be adjusted
properly, the air filter element should be clean,
and the engine should have adequate compres-
sion.
1. Start the engine and let it warm up for several
minutes.
2. Check:
• Engine idling speed
Out of specification Go to next step.
3-8
PERIODIC MAINTENANCE
• Fuel tank
Engine idling speed Refer to “FUEL TANK” on page 7-1.
1250–1450 r/min 3. Disconnect:
• Intake air pressure sensor hose
3. Check: Refer to “THROTTLE BODIES” on page 7-8.
• ISC (idle speed control) learning value 4. Install:
“00” or “01” Check the intake system. • Hose “1” (Parts No.: 5JW-24311-00)
“02” Clean the ISC (idle speed control) • 3-way joint “2” (Parts No.: 90413-05014)
valve. • Vacuum gauge hose #1 “3”
Refer to “CLEANING THE ISC (IDLE SPEED • Vacuum gauge hose #2 “4”
CONTROL) VALVE” on page 7-11. • Intake air pressure sensor hose “5”
a. Connect the Yamaha diagnostic tool. • Vacuum gauge “6”
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION Vacuum gauge
AND DIAGNOSTIC CODE TABLE” on 90890-03094
page 9-1. Vacuummate
YU-44456
Yamaha diagnostic tool USB
90890-03256 A
Yamaha diagnostic tool (A/I)
90890-03262
6
b. Check the ISC (idle speed control) leaning 1
value.
2
EAS30797
3-9
PERIODIC MAINTENANCE
3-10
PERIODIC MAINTENANCE
EAS30798 EAS30626
CHECKING THE THROTTLE BODY JOINTS CHECKING THE CANISTER (except for
1. Remove: Oceania)
• Passenger seat 1. Remove:
• Rider seat • Passenger seat
Refer to “GENERAL CHASSIS (1)” on • Rider seat
page 4-1. Refer to “GENERAL CHASSIS (1)” on
• Air scoop (left) page 4-1.
• Air scoop (right) • Air scoop (left)
• Fuel tank center cover (fuel tank side covers) • Air scoop (right)
Refer to “GENERAL CHASSIS (4)” on • Fuel tank center cover (fuel tank side covers)
page 4-9. Refer to “GENERAL CHASSIS (4)” on
• Fuel tank page 4-9.
Refer to “FUEL TANK” on page 7-1. • Fuel tank
2. Disconnect: Refer to “FUEL TANK” on page 7-1.
• Intake air pressure sensor hose 2. Check:
• Canister purge hose (except for Oceania) • Canister
Refer to “THROTTLE BODIES” on page 7-8. • Canister purge hose
3. Remove: • Fuel tank breather hose
• Throttle body • Canister breather hose
Refer to “THROTTLE BODIES” on page 7-8. Cracks/damage Replace.
4. Check: 3. Install:
• Throttle body joint • Fuel tank
Cracks/damage Replace. Refer to “FUEL TANK” on page 7-1.
5. Install: • Fuel tank center cover (fuel tank side covers)
• Throttle body • Air scoop (right)
Refer to “THROTTLE BODIES” on page 7-8. • Air scoop (left)
6. Connect: Refer to “GENERAL CHASSIS (4)” on
• Intake air pressure sensor hose page 4-9.
• Canister purge hose (except for Oceania) • Rider seat
Refer to “THROTTLE BODIES” on page 7-8. • Passenger seat
7. Install: Refer to “GENERAL CHASSIS (1)” on
• Fuel tank page 4-1.
Refer to “FUEL TANK” on page 7-1.
EAS31130
• Fuel tank center cover (fuel tank side covers) REPLACING THE AIR FILTER ELEMENT
• Air scoop (right) AND CLEANING THE CHECK HOSE
• Air scoop (left)
TIP
Refer to “GENERAL CHASSIS (4)” on
page 4-9. There is an air filter check hose “1” at the bottom
• Rider seat of the air filter case. If dust and/or water collects
• Passenger seat in this hose, clean the air filter check hose and
Refer to “GENERAL CHASSIS (1)” on replace the air filter element.
page 4-1.
1
3-11
PERIODIC MAINTENANCE
1. Remove:
• Passenger seat Air filter element screw
• Rider seat 1.6 N·m (0.16 kgf·m, 1.2 lb·ft)
T.
R.
Refer to “GENERAL CHASSIS (1)” on Air duct bracket screw
page 4-1. 1.6 N·m (0.16 kgf·m, 1.2 lb·ft)
• Air scoop (left) ECA14401
• Air scoop (right) NOTICE
• Fuel tank center cover (fuel tank side covers) Never operate the engine without the air filter
Refer to “GENERAL CHASSIS (4)” on element installed. Unfiltered air will cause
page 4-9. rapid wear of engine parts and may damage
• Fuel tank the engine. Operating the engine without the
Refer to“FUEL TANK” on page 7-1. air filter element will also affect carburetor
2. Remove: synchronization, leading to poor engine per-
• Air duct bracket “1” formance and possible overheating.
Refer to “AIR FILTER” on page 7-7.
6. Install:
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
1 • Fuel tank center cover (fuel tank side covers)
• Air scoop (right)
• Air scoop (left)
Refer to “GENERAL CHASSIS (4)” on
page 4-9.
• Rider seat
• Passenger seat
3. Remove: Refer to “GENERAL CHASSIS (1)” on
• Air filter element “1” page 4-1.
EAS30629
4. Check:
• Air filter element
a
Damage Replace.
TIP
• Replace the air filter element every 40000 km
(24000 mi) of operation.
• The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.
5. Install:
2. Adjust:
• Air filter element • Clutch lever free play
• Air duct bracket
3-12
PERIODIC MAINTENANCE
1
4
3
2
1 2 EWA17050
WARNING
• After adjusting the brake lever position,
make sure the pin on the brake lever holder
is firmly inserted in the hole in the adjusting
dial.
• 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
EAS30801
air must be removed by bleeding the brake
CHECKING THE BRAKE OPERATION
system. Air in the brake system will consid-
1. Check:
erably reduce brake performance resulting
• Brake operation
in loss of control and possibly cause an ac-
Brake not working properly Check the
cident. Therefore, check and if necessary,
brake system.
bleed the brake system.
Refer to “FRONT BRAKE” on page 4-32 and
“REAR BRAKE” on page 4-46. ECA13490
TIP NOTICE
Drive on the dry road, operate the front and rear After adjusting the brake lever position,
brakes separately and check to see if the brakes make sure there is no brake drag.
are operating properly.
3-13
PERIODIC MAINTENANCE
EAS30633
2. Adjust:
• Rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-28.
a a
EAS30634
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt “a” is 1 1
visible through the hole “b”.
c. Tighten the locknut “1” to specification.
3-14
PERIODIC MAINTENANCE
WARNING
Always bleed the brake system when the
brake related parts are removed. B
1
ECA18050
NOTICE 2
• Bleed the brake system in the following or-
der.
• 1st step: Front brake calipers
• 2nd step: Rear brake caliper
EWA16530
WARNING
Bleed the ABS whenever: A. Front brake caliper
• the system is disassembled. B. Rear brake caliper
• a brake hose is loosened, disconnected or d. Place the other end of the hose into a con-
replaced. tainer.
• the brake fluid level is very low. e. Slowly apply the brake several times.
• brake operation is faulty. f. Fully squeeze the brake lever or fully de-
press the brake pedal and hold it in position.
TIP
g. Loosen the bleed screw.
• Be careful not to spill any brake fluid or allow
TIP
the brake master cylinder reservoir or brake
fluid reservoir to overflow. Loosening the bleed screw will release the pres-
• When bleeding the ABS, make sure that there sure and cause the brake lever to contact the
is always enough brake fluid before applying throttle grip or the brake pedal to fully extend.
the brake. Ignoring this precaution could allow h. Tighten the bleed screw and then release
air to enter the ABS, considerably lengthening the brake lever or brake pedal.
the bleeding procedure. i. Repeat steps (e) to (h) until all of the air
• If bleeding is difficult, it may be necessary to let bubbles have disappeared from the brake
the brake fluid settle for a few hours. fluid in the plastic hose.
• Repeat the bleeding procedure when the tiny j. Check the operation of the hydraulic unit.
bubbles in the hose have disappeared. Refer to “HYDRAULIC UNIT OPERATION
1. Bleed: TESTS” on page 4-63.
ECA18060
• ABS NOTICE
a. Fill the brake master cylinder reservoir or Make sure that the main switch is turned to
brake fluid reservoir to the proper level with “OFF” before checking the operation of the
the specified brake fluid. hydraulic unit.
b. Install the diaphragm (brake master cylin-
der reservoir or brake fluid reservoir). k. After operating the ABS, repeat steps (e) to
c. Connect a clear plastic hose “1” tightly to (i), and then fill the brake master cylinder
the bleed screw “2”. reservoir or brake fluid reservoir to the prop-
er level with the specified brake fluid.
l. Tighten the bleed screw to specification.
3-15
PERIODIC MAINTENANCE
EWA13090
WARNING
Never attempt to make any repairs to the
wheel.
TIP
B After a tire or wheel has been changed or re-
placed, always balance the wheel.
EAS30640
a CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• Tire air pressure
Out of specification Regulate.
A. Front brake
B. Rear brake
3-16
PERIODIC MAINTENANCE
EWA13181
1. Tire tread depth
WARNING 2. Side wall
• The tire pressure should only be checked 3. Wear indicator
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension must Wear limit (front)
be adjusted according to the total weight 1.6 mm (0.06 in)
(including cargo, rider, passenger and ac- Wear limit (rear)
cessories) and the anticipated riding 1.6 mm (0.06 in)
speed. EWA14090
3-17
PERIODIC MAINTENANCE
EAS31923
TIP
DRIVE CHAIN SLACK
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the di- Checking the drive chain slack
rection of wheel rotation. EWA13120
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
1. Shift the transmission into the neutral posi-
EAS30641 tion.
CHECKING THE WHEEL BEARINGS 2. Check:
The following procedure applies to all of the Drive chain slack “a”
wheel bearings. Out of specification Adjust.
1. Check:
• Wheel bearing Drive chain slack (Maintenance
Refer to “CHECKING THE FRONT WHEEL” stand)
on page 4-18 and “CHECKING THE REAR 56.0–61.0 mm (2.20–2.40 in)
WHEEL” on page 4-27. Drive chain slack (Sidestand)
51.0–56.0 mm (2.01–2.20 in)
EAS30802
Limit
CHECKING THE SWINGARM OPERATION 58.0 mm (2.28 in)
1. Check:
• Swingarm operation
Swingarm not working properly Check the
swingarm.
Refer to “SWINGARM” on page 4-90.
2. Check:
• Swingarm excessive play
Refer to “SWINGARM” on page 4-90.
EAS30643
Recommended lubricant
Lithium-soap-based grease
3-18
PERIODIC MAINTENANCE
TIP
2 1 Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Blinding/looseness Adjust the steering
head.
c. Tighten the wheel axle nut to specification. 3. Remove:
• Upper bracket
Wheel axle nut Refer to “FRONT FORK” on page 4-72.
105 N·m (10.5 kgf·m, 77 lb·ft) 4. Adjust:
T.
R.
• Steering head
d. Tighten the drive chain puller locknuts to
specification. a. Loosen the cap nut “1”, and then tighten it to
specification with a steering nut wrench “2”.
Drive chain puller locknut TIP
16 N·m (1.6 kgf·m, 12 lb·ft) • Set the torque wrench at a right angle to the
T.
R.
3-19
PERIODIC MAINTENANCE
EAS30647
Recommended lubricant
Silicone grease
Steering nut wrench
90890-01403 EAS30649
EAS30650
R.
3-20
PERIODIC MAINTENANCE
EAS30653
Spring preload
CHECKING THE FRONT FORK ECA13590
EAS30808
321
CHECKING THE REAR SHOCK ABSORBER 2 7654
ASSEMBLY 1
Refer to “CHECKING THE REAR SHOCK AB- 4
SORBER ASSEMBLY” on page 4-88. a
EAS30655
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
3-21
PERIODIC MAINTENANCE
TIP
To obtain a precise adjustment, it is advisable to
check the actual total number of turns of the
damping force adjusting mechanism. This ad-
justment range may not exactly match the spec- b
ifications listed due to small differences in a
production.
Recommended brand
YAMALUBE
SAE viscosity grades
b 1 a 10W-40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
3-22
PERIODIC MAINTENANCE
ECA13361
a. Remove the oil filter cartridge “1” with an oil
NOTICE
filter wrench “2”.
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
Oil filter wrench
clutch slippage. Therefore, do not add any 90890-01426
chemical additives or use engine oils with a Oil filter wrench
grade of “CD” or higher and do not use oils YU-38411
labeled “ENERGY CONSERVING II”.
• Do not allow foreign materials to enter the
crankcase.
4. Start the engine, warm it up for several min-
utes, and then turn it off.
5. Check the engine oil level again.
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled. 2 1
6. Install:
• Engine oil drain bolt
2 3 (along with the gasket New )
4. Drain: 7. Fill:
• Engine oil • Oil pan
(completely from the oil pan) (with the specified amount of the recom-
5. If the oil filter cartridge is also to be replaced, mended engine oil)
perform the following procedure.
3-23
PERIODIC MAINTENANCE
EWA12980
8. Install:
• Engine oil filler cap
(along with the O-ring New )
9. Start the engine, warm it up for several min-
utes, and then turn it off. 1
10.Check:
5. Install:
• Engine
• Oil pressure gauge “1”
(for engine oil leaks)
• Adapter “2”
11.Check:
• Engine oil level
Pressure gauge
Refer to “CHECKING THE ENGINE OIL 90890-03153
LEVEL” on page 3-22. Pressure gauge
EAS30810 YU-03153
MEASURING THE ENGINE OIL PRESSURE Oil pressure adapter H
1. Stand the vehicle on a level surface. 90890-03139
TIP
• Place the vehicle on the suitable stand.
• Make sure that the vehicle is upright. 1
2. Check:
• Engine oil level
Below the minimum level mark “a” Add the
recommended engine oil to the proper level.
2
6. Measure:
• Engine oil pressure
(at the following conditions)
Oil pressure
a
280.0 kPa/5000 r/min (2.80 kgf/
cm²/5000 r/min, 40.6 psi/5000 r/
min)
3. Start the engine, warm it up for several min-
utes, and then turn it off. Out of specification Check.
ECA13410
3-24
PERIODIC MAINTENANCE
TIP
• Oil cooler “4”
• Oil cooler inlet hose “5”
Lubricate the O-ring with a thin coat of lithium-
• Oil cooler outlet hose “6”
soap-based grease.
• Water jacket joint “7”
• Water jacket joint inlet hose “8”
EAS30811
11
12
a
b
9 5
6
ECA13470
NOTICE 4
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is 10
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
3-25
PERIODIC MAINTENANCE
EAS30813
2
7. Drain:
• Coolant
(from the engine and radiator)
8. Install:
• Coolant drain bolt
1 • Copper washer New
10.Fill:
4. Remove: • Cooling system
• Coolant reservoir bolt “1” (with the specified amount of the recom-
• Coolant reservoir quick fastener “2” mended coolant)
• Coolant reservoir cover “3”
• Coolant reservoir “4”
• Collar “5”
3-26
PERIODIC MAINTENANCE
Recommended antifreeze 2
High-quality ethylene glycol anti- 1
freeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze: water) a
Radiator (including all routes)
b
1.60 L (1.69 US qt, 1.41 Imp.qt)
Coolant reservoir (up to the max-
imum level mark)
0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator cap bolt
Handling notes for coolant 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
T.
R.
Coolant is potentially harmful and should be
handled with special care. 12.Fill:
EWA13040 • Coolant reservoir
WARNING (with the recommended coolant to the maxi-
• If coolant splashes in your eyes, thorough- mum level mark “a”)
ly wash them with water and consult a doc-
tor. a
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13481
NOTICE
• Adding water instead of coolant lowers the 13.Install:
antifreeze content of the coolant. If water is • Coolant reservoir cap
used instead of coolant, check, and if nec- 14.Start the engine, warm it up for several min-
essary, correct the antifreeze concentra- utes, and then turn it off.
tion of the coolant. 15.Check:
• Use only distilled water. However, if dis- • Coolant level
tilled water is not available, soft water may Refer to “CHECKING THE COOLANT LEV-
be used. EL” on page 3-25.
• If coolant comes into contact with painted TIP
surfaces, immediately wash them with wa-
Before checking the coolant level, wait a few
ter.
minutes until the coolant has settled.
• Do not mix different types of antifreeze.
16.Install:
11.Install:
• Air scoop (right)
• Radiator cap “1”
Refer to “GENERAL CHASSIS (4)” on
• Radiator cap bolt “2”
page 4-9.
TIP
Align the hole “a” in the radiator cap with the hole
“b” in the radiator.
3-27
PERIODIC MAINTENANCE
EAS31145
switch is properly adjusted when the brake light CHECKING THE THROTTLE GRIP
comes on just before the braking effect starts. OPERATION
1. Check:
1. Check: • Throttle cable
• Rear brake light operation timing Damage/deterioration Replace.
Incorrect Adjust. • Throttle cable installation
2. Adjust: Incorrect Reinstall the throttle cables.
• Rear brake light operation timing Refer to “HANDLEBAR” on page 4-67.
a. Hold the main body “1” of the rear brake 2. Check:
light switch so that it does not rotate and • Throttle grip movement
turn the adjusting nut “2” until the rear brake Rough movement Lubricate or replace the
light comes on at the proper time. defective part(s).
Recommended lubricant
Suitable cable lubricant
TIP
With the engine stopped, turn the throttle grip
1 2 slowly and release it. Make sure that the throttle
grip turns smoothly and returns properly when
released.
Repeat this check with the handlebar turned all
the way to the left and right.
EAS30660
3-28
PERIODIC MAINTENANCE
TIP TIP
Prior to adjusting the throttle grip free play, throt- Make sure that the adjusting nut is covered com-
tle body synchronization should be adjusted pletely by the rubber cover.
properly.
EAS30816
Throttle body side CHECKING AND CHARGING THE BATTERY
a. Loosen the locknut “1” on the accelerator Refer to “CHECKING AND CHARGING THE
cable. BATTERY” on page 8-146.
b. Turn the adjusting nut “2” until the specified
EAS30662
throttle grip free play is obtained. CHECKING THE FUSES
c. Tighten the locknut. Refer to “CHECKING THE FUSES” on page 8-
145.
Throttle cable locknut (throttle
body side) EAS30665
T.
2
1 1
TIP
If the specified throttle grip free play cannot be
obtained on the throttle body side of the cable,
use the adjusting nut on the handlebar side.
Handlebar side
a. Slide back the rubber cover “1”.
b. Loosen the locknut “2”. 2
c. Turn the adjusting nut “3” until the specified
throttle grip free play is obtained.
1 2
3
3
2. Disconnect:
• Headlight coupler “1”
3-29
PERIODIC MAINTENANCE
3. Remove:
• Headlight bulb cover “1”
1
10.Install:
• Headlight assembly “1”
4. Unhook: TIP
• Headlight bulb holder “1” Fit the projections “a” on the headlight bracket
5. Remove: into the holes “b” in the headlight assembly.
• Headlight bulb “2”
1
2 1
a
EWA13320 11.Install:
WARNING • Headlight assembly bolt “1”
Since the headlight bulb gets extremely hot,
keep flammable products and your hands Headlight assembly bolt
away from the bulb until it has cooled down. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
6. Install: TIP
• Headlight bulb New When the headlight assembly bolts are tight-
Secure the new headlight bulb with the head- ened to specification, there may be gaps “a” be-
light bulb holder. tween the washers and the grommets as shown
ECA13690
in the illustration.
NOTICE
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the a
bulb and the luminous flux will be adversely 1
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
7. Hook:
• Headlight bulb holder
8. Install:
• Headlight bulb cover
9. Connect:
• Headlight coupler “1”
3-30
PERIODIC MAINTENANCE
EAS30664
2. Adjust:
• Headlight beam (horizontally)
TIP
To adjust the headlight beam (horizontally), in-
sert a crosshead screwdriver into the hole “a” in
the headlight assembly, and then turn the ad-
justing screw.
3-31
PERIODIC MAINTENANCE
3-32
CHASSIS
FRONT FORK................................................................................................4-72
REMOVING THE FRONT FORK LEGS.................................................. 4-76
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-76
CHECKING THE FRONT FORK LEGS .................................................. 4-77
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-77
INSTALLING THE FRONT FORK LEGS ................................................ 4-81
SWINGARM................................................................................................... 4-90
REMOVING THE SWINGARM................................................................4-93
CHECKING THE SWINGARM ................................................................4-93
CHECKING THE CONNECTING ARM ...................................................4-93
INSTALLING THE CONNECTING ARM ................................................. 4-94
INSTALLING THE SWINGARM ..............................................................4-94
CHAIN DRIVE................................................................................................4-96
REMOVING THE DRIVE CHAIN............................................................. 4-98
REMOVING THE DRIVE SPROCKET ....................................................4-98
CHECKING THE DRIVE CHAIN ............................................................. 4-98
CHECKING THE DRIVE SPROCKET...................................................4-100
CHECKING THE REAR WHEEL SPROCKET......................................4-100
CHECKING THE REAR WHEEL DRIVE HUB ......................................4-100
INSTALLING THE DRIVE SPROCKET.................................................4-100
INSTALLING THE DRIVE CHAIN .........................................................4-100
GENERAL CHASSIS (1)
EAS20026
3 2
7 5
6 10
8
9
7 N·m (0.7 kgf·m, 5.2 lb·ft)
4
4-1
GENERAL CHASSIS (1)
EAS31125
2. Install:
INSTALLING THE RIDER SEAT
• Passenger seat “1”
1. Install:
TIP
• Rider seat “1”
Insert the projections “a” on the front of the pas-
Rider seat bolt senger seat into the grooves “b” as shown, and
7 N·m (0.7 kgf·m, 5.2 lb·ft) then push the rear of the seat down to lock it in
T.
R.
place.
TIP
Fit the slot “a” in the rider seat onto the projection 1
“b” on the rider seat bracket 1 as shown, and
then place the seat in the original position.
a
b
1
a
b
EAS31126
1
b
b
a 1
a
4-2
GENERAL CHASSIS (2)
EAS20155
8
LT
4
7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.8 N·m (0.28 kgf·m, 2.1 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
4-3
GENERAL CHASSIS (2)
14
12
LT
13
10
11
7 N·m (0.7 kgf·m, 5.2 lb·ft) 2.8 N·m (0.28 kgf·m, 2.1 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
4-4
GENERAL CHASSIS (2)
EAS31098
3 2 a d
1
2
2
3
2 e
g
1 1
b f
EAS31099 d. Install the rear side cover bolts “3”, rear side
INSTALLING THE REAR SIDE COVERS cover bolts “4”, rear side cover bolts “5”,
The following procedure applies to both of the rear side cover screws “6”, and quick fas-
rear side covers. teners “7”, and then tighten them to specifi-
1. Install: cation.
• Rear side cover “1”
a. Fit the grommet “a” on the rear side cover Rear side cover bolt (M8 16
onto the projection “b”. mm)
T.
R.
4-5
GENERAL CHASSIS (2)
EAS31101
EAS31127 a 1
INSTALLING THE LOWER TAIL COVER
1. Install:
• Lower tail cover “1”
a. Fit the projection “a” on the tail/brake light
assembly into the hole “b” in the lower tail
cover.
b. Install the quick fastener.
b
a
EAS31100
4-6
GENERAL CHASSIS (3)
EAS20156
1 7
11 3
4
6 1
2 5
9
7 N·m (0.7 kgf·m, 5.2 lb·ft)
8
4.0 N·m (0.4 kgf·m, 3 lb·ft)
4-7
GENERAL CHASSIS (3)
EAS31128
TIP
• Fit the projections “a” on the headlight bracket
into the holes “b” in the headlight assembly.
• When the headlight assembly bolts are tight-
ened to specification, there may be gaps “c”
between the washers and the grommets as
shown in the illustration.
2 c
4-8
GENERAL CHASSIS (4)
EAS20157
5 7
6 3
4-9
GENERAL CHASSIS (4)
EAS31061
2 2
EAS31104
4-10
GENERAL CHASSIS (4)
EAS31105
b
2
4 1
2 3
4 3 3 1
c. Install the fuel tank center cover bolts “5”,
and then tighten them to specification.
4-11
GENERAL CHASSIS (5)
EAS20158
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
3
1
2
4-12
GENERAL CHASSIS (5)
T.R
.
5
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
7 N•m (0.7 kgf•m, 5.2 lb•ft)
.
T.R
.
6
7
13 15
14
8
11 9
12
10
4-13
GENERAL CHASSIS (5)
T.R
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
7 N•m (0.7 kgf•m, 5.2 lb•ft)
.
T.R
.
16
17
19
18
4-14
GENERAL CHASSIS (5)
EAS31108
1 1
2. Install:
1 b • Fuel tank cover bracket “1”
• Electrical components tray 1 “2”
T.
R.
a
TIP
Make sure that the projection “a” on the fuel tank
EAS31109
cover bracket contacts the frame.
INSTALLING THE ECU (engine control unit)
1. Connect:
• ECU coupler “1” 2
TIP
Connect the ECU coupler, and then push the 1
lock lever “a” of the coupler in the direction of the
arrow shown. a
1 a
3. Install:
• Intake air pressure sensor “1”
TIP
EAS31129
Make sure that the intake air pressure sensor
INSTALLING THE ELECTRICAL contacts the frame.
COMPONENTS TRAYS
1. Install:
• Electrical components tray 2 “1”
TIP
Tighten the electrical components tray 2 nuts
and bolt in the proper tightening sequence as
shown.
4-15
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake discs
40 N•m (4.0 kgf•m, 30 lb•ft) 1
T.R
.
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
3 18 N•m (1.8 kgf•m, 13 lb•ft)
T.R
.
2
2 New
5
LT
(5)
3
4 7
18 N•m (1.8 kgf•m, 13 lb•ft)
T.R
.
LT
LT
6 New 9
(5)
7
New (3) 9
LT
LT 8
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
4-16
FRONT WHEEL
New 1
New 2
LS
3
New 2
New 1
LS
4-17
FRONT WHEEL
EAS30145
NOTICE
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor; otherwise, the
sensor or rotor may be damaged, resulting
in improper performance of the ABS sys-
tem.
• Do not drop the front wheel sensor rotor or c. Remove the wheel bearings “3” with a gen-
subject it to shocks. eral bearing puller.
• If any solvent gets on the front wheel sen-
sor rotor, wipe it off immediately.
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Front brake hose/lead holder
• Front reflector bracket EAS30147
EAS30146
4-18
FRONT WHEEL
1. Check:
Radial wheel runout limit • Front wheel sensor “1”
1.0 mm (0.04 in) Cracks/bends/distortion Replace.
Lateral wheel runout limit Iron powder/dust Clean.
0.5 mm (0.02 in)
2. Check:
• Front wheel sensor rotor “1”
4. Check:
Cracks/damage/scratches Replace the
• Wheel bearing front wheel sensor rotor.
Front wheel turns roughly or is loose Re-
Iron powder/dust/solvent Clean.
place the wheel bearings.
TIP
• Oil seal
Damage/wear Replace. • The wheel sensor rotor is installed on the inner
side of the wheel hub.
• When cleaning the wheel sensor rotor, be
careful not to damage the surface of the sensor
rotor.
EAS30155
NOTICE
3. Measure:
• Handle the ABS components with care • Wheel sensor rotor deflection
since they have been accurately adjusted. Out of specification Clean the installation
Keep them away from dirt and do not sub- surface of the wheel sensor rotor and correct
ject them to shocks. the wheel sensor rotor deflection, or replace
• The front wheel sensor cannot be disas- the wheel sensor rotor.
sembled. Do not attempt to disassemble it.
If faulty, replace with a new one. Wheel sensor rotor deflection
• Keep any type of magnets (including mag- limit
netic pick-up tools, magnetic screwdrivers, 0.25 mm (0.0098 in)
etc.) away from the front wheel sensor or
front wheel sensor rotor. a. Hold the dial gauge at a right angle against
• Do not drop or shock the wheel sensor or the wheel sensor rotor surface.
the wheel sensor rotor. b. Measure the wheel sensor rotor deflection.
TIP
Do not touch the surface of the wheel sensor ro-
tor with a sharp object.
4-19
FRONT WHEEL
EAS30151
NOTICE
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made
only with the outer race “3”.
TIP
Use a socket “4” that matches the diameter of
the wheel bearing outer race.
LOCTITE® TIP
ECA18100 Place a suitable washer “1” between the socket
NOTICE “2” and the bearing so that both the inner race
Replace the wheel sensor rotor bolts with “3” and outer race “4” are pressed at the same
new ones. time, and then press the bearing until the inner
race makes contact with the spacer “5”.
d. If the deflection is still above specification,
replace the wheel sensor rotor.
TIP
Install the wheel sensor rotor with the stamped
mark “a” facing outward.
4-20
FRONT WHEEL
EAS30152
LOCTITE®
4. Install:
Front brake disc bolt
• Collar
18 N·m (1.8 kgf·m, 13 lb·ft)
LOCTITE® • Front wheel
• Front wheel axle
ECA21011
TIP
NOTICE
Install the front wheel with the mark “a” on the
• Do not drop the wheel sensor rotor or sub- front tire pointing in the direction of wheel rota-
ject it to shocks. tion.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones. a
TIP
• Install the wheel sensor rotor with the stamped
mark “a” facing outward.
• Install each front brake disc so that the cham-
fered portions of the rivets “b” face outward.
• Tighten the brake disc bolts in stages and in a
crisscross pattern. 5. Tighten:
• Front wheel axle
• Front wheel axle pinch bolt
4-21
FRONT WHEEL
TIP
Front wheel axle Measure the distance between the front wheel
65 N·m (6.5 kgf·m, 48 lb·ft) sensor rotor and front wheel sensor in several
T.
R.
Front wheel axle pinch bolt places in one rotation of the front wheel. Do not
23 N·m (2.3 kgf·m, 17 lb·ft)
turn the front wheel while the thickness gauge is
ECA19760 installed. This may damage the front wheel sen-
NOTICE sor rotor and the front wheel sensor.
Before tightening the wheel axle, push down
hard on the handlebars several times and
Thickness gauge
check if the front fork rebounds smoothly. 90890-03180
TIP Feeler gauge set
YU-26900-9
First, tighten the wheel axle, then the wheel axle
pinch bolt.
a
6. Install:
• Front wheel sensor
ECA21020
NOTICE
Make sure there are no foreign materials in 2 1
the front wheel sensor rotor and front wheel 8. Install:
sensor. Foreign materials cause damage to • Front reflector bracket
the front wheel sensor rotor and front wheel • Front brake caliper
sensor. • Front brake hose/lead holder “1”
the wheel sensor lead for twists. Front brake hose/lead holder bolt
• To route the front wheel sensor lead, refer to 8 N·m (0.8 kgf·m, 5.9 lb·ft)
“CABLE ROUTING” on page 2-15. EWA13500
7. Measure: WARNING
• Distance “a” Make sure the brake hose is routed properly.
(between the front wheel sensor rotor “1” and
TIP
front wheel sensor “2”)
Out of specification Check the wheel bear- Install the front brake hose/lead holder so that
ing for looseness, and the front wheel sensor the projection “a” on the holder contacts the
and sensor rotor installation conditions stopper “b” on the front fork.
