Tracer 9gt - Taller

2021
SERVICE MANUAL
Tracer 9
Tracer 9 GT
MTT890
MTT890D
B5U-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
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result

WARNING in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
EAS20002
MTT890/MTT890D
SERVICE MANUAL
©2021 by Yamaha Motor Co., Ltd.
First edition, February 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1
2
4
5
6 7
G088877
EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
Tightening torque LS Lithium-soap-based grease

T.
R.
Wear limit, clearance M Molybdenum disulfide grease
Engine speed S Silicone grease
Electrical data Apply locking agent (LOCTITE®).

LT
Engine oil New Replace the part with a new one.

E
EAS10003
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
SELF DIAGNOSTIC 9
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
GLOSSARY............................................................................................... 1-2
DISPLAYS .................................................................................................1-2
SETTINGS MENU .....................................................................................1-8
BASIC SERVICE INFORMATION.................................................................1-12

ELECTRICAL SYSTEM...........................................................................1-12
SPECIAL TOOLS .......................................................................................... 1-13

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the seat. This information will be needed to order
spare parts.
1-1
FEATURES
EAS20008
MTT890D
FEATURES
EAS31706
GLOSSARY
ABS - Anti-lock Brake System 3
ABS ECU - Anti-lock Brake System Electronic 2
Control Unit 4
BC - Brake Control 1
ECU - Engine Control Unit
LIF - Lift Control System 5
QS - Quick Shift
SCS - Slide Control System
TCS - Traction Control System 11 10 9 8 7 6
SCU - Suspension Control Unit
LAP 02 0 0 : 1 2 . 3 4
EAS31707 12
LATEST 00:01.23
DISPLAYS
This vehicle is equipped with two display
screens: a main display and a sub-display 17 16 15 14 13
The following items can be found on the dis-
plays:
MTT890
1. Speedometer
2. Tachometer
3. Quick shift Indicator “QS” (for MTT890D)
4. Transmission gear display
3 5. Vehicle information displays
2
4 6. Settings menu icon “ ”
1 7. Grip warmer indicator (for MTT890D)
8. Seat heater indicator (for MTT890D)
5 9. Brake control icon “BC”
10. Clock
11. MODE display
11 10 9 8 7 6 12. Lap timer
13. Oil pressure warning “ ”
LAP 02 0 0 : 1 2 . 3 4
12 14. Coolant temperature warning “ ”
LATEST 00:01.23
15. Auxiliary system warning “ ”
16. SCU trouble warning “ ” (for MTT890D)
17 15 14 13 17. Error mode warning “Err” (replaces clock when
activated)
1-2
FEATURES
1 1
1. Vehicle information displays 1. Vehicle information displays
TIP The six vehicle information displays can be indi-

• This model uses thin-film-transistor liquid-crys- vidually set to show the following items:
tal displays (TFT LCD) for good contrast and • ODO: odometer
readability in various lighting conditions. How- • F-TRIP: fuel reserve tripmeter (main display
ever, due to the nature of this technology, it is (upper) only)
normal for a small number of pixels to be inac- • TRIP1: tripmeter
tive. • TRIP2: tripmeter
• The display units can be switched between ki- • F.AVE: average fuel economy
lometers/miles and celsius/fahrenheit. • F.CRNT: instantaneous fuel economy
• A.TEMP: air temperature
EWA18210
• C.TEMP: coolant temperature
WARNING
• Fuel meter
Stop the vehicle before making any setting • FUEL CON: amount of fuel consumed
changes. Changing settings while riding can • TRIP TIME: running time
distract the operator and increase the risk of • : cruise control speed setting
an accident. Operate the vehicle information displays as fol-
Speedometer lows:
The speedometer shows the vehicle’s traveling Rotate the wheel switch to move the cursor over
speed. an information display.
Tachometer Push the wheel switch inward and the selected
The tachometer shows the engine speed, as display will highlight gray.
measured by the rotational velocity of the crank- Rotate the wheel switch to choose a different
shaft, in revolutions per minute (r/min). display item.
ECA19660
Push the wheel switch inward to confirm the new
NOTICE display item.
Do not operate the engine in the tachometer TIP
red zone. • In LAP TIME mode, the two vehicle information
Vehicle information displays displays on the main display screen are re-
placed by lap information.
• TRIP1, TRIP2, F-TRIP, F.AVE, FUEL CON
and TRIP TIME items can be individually reset.
1. Vehicle information displays
1-3
FEATURES
Odometer: Average fuel economy:
The odometer shows the total distance traveled The average fuel economy display can be set to
by the vehicle. “km/L” or “L/100km”.
TIP TIP
ODO will lock at 999999 and cannot be reset. After resetting the average fuel economy dis-
play, “--.-” will be shown until the vehicle has
Fuel reserve tripmeter:
traveled 1 km.
Instantaneous fuel economy:
When the fuel tank reserve level has been

reached, F-TRIP appears automatically and be-
gins recording distance traveled from that point. The instant fuel economy display can be set to
After refueling and traveling some distance, F- “km/L” or “L/100km”.
TRIP will automatically disappear. TIP
Tripmeters: If traveling at speeds under 10 km/h, “--.-” will be
displayed.
Air temperature:
TRIP1 and TRIP2 show the distance traveled

since they were last set to zero.
TIP
The air temperature is displayed from –9 °C (16
TRIP1 and TRIP2 will reset to 0 and begin
°F) to 50 °C (122 °F) in 1 °C (1 °F) increments.
counting again after 9999.9 has been reached.
The temperature displayed may vary from the
actual ambient temperature.
TIP
• “--” will be displayed if the detected tempera-
ture is lower.
1-4
FEATURES
• “--” will be displayed if the detected tempera- TIP

ture is higher. The instantaneous fuel consumption function
Coolant temperature: should be used for general reference only. Do
not use this figure to estimate the distance that
can be traveled on the current tank of fuel.
Trip time:
The coolant temperature is displayed from 40 °C

(104 °F) to 124 °C (255 °F) in 1 °C (1 °F) incre-
ments.
TIP Displays engine running time.
• If the vehicle coolant temperature is below 40 Cruise control speed setting:
°C (104 °F) the coolant temperature display will
read “Lo”
• If the vehicle coolant temperature is above 124
°C (255 °F) the coolant temperature display will
read “Hi”
Fuel Meter:
Displays the selected speed setting for the

cruise control system.
To reset information display items (if able):
1. Rotate the wheel switch to highlight one of
the six vehicle information displays.
2. Press the wheel switch inward to select the
information display.
The fuel meter indicates the amount of fuel in the
3. Rotate the wheel switch to select the desired
fuel tank. The display segments of the fuel meter
information display item.
disappear from “F” (full) towards “E” (empty) as
4. Press and hold the wheel switch inward until
the fuel level decreases. When the last segment
the display item is reset.
starts flashing, refuel as soon as possible.
Transmission gear display
Fuel consumption trip meter:
This shows which gear the transmission is in.
This model has 6 gears and a neutral position.
The neutral position is indicated by the neutral
indicator light “ ” and by the transmission gear
display “ ”.
Displays how much fuel has been consumed

since the trip meter was last reset.
1-5
FEATURES
MODE display (for MTT890D) MODE display (for MTT890)
This display shows the currently selected “D-

MODE” and “TCS-MODE” settings. The mode
that is enlarged and displayed on the right can
be adjusted using the MODE up/down switches.
This display shows the currently selected “D- Use the “MODE” switch to toggle left-right be-
MODE”, “SUS-MODE” and “TCS-MODE” set- tween “TCS-MODE” and “D-MODE”.
tings. The mode that is enlarged and displayed TIP
on the right can be adjusted using the MODE up/ • When the malfunction indicator light “ ”, the
down switches. Use the “MODE” switch to rotate
auxiliary system warning “ ”, or the coolant
counterclockwise between “TCS-MODE”, “SUS-
MODE” and “D-MODE”. temperature warning “ ” are on, “D-MODE”,
and “TCS-MODE” cannot be adjusted.
TIP
• The previously selected modes will be dis-
• When the malfunction indicator light “ ”, the played when the vehicle power is turned on.
auxiliary system warning “ ”, or the coolant To turn off the traction control system, select
temperature warning “ ” are on, “D-MODE”, “TCS-MODE” with the “MODE” switch, then
“SUS-MODE” and “TCS-MODE” cannot be ad- push and hold the MODE up switch until “OFF”
justed. is displayed. To turn TCS back on, press the
• When the SCU trouble warning “ ” is on, MODE down switch (“TCS-MODE” will return to
“SUS-MODE” cannot be adjusted. its previous setting).
• The previously selected modes will be dis- TIP
played when the vehicle power is turned on.
• When “TCS-MODE” has been set to “OFF”,
To turn off the traction control system, select the TCS, SCS and LIF systems are all turned
“TCS-MODE” with the “MODE” switch, then off together.
push and hold the MODE up switch until “OFF” • The “TCS-MODE OFF” and “TCS-MODE M”
is displayed. To turn TCS back on, press the settings can only be selected while the vehicle
MODE down switch (“TCS-MODE” will return to is stopped.
its previous setting).
Clock
TIP The clock uses a 12-hour time system.
• When “TCS-MODE” has been set to “OFF”, Quick shift indicator “QS” (for MTT890D)
the TCS, SCS and LIF systems are all turned When able to shift, the respective QS or
off together. turns green.
• The “TCS-MODE OFF” and “TCS-MODE M” When unable to shift, QS is white.
settings can only be selected while the vehicle If the QS function is turned OFF, QS itself
is stopped. is not displayed.
The QS functions can be turned on or off in the
setting MENU.
TIP
The upshift and downshift functions are inde-
pendent and can be activated separately.
1-6
FEATURES
For more information on the QS system. The function of the wheel switch can be locked
into grip warmer/seat heater mode by pressing
Setting menu icon “ ” and holding the wheel switch inward while the
Choose this icon and push the wheel switch to grip warmer indicator or the seat heater indicator
access the settings MENU. is highlighted by the cursor.
Grip warmer indicator (for MTT890D) In this mode, the temperature levels can be in-
The grip warmers can be used when the engine stantly adjusted by rotating the wheel switch up/
is running. There are 10 temperature levels. down.
When activated, the indicator will display the While in this mode, press the wheel switch in-
temperature level from 1 (lowest) to 10 (highest). ward to toggle between the grip warmer and
To activate the grip warmer, use the wheel seat heater functions.
switch to highlight the grip warmer display with To exit this mode and return the wheel switch to
the cursor. its normal functionality, press and hold the wheel
Press the wheel switch inward to select the grip switch inward.
warmer function. TIP
Once selected, rotate the wheel switch up and
The current grip warmer/seat heater settings are
down to adjust the temperature level.
saved when the vehicle is turned off.
Press the wheel switch inward to confirm the
temperature level and exit the grip warmer func- Lap timer
tion. This stopwatch function can be activated
ECA17932
through the settings MENU.
NOTICE
Once activated, the two vehicle information dis-
• Be sure to wear gloves when using the grip plays on the main display screen are replaced
warmers. with:
• Do not use the grip warmers in warm
weather.
• If the handlebar grip or throttle grip be-
comes worn or damaged, stop using the
grip warmers and replace the grips.
Seat heater indicator (for MTT890D)
The seat heater can be used when the engine is 1 LAP 02 00:12.34 2
running. There are 10 temperature levels. When
LATEST 00:30.23 3
activated, the indicator will display the tempera-
ture level from 1 (lowest) to 10 (highest).
To activate the seat heater, use the wheel switch 1. Lap count
to highlight the seat heater display with the cur- 2. Current lap time
sor. 3. Latest/Previous lap time
Press the wheel switch inward to select the seat To start the timer, push the dimmer/pass switch
heater function. down towards “PASS”.
Once selected, rotate the wheel switch up and Each push of the dimmer/pass switch will in-
down to adjust the temperature level. crease the lap count by 1 and reset the current
Press the wheel switch inward to confirm the lap timer.
temperature level and exit the seat heater func- To pause the lap timer, press the wheel switch
tion. inward.
ECA25721
NOTICE To unpause the timer, push the dimmer/pass

switch down towards “PASS” and the timer will
• Be sure to wear protective clothing that
resume without counting a new lap.
covers your hip and legs when using the
To exit the lap time mode, turn it off in the set-
seat heater.
tings MENU.
• Do not use the seat heater in warm weather.
• If the seat becomes worn or damaged, stop TIP
using the seat heater and replace the seat. • The engine must be running to start the lap tim-
er.
1-7
FEATURES
• The headlight will flash when the dimmer/pass ECA26410
switch is pressed. NOTICE

• Whenever the lap timer is paused, it can be re- Do not continue to operate the engine if the
sumed using the dimmer/pass switch. oil pressure is low.
Brake control icon “BC” EAS33582
This icon is replaced by the auxiliary system SETTINGS MENU
warning and coolant temperature warning indi-
cators when they are activated. MENU
Error mode warning “Err” Exit
When an internal error occurs (e.g., communica-
Display Setting
tion with a system controller has been cut off),
Manual TCS Setting
the error mode warning will appear as follows.
Vehicle Setting
“Err” and “ ” indicator light indicates an ECU
Shift Indicator
error.
“Err” and the SCU trouble warning “ ” indicates km/h
a SCU error (for MTT890D).

“Err” only indicates an ABS ECU error. The settings MENU screen contains the follow-
TIP ing settings modules. Select a module to make
related settings changes.
Depending on the nature of the error, the display
may not function properly and the TCS settings Module Description
may be impossible to change. Additionally, the Exit MENU and return
ABS may not function properly. Use extra care “Exit”
the main display
when braking and check the vehicle immediate- Switch lap time mode
ly. “Display Setting” on/off and adjust the
tachometer color
SCU trouble warning “ ” (for MTT890D)
This icon appears if a problem is detected in the Adjust TCS/SCS/LIF
“Manual TCS Setting” settings for the “TCS-
front or rear suspension.
MODE M”
Auxiliary system warning “ ”
“Vehicle Setting” Adjust BC/QS settings
This icon appears if a problem is detected in a
non-engine-related system. Turn the shift indicator
“Shift Indicator” on/off and adjust ta-
Coolant temperature warning “ ” chometer settings
This icon appears if the coolant temperature View and reset mainte-
reaches 116 °C (241 °F) or higher. Stop the ve- “Maintenance”
nance intervals
hicle and turn off the engine. Allow the engine to Set fuel consumption
cool. “Unit” and measurement
ECA10022
units
NOTICE
Adjust screen bright-
Do not continue to operate the engine if it is “Brightness”
ness
overheating.
“Clock” Adjust the clock
Oil pressure warning “ ” “SUS. Sensor Calibra- Perform a sensor cali-
This icon appears when the engine oil pressure tion” (for MTT890D) bration
is low. When the vehicle is first turned on, engine Return all settings to
“All Reset”
oil pressure has yet to build, so this icon will factory default
come on and stay on until the engine has been
started. Settings MENU access and operation
How to use the settings MENU:
TIP
Rotate the wheel switch up or down to highlight
If a malfunction is detected, the oil pressure items or increase/decrease values and briefly
warning icon will flash repeatedly. press the wheel switch inward to confirm the se-
lection.
1-8
FEATURES
Press and hold the wheel switch until the screen TCS
returns to the main display to exit the MENU at This model uses a variable traction control sys-
any time. tem. For each setting level, the further the vehi-
TIP cle is leaned over, the greater the amount of
• Certain settings menu screens have an up- traction control (system intervention) is applied.
ward pointing triangle mark item. Select the tri- There are 3 setting levels available for the “TCS-
angle mark to save settings changes and exit MODE M”.
the current screen. Setting level 1 applies the least amount of over-
• Should vehicle motion be detected, the screen all system intervention, while setting level 3 ap-
will automatically exit the settings MENU and plies the greatest amount of overall traction
return to the main display. control.
• To ensure that the desired settings changes TIP
are saved, be sure to exit each menu via the tri- • TCS can only be turned on or off via the main
angle mark (if displayed). Exiting the settings screen using the MODE switches.
menu by pressing and holding the wheel • SCS and LIF can be turned off independently
switch may not save settings changes. of TCS for “TCSMODE M”.
• When “TCS-MODE” has been set to “OFF” on
“Display Setting”
the main display: TCS, SCS and LIF are all
turned off together.
Display Setting
SCS
Lap Time OFF SCS can be set to OFF, 1, 2, and 3.
OFF turns the slide control system off, setting
Tacho Color OFF
level 1 provides the least amount of system in-
tervention, and setting level 3 provides the
greatest amount of system intervention.
km/h
LIF
LIF can be set to OFF, 1, 2, and 3.
This module allows you to switch the lap time Setting level 1 provides the least amount of sys-
mode and tachometer color mode ON/OFF. tem intervention and setting 3 most strongly re-
When the lap time mode is ON, the twin vehicle duces the rate of wheel lift.
information displays on the main display screen OFF turns LIF off.
will show a lap timer and a lap counter. To exit “Vehicle Setting”
the lap time mode, the turn lap timer OFF in the
Display Setting module.
Vehicle Setting
To change the tachometer to color mode, select
BC Setting
ON.
“Manual TCS Setting” QS Setting
Manual TCS Setting
TCS 1 km/h
SCS 1
LIF 1 The vehicle setting module allows you to adjust

setting for the BC and QS systems.
km/h
This module allows you to customize the “TCS-