(warpage caused by overtorque, wrong in-
stallation direction, rotor decentering, LOC- b
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser- a
vice and caught foreign materials). If there is 1
any defective part, repair or replace the de-
fective part.
4-22
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel
16 N•m (1.6 kgf•m, 12 lb•ft) 7 105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
T.R
.
.
8
10
5
4
3
6
4
3
S
2
1
.
LT
T.R
.
4-23
REAR WHEEL
T.R
T.R
.
.
12
11
15
13 12
14
16 S
LT
T.R
.
4-24
REAR WHEEL
1 2
(6)
3
11
4
LS
LS
6 5
New 7
8
LS
9
LT
10
(3)
(5)
LT
4-25
REAR WHEEL
2 New
3
2 New
1 New
LS
4-26
REAR WHEEL
EAS30156
4. Remove:
REMOVING THE REAR WHEEL (DISC
• Wheel axle nut “1”
BRAKE)
ECA21030
• Washer
NOTICE • Rear wheel axle “2”
• Keep any type of magnets (including mag- • Drive chain slack adjusting plate
netic pick-up tools, magnetic screwdrivers, • Rear wheel
etc.) away from the rear wheel sensor or TIP
rear wheel sensor rotor; otherwise, the sen- Push the rear wheel forward and remove the
sor or rotor may be damaged, resulting in drive chain from the rear wheel sprocket.
improper performance of the ABS system.
• Do not drop the rear wheel sensor rotor or
subject it to shocks.
• If any solvent gets on the rear wheel sensor 2 1
rotor, wipe it off immediately.
1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
EAS30158
TIP DISASSEMBLING THE REAR WHEEL
Place the vehicle on a suitable stand so that the 1. Remove:
rear wheel is elevated. • Oil seal
2. Remove: • Wheel bearing
• Rear wheel sensor Refer to “DISASSEMBLING THE FRONT
• Rear brake caliper WHEEL” on page 4-18.
ECA21040
EAS30159
NOTICE CHECKING THE REAR WHEEL
• Do not depress the brake pedal when re- 1. Check:
moving the brake caliper. • Rear wheel axle
• Be sure not to contact the sensor electrode • Wheel bearing
to any metal part when removing the rear • Oil seal
wheel sensor from the rear brake caliper Refer to “CHECKING THE FRONT WHEEL”
bracket. on page 4-18.
2. Check:
3. Loosen:
• Tire
• Chain puller locknut “1”
• Rear wheel
• Drive chain adjusting nut “2”
Damage/wear Replace.
Refer to “CHECKING THE TIRES” on
2 1 page 3-16 and “CHECKING THE WHEELS”
on page 3-16.
3. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-18.
4-27
REAR WHEEL
EAS30160
TIP
CHECKING THE REAR WHEEL DRIVE HUB
1. Check: • Install the rear wheel sprocket so that the
• Rear wheel drive hub “1” stepped side “a” of the sprocket faces away
Cracks/damage Replace. from the hub.
• Rear wheel drive hub damper “2” • Tighten the rear wheel sprocket nuts in stages
Damage/wear Replace. and in a crisscross pattern.
2
a
1 2 2
EAS30161
EAS30167
CHECKING AND REPLACING THE REAR
MAINTENANCE OF THE REAR WHEEL
WHEEL SPROCKET
SENSOR AND SENSOR ROTOR
1. Check: ECA21060
4-28
REAR WHEEL
ECA21011
Recommended lubricant
Lithium-soap-based grease
4-29
REAR WHEEL
5. Install:
• Collar (right)
3
• Collar (left)
• Brake caliper bracket “1”
• Rear wheel e
• Chain puller “2”
• Drive chain slack adjusting plate
• Rear wheel axle
• Washer
• Wheel axle nut
• Swingarm end plate “3” 6. Install:
TIP • Rear brake caliper
• Rear brake caliper retaining bolt
• Install the rear wheel with the mark “a” on the
• Rear brake caliper bolt
rear tire pointing in the direction of wheel rota-
7. Fit the space “a” between the side plates of
tion.
the drive chain “1” onto the rib “b” on the drive
• Align the projection “b” in the swingarm with the
chain guide “2”.
slot “c” of the brake caliper bracket.
• Make sure that the arrow mark “d” on each
chain puller points upward.
• Make sure that the arrow mark “e” on each 1
swingarm end plate points upward.
a
2
a
b
8. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN SLACK” on page 3-
18.
9. Tighten:
• Wheel axle nut
• Rear brake caliper retaining bolt
• Rear brake caliper bolt
2
Wheel axle nut
105 N·m (10.5 kgf·m, 77 lb·ft)
T.
R.
4-30
REAR WHEEL
EWA13500
WARNING
a
Make sure the brake hose is routed properly.
10.Install:
• Rear wheel sensor 2
2
R.
ECA21080 1
NOTICE
Make sure there are no foreign materials in
the rear wheel sensor rotor and rear wheel
sensor. Foreign materials cause damage to
the rear wheel sensor rotor and rear wheel
sensor.
TIP
To route the rear wheel sensor lead, refer to
“CABLE ROUTING” on page 2-15.
11.Measure:
• Distance “a”
(between the rear wheel sensor rotor “1” and
rear wheel sensor “2”)
Out of specification Check the wheel bear-
ing for looseness, and the rear wheel sensor
and sensor rotor installation conditions
(warpage caused by overtorque, wrong in-
stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
vice and caught foreign materials). If there is
any defective part, repair or replace the de-
fective part.
TIP
Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
places in one rotation of the rear wheel. Do not
turn the rear wheel while the thickness gauge is
installed. This may damage the rear wheel sen-
sor rotor and the rear wheel sensor.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
4-31
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
5
8
New 7
LS 3
6
2
1
5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
4
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Front reflector bracket 1
6 Front brake caliper 1
7 Brake caliper bleed screw 1 Left side only.
8 Brake caliper bleed screw 1 Right side only.
4-32
FRONT BRAKE
1
2
T.R
S
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
4 6
New
7
5
4-33
FRONT BRAKE
10
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.
T.R
S
.
11
New 8
4-34
FRONT BRAKE
BF
2
BF
1 New
4-35
FRONT BRAKE
4 5
3 New
7
2 New
1
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of
the front brake calipers.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
1 Front brake hose union bolt 1
2 Brake hose gasket 1 Left side only.
3 Brake hose gasket 2
Brake hose (hydraulic unit to left front brake cal-
4 1 Left side only.
iper)
Brake hose (left front brake caliper to right front
5 1
brake caliper)
6 Front reflector bracket 1
7 Front brake caliper 1
4-36
FRONT BRAKE
9
8
New 7 BF
New 6
New
5
LS
4
2
7 New
4
1 6 New
5 S
5
New 6
New 7
BF 5
S
6 New
7 New
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Brake caliper bleed screw 1 Left side only.
9 Brake caliper bleed screw 1 Right side only.
4-37
FRONT BRAKE
EAS30168
d. Hold the dial gauge at a right angle against
INTRODUCTION
EWA14101
the brake disc surface.
WARNING e. Measure the deflection 1.5 mm (0.06 in) be-
Disc brake components rarely require disas- low the edge of the brake disc.
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
• Never use solvents on internal brake com-
ponents. 4. Measure:
• Use only clean or new brake fluid for clean- • Brake disc thickness
ing brake components. Measure the brake disc thickness at a few dif-
• Brake fluid may damage painted surfaces ferent locations.
and plastic parts. Therefore, always clean Out of specification Replace.
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with Brake disc thickness limit
the eyes as it can cause serious injury. 4.0 mm (0.16 in)
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS30169
LOCTITE®
Brake disc runout limit (as mea- ECA19150
4-38
FRONT BRAKE
3
1
LT a
d. Measure the brake disc deflection.
3. Measure:
e. If out of specification, repeat the adjustment
• Brake pad wear limit “a”
steps until the brake disc deflection is within
Out of specification Replace the brake
specification.
pads as a set.
f. If the brake disc deflection cannot be
brought within specification, replace the
Brake pad lining thickness limit
brake disc. 0.5 mm (0.02 in)
6. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-16.
EAS30170
4-39
FRONT BRAKE
EAS30724
brake calipers.
R.
A
5. Install: 3 4
• Brake pad pin
• Brake pad clip
• Front reflector bracket
• Front brake caliper 1
Front brake caliper bolt
40 N·m (4.0 kgf·m, 30 lb·ft) 2
T.
R.
6. Check: B
• Brake fluid level 4
Below the minimum level mark “a” Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
1
LEVEL” on page 3-16.
2
a
A. Left side
B. Right side
7. Check:
• Brake lever operation
Soft or spongy feeling Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
4-40
FRONT BRAKE
EAS30172 EAS30173
WARNING
Whenever a brake caliper is disassembled,
4 replace the brake caliper piston dust seals
and brake caliper piston seals.
b
2
3
a
c. Remove the brake caliper piston dust seals 1
and brake caliper piston seals. 1
d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
4-41
FRONT BRAKE
EAS30174
EAS30175
2
INSTALLING THE FRONT BRAKE CALIPERS 6
The following procedure applies to both of the A. Left side
brake calipers. B. Right side
1. Install:
2. Install:
• Front brake caliper “1”
• Brake pad
• Front reflector bracket “2”
• Brake pad spring
• Brake hose gasket “3” New • Brake pad pin
• Brake hose (hydraulic unit to left front brake • Brake pad clip
caliper) “4” Refer to “REPLACING THE FRONT BRAKE
• Brake hose (left front brake caliper to right PADS” on page 4-39.
front brake caliper) “5” 3. Fill:
• Brake hose union bolt “6” • Brake master cylinder reservoir
(with the specified amount of the specified
Front brake caliper bolt brake fluid)
40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
4-42
FRONT BRAKE
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system 2
Refer to “BLEEDING THE HYDRAULIC
1
BRAKE SYSTEM (ABS)” on page 3-15.
3
5. Check:
• Brake fluid level EAS30725
Below the minimum level mark “a” Add the CHECKING THE FRONT BRAKE MASTER
specified brake fluid to the proper level. CYLINDER
Refer to “CHECKING THE BRAKE FLUID 1. Check:
LEVEL” on page 3-16. • Brake master cylinder
Damage/scratches/wear Replace.
• Brake fluid delivery passage
(brake master cylinder body)
a Obstruction Blow out with compressed air.
2. Check:
• Brake master cylinder kit
Damage/scratches/wear Replace.
3. Check:
• Brake master cylinder reservoir “1”
• Brake master cylinder reservoir diaphragm
6. Check: holder “2”
• Brake lever operation Cracks/damage Replace.
Soft or spongy feeling Bleed the brake sys- • Brake master cylinder reservoir diaphragm
tem. “3”
Refer to “BLEEDING THE HYDRAULIC Damage/wear Replace.
BRAKE SYSTEM (ABS)” on page 3-15.
EAS30179
4-43
FRONT BRAKE
EAS30181
T.
EWA13520
R.
WARNING EWA13531
TIP
• Install the front brake master cylinder holder
with the “UP” mark “a” facing up.
• Align the end of the front brake master cylinder 15-25˚
holder with the punch mark “b” on the handle- a
bar.
• First, tighten the upper bolt, then the lower bolt. 3. Fill:
• There should be more than 11 mm (0.43 in) for • Brake master cylinder reservoir
clearance between the right handlebar switch (with the specified amount of the specified
and the front brake master cylinder holder. Al- brake fluid)
so, the punch mark should be seen.
Specified brake fluid
DOT 4
b
a
2. Install:
• Brake hose (front brake master cylinder to
hydraulic unit)
• Brake hose gasket New
• Brake hose union bolt
4-44
FRONT BRAKE
EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
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” on page 3-16.
6. Check:
• Brake lever operation
Soft or spongy feeling Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
4-45
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads
T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
5
S
10
S 9
8
LT
S
8
4 2 1
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
7
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
4-46
REAR BRAKE
T.R
T.R
T.R
.
.
2 New 8 7
1
3
6
4
New
5
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
LT
LS
4-47
REAR BRAKE
T.R
T.R
T.R
.
.
New 10
9
15
13
New 12
T.R
.
16
14
LT
LS
11
4-48
REAR BRAKE
5
2
New
2
New BF
4
3 New
BF
18 N•m (1.8 kgf•m, 13 lb•ft)
T.R
.
4-49
REAR BRAKE
T.R
.
1
New 2
3
4
LT
LT
S
6
5
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
4-50
REAR BRAKE
T.R
10
.
7
New 8
New 9
BF
6
5
T.R
. 2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
4
3
S 4
4-51
REAR BRAKE
EAS30183
INTRODUCTION
EWA14101
Brake disc thickness limit
WARNING 4.5 mm (0.18 in)
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
• Never disassemble brake components un- DISCS” on page 4-38.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
sembly. 6. Install:
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-23.
• Use only clean or new brake fluid for clean- EAS30185
ing brake components. REPLACING THE REAR BRAKE PADS
• Brake fluid may damage painted surfaces TIP
and plastic parts. Therefore, always clean
When replacing the brake pads, it is not neces-
up any spilt brake fluid immediately.
sary to disconnect the brake hose or disassem-
• Avoid brake fluid coming into contact with
ble the brake caliper.
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING 1. Measure:
THE EYES: • Brake pad wear limit “a”
• Flush with water for 15 minutes and get im- Out of specification Replace the brake
mediate medical attention. pads as a set.
4-52
REAR BRAKE
T.
R.
Brake caliper bleed screw LOCTITE®
5 N·m (0.5 kgf·m, 3.7 lb·ft) Rear brake caliper retaining bolt
T.
R.
6. Check:
• Brake pedal operation
Soft or spongy feeling Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
3. Lubricate:
• Rear brake caliper bolt
• Rear brake caliper retaining bolt
4-53
REAR BRAKE
EAS30186
3 WARNING
Whenever a brake caliper is disassembled,
a. Blow compressed air into the brake hose replace the brake caliper piston dust seal
joint opening “a” to force out the piston from and brake caliper piston seal.
the brake caliper.
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
4-54
REAR BRAKE
T.
R.
1 4 3
2
2. Check:
• Rear brake caliper bracket “1” 1
Cracks/damage Replace.
Refer to “REAR WHEEL” on page 4-23.
EWA13531
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA19080
NOTICE
When installing the brake hose onto the
1 brake caliper “1”, make sure the brake pipe
“a” passes between the projections “b” on
the brake caliper.
EAS30189
WARNING
• Before installation, all internal brake com-
b
ponents should be cleaned and lubricated a
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the brake caliper 1
piston dust seal and brake caliper piston
seal to swell and distort.
• Whenever a brake caliper is disassembled, 2. Remove:
replace the brake caliper piston dust seal • Rear brake caliper
and brake caliper piston seal. 3. Install:
• Brake pad insulator
Specified brake fluid (onto the brake pads)
DOT 4 • Brake pad shim
(onto the brake pads)
EAS30190 • Brake pad spring
INSTALLING THE REAR BRAKE CALIPER (into the rear brake caliper)
1. Install: • Brake pad
• Rear brake caliper “1” • Rear brake caliper
(temporarily) Refer to “REPLACING THE REAR BRAKE
• Brake hose gasket “2” New PADS” on page 4-52.
• Brake hose (hydraulic unit to rear brake cali-
per) “3”
• Rear brake hose union bolt “4”
4-55
REAR BRAKE
LOCTITE®
Rear brake caliper retaining bolt a
27 N·m (2.7 kgf·m, 20 lb·ft)
Brake pad retaining bolt
17 N·m (1.7 kgf·m, 13 lb·ft)
Screw plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
7. Check:
4. Fill: • Brake pedal operation
• Brake fluid reservoir Soft or spongy feeling Bleed the brake sys-
(with the specified amount of the specified tem.
brake fluid) Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
Specified brake fluid
DOT 4 EAS30193
NOTICE 3
Brake fluid may damage painted surfaces
2
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC EAS30194
4-56
REAR BRAKE
3. Check:
• Brake fluid reservoir “1” Rear brake hose/lead guide bolt
• Brake fluid reservoir diaphragm holder “2” 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Cracks/damage Replace. Rear brake hose/lead holder bolt
• Brake fluid reservoir diaphragm “3” 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Damage/wear Replace.
1
2
b
1
a
4. Check:
• Brake hose
• Brake fluid reservoir hose
Cracks/damage Replace. 2
EAS30195
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated 2. Install:
with clean or new brake fluid. • Brake hose gasket New
• Never use solvents on internal brake com- • Brake hose (rear brake master cylinder to hy-
ponents. draulic unit)
• Brake hose union bolt
Specified brake fluid • Brake fluid reservoir hose
DOT 4
Rear brake hose union bolt
1. Install: 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
EAS30196
WARNING
INSTALLING THE REAR BRAKE MASTER Proper brake hose routing is essential to in-
CYLINDER sure safe vehicle operation.
1. Install: ECA14160
• Rear brake hose/lead guide “1” NOTICE
• Rear brake hose/lead holder “2” When installing the brake hose onto the
TIP brake master cylinder, make sure the brake
• Fit the projection “a” on the rear brake hose/ pipe touches the projection “a” as shown.
lead guide into the hole “b” in the swingarm.
• Make sure that the projection “c” on the rear
brake hose/lead holder contacts the swingarm.
4-57
REAR BRAKE
6. Adjust:
3. Fill:
• Brake pedal position
• Brake fluid reservoir
Refer to “ADJUSTING THE REAR DISC
(with the specified amount of the specified
BRAKE” on page 3-14.
brake fluid)
7. Adjust:
• Rear brake light operation timing
Specified brake fluid
DOT 4 Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-28.
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
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” on page 3-16.
4-58
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS20032
T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)
New
T.R
.
2
2
New 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
New
New
New
4-59
ABS (ANTI-LOCK BRAKE SYSTEM)
T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)
3 New
T.R
.
7 3 New 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
New 3
6
5
4
New 3
3 New
4-60
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS31036
TIP
REMOVING THE HYDRAULIC UNIT
ASSEMBLY Do not operate the brake lever and brake pedal
ECA21091 while removing the brake hoses.
NOTICE ECA14530
2. Remove:
• Brake hoses
4-61
ABS (ANTI-LOCK BRAKE SYSTEM)
4-62
ABS (ANTI-LOCK BRAKE SYSTEM)
ECA14770
A B NOTICE
Always check the operation of the hydraulic
unit according to the brake lever and the
brake pedal response.
8. Delete the fault codes. (Refer to “[B-3] DE-
LETING THE FAULT CODES” on page 8-
141.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-66.)
A. The ABS ECU coupler is connected cor-
rectly. EAS31040
B. The ABS ECU coupler is not connected. HYDRAULIC UNIT OPERATION TESTS
5. Fill: The reaction-force pulsating action generated in
• Brake master cylinder reservoir the brake lever and brake pedal when the ABS is
• Brake fluid reservoir activated can be tested when the vehicle is
(with the specified amount of the specified stopped.
brake fluid) The hydraulic unit operation can be tested using
the following two methods.
Specified brake fluid • Brake line routing confirmation: this test
DOT 4 checks the function of the ABS after the sys-
tem was disassembled, adjusted, or serviced.
EWA13090
• ABS reaction-force confirmation: this test gen-
WARNING erates the same reaction-force pulsating action
• Use only the designated brake fluid. Other that is generated in the brake lever and brake
brake fluids may cause the rubber seals to pedal when the ABS is activated.
deteriorate, causing leakage and poor
brake performance. Brake line routing confirmation
• Refill with the same type of brake fluid that EWA13120
4-63
ABS (ANTI-LOCK BRAKE SYSTEM)
4-64
ABS (ANTI-LOCK BRAKE SYSTEM)
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
1
TIP
• For the ABS reaction-force confirmation, use 2
the diagnosis mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
6. Start the Yamaha diagnostic tool and display
• Before performing the ABS reaction-force con-
the diagnosis mode screen.
firmation, make sure that no malfunctions have
7. Select code No. 1, “ABS reaction-force con-
been detected in the ABS ECU and that the
firmation”.
wheels are not rotating.
8. Click “Actuator Check”, and then operate the
1. Place the vehicle on a suitable stand. brake lever and brake pedal simultaneously.
2. Turn the main switch to “OFF”. TIP
3. Remove: • The hydraulic unit operates 1 second after the
• Passenger seat brake lever and brake pedal are operated si-
• Rider seat multaneously and continues for approximately
Refer to “GENERAL CHASSIS (1)” on 5 seconds.
page 4-1. • The operation of the hydraulic unit can be con-
4. Check: firmed using the indicator.
• Battery voltage On: The hydraulic unit is operating.
Lower than 12.8 V Charge or replace the Flashing: The conditions for operating the hy-
battery. draulic unit have not been met.
Off: The brake lever and brake pedal are not
Battery voltage being operated.
Higher than 12.8 V
9. A reaction-force pulsating action is generated
TIP in the brake lever “1” and continues for a few
If the battery voltage is lower than 12.8 V, charge seconds.
the battery, and then perform ABS reaction- TIP
force confirmation. • The reaction-force pulsating action consists of
quick pulses.
• Be sure to continue operating the brake lever
and brake pedal even after the pulsating action
has stopped.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
4-65
ABS (ANTI-LOCK BRAKE SYSTEM)
10.After the pulsating action has stopped in the 16.Check for brake fluid leakage around the hy-
brake lever, it is generated in the brake pedal draulic unit.
“1” and continues for a few seconds. Brake fluid leakage Replace the hydraulic
TIP unit, brake hoses, and related parts as a set.
• The reaction-force pulsating action consists of 17.If the operation of the hydraulic unit is normal,
quick pulses. delete all of the fault codes.
• Be sure to continue operating the brake lever EAS31041
and brake pedal even after the pulsating action CHECKING THE ABS WARNING LIGHT
has stopped. After all checks and servicing are completed, en-
• “ON” and “OFF” on the tool screen indicate sure that the ABS warning light goes off by walk-
when the brakes are being applied and re- ing the vehicle at a speed of faster than 10 km/h
leased respectively. (6.2 mph) or performing a trial run.
1
11.After the pulsating action has stopped in the
brake pedal, it is generated in the brake lever
and continues for a few seconds.
TIP
• The reaction-force pulsating action consists of
quick pulses.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
ECA18280
NOTICE
• Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le-
ver, in this order.
• If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
12.Turn the main switch to “OFF”.
13.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
stall the protective cap.
14.Turn the main switch to “ON”.
15.Set the start/engine stop switch to “ ”.
4-66
HANDLEBAR
EAS20033
HANDLEBAR
Removing the handlebar
1
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
4
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
1 LS
7 LS
LS 7
2 5
6
LS
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
8
6
8 5
10 N•m (1.0 kgf•m, 7.4 lb•ft) 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
.
.
T.R
.
4-67
HANDLEBAR
T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
LS LS
14
LS
15 17
LS
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
17
11 18
9
16
12
10 11
13 19
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
.
.
T.R
.
4-68
HANDLEBAR
EAS30203 EAS30204
TIP NOTICE
Blow compressed air between the left handlebar First, tighten the bolts on the front side of the
and the handlebar grip, and gradually push the handlebar holder, and then on the rear side.
grip off the handlebar.
TIP
• The upper handlebar holders should be in-
stalled with the punch marks “a” facing for-
ward.
• Align the punch mark “b” on the handlebar with
the left side upper surface of the lower handle-
bar holder “3”.
3 1
4-69
HANDLEBAR
3. Install: 4. Install:
• Clutch lever holder “1” • Handlebar grip “1”
• Clutch lever “2” • Grip end (left) “2”
• Clutch lever pivot bolt “3”
• Clutch cable Grip end
• Clutch switch “4” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Clutch lever holder pinch bolt a. Apply a thin coat of rubber adhesive onto
11 N·m (1.1 kgf·m, 8.1 lb·ft) the end of the left handlebar.
T.
R.
Clutch lever pivot nut b. Side the handlebar grip over the end of the
7 N·m (0.7 kgf·m, 5.2 lb·ft) left handlebar.
c. Wipe off any excess rubber adhesive with a
TIP clean rag.
• Align the center of slit on the clutch lever holder EWA13700
1
a
2 1
3 b 5. Install:
c • Handlebar switch (left) “1”
2
Handlebar switch screw (left)
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
TIP
Align the projection “a” on the left handlebar
switch with the hole “b” in the handlebar.
e
2 a
d b
4 LT
LT
4-70
HANDLEBAR
6. Install: TIP
• Throttle grip “1” • Make sure that the throttle cable holder 1 “1”
• Throttle cable contacts the throttle cable adjusting nut and
• Grip end (right) that the open ends of the holder are pointing
• Throttle cable housing “2” rearward.
• Align the throttle cable holder 2 “2” with the
Grip end edge “a” of the front brake master cylinder.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Align the projection “a” on the throttle cable
housing with the hole “b” in the handlebar.
• There should be 1–3 mm (0.04–0.12 in) of
clearance “c” between the throttle grip and the 1
grip end.
c
b 2
2
1
a a
2
7. Install: 9. Install:
• Handlebar switch (right) “1” • Front brake master cylinder assembly
Refer to “INSTALLING THE FRONT BRAKE
Handlebar switch screw (right) MASTER CYLINDER” on page 4-44.
2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 10.Adjust:
T.
R.
4-71
FRONT FORK
EAS20034
FRONT FORK
Removing the front fork legs
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
T.R
.
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
4-72
FRONT FORK
T.R
.
5 5
8 10
4
7
10
11
1
2
4-73
FRONT FORK
2
New 3
LS
New 7
4
New 8
New LS
5
New
1
6
New
New 10
9 LT
LT
4-74
FRONT FORK
New
LS
New
New
New 15
LS
16
New 17
14
21
12
New 18
11 19
20 New
LT
LT
13
30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
.
4-75
FRONT FORK
EAS30206 EAS30207
REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the The following procedure applies to both of the
front fender side covers and front fork legs. front fork legs.
1. Remove: 1. Drain:
• Front fender • Fork oil
2. Stand the vehicle on a level surface. TIP
EWA13120
Stroke the outer tube several times while drain-
WARNING
ing the fork oil.
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
front wheel is elevated.
3. Loosen:
• Front fork cap bolt “1”
• Upper bracket pinch bolt (left and right) “2”
• Upper bracket pinch bolt (center) “3”
• Lower bracket pinch bolt “4” 2. Remove:
2 • Dust seal “1”
• Oil seal clip “2”
1
(with a flathead screwdriver)
2 ECA14180
NOTICE
Do not scratch the inner tube.
3
4
3. Remove:
• Front fork damper rod bolt “1”
• Copper washer
EWA13640 TIP
WARNING While holding the damper rod with the damper
Before loosening the upper and lower brack- rod holder “2” and T-handle “3”, loosen the front
et pinch bolts, support the front fork leg. fork damper rod bolt.
4-76
FRONT FORK
4. Remove:
• Inner tube
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in
a vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but care- 3. Check:
fully. • Damper rod
ECA14190
Damage/wear Replace.
NOTICE Obstruction Blow out all of the oil passag-
• Excessive force will damage the oil seal es with compressed air.
and bushing. A damaged oil seal or bush- • Oil flow stopper
ing must be replaced. Damage Replace.
• Avoid bottoming the inner tube into the out- ECA14200
EAS30209
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• Fork spring free length “a”
Out of specification Replace.
4-77
FRONT FORK
a 2. Lubricate:
• Inner tube’s outer surface
2
Recommended oil
Yamaha Suspension Oil G10
LOCTITE®
TIP
While holding the damper rod assembly with the
damper rod holder “2” and T-handle “3”, tighten
the front fork damper rod bolt.
4-78
FRONT FORK
TIP
Damper rod holder • Before installing the oil seal, lubricate its lips
90890-01460 with lithium-soap-based grease.
T-handle • Lubricate the outer surface of the inner tube
90890-01326
with fork oil.
T-handle 3/8" drive 60 cm long
• Before installing the oil seal, cover the top of
YM-01326
the front fork leg with a plastic bag to protect
the oil seal during installation.
4 2
New 1
3 8. Install:
2 • Oil seal clip “1” New
New 1 TIP
7. Install: Adjust the oil seal clip so that it fits into the outer
• Oil seal “1” New tube’s groove.
(with the fork seal driver attachment “2” and
fork seal driver weight “3”)
ECA14220
NOTICE
Make sure the numbered side of the oil seal New 1
faces up.
4-79
FRONT FORK
9. Install:
• Dust seal “1” New
(with the fork seal driver weight “2”)
12.Install:
• Fork spring
2 • Spring seat
• Spacer
• Front fork cap bolt
(along with the O-ring New )
TIP
New 1 • Before installing the front fork cap bolt, lubri-
10.Fill: cate its O-ring with grease.
• Front fork leg • Temporarily tighten the front fork cap bolt.
(with the specified amount of the recom- • Tighten the front fork cap bolt specified torque,
mended fork oil) when installing the front fork with upper brack-
et.
Quantity (left) 13.Install:
405.0 cm³ (13.69 US oz, 14.28 • Protector “1”
Imp.oz)
TIP
Quantity (right)
405.0 cm³ (13.69 US oz, 14.28 Align the projection “a” on the protector with the
Imp.oz) slot “b” in the outer tube.
Recommended oil
Yamaha Suspension Oil G10
11.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the outer 1 a
tube fully compressed and without the fork
spring) b
Out of specification Correct.
Level (left)
160 mm (6.3 in)
Level (right)
160 mm (6.3 in)
TIP
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
4-80
FRONT FORK
EAS30210
T.
front fork legs.
R.
Upper bracket pinch bolt (center)
1. Install: 21 N·m (2.1 kgf·m, 15 lb·ft)
• Front fork leg “1” Upper bracket pinch bolt (left and
Temporarily tighten the lower bracket pinch right)
bolts. 26 N·m (2.6 kgf·m, 19 lb·ft)
Front fork cap bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
1
4. Install:
• Front fender
T.
R.
2. Install:
• Upper bracket “1”
TIP
• Before installing the upper bracket, remove
any grease from the outer surface “a” of the
cap nut.
• Make sure the inner tube end is flush with the
top of the upper bracket.
3. Tighten:
• Lower bracket pinch bolt
• Upper bracket pinch bolt (center)
• Upper bracket pinch bolt (left and right)
• Front fork cap bolt
4-81
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
1st 52 N•m (5.2 kgf•m, 38 lb•ft)
*2nd 18 N•m (1.8 kgf•m, 13 lb•ft)
T.
R.
LS
LS
4
LS
2
1
4-82
STEERING HEAD
T.
R.
LS
11
LS
10
6
LS
4-83
STEERING HEAD
EAS30213
a. Remove the bearing races from the steer-
REMOVING THE LOWER BRACKET
ing head pipe “1” with a long rod “2” and
1. Stand the vehicle on a level surface.
EWA13120
hammer.
WARNING b. Remove the bearing race “3” from the lower
Securely support the vehicle so that there is bracket with a floor chisel “4” and hammer.
no danger of it falling over. c. Install a new dust seal and new bearing rac-
es.
2. Remove: ECA14270
2
1
EAS30214
2. Check:
• Bearing
• Bearing race
Damage/pitting Replace the bearings and
bearing races as a set.
3. Replace:
• Bearing
• Bearing race
4-84
STEERING HEAD
EAS30216
T.
• Upper bearing
R.
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
• Lower bearing Front brake hose lower holder
bolt
Recommended lubricant 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Lithium-soap-based grease
TIP
2. Install:
• Make sure that the front brake hose holder
• Lower bracket cap “1”
bracket contacts the projection “a” on the lower
(onto the lower bracket “2”)
bracket.
TIP • Make sure that the projection “b” on the front
Face the holes “a” in the lower bracket cap rear- brake hose lower holder fits into the hole in the
ward. front brake hose upper holder.