MODE M” which is accessible on the main dis-
play using the MODE switches.
1-9
FEATURES
BC “Shift Indicator”
BC Setting Shift Indicator
BC 2
IND Mode ON
IND Start 8000 r/min
IND Stop 10000 r/min
km/h km/h
The brake control system has two settings, BC1 This module allows a custom shift indicator to be
and BC2. Select BC1 when only standard ABS set. When the engine r/min (rotations per min-
is desired. Select BC2 to have the brake control ute) are in the specified range, the gear indicator
system further regulate brake pressure while will flash.
cornering to suppress lateral wheel slip. This module has 3 options:
TIP “IND Mode” - the shift indicator can be turned
For skilled riders and when riding at the track, ON/OFF
due to varying conditions, the BC2 brake system “IND Start” - the r/min at which the indicator
may engage sooner than expected relative to starts flashing can be chosen.
your desired cornering speed or intended cor- Once selected, rotate the wheel switch up/down
nering line. to increase or decrease the r/min value by incre-
ments of 200 r/min.
QS “IND Start” is settable between 6000–12800 r/
min.
QS Setting “IND Stop” - the r/min at which the indicator
stops flashing can be chosen.
QS ON Once selected, rotate the wheel switch up/down
QS ON
to increase or decrease the r/min value by incre-
ments of 200 r/min.
“IND Stop” is settable between 6200–13000 r/
km/h
min.
“Maintenance”
The quick shift system indicators are divided into

Maintenance
QS and QS sections.
QS and QS are not linked and can be inde- OIL 1000 km
pendently turned on or off. INTERVAL 1 1000 km
QS can be set to ON or OFF. INTERVAL 2 1000 km

OFF turns the respective upshift or downshift
function off, and the clutch lever must then be
used when shifting in that direction. km/h
TIP
• If the QSS setting cannot be changed: turn the This module allows you to record the distance
engine off with the gear position set to neutral, traveled between engine oil changes (use the
then change the setting. OIL item), and for two other items of your choice
• If the QSS is not equipped on the vehicle: this (use INTERVAL 1 and INTERVAL 2).
module is still displayed and can be accessed To reset a maintenance trip meter, select it and
from the settings MENU but it is inoperable and then press and hold the wheel switch.
any changes cannot be saved. TIP
Maintenance item names cannot be changed.
1-10
FEATURES
“Unit” After confirming the minutes, you will be re-

turned to the top MENU screen.
Unit
“SUS. Sensor Calibration” (for MTT890D)
km or mile km
SUS. Sensor Calibration
km/L or L/100km L/100km
°C or °F °C
Result : .....
Execute
km/h
This module allows you to switch the display be- km/h

tween metric and imperial measurement units.
When using kilometers, the fuel consumption After any service to the rear suspension, a sen-
units can be changed between “km/L” or “L/ sor calibration must be performed using this
100km”. When using miles, MPG will be avail- module.
able. Select “Execute” and within approx. 5 seconds
Temperature units can be switched between the result of the calibration (success/failed) will
Celsius and Fahrenheit. be displayed.
“Brightness” TIP
When performing the sensor calibration, place
Brightness the motorcycle on the centerstand and there
should be no weight on the motorcycle.
“All Reset”
1
All Reset
km/h
NO
YES
This module allows you to adjust the general
brightness level of the display screens.
Select the desired brightness level by rotating km/h
the wheel switch, and then press the wheel
switch to fix the setting and return to the top
MENU screen. This module resets all settings items (except the
“Clock” odometers, Clock and SUS. Sensor Calibration
(for MTT890D)) to their default or factory pre-
Clock
sets.
Select YES to reset all items. After selecting
YES, all items will be reset and the screen will
automatically return to the top MENU screen.
10 0 0
km/h
This module allows you to set the clock.

When the clock module is selected, the hours
will be highlighted.
Set the hours by rotating the wheel switch. Push
the switch to confirm and highlight the minutes.
1-11
BASIC SERVICE INFORMATION
EAS20010
BASIC SERVICE INFORMATION

EAS30014
ELECTRICAL SYSTEM
Electrical parts handling

ECA27350
NOTICE
• Do not perform angle adjustment of the IMU
and battery box by pinching the washer
and related parts.
• When installing the IMU, apply a thin coat of
silicone grease onto the washer and collar
where they contact the IMU grommet.
• When installing the IMU, use only a genuine
bolt and washer, and tighten the bolt to the
specified torque.
• Pay attention not to expose the IMU to
strong shocks, such as striking or drop-
ping it.
• Do not place any foreign objects in and
around the battery box.
• Do not obstruct breather opening “a” of the
IMU.
• Do not clean the breather opening and do
not blow it with compressed air.
• When replacing the collar or grommet, re-
place all four collars and grommets.
• Use only the specified genuine YAMAHA
battery. Using a different battery may cause
the IMU to fail and the engine to stall.
1-12
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, 3-11, 3-33,
90890-03267 4-70, 4-72, 7-12,
9-2, 9-37, 9-38
Yamaha diagnostic tool (A/I) 3-4, 3-11, 3-33,

90890-03264 4-70, 4-72, 7-12,
9-2, 9-37, 9-38
Thickness gauge 3-6, 4-32, 4-39,

90890-03268 5-28, 5-52
Feeler gauge set
YU-26900-9
Valve lapper (ø14) 90890-04101

3-7
90890-04101
Valve lapper (ø14)
YM-A8998
YM-A8998
Vacuum gauge 3-9

90890-03094
Vacuummate
YU-44456
YU-44456
1-13
SPECIAL TOOLS
Reference
pages
Carburetor angle driver 2 3-9
90890-03173
Steering nut wrench 3-20, 4-114

90890-01403
Exhaust flange nut wrench
YU-A9472
Oil filter wrench 3-26

90890-01426
Oil filter wrench
YU-38411
Oil pressure gauge joint 18 mm 3-27

90890-04176
YU-04176
ø18
Oil pressure gauge set 3-27

90890-03120
Fork spring compressor 4-90, 4-95

90890-01441
Fork spring compressor
YM-01441
Rod holder 4-90, 4-95

90890-01434
Damper rod holder double ended
YM-01434
Damper rod holder (ø27) 4-91, 4-92,

90890-01423 4-104, 4-106
Damping rod holder
YM-01423
Fork seal driver 4-93, 4-93, 4-93,

90890-01442 4-106, 4-106,
Adjustable fork seal driver (36–46 mm) 4-107
YM-01442
1-14
SPECIAL TOOLS
Reference
pages
Rod puller 4-94, 4-95
90890-01437
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Rod puller attachment (M10 long) 4-94, 4-95

90890-01578 90890-01578
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Front fork hexagonal cap bolt wrench 42mm 4-102, 4-102,

90890-01906 4-110, 4-111
Front fork hexagonal cap bolt wrench 42mm 42
YM-01906
Fork spring compression tool 29mm 4-102, 4-109

90890-01907
Fork spring compression tool 29mm
YM-01907
Damper rod holder 18.5mm 4-102, 4-109,

18.5
90890-01908 4-109
Damper rod holder 18.5mm
YM-01908
Fork solenoid power supply tool (6V) 4-104, 4-108

90890-01909
Fork solenoid power supply tool (6V)
YM-01909
Ring nut wrench 4-114

90890-01268
Spanner wrench
YU-01268
1-15
SPECIAL TOOLS
Reference
pages
Drive chain cut & rivet tool 4-132, 4-134
90890-01550
Drive chain cut & rivet tool
YM-01550
Compression gauge 90890-03081 5-7

90890-03081
Engine compression tester
YU-33223
YU-33223
Compression gauge extension 122mm 5-7

90890-04136
Compression gauge extension 122mm
YM-04136
Pivot shaft wrench 5-14, 5-14, 5-15

90890-01518
Frame spanner socket
YM-01518
Pivot shaft wrench adapter 5-14, 5-14, 5-15

90890-01476
Camshaft wrench 5-20, 5-23

90890-04162
Camshaft wrench
YM-04162
Valve spring compressor 5-32, 5-36

90890-04200
Valve spring compressor
YM-04019
Valve spring compressor attachment (ø23) 5-32, 5-36

90890-04179
Valve spring compressor adapter (ø23)
YM-04179
23
1-16
SPECIAL TOOLS
Reference
pages
Valve guide remover (ø4.5) 5-33
90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø4.5) 5-33

90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide reamer (ø4.5) 5-33

90890-04118
Valve guide reamer (4.5 mm)
YM-04118
Sheave holder 5-40, 5-40, 5-41,

90890-01903 5-41
Primary clutch holder
YS-01880-A
Flywheel puller 5-40

90890-01362
Heavy duty puller
YU-33270-B
Yamaha bond No. 1215 5-42, 5-67

90890-85505
Three bond No. 1215®
Digital circuit tester (CD732) 5-45, 8-42, 8-43,

90890-03243 8-45, 8-46, 8-46,
Model 88 Multimeter with tachometer 8-47, 8-48, 8-48,
YU-A1927 8-49, 8-50, 8-50,
8-51, 8-51, 8-52,
8-52
Clutch holder 5-51, 5-54
90890-04199
Universal clutch holder
YM-91042
1-17
SPECIAL TOOLS
Reference
pages
Piston pin puller set 5-72
90890-01304
Piston pin puller
YU-01304
YU-01304
Connecting rod big end bearing installer 5-74, 5-77

90890-04193 ø8.1 ø9.1
ø7
Connecting rod big end bearing installer
YM-04193
Piston installing tool 5-79

90890-04161
Piston installing tool
YM-04161
Radiator cap tester 6-5, 6-5

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 6-5, 6-5

90890-01352
Pressure tester adapter
YU-33984
YU-33984
1-18
SPECIAL TOOLS
Reference
pages
Mechanical seal installer 6-14
90890-04078
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver 6-14

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Pressure gauge 7-11, 7-11

90890-03153
Pressure gauge
YU-03153
Fuel injector pressure adapter 7-11

90890-03210
Fuel injector pressure adapter
YU-03210
Fuel pressure adapter 7-11

90890-03176
Fuel pressure adapter
YM-03176
Ignition checker 8-46

90890-06754
Oppama pet–4000 spark checker
YM-34487
1-19
SPECIAL TOOLS
TIP
Yamaha diagnostic tool (A/I) 90890-03264
This special tool includes the YDT sub harness (6P) (90890-03266).
TIP
YDT sub harness (6P) 90890-03266
If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-03266)
is separately required.
TIP
Fork solenoid power supply tool (6V) 90890-01909
Four AA batteries are required.
1-20
SPECIAL TOOLS
1-21
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-6
ELECTRICAL SPECIFICATIONS ...................................................................2-9
TIGHTENING TORQUES .............................................................................. 2-11

2
ENGINE TIGHTENING TORQUES......................................................... 2-11
CHASSIS TIGHTENING TORQUES.......................................................2-12
CABLE ROUTING ......................................................................................... 2-13

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model B5U1 (MTT890)
BAP1 (MTT890D)
Dimensions
Overall length 2175 mm (85.6 in)
Overall width 885 mm (34.8 in)
Overall height 1430/1470 mm (56.3/57.9 in)
Wheelbase 1500 mm (59.1 in)
Ground clearance 135 mm (5.31 in)
Minimum turning radius 3.1 m (10.17 ft)
Weight
Curb weight 213 kg (470 lb) (MTT890)
220 kg (485 lb) (MTT890D)
Loading
Maximum load 193 kg (425 lb)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 890 cm³
Cylinder arrangement Inline
Number of cylinders 3-cylinder
Bore × stroke 78.0 × 62.1 mm (3.07 × 2.44 in)
Compression ratio 11.5 : 1
Compression pressure 1365–1758 kPa/600 r/min (13.7–17.6 kgf/cm²/
600 r/min, 194.3–250.1 psi/600 r/min)
Fuel
Recommended fuel Premium unleaded gasoline (E10 acceptable)
Fuel tank capacity 19 L (5.0 US gal, 4.2 Imp.gal)
Fuel reserve amount 3.0 L (0.79 US gal, 0.66 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 2.80 L (2.96 US qt, 2.46 Imp.qt)
With oil filter removal 3.20 L (3.38 US qt, 2.82 Imp.qt)
Quantity (disassembled) 3.50 L (3.70 US qt, 3.08 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Oil pressure 200.0 kPa/5000 r/min (2.00 kgf/cm²/5000 r/min,
29.0 psi/5000 r/min)
Cooling system
Coolant quantity
Radiator (including all routes) 1.72 L (1.82 US qt, 1.51 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.28 L (0.30 US qt, 0.25 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9
psi)
Cooling system leak test pressure 137.3 kPa (1.37 kgf/cm², 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)
Spark plug(s)
Manufacturer/model NGK/LMAR9A-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
2-2
Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Camshaft
Camshaft cap inside diameter 24.500–24.521 mm (0.9646–0.9654 in)
Camshaft journal diameter 24.459–24.472 mm (0.9630–0.9635 in)
Camshaft-journal-to-camshaft-cap clearance
limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height limit (Intake) 35.590 mm (1.4012 in)
Lobe height limit (Exhaust) 35.620 mm (1.4024 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.11–0.20 mm (0.0043–0.0079 in)
Exhaust 0.28–0.32 mm (0.0110–0.0126 in)
Valve dimensions
Valve seat contact width limit (intake) 1.6 mm (0.06 in)
Valve seat contact width limit (exhaust) 1.8 mm (0.07 in)
Valve stem diameter limit (intake) 4.445 mm (0.1750 in)
Valve stem diameter limit (exhaust) 4.430 mm (0.1744 in)
Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Valve-stem-to-valve-guide clearance limit
(intake) 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance limit
(exhaust) 0.100 mm (0.0039 in)
Valve stem runout 0.020 mm (0.0008 in)
Valve spring
Free length limit (intake) 37.34 mm (1.47 in)
Free length limit (exhaust) 35.89 mm (1.41 in)
Cylinder
Bore 78.000–78.010 mm (3.0709–3.0713 in)
Wear limit 78.060 mm (3.0732 in)
Piston
Diameter 77.975–77.990 mm (3.0699–3.0705 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
Piston pin bore inside diameter limit 17.043 mm (0.6710 in)
Piston pin outside diameter limit 16.970 mm (0.6681 in)
Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 1.15 mm (0.0453 in)
Side clearance limit 0.115 mm (0.0045 in)
2-3
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 0.013–0.037 mm (0.0005–0.0015 in)
Bearing color code
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
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 0.023–0.047 mm (0.0009–0.0019 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 5.0–10.0 mm (0.20–0.39 in)
Assembly width 42.7–43.5 mm (1.68–1.71 in)
Friction plate 1 thickness 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 6 pcs
Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in)
Clutch plate 1 thickness 2.18–2.42 mm (0.086–0.095 in)
Clutch plate 2 thickness 1.90–2.10 mm (0.075–0.083 in)
Clutch spring free length limit 42.53 mm (1.67 in)
Drivetrain
Primary reduction ratio 1.681 (79/47)
Transmission type Constant mesh 6-speed
Gear ratio
1st 2.571 (36/14)
2-4
2nd 1.947 (37/19)

3rd 1.619 (34/21)
4th 1.381 (29/21)
5th 1.190 (25/21)
6th 1.037 (28/27)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 2.813 (45/16)
Shifting mechanism
Installed shift rod length 236.4–238.4 mm (9.31–9.39 in)
Air filter
Air filter element Oil-coated paper element
Fuel injector
Resistance 12.0 Ω
Idling condition
Engine idling speed 1200–1400 r/min
O2 feedback control Active
Coolant temperature 90–110 °C (194–230 °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)
2-5
CHASSIS SPECIFICATIONS
EAS20015
Chassis
Caster angle 25.0 °
Trail 108 mm (4.3 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/C × MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.40 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C × MT5.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.40 mm (0.02 in)
Front tire
Type Tubeless
Size 120/70ZR17M/C (58W)
Manufacturer/model BRIDGESTONE/BATTLAX SPORT TOURING
T32F
Rear tire
Type Tubeless
Size 180/55ZR17M/C (73W)
Manufacturer/model BRIDGESTONE/BATTLAX SPORT TOURING
T32R
Tire air pressure (measured on cold tires)