1
a
1
a
3. Install:
• Lower bracket
• Cap nut “1” b
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-19.
TIP
Before installing the cap nut, remove any grease 2
from the contact surfaces “a” between the cap 3
nut and the bearing cover and from the threads
“b” of the lower bracket and cap nut.
1
b
4. Install:
• Front brake hose holder bracket “1”
• Headlight bracket
• Front brake hose upper holder “2”
• Front brake hose lower holder “3”
4-85
REAR SHOCK ABSORBER ASSEMBLY
EAS20036
T.R
.
2
3
5
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
4
2
New
6
New
New 8
LS
7
New 8 New
New
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
LS
4-86
REAR SHOCK ABSORBER ASSEMBLY
T.R
.
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
10
14
17 New
18 17 New
16 14
New 9
LS
15
New 12 13 New
12 New 10
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
11
LS
4-87
REAR SHOCK ABSORBER ASSEMBLY
EAS30826 EAS30219
HANDLING THE REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER
EWA13740
ASSEMBLY
WARNING 1. Stand the vehicle on a level surface.
This rear shock absorber contains highly EWA13120
• Do not subject the rear shock absorber to CHECKING THE REAR SHOCK ABSORBER
an open flame or any other source of high ASSEMBLY
heat. High heat can cause an explosion due 1. Check:
to excessive gas pressure. • Rear shock absorber rod
• Do not deform or damage the rear shock Bends/damage Replace the rear shock
absorber in any way. Rear shock absorber absorber assembly.
damage will result in poor damping perfor- • Rear shock absorber assembly
mance. Gas leaks Replace the rear shock absorb-
er assembly.
EAS30729
• Spring
DISPOSING OF A REAR SHOCK ABSORBER Damage/wear Replace the rear shock ab-
1. Gas pressure must be released before dis- sorber assembly.
posing of a rear shock absorber. To release • Bolt
the gas pressure, drill a 2–3 mm (0.08– 0.12 Bends/damage/wear Replace.
in) hole through the rear shock absorber at a EAS31112
point 20–25 mm (0.79–0.98 in) from its end CHECKING THE RELAY ARM
as shown. 1. Check:
EWA13760
• Relay arm
WARNING
Damage/wear Replace.
Wear eye protection to prevent eye damage 2. Check:
from released gas or metal chips. • Bearing
• Oil seal
20-25 mm Damage/pitting Replace.
(0.79-0.98 in) 3. Check:
• Collar
Damage/scratches Replace.
EAS30222
Recommended lubricant
Lithium-soap-based grease
2. Install:
• Bearing “1”
• Oil seal “2” New
• Spacer “3”
(to the relay arm “4”)
4-88
REAR SHOCK ABSORBER ASSEMBLY
TIP
When installing the oil seals to the relay arm,
face the character stamps of the oil seals out-
side. a
4. Tighten:
a a • Connecting arm nut
• Relay arm nut
T.
R.
b b 40 N·m (4.0 kgf·m, 30 lb·ft)
Relay arm nut
New 2 2 New 40 N·m (4.0 kgf·m, 30 lb·ft)
EAS30225
New 2 2 New
a a
a
3 1 2. Tighten:
b b • Rear shock absorber assembly nut (front
side)
New 2 2 New
• Rear shock absorber bolt (rear side)
A. Left side
B. Right side Rear shock absorber assembly
bolt (front side)
3. Install:
T.
R.
4-89
SWINGARM
EAS20037
SWINGARM
Removing the swingarm
10 N•m (1.0 kgf•m, 7.4 lb•ft) LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) New New
T.R
.
1 LS
2
T.R
.
110 N•m (11 kgf•m, 81 lb•ft)
T.R
.
New
LS
New
LS
LT
LT
3
LT
LT
New
45 N•m (4.5 kgf•m, 33 lb•ft)
LS
T.R
4
.
4-90
SWINGARM
T.R
T.R
.
.
LS
5
52 N•m (5.2 kgf•m, 38 lb•ft)
T.R
.
110 N•m (11 kgf•m, 81 lb•ft)
T.R
.
New
14
16
LS 6
8 10 15 New 7
12
13
LS
LT
LT
14
13
12
LT
LT 16
New 11
45 N•m (4.5 kgf•m, 33 lb•ft)
LS
T.R
.
4-91
SWINGARM
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) New New
T.R
.
LS
18
19 20
21
17 20
T.R
.
110 N•m (11 kgf•m, 81 lb•ft)
T.R
.
New
LS 17
New
LS
LT
LT
LT
LT
New
45 N•m (4.5 kgf•m, 33 lb•ft)
LS
T.R
.
4-92
SWINGARM
EAS30226 EWA13770
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
2. Measure:
• Swingarm side play
• Swingarm vertical movement 3. Wash:
a. Measure the tightening torque of the pivot • Pivot shaft
shaft nut. • Dust cover
• Collar
Pivot shaft nut • Bearing
110 N·m (11 kgf·m, 81 lb·ft) • Washer
T.
R.
3
3. Remove: 2
• Swingarm 1
EAS31113
EAS30227
CHECKING THE CONNECTING ARM
CHECKING THE SWINGARM
1. Check:
1. Check:
• Connecting arm
• Swingarm
Damage/wear Replace.
Bends/cracks/damage Replace.
2. Check:
2. Check:
• Bearing
• Pivot shaft
• Oil seal
Roll the pivot shaft on a flat surface.
Damage/pitting Replace.
Bends Replace.
3. Check:
• Collar
Damage/scratches Replace.
4-93
SWINGARM
EAS31114
2. Install: a
• Bearing “1”
• Oil seal “2” New EAS30228
TIP
Align two flat sides “a” of the connecting arm bolt
with the projections “b” on the frame.
4-94
SWINGARM
2 New 2 New
New 2 2 New
1 1
A B
b
a c b d
A. Left side
B. Right side
3. Adjust:
• Drive chain slack
Refer to “DRIVE CHAIN SLACK” on page 3-
18.
4-95
CHAIN DRIVE
EAS20038
CHAIN DRIVE
Removing the drive chain
LS
LT
5
14 N•m (1.4 kgf•m, 10 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
.
1
9 N•m (0.9 kgf•m, 6.6 lb•ft) 3
T.R
.
7
6
E
LT
LT
LT
4-96
CHAIN DRIVE
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
12
E
LT
LT
LT
4-97
CHAIN DRIVE
EAS30229
TIP
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
EAS31115
2. Remove: REMOVING THE DRIVE SPROCKET
• Drive chain “1” 1. Straighten the drive sprocket nut ribs “a”.
TIP
Push the rear wheel forward and remove the a
drive chain from the rear wheel sprocket. Refer
to “DRIVE CHAIN SLACK” on page 3-18.
NOTICE
Make sure that the pivot shaft nut does not 2. Loosen:
come off the pivot shaft. • Drive sprocket nut
b. Tap the pivot shaft nut to push the pivot TIP
shaft to the left. Loosen the drive sprocket nut while pressing the
brake pedal.
3 2
EAS30230
4-98
CHAIN DRIVE
ECA14290
TIP
NOTICE
• When measuring a 15-link section of the drive
• This motorcycle has a drive chain with
chain, make sure that the drive chain is taut.
small rubber O-rings “1” between the drive
• Perform this procedure 2–3 times, at a different
chain side plates. Never use high-pressure
location each time.
water or air, steam, gasoline, certain sol-
vents (e.g., benzine), or a coarse brush to
clean the drive chain. High-pressure meth-
ods could force dirt or water into the drive
chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosene to clean the drive chain.
• Do not soak the drive chain in kerosene for
more than ten minutes, otherwise the O-
rings can be damaged.
2. Check:
• Drive chain
Stiffness Clean and lubricate or replace.
4. Check:
• O-ring “1”
Damage Replace the drive chain.
3. Clean: • Drive chain roller “2”
• Drive chain Damage/wear Replace the drive chain.
a. Wipe the drive chain with a clean cloth. • Drive chain side plate “3”
b. Put the drive chain in kerosene and remove Damage/wear/cracks Replace the drive
any remaining dirt. chain.
c. Remove the drive chain from the kerosene
and completely dry it.
4-99
CHAIN DRIVE
EAS31116
T.
R.
TIP
5. Lubricate:
• While applying the rear brake, tighten the drive
• Drive chain
sprocket nut.
• Install washer with the “OUT” mark “a” facing
Recommended lubricant
out.
Chain lubricant suitable for O-
ring chains • Stake the drive sprocket nut at cutouts “b” in
the drive axle.
EAS30231
a
b. Correct
LOCTITE®
4-100
CHAIN DRIVE
6. Measure:
• Installed shift rod length “a” and “b”
Incorrect Adjust.
1
3. Lubricate:
• Drive chain
a
Recommended lubricant
Chain lubricant suitable for O-
ring chains b
4-101
CHAIN DRIVE
90˚
8. Adjust:
• Drive chain slack
Refer to“DRIVE CHAIN SLACK” on page 3-
18.
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
4-102
CHAIN DRIVE
4-103
ENGINE
CAMSHAFTS.................................................................................................5-20
REMOVING THE CAMSHAFTS..............................................................5-24
CHECKING THE CAMSHAFTS ..............................................................5-25
CHECKING THE CAMSHAFT SPROCKETS .........................................5-26
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-26
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-27
INSTALLING THE CAMSHAFTS ............................................................ 5-27
INSTALLING THE CYLINDER HEAD COVER ....................................... 5-30
CLUTCH ........................................................................................................5-55
REMOVING THE CLUTCH ..................................................................... 5-59
CHECKING THE FRICTION PLATES.....................................................5-60
CHECKING THE CLUTCH PLATES .......................................................5-60
CHECKING THE CLUTCH SPRINGS.....................................................5-60
CHECKING THE CLUTCH HOUSING ....................................................5-61
CHECKING THE CLUTCH BOSS........................................................... 5-61
CHECKING THE PRESSURE PLATE ....................................................5-61
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-61
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-61
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-62
INSTALLING THE CLUTCH.................................................................... 5-62
SHIFT SHAFT................................................................................................5-65
CHECKING THE SHIFT SHAFT ............................................................. 5-67
CHECKING THE STOPPER LEVER ......................................................5-67
INSTALLING THE SHIFT SHAFT ........................................................... 5-67
CRANKCASE ................................................................................................5-74
DISASSEMBLING THE CRANKCASE....................................................5-76
CHECKING THE CRANKCASE ..............................................................5-76
ASSEMBLING THE CRANKCASE.......................................................... 5-76
INSTALLING THE OIL PRESSURE SWITCH.........................................5-78
TRANSMISSION............................................................................................ 5-97
REMOVING THE TRANSMISSION ......................................................5-101
CHECKING THE SHIFT FORKS...........................................................5-101
CHECKING THE SHIFT DRUM ASSEMBLY........................................5-101
CHECKING THE TRANSMISSION .......................................................5-102
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ............................5-102
INSTALLING THE TRANSMISSION .....................................................5-103
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20298
12
11
10
14
9 9
15
6
7
5 4 2
3
1. Oil strainer
2. Oil pump
3. Relief valve
4. Oil cooler
5. Oil filter cartridge
6. Main gallery
7. Oil pressure switch
8. Crankshaft
9. Oil nozzle
10. Balancer shaft assembly
11. Timing chain tensioner
12. Intake camshaft
13. Exhaust camshaft
14. Main axle
15. Drive axle
5-1
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS32363
LUBRICATION DIAGRAMS
Crankcase, cylinder, and cylinder head (right side view)
2
3
9 6
7
8
1. Timing chain tensioner
2. Intake camshaft
3. Exhaust camshaft
4. Crankshaft
5. Oil filter cartridge
6. Oil cooler
7. Oil drain bolt
8. Oil strainer
9. Oil pump
5-2
LUBRICATION SYSTEM CHART AND DIAGRAMS
5 4
1. Crankshaft
2. Balancer shaft assembly
3. Connecting rod
4. Oil cooler
5. Oil filter cartridge
5-3
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil pump
2. Oil pressure switch
3. Oil filter cartridge
4. Oil cooler
5. Oil strainer
5-4
LUBRICATION SYSTEM CHART AND DIAGRAMS
2
1. Intake camshaft
2. Cylinder head
3. Exhaust camshaft
5-5
LUBRICATION SYSTEM CHART AND DIAGRAMS
4
1. Oil nozzle
2. Piston
3. Crankshaft
4. Main gallery
5-6
LUBRICATION SYSTEM CHART AND DIAGRAMS
5-7
ENGINE INSPECTION
EAS20041
7. Install:
ENGINE INSPECTION • Extension “1”
EAS30249
• Compression gauge “2”
MEASURE THE COMPRESSION PRESSURE
The following procedure applies to all of the cyl- Compression gauge extension
inders. 122mm
90890-04136
TIP
Compression gauge extension
Insufficient compression pressure will result in a 122mm
loss of performance. YM-04136
1. Measure: Compression gauge
• Valve clearance 90890-03081
Out of specification Adjust. Engine compression tester
YU-33223
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-6.
2. Start the engine, warm it up for several min-
utes, and then turn it off. 2
3. Remove:
• Passenger seat
• Rider seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
• Air scoop (left)
1
• Air scoop (right)
• Fuel tank center cover (fuel tank side covers) 8. Measure:
Refer to “GENERAL CHASSIS (4)” on • Compression pressure
page 4-9. Out of specification Refer to steps (c) and
• Fuel tank (d).
Refer to “FUEL TANK” on page 7-1. TIP
4. Disconnect: Due to the engine characteristics, the compres-
• Ignition coil coupler “1” sion pressure is different for cylinder #1 and cyl-
5. Remove: inder #2.
• Ignition coil “2”
Compression pressure
643–828 kPa/495 r/min (6.4–8.3
kgf/cm²/495 r/min, 91.6–117.9
psi/495 r/min) (MTN660-AJ)
765–985 kPa/355 r/min (7.7–9.9
1 kgf/cm²/355 r/min, 108.9–140.2
psi/355 r/min) (MTN690-A,
2 MTN690-AJ, MTN690-U)
Compression pressure (#2 cylin-
der)
6. Remove:
626–806 kPa/495 r/min (6.3–8.1
• Spark plug kgf/cm²/495 r/min, 89.1–114.7
ECA13340
psi/495 r/min) (MTN660-AJ)
NOTICE
687–884 kPa/355 r/min (6.9–8.8
Before removing the spark plugs, use com- kgf/cm²/355 r/min, 97.8–125.8
pressed air to blow away any dirt accumulat- psi/355 r/min) (MTN690-A,
ed in the spark plug wells to prevent it from MTN690-AJ, MTN690-U)
falling into the cylinders.
5-8
ENGINE INSPECTION
WARNING
ADJUSTING THE EXHAUST GAS VOLUME
To prevent sparking, ground all spark plug TIP
leads before cranking the engine. • Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume.
TIP • To adjust the exhaust gas volume, use the CO
The difference in compression pressure be- adjustment mode of the Yamaha diagnostic
tween cylinders should not exceed 100 kPa (1 tool. For more information, refer to the opera-
kg/cm², 14 psi). tion manual of the Yamaha diagnostic tool.
c. If the compression pressure is above the 1. Connect the Yamaha diagnostic tool to the
maximum specification, check the cylinder coupler. For information about connecting the
head, valve surfaces and piston crown for Yamaha diagnostic tool, refer to “YAMAHA
carbon deposits. DIAGNOSTIC TOOL” on page 8-36.
Carbon deposits Eliminate.
d. If the compression pressure is below the Yamaha diagnostic tool USB
minimum specification, pour a teaspoonful 90890-03256
of engine oil into the spark plug bore and Yamaha diagnostic tool (A/I)
measure again. 90890-03262
Refer to the following table.
EAS31133
Compression pressure (with oil applied into CHECKING THE CYLINDER HEAD
the cylinder) BREATHER HOSE
Reading Diagnosis 1. Remove:
• Passenger seat
Higher than without Piston ring(s) wear or • Rider seat
oil damage Repair.
Refer to “GENERAL CHASSIS (1)” on
Same as without oil Pistons, valves, cylin- page 4-1.
der head gasket or • Air scoop (left)
piston ring(s) possibly • Air scoop (right)
defective Repair. • Fuel tank center cover (fuel tank side covers)
Refer to “GENERAL CHASSIS (4)” on
9. Install: page 4-9.
• Spark plug • Fuel tank
• Ignition coil Refer to “FUEL TANK” on page 7-1.
2. Check:
Spark plug • Cylinder head breather hose “1”
13 N·m (1.3 kgf·m, 9.6 lb·ft) Cracks/damage Replace.
T.
10.Connect: ECA14920
5-9
ENGINE INSPECTION
3. Install:
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Fuel tank center cover (fuel tank side covers)
• Air scoop (right)
• Air scoop (left)
Refer to “GENERAL CHASSIS (4)” on
page 4-9.
• Rider seat
• Passenger seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
5-10
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler and exhaust pipe
T.
R.
20 N•m (2.0 kgf•m, 15 lb •ft)
T.
R.
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
4
5 4
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
LS
3 New
New 3
1 (4)
6
5-11
ENGINE REMOVAL
10 N•m (1.0 kgf•m, 7.4 lb•ft) 2.2 N•m (0.22 kgf•m, 1.6 lb•ft)
T.R
.
T.R
.
5-12
ENGINE REMOVAL
10 N•m (1.0 kgf•m, 7.4 lb•ft) 2.2 N•m (0.22 kgf•m, 1.6 lb•ft)
T.R
.
T.R
.
5-13
ENGINE REMOVAL
12
7
9
8
13
10
11
3 4 5 6
10 N•m (1.0 kgf•m, 7.4 lb•ft) 2.2 N•m (0.22 kgf•m, 1.6 lb•ft)
T.R
.
T.R
.
5-14
ENGINE REMOVAL
T.
R.
25 N•m (2.5 kgf•m, 18 lb •ft)
T.
R.
2 6
7
5 8
3
55 N•m (5.5 kgf•m, 41 lb •ft)
T.
R.
4 1
55 N•m (5.5 kgf•m, 41 lb •ft)
T.
R.
7 N•m (0.7 kgf•m, 5.2 lb •ft)
T.
R.
T.
R.
3 11
9 44 N•m (4.4 kgf•m, 32 lb •ft)
T.
R.
10
5-15
ENGINE REMOVAL
T.R
.
.
15 14
T.R
.
a
15 17
T.R
.
13
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
44 N•m (4.4 kgf•m, 32 lb•ft)
T.R
.
12
16
55 N•m (5.5 kgf•m, 41 lb•ft)
T.R
.
5-16
ENGINE REMOVAL
EAS30250 ECA21181
2
1
2 1
EAS30251
1. Remove: INSTALLING THE ENGINE
• Engine mounting bolt (rear lower side) “1” 1. Install: (for models with a stamped “1” mark
a. Loosen the pivot shaft nut “2”, and then re- on the frame)
move the footrest bracket bolts “3”. • Plate “1”
A B
TIP
• Install the plate only for frames that have a
stamped “1” mark at the location “a”.
• Fit the projections “b” on the plate into the slots
2 “c” in the frame.
c b
3 1
A. Left side
B. Right side
b. Move the footrest bracket “4” rearward, and a
then loosen the engine mounting bolt (rear
FWD
lower side).
2. Install:
• Engine “2”
3. Install:
• Engine mounting bolt (rear upper side) “3”
• Engine mounting nut (rear upper side) “4”
• Engine mounting bolt (rear lower side) “5”
• Engine mounting nut (rear lower side) “6”
1 • Engine mounting bolt (left front side) “7”
4 • Engine mounting bolt (right front side) “8”
• Engine mounting bolt (right upper side) “9”
2. Remove: • Engine bracket bolt (right) “10”
• Engine mounting bolt (rear upper side) “1” • Engine bracket (right) “11”
a. Remove the rear brake hose joint bracket TIP
bolt “2”. Temporarily tighten the bolts and nuts.
b. Move the rear brake hose joint bracket “3”
slightly rearward, and then remove the en-
gine mounting bolt (rear upper side).
5-17
ENGINE REMOVAL
4. Tighten:
• Engine mounting nut (rear upper side) “4”
• Engine mounting nut (rear lower side) “6” 5
4
• Engine mounting bolt (left front side) “7”
3
Engine mounting nut (rear upper
side) 13
T.
R.
55 N·m (5.5 kgf·m, 41 lb·ft) contacts the projection “a” on the frame.
Engine mounting bolt (right front
side)
75 N·m (7.5 kgf·m, 55 lb·ft) a
Engine mounting bolt (right up-
per side) 2
55 N·m (5.5 kgf·m, 41 lb·ft)
Engine bracket bolt (right) 1
25 N·m (2.5 kgf·m, 18 lb·ft)
Engine bracket bolt (left)
25 N·m (2.5 kgf·m, 18 lb·ft)
8. Install:
• Clutch cable guide “1”
TIP
Make sure that the projection “a” on the clutch
cable guide contacts the frame.
5-18
ENGINE REMOVAL
5-19
CAMSHAFTS
EAS20043
CAMSHAFTS
Removing the cylinder head cover
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
13 N•m (1.3 kgf•m, 9.6 lb •ft) S
T.
R.
(4)
1
S
T.
R.
New
New
(6)
4.0 N•m (0.40 kgf•m, 3.0 lb •ft) LT
T.
R.
5-20
CAMSHAFTS
T.
R.
3
T.
R.
3
(4)
2
4
S
4
13 N•m (1.3 kgf•m, 9.6 lb •ft)
T.
R.
5
8 New
7
New 6
9 (6)
4.0 N•m (0.40 kgf•m, 3.0 lb •ft) LT
T.
R.
5-21
CAMSHAFTS
T.
R.
10 N•m (1.0 kgf•m, 7.4 lb •ft) (6)
6
T.
R.
E E
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
7
24 N•m (2.4 kgf•m, 18 lb •ft)
T.
R.
7 7 7
9
10 8 E
11 M
M
M
3
New 4 E
T.
R.
New
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
New
LS 10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
5-22
CAMSHAFTS
T.
R.
10 N•m (1.0 kgf•m, 7.4 lb •ft) (6)
T.
R.
E E
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
14
E
M
14 M
New E 13
12
24 N•m (2.4 kgf•m, 18 lb •ft) E
T.
R.
T.
R.
New
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
New
LS 10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
5-23
CAMSHAFTS
EAS30256 ECA13720
1
2
1
2
2. Align:
• Mark “a” on the generator rotor
(with the slot “b” in the generator rotor cover) 5. Remove:
a. Turn the crankshaft counterclockwise. • Intake camshaft “1”
b. When piston #1 is at TDC on the exhaust • Exhaust camshaft “2”
stroke, align the TDC mark “a” on the gen- TIP
erator rotor with the slot “b” in the generator To prevent the timing chain from falling into the
rotor cover. crankcase, fasten it with a wire “3”.
b 1
3
a
3. Remove: 6. Remove:
• Timing chain tensioner “1” • Intake camshaft sprocket “1”
• Timing chain tensioner gasket
TIP
a. Insert the hexagon wrench “2” (part No.: While holding the intake camshaft sprocket with
1WS-12228-00) into the timing chain ten- the rotor holding tool “2”, loosen the intake cam-
sioner. shaft sprocket bolts.
b. Remove the timing chain tensioner.
4. Remove:
• Intake camshaft cap “1”
• Exhaust camshaft cap “2”
5-24
CAMSHAFTS
2
1
1
2
7. Remove: 3. Measure:
• Exhaust camshaft sprocket “1” • Camshaft runout
TIP Out of specification Replace.
While holding the exhaust camshaft with a suit-
able tool, loosen the exhaust camshaft sprocket Camshaft runout limit
bolts. 0.030 mm (0.0012 in)
4. Measure:
EAS30257
5-25
CAMSHAFTS
EAS30936
TIP
CHECKING THE CAMSHAFT SPROCKETS
• Tighten the camshaft cap bolts in stages and in 1. Check:
a crisscross pattern, working from the inner • Camshaft sprocket
caps out. More than 1/4 tooth wear “a” Replace the
• Do not turn the camshaft when measuring the camshaft sprockets and timing chain as a set.
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.
1. Timing chain
2. Camshaft sprocket
EAS30266
5-26
CAMSHAFTS
T.
R.
TIP
• Make sure that the marks “a” on the intake
camshaft sprocket are aligned with cam lobe
#1 “b” as shown in the illustration.
• While holding the intake camshaft sprocket
with the rotor holding tool “2”, tighten the intake
EAS30267
camshaft sprocket bolts in the proper tighten-
CHECKING THE DECOMPRESSION SYSTEM ing sequence as shown.
1. Check:
• Decompression system
Rotor holding tool
TIP 90890-01235
• Check that the decompressor lever pins “1” Universal magneto and rotor
projects from the camshaft. holder
• Check that the decompressor cams “2” and de- YU-01235
compressor lever pins “1” moves smoothly.
1
2
1
b
a
2
EAS30269
5-27
CAMSHAFTS
ECA20930
1 a 2 1 a 3 NOTICE
• Lubricate the camshaft cap bolts with the
engine oil.
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
1 1 camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
4. Install:
• Exhaust camshaft sprocket “1” TIP
• When installing the timing chain, start with the
Exhaust camshaft sprocket bolt exhaust camshaft and be sure to keep the tim-
24 N·m (2.4 kgf·m, 18 lb·ft) ing chain as tight as possible on the exhaust
T.
R.
side.
TIP
• Make sure that the match marks “a” on the ex-
• Make sure that the mark “a” on the exhaust haust camshaft sprocket and cam lobe #1 “b”
camshaft sprocket is aligned with cam lobe #1 are aligned with the cylinder head edge “c” as
“b” as shown in the illustration. shown in the illustration.
• While holding the exhaust camshaft with a suit- • Temporarily tighten the exhaust camshaft cap
able tool, tighten the exhaust camshaft sprock- bolts, and then tighten the bolts to specification
et bolts. in a crisscross pattern.
• Tighten the camshaft sprocket bolts in the
tightening sequence as shown.
Exhaust camshaft cap bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
1 1
a 2
c
b
b a
6. Install:
• Timing chain “1”
a (onto the intake camshaft sprocket “2”)
• Intake camshaft
1
1 • Intake camshaft cap
ECA20930
1
2 NOTICE
• Lubricate the camshaft cap bolts with the
5. Install: engine oil.
• Timing chain “1” • The camshaft cap bolts must be tightened
(onto the exhaust camshaft sprocket “2”) evenly or damage to the cylinder head,
• Exhaust camshaft camshaft caps, and camshafts will result.
• Exhaust camshaft cap • Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
5-28
CAMSHAFTS
1
c. Install a new timing chain tensioner gasket
a 2 “3”, the timing chain tensioner “4”, and the
b timing chain tensioner bolts “5” on the cylin-
der block.
TIP
Be sure to install the timing chain tensioner gas-
ket so that the portion “a” of the gasket is pro-
truding from the upper inner side of the timing
b. Tighten the intake camshaft cap bolts. chain tensioner.
TIP
Temporarily tighten the intake camshaft cap
bolts, and then tighten the bolts to specification 5
in a crisscross pattern.
a 3 New
Intake camshaft cap bolt
4
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
7. Install:
• Timing chain tensioner
d. Tighten the timing chain tensioner bolts to
• Timing chain tensioner gasket New specification.
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the timing chain Timing chain tensioner bolt
tensioner rod fully counterclockwise with a 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
5-29
CAMSHAFTS
T.
R.
chain tensioner cap bolt to specification.
2
8. Turn: 1
• Crankshaft
(several turns counterclockwise)
9. Check:
• Mark “a”
Make sure the mark “a” on the generator rotor EAS30274
is aligned with the slot “b” in the generator ro- INSTALLING THE CYLINDER HEAD COVER
tor cover. 1. Install:
• Camshaft sprocket match mark • Timing chain guide (top side)
Make sure the match marks “c” on the cam- • Cylinder head cover gasket “1” New
shaft sprockets are aligned with the cylinder (to the cylinder head cover)
head mating surface “d”. • Cylinder head cover “2”
Out of alignment Adjust.
Refer to the installation steps above. Cylinder head cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
b
TIP
• Apply Yamaha bond No.1215 “3” onto the mat-
a ing surfaces of the cylinder head cover gasket
and cylinder head.
• After installing the cylinder head cover gasket
“1” to the cylinder head cover, cut off the “a”
section.
• Make sure that the projection “b” on the cylin-
c der head cover gasket is positioned on the ex-
c c haust side of the rib “c” on the cylinder head
d cover.
5-30
CAMSHAFTS
c
b
2
A
A. Exhaust side
2. Install:
• Spark plug
• Ignition coil “1”
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
TIP
Install the ignition coils “1” in the direction shown
in the illustration.
5-31
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
New 1st 10 N•m (1.0 kgf•m, 7.4 lb •ft)
10 N•m (1.0 kgf•m, 7.4 lb •ft) (6) 2nd 40 N•m (4.0 kgf•m, 30 lb •ft)
T.
R.
T.
R.
*3rd 20 N•m (2.0 kgf•m, 15 lb •ft)
16 N•m (1.6 kgf•m, 12 lb •ft) Specified angle 90°
T.
R.
T.
R.
E 75 N•m (7.5 kgf•m, 55 lb •ft)
T.
R.
New
LT
T.
R.
S
55 N•m (5.5 kgf•m, 41 lb •ft)
T.
R.
New
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Order Job/Parts to remove Q’ty Remarks
Refer to “GENERAL CHASSIS (1)” on
Rider seat/Passenger seat page 4-1.
Air scoop (left)/Air scoop (right)/Fuel tank center Refer to “GENERAL CHASSIS (4)” on
cover (fuel tank side covers) page 4-9.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Air duct bracket Refer to “AIR FILTER” on page 7-7.
Throttle bodies Refer to “THROTTLE BODIES” on page 7-8.
Footrest assembly (right) Refer to “REAR BRAKE” on page 4-46.
5-32
CYLINDER HEAD
T.
R.
*3rd 20 N•m (2.0 kgf•m, 15 lb •ft)
16 N•m (1.6 kgf•m, 12 lb •ft) Specified angle 90°
T.
R.
T.
R.
E 75 N•m (7.5 kgf•m, 55 lb •ft)
T.
R.
1 3
2
New
LT
T.
R.
S
55 N•m (5.5 kgf•m, 41 lb •ft)
T.
R.
New
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Order Job/Parts to remove Q’ty Remarks
Muffler assembly Refer to “ENGINE REMOVAL” on page 5-11.
Disconnect.
Oil cooler inlet hose Refer to “OIL COOLER” on page 6-5.
Radiator Refer to “RADIATOR” on page 6-2.
Cylinder head cover/Intake camshaft/Exhaust Refer to “CAMSHAFTS” on page 5-20.
camshaft
Clutch cover Refer to “CLUTCH” on page 5-55.
Thermostat Refer to “THERMOSTAT” on page 6-8.
1 Coolant temperature sensor coupler 1 Disconnect.
2 Coolant temperature sensor 1
3 Engine bracket bolt (left) 2
5-33
CYLINDER HEAD
T.
R.
*3rd 20 N•m (2.0 kgf•m, 15 lb •ft)
16 N•m (1.6 kgf•m, 12 lb •ft) Specified angle 90°
T.
R.
T.
R.
E 75 N•m (7.5 kgf•m, 55 lb •ft)
T.
R.
4
10
5
New
12
8 LT
7
6
6
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
11 S 13
55 N•m (5.5 kgf•m, 41 lb •ft)
T.
R.