1 person
Front 250 kPa (2.50 kgf/cm², 36 psi)
Rear 290 kPa (2.90 kgf/cm², 42 psi)
2 persons
Front 250 kPa (2.50 kgf/cm², 36 psi)
Rear 290 kPa (2.90 kgf/cm², 42 psi)
Front brake
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 15.87 mm (0.62 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
Rear brake
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
2-6
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
Shock absorber Hydraulic damper
Fork spring free length limit 268.9 mm (10.59 in) (MTT890)
277.6 mm (10.93 in) (MTT890D)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil 01
Quantity (left) 373.0 cm³ (12.61 US oz, 13.16 Imp.oz)
(MTT890D)
493.0 cm³ (16.67 US oz, 17.39 Imp.oz)
(MTT890)
Quantity (right) 362.0 cm³ (12.24 US oz, 12.77 Imp.oz)
(MTT890D)
479.0 cm³ (16.19 US oz, 16.89 Imp.oz)
(MTT890)
Level (left) 133 mm (5.2 in) (MTT890D)
96 mm (3.8 in) (MTT890)
Level (right) 133 mm (5.2 in) (MTT890D)
97 mm (3.8 in) (MTT890)
Spring preload
Unit for adjustment Turn (MTT890D)
Adjustment value (Soft) 0 (MTT890D)
Adjustment value (STD) 2 (MTT890D)
Adjustment value (Hard) 10 (MTT890D)
Adjustment value (Soft) 19.0 mm (0.75 in) (MTT890)
Adjustment value (STD) 16.0 mm (0.63 in) (MTT890)
Adjustment value (Hard) 4.0 mm (0.16 in) (MTT890)
Rebound damping
Unit for adjustment Click (MTT890)
Adjustment value from the start position (Soft) 11 (MTT890)
Adjustment value from the start position (STD) 6 (MTT890)
Adjustment value from the start position (Hard) 1 (MTT890)
Rear suspension
Shock absorber Gas-hydraulic damper
Spring preload
Unit for adjustment Cam position (MTT890)
Click (MTT890D)
Adjustment value (Soft) 1
Adjustment value (STD) 11 (MTT890D)
4 (MTT890)
Adjustment value (Hard) 24 (MTT890D)
7 (MTT890)
Rebound damping
Unit for adjustment Turn (MTT890)
Adjustment value from the start position (Soft) 2 1/2 (MTT890)
Adjustment value from the start position (STD) 1 (MTT890)
Adjustment value from the start position (Hard) 0 (MTT890)
2-7
Drive chain
Size 525
Chain type Sealed type
Number of links 118
Drive chain slack (Mainstand) 45.0–50.0 mm (1.77–1.97 in)
Drive chain slack limit (Mainstand) 55.0 mm (2.17 in)
15-link length limit 239.3 mm (9.42 in)
2-8
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Ignition system
Ignition timing (B.T.D.C.) 3.0–7.0 °/1300 r/min
Engine control unit

Model TBDF5X (MTT890D)
TBDF6E (MTT890)
Ignition coil
Primary coil resistance 1.19–1.61 Ω
Secondary coil resistance 8.50–11.50 kΩ
Charging system
Charging system AC magneto
Standard output 14.0 V, 29.6 A at 5000 r/min
Stator coil resistance 0.152–0.228 Ω
Rectifier/regulator
Regulated voltage (DC) 14.3–14.7 V
Battery
Model YTZ10S
Voltage, capacity 12 V, 8.6 Ah (10 HR)
Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal light LED
Rear turn signal light LED
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED
Indicator light
Neutral indicator light LED
Stability control indicator light LED
Oil pressure and Coolant temperature warning
light LED
High beam indicator light LED
Turn signal indicator light LED
Fuel level warning light LED
Malfunction indicator light LED
ABS warning light LED
Cruise control “SET” indicator light LED
Cruise control “ON” indicator light LED
Auxiliary system warning light LED
Immobilizer system indicator light LED
2-9
Starter motor
Brush overall length limit 6.5 mm (0.26 in)
Mica undercut (depth) 0.70 mm (0.03 in)
Grip warmer
Grip warmer resistance (L) 6.3–7.7 Ω (MTT890D)
Grip warmer resistance (R) 6.3–7.7 Ω (MTT890D)
Fuel sender unit

Sender unit resistance (full) 9.0–11.0 Ω
Sender unit resistance (empty) 213.0–219.0 Ω
Fuel injection sensor

Crankshaft position sensor resistance 228–342 Ω
Intake air temperature sensor resistance 5400–6600 Ω at 0 °C (5400–6600 Ω at 32 °F)
Intake air temperature sensor resistance 290–390 Ω at 80 °C (290–390 Ω at 176 °F)
Intake air pressure sensor output voltage 3.59–3.67 V at 101.3 kPa (3.59–3.67 V at 1.01
kgf/cm², 3.59–3.67 V at 14.7 psi)
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)
Fuse(s)
Main fuse 50.0 A
Headlight fuse 7.5 A
Brake light fuse 2.0 A
Signaling system fuse 7.5 A
Ignition fuse 10.0 A
Radiator fan motor fuse 15.0 A
ABS ECU fuse 7.5 A
SCU fuse 7.5 A (MTT890D)
Fuel injection system fuse 7.5 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
Accessory fuse 2 2.0 A
Terminal fuse 1 2.0 A
Terminal fuse 2 2.0 A
Backup fuse 7.5 A
Cruise control fuse 2.0 A
Electronic throttle valve fuse 7.5 A
Heater fuse 7.5 A
Ignition fuse 2 7.5 A
Backup fuse 2 15.0 A
2-10
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Exhaust pipe nut M8 6 20 N·m (2.0 kgf·m, 15 lb·ft)
Spark plug M10 3 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Cylinder head cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Generator rotor bolt M12 1 75 N·m (7.5 kgf·m, 55 lb·ft) E
Generator cover bolt M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT
Generator cover bolt M6 8 12 N·m (1.2 kgf·m, 8.9 lb·ft)

Stake.
Clutch boss nut M20 1 125 N·m (12.5 kgf·m, 92 lb·ft)
LT
Clutch spring bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Clutch cover bolt M6 11 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Oil filter cartridge M20 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Oil filter cartridge union bolt M20 1 70 N·m (7.0 kgf·m, 52 lb·ft) E
Water pump drain bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Engine oil drain bolt M14 1 43 N·m (4.3 kgf·m, 32 lb·ft)
2-11
TIGHTENING TORQUES
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Front wheel axle M16 1 72 N·m (7.2 kgf·m, 53 lb·ft)
Front wheel axle pinch bolt M8 1 23 N·m (2.3 kgf·m, 17 lb·ft)
Rear wheel sprocket nut M10 6 80 N·m (8.0 kgf·m, 59 lb·ft)
Rear wheel axle nut M18 1 105 N·m (10.5 kgf·m, 77 lb·ft)
Rear brake caliper bolt (front) M12 1 27 N·m (2.7 kgf·m, 20 lb·ft) S
S
Rear brake caliper bolt (rear) M8 1 22 N·m (2.2 kgf·m, 16 lb·ft) and
LT
Brake caliper bleed screw M8 3 5 N·m (0.5 kgf·m, 3.7 lb·ft)

Front brake caliper bolt M10 4 35 N·m (3.5 kgf·m, 26 lb·ft)
Upper handlebar holder bolt M8 4 22 N·m (2.2 kgf·m, 16 lb·ft)
Lower handlebar holder nut M10 2 40 N·m (4.0 kgf·m, 30 lb·ft)
Clutch cable locknut M8 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Lower bracket pinch bolt M8 4 23 N·m (2.3 kgf·m, 17 lb·ft)
Upper bracket pinch bolt M8 2 26 N·m (2.6 kgf·m, 19 lb·ft)
Lower ring nut M25 1 See TIP.
Stake.
Drive sprocket nut M22 1 160 N·m (16 kgf·m, 118 lb·ft)
LT
TIP
Lower ring nut
1. Tighten the ring nut to approximately 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen
the lower ring nut completely.
2. Tighten the lower ring nut to 14 N·m (1.4 kgf·m, 10 lb·ft).
2-12
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view) (for MTT890)
H J
9
3
I
10 2
I
1 2
14 3
13,G
4,A
12
5
6
B
7
EF
11,E
B
D
8
10,N 16 10 99 CC
M 15
L
K
9
12
2-13
CABLE ROUTING
1. Clutch cable N. Route the front brake light switch lead over the
2. Handlebar switch lead (left) handlebar switch lead (right).
3. Clutch switch lead
4. Auxiliary DC jack lead
5. Headlight control unit
6. Headlight assembly coupler
7. Auxiliary light coupler
8. Wire harness
9. Handlebar switch lead (right)
10. Front brake light switch lead
11. Sub-wire harness coupler (headlight control unit)
12. Sub-wire harness (meter)
13. Sub-wire harness coupler (meter)
14. Front brake hose
15. Headlight assembly
16. Front brake light switch
A. Route the auxiliary DC jack lead under the pipe of
headlight bracket.
B. 10 mm (0.39 in) or less
C. Fasten the front brake light switch lead and
handlebar switch lead (right) with the band at the
tape of the front brake light switch lead. Position
the band within 10 mm (0.39 in) of the holder
where the handlebar switch lead (right) are
secured to the frame. Route the front brake light
switch lead to the outside of the handlebar switch
lead (right).
D. Fasten the front brake light switch lead and
tape of the front brake light switch lead. Route the
front brake light switch lead to the outside of the
handlebar switch lead (right).
E. Install the sub-wire harness coupler (headlight
control unit) into the rib on the support stay.
Position the coupler to left side of rib.
F. Fasten the front brake light switch lead and
tape of the front brake light switch lead. Position
the band within 10 mm (0.39 in) of the holder
where the handlebar switch lead (right) are
secured to the upper bracket. Route the front brake
light switch lead to the front of the handlebar switch
lead (right).
G. Insert the projection on the turn signal light coupler
(left) into the hole in the headlight bracket.
H. Fasten the front brake light switch lead and
handlebar switch lead (right) with a plastic band.
Face the buckle of the plastic band upward with the
end pointing forward. Fasten the straight portion of
the handlebar with the plastic band.
I. Forward
J. Fasten the clutch switch lead and handlebar switch
lead (left) with a plastic band. Face the buckle of
the plastic band upward with the end pointing
forward. Fasten the straight portion of the
handlebar with the plastic band.
K. Position the holder to the outside with the edge of
the front brake light switch.
L. Fasten the handlebar switch lead and front brake
light switch lead. Make sure that the catch of the
holder is not downward.
M. Forward
2-14
CABLE ROUTING
Handlebar (front view) (for MTT890D)

H J
11 3
12 18 I 2 1 2 3
I
18 17 4
16,G 5,A
15 6
7
14
B 8
9
F
E
13,E
B
D
C
10
20 612 5 CB
11 19
M 12,N
L
K
11 14
2-15
CABLE ROUTING
1. Clutch cable L. Fasten the handlebar switch lead and front brake
2. Handlebar switch lead (left) light switch lead. Make sure that the catch of the
3. Grip warmer lead (left) holder is not downward.
4. Clutch switch lead M. Forward
5. Auxiliary DC jack N. Route the front brake light switch lead over the
6. Sub-wire harness (front fork solenoid (left))
7. Headlight control unit
8. Headlight assembly coupler
9. Auxiliary light coupler
10. Wire harness
11. Handlebar switch lead (right)
12. Front brake light switch lead
13. Sub-wire harness coupler (headlight control unit)
15. Sub-wire harness (front fork solenoid (right))
17. Front brake hose
18. Grip warmer lead (right)
A. Route the auxiliary DC jack lead under the pipe of
headlight bracket.
B. 10 mm (0.39 in) or less
C. Fasten the front brake light switch lead and
handlebar lead wires assembly (right) with the
band at the tape of the front brake light switch lead.
Position the band within 10 mm (0.39 in) of the
holder where the handlebar lead wires assembly
(right) are secured to the frame. Route the front
brake light switch lead to the outside of the
D. Fasten the front brake light switch lead and
tape of the front brake light switch lead. Route the
front brake light switch lead to the outside of the
handlebar lead wires assembly (right).
E. Install the sub-wire harness coupler (sub-wire
harness (headlight control unit)) into the rib on the
support stay. Position the coupler to left side of rib.
F. Fasten the front brake light switch lead and
handlebar lead wires assembly (right) with the
band at the tape of the front brake light switch lead.
Position the band within 10 mm (0.39 in) of the
holder where the handlebar lead wires assembly
(right) are secured to the upper bracket. Route the
front brake light switch lead to the front of the
handlebar lead wires assembly (right).
G. Insert the projection on the turn signal light coupler
(left) into the hole in the headlight bracket.
H. Fasten the front brake light switch lead, handlebar
switch lead (right), and grip warmer lead (right)
with a plastic band. Face the buckle of the plastic
band upward with the end pointing forward. Fasten
the straight portion of the handlebar with the plastic
band.
I. Forward
J. Fasten the clutch switch lead, handlebar switch
lead (left) and grip warmer lead (left) with a plastic
band. Face the buckle of the plastic band upward
with the end pointing forward. Fasten the straight
portion of the handlebar with the plastic band.
K. Position the holder to the outside with the edge of
the front brake light switch.
2-16
CABLE ROUTING
Handlebar (right side view) (for MTT890)
9
4,B
Q 1 2 3,A 5
P R
6
1
20 2
1 7,C
2 9
8
10,D
10,D 1
1
2
6,F 5,F
S
16 17,M 2 18,N 19,O

15 9,G 11
14,L
1 T
9
2 1
13 2 9,K J I 12,H 21
2-17
CABLE ROUTING
1. Front brake light switch lead P. Position the buckle of the plastic band at the
2. Handlebar switch lead (right) location shown in the illustration. Cut off the excess
3. Meter coupler end of the plastic band to 5 mm (0.20 in) or less.
Point the ends of the plastic band inward.
4. Auxiliary DC jack lead
5. Front turn signal light lead (right) Q. 90°
6. Front turn signal light lead (left) R. Forward
7. Front turn signal light coupler (right) S. Route the front brake light switch lead to the front
of the line connecting the band and the holder.
8. Auxiliary DC jack coupler
T. Insert the projection on the holder into the hole in
9. Sub-wire harness (meter) the headlight assembly. Face the catch of holder
10. Front brake light switch coupler downward. Fasten the front brake light switch lead
11. Auxiliary light assembly at the positioning tape.
12. Handlebar switch coupler (right) (accelerator
position sensor)
13. Grip warmer coupler (right) (option)
14. Handlebar switch coupler (right) (stop/run/start
switch)
15. Grip warmer coupler (left) (option)
16. Handlebar switch coupler (right) (menu switch)
17. Wire harness
18. Clutch switch coupler
20. Lower handlebar holder
A. Install the coupler cover completely until it contacts
with the meter assembly.
B. Route the auxiliary DC jack lead between the
headlight bracket and auxiliary light assembly.
Route the auxiliary DC jack lead to the rear of the
front turn signal light lead (left), and over the front
turn signal light lead (right).
C. Insert the projection on the front turn signal light
coupler (right) into the hole in the headlight
bracket.
D. Insert the projection on the front brake light switch
coupler into the hole in the headlight bracket.
E. Route the front brake light switch lead over the
bottom edge of holder.
F. Route the front turn signal light lead between the
auxiliary light assembly and headlight bracket.
G. Route the sub-wire harness (meter) under the pipe
of headlight bracket.
H. Insert the projection on the handlebar switch
coupler (right) (accelerator position sensor) into
the hole in the headlight bracket.
I. Insert the projection on the clutch switch lead
holder into the hole in the headlight bracket.
J. Route the wire harness to the front of the headlight
bracket.
K. Route the sub-wire harness (meter) above the pipe
L. Insert the projection on the handlebar switch
coupler (right) (stop/run/start switch) into the hole
in the headlight bracket.
M. Route the wire harness to the outside of headlight
bracket.
N. Insert the projection on the clutch switch coupler
into the hole in the headlight bracket.
O. Route the clutch switch lead to the front of the
headlight bracket.
2-18
CABLE ROUTING
Handlebar (right side view) (for MTT890D)
P
Q R 1 2,A 3 4 5,B 7,D
8
23
6,C 9
4
22 1 3
2
10,E
3
1
11
12
12
13,F
14
13,F
1
G
3
1
8,H
9,H
S
21,O 1
20
15
19 12,I
18,N
3 T
12
1 3
L K 16,J 1 24
17 1 12,M
2-19
CABLE ROUTING
1. Handlebar switch lead (right) N. Insert the projection on the handlebar switch
2. Front fork solenoid lead (right) coupler (right) (stop/run/start switch) into the hole
3. Front brake light switch lead in the headlight bracket.
4. Grip warmer lead (right) O. Route the wire harness to the outside of headlight
bracket.
5. Coupler cover
6. Meter coupler P. 90°
7. Auxiliary DC jack lead Q. Position the buckle of the plastic band at the
location shown in the illustration. Cut off the excess
8. Front turn signal light lead (right) end of the plastic band to 5 mm (0.20 in) or less.
9. Front turn signal light lead (left) Point the ends of the plastic band inward.
10. Front turn signal light coupler (right) R. Forward
11. Auxiliary DC jack coupler S. Route the front brake light switch lead to the front
12. Sub-wire harness (meter) of the line connecting the band and the holder.
13. Front brake light switch coupler T. Insert the projection on the holder into the hole in
14. Sub-wire harness coupler (front fork solenoid the headlight assembly. Face the catch of holder
(right)) downward. Fasten the front brake light switch lead
15. Auxiliary light assembly at the positioning tape.
16. Handlebar switch coupler (right) (accelerator
position sensor)
17. Grip warmer coupler (right)
18. Handlebar switch coupler (right) (stop/run/start
switch)
19. Grip warmer coupler (left)
20. Handlebar switch coupler (right) (menu switch)
21. Wire harness
23. Sub-wire harness (front fork solenoid (right))
A. Route the front fork solenoid lead (right) to the
inside of the handlebar switch lead (right), front
brake light switch lead and grip warmer lead (right),
and then connect the front fork solenoid coupler
(right) in the coupler cover.
B. Slide the coupler cover until the coupler is covered
and face the open side of the coupler cover to
lower side of the vehicle.
C. Install the coupler cover completely until it contacts
with the meter assembly.
D. Route the auxiliary DC jack lead between the
headlight bracket and auxiliary light assembly.
Route the auxiliary DC jack lead to the rear of the
front turn signal light lead (left), and over the front
turn signal light lead (right).
E. Insert the projection on the front turn signal light
coupler (right) into the hole in the headlight
bracket.
F. Insert the projection on the front brake light switch
coupler into the hole in the headlight bracket.
G. Route the front brake light switch lead over the
bottom edge of holder.
H. Route the front turn signal light lead between the
auxiliary light assembly and headlight bracket.
I. Route the sub-wire harness (meter) under the pipe
J. Insert the projection on the handlebar switch
coupler (right) (accelerator position sensor) into
the hole in the headlight bracket.
K. Insert the projection on the clutch switch lead
holder into the hole in the headlight bracket.
L. Route the wire harness to the front of the headlight
bracket.
M. Route the sub-wire harness (meter) above the pipe
2-20
CABLE ROUTING
Handlebar (left side view) (for MTT890)