15
New 14 9
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Order Job/Parts to remove Q’ty Remarks
4 Engine mounting bolt (left upper side) 1
5 Engine bracket (left) 1
6 Engine bracket bolt (right) 2
7 Engine mounting bolt (right upper side) 1
8 Engine bracket (right) 1
9 Engine mounting bolt (right front side) 1
10 Engine mounting bolt (left front side) 1
11 Timing chain bolt (right side of cylinder head) 1
12 Timing chain guide (exhaust side) 1
13 Cylinder head 1
14 Cylinder head gasket 1
15 Dowel pin 2
5-34
CYLINDER HEAD
T.
R.
*3rd 20 N•m (2.0 kgf•m, 15 lb •ft)
16 N•m (1.6 kgf•m, 12 lb •ft) Specified angle 90°
T.
R.
T.
R.
E 75 N•m (7.5 kgf•m, 55 lb •ft)
T.
R.
16
17
New
LT
T.
R.
S
55 N•m (5.5 kgf•m, 41 lb •ft)
T.
R.
New
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Order Job/Parts to remove Q’ty Remarks
16 Timing chain 1
17 Timing chain guide (intake side) 1
5-35
CYLINDER HEAD
EAS30276
1
1
2
1 2
6 4
2
3 8
EAS30278
• Loosen each bolt 1/2 of a turn at a time. After CHECKING THE CYLINDER HEAD
all of the bolts are fully loosened, remove them. 1. Eliminate:
• Combustion chamber carbon deposit
• M6 45 mm: “1”, “2” (with a rounded scraper)
• M10 100 mm: “3”–“8” TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
• Valve seats
2. Check:
• Cylinder head
Damage/scratches Replace.
• Cylinder head water jacket
Mineral deposits/rust Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification Resurface the cylinder
head.
Warpage limit
0.10 mm (0.0039 in)
5-36
CYLINDER HEAD
T.
R.
2nd: 40 N·m (4.0 kgf·m, 30 lb·ft)
*3rd: 20 N·m (2.0 kgf·m, 15 lb·ft)
Specified angle 90
Cylinder head bolt (“7”, “8”)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
×2
b. Measure the warpage. ×6 FWD
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder 2
head using a figure-eight sanding pattern.
TIP 6 4 8
To ensure an even surface, rotate the cylinder
head several times.
EAS30282
7
INSTALLING THE CYLINDER HEAD 3 5
1. Install:
1
• Cylinder head
• Cylinder head bolt (M10) (6) New
• Cylinder head bolt (M6) (2)
TIP
• Pass the timing chain through the timing chain
cavity.
• Lubricate the cylinder head bolt (M10) threads
and mating surface with engine oil.
2. Tighten:
• Cylinder head bolt “1”–“6”
• Cylinder head bolt “7”, “8”
5-37
VALVES AND VALVE SPRINGS
EAS20045
S 8 New
S
New 8
9
9
New 10
10 New
6 M
5-38
VALVES AND VALVE SPRINGS
EAS30283
TIP
REMOVING THE VALVES
The following procedure applies to all of the Remove the valve cotters by compressing the
valves and related components. valve spring with the valve spring compressor
TIP
“1” and the valve spring compressor attachment
“2”.
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal. Valve spring compressor
90890-04019
1. Remove: Valve spring compressor
• Valve lifter “1” YM-04019
• Valve pad “2” Valve spring compressor attach-
TIP ment
Make a note of the position of each valve lifter 90890-01243
and valve pad so that they can be reinstalled in Valve spring compressor adapter
their original place. (26 mm)
YM-01253-1
2. Check:
• Valve sealing 4. Remove:
Leakage at the valve seat Check the valve • Valve spring retainer “1”
face, valve seat, and valve seat width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-41. • Valve stem seal “4”
a. Pour a clean solvent “a” into the intake and • Valve spring seat “5”
exhaust ports. TIP
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
1
4
3 5
3. Remove:
• Valve cotter
5-39
VALVES AND VALVE SPRINGS
EAS30284
CHECKING THE VALVES AND VALVE a. Remove the valve guide with the valve
GUIDES guide remover “1”.
The following procedure applies to all of the
valves and valve guides.
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”
b. Install the new valve guide with the valve
guide installer “2” and valve guide remover
Valve-stem-to-valve-guide clear- “1”.
ance (intake)
0.010–0.037 mm (0.0004–0.0015 Valve guide position
in) 14.8–15.2 mm (0.58–0.60 in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
TIP
After replacing the valve guide, reface the valve
2. Replace:
seat.
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 C (212 F) in an oven.
5-40
VALVES AND VALVE SPRINGS
EAS30285
5-41
VALVES AND VALVE SPRINGS
5-42
VALVES AND VALVE SPRINGS
EAS30288
2. Measure:
• Valve spring tilt “a”
Out of specification Replace the valve
spring.
Recommended lubricant
Molybdenum disulfide oil
3. Lubricate:
• Valve stem seal “2”
(with the recommended lubricant)
Recommended lubricant
Silicone fluid
EAS30287
4. Install:
• Valve spring seat “1”
(into the cylinder head)
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
5-43
VALVES AND VALVE SPRINGS
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
5
2 New
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
b. Smaller pitch
5. Install: 7. Lubricate:
• Valve cotter • Valve lifter
TIP (with the recommended lubricant)
Install the valve cotters by compressing the
valve spring with the valve spring compressor Recommended lubricant
“1” and the valve spring compressor attachment Engine oil
“2”.
8. Install:
• Valve pad
Valve spring compressor • Valve lifter
90890-04019 TIP
Valve spring compressor
• The valve lifter must move smoothly when ro-
YM-04019
tated with a finger.
Valve spring compressor attach-
ment • Each valve lifter and valve pad must be rein-
90890-01243 stalled in their original position.
Valve spring compressor adapter
(26 mm)
YM-01253-1
5-44
GENERATOR AND STARTER CLUTCH
EAS20140
1
E
E
32 N•m (3.2 kgf•m, 24 lb •ft)
T.
R.
LT
LT
LT
LT
(3) E
E
LS (3)
E New
New
New LT
LT
E LS
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
New LT
LT
(8)
15 N•m (1.5 kgf•m, 11 lb •ft) 12 N•m (1.2 kgf•m, 8.9 lb •ft) 12 N•m (1.2 kgf•m, 8.9 lb •ft)
T.
R.
T.
R.
T.
R.
5-45
GENERATOR AND STARTER CLUTCH
9 2
E
12
E
32 N•m (3.2 kgf•m, 24 lb •ft)
T.
R.
9
LT
LT
5 LT
LT
(3) E
E 8 10
7
LS (3)
E New
New 6
New LT
LT
E LS 11 10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
70 N•m (7.0 kgf•m, 52 lb •ft) 3
T.
R.
New LT
LT
4
(8)
15 N•m (1.5 kgf•m, 11 lb •ft) 12 N•m (1.2 kgf•m, 8.9 lb •ft) 12 N•m (1.2 kgf•m, 8.9 lb •ft)
T.
R.
T.
R.
T.
R.
5-46
GENERATOR AND STARTER CLUTCH
E 17 13
E
32 N•m (3.2 kgf•m, 24 lb •ft)
T.
R.
19
LT
LT 14
LT
LT
(3) E
E
15 LS (3)
E New
New
New LT
LT
E LS
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
70 N•m (7.0 kgf•m, 52 lb •ft)
T.
R.
New LT
LT
(8)
15 N•m (1.5 kgf•m, 11 lb •ft) 12 N•m (1.2 kgf•m, 8.9 lb •ft) 12 N•m (1.2 kgf•m, 8.9 lb •ft)
T.
R.
T.
R.
T.
R.
5-47
GENERATOR AND STARTER CLUTCH
EAS30867
TIP EAS30869
• Install the flywheel puller bolts to the threaded CHECKING THE STARTER CLUTCH
holes of the starter clutch. 1. Check:
• Make sure the flywheel puller is centered over • Starter clutch roller
the generator rotor. Damage/wear Replace.
2. Check:
• Starter clutch idle gear
Flywheel puller • Starter clutch gear
90890-01362 Burrs/chips/roughness/wear Replace the
Heavy duty puller defective part(s).
YU-33270-B
3. Check:
• Starter clutch gear contact surface
Damage/pitting/wear Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
5-48
GENERATOR AND STARTER CLUTCH
B EAS30872
INSTALLING THE STARTER CLUTCH the woodruff key is properly seated in the key-
1. Install: way of the crankshaft.
• Starter clutch “1” • Lubricate the generator rotor bolt threads and
washer mating surfaces with engine oil.
Starter clutch bolt 2. Tighten:
32 N·m (3.2 kgf·m, 24 lb·ft) • Generator rotor bolt “1”
T.
R.
LOCTITE®
Generator rotor bolt
TIP
70 N·m (7.0 kgf·m, 52 lb·ft)
T.
5-49
GENERATOR AND STARTER CLUTCH
1 a
1
3
2
1 2 2
3. Install: 6. Install:
• Bearing “1” • Generator cover gasket New
TIP • Generator cover
Make sure that the bearing does not protrude
past the surface “a” of the cylinder. Generator cover bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
LOCTITE®
a Generator cover bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
TIP
• Tighten the generator cover bolts in stages and
in a crisscross pattern.
1 • Apply LOCTITE® to the threads of only the
1
generator cover bolts “1” shown in the illustra-
tion.
4. Apply:
• Sealant
(onto the stator coil lead grommet)
7. Connect:
• Stator coil coupler
• Crankshaft position sensor coupler
TIP
To route the stator coil lead, refer to “CABLE
ROUTING” on page 2-15.
5. Install:
• Bearing “1”
TIP
Make sure that the bearing contacts the surface
“a” of the generator cover “2”.
5-50
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
7 N•m (0.7 kgf•m, 5.2 lb •ft)
T.
R.
3
4
T.
R.
5
1
New
5-51
ELECTRIC STARTER
6
3
4
5 New
5 New
1 New
5-52
ELECTRIC STARTER
EAS30325
a
a
3. Measure:
• Armature assembly resistance 5. Measure:
Out of specification Replace the starter • Brush spring force
motor. Out of specification Replace the brush
a. Measure the armature assembly resistance holder set.
with the digital circuit tester.
Brush spring force
6.03–6.52 N (615–665 gf, 21.71–
Digital circuit tester (CD732)
23.47 oz)
90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
6. Check:
• Gear teeth
Damage/wear Replace the starter motor.
5-53
ELECTRIC STARTER
7. Check: EAS30327
2. Install:
• Coupler and hose bracket “1”
2. Install: TIP
• Starter motor yoke “1”
Make sure that the tab “a” on the coupler and
• Starter motor front cover “2”
hose holder bracket contacts the projection “b”
• Starter motor rear cover “3”
on the cylinder block.
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front cover 1
and rear covers.
b a b
b
3 1 2
5-54
CLUTCH
EAS20055
CLUTCH
Removing the clutch cover and pull lever shaft
New
T.
R.
LS
T.
R.
2
New 4
5
LT
LT
3 (10)
3
12 N•m (1.2 kgf•m, 8.9 lb •ft)
T.
R.
5-55
CLUTCH
8
9
T.
R.
11
LS
12
6 E
13
12 N•m (1.2 kgf•m, 8.9 lb •ft)
T.
R.
14
6 New 10
LT
LT
(10)
5-56
CLUTCH
T.
R.
5 E
6 7 2
1
6 7 3
4
6 7 (6)
(6)
6 7
6 7
6
5
11
LT
10
E 9
8
LT
E
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
New
E
95 N•m (9.5 kgf•m, 70 lb •ft)
T.
R.
5-57
CLUTCH
T.
R.
E
(6)
(6)
17
16
14
13
15
12
18
LT
LT
E
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
New
E
95 N•m (9.5 kgf•m, 70 lb •ft)
T.
R.
5-58
CLUTCH
EAS30346
5. Loosen:
REMOVING THE CLUTCH
• Clutch boss nut “1”
1. Remove:
TIP
• Clutch cover “1”
• Gasket While holding the clutch boss “2” with the univer-
TIP
sal clutch holder “3”, loosen the clutch boss nut.
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the Universal clutch holder
bolts are fully loosened, remove them. 90890-04086
Universal clutch holder
YM-91042
2
1
2. Remove:
• Compression spring bolt “1” 3
• Compression spring 6. Remove:
• Pressure plate “2” • Spacer “1”
• Pull rod “3” • Bearing “2”
TIP • Clutch housing “3”
Loosen the compression spring bolts in stages a. Remove the spacer and bearing.
and in a crisscross pattern.
1 2
1
2
3
3
a
4
5-59
CLUTCH
EAS30348 EAS30349
EAS30351
5-60
CLUTCH
EAS30353
EAS30354
EAS30352
CHECKING THE PRESSURE PLATE
CHECKING THE CLUTCH HOUSING 1. Check:
1. Check: • Pressure plate “1”
• Clutch housing dog Cracks/damage Replace.
Damage/pitting/wear Deburr the clutch • Bearing “2”
housing dogs or replace the clutch housing. Damage/wear Replace.
TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation. 1
2
EAS30356
5-61
CLUTCH
EAS30358
TIP
CHECKING THE PULL LEVER SHAFT AND
PULL ROD • Lubricate the conical spring washer and clutch
1. Check: boss nut threads with engine oil.
• Pull lever shaft pinion gear teeth “1” • Install the washer on the main axle with the
• Pull rod teeth “2” “OUT” mark facing away from the vehicle.
Damage/wear Replace the pull rod and • While holding the clutch boss “1” with the uni-
pull lever shaft as a set. versal clutch holder “3”, tighten the clutch boss
nut.
• Stake the clutch boss nut at a cutout “a” in the
main axle.
2. Check: 2
• Pull rod bearing
Damage/wear Replace.
EAS30363
3. Install:
• Friction plate 1 “1”
• Friction plate 2 “2”
TIP
• First, install a friction plate, and then alternate
a 1
between a clutch plate and a friction plate.
2. Install:
• Align a projection on friction plate 1 with the
• Thrust plate
punch mark “a” on the clutch housing and align
• Clutch boss “1”
a projection on friction plate 2 with the “ ”
• Washer
mark “b” on the housing.
• Conical spring washer
• Clutch boss nut “2” New
5-62
CLUTCH
a New 2
1 b 1 b
a
1
4. Install: a
• Bearing
• Pull rod “1”
• Pressure plate “2”
• Clutch spring
• Clutch spring bolt “3”
TIP
• Apply lithium-soap-based grease onto the pull 6. Install:
rod. • Pull lever
• Tighten the clutch spring bolts in stages and in TIP
a crisscross pattern. • Install the pull lever with the “UP” mark “a” fac-
ing toward upper side.
3 1 • When installing the pull lever, push the pull le-
ver and check that the punch mark “b” on the
pull lever aligns with the mark “c” on the clutch
cover.
2
5. Install:
• Bearing “1”
• Oil seal “2” New
(to the clutch cover)
TIP
• Lubricate the bearings with engine oil and lubri- b
cate the oil seal with lithium-soap-based
grease.
• Install the bearings until they contact the sur-
faces “a” and install the oil seal until it contacts
the surface “b” as shown in the illustration.
5-63
CLUTCH
7. Install: TIP
• Dowel pin “1” • Install the clutch cable so that the clutch cable
• Clutch cover gasket “2” New length “a” is 51.6–62.2mm (2.03–2.45 in) as
• Clutch cover “3” shown in the illustration. In addition, make sure
• Clutch cable holder “4” that the vehicle is positioned upright when
measuring the clutch cable length.
Clutch cover bolt • After installing the clutch cable, bend the pro-
12 N·m (1.2 kgf·m, 8.9 lb·ft) jection “b” on the pull lever.
T.
R.
TIP
• Align the slit “a” in the impeller shaft with the
projection “b” on the oil pump driven sprocket.
• Face the serrations on the clutch pull rod “5”
rearward and align the rod with the hole “c” in
the clutch cover.
• Make sure that the pull rod teeth and pull lever
shaft pinion gear are engaged.
• Apply locking agent (LOCTITE®) to the
threads of only the clutch cable holder bolts “6”
shown in the illustration. b 1
• Tighten the bolts in stages and in a crisscross
pattern.
1 2
3 9. Adjust:
5
LS • Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
a FREE PLAY” on page 3-12.
b
c
Clutch lever free play
1 5.0–10.0 mm (0.20–0.39 in)
4
6
3
8. Connect:
• Clutch cable “1”
5-64
SHIFT SHAFT
EAS20057
SHIFT SHAFT
Removing the shift shaft and stopper lever
LS
1 2
New
E
New
LT
8
4
5 22 N•m (2.2 kgf•m, 16 lb •ft)
6
T.
R.
New
E 9
E
5-65
SHIFT SHAFT
LS
12 13
New
E
New
11
LT
T.
R.
New
E
10
E
5-66
SHIFT SHAFT
EAS30377 EAS30381
TIP
• Apply engine oil onto the bearing.
1 • Make sure that the bearing does not protrude
past the line “b” shown in the illustration.
• Lubricate the oil seal lips with lithium-soap-
2 based grease.
New 2 1
EAS30378
LOCTITE®
TIP
• Hook the end of the shift shaft spring “2” onto
the shift shaft spring stopper “1”.
• Hook the ends of the stopper lever spring “3”
onto the stopper lever “4” and the stopper lever
spring hook “5”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
2
5
4
3
5-67
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump
LT
T.
R.
12 N•m (1.2 kgf•m, 8.9 lb •ft)
T.
R.
2
1
5-68
OIL PUMP
11
5
6
4
E
3
10 1
9
8
7 New
11
E
E
5-69
OIL PUMP
EAS30336
EAS30338
Inner-rotor-to-outer-rotor-tip 1
clearance
0.03–0.08 mm (0.0012–0.0032
in) 2
Limit
0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
0.09–0.15 mm (0.0035–0.0059
in)
Limit
0.22 mm (0.0087 in)
5-70
OIL PUMP
EAS30342
4. Check:
ASSEMBLING THE OIL PUMP
• Oil pump operation
1. Lubricate:
Refer to “CHECKING THE OIL PUMP” on
• Inner rotor
page 5-70.
• Outer rotor
(with the recommended lubricant) EAS30343
T.
R.
ECA20940
Recommended lubricant
NOTICE
Engine oil
After installing the oil pump drive chain and
3. Install: driven sprocket, make sure the oil pump
• Oil pump driven sprocket “1” turns smoothly.
• Pin “2”
• Outer rotor “3”
• Inner rotor “4”
• Oil pump cover “5”
• Oil pump cover screw “6” 2
1
TIP
Align the pin in the oil pump shaft with the
grooves “a” in the inner rotor.
2 1 3
4
5
5-71
OIL PAN
EAS20177
OIL PAN
Removing the oil pan
New 3
1
New
New
4
LT LT
10 N•m (1.0 kgf•m, 7.4 lb •ft) 10 N•m (1.0 kgf•m, 7.4 lb •ft) (11)
T.
T.
R.
R.
5-72
OIL PAN
EAS31068
a
1
EAS31069
TIP
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
2. Install:
• Gasket New
• Engine oil drain bolt
5-73
CRANKCASE
EAS20059
CRANKCASE
Separating the crankcase
1st 24 N•m (2.4 kgf•m, 18 lb •ft) New 24 N•m (2.4 kgf•m, 18 lb •ft)
(6)
T.
R.
*2nd 17 N•m (1.7 kgf•m, 13 lb •ft)
(6) New 10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
(2)
T.
Final Specified angle 60°
R.
(8) 10 N•m (1.0 kgf•m, 7.4 lb •ft)
(3)
T.
R.
E E
24 N•m (2.4 kgf•m, 18 lb •ft)
(2)
T.
R.
E
E
T.
R.
LS
T.
R.
15 N•m (1.5 kgf•m, 11 lb •ft)
T.
R.
4.0 N•m (0.40 kgf•m, 3.0 lb •ft)
T.
R.
T.
R.
LT
LT LT
LT
LS LT
New
LS
LT New
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Order Job/Parts to remove Q’ty Remarks
Engine Refer to “ENGINE REMOVAL” on page 5-11.
Cylinder head cover Refer to “CAMSHAFTS” on page 5-20.
Cylinder head Refer to “CYLINDER HEAD” on page 5-32.
Refer to “GENERATOR AND STARTER
Starter clutch CLUTCH” on page 5-45.
Refer to “ELECTRIC STARTER” on page 5-
Starter motor 51.
Clutch housing Refer to “CLUTCH” on page 5-55.
Oil strainer Refer to “OIL PAN” on page 5-72.
5-74
CRANKCASE
T.
R.
*2nd 17 N•m (1.7 kgf•m, 13 lb •ft)
(6) New 10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
(2)
T.
Final Specified angle 60°
R.
(8) 10 N•m (1.0 kgf•m, 7.4 lb •ft)
(3)
T.
R.
E E
24 N•m (2.4 kgf•m, 18 lb •ft) 5
(2)
T.
R.
E
E
6
8 N•m (0.8 kgf•m, 5.9 lb •ft)
T.
R.
LS
1
T.
R.
8 15 N•m (1.5 kgf•m, 11 lb •ft)
T.
4.0 N•m (0.40 kgf•m, 3.0 lb •ft)
R.
T.
R.
T.
R.
LT
LT LT
LT
7 4
LS LT
New
3 LS
LT New 2
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque.
Order Job/Parts to remove Q’ty Remarks
Oil cooler Refer to “OIL COOLER” on page 6-5.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-96.
1 Oil pressure switch 1
2 Cylinder plug 1
3 Gear position switch 1
4 Balancer shaft access cover 1
5 Main gallery bolt 1
6 Crankcase 1
7 Dowel pin 3
8 Blind plate 1
5-75
CRANKCASE
EAS30389 ECA13900
Recommended lubricant
Engine oil
×8 2. Apply:
×3 ×2 ×2 • Sealant
×6 ×6
(onto the crankcase mating surfaces)
14
5 4 2 1 Yamaha bond No. 1215
3 90890-85505
15 11 (Three bond No.1215®)
12 10 ECA20880
NOTICE
22 26 24
Do not allow any sealant to come into con-
tact with the oil gallery, crankshaft journal
25 27 23
bearings, or balancer shaft journal bearings.
16 20 18 9
21 17 8
19
13
6 7
3. Remove:
• Crankcase
• Dowel pin
5-76
CRANKCASE
TIP
• Tighten the bolts “1”–“16” in the order of the
embossed numbers on the crankcase.
• Lubricate the bolts “1”–“6” threads, mating sur-
faces and washers with engine oil.
• Lubricate the bolts “7”–“12” threads, mating
surfaces and O-rings with engine oil.
• Lubricate the bolts “13”–“27” threads and mat-
ing surfaces with engine oil.
• M9 80 mm bolt (6) (bolts with washers):
“1”–“6” New
• M8 70 mm bolt (6) (bolts with new O-
rings): “7”–“12”
• M8 65 mm bolt (2): “13”, “14”
• M6 65 mm bolt (2): “15”, “16”
• M6 40 mm bolt (8): “17”, “18”, “21”–“24”,
“26”, “27”
• M6 60 mm bolt (3): “19”, “20”, “25”
3. Install:
• Dowel pin ×8
4. Set the shift drum assembly and transmission ×2 ×3
gears in the neutral position. ×2
×6 ×6
5. Install:
• Crankcase “1” 14
(onto the cylinder “2”) 23 24 26 27
ECA13980 25
NOTICE 13 17
Before tightening the crankcase bolts, make 16 18
sure the transmission gears shift correctly
when the shift drum assembly is turned by 6 2 4
hand.
3 1 5
12 8 10 19
1
7 11 20
9
15
22 21
2
7. Tighten:
• Crankcase bolt “1”–“6”
5-77
CRANKCASE
EWA16610
WARNING
If the bolt is tightened more than the speci-
fied angle, do not loosen the bolt and then re- ×8
tighten it. Instead, replace the bolt with a new ×2 ×2 ×3
one and perform the procedure again. ×6 ×6
ECA20890
14
NOTICE 26 27
23 24
Do not use a torque wrench to tighten the 25
bolt to the specified angle. 13 17
16 18
TIP
Tighten the bolts in the tightening sequence cast
on the crankcase.
12 8 10 19
7 11 20
9
15
×6 22 21
EAS31071
2. Apply:
• Sealant
(onto the oil pressure switch threads)
Crankcase bolts “15”–“27” • Apply Three bond No.1215® to the threads “a”
10 N·m (1.0 kgf·m, 7.4 lb·ft) of the oil pressure switch. However, do not ap-
ply Three bond No.1215® to the portion “b” of
TIP the oil pressure switch.
• Tighten the bolts “7”–“16” in the tightening se- • Install the oil pressure switch lead so that it is
quence cast on the crankcase. routed within the range shown in the illustra-
• Tighten the bolts “17”–“27” in any tightening tion.
sequence using a crisscross pattern.
5-78
CRANKCASE
1 1
10˚
b a
45˚
2
2
5-79
CONNECTING RODS AND PISTONS
EAS20132
New
New
3
M M 7
1
E E
2
E
4 New
6
4 New
E
5-80
CONNECTING RODS AND PISTONS
New
New
M M
E E
New
New
10
9
E
8
5-81
CONNECTING RODS AND PISTONS
EAS30745
1 5
3. Remove:
• Top ring
• 2nd ring
• Oil ring
TIP
When removing a piston ring, open the end gap
2. Remove: with your fingers and lift the other side of the ring
• Piston pin clip “1” over the piston crown.
• Piston pin “2”
• Piston “3”
• Connecting rod “4”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• For reference during installation, put identifica-
tion marks on the piston crown.
• Before removing the piston pin, deburr the pis- EAS30747
ton pin clip groove and the piston pin bore ar- CHECKING THE CYLINDER AND PISTON
ea. If both areas are debarred and the piston The following procedure applies to all of the cyl-
pin is still difficult to remove, remove it with the inders and pistons.
piston pin puller set “5”. 1. Check:
• Piston wall
• Cylinder wall
Piston pin puller set Vertical scratches Replace the cylinder,
90890-01304 and replace the piston and piston rings as a
Piston pin puller set.
YU-01304
2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore with the cylinder
bore gauge.
5-82
CONNECTING RODS AND PISTONS
Top ring
Ring side clearance
0.030–0.065 mm (0.0012–0.0026
in)
Side clearance limit
0.115 mm (0.0045 in)
2nd ring
b. If out of specification, replace the cylinder, Ring side clearance
and replace the piston and piston rings as a 0.020–0.055 mm (0.0008–0.0022
set. in)
c. Measure piston skirt diameter “P” with the Side clearance limit
micrometer. 0.115 mm (0.0045 in)
Diameter
77.970–77.985 mm (3.0697–
3.0703 in) (MTN660-AJ)
79.970–79.985 mm (3.1484–
3.1490 in) (MTN690-A, MTN690-
AJ, MTN690-U)
a
2. Install:
• Piston ring
P
(into the cylinder)
TIP
Use the piston crown to level the piston ring near
bottom of cylinder “a”, where cylinder wear is
a. 8.0 mm (0.31 in) from the bottom edge of the lowest.
piston
5-83
CONNECTING RODS AND PISTONS
3. Measure: EAS30749
a. Bottom of cylinder
b. Top of cylinder
3. Measure:
• Piston pin bore inside diameter “b”
Out of specification Replace the piston.
4. Calculate:
• Piston-pin-to-piston-pin-bore clearance
Out of specification Replace the piston pin
and piston as a set.
5-84
CONNECTING RODS AND PISTONS
Piston-pin-to-piston-pin-bore
clearance
0.009–0.025 mm (0.0004–0.0010
in)
EAS30750
5-85
CONNECTING RODS AND PISTONS
TIP
To install the big end bearing, care should be
taken not to install it at an angle and the position
should not be out of alignment.
T.
R.
a. Side machined face
b. Thrusting faces
f. Loosen the connecting rod bolts, remove
the connecting rod and connecting rod cap
and install these parts to the crankshaft with
the big end bearing kept in the current con-
dition.
TIP
• Do not move the connecting rod or crankshaft 180˚
until the clearance measurement has been
EWA16610
completed.
WARNING
• Make sure that the projection “a” on the con-
If the bolt is tightened more than the speci-
necting rod cap faces the same direction as the
fied angle, do not loosen the bolt and then re-
“Y” mark “b” on the connecting rod.
tighten it. Instead, replace the bolt with a new
• Make sure the “Y” marks “b” on the connecting
one and perform the procedure again.
rods face towards the left side of the crank-
shaft. ECA20890
NOTICE
Do not use a torque wrench to tighten the
bolt to the specified angle.
j. After the installation, check that the section
shown “a” is flush with each other by touch-
ing the surface.
h. Put a mark “1” on the corner of the connect- k. Remove the connecting rod and big end
ing rod bolt “2” and the connecting rod cap bearings.
“3”.
5-86
CONNECTING RODS AND PISTONS
EAS30751
5-87
CONNECTING RODS AND PISTONS
TIP
To install the big end bearing, care should be
taken not to install it at an angle and the position
should not be out of alignment.
NOTICE 3. Install:
Tighten the connecting rod bolts using the • Oil ring expander “1”
plastic-region tightening angle method. Al- • Lower oil ring rail “2”
ways install new bolts. • Upper oil ring rail “3”
• 2nd ring “4”
TIP • Top ring “5”
Install by carrying out the following procedures in TIP
order to assemble in the most suitable condition. Be sure to install the piston rings so that the
manufacturer’s marks “a” face up.
a. Replace the connecting rod bolts with new
ones.
b. Clean the connecting rod bolts and lubri-
cate the bolt threads and seats with molyb-
denum disulfide oil.
c. After installing the big end bearing, assem-
ble the connecting rod and connecting rod
cap without installing them onto the crank-
shaft.
d. Tighten the connecting rod bolt while
checking that the sections shown “a” and
“b” are flush with each other by touching the 4. Install:
surface. • Piston “1”
(onto the respective connecting rod “2”)
Connecting rod bolt • Piston pin “3”
30 N·m (3.0 kgf·m, 22 lb·ft) • Piston pin clip “4” New
T.
R.
5-88
CONNECTING RODS AND PISTONS
a Recommended lubricant
b Engine oil
8. Install:
2 • Connecting rod assembly “1”
1 (into the cylinder and onto the crankshaft pin)
3
New 4 • Connecting rod cap
(onto the connecting rod)
TIP
• While compressing the piston ring with piston
ring compressor “2”, install the connecting rod
assembly into the cylinder with the other hand.
• Make sure the “Y” marks “a” on the connecting
rods face towards the left side of the crank-
shaft.
c • Make sure that the projection “b” on the con-
d necting rod cap faces the same direction as the
4 “Y” mark “a” on the connecting rod.
5. Lubricate: • Apply Molybdenum disulfide oil to the threads
• Piston and seats of the connecting rod bolt.
• Piston ring
• Cylinder Piston ring compressor
(with the recommended lubricant) 90890-05158
Piston ring compressor
Recommended lubricant YM-08037
Engine oil
6. Offset:
• Piston ring end gap
A
45˚ 45˚
a,b c
90˚
d,e
5-89
CONNECTING RODS AND PISTONS
180˚
EWA16610
9. Tighten: WARNING
• Connecting rod bolt “1” If the bolt is tightened more than the speci-
1 fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
ECA20890
1
NOTICE
Do not use a torque wrench to tighten the
bolt to the specified angle.
d. After the installation, check that the section
shown “a” is flush with each other by touch-
TIP ing the surface.