I
B 4 H J
3 5 7
6 G,4
2,A
1 7
14 6
5
I
H
J
5
14 4
6
6 14
8
9 5
13,F
C
4
10,D
11,E
11
10
12
14 L
14
4 H 14
10 10
2-21
CABLE ROUTING
1. Grip warmer coupler (left) (option)

2. Fuel tank side cover front panel (left)
3. Auxiliary DC jack coupler 1 (option)
4. Clutch cable
5. Handlebar switch lead (left)
9. Coupler bracket
10. Wire harness
12. Accessory light coupler (option)
14. Horn lead
A. Position the couplers inside of the fuel tank side
cover front panel (left).
B. Fasten the handlebar switch lead (left), clutch
switch lead, clutch cable and horn lead with a
plastic locking tie. Position the plastic locking tie at
the front of mating surface of the lower handlebar
holder and upper bracket.
C. Insert the projection on the handlebar switch lead
holder into the hole in the coupler bracket.
D. Route the wire harness to the outside of the front
fork.
E. Route the sub-wire harness (meter) through the
cutout in the headlight assembly.
F. Insert the projection on the sub-wire harness
coupler (meter) into the hole in the headlight
assembly.
G. Route the clutch cable to the inside of the
handlebar switch lead (left), clutch switch lead and
horn lead.
H. Forward
I. 90°
J. Position the buckle of the plastic band at the
end of the plastic band to 5 mm (0.20 in) or less.
K. 65–75 mm (2.56–2.95 in)
L. Route the horn lead to the front of the front fork.
Face the buckle of the plastic locking tie rearward,
and then cut off the excess end of the plastic
locking tie to 5 mm (0.20 in) or less.
2-22
CABLE ROUTING
Handlebar (left side view) (for MTT890D)

4 L
B 5 6 7,C 8 M
K
3 9 20
10 8,J
2,A 19
1 11,D 5
10
11 9 6
L
K
M
9
19 8
5 6 10
18,I
5 19
12
13
17,H E 5
14,F 8
15,G
14 15
16
19 O
19
8 K 19
14 14
2-23
CABLE ROUTING
1. Sub-wire harness coupler (front fork solenoid (left))

2. Fuel tank side cover front panel (left)
3. Grip warmer coupler (left)
4. Auxiliary DC jack coupler 1 (option)
5. Sub-wire harness (front fork solenoid (left))
6. Grip warmer lead (left)
7. Coupler cover
8. Clutch cable
11. Front fork solenoid lead (left)
13. Coupler bracket
14. Wire harness
16. Accessory light coupler (option)
18. Auxiliary light lead
19. Horn lead
A. Position the couplers inside of the fuel tank side
cover front panel (left).
B. Fasten the handlebar switch lead (left), grip
warmer lead (left), sub-wire harness (front fork
solenoid (left)), clutch switch lead, clutch cable and
horn lead with a plastic locking tie. Position the
plastic locking tie at the front of mating surface of
the lower handlebar holder and upper bracket.
C. Slide the coupler cover until the coupler is covered
underside of the vehicle.
D. Route the front fork solenoid lead (left) to the
inside of the handlebar switch lead (left), clutch
switch lead and grip warmer lead (left), and then
connect the front fork solenoid coupler (left) on the
font side of the lower handlebar holder.
E. Insert the projection on the handlebar switch lead
holder into the hole in the coupler bracket.
F. Route the wire harness to the outside of the front
fork.
G. Route the sub-wire harness (meter) through the
cutout in the headlight assembly.
H. Insert the projection on the sub-wire harness
coupler (meter) into the hole in the headlight
assembly.
I. Route the auxiliary light lead under the headlight
bracket.
J. Route the clutch cable to the inside of the
handlebar switch lead (left), clutch switch lead,
horn lead, sub-wire harness (front fork solenoid
(left)) and grip warmer lead (left).
K. Forward
L. 90°
M. Position the buckle of the plastic band at the
end of the plastic band to 5 mm (0.20 in) or less.
N. 65–75 mm (2.56–2.95 in)
O. Route the horn lead to the front of the front fork.
Face the buckle of the plastic locking tie rearward,
and then cut off the excess end of the plastic
locking tie to 5 mm (0.20 in) or less.
2-24
CABLE ROUTING
Frame and engine (right side view) (for MTT890)
5 7 19
6
4
4 G 20
J 16
18 I
H
17 9,K
21 L H
1 2
1 1
3 4,A 5
1 6 7 8 9,B 10
11
18
D
17
12
13
E
16 15 14 F
12,P H
1 13
H 4,M
18 J
17 N
Q
11
22
21 4,O
11
J
2-25
CABLE ROUTING
1. Battery box
2. Rectifier/regulator
3. Rectifier/regulator cover
4. Wire harness
5. Canister purge hose (purge cut valve solenoid to
canister)
6. Canister
7. Fuel tank breather hose
8. Purge cut valve solenoid coupler
9. Clutch cable
10. Stator coil assembly lead
11. Radiator hose (cylinder head to radiator)
12. Sub-wire harness (oil pressure switch)
13. Radiator inlet hose
14. Oil pressure switch
15. Starter motor
16. Starter motor lead
17. Rear brake light switch lead
18. Rear wheel sensor lead
19. Coolant temperature sensor coupler
20. Neutral switch coupler
21. Neutral switch
22. Frame
A. Make sure that the wire harness are not pinched
by the rectifier/regulator cover.
B. Route the clutch cable to the front of the stator coil
assembly lead and canister.
C. Face the end of the plastic locking tie rearward and
cut off the excess.
D. Fasten the wire harness at the gray tape with a
plastic locking tie. Face the buckle of the plastic
locking tie rearward. Face the end of the plastic
locking tie rearward and cut off the excess.
E. Route the sub-wire harness (oil pressure switch) to
the inside of the radiator inlet hose.
F. Fasten the sub-wire harness (oil pressure switch)
with the holder.
G. Fasten the wire harness, rear brake light switch
lead and rear wheel sensor lead with holder at the
gray tape on the wire harness. Face the catch of
holder outward.
H. Outside of vehicle
I. Inside of vehicle
J. Forward
K. Route the clutch cable on the front side of the
starter motor lead.
L. Position the neutral switch coupler installation
direction within the range as shown in the
illustration.
M. Route the wire harness to inside of the frame.
N. Fasten the wire harness and radiator hose
(cylinder head to radiator) with holder at the gray
tape on the wire harness. Face the catch of holder
forward.
O. Route the wire harness on the upper side of the
radiator hose (cylinder head to radiator)
P. Route the sub-wire harness (oil pressure switch) to
the outside of the radiator inlet hose.
Q. Face the buckle of the plastic band inward. Face
the end of the plastic locking tie rearward.
2-26
CABLE ROUTING
Frame and engine (right side view) (for MTT890D)
6 8 20
5,M 7
4
4 G
17
19 J
H I
18 21
10,K
22 L H
1 2 3 4,A 5 6 7 8 9 10,B 11
12
19
D
18
13
14
E
17 16 15 F
13,Q H
1 14
H 4,N
19 J
18 O
R
12
23
22 4,P
12
J
2-27
CABLE ROUTING
1. Battery box R. Face the buckle of the plastic band inward. Face
2. Rectifier/regulator the end of the plastic locking tie rearward.
3. Rectifier/regulator cover
4. Wire harness
5. Sub-wire harness (neutral switch)
canister)
7. Canister
9. Purge cut valve solenoid coupler
10. Clutch cable
13. Sub-wire harness (oil pressure switch)
16. Starter motor
20. Coolant temperature sensor coupler
21. Neutral switch coupler
22. Neutral switch
23. Frame
A. Make sure that the wire harness are not pinched
by the rectifier/regulator cover.
B. Route the clutch cable to the front of the stator coil
assembly lead and canister.
C. Face the end of the plastic locking tie rearward and
cut off the excess.
D. Fasten the wire harness at the gray tape with a
plastic locking tie. Face the buckle of the plastic
locking tie rearward. Face the end of the plastic
locking tie rearward and cut off the excess.
E. Route the sub-wire harness (oil pressure switch) to
the inside of the radiator inlet hose.
F. Fasten the sub-wire harness (oil pressure switch)
with the holder.
G. Fasten the wire harness, rear brake light switch
lead and rear wheel sensor lead with holder at the
gray tape on the wire harness. Face the catch of
holder outward.
H. Outside of vehicle
I. Inside of vehicle
J. Forward
K. Route the clutch cable on the front side of the
starter motor lead.
L. Position the neutral switch coupler installation
direction within the range as shown in the
illustration.
M. Route the sub-wire harness (neutral switch) to
inside of the wire harness.
N. Route the wire harness to inside of the frame.
O. Fasten the wire harness and radiator hose
(cylinder head to radiator) with holder at the gray
tape on the wire harness. Face the catch of holder
forward.
P. Route the wire harness on the upper side of the
radiator hose (cylinder head to radiator)
Q. Route the sub-wire harness (oil pressure switch) to
the outside of the radiator inlet hose.
2-28
CABLE ROUTING
Frame (front left side view)
16 18
9
19
10
17
F 20,K
1,J
G 21,K
11
12 22,K
15,I 13
14,H 9
1,A
2
3
8
7,D
6,C
O
L
23,N
M
4
2-29
CABLE ROUTING

3. Shift sensor lead (for MTT890D)
4. O2 sensor
5. Radiator outlet hose
6. Clutch cable
7. O2 sensor coupler
8. SCU coupler (for MTT890D)
9. Wire harness
10. Handlebar switch coupler (left)
11. Radiator fan motor coupler
12. Radiator fan motor lead
13. Brake hose
14. Wire harness (to oil pressure switch)
15. Immobilizer coupler
16. ECU (Engine Control Unit)
17. ECU coupler 3
18. ECU coupler 2
19. ECU coupler 1
20. Wire harness (to ECU coupler)
21. O2 sensor lead
A. Route the handlebar switch lead (left) to the
outside of the clutch cable.
B. Fasten the O2 sensor lead at the narrow portion on
the radiator bracket with plastic locking tie. Face
the buckle of the plastic locking tie rearward. Point
the ends of the plastic locking tie rearward, and
then cut off the excess end of the plastic locking
tie.
C. Route the clutch cable to the inside of the frame.
D. Insert the O2 sensor coupler into the hole in the
radiator bracket.
E. Fasten the wire harness at the narrow portion on
the radiator bracket with plastic locking tie. Face
the buckle of the plastic locking tie rearward. Point
the ends of the plastic locking tie rearward, and
then cut off the excess end of the plastic locking
tie.
F. Insert the projection on the wire harness holder
into the hole in the coupler cover.
G. Insert the radiator fan motor coupler into the hole
of the coupler cover.
H. Route the wire harness (to oil pressure switch)
between the brake hoses and frame.
I. Insert the immobilizer unit coupler into the rib of
coupler cover.
J. Route the handlebar switch lead (left) on the rear
side of the wire harness
K. Pass the wire harness through the guide of the air
filter assembly.
L. Outside of vehicle
M. Downward
N. Route the O2 sensor lead to the inside of the
radiator outlet hose.
O. Face the buckle of the plastic locking tie inward.
Face the end of the plastic locking tie downward
and cut off the excess.
2-30
CABLE ROUTING
Frame (rear left side view)
E A B 11,C D 1
7 2
7 2
9 9
8 8
10,F G
7 I
5
H
8,J
8 7 6 5
K 2
1
12
13,L
13,L
M
17
15
16,N
14
2-31
CABLE ROUTING
1. Angular position sensor lead (for MTT890D)

3. Gear position sensor coupler
4. Gear position sensor
5. Shift sensor (for MTT890D)
6. Sidestand switch
7. Sidestand switch lead
8. Fuel tank drain hose
9. Canister breather hose
11. Wire harness
canister)
13. Rear shock absorber assembly solenoid lead (for
MTT890D)
14. Angular position sensor (for MTT890D)
15. Angular position sensor bracket (for MTT890D)
16. Hose (rear shock absorber assembly) (for
MTT890D)
17. Rear frame
A. To fuel pump
B. Route the angular position sensor lead on the
outside of the starter motor lead. (for MTT890D)
C. Route the wire harness (to gear position sensor)
on the outside of the starter motor lead.
D. Insert the projection on the angular position sensor
lead holder into the hole in the battery box. (for
MTT890D)
E. Route the angular position sensor lead on the
outside of the wire harness (to gear position
sensor). (for MTT890D)
F. Route the shift sensor lead to the front of the shift
sensor. (for MTT890D)
G. Point the open ends of the holder to the right. (for
MTT890D)
H. Left side of vehicle (for MTT890D)
I. Forward (for MTT890D)
J. Face the paint mark on the fuel tank drain hose
outward. Align the holder with the paint mark on
the fuel tank drain hose.
K. For MTT890D
L. Route the rear shock absorber assembly solenoid
lead on the left side of the starter motor lead and
above the canister purge hose. (for MTT890D)
M. Route the hose (rear shock absorber assembly)
over the guide on the angular position sensor
bracket. (for MTT890D)
N. Route the hose (rear shock absorber assembly)
between the guide on the angular position sensor
bracket and rear frame. (for MTT890D)
2-32
CABLE ROUTING
Top view 1
1 2 3 4 5 6 7 8,A
27 9
27
10
11
11
26 12,B
25
24
23,L
13
M 14
33
15,C
N
G 16
23,F
22
21,E
33 28
20 19 18,D 17
H
23
21 32,K
31
30
29 I
33
23,L 28
23,J
M
28
N
2-33
CABLE ROUTING
1. Injector #1 coupler J. Route the rear brake light switch lead over the sub-
2. Ignition coil #1 coupler wire harness (neutral switch) (between clamp and
3. Intake air pressure sensor 2 coupler rear brake light switch coupler). (for MTT890D)
4. Ignition coil #2 coupler K. Route the angular position sensor lead to the left
side of the wire harness (to ground lead). (for
5. Injector #2 coupler
MTT890D)
6. Intake air pressure sensor 1 coupler
L. Fasten the rear brake light switch lead at the gray
7. Ignition coil #3 coupler tape with a plastic locking tie.
8. Ignition coil #3 lead M. Fasten the wire harness (to rectifier/regulator
9. Injector #3 coupler coupler) at the white tape with a plastic locking tie.
10. Throttle position sensor coupler N. Point the end of the plastic locking tie rearward.
11. Throttle body
12. Coupler cover
13. Throttle servo motor coupler
14. Wire harness (to coolant temperature sensor)
16. Crankshaft position sensor coupler
17. Fuel pump coupler
19. Rear wheel sensor coupler
20. Starter relay
21. Joint coupler
22. Rear brake light switch coupler
24. Sidestand switch coupler
25. Shift sensor coupler (for MTT890D)
26. Stator coil coupler
27. Wire harness
28. Sub-wire harness (neutral switch) (for MTT890D)
29. Frame ground lead
30. Angular position sensor coupler (for MTT890D)
31. Rear shock absorber assembly solenoid coupler
(for MTT890D)
32. Angular position sensor lead (for MTT890D)
33. Wire harness (to rectifier/regulator)
A. Route the ignition coil #3 lead to the left side of the
cylinder head breather hose.
B. Slide the coupler cover until the coupler is covered
underside of the vehicle.
C. Route the fuel tank breather hose to the left side of
the wire harness (to throttle servo motor) and wire
harness (to coolant temperature sensor). Route
the fuel tank breather hose to the right side of the
wire harness (to stator coil), wire