Tighten the connecting rod bolts using the fol- EWA17120
5-90
CRANKSHAFT AND BALANCER SHAFT
EAS20178
6 4
E
3
3
E
5 1
E
5 5
E E
2
2
E
2
E
5-91
CRANKSHAFT AND BALANCER SHAFT
EAS31072
3. Check:
REMOVING THE BALANCER SHAFT
• Balancer shaft assembly
JOURNAL BEARINGS
Cracks/damage/wear Replace the balanc-
1. Remove:
er shaft assembly and journal bearings.
• Balancer shaft journal lower bearing
Dirt Clean.
(from the crankcase)
• Bearing
• Balancer shaft journal upper bearing
Damage/wear Replace.
(from the cylinder)
4. Measure:
TIP • Balancer shaft-journal-to-balancer shaft-jour-
Identify the position of each balancer shaft jour- nal-bearing clearance
nal bearing so that it can be reinstalled in its orig- Out of specification Replace the balancer
inal place. shaft journal bearings.
5-92
CRANKSHAFT AND BALANCER SHAFT
TIP
• The numbers “A” stamped into the crankcase
and the numbers “B” stamped into the balancer
shaft web are used to determine the replace-
ment balancer shaft journal bearing sizes.
• J1–J3 refer to the bearings shown in the crank-
case and balancer shaft web illustration.
• If J1–J3 are the same, use the same size for all
2
of the bearings.
d. Install the balancer shaft journal lower bear-
ings “3” into the crankcase and assemble
the crankcase and cylinder.
TIP J1 J2 J3
• Align the projections “c” of the balancer shaft
journal lower bearings with the notches “d” in
the crankcase.
• Do not move the balancer shaft until the clear-
ance measurement has been completed.
c 3
J1 J2 J3
e. Tighten the bolts to specification in the tight-
B
ening sequence cast on the crankcase. J1 J2 J3
Refer to “CRANKCASE” on page 5-74.
f. Remove the crankcase and the balancer
shaft journal lower bearings.
g. Measure the compressed Plastigauge®
width “e” on each balancer shaft journal.
If the balancer shaft-journal-to-balancer
shaft-journal-bearing clearance is out of
specification, select replacement balancer
shaft journal bearings. For example, if the crankcase J1 and balanc-
er shaft web J1 numbers are 6 and 5 respec-
tively, then the bearing size for J1 is:
J1 (crankcase) – J1 (balancer shaft web)
=6–5=
1 (blue)
5. Select:
• Balancer shaft journal bearing (J1–J3)
5-93
CRANKSHAFT AND BALANCER SHAFT
ECA13920
Runout limit
0.030 mm (0.0012 in)
c. Put a piece of Plastigauge® “2” on each
crankshaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
3. Check:
• Crankshaft journal surface
• Crankshaft pin surface
• Bearing surface
Scratches/wear Replace the crankshaft.
4. Measure: d. Install the crankshaft journal lower bearings
• Crankshaft-journal-to-crankshaft-journal- “3” into the crankcase and assemble the
bearing clearance crankcase and cylinder.
Out of specification Replace the crank-
shaft journal bearings.
5-94
CRANKSHAFT AND BALANCER SHAFT
TIP
• Align the projections “d” of the crankshaft jour- J1 J2 J3
nal lower bearings with the notches “e” in the
crankcase.
• Do not move the crankshaft until the clearance
measurement has been completed.
d A
5-95
CRANKSHAFT AND BALANCER SHAFT
EAS31077
A b a
1
b
A. Upper crankcase
B. Lower crankcase
2. Install:
• Balancer shaft “1”
B
1 TIP
Align the punch mark “a” in the balancer drive
a gear with the punch mark “b” in the balancer
driven gear.
b
a
1 b
A. Cylinder
B. Crankcase
EAS31078
5-96
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
E 1
4
7
5
E
9 E
E
8
3 LT
6
2
LT
3
E
10 N•m (1.0 kgf•m, 7.4 lb •ft)
LT
T.
R.
5-97
TRANSMISSION
6
13
7 New
M 8
9 New
10
11 1
2
3
12
M 4
5
M
M
M
5-98
TRANSMISSION
6
5
M
New 4
M
3
2
1 New
New
12
M
11
10
New
LS
M
New
M
M
M M
5-99
TRANSMISSION
M
New 18
M
17
16
15 New
14
22
13 New
M
19 New
LS
M
20 New
21
M 23
M
M M
5-100
TRANSMISSION
EAS30430
1 2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends Replace.
EWA12840
2 WARNING
Do not attempt to straighten a bent shift fork
guide bar.
2. Remove:
• Bearing retainer
• Main axle assembly bearing housing “1”
• Main axle assembly “2”
a. Insert two bolts “3” of the proper size, as
shown in the illustration, into the main axle
assembly bearing housing.
2
1 3. Check:
• Shift fork movement
3 (along the shift fork guide bar)
Rough movement Replace the shift forks
and shift fork guide bar as a set.
The following procedure applies to all of the shift CHECKING THE SHIFT DRUM ASSEMBLY
forks. 1. Check:
1. Check: • Shift drum groove
• Shift fork cam follower “1” Damage/scratches/wear Replace the shift
• Shift fork pawl “2” drum assembly.
Bends/damage/scoring/wear Replace the • Shift drum segment “1”
shift fork. Damage/wear Replace the shift drum as-
sembly.
• Shift drum bearing “2”
Damage/pitting Replace the shift drum as-
sembly.
5-101
TRANSMISSION
EAS30433
2 a
3. Check: 1
• Transmission gear
Blue discoloration/pitting/wear Replace
the defective gear(s).
5-102
TRANSMISSION
EAS30438
A INSTALLING THE TRANSMISSION
b 1. Install:
• Main axle assembly “1”
• Bearing retainer
T.
c
R.
LOCTITE®
TIP
B Use a suitable pin “a” to position the bearing
b housing, and then install the housing until it con-
tacts the cylinder.
c
1
A. Main axle
B. Drive axle
a
2. Install:
• Toothed lock washer retainer “1”
• Toothed lock washer “2” 2. Install:
• Shift fork “C”
TIP
• Shift drum assembly
• With the toothed lock washer retainer in the • Shift fork guide bar
groove “a” in the axle, align the projection “b”
TIP
on the retainer with an axle spline “c”, and then
install the toothed lock washer. • The embossed marks on the shift forks should
• Be sure to align the projection on the toothed face towards the right side of the engine.
lock washer that is between the alignment • Install shift fork “C” into the groove in the 3rd
marks “e” with the alignment mark “d” on the pinion gear on the main axle.
retainer. 3. Install:
• Be sure the toothed lock washer retainer • Shift fork “L” “1”
sharp-edged corner “f” is positioned opposite • Shift fork “R” “2”
side to the toothed lock washer. • Shift fork guide bar
• Shift drum retainer
e d • Drive axle assembly “3”
1 2 e
Shift drum retainer bolt
c b
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
f a 2
1
c
5-103
TRANSMISSION
TIP
• Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.
• Make sure that the projection “a” on the drive
axle assembly is inserted into the slot in the
cylinder.
• Make sure that the drive axle bearing circlip “b”
and flange “c” of the oil seal are inserted into
the grooves in the cylinder.
2
1
a b c
4. Check:
• Transmission
Rough movement Repair.
TIP
Oil each gear, shaft, and bearing thoroughly.
5-104
TRANSMISSION
5-105
COOLING SYSTEM
OIL COOLER...................................................................................................6-5
CHECKING THE OIL COOLER ................................................................6-7
CHECKING THE WATER JACKET JOINT ............................................... 6-7
INSTALLING THE OIL COOLER .............................................................. 6-7
THERMOSTAT ................................................................................................6-8
CHECKING THE THERMOSTAT.............................................................. 6-9
INSTALLING THE THERMOSTAT............................................................ 6-9
WATER PUMP...............................................................................................6-10
DISASSEMBLING THE WATER PUMP.................................................. 6-12
CHECKING THE WATER PUMP ............................................................ 6-12
ASSEMBLING THE WATER PUMP........................................................ 6-12
INSTALLING THE CLUTCH COVER ......................................................6-14
6
COOLING SYSTEM DIAGRAMS
EAS20299
8 2
3
6 5 4
8
5
4
10
3
6
1. Thermostat
2. Oil cooler inlet hose
3. Oil cooler
4. Oil cooler outlet hose
5. Water jacket joint inlet hose
6. Water pump outlet pipe
7. Water pump inlet pipe
8. Radiator outlet hose
9. Water jacket joint
10. Water pump
6-1
RADIATOR
EAS20063
RADIATOR
Removing the radiator
2.0 N•m (0.20 kgf•m, 1.5 lb •ft)
T.
R.
8 N•m (0.8 kgf•m, 5.9 lb •ft)
T.
R.
3
1.0 N•m (0.10 kgf•m, 0.73 lb •ft)
T.
R.
6-2
RADIATOR
T.
R.
12
8 N•m (0.8 kgf•m, 5.9 lb •ft)
T.
R.
10
14
8
9
1.0 N•m (0.10 kgf•m, 0.73 lb •ft)
T.
R.
7
5 N•m (0.5 kgf•m, 3.7 lb •ft)
T.
R.
13
6-3
RADIATOR
EAS30439
6-4
OIL COOLER
EAS20064
OIL COOLER
Removing the oil cooler
2.0 N•m (0.20 kgf•m, 1.5 lb •ft)
T.
R.
LS
3
2 New
LS
New
E
17 N•m (1.7 kgf•m, 13 lb •ft) 40 N•m (4.0 kgf•m, 30 lb •ft)
T.
T.
R.
R.
6-5
OIL COOLER
LS
New
LS
4
New 8
5
6
7
E
E
17 N•m (1.7 kgf•m, 13 lb •ft) 40 N•m (4.0 kgf•m, 30 lb •ft)
T.
T.
R.
R.
6-6
OIL COOLER
EAS30441
• Crankcase
CHECKING THE OIL COOLER
(with the specified amount of the recom-
1. Check:
mended engine oil)
• Oil cooler
Refer to “CHANGING THE ENGINE OIL” on
Cracks/damage Replace.
page 3-23.
2. Check:
4. Check:
• Oil cooler inlet hose
• Cooling system
• Oil cooler outlet hose
Leaks Repair or replace any faulty part.
• Water pump outlet hose
Refer to “INSTALLING THE RADIATOR” on
Cracks/damage Replace.
page 6-4.
EAS31123 5. Measure:
CHECKING THE WATER JACKET JOINT • Radiator cap opening pressure
1. Check: Below the specified pressure Replace the
• Water jacket joint radiator cap.
Mineral deposits/rust Eliminate. Refer to “CHECKING THE RADIATOR” on
EAS30442
page 6-4.
INSTALLING THE OIL COOLER
1. Clean:
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• Gasket New
• Oil cooler “1”
• Oil filter cartridge union bolt
TIP
• Before installing the oil cooler, apply engine oil
lightly to the oil filter cartridge union bolt.
• Align the projection “a” on the oil cooler with the
slot “b” in the crankcase.
a
3. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-26.
6-7
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat
4
2
5 1
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
New
6-8
THERMOSTAT
EAS30443 EAS30939
82 95
179.6 203
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
2. Check:
• Thermostat cover
Cracks/damage Replace.
6-9
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
7 N•m (0.7 kgf•m, 5.2 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
.
.
1
4 LS
3
2 5
LS
LT
New
New
New
LS
(10)
New 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
E
New LT
LS
LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
6-10
WATER PUMP
T.R
7 N•m (0.7 kgf•m, 5.2 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
.
.
LS
LS
LT
New
New
New 8
10 LS
E
New LT
LS
7 LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
6-11
WATER PUMP
EAS30446 EAS30447
2
3
1 New
3. Remove:
• Bearing “1” a
• Oil seal “2”
TIP
2. Install:
Remove the bearing and oil seal from the out-
• Water pump seal (housing side) “1” New
side of the clutch cover “3”.
(into the clutch cover “2”)
ECA14080
NOTICE
1 Never lubricate the water pump seal surface
2 with oil or grease.
TIP
3
Use the special tools and a press to press the
water pump seal (housing side) straight in until it
touches the clutch cover.
6-12
WATER PUMP
TIP
Mechanical seal installer (ø33) If the surface “a” of the water pump seal (impel-
90890-04132 ler side) that contacts the water pump seal
Water pump seal installer (ø33) (housing side) is dirty, clean it.
YM-33221-A
Middle driven shaft bearing driv-
er Mechanical seal (impeller side)
90890-04058 0.15 mm (0.006 in)
Middle drive bearing installer 40
& 50 mm
YM-04058
1
4 A
2
3
New 1 a
2 1. Straightedge
2. Impeller
1 New
4. Measure:
• Water pump seal (impeller side)
Out of specification Repeat steps (3) and
(4).
ECA14090
NOTICE
Make sure the rubber damper and rubber
damper holder are flush with the impeller.
6-13
WATER PUMP
EAS31117
3. Check:
INSTALLING THE CLUTCH COVER
• Cooling system
1. Install:
Leaks Repair or replace the faulty part.
• Dowel pin “1”
4. Measure:
• Clutch cover gasket “2” New • Radiator cap opening pressure
• Clutch cover “3” Below the specified pressure Replace the
radiator cap.
Clutch cover bolt Refer to “CHECKING THE RADIATOR” on
12 N·m (1.2 kgf·m, 8.9 lb·ft) page 6-4.
T.
R.
1 2
3
4
LS
a
b
c
1
6 e
d
2. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-26.
6-14
WATER PUMP
6-15
FUEL SYSTEM
7
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank and fuel pump
30 N•m (3.0 kgf•m, 22 lb •ft)
T.
R.
T.
R.
6
New
1
5
3
2
(4)
4
7-1
FUEL TANK
T.
R.
9
New
8 10
(4)
7-2
FUEL TANK
2
1
4 3
5
7 N•m (0.7 kgf•m, 5.2 lb •ft)
T.
R.
9
7
8
7-3
FUEL TANK
EAS30450 EAS30451
ECA20020
CHECKING THE FUEL PUMP BODY
NOTICE
1. Check:
• Fuel pump body
Although the fuel has been removed from
Obstruction Clean.
the fuel tank, be careful when removing the
Cracks/damage Replace fuel pump as-
fuel hose, since there may be fuel remaining
sembly.
in it.
EAS31330
1 2
3. Remove:
• Fuel tank
TIP
Do not set the fuel tank down on the installation
surface of the fuel pump. Be sure to lean the fuel
tank against a wall or the like.
7-4
FUEL TANK
EAS30456 EAS31081
T.
T.
R.
R.
TIP TIP
• Do not damage the installation surfaces of the Make sure that the arrow mark “a” on the front
fuel tank when installing the fuel pump. fuel tank bracket points toward the hole “b” in the
• Always use a new fuel pump gasket. fuel tank.
• The gasket lip “a” shall face toward the fuel
tank.
• Align the projection “b” on the fuel pump with
the punch mark “c” on the fuel tank. 1
• Align the slot in the fuel pump bracket with the
projection “b” on the fuel pump. a
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
b
a 2. Install:
• Grommet
• Collar
• Rear fuel tank bracket “1”
TIP
3 Make sure that the arrow mark “a” on the rear
1 fuel tank bracket points toward the punch mark
“b” on the fuel tank.
FWD
2
a
b 4
c
b
7-5
FUEL TANK
EAS30457
NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position; otherwise, the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel rail
and fuel pump until a distinct “click” is heard.
• To install the fuel hose, slide the fuel hose con-
nector cover “1” on each end of the hose in the
direction of the arrow shown.
1
3. Connect:
• Fuel pump coupler
• Fuel tank breather hose
• Fuel tank overflow hose
• Intake air temperature sensor
4. Tighten:
• Rear fuel tank bracket bolt
5. Tighten:
• Rear fuel tank bracket bolt
7-6
AIR FILTER
EAS20198
AIR FILTER
Removing the air filter element
T.
R.
2
(4)
1
T.
R.
3
New
7-7
THROTTLE BODIES
EAS20070
THROTTLE BODIES
Removing the air filter case and throttle bodies
7 N•m (0.7 kgf•m, 5.2 lb •ft)
T.
R.
2 1
T.
R.
10 N•m (1.0 kgf•m, 7.4 lb •ft)
4.5 N•m (0.45 kgf•m, 3.3 lb •ft) 10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
T.
R.
R.
7-8
THROTTLE BODIES
T.
R.
3
3
3 5
5
14 12
10 12
10 13 6
14
3.0 N•m (0.30 kgf•m, 2.2 lb •ft)
15
T.
R.
10
11
7
16
T.
R.
9
11
8
4.5 N•m (0.45 kgf•m, 3.3 lb •ft) 10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
T.
R.
R.
7-9
THROTTLE BODIES
T.
R.
2
1
5
New
New New
3
New
7-10
THROTTLE BODIES
EAS30475 EAS30479
NOTICE
• Observe the following precautions; other-
2
wise, the throttle bodies may not operate
properly.
• Do not open the throttle valves quickly.
EAS30477 • Do not subject the throttle bodies to exces-
CHECKING THE INJECTORS sive force.
1. Check: • Wash the throttle bodies in a petroleum-
• Injector based solvent.
Obstruction Replace and check the fuel • Do not use any caustic carburetor cleaning
pump/fuel supply system. solution.
Deposit Replace. • Do not apply cleaning solvent directly to
Damage Replace. any plastic parts, sensors, or seals.
2. Check: • Do not directly push the throttle valves to
• Injector resistance open them.
Refer to “CHECKING THE FUEL INJEC- • Do not turn the bypass air screws “a”; oth-
TORS” on page 8-157. erwise, the throttle body synchronization
will be affected.
7-11
THROTTLE BODIES
TIP
• Do not allow any petroleum-based solvent to
a
enter the opening for the injectors.
• Do not apply any petroleum-based solvent to
the portions of the throttle valve shafts be-
a tween the throttle bodies.
e. Remove the carbon deposits from the in-
side of each throttle body in a downward di-
rection, from the air filter case side of the
a. Place the throttle bodies on a flat surface throttle body to the engine side.
ECA18470
with the air filter case side facing up.
NOTICE
b. Install the caps (895-14169-00) onto the
hose fittings “a”. • Do not use a tool, such as a wire brush, to
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
aged.
a • Do not allow carbon deposits or other for-
eign materials to enter any of the passages
in each throttle body or in the space be-
a tween the throttle valve shaft and the throt-
tle body.
f. After removing the carbon deposits, clean
the inside of the throttle bodies with a petro-
c. Push the lever in the direction shown in the
leum-based solvent, and then dry the throt-
illustration to hold the throttle valves in the
tle bodies using compressed air.
open position.
EWA16680
g. Make sure that there are no carbon depos-
WARNING its or other foreign materials in any of the
When cleaning the throttle bodies, be careful passages “a” in each throttle body or in the
not to injure yourself on the throttle valves or space “b” between the throttle valve shaft
other components of the throttle bodies. and the throttle body.
ECA21190
b
NOTICE
• Do not use tools to open the throttle valves
or to keep them in the open position.
• Do not open the throttle valves quickly.
a
b
7-12
THROTTLE BODIES
ECA21230
T.
R.
agent. 5 N·m (0.5 kgf·m, 3.7 lb·ft)
• Do not spray the cleaning agent directly
onto the ISC valve or throttle bodies and do TIP
not immerse them in the cleaning agent. Align the slot “a” in the ISC valve plate with the
• To prevent scratching the components, do projection “b” on the ISC valve.
not use a brush, metal file, or other abra-
sive tool. a
• Do not clean with compressed air.
• Do not allow the removed deposits or for-
eign materials to adhere to the sealing sur-
b
faces of the O-ring.
• Do not scratch or deform the ISC valve or
air passage; otherwise, poor starting per-
formance, an unstable engine idling speed,
or uncontrollable engine speed could re-
sult.
• Do not clean any areas other than those in- Resetting the ISC (idle speed control) learn-
dicated in the illustrations. If the cleaning ing values
agent attaches to the ISC valve or enters 1. Install:
the throttle bodies, thoroughly wipe it off. • Throttle bodies
2. Reset:
TIP
• ISC (idle speed control) learning values
Clean the area “a” of the ISC valve and the ISC Use the diagnostic code number “67”.
valve installation hole “b” in the throttle bodies. Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on
page 9-1.
1
Yamaha diagnostic tool USB
90890-03256
a Yamaha diagnostic tool (A/I)
90890-03262
3. Reset:
• O2 feedback learning value
Use the diagnostic code number “87”.
Refer to “SELF-DIAGNOSTIC FUNCTION
b AND DIAGNOSTIC CODE TABLE” on
page 9-1.
4. Adjust:
3. Install:
• Throttle bodies synchronizing
• O-ring New Out of specification Replace the throttle
• ISC (Idle Speed Control) valve bodies.
• ISC (Idle Speed Control) valve plate Refer to “SYNCHRONIZING THE THROT-
TLE BODIES” on page 3-9.
7-13
THROTTLE BODIES
EAS31160
1. Check:
REPLACING THE THROTTLE BODIES
• Throttle position sensor
1. Remove the throttle bodies from the vehicle.
2. Adjust:
2. Install a new throttle bodies to the vehicle.
• Throttle position sensor angle
3. Reset:
• ISC learning values a. Temporary tighten the throttle position sen-
Use the diagnostic code number “67”. sor bolts.
Refer to “SELF-DIAGNOSTIC FUNCTION b. Check that the throttle valves are fully
AND DIAGNOSTIC CODE TABLE” on closed.
page 9-1. c. Connect the throttle position sensor to the
wire harness.
Yamaha diagnostic tool USB d. Remove the protective cap “1”, and then
90890-03256 connect the Yamaha diagnostic tool to cou-
Yamaha diagnostic tool (A/I) pler “2”.
90890-03262 TIP
For information about using the Yamaha diag-
4. Reset: nostic tool, refer to the operation manual that is
• O2 feedback learning value included with the tool.
Use the diagnostic code number “87”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on
page 9-1.
EAS30792
EAS30485
WARNING
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
7-14
THROTTLE BODIES
EAS31124
INSTALLING THE FUEL INJECTORS a. Connect the fuel injector pressure adapter
ECA20000 “1” to the fuel rail “2”, and then connect an
NOTICE air compressor “3” to the adapter.
• Always use new O-rings. b. Connect the pressure gauge “4” to the fuel
• When checking the injectors, do not allow injector pressure adapter “1”.
any foreign material to enter or adhere to
the injectors, fuel rail, or O-rings. Pressure gauge
• Be careful not to twist or pinch the O-rings 90890-03153
when installing the injectors. Pressure gauge
• If an injector is subject to strong shocks or YU-03153
excessive force, replace it. Fuel injector pressure adapter
• If installing the original fuel rail and screws, 90890-03210
remove the white paint marks using a Fuel injector pressure adapter
cleaning solvent. Otherwise, paint chips on YU-03210
the screw seats could prevent the screws
from being tightened to the specified
torque.
1. Install new seals onto the end of each injec-
tor.
2. Install the fuel injectors “1” to the fuel rail “2”.
ECA18440
3. Install the fuel injector assemblies to the
NOTICE
throttle bodies.
4. Check the injector pressure after the fuel in- Never exceed the specified air pressure or
jectors are installed to the throttle bodies. damage could occur.
Refer to “CHECKING THE INJECTOR f. Close the valve on the fuel injector pressure
PRESSURE” on page 7-15. adapter.
EAS30481
g. Check that the specified air pressure is held
CHECKING THE INJECTOR PRESSURE for about one minute.
TIP Pressure drops Check the pressure
• After installing the fuel injectors, perform the gauge and adapter.
following steps to check the injector pressure. Check the seals and O-rings, and then rein-
• Do not allow any foreign materials to enter the stall.
fuel lines. Replace the fuel injectors.
1. Check:
• Injector pressure
7-15
THROTTLE BODIES
EAS30482
c. Connect the pressure gauge “3” and adapt-
CHECKING THE FUEL PRESSURE
er “4” to the fuel hose “2”.
1. Remove:
• Passenger seat
Pressure gauge
• Rider seat 90890-03153
Refer to “GENERAL CHASSIS (1)” on Pressure gauge
page 4-1. YU-03153
• Air scoop (left) Fuel pressure adapter
• Air scoop (right) 90890-03176
• Fuel tank center cover (fuel tank side covers) Fuel pressure adapter
• Refer to “GENERAL CHASSIS (4)” on YM-03176
page 4-9.
2. Check:
• Fuel pressure
a. Remove the rear fuel tank bracket bolts “1”
and holdup the fuel tank. 4
ECA20070
NOTICE 3
When lifting up the fuel tank, be careful not 2
to pull the fuel tank overflow hose and fuel
tank breather hose.
d. Start the engine.
e. Measure the fuel pressure.
7-16
THROTTLE BODIES
EAS30937
TIP
Be sure to install the throttle body joints “1” as
shown in the illustration.
1
a b
A B
45˚
70˚
a. #1 cylinder
b. #2 cylinder
A. Left
B. Right
EAS31092
TIP
• Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.
• Face the screw head “c” of the air filter case
joint clamp outward.
a a
b c c b
7-17
ELECTRICAL SYSTEM
CHARGING SYSTEM....................................................................................8-13
CIRCUIT DIAGRAM ................................................................................ 8-13
TROUBLESHOOTING ............................................................................8-15
R/W
B
L/W L/WL/WL/W R/W R/W R/W R/W R/W R/W R/W 25 25 O R/B
G/W B/L W P Y/W W/R W/R Y/W P W B/L G/W L/R L/R L/R L/R L/R Y Y Y Y B/L B/L B/L
O Gy Sb G/B R/L R/L R/B R/B R/L R/L G/B Sb Gy O (B)
B
16 B/L 32
Br/L
Gy
B/G 27
B
Gy B
22 R/W L/W R/B W/L R/L
L/W L/Y R/W L/G B/R Sb B/Y Sb/W Gy
Gy B/L
Sb B/R L /G
25 B/R B/R
26 B B L/G B
L Gy
Br/L (B)
B/R B/R B/R (B)
L/G B B
L
L
Br/L B/L
36
R/W R/W
Br/L R/W R/W
7
B Dg W/L R/W
Y Ch Br/W L/R R/B
R/W R/B
63 (B)
8-1
Sb
B
G G G
Sb L Y/G B/L 40 L
Y/G Y/G B
62 B/L
Sb B/W
P
W
Gy
O
W/R
Y/W
O Y/W W Sb Sb P Gy W/R
Gy W/R P
W O Y/W
(B) (B)
B/G
B
B/G
B/G
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B B/G B/W
1. Main switch
7. Ignition fuse
10. Backup 2 fuse
15. Battery
16. Engine ground
18. Main fuse
22. Relay unit
25. Joint coupler
26. Sidestand switch
27. Crankshaft position sensor
30. Ignition coil #1
31. Ignition coil #2
32. Spark plug
36. ECU (Engine Control Unit)
40. Lean angle sensor
62. Gear position switch
63. Handlebar switch (right)
66. Start/engine stop switch
A. Wire harness
C. Sub-wire harness (gear position switch,
coolant temperature sensor, fuel injector)
8-2
IGNITION SYSTEM
EAS30491
9 5
8
6
11 10
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Start/engine stop switch
6. Ignition coil
7. Spark plug
8. ECU (Engine Control Unit)
9. Relay unit (diode)
10. Sidestand switch
11. Gear position switch
8-3
IGNITION SYSTEM
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger seat
2. Rider seat
3. Rider seat bracket 1
4. Rider seat bracket 2
5. Air scoop (left)
6. Air scoop (right)
7. Fuel tank center cover (fuel tank side covers)
8. Fuel tank
9. Drive sprocket cover
10.Headlight assembly
OK
OK
OK
NG
OK
OK
8-4
IGNITION SYSTEM
OK
OK
OK
OK
OK
OK
OK
8-5
IGNITION SYSTEM
8-6
EAS30493
EAS20073
R/W
B
(B)
18 R/B
R/W R R
1 R/W R R/W R/B
15 L/W R/W
Br/L Br/L
ON
OFF (B) 19
P
B
B
16
Br/L
B/G
B R/B
B L/ W L/W
25 25 B/R B/R
B/Y
B/Y
26 B B L/G B B/Y
B/Y B/R
Br/L (B)
B/Y B/Y B/Y B/R B/R B/R (B)
L/G B B
Br/L
36
ELECTRIC STARTING SYSTEM
R/W R/W
Br/L R/W R/W
7
B Dg W/L R/W
Y Ch Br/W L/R R/B
R/W R/B W/L
63 (B)
8-7
Sb
B
B
Sb B
62
Sb B/W
P
W
B/R Y G/L Br/W Dg Gy
B/R B/Y Ch L/R G B/Y P O
68 W/R
B/Y B/R L/B Br Y/W
Dg Br/W L/B Y B/Y
B/W B/R G Br Ch
69 O Y/W W Sb Sb P Gy W/R
Gy W/R P
B/R W O Y/W
B/Y (B) (B)
(B) B/W
B/G
B B
B/G
B/G B/G B/W
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B
B
1. Main switch
7. Ignition fuse
10. Backup 2 fuse
15. Battery
16. Engine ground
18. Main fuse
19. Starter relay
20. Starter motor
22. Relay unit
23. Starting circuit cut-off relay
25. Joint coupler
26. Sidestand switch
36. ECU (Engine Control Unit)
62. Gear position switch
63. Handlebar switch (right)
66. Start/engine stop switch
68. Handlebar switch (left)
69. Clutch switch
A. Wire harness
C. Sub-wire harness (gear position switch,
coolant temperature sensor, fuel injector)
8-8
ELECTRIC STARTING SYSTEM
EAS30494
12
11
4
6 6
10
6
6
7 a
6
8 9 10
b
8-9
ELECTRIC STARTING SYSTEM
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger seat
2. Rider seat
3. Rider seat bracket 1
4. Air scoop (left)
5. Air scoop (right)
6. Fuel tank center cover (fuel tank side covers)
7. Fuel tank
8. Throttle body
9. Air filter case
10.Canister
11.Starter motor
12.Drive sprocket cover
13.Headlight assembly
OK
OK
NG
OK
OK
8-10
ELECTRIC STARTING SYSTEM
OK
OK
OK
OK
OK
OK
OK
OK
8-11
ELECTRIC STARTING SYSTEM
8-12
CHARGING SYSTEM
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
R R
18
R
L/W R/W
R R
(B)
16
15
R
B
R
W W W
W W W
14
13
B
R
(B)
B
R
R
R
8-13
CHARGING SYSTEM
13. AC magneto
14. Rectifier/regulator
15. Battery
16. Engine ground
18. Main fuse
8-14
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger seat
2. Rider seat
3. Rider seat bracket 1
4. Air scoop (left)
OK
OK
OK
OK
OK
8-15
CHARGING SYSTEM
8-16
EAS30498
EAS20075
L /R
R/W L/R
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
R W/G Br/L Y/G Br/W L/W G/B B/Y R/B
R
R R P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
R R
R R
CIRCUIT DIAGRAM
(B)
18
R/W R R
1 R/W R R/W R/B
15 L/W R/W
Br/L Br/L
ON
OFF (B)
P
B
16
LIGHTING SYSTEM
Br/L
B/G
Br/L
Br/L
36
R/W
Br/L R/W R/W R/W
7 L/R 48
L/R L/R
8 R/Y L/R
R/Y
9
R R/B 51
10 51
8-17
Y/B
B
R/W
B/W
B/W
Y 57
Y Y
L/R
82 L/R 78 L/R L/R G Y
L 81 L 79 L L
L L L 80 B/W
B B B
83
L/R B L/R L/R B B B G
B B Y B G/R G/W L/R L/B Sb/W Y Dg Ch G/R
B
(B) Gy O W/R Y/W P W R/W R/G G/B B/W
(Gy)
B B/G
(Gy)
L Y B
B/G
B B/G
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B B/GB/WB/W
B
B
Y L/R B/W B B B B 25 B/G B B B/W B/W B/G
B/G
B/W B B B/W B/W B/W
(Y)
B/W
LIGHTING SYSTEM
LIGHTING SYSTEM
1. Main switch
7. Ignition fuse
8. Signaling system fuse
9. Headlight fuse
10. Backup 2 fuse
15. Battery
16. Engine ground
18. Main fuse
25. Joint coupler
36. ECU (Engine Control Unit)
48. Meter assembly
51. Meter light
57. High beam indicator light
68. Handlebar switch (left)
70. Dimmer switch
71. Pass switch
78. Headlight assembly
79. Auxiliary light
80. Headlight
81. License plate light
82. Tail/brake light assembly
83. Tail/brake light
86. Headlight relay
8-18
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light or meter
light.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger seat
2. Rider seat
3. Rider seat bracket 1
4. Air scoop (left)
5. Air scoop (right)
6. Fuel tank center cover (fuel tank side covers)
7. Fuel tank
8. Headlight assembly
OK
OK
OK
OK
OK
OK
8-19
LIGHTING SYSTEM
OK
OK
8-20
EAS30500
EAS20076
R/W
B
(B)
18 Br Y L/R Y
R/W R R
1 R/W R (B) (B) R/W
21 R/B
15 L/W R/W
Br/L Br/L Y Br Y L/R
ON
OFF (B)
P
Br/R Br/R B
16
B
Br/L Br/R B/G
B/G
SIGNALING SYSTEM
B Sb/W
Sb
Br/R L/R
4
Br/W
Br/L 5
Br/L Br/L
Br/L B/L
36
R/W
Br/L R/W R/W R/W
7 L/R 48
L/R L/R L/R
L/R B Dg W/L R/W
8 Y Ch Br/W L/R R/B
G/W B/L
63 L/R Y 50 38 (B)
(B)
Sb/W B/L B B/L B/L G/W G/W B G/W G/W
B/L B/L L/W
65 R/W L/W Dg B
R R/B L/B
R/B B/L Br/W Ch B/L
(B) L/R
10 64
R/G
8-21
11 Sb
Br/W B
Ch Br/W Dg 52
L/R Sb B
62 R/W
R/G
67 Br/W Sb B/W
L/R Br/W Br/W Br/W P W W B W W
L/R
W P P B P P
B/R Y G/L Br/W Dg Gy Y/W Y/W B Y/W Y/W L/B
Ch L/R G B/Y P B W/Y
68 Br/W L/R O W/R W/R W/R W/R 53
W/R O O B O O
B/Y B/R L/B Br Y/W Gy Gy B Gy Gy
Dg Br/W L/B Y B/Y G/W
B/W B/R G Br Ch G/R
73 O Y/W W Sb Sb P Gy W/R
Gy W/R P 54
72 W O Y/W G/R L/R
Y
43
82 77 Ch 76 Ch 75 Dg Dg 74 58
Ch B
L
Ch Ch Dg Dg 59 R/L B G/W B
B B B B Dg B/W
(B) B/G
(Gy) (Gy) (B) (B) B B Gy
W W 42 W Gy
B
83 B B B B
Ch Ch Dg Dg
B W
B B B B
G/R G/W L/R L/B Sb/W Y Dg Ch G/R
(Gy) (Gy) B (B) (B) Gy O W/R Y/W P W R/W R/G G/B B/W
B B/G
(Gy)
L Y B
B/G
B B/G
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B B/GB/WB/W R/W W R B W G G/R W/Y B
B B
B
B R/L Y G G Br/W L/R L/B B/L B/G
Y L/R B/W B B B 25 B/G B B B/W B/W B/G
B/G
B/W B B B/W B/W B/W
(Y) (B)
B/W
SIGNALING SYSTEM
SIGNALING SYSTEM
1. Main switch
4. Parking lighting fuse
5. ABS control unit fuse
7. Ignition fuse
8. Signaling system fuse
10. Backup 2 fuse
11. Backup 1 fuse
15. Battery
16. Engine ground
18. Main fuse
21. Rear brake light switch
22. Relay unit
25. Joint coupler
36. ECU (Engine Control Unit)
38. Coolant temperature sensor
42. Rear wheel sensor
43. ABS ECU (electronic control unit)
45. Fuel sender
47. Oil pressure switch
48. Meter assembly
50. Neutral indicator light
52. Tachometer
53. Multi-function meter
54. Oil pressure warning light
56. Coolant temperature warning light
58. Turn signal indicator light (left)
59. Turn signal indicator light (right)
61. Horn
62. Gear position switch
63. Handlebar switch (right)
64. Front brake light switch
65. Hazard switch
67. Turn signal/hazard relay
68. Handlebar switch (left)
72. Turn signal switch
73. Horn switch
74. Rear turn signal light (right)
75. Front turn signal light (right)
76. Rear turn signal light (left)
77. Front turn signal light (left)
82. Tail/brake light assembly
83. Tail/brake light
A. Wire harness
C. Sub-wire harness (gear position switch,
coolant temperature sensor, fuel injector)
8-22
SIGNALING SYSTEM
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• The fuel meter fails to come on.
• The speedometer fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger seat
2. Rider seat
3. Rider seat bracket 1
4. Air scoop (left)
5. Air scoop (right)
6. Fuel tank center cover (fuel tank side covers)
7. Fuel tank
8. Drive sprocket cover
9. Headlight assembly
OK
OK
OK
OK
8-23
SIGNALING SYSTEM
OK
OK
OK
OK
OK
The turn signal light, turn signal indicator light or both fail to blink.
OK
OK
8-24
SIGNALING SYSTEM
OK
OK
OK
OK
OK
OK
8-25
SIGNALING SYSTEM
The oil pressure warning light fails to come on when the main switch is set to “ON”.
OK
OK
The oil pressure warning light remains on after the engine is started.
OK
OK
The fuel meter, fuel level warning light, or both fail to come on.
OK
OK
8-26
SIGNALING SYSTEM
OK
OK
OK
OK
8-27
SIGNALING SYSTEM
8-28
EAS30502
EAS20077
R/W
B
(B) (B)
B/L B/L B/L B/L B/L B/L
R/W
A C B/L B/L B/L B/L
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
(Y)
R W/G Br/L Y/G Br/W L/W G/B B/Y R/B
R
R R P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
R R
R R
CIRCUIT DIAGRAM
(B)
18
R/W R R
1 R/W R R/W R/B
15 L/W R/W
Br/L Br/L
ON
OFF (B)
P
B
COOLING SYSTEM
16
Br/L
B/G
Br/L
Br/L B/L
36
R/W
Br/L R/W R/W
R/W
7
G/W B/L
38 (B)
B/L B B/L B/L G/W G/W B G/W G/W
R R/B
10
8-29
R
12 B
B/W
R R/W
85
L R
L
R/W G/Y
84
L B
(B)
B
B L
B/G
(B) B
B/G
B/G
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B B/G B/W
B
1. Main switch
7. Ignition fuse
10. Backup 2 fuse
12. Radiator fan motor fuse
15. Battery
16. Engine ground
18. Main fuse
25. Joint coupler
36. ECU (Engine Control Unit)
38. Coolant temperature sensor
84. Radiator fan motor
85. Radiator fan motor relay
A. Wire harness
C. Sub-wire harness (gear position switch,
coolant temperature sensor, fuel injector)
8-30
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger seat
2. Rider seat
3. Rider seat bracket 1
4. Air scoop (left)
5. Air scoop (right)
6. Fuel tank center cover (fuel tank side covers)
7. Fuel tank
OK
OK
OK
OK
OK
OK
8-31
COOLING SYSTEM
OK
8-32
EAS30504
EAS20078
C
(B) (B)
25 25 B/R B/R
B/Y R/L G/B
B/Y
B B L/G B B/Y (Gy) Br/L P/L W/G R/G
Br/W B/R 26
B/Y (B)
Br/L (B) Gy
5 B/Y B/Y B/Y B/R B/R B/R (B) L
L/G B B
Br/L Br/L L L
36 R/G R/G C R/G R/G 35
Br/L B/L
W/G W/G C W/G W/G
Br/L Br/L C Br/L Br/L
R/W R/W Br/W B/L
Br/L R/W R/W R/W 37 P/L P/L C P/L P/L
R/W (B)
7 B/L Br/W Br/W
48
B Dg W/L R/W
G/W B/L
R/Y Y Ch Br/W L/R R/B
R/W R/B B/L P/W L
63 (B)
38 (B)
9 (L) B/L B B/L B/L G/W G/W B G/W G/W
B/L B/L L/W
66 R/W L/W Dg B
R R/B 39 L/B
R/W R/B B/L Br/W Ch B/L
(B) L L/R
10 B/L
R/G P/W P/W
8-33
11 Sb
Y/B
B
G G G G/Y
Sb L Y/G B/L 40 L
Y/G Y/G B
62 R/W B/L
R/G R/L
Sb B/W
P
L/R
W
B/R Y G/L Br/W Dg Gy L/B
Ch L/R G B/Y P W/Y
68 B/R B/Y O 53
W/R
R/L
R/W B/Y B/R L/B Br Y/W
R/Y Dg Br/W L/B Y B/Y R/L
B/W B/R G Br Ch R/L R/L R/L B R/L
R/L
86 85 69 O Y/W W Sb Sb P Gy W/R R/L B R/L
Gy W/R P
B/R W O Y/W L/R
B/Y (B) (B) L/R L/R L/R L/R
(B) B/W
25
Y /B G/Y 55 L/R L/R Br/W
R/Y R L/B L/B L/B L/B
G/L L L/B
(B)
R/Y Y/B R/W G/Y L/R
R/L
25 W/Y
L/B L/B L/B
46 L/R
L/B
43
B B
R/L B G/W B
B/W
(B) B/G B B Gy
W W 42 W Gy
B
B W
G/R G/W L/R L/B Sb/W Y Dg Ch G/R
Gy O W/R Y/W P W R/W R/G G/B B/W
B/G
B (Gy)
B/G
B/G L/R L/B R/W
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B B B B/GB/WB/W R/W W R B W G G/R W/Y B
R/W B B
44 L/B R/L Y G G Br/W L/R L/B B/L B/G
25 B/G B B B/W B/W B/G L/R
B/G
B B B/W B/W B/W
B (Y) (B)
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
1. Main switch
5. ABS control unit fuse
7. Ignition fuse
9. Headlight fuse
10. Backup 2 fuse
11. Backup 1 fuse
15. Battery
16. Engine ground
18. Main fuse
22. Relay unit
23. Starting circuit cut-off relay
24. Fuel pump relay
25. Joint coupler
26. Sidestand switch
27. Crankshaft position sensor
28. O2 sensor
29. Throttle position sensor
30. Ignition coil #1
31. Ignition coil #2
32. Spark plug
33. Fuel injector #1
34. Fuel injector #2
35. ISC (Idle Speed Control) unit
36. ECU (Engine Control Unit)
37. Intake air temperature sensor
38. Coolant temperature sensor
39. Intake air pressure sensor
40. Lean angle sensor
42. Rear wheel sensor
43. ABS ECU (electronic control unit)
44. Yamaha diagnostic tool coupler
46. Fuel pump
48. Meter assembly
53. Multi-function meter
55. Engine trouble warning light
62. Gear position switch
63. Handlebar switch (right)
66. Start/engine stop switch
68. Handlebar switch (left)
69. Clutch switch
85. Radiator fan motor relay
86. Headlight relay
A. Wire harness
C. Sub-wire harness (gear position switch,
coolant temperature sensor, fuel injector)
D. Sub-wire harness (throttle position sensor,
ISC)
8-34
FUEL INJECTION SYSTEM
EAS30505
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
a. Check the fault code numbers that have a condition of “Malfunction” using the Yamaha diagnostic
tool.
b. Identify the faulty system with the fault code number.
c. Identify the probable cause of the malfunction.
2. Check and repair the probable cause of the malfunction.
Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOT- Check and repair.
ING DETAILS (FAULT CODE)” on page 8-37.
Monitor the operation of the sensors and actua-
tors in the diagnostic mode. Refer to “TROU-
BLESHOOTING DETAILS (FAULT CODE)” on
page 8-37 and “SELF-DIAGNOSTIC FUNC-
TION AND DIAGNOSTIC CODE TABLE” on
page 9-1.
8-35
FUEL INJECTION SYSTEM
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “DIAG-
NOSTIC CODE: SENSOR OPERATION TABLE” on page 9-9 and “DIAGNOSTIC CODE: ACTUA-
TOR OPERATION TABLE” on page 9-12.
01: Throttle position sensor signal (throttle angle)
30: Cylinder-#1 ignition coil
31: Cylinder-#2 ignition coil
36: Fuel injector #1
37: Fuel injector #2
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the en-
gine.
EAS30951
TIP
A generic scan tool can also be used to identify malfunctions.
8-36
FUEL INJECTION SYSTEM
EAS31791
8-37
FUEL INJECTION SYSTEM
8-38
FUEL INJECTION SYSTEM
2 Connection of wire harness Improperly connected Turn the main switch to “ON”,
ECU coupler. Connect the coupler securely and then check the condition
Check the locking condition or replace the wire harness. of the fault code using the
of the coupler. malfunction mode of the
Disconnect the coupler and Yamaha diagnostic tool.
check the pins (bent or bro- Condition is “Recover” Go
ken terminals and locking to item 6 and finish the ser-
condition of the pins). vice.
Condition is “Malfunction”
Start the engine, and then
check the condition of the
fault code.
Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 3.
TIP
For this check, also set the en-
gine stop switch to “ON”.
3 Wire harness continuity. Open or short circuit Prop- Turn the main switch to “ON”,
erly connect or replace the and then check the condition
wire harness. of the fault code using the
Between O2 sensor coupler malfunction mode of the
and ECU coupler. Yamaha diagnostic tool.
pink/black–pink/black Condition is “Recover” Go
Between O2 sensor coupler to item 6 and finish the ser-
and joint coupler. vice.
red/white–red/white Condition is “Malfunction”
Between main switch and ig- Start the engine, and then
nition fuse. check the condition of the
brown/blue–brown/blue fault code.
Between ignition fuse and Condition is “Recover” Go
joint coupler. to item 6 and finish the ser-
red/white–red/white vice.
Condition is “Malfunction”
Go to item 4.
TIP
For this check, also set the en-
gine stop switch to “ON”.
8-39
FUEL INJECTION SYSTEM
4 Defective O2 sensor heater. Replace the O2 sensor. Turn the main switch to “ON”,
and then check the condition
of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Start the engine, and then
check the condition of the
fault code.
Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
TIP
For this check, also set the en-
gine stop switch to “ON”.
8-40
FUEL INJECTION SYSTEM
8-41
FUEL INJECTION SYSTEM
3-1
2
1 5V 5V
L
3 L
P/W
4 P/W
B/L
5 B/L
B/L P/W L
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
B/L P/W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
8-42
FUEL INJECTION SYSTEM
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
B/L P/W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
B/L P/W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-37.
3-8 [For P0107/P0108] Short circuit
Between intake air pressure sensor output terminal (pink/white) “a” of ECU coupler and any
other ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
a
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
4 Installed condition of intake Check for looseness or pinch- Turn the main switch to “ON”,
air pressure sensor. ing. and then check the condition
Improperly installed sensor of the fault code using the
Reinstall or replace the malfunction mode of the
sensor. Yamaha diagnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
8-43
FUEL INJECTION SYSTEM
5 Defective intake air pressure Execute the diagnostic mode. Crank the engine, and then
sensor. (Code No. 03) check the condition of the
When engine is stopped: fault code using the malfunc-
Atmospheric pressure at the tion mode of the Yamaha di-
current altitude and weather agnostic tool.
conditions is indicated. Condition is “Recover” Go
At sea level: Approx. 101 kPa to item 7 and finish the ser-
(757.6 mmHg, 29.8 inHg) vice.
1000 m (3300 ft) above sea Condition is “Malfunction”
level: Approx. 90 kPa (675.1 Go to item 6.
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea
level: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea
level: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
When engine is cranking:
Make sure that the indication
value changes.
The value does not change
when engine is cranking.
Check the intake air pressure
sensor.
Replace if defective.
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-44
FUEL INJECTION SYSTEM
8-45
FUEL INJECTION SYSTEM
3-1
2
5V
1
Br/W
3 Br/W
B/L B/L
4
Br/W B/L
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
Br/W B/L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
8-46
FUEL INJECTION SYSTEM
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
Br/W B/L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
3-6 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-37.
3-7 [For P0112/P0113] Short circuit
Between intake air temperature sensor output terminal (brown/white) “a” of ECU coupler and
any other ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
b a
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
4 Installed condition of intake Check for looseness or pinch- Turn the main switch to “ON”,
air temperature sensor. ing. and then check the condition
Improperly installed sensor of the fault code using the
Reinstall or replace the malfunction mode of the
sensor. Yamaha diagnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Defective intake air tempera- Execute the diagnostic mode. Turn the main switch to “ON”,
ture sensor. (Code No. 05) and then check the condition
When engine is cold: of the fault code using the
Displayed temperature is malfunction mode of the
close to the ambient tem- Yamaha diagnostic tool.
perature. Condition is “Recover” Go
The displayed temperature is to item 7 and finish the ser-
not close to the ambient tem- vice.
perature. Check the intake Condition is “Malfunction”
air temperature sensor. Go to item 6.
Replace if defective.
Refer to “CHECKING THE
INTAKE AIR TEMPERA-
TURE SENSOR” on page 8-
155.
8-47
FUEL INJECTION SYSTEM
8-48
FUEL INJECTION SYSTEM
3 Wire harness continuity. Open or short circuit Re- Turn the main switch to “ON”,
place the wire harness. and then check the condition
of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 4.
3-1
2
5V
1
G/W
3 G/W
B/L B/L
4
G/W B/L
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
G/W B/L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
8-49
FUEL INJECTION SYSTEM
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
G/W B/L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
3-6 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-37.
3-7 [For P0117/P0118] Short circuit
Between coolant temperature sensor output terminal (green/white) “a” of ECU coupler and
any other ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
b
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
4 Installed condition of coolant Check for looseness or pinch- Turn the main switch to “ON”,
temperature sensor. ing. and then check the condition
Improperly installed sensor of the fault code using the
Reinstall or replace the malfunction mode of the
sensor. Yamaha diagnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Defective coolant tempera- Execute the diagnostic mode. Turn the main switch to “ON”,
ture sensor. (Code No. 06) and then check the condition
When engine is cold: of the fault code using the
Displayed temperature is malfunction mode of the
close to the ambient tem- Yamaha diagnostic tool.
perature. Condition is “Recover” Go
The displayed temperature is to item 7 and finish the ser-
not close to the ambient tem- vice.
perature Check the cool- Condition is “Malfunction”
ant temperature sensor. Go to item 6.
Replace if defective.
Refer to “CHECKING THE
COOLANT TEMPERATURE
SENSOR” on page 8-154.
8-50
FUEL INJECTION SYSTEM
8-51
FUEL INJECTION SYSTEM
3 Wire harness continuity. Open or short circuit Re- Turn the main switch to “ON”,
place the wire harness. and then check the condition
of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is “Recover” Go
to item 8 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 4.
3-1
2
1 5V
L
3 L
W
4 W
B/L
5 B/L
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
B/L W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
B/L W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
8-52
FUEL INJECTION SYSTEM
B/L W L
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
B/L W L W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-37.
3-8 [For P0122/P0123] Short circuit
Between throttle position sensor output terminal (white) “a” of ECU coupler and any other
ECU coupler terminal “b”.
If there is continuity, replace the wire harness.
b a
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
4 Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”,
position sensor. ing. and then check the condition
Improperly installed sensor of the fault code using the
Reinstall or adjust the sen- malfunction mode of the
sor. Yamaha diagnostic tool.
Refer to “ADJUSTING THE Condition is “Recover” Go
THROTTLE POSITION SEN- to item 8 and finish the ser-
SOR” on page 7-14. vice.
Condition is “Malfunction”
Go to item 5.
8-53
FUEL INJECTION SYSTEM
5 Throttle position sensor resis- Measure the throttle position Turn the main switch to “ON”,
tance. sensor resistance. and then check the condition
black/blue–blue of the fault code using the
Refer to “CHECKING THE malfunction mode of the
THROTTLE POSITION SEN- Yamaha diagnostic tool.
SOR” on page 8-155. Condition is “Recover” Go
to item 8 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 6.
6 Defective throttle position Check throttle position sen- Turn the main switch to “ON”,
sensor. sor signal. and then check the condition
Execute the diagnostic mode. of the fault code using the
(Code No. 01) malfunction mode of the
When the throttle valves are Yamaha diagnostic tool.
fully closed: Condition is “Recover” Go
A value of 11–21 is indicated. to item 8 and finish the ser-
When throttle valves are fully vice.
open: Condition is “Malfunction”
A value of 96–106 is indicat- Go to item 7.
ed.
An indicated value is out of
the specified range Re-
place the throttle position
sensor.
7 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
8 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-54
FUEL INJECTION SYSTEM
8-55
FUEL INJECTION SYSTEM
5 Defective O2 sensor. Check the O2 sensor. Turn the main switch to “ON”,
Defective Replace the O2 and then check the condition
sensor. of the fault code using the
Refer to “ENGINE REMOV- malfunction mode of the
AL” on page 5-11. Yamaha diagnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 6.
6 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-56
FUEL INJECTION SYSTEM
8-57
FUEL INJECTION SYSTEM
8-58
FUEL INJECTION SYSTEM
5 Wire harness continuity. Open or short circuit Re- Execute the diagnostic mode.
place the wire harness. (Code No. 37)
Between fuel injector coupler Operating sound Go to
and sub-wire harness cou- item 7.
pler. No operating sound Go to
green/black–green/black item 6.
red/blue–red/blue
Between sub-wire harness
coupler and ECU coupler.
green/black–green/black
red/blue–red/blue
Between sub-wire harness
coupler and relay unit cou-
pler.
red/blue–red/blue
6 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
7 Delete the fault code and Start the engine and let it idle
check that the engine trouble for approximately 5 seconds.
warning light goes off. Confirm that the fault code
has a condition of “Recover”
using the malfunction mode
of the Yamaha diagnostic
tool, and then delete the fault
code.
8-59
FUEL INJECTION SYSTEM
2 Connection of ECU coupler. Improperly connected Crank the engine, and then
Check the locking condition Connect the coupler securely check the condition of the
of the coupler. or replace the wire harness. fault code using the malfunc-
Disconnect the coupler and tion mode of the Yamaha di-
check the pins (bent or bro- agnostic tool.
ken terminals and locking Condition is “Recover” Go
condition of the pins). to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 3.
3 Wire harness continuity. Open or short circuit Re- Crank the engine, and then
place the wire harness. check the condition of the
Between crankshaft position fault code using the malfunc-
sensor coupler and ECU cou- tion mode of the Yamaha di-
pler. agnostic tool.
gray–gray Condition is “Recover” Go
Between crankshaft position to item 7 and finish the ser-
sensor coupler and joint cou- vice.
pler. Condition is “Malfunction”
black/blue–black/blue Go to item 4.
Between joint coupler and
ECU coupler.
black/blue–black/blue
4 Installed condition of crank- Improperly installed sensor Crank the engine, and then
shaft position sensor. Reinstall or replace the check the condition of the
Check for looseness or pinch- sensor. fault code using the malfunc-
ing. Refer to “GENERATOR AND tion mode of the Yamaha di-
Check the gap between the STARTER CLUTCH” on agnostic tool.
crankshaft position sensor page 5-45. Condition is “Recover” Go
and the generator rotor. to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine, and then
sensor. sensor. check the condition of the
Refer to “CHECKING THE fault code using the malfunc-
CRANKSHAFT POSITION tion mode of the Yamaha di-
SENSOR” on page 8-151. agnostic tool.
Replace if defective. Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 6.
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-60
FUEL INJECTION SYSTEM
8-61
FUEL INJECTION SYSTEM
4 Installed condition of cylin- Check for looseness or pinch- Start the engine and let it idle
der-#1 ignition coil. ing. for approximately 5 seconds.
Improperly installed ignition Check the condition of the
coil Reinstall or replace the fault code using the malfunc-
ignition coil. tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Defective cylinder-#1 ignition Measure the primary coil re- Start the engine and let it idle
coil. sistance of the cylinder-#1 ig- for approximately 5 seconds.
nition coil. Check the condition of the
Replace if out of specifica- fault code using the malfunc-
tion. tion mode of the Yamaha di-
Refer to “CHECKING THE agnostic tool.
IGNITION COILS” on page 8- Condition is “Recover” Go
150. to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 6.
6 Malfunction in ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark Replace the
ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-62
FUEL INJECTION SYSTEM
8-63
FUEL INJECTION SYSTEM
4 Installed condition of cylin- Check for looseness or pinch- Start the engine and let it idle
der-#2 ignition coil. ing. for approximately 5 seconds.
Improperly installed ignition Check the condition of the
coil Reinstall or replace the fault code using the malfunc-
ignition coil. tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Defective cylinder-#2 ignition Measure the primary coil re- Start the engine and let it idle
coil. sistance of the cylinder-#2 ig- for approximately 5 seconds.
nition coil. Check the condition of the
Replace if out of specifica- fault code using the malfunc-
tion. tion mode of the Yamaha di-
Refer to “CHECKING THE agnostic tool.
IGNITION COILS” on page 8- Condition is “Recover” Go
150. to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 6.
6 Malfunction in ECU. Execute the diagnostic mode. Service is finished.
(Code No. 31)
No spark Replace the
ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-64
FUEL INJECTION SYSTEM
8-65
FUEL INJECTION SYSTEM
A-4 Connection of ECU coupler. Improperly connected Execute the diagnostic mode.
Check the locking condition Connect the coupler securely (Code No. 07)
of the coupler. or replace the wire harness. Rotate the rear wheel by
Disconnect the coupler and hand and check that the indi-
check the pins (bent or bro- cated value increases.
ken terminals and locking Value increases Go to item
condition of the pins). A-8.
Value does not increase
Go to item A-5.
A-5 Rear wheel sensor lead con- Open or short circuit, or de- Execute the diagnostic mode.
tinuity, or defective rear fective sensor Replace the (Code No. 07)
wheel sensor. rear wheel sensor. Rotate the rear wheel by
Between rear wheel sensor hand and check that the indi-
coupler and ABS ECU cou- cated value increases.
pler. Value increases Go to item
black–black A-8.
white–white Value does not increase
Between ABS ECU coupler Go to item A-6.
and ECU coupler.
white/yellow–white/yellow
A-6 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
Refer to “REPLACING THE (Code No. 07)
ECU (engine control unit)” on Rotate the rear wheel by
page 8-145. hand and check that the indi-
cated value increases.
Value increases Go to item
A-8.
Value does not increase
Go to item A-7.
A-7 Malfunction in ABS ECU. Replace the ABS ECU. Go to item A-8.
A-8 Delete the fault code and Turn the main switch to “ON”,
check that the engine trouble and then rotate the rear
warning light goes off. wheel by hand.
Start the engine, and input
the vehicle speed signals by
operating the vehicle at 20 to
30 km/h(12 to 19 mph).
Confirm that the fault code
has a condition of “Recover”
using the malfunction mode
of the Yamaha diagnostic
tool, and then delete the fault
code.
Delete this fault code even if it
has a condition of “Malfunc-
tion”.
8-66
FUEL INJECTION SYSTEM
8-67
FUEL INJECTION SYSTEM
B-4 Wire harness continuity. Open or short circuit Re- Execute the diagnostic mode.
place the wire harness. (Code No. 21)
Between ECU coupler and When the transmission is in
joint coupler. neutral: “ON”
black/yellow–black/yellow When the transmission is in
Between joint coupler and re- gear with the clutch lever re-
lay unit coupler. leased: “OFF”
black/yellow–black/yellow Correct indication Go to
Between relay unit coupler item B-9.
and sub-wire harness cou- Incorrect indication Go to
pler. item B-5.
sky blue–sky blue
Between sub-wire harness
coupler and gear position
switch coupler.
sky blue–sky blue
B-5 Defective relay unit. Check the relay unit. Execute the diagnostic mode.
Replace if defective. (Code No. 21)
Refer to “CHECKING THE When the transmission is in
RELAY UNIT (DIODE)” on neutral: “ON”
page 8-149. When the transmission is in
gear with the clutch lever re-
leased: “OFF”
Correct indication Go to
item B-9.
Incorrect indication Go to
item B-6.
B-6 Defective gear position Check the gear position Execute the diagnostic mode.
switch. switch. (Code No. 21)
Replace if defective. When the transmission is in
Refer to “CHECKING THE neutral: “ON”
GEAR POSITION SWITCH” When the transmission is in
on page 8-156. gear with the clutch lever re-
leased: “OFF”
Correct indication Go to
item B-9.
Incorrect indication Go to
item B-7.
B-7 Faulty shift drum (neutral de- Malfunction Replace the Execute the diagnostic mode.
tection area). shift drum. (Code No. 21)
Refer to “TRANSMISSION” When the transmission is in
on page 5-97. neutral: “ON”
When the transmission is in
gear with the clutch lever re-
leased: “OFF”
Correct indication Go to
item B-9.
Incorrect indication Go to
item B-8.
B-8 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
8-68
FUEL INJECTION SYSTEM
B-9 Delete the fault code and Turn the main switch to “ON”,
check that the engine trouble and then rotate the rear
warning light goes off. wheel by hand.
Start the engine, and input
the vehicle speed signals by
operating the vehicle at 20 to
30 km/h(12 to 19 mph).
Confirm that the fault code
has a condition of “Recover”
using the malfunction mode
of the Yamaha diagnostic
tool, and then delete the fault
code.
Delete this fault code even if it
has a condition of “Malfunc-
tion”.
8-69
FUEL INJECTION SYSTEM
C-2 Clutch lever adjustment. Refer to “ADJUSTING THE Execute the diagnostic mode.
CLUTCH LEVER FREE (Code No. 21)
PLAY” on page 3-12. When the clutch lever is re-
leased with the transmission
in gear and when the side-
stand is retracted: “OFF”
When the clutch lever is
squeezed with the transmis-
sion in gear and when the
sidestand is retracted: “ON”
Correct indication Go to
item C-8.
Incorrect indication Go to
item C-3.
C-3 Connection of clutch switch Improperly connected Execute the diagnostic mode.
coupler. Connect the coupler securely (Code No. 21)
Check the locking condition or replace the wire harness. When the clutch lever is re-
of the coupler. leased with the transmission
Disconnect the coupler and in gear and when the side-
check the pins (bent or bro- stand is retracted: “OFF”
ken terminals and locking When the clutch lever is
condition of the pins). squeezed with the transmis-
sion in gear and when the
sidestand is retracted: “ON”
Correct indication Go to
item C-8.
Incorrect indication Go to
item C-4.
C-4 Connection of ECU coupler. Improperly connected Execute the diagnostic mode.
Check the locking condition Connect the coupler securely (Code No. 21)
of the coupler. or replace the wire harness. When the clutch lever is re-
Disconnect the coupler and leased with the transmission
check the pins (bent or bro- in gear and when the side-
ken terminals and locking stand is retracted: “OFF”
condition of the pins). When the clutch lever is
squeezed with the transmis-
sion in gear and when the
sidestand is retracted: “ON”
Correct indication Go to
item C-8.
Incorrect indication Go to
item C-5.
8-70
FUEL INJECTION SYSTEM
C-5 Wire harness continuity. Open or short circuit Re- Execute the diagnostic mode.
place the wire harness. (Code No. 21)
Between clutch switch cou- When the clutch lever is re-
pler and left handlebar switch leased with the transmission
coupler. in gear and when the side-
black/red–black/red stand is retracted: “OFF”
black/yellow–black/yellow When the clutch lever is
Between left handlebar squeezed with the transmis-
switch coupler and joint cou- sion in gear and when the
pler. sidestand is retracted: “ON”
black/red–black/red Correct indication Go to
black/yellow–black/yellow item C-8.
Between joint coupler and Incorrect indication Go to
ECU coupler. item C-6.
black/red–black/red
black/yellow–black/yellow
C-6 Defective clutch switch. Check the clutch switch. Execute the diagnostic mode.
Replace if defective. (Code No. 21)
Refer to “CHECKING THE When the clutch lever is re-
SWITCHES” on page 8-144. leased with the transmission
in gear and when the side-
stand is retracted: “OFF”
When the clutch lever is
squeezed with the transmis-
sion in gear and when the
sidestand is retracted: “ON”
Correct indication Go to
item C-8.
Incorrect indication Go to
item C-7.
C-7 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
C-8 Delete the fault code and Turn the main switch to “ON”,
check that the engine trouble and then rotate the rear
warning light goes off. wheel by hand.
Start the engine, and input
the vehicle speed signals by
operating the vehicle at 20 to
30 km/h(12 to 19 mph).
Confirm that the fault code
has a condition of “Recover”
using the malfunction mode
of the Yamaha diagnostic
tool, and then delete the fault
code.
Delete this fault code even if it
has a condition of “Malfunc-
tion”.
8-71
FUEL INJECTION SYSTEM
8-72
FUEL INJECTION SYSTEM
A-3 Throttle valve does not fully Check the throttle body as- Start the engine and let it idle
close. sembly. for approximately 10 sec-
Refer to “THROTTLE BOD- onds.
IES” on page 7-8. Check the condition of the
Check the throttle grip free fault code using the malfunc-
play. tion mode of the Yamaha di-
Refer to “CHECKING THE agnostic tool.
THROTTLE GRIP OPERA- Condition is “Recover” Go
TION” on page 3-28. to item A-6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item A-4.
A-4 ISC valve is not moving cor- Replace the throttle body as- Start the engine and let it idle
rectly. sembly. for approximately 10 sec-
onds.
Check the condition of the
fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item A-6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item A-5.
A-5 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
A-6 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-73
FUEL INJECTION SYSTEM
8-74
FUEL INJECTION SYSTEM
B-5 Installed condition of ISC Check for looseness or pinch- Execute the diagnostic mode.
(idle speed control) unit. ing. (Code No. 54)
Improperly installed ISC (idle ISC operating sound is heard
speed control) unit Rein- Go to item B-8.
stall the ISC (idle speed con- ISC operating sound is not
trol) unit. heard Go to item B-6.
Check the intake air passag-
es for air leaks.
B-6 ISC valve is not moving cor- Replace the throttle body as- Execute the diagnostic mode.
rectly. sembly. (Code No. 54)
ISC operating sound is heard
Go to item B-8.
ISC operating sound is not
heard Go to item B-7.
B-7 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
B-8 Delete the fault code and Start the engine and let it idle
check that the engine trouble for approximately 10 sec-
warning light goes off. onds.
Confirm that the fault code
has a condition of “Recover”
using the malfunction mode
of the Yamaha diagnostic
tool, and then delete the fault
code.
8-75
FUEL INJECTION SYSTEM
2 Connection of wire harness Improperly connected Turn the main switch to “ON”,
ECU coupler. Connect the coupler securely and then check the condition
Check the locking condition or replace the wire harness. of the fault code using the
of the coupler. malfunction mode of the
Disconnect the coupler and Yamaha diagnostic tool.
check the pins (bent or bro- Condition is “Recover” Go
ken terminals and locking to item 6 and finish the ser-
condition of the pins). vice.
Condition is “Malfunction”
Go to item 3.
3 Wire harness continuity. Open or short circuit Prop- Turn the main switch to “ON”,
erly connect or replace the and then check the condition
wire harness. of the fault code using the
Between ISC (idle speed malfunction mode of the
control) unit coupler and sub- Yamaha diagnostic tool.
wire harness coupler. Condition is “Recover” Go
red/green–red/green to item 6 and finish the ser-
pink/blue–pink/blue vice.
white/green–white/green Condition is “Malfunction”
brown/blue–brown/blue Go to item 4.
Between sub-harness and
ECU coupler.
red/green–red/green
pink/blue–pink/blue
white/green–white/green
brown/blue–brown/blue
4 Faulty ISC valve operation. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 54) and then check the condition
ISC operating sound is not of the fault code using the
heard Replace the ISC malfunction mode of the
valve. Yamaha diagnostic tool.
Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
6 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-76
FUEL INJECTION SYSTEM
8-77
FUEL INJECTION SYSTEM
8-78
FUEL INJECTION SYSTEM
4 “11” is indicated in diagnostic Turn the main switch to Set the main switch to “ON”,
mode (code No. 60). EE- “OFF”. and then check the condition
PROM data error for ISC (idle of the fault code using the
speed control) learning val- malfunction mode of the
ues. Yamaha diagnostic tool.
“12” is indicated in the diag- Condition is “Recover” Go
nostic mode. (Code No. 60) to item 6 and finish the ser-
EEPROM data error for O2 vice.
feedback learning values. Condition is “Malfunction”
“13” is indicated in the diag- Repeat item 1.
nostic mode. (Code No. 60) If the same number is indicat-
EEPROM data error for OBD ed, go to item 5.
memory values.
5 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
6 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-79
FUEL INJECTION SYSTEM
8-80
FUEL INJECTION SYSTEM
3 Wire harness continuity. Open or short circuit Re- Start the engine and let it idle
place the wire harness. for approximately 5 seconds.
Between relay unit coupler Check the condition of the
and ECU coupler. fault code using the malfunc-
red/blue–red/blue tion mode of the Yamaha di-
blue/yellow–blue/yellow agnostic tool.
Between relay unit coupler Condition is “Recover” Go
and joint coupler. to item 7 and finish the ser-
red/white–red/white vice.
Between joint coupler and ig- Condition is “Malfunction”
nition fuse. Go to item 4.
red/white–red/white
Between ignition fuse and
main switch coupler.
brown/blue–brown/blue
Between main switch coupler
and starter relay coupler.
red–red
Between starter relay coupler
and battery terminal.
red–red
4 Defective relay unit. Execute the diagnostic mode. Start the engine and let it idle
(Code No. 50) for approximately 5 seconds.
No operating sound Re- Check the condition of the
place the relay unit. fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Defective relay unit. Execute the diagnostic mode. Start the engine and let it idle
(Code No. 09) for approximately 5 seconds.
Fuel system voltage is below Check the condition of the
3 V Replace the relay unit. fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 6.
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-81
FUEL INJECTION SYSTEM
8-82
FUEL INJECTION SYSTEM
4 Wire harness continuity. Open or short circuit Re- Turn the main switch to “ON”,
place the wire harness. and then extend and retract
Between sidestand switch the sidestand.
coupler and relay unit cou- Check the condition of the
pler. fault code using the malfunc-
blue/green–blue/green tion mode of the Yamaha di-
Between relay unit coupler agnostic tool.
and joint coupler. Condition is “Recover” Go
black/red–black/red to item 7 and finish the ser-
Between joint coupler and vice.
ECU coupler. Condition is “Malfunction”
black/red–black/red Go to item 5.
5 Defective sidestand switch. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 20) and then extend and retract
Shift the transmission into the sidestand.
gear. Check the condition of the
Sidestand retracted: “ON” fault code using the malfunc-
Sidestand extended: “OFF” tion mode of the Yamaha di-
Replace if defective. agnostic tool.
Condition is “Recover” Go
to item 7 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 6.
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-83
FUEL INJECTION SYSTEM
8-84
FUEL INJECTION SYSTEM
5 Wire harness continuity be- Open or short circuit Re- Turn the main switch to “ON”,
tween main switch and ECU place the wire harness. and then check the condition
coupler. Between main switch and ig- of the fault code using the
nition fuse. malfunction mode of the
brown/blue–brown/blue Yamaha diagnostic tool.
Between ignition fuse and Condition is “Recover” Go
joint coupler. to item 7 and finish the ser-
red/white–red/white vice.
Between joint coupler and Condition is “Malfunction”
ECU coupler. Go to item 6.
red/white–red/white
6 Malfunction in ECU. Replace the ECU. Service is finished.
7 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-85
FUEL INJECTION SYSTEM
2 Connection of ECU coupler. Improperly connected Turn the main switch to “ON”,
Check the locking condition Connect the coupler securely then to “OFF”, and then back
of the coupler. or replace the wire harness. to “ON”.
Disconnect the coupler and Check the condition of the
check the pins (bent or bro- fault code using the malfunc-
ken terminals and locking tion mode of the Yamaha di-
condition of the pins). agnostic tool.
Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 3.
3 Wire harness continuity. Open or short circuit Re- Turn the main switch to “ON”,
place the wire harness. then to “OFF”, and then back
to “ON”.
Check the condition of the
fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 4.
3-1
2
1 5V 5V
L
3 L
Y/G
4 Y/G
B/L
5 B/L
G G G
L Y/G B/L
8-86
FUEL INJECTION SYSTEM
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
G G G
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
L Y/G B/L
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
G G G
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
L Y/G B/L
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
G G G
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
L Y/G B/L
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-37.
8-87
FUEL INJECTION SYSTEM
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R
W/G Br/L Y/G Br/W L/W G/B B/Y R/B
P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
4 Defective lean angle sensor. Refer to “CHECKING THE Turn the main switch to “ON”,
LEAN ANGLE SENSOR” on then to “OFF”, and then back
page 8-151. to “ON”.
Check the condition of the
fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
6 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-88
FUEL INJECTION SYSTEM
8-89
FUEL INJECTION SYSTEM
3 Connection of ECU coupler. Improperly connected Start the engine and let it idle
Check the locking condition Connect the coupler securely for approximately 10 sec-
of the coupler. or replace the wire harness. onds.
Disconnect the coupler and Check the condition of the
check the pins (bent or bro- fault code using the malfunc-
ken terminals and locking tion mode of the Yamaha di-
condition of the pins). agnostic tool.
Condition is “Recover” Go
to item 8 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 4.
Also, delete this fault code,
which has a condition of “Mal-
function”.
4 Wire harness continuity. Open or short circuit Re- Start the engine and let it idle
place the wire harness. for approximately 10 sec-
Between O2 sensor coupler onds.
and ECU coupler. Check the condition of the
gray/green–gray/green fault code using the malfunc-
pink/black–pink/black tion mode of the Yamaha di-
Between O2 sensor coupler agnostic tool.
and joint coupler. Condition is “Recover” Go
black/blue–black/blue to item 8 and finish the ser-
red/white–red/white vice.
Between joint coupler and Condition is “Malfunction”
ECU coupler. Go to item 5.
black/blue–black/blue Also, delete this fault code,
red/white–red/white which has a condition of “Mal-
Between joint coupler and ig- function”.
nition fuse.
red/white–red/white
5 Check fuel pressure. Refer to “CHECKING THE Start the engine and let it idle
FUEL PRESSURE” on for approximately 10 sec-
page 7-16. onds.
Check the condition of the
fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item 8 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 6.
Also, delete this fault code,
which has a condition of “Mal-
function”.
8-90
FUEL INJECTION SYSTEM
6 Defective O2 sensor. Check the O2 sensor. Start the engine and let it idle
Replace if defective. for approximately 10 sec-
Refer to “ENGINE REMOV- onds.
AL” on page 5-11. Check the condition of the
fault code using the malfunc-
tion mode of the Yamaha di-
agnostic tool.
Condition is “Recover” Go
to item 8 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 7.
Also, delete this fault code,
which has a condition of “Mal-
function”.
7 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
8 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
EAS31790
8-91
FUEL INJECTION SYSTEM
2 Connection of ECU coupler. Improperly connected Turn the main switch to “ON”,
Check the locking condition Connect the coupler securely and then check the condition
of the coupler. or replace the wire harness. of the fault code using the
Disconnect the coupler and malfunction mode of the
check the pins (bent or bro- Yamaha diagnostic tool.
ken terminals and locking Condition is “Recover” Go
condition of the pins). to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 3.
3 Wire harness continuity. Open or short circuit Re- Turn the main switch to “ON”,
place the wire harness. and then check the condition
Between meter assembly of the fault code using the
coupler and ECU coupler. malfunction mode of the
blue/black–blue/black Yamaha diagnostic tool.
blue/red–blue/red Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”,
and then check the condition
of the fault code using the
malfunction mode of the
Yamaha diagnostic tool.
Condition is “Recover” Go
to item 6 and finish the ser-
vice.
Condition is “Malfunction”
Go to item 5.
5 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-145.
6 Delete the fault code and Confirm that the fault code
check that the engine trouble has a condition of “Recover”
warning light goes off. using the Yamaha diagnostic
tool, and then delete the fault
code.
8-92
FUEL INJECTION SYSTEM
8-93
FUEL INJECTION SYSTEM
8-94
EAS30513
EAS20081
R/W
R/W
R /W
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
R W/G Br/L Y/G Br/W L/W G/B B/Y R/B
R
R R P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
R R
R R R/B
CIRCUIT DIAGRAM
(B)
18 R/B
R/W R R
1 R/W R R/W R/B
15 L/W R/W
Br/L Br/L
ON
OFF (B)
P
B
16
Br/L
B/G
R/B
FUEL PUMP SYSTEM
R/W
L/Y
R/L L/Y
Br/L
Br/L
36
R/W R/W
Br/L R/W R/W
7
B Dg W/L R/W
Y Ch Br/W L/R R/B
R/W R/B
63 (B)
8-95
B
B/W
R/L
R/L
R/L
46
B
R/L B G/W B
(B)
B/G
B/G
B/G
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B B B/G B/W
1. Main switch
7. Ignition fuse
10. Backup 2 fuse
15. Battery
16. Engine ground
18. Main fuse
22. Relay unit
24. Fuel pump relay
25. Joint coupler
36. ECU (Engine Control Unit)
46. Fuel pump
63. Handlebar switch (right)
66. Start/engine stop switch
8-96
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger seat
2. Rider seat
3. Rider seat bracket 1
4. Air scoop (left)
5. Air scoop (right)
6. Fuel tank center cover (fuel tank side covers)
7. Fuel tank
8. Headlight assembly
OK
OK
OK
OK
OK
OK
8-97
FUEL PUMP SYSTEM
OK
8-98
EAS30519
17 B B/W EAS20084
Y/L
R/W
R/G B B Lg G/B
R/G
R/W Lg Y/L
R/W
B/W R/G
L/W L/WL/WL/W R/W R/W R/W R/W R/W R/W R/W 25
Y/L G/B R/W L/R L/R L/R L/R L/R Y Y Y Y B/L B/L B/L
R /W
R /W
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
R W/G Br/L Y/G Br/W L/W G/B B/Y R/B
R
R R P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
R R
R R
CIRCUIT DIAGRAM
(B)
18
R/W R R
1 R/W R R/W R/B
15 L/W R/W Y/L
Br/L Br/L
ON
OFF (B)
P
B
16
Br/L
B/G
IMMOBILIZER SYSTEM
Br/L
Br/L
36
R/W
Br/L R/W R/W R/W
7 48 49
G/B
R R/B
10 R/G
R/G
8-99
11
B
R/W
R/G
B/W
53
B/W
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B B/GB/WB/W
1. Main switch
7. Ignition fuse
10. Backup 2 fuse
11. Backup 1 fuse
15. Battery
16. Engine ground
17. Immobilizer unit
18. Main fuse
25. Joint coupler
36. ECU (Engine Control Unit)
48. Meter assembly
49. Immobilizer system indicator light
53. Multi-function meter
8-100
IMMOBILIZER SYSTEM
EAS30520
GENERAL INFORMATION
This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the
standard keys. This system consists of the following:
• a code re-registering key (with a red bow)
• two standard keys (with a black bow) that can be re-registered with new codes
• a transponder (which is installed in the code re-registering key)
• an immobilizer unit
• the ECU
• an immobilizer system indicator light
The key with the red bow is used to register codes in each standard key. Do not use the key with the
red bow for driving. It should only be used for re-registering new codes in the standard keys. The im-
mobilizer system cannot be operated with a new key until the key is registered with a code. If you lose
the code re-registering key, the ECU and main switch (equipped with the immobilizer unit) need to be
replaced.
Therefore, always use a standard key for driving. (See NOTICE.)
TIP
Each standard key is registered during production, therefore re-registering at purchase is not neces-
sary.
ECA14971
NOTICE
• DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, regis-
tering new codes in the standard keys is impossible. The standard keys can still be used to
start the vehicle. However, if code re-registering is required (e.g., if a new standard key is made
or all keys are lost) the entire immobilizer system must be replaced. Therefore, it is highly rec-
ommended to use either standard key for driving, and to keep the code re-registering key in a
safe place.
• Do not submerse the keys in water.
• Do not expose the keys to excessively high temperatures.
• Do not place the keys close to magnets (this includes, but is not limited to, products such as
speakers, etc.).
• Do not place heavy items on the keys.
• Do not grind the keys or alter their shape.
• Do not disassemble the key bows.
• Do not put two keys of any immobilizer system on the same key ring.
• Keep the standard keys as well as other immobilizer system keys away from the code re-reg-
istering key.
• Keep other immobilizer system keys away from the main switch as they may cause signal in-
terference.
8-101
IMMOBILIZER SYSTEM
EAS30521
Parts to be replaced
Main switch/im-
mobilizer unit Accesso- Key registration re-
Standard quirement
Main ECU ry lock*
Immobiliz- key
switc and key
er unit
h
Standard key is lost New standard key
All keys have been Code re-registering
lost (including code key and standard
re-registering key) keys
Code re-registering
ECU is defective key and standard
keys
Code re-registering
Immobilizer unit is de-
key and standard
fective
keys
Code re-registering
Main switch is defec-
key and standard
tive
keys
Accessory lock* is de-
Not required
fective
* Accessory locks mean the seat lock and fuel tank cap.
Standby mode:
To enable the immobilizer system, turn the ignition key to “OFF”. 30 seconds later, the indicator light will
start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time, the
indicator light will stop flashing, but the immobilizer system is still enabled.
8-102
IMMOBILIZER SYSTEM
Standby mode
8-103
IMMOBILIZER SYSTEM
8-104
IMMOBILIZER SYSTEM
EAS30522
TROUBLESHOOTING
When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor
flashes.
OK
OK
OK
OK
8-105
IMMOBILIZER SYSTEM
EAS30523
8-106
IMMOBILIZER SYSTEM
Fault
Part Symptom Cause Action
code
55 IMMOBILIZER Key code registra- Same standard key was Register another
UNIT tion malfunction. attempted to be regis- standard key.
tered two consecutive
times.
56 ECU Unidentified code is Noise interference or 1. Check the wire
received. disconnected lead/ca- harness and
ble. connector.
2. Replace the
main switch/im-
mobilizer unit.
3. Replace the
ECU.
Refer to “RE-
PLACING THE
ECU (engine
control unit)” on
page 8-145.
a. Light on
b. Light off
8-107
IMMOBILIZER SYSTEM
8-108
EAS30988
EAS20085
A
R R
A B R/W Y
Y Y Y L/R
R A R R/W L/R
L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O
R W/G Br/L Y/G Br/W L/W G/B B/Y R/B
R
R R R P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
R R
R R
CIRCUIT DIAGRAM
(B)
18 Br Y L/R Y
R/W R R
1 R/W R (B) (B) R/W
21 R/B
15 L/W R/W
Br/L Br/L Y Br Y L/R
ON
OFF (B)
P
B
16
B
Br/L B/G
B/G
R R/W
2
R/L
Br/W
Br/L 5
Br/L Br/L
Br/L
36
R/W
Br/L R/W R/W R/W
7 L/R 48
L/R L/R L/R
B Dg W/L R/W
8 Y Ch Br/W L/R R/B
L/R Y
63 (B)
ABS (ANTI-LOCK BRAKE SYSTEM)
8-109
B
R/W
B/W
L/R
L/B
W/Y
53
L/R
25 W/Y
L/B L/B L/B
L/R
L/B
Y
43
82 W R
L G/R
W W Gy
Y R R W 41 W Gy
B/W
B/G B B Gy
W W 42 W Gy
60 B
83 G/R
B W
G/R G/W L/R L/B Sb/W Y Dg Ch G/R
Gy O W/R Y/W P W R/W R/G G/B B/W
B/G
(Gy)
L Y
B/G
B B/G L/R L/B
*Refer to “WIRING DIAGRAM” for the wire harness colors of MTN690-U ECU coupler.
B B/GB/WB/W R/W W R B W G G/R W/Y B
B
R/W B B
44 L/B R/L Y G G Br/W L/R L/B B/L B/G
Y L/R B/W 25 B/G B B B/W B/W B/G L/R
B/G
B/W B B B/W B/W B/W
B (Y) (B)
B/W
ABS (ANTI-LOCK BRAKE SYSTEM)
ABS (ANTI-LOCK BRAKE SYSTEM)
1. Main switch
2. ABS solenoid fuse
3. ABS motor fuse
5. ABS control unit fuse
7. Ignition fuse
8. Signaling system fuse
10. Backup 2 fuse
15. Battery
16. Engine ground
18. Main fuse
21. Rear brake light switch
25. Joint coupler
36. ECU (Engine Control Unit)
41. Front wheel sensor
42. Rear wheel sensor
43. ABS ECU (electronic control unit)
44. Yamaha diagnostic tool coupler
48. Meter assembly
53. Multi-function meter
60. ABS warning light
63. Handlebar switch (right)
64. Front brake light switch
82. Tail/brake light assembly
83. Tail/brake light
A. Wire harness
B. Positive battery sub-wire harness
8-110
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS30990
5 1
4 (B)
W Gy B W
3
L/R L/B
R/W B
8-111
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS30991
1
2
EAS30992
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.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-141.
8-112
ABS (ANTI-LOCK BRAKE SYSTEM)
Special precautions for handling and servicing a vehicle equipped with ABS
ECA18490
NOTICE
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction oc-
curs.)
EAS30993
WARNING
• Perform the troubleshooting [A][B][C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.
8-113
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS30994
[A] Turn the main switch to “ ON ”, Fails to • The ABS warning light (LED)
come on [A-1] Does only the ABS
and check the ABS warning Yes is defective.
warning light fail to Return to [A].
light. • The wire harness is grounded
come on?
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.
No
• The main switch is defective.
[A-2] Do all indicator lights Yes • The battery voltage is low. Return to [A].
fail to come on? • The main fuse is blown.
• The meter assembly circuit is
defective.
Cannot
[A-3] The ABS warning light comes communicate [A-4] Only the ABS ECU Yes
• The ABS control unit fuse is blown.
on. • The ABS ECU coupler is Return to [A].
fails to communicate.
Connect the Yamaha disconnected.
diagnostic tool, and then
• The wire harness is defective.
execute functional diagnosis.
Can the tool communicate with • The hydraulic unit assembly
the ABS ECU? is defective.
No
Can communicate
[A-5] ABS ECU and FI ECU Yes • The connection with the Yamaha
Return to [A].
fail to communicate. diagnostic tool is defective.
• The wire harness is defective.
[B-1] Check for ABS fault Yes [B-2] Diagnose by the fault [B-3] Delete the fault codes.
Return to [A].
codes in the screen for the code.
Yamaha diagnostic tool.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect.
• The brake hoses and brake
[C-1] Perform the final checks. No pipes are not connected
Were all of the final checks correctly. Return to [A].
completed normally? The ABS warning light does
not go off when the light is
Yes checked.
(Check that the ABS warning • The malfunction is not
light goes off during the ABS
corrected.
warning light check.)
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The meter assembly circuit
is defective.
• The ABS warning light circuit
in the hydraulic unit assembly
is defective.
Finished.
8-114
ABS (ANTI-LOCK BRAKE SYSTEM)
EWA16710
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.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-141.
EAS30995
8-115
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS31135
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE (The select unit screen does not appear.)
1. ABS control unit fuse
• Check the ABS control unit fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-145.
• If the ABS control unit fuse is blown, replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-61.
3. Wire harness
• Open circuit between the main switch and the ABS ECU, or between the ABS ECU and the ground.
Check for continuity between brown/blue terminal of the main switch coupler and brown/white ter-
minal of the ABS ECU coupler.
Check for continuity between black/green terminal of the ABS ECU coupler and the ground, and be-
tween the black terminal of the ABS ECU coupler and ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler.
Check for continuity between blue/red terminal of the ABS ECU coupler and blue/red terminal of the
Yamaha diagnostic tool coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal of
the Yamaha diagnostic tool coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS31136
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE (Cannot connect due to a tool error.)
1. Yamaha diagnostic tool
Check that the Yamaha diagnostic tool is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler.
Check for continuity between blue/red terminal of the ABS ECU coupler and blue/red terminal of the
Yamaha diagnostic tool coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal of
the Yamaha diagnostic tool coupler. (CANL)
EAS31137
8-116
ABS (ANTI-LOCK BRAKE SYSTEM)
Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.
Fault code
Item Symptom Check point
No.
11* Front wheel sensor (inter- Front wheel sensor signal • Foreign material ad-
25* mittent pulses or no puls- is not received properly. hered around the front
es) (Pulses are not received wheel sensor
or are received intermit- • Incorrect installation of
tently while the vehicle is the front wheel
traveling.) • Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
12 Rear wheel sensor (inter- Rear wheel sensor signal • Foreign material ad-
mittent pulses or no puls- is not received properly. hered around the rear
es) (Pulses are not received wheel sensor
or are received intermit- • Incorrect installation of
tently while the vehicle is the rear wheel
traveling.) • Defective sensor rotor or
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor
8-117
ABS (ANTI-LOCK BRAKE SYSTEM)
Fault code
Item Symptom Check point
No.
13* Front wheel sensor (ab- Front wheel sensor signal • Foreign material ad-
26* normal pulse period) is not received properly. hered around the front
(The pulse period is ab- wheel sensor
normal while the vehicle is • Incorrect installation of
traveling.) the front wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal • Foreign material ad-
27* mal pulse period) is not received properly. hered around the rear
(The pulse period is ab- wheel sensor
normal while the vehicle is • Incorrect installation of
traveling.) the rear wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor
15 Front wheel sensor (open Open or short circuit is de- • Defective coupler be-
or short circuit) tected in the front wheel tween the front wheel
sensor. sensor and the hydraulic
unit assembly
• Open or short circuit in
the wire harness be-
tween the front wheel
sensor and the hydraulic
unit assembly
• Defective front wheel
sensor or hydraulic unit
assembly
16 Rear wheel sensor (open Open or short circuit is de- • Defective coupler be-
or short circuit) tected in the rear wheel tween the rear wheel
sensor. sensor and the hydraulic
unit assembly
• Open or short circuit in
the wire harness be-
tween the rear wheel
sensor and the hydraulic
unit assembly
• Defective rear wheel
sensor or hydraulic unit
assembly
8-118
ABS (ANTI-LOCK BRAKE SYSTEM)
Fault code
Item Symptom Check point
No.
17* Front wheel sensor (miss- Front wheel sensor signal • Foreign material ad-
45* ing pulses) is not received properly. hered around the front
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the front wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
18* Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad-
46* ing pulses) is not received properly. hered around the rear
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the rear wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor
21 Hydraulic unit assembly Solenoid drive circuit in • Defective hydraulic unit
(defective solenoid drive the hydraulic unit assem- assembly
circuit) bly is open or short-circuit-
ed.
24 Brake light switch or tail/ Brake light signal is not re- • Defective signaling sys-
brake light ceived properly while the tem (tail/brake light or
vehicle is traveling. (Brake brake light switch)
light circuit, or front or rear • Defective coupler be-
brake light switch circuit) tween the signaling sys-
tem (tail/brake light or
brake light switch) and
the hydraulic unit assem-
bly
• Open or short circuit in
the wire harness be-
tween the signaling sys-
tem (tail/brake light or
brake light switch) and
the hydraulic unit assem-
bly
• Defective hydraulic unit
assembly
8-119
ABS (ANTI-LOCK BRAKE SYSTEM)
Fault code
Item Symptom Check point
No.
31 Hydraulic unit assembly Power is not supplied to • Blown ABS solenoid fuse
(abnormal ABS solenoid the solenoid circuit in the • Defective coupler be-
power supply) hydraulic unit assembly. tween the battery and the
hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective hydraulic unit
assembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS sole- the solenoid power supply assembly
noid power supply circuit) circuit in the hydraulic unit
assembly.
33 Hydraulic unit assembly Power is not supplied to • Blown ABS motor fuse
(abnormal ABS motor the motor circuit in the hy- • Defective coupler be-
power supply) draulic unit assembly. tween the battery and the
hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective hydraulic unit
assembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS motor the motor power supply assembly
power supply circuit) circuit in the hydraulic unit
assembly.
41 Front wheel ABS (intermit- • Pulses from the front • Incorrect installation of
tent wheel speed pulses or wheel sensor are re- the front wheel sensor
incorrect depressuriza- ceived intermittently • Incorrect rotation of the
tion) while the vehicle is trav- front wheel
eling. • Front brake dragging
• Front wheel will not re- • Defective hydraulic unit
cover from the locking assembly
tendency even though
the signal is transmitted
from the ABS ECU to re-
duce the hydraulic pres-
sure.
8-120
ABS (ANTI-LOCK BRAKE SYSTEM)
Fault code
Item Symptom Check point
No.
42 Rear wheel ABS (intermit- • Pulses from the rear • Incorrect installation of
47 tent wheel speed pulses or wheel sensor are re- the rear wheel sensor
incorrect depressuriza- ceived intermittently (for fault code No. 42)
tion) while the vehicle is trav- • Incorrect rotation of the
eling. (for fault code No. rear wheel
42) • Rear brake dragging
• Rear wheel will not re- • Defective hydraulic unit
cover from the locking assembly
tendency even though
the signal is transmitted
from the ABS ECU to re-
duce the hydraulic pres-
sure.
43 Front wheel sensor (miss- Front wheel sensor signal • Foreign material ad-
ing pulses) is not received properly. hered around the front
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the front wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
44 Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad-
ing pulses) is not received properly. hered around the rear
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the rear wheel
• Defective sensor rotor or
incorrect installation of
the rotor
• Defective rear wheel
sensor or incorrect in-
stallation of the sensor
51 • Vehicle system power • Power voltage supplied • Defective battery
52 supply (voltage of ABS to the ABS ECU in the • Disconnected battery
ECU power supply is hydraulic unit assembly terminal
high) (for fault code No. is too high. (for fault code • Defective charging sys-
51) No. 51) tem
• Vehicle system power • Power voltage supplied
supply (voltage of wheel to the wheel sensor is too
sensor power supply is high. (for fault code No.
high) (for fault code No. 52)
52)
8-121
ABS (ANTI-LOCK BRAKE SYSTEM)
Fault code
Item Symptom Check point
No.
53 Vehicle system power Power voltage supplied to • Defective battery
supply (voltage of ABS the ABS ECU in the hy- • Defective coupler be-
ECU power supply is low) draulic unit assembly is tween the battery and the
too low. hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective charging sys-
tem
54 Hydraulic unit assembly Abnormality is detected in • Defective battery
(defective ABS solenoid the solenoid or motor pow- • Defective coupler be-
and ABS motor power er supply circuit in the hy- tween the battery and the
supply circuits) draulic unit assembly. hydraulic unit assembly
• Open or short circuit in
the wire harness be-
tween the battery and the
hydraulic unit assembly
• Defective charging sys-
tem
• Defective hydraulic unit
assembly
55 Hydraulic unit assembly Abnormal data is detected • Defective hydraulic unit
(defective ABS ECU) in the hydraulic unit as- assembly
sembly.
56 Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit
(abnormal internal power the power supply circuit in assembly
supply) the hydraulic unit assem-
bly.
63 Front wheel sensor power Power voltage supplied • Short circuit in the wire
supply (voltage of power from the ABS ECU to the harness between the
supply is low) front wheel sensor is too front wheel sensor and
low. the hydraulic unit assem-
bly
• Defective front wheel
sensor
• Defective hydraulic unit
assembly
64 Rear wheel sensor power Power voltage supplied • Short circuit in the wire
supply (voltage of power from the ABS ECU to the harness between the
supply is low) rear wheel sensor is too rear wheel sensor and
low. the hydraulic unit assem-
bly
• Defective rear wheel
sensor
• Defective hydraulic unit
assembly
8-122
ABS (ANTI-LOCK BRAKE SYSTEM)
11
Fault code No.
25
Item Front wheel sensor (intermittent pulses or no pulses)
Front wheel sensor signal is not received properly. (Pulses are
Symptom not received or are received intermittently while the vehicle is
traveling.)
Or- Item/components and probable
Check or maintenance job
der cause
1 Foreign material adhered around the Check the surface of the sensor rotor and wheel
front wheel sensor sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if neces-
sary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion,
and bends.
Refer to “CHECKING THE FRONT WHEEL” on
page 4-18.
3 Defective sensor rotor or incorrect in- Check the surface of the sensor rotor for damage.
stallation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR” on
page 4-19.
4 Defective front wheel sensor or incor- Check the wheel sensor for damage and the in-
rect installation of the sensor stalled condition of the sensor. Repair or replace
the wheel sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR” on
page 4-19.
8-123
ABS (ANTI-LOCK BRAKE SYSTEM)
13
Fault code No.
26
Item Front wheel sensor (abnormal pulse period)
Front wheel sensor signal is not received properly. (The pulse
Symptom
period is abnormal while the vehicle is traveling.)
Or- Item/components and probable
Check or maintenance job
der cause
1 Foreign material adhered around the Check the surface of the sensor rotor and wheel
front wheel sensor sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if neces-
sary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion,
and bends.
Refer to “CHECKING THE FRONT WHEEL” on
page 4-18.
3 Defective sensor rotor or incorrect in- Check the surface of the sensor rotor for damage.
stallation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR” on
page 4-19.
4 Defective front wheel sensor or incor- Check the wheel sensor for damage and the in-
rect installation of the sensor stalled condition of the sensor. Repair or replace
the wheel sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR” on
page 4-19.
8-124
ABS (ANTI-LOCK BRAKE SYSTEM)
14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)
Rear wheel sensor signal is not received properly. (The pulse
Symptom
period is abnormal while the vehicle is traveling.)
Or- Item/components and probable
Check or maintenance job
der cause
1 Foreign material adhered around the Check the surface of the sensor rotor and wheel
rear wheel sensor sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if neces-
sary.
2 Incorrect installation of the rear wheel Check the components for looseness, distortion,
and bends.
Refer to “CHECKING THE REAR WHEEL” on
page 4-27.
3 Defective sensor rotor or incorrect in- Check the surface of the sensor rotor for damage.
stallation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.
4 Defective rear wheel sensor or incor- Check the wheel sensor for damage and the in-
rect installation of the sensor stalled condition of the sensor. Repair or replace
the wheel sensor if necessary.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.
8-125
ABS (ANTI-LOCK BRAKE SYSTEM)
6 7
6. ABS ECU
7. Front wheel sensor
3 Defective front wheel sensor or hy- If the above items were performed and no malfunc-
draulic unit assembly tions were found, the wheel sensor or hydraulic unit
assembly is defective. Replace the wheel sensor or
hydraulic unit assembly.
Refer to “FRONT WHEEL” on page 4-16 and “ABS
(ANTI-LOCK BRAKE SYSTEM)” on page 4-59.
8-126
ABS (ANTI-LOCK BRAKE SYSTEM)
6 7
6. ABS ECU
7. Rear wheel sensor
3 Defective rear wheel sensor or hy- If the above items were performed and no malfunc-
draulic unit assembly tions were found, the wheel sensor or hydraulic unit
assembly is defective. Replace the wheel sensor or
hydraulic unit assembly.
Refer to “REAR WHEEL” on page 4-23 and “ABS
(ANTI-LOCK BRAKE SYSTEM)” on page 4-59.
8-127
ABS (ANTI-LOCK BRAKE SYSTEM)
17
Fault code No.
45
Item Front wheel sensor (missing pulses)
Front wheel sensor signal is not received properly. (Missing
Symptom
pulses are detected in the signal while the vehicle is traveling.)
Or- Item/components and probable
Check or maintenance job
der cause
1 Foreign material adhered around the Check the surface of the sensor rotor and wheel
front wheel sensor sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if neces-
sary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion,
and bends.
Refer to “CHECKING THE FRONT WHEEL” on
page 4-18.
3 Defective sensor rotor or incorrect in- Check the surface of the sensor rotor for damage.
stallation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR” on
page 4-19.
4 Defective front wheel sensor or incor- Check the wheel sensor for damage and the in-
rect installation of the sensor stalled condition of the sensor. Repair or replace
the wheel sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR” on
page 4-19.
18
Fault code No.
46
Item Rear wheel sensor (missing pulses)
Rear wheel sensor signal is not received properly. (Missing
Symptom
pulses are detected in the signal while the vehicle is traveling.)
Or- Item/components and probable
Check or maintenance job
der cause
1 Foreign material adhered around the Check the surface of the sensor rotor and wheel
rear wheel sensor sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if neces-
sary.
8-128
ABS (ANTI-LOCK BRAKE SYSTEM)
18
Fault code No.
46
Item Rear wheel sensor (missing pulses)
Rear wheel sensor signal is not received properly. (Missing
Symptom
pulses are detected in the signal while the vehicle is traveling.)
Or- Item/components and probable
Check or maintenance job
der cause
2 Incorrect installation of the rear wheel Check the components for looseness, distortion,
and bends.
Refer to “CHECKING THE REAR WHEEL” on
page 4-27.
3 Defective sensor rotor or incorrect in- Check the surface of the sensor rotor for damage.
stallation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.
4 Defective rear wheel sensor or incor- Check the wheel sensor for damage and the in-
rect installation of the sensor stalled condition of the sensor. Repair or replace
the wheel sensor if necessary.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.
8-129
ABS (ANTI-LOCK BRAKE SYSTEM)
8-130
ABS (ANTI-LOCK BRAKE SYSTEM)
8-131
ABS (ANTI-LOCK BRAKE SYSTEM)
8-132
ABS (ANTI-LOCK BRAKE SYSTEM)
8-133
ABS (ANTI-LOCK BRAKE SYSTEM)
42
Fault code No.
47
Rear wheel ABS (intermittent wheel speed pulses or incorrect
Item
depressurization)
• Pulses from the rear wheel sensor are received intermittently
while the vehicle is traveling. (for fault code No. 42)
Symptom • Rear wheel will not recover from the locking tendency even
though the signal is transmitted from the ABS ECU to reduce
the hydraulic pressure.
Or- Item/components and probable
Check or maintenance job
der cause
3 Incorrect rotation of the rear wheel Check that there is no brake disc drag on the wheel
and make sure that it rotates smoothly.
Refer to “CHECKING THE REAR WHEEL” on
page 4-27.
4 Rear brake dragging Check that the brake fluid pressure is correctly
transmitted to the brake caliper when the brake
pedal is operated and that the pressure decreases
when the pedal is released.
Refer to “CHECKING THE REAR BRAKE DISC” on
page 4-52.
5 Defective hydraulic unit assembly If the above items were performed and no malfunc-
tions were found, replace the hydraulic unit assem-
bly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on
page 4-59.
8-134
ABS (ANTI-LOCK BRAKE SYSTEM)
8-135
ABS (ANTI-LOCK BRAKE SYSTEM)
8-136
ABS (ANTI-LOCK BRAKE SYSTEM)
8-137
ABS (ANTI-LOCK BRAKE SYSTEM)
4 5
4. ABS ECU
5. Front wheel sensor
8-138
ABS (ANTI-LOCK BRAKE SYSTEM)
2 1
R/W W R B W G G/R W/Y B
W R W Gy
R/L Y G G Br/W L/R L/B B/L B/G
3 4
3. ABS ECU
4. Front wheel sensor
3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on
page 4-59.
8-139
ABS (ANTI-LOCK BRAKE SYSTEM)
2 1
R/W W R B W G G/R W/Y B
B W W Gy
R/L Y G G Br/W L/R L/B B/L B/G
4 5
4. ABS ECU
5. Rear wheel sensor
2 Defective rear wheel sensor • Check that there is no short circuit between the
gray terminal “1” and the white terminal “2”.
• If there is a short circuit, the wheel sensor is defec-
tive. Repair or replace the wheel sensor.
2 1
3 4
3. ABS ECU
4. Rear wheel sensor
3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on
page 4-59.
8-140
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS31139
EAS31140
Checking procedures
1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-16.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (DISC BRAKE)” on page 4-21 and “INSTALLING THE
REAR WHEEL (REAR BRAKE DISC)” on page 4-29.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-63.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 8-141.
5. Checking the ABS warning light.
Refer to “CHECKING THE ABS WARNING LIGHT” on page 4-66.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between green/red terminal of the ABS ECU coupler and green/red terminal of
the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.
8-141
ELECTRICAL COMPONENTS
EAS20089
ELECTRICAL COMPONENTS
1 3 4 5 6
2
8
18
17
10
11
16
15 13 12
14
1. Main switch
2. Front brake light switch
3. Clutch switch
4. Rectifier/regulator
5. Ignition coil
6. Battery
7. Fuse box 1
8. Fuse box 2
9. Main fuse
10. Starter relay
11. Rear brake light switch
12. Sidestand switch
13. O2 sensor
14. Gear position switch
15. Oil pressure switch
16. Horn
17. Radiator fan motor
18. ECU (Engine Control Unit)
8-142
ELECTRICAL COMPONENTS
1 2 3
15
4
14
13
12
11
7
10
8
9
1. Intake air temperature sensor
2. Hydraulic unit assembly
3. Intake air pressure sensor
4. Fuel pump
5. Lean angle sensor
6. Rear wheel sensor
7. Coolant temperature sensor
8. Crankshaft position sensor
9. Fuel injector
10. Throttle position sensor
11. Front wheel sensor
12. Radiator fan motor relay
13. Headlight relay
14. Relay unit
15. Turn signal/hazard relay
8-143
ELECTRICAL COMPONENTS
EAS30549
R/W L/W Dg B
Dg Br/W L/B Y B/Y
R/B B/L Br/W Ch B/L
B/W B/R G Br Ch
11 1 R/W R/B L/W B
Y L/B G
10 L/B Y 2 Ch Br/W Dg
9 Ch Br/W Dg 3
8 Br B/W
B/L B/L
7
4
Br Y
B/R
B/Y
5
6
Br/R
R/W Br/L Br/R
ON B B
OFF R/W
P
Br/L
8-144
ELECTRICAL COMPONENTS
EAS30551
8-145
ELECTRICAL COMPONENTS
EAS30552
TIP
CHECKING AND CHARGING THE BATTERY
EWA13290 Since VRLA (Valve Regulated Lead Acid) bat-
WARNING teries are sealed, it is not possible to check the
Batteries generate explosive hydrogen gas charge state of the battery by measuring the
and contain electrolyte which is made of poi- specific gravity of the electrolyte. Therefore, the
sonous and highly caustic sulfuric acid. charge of the battery has to be checked by mea-
Therefore, always follow these preventive suring the voltage at the battery terminals.
measures:
1. Remove:
• Wear protective eye gear when handling or
• Passenger seat
working near batteries.
• Rider seat
• Charge batteries in a well-ventilated area.
• Rider seat bracket 1
• Keep batteries away from fire, sparks or
Refer to “GENERAL CHASSIS (1)” on
open flames (e.g., welding equipment,
page 4-1.
lighted cigarettes).
2. Disconnect:
• DO NOT SMOKE when charging or han-
• Battery lead
dling batteries.
(from the battery terminals)
• KEEP BATTERIES AND ELECTROLYTE ECA13640
8-146
ELECTRICAL COMPONENTS
Starter relay
1 2
3
R R
L/W R/W
1 2
4
6. Check:
• Battery terminal 1. Positive battery terminal
Dirt Clean with a wire brush. 2. Negative battery terminal
Loose connection Connect properly. 3. Positive tester probe
7. Lubricate: 4. Negative tester probe
• Battery terminals
Relay operation
Recommended lubricant Continuity
Dielectric grease (between “3” and “4”)
8. Install:
Relay unit (starting circuit cut-off relay)
• Rider seat bracket 1
• Rider seat
• Passenger seat
Refer to “GENERAL CHASSIS (1)” on
page 4-1.
EAS30553
8-147
ELECTRICAL COMPONENTS
Result
Continuity
R/W L/W R/B W/L R/L
L/W L/Y R/W L/G B/R Sb B/Y Sb/W
(between “3” and “4”)
EAS30794
Result
Continuity
(between “3” and “4”)
L
b. Turn the main switch to “ON”.
G/Y
c. Measure the turn signal/hazard relay input
voltage.
2. Check:
• Turn signal/hazard relay output voltage
Out of specification Replace.
8-148
ELECTRICAL COMPONENTS
8-149
ELECTRICAL COMPONENTS
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
8-150
ELECTRICAL COMPONENTS
1 Gy B 2
e. Crank the engine by pushing the “ ” side of CHECKING THE LEAN ANGLE SENSOR
the start/engine stop switch and gradually 1. Remove:
increase the spark gap until a misfire oc- • Lean angle sensor
curs. (from the battery box.)
2. Check:
EAS30560
• Lean angle sensor output voltage
CHECKING THE CRANKSHAFT POSITION
Out of specification Replace.
SENSOR
1. Disconnect:
Operating angle
• Crankshaft position sensor coupler 65
(from the wire harness) Output voltage up to operating
2. Check: angle
• Crankshaft position sensor resistance 0.4–1.4 V
Out of specification Replace the crank- Output voltage over operating
shaft position sensor. angle
3.7–4.4 V
Crankshaft position sensor re-
sistance a. Connect the test harness– lean angle sen-
228–342 sor (6P) “1” to the lean angle sensor and
wire harness as shown.
a. Connect the digital circuit tester to the b. Connect the digital circuit tester to the test
crankshaft position sensor coupler as harness– lean angle sensor (6P).
shown.
Digital circuit tester (CD732)
Digital circuit tester (CD732) 90890-03243
90890-03243 Model 88 Multimeter with ta-
Model 88 Multimeter with ta- chometer
chometer YU-A1927
YU-A1927 Test harness– lean angle sensor
(6P)
• Positive tester probe 90890-03209
Gray “1” Test harness– lean angle sensor
• Negative tester probe (6P)
Black “2” YU-03209
8-151
ELECTRICAL COMPONENTS
EAS30566
8-152
ELECTRICAL COMPONENTS
EAS30680
1 2
8-153
ELECTRICAL COMPONENTS
EAS30938 EAS30578
3
1
L B
2
1 2
d. Heat the coolant or let it cool down to the
specified temperatures.
c. Measure the radiator fan motor movement. e. Measure the coolant temperature sensor
resistance.
3. Install:
• Coolant temperature sensor
8-154
ELECTRICAL COMPONENTS
TIP
Coolant temperature sensor When installing the throttle position sensor, ad-
16 N·m (1.6 kgf·m, 12 lb·ft) just its angle properly. Refer to “ADJUSTING
T.
R.
EAS30581
THE THROTTLE POSITION SENSOR” on
CHECKING THE THROTTLE POSITION page 7-14.
SENSOR
1. Remove: EAS30594
3
1
b. Check the throttle position sensor maxi-
mum resistance.
3. Install: 2
• Throttle position sensor
8-155
ELECTRICAL COMPONENTS
5 7 3 1
f e
g O Y/W W Sb
d
Gy W/R P
b
c
a 4 6 2
8-156
ELECTRICAL COMPONENTS
EAS30681
Resistance
12.0 @20 C (12.0 @68 F)
1 2
8-157
APPENDIX
9
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20311
9-1
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-2
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-3
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-6
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-7
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
9-8
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS32425
9-9
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
Item Tool display Procedure
code No.
08 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
09 Fuel system voltage Approximately 12.0 Set the start/engine stop
(battery voltage) switch to “ ”, and then
compare the actually mea-
sured battery voltage with
the tool display value. (If
the actually measured bat-
tery voltage is low, re-
charge the battery.)
20 Sidestand switch Extend and retract the
sidestand (with the trans-
mission in gear).
• Stand retracted ON
• Stand extended OFF
21 Gear position switch and Operate the transmission,
clutch switch clutch lever, and side-
stand.
• Transmission is in neu- ON
tral
• Transmission is in gear OFF
or the clutch lever re-
leased
• Clutch lever is squeezed ON
with the transmission in
gear and when the side-
stand is retracted
• Clutch lever is squeezed OFF
with the transmission in
gear and when the side-
stand is extended
9-10
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
Item Tool display Procedure
code No.
60 EEPROM fault code dis-
play
• No history 00 —
• No malfunctions detect-
ed (If the self-diagnosis
fault code P062F is indi-
cated, the ECU is defec-
tive.)
• History exists 01–02 (CO adjustment —
Display the EEPROM value)
writing error for fault • (If more than one cylin-
code No. P062F. der is defective, the dis-
If more than one item is play alternates every two
defective, the displays seconds to show all the
alternates every two sec- detected cylinder num-
onds to show all the de- bers.
tected numbers. When all cylinder num-
bers are shown, the dis-
play repeats the same
process.)
11 (Data error for ISC (idle
speed control) learning
values)
12 (O2 feedback learning
value)
13 (OBD memory value)
67 ISC (idle speed control) 00 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. stop switch from “ ” to
01 “ ” 3 times in 5 seconds.
It is not necessary to erase
the ISC (idle speed con-
trol) learning data.
02
It is necessary to erase the
ISC (idle speed control)
learning data.
70 Control number 0–254 [-] —
87 O2 feedback learning data 00 To erase the O2 feedback
erasure O2 feedback learning data learning data, set the en-
has been erased. gine stop switch from “ ”
01 to “ ” 3 times in 5 sec-
O2 feedback learning data onds.
has not been erased.
9-11
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS32426
9-12
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
Item Actuation Procedure
code No.
52 Headlight relay Actuates the headlight re- Check that the headlight
lay five times at five-sec- relay is actuated five times
ond intervals. by listening for the operat-
The “check” indicator on ing sound.
the Yamaha diagnostic
tool screen come on each
time the relay is actuated.
54 ISC valve Fully closes the ISC valve, Check that the ISC unit is
and then opens the valve. actuated three times by
This operation is per- listening for the operating
formed 3 times and takes sound.
approximately 6 seconds
each time. The “check” in-
dicator on the Yamaha di-
agnostic tool screen come
on during the operation.
9-13
EVENT CODE TABLE
EAS20316
9-14
EVENT CODE TABLE
9-15
EVENT CODE TABLE
9-16
EAS20091
54. Oil pressure warning light EAS30613
A C
(B) (B)
R A R L/W
L/W
L/W
R/W R/W
R/W R/W
Y Y Y L/R
L/R L/R
B/L B/L B/L B/L B/L B/L B/L B/L B/L B/L
W
B B
L
R/B
30
A C B/L B/L B/L B/L
(B)
B L L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R Gy/R G/Y O O
(Y)
R
R
R/B B/L
R/W Gy/G
W/G Br/L Y/G Br/W L/W G/B B/Y R/B 32
R R R R R/B P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
R R C R/W P/B
R R R/B Gy/G B/L
B/L
W W W
18 Br Y L/R Y (B)
(B) Gy/R R/B
1 R/W
R/W R R R
21 (B)
R/B
R/W (B)
Br/L Br/L 13 15 L/W R/W R/W
(B)
Y/L
R/B
ON
OFF (B) 19 L/W
Y Br Y L/R
P/B R/B
31
P W W W O
Gy/G
Br/R Br/R B Gy/R Gy/R
L/W
16 B
B
B/L 32
Br/L Br/R 14 R
B B/G
29 B/L
W W C W W
B R B/G 27 Gy
B
B
L/W L/W
R/B
Sb/W R/W L
33
(B) B
B R/B R/B B R/B R/B R/L
22 Gy B
R R/W
20 23 24 R/W L/W R/B W/L R/L B/L W L R/L R/B
L/W L/Y R/W L/G B/R Sb B/Y Sb/W Gy L
2 Gy B/L (B) (Gy)
R/L
R/W B/Y Sb B/R L/G L/Y
C
34
L
3 W/L R/L L/Y
G/B G/B B G/B G/B R/L
11 Sb
Y/B
R Br/W
Ch Br/W Dg B
B
52 G G G
40 G/Y
12 L/R Sb L Y/G B/L L
Y/G Y/G B
62 R/W B/L
67 Br/W Sb
R/G R/L B/W
L/R Br/W Br/W Br/W P W W B W W G G G
L/R
W P P B P P
B/R Y G/L Br/W Dg Gy Y/W Y/W B Y/W Y/W L/B
68 B/R B/Y G/L Ch L/R G B/Y P Br/W L/R O W/R W/R B W/R W/R 53 W/Y
W/R O O B O O
R/L
Y/W Gy Gy B Gy Gy
R/Y R/Y R R/W B/Y B/R L/B
Dg Br/W L/B Y B/Y
Br R/L
G/W
B/W B/R G Br Ch R/L R/L R/L B R/L
86 85 69 70 71 73 O Y/W W Sb
G/R
R/L
R/L B R/L
B/R 72 Gy W/R P
Sb P Gy W/R
W O Y/W
54 L/R
G/R
B/Y (B) (B) L/R L/R L/R L/R
B/W
(B)
25
G/L Y/B R/Y L G/Y R Y G Ch Dg P
55 G/R L/B L/B L/B L/B
L/R L/R Br/W
L L/B R/L
G/L (B)
R/Y Y/B R/W G/Y Ch Ch
P
56 R/L G/W
L/R R/W G
Ch Ch
Dg 61 47 25 W/Y
Ch
Dg Dg
B
46 45 L/B L/B L/B
L/R
Y Dg Dg 57
L
Y L/R
Y Y L/B
G
43
82 L/R 78 L/R L/R G Y 77 76 75 Dg Dg 74 58 G
84 Ch Ch W R
L 81 79 L
Ch B B G/R
W W Gy
L L Ch Ch Dg Dg 59 R/L B G/W B Y R R W 41 W Gy
L L L 80 B
(Gy)
B B B Dg B/W
(B) B/G B B Gy
L B
83
B B B (Gy) (B) (B)
60 B W W 42 W Gy
(B) B B B B G/R
Ch Ch Dg Dg B/L B/L
L/R B L/R L/R B B B G B W
B
B L B
B B Y B
B B B B
G/R G/W L/R L/B Sb/W Y Dg Ch G/R
25
(B) (Gy) (Gy) B (B) (B) Gy O W/R Y/W P W R/W R/G G/B B/W
(Gy)
B B B/G
B (Gy)
(B) L Y B
B/G
B B B/G L/R L/B R/W
B B B B/GB/WB/W R/W W R B W G G/R W/Y B
B B B
B
R/W B
44 L/B R/L Y G G Br/W L/R L/B B/L B/G
Y L/R B/W B B B B B B B B/G 25 B/G B B B/W B/W B/G
B/W B/W B/W
L/R
B/W B B
B B/W B/W (Y) (B)
B/W
B/W R/Y
R/Y
87 B/W
MTN660-AJ/MTN690-A/MTN690-AJ 2018 MTN660-AJ/MTN690-A/MTN690-AJ 2018 MTN660-AJ/MTN690-A/MTN690-AJ 2018 MTN660-AJ/MTN690-A/MTN690-AJ 2018 MTN660-AJ/MTN690-A/MTN690-AJ 2018
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
A C
17
(B) (B)
A B A D
B
25 25
28 (B)
(B) (B)
A
30
A C (B)
(Y)
32
C
18 (B)
(B)
1 21 (B) (B)
13 15 (B)
ON
OFF (B) 19 31
P
16
32
14 29 C
27
33
(B)
B
22
20 23 24
2 (B) (Gy)
C
34
3 B
25 25
4
26 (Gy)
(B)
5 (B)
(B)
36 C 35
6 C
C
37 (B)
C
7 48 49
8
63 50 38 (B)
(B)
9 (L) B B
65 66 51 39
10 64 (B)
51
11
B
52 40
12
62
67
B
B
B
68 B 53
B
B
86 85 69 70 71 73 B
72 54
(B) (B)
(B)
25
55
(B)
56
61 47 25
46 45
57
43
82 78 77 76 75 74 58
84
81 79 59 41
80 (Gy)
(B)
83
(Gy) (B) (B)
60 42
(B)
25
(B) (Gy) (Gy) (B) (B)
(Gy)
(Gy)
(B)
44
25
(Y) (B)
87
MTN690-U 2018 MTN690-U 2018 MTN690-U 2018 MTN690-U 2018 MTN690-U 2018
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
A C
(B) (B)
R A R L/W
L/W
L/W
R/W R/W
R/W R/W
Y Y Y L/R
L/R L/R
B/L B/L B/L B/L B/L B/L B/L B/L B/L B/L
W
B B
L
R/B
30
A C B/L B/L B/L B/L
(B)
B L L/R L/B Y/L Gy B/L W L P/W R/W L/Y B/R O G/Y Gy/R O
(Y)
R
R
R/B B/L
R/W Gy/G
W/G Br/L Y/G Br/W L/W G/B B/Y R/B 32
R R R R R/B P/L R/G G/W Gy/G W/Y R/L R/B P/B B/W Y/B B
R R C R/W P/B
R R R/B Gy/G B/L
B/L
W W W
18 Br Y L/R Y (B)
(B) Gy/R R/B
1 R/W
R/W R R R
21 (B)
R/B
R/W (B)
Br/L Br/L 13 15 L/W R/W R/W
(B)
Y/L
R/B
ON
OFF (B) 19 L/W
Y Br Y L/R
P/B R/B
31
P W W W O
Gy/G
Br/R Br/R B Gy/R Gy/R
L/W
16 B
B
B/L 32
Br/L Br/R 14 R
B B/G
29 B/L
W W C W W
B R B/G 27 Gy
B
B
L/W L/W
R/B
Sb/W R/W L
33
(B) B
B R/B R/B B R/B R/B R/L
22 Gy B
R R/W
20 23 24 R/W L/W R/B W/L R/L B/L W L R/L R/B
L/W L/Y R/W L/G B/R Sb B/Y Sb/W Gy L
2 Gy B/L (B) (Gy)
R/L
R/W B/Y Sb B/R L/G L/Y
C
34
L
3 W/L R/L L/Y
G/B G/B B G/B G/B R/L
11 Sb
Y/B
R Br/W
Ch Br/W Dg B
B
52 G G G
40 G/Y
12 L/R Sb L Y/G B/L L
Y/G Y/G B
62 R/W B/L
67 Br/W Sb
R/G R/L B/W
L/R Br/W Br/W Br/W P W W B W W G G G
L/R
W P P B P P
B/R Y G/L Br/W Dg Gy Y/W Y/W B Y/W Y/W L/B
68 B/R B/Y G/L Ch L/R G B/Y P Br/W L/R O W/R W/R B W/R W/R 53 W/Y
W/R O O B O O
R/L
Y/W Gy Gy B Gy Gy
R/Y R/Y R R/W B/Y B/R L/B
Dg Br/W L/B Y B/Y
Br R/L
G/W
B/W B/R G Br Ch R/L R/L R/L B R/L
86 85 69 70 71 73 O Y/W W Sb
G/R
R/L
R/L B R/L
B/R 72 Gy W/R P
Sb P Gy W/R
W O Y/W
54 L/R
G/R
B/Y (B) (B) L/R L/R L/R L/R
B/W
(B)
25
G/L Y/B R/Y L G/Y R Y G Ch Dg P
55 G/R L/B L/B L/B L/B
L/R L/R Br/W
L L/B R/L
G/L (B)
R/Y Y/B R/W G/Y Ch Ch
P
56 R/L G/W
L/R R/W G
Ch Ch
Dg 61 47 25 W/Y
Ch
Dg Dg
B
46 45 L/B L/B L/B
L/R
Y Dg Dg 57
L
Y L/R
Y Y L/B
G
43
82 L/R 78 L/R L/R G Y 77 76 75 Dg Dg 74 58 G
84 Ch Ch W R
L 81 79 L
Ch B B G/R
W W Gy
L L Ch Ch Dg Dg 59 R/L B G/W B Y R R W 41 W Gy
L L L 80 B
(Gy)
B B B Dg B/W
(B) B/G B B Gy
L B
83
B B B (Gy) (B) (B)
60 B W W 42 W Gy
(B) B B B B G/R
Ch Ch Dg Dg B/L B/L
L/R B L/R L/R B B B G B W
B
B L B
B B Y B
B B B B
G/R G/W L/R L/B Sb/W Y Dg Ch G/R
25
(B) (Gy) (Gy) B (B) (B) Gy O W/R Y/W P W R/W R/G G/B B/W
(Gy)
B B B/G
B (Gy)
(B) L Y B
B/G
B B B/G L/R L/B R/W
B B B B/GB/WB/W R/W W R B W G G/R W/Y B
B B B
B
R/W B
44 L/B R/L Y G G Br/W L/R L/B B/L B/G
Y L/R B/W B B B B B B B B/G 25 B/G B B B/W B/W B/G
B/W B/W B/W
L/R
B/W B B
B B/W B/W (Y) (B)
B/W
B/W R/Y
R/Y
87 B/W
MTN690-U 2018 MTN690-U 2018 MTN690-U 2018 MTN690-U 2018 MTN690-U 2018
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
A C
17
(B) (B)
A B A D
B
25 25
28 (B)
(B) (B)
A
30
A C (B)
(Y)
32
C
18 (B)
(B)
1 21 (B) (B)
13 15 (B)
ON
OFF (B) 19 31
P
16
32
14 29 C
27
33
(B)
B
22
20 23 24
2 (B) (Gy)
C
34
3 B
25 25
4
26 (Gy)
(B)
5 (B)
(B)
36 C 35
6 C
C
37 (B)
C
7 48 49
8
63 50 38 (B)
(B)
9 (L) B B
65 66 51 39
10 64 (B)
51
11
B
52 40
12
62
67
B
B
B
68 B 53
B
B
86 85 69 70 71 73 B
72 54
(B) (B)
(B)
25
55
(B)
56
61 47 25
46 45
57
43
82 78 77 76 75 74 58
84
81 79 59 41
80 (Gy)
(B)
83
(Gy) (B) (B)
60 42
(B)
25
(B) (Gy) (Gy) (B) (B)
(Gy)
(Gy)
(B)
44
25
(Y) (B)
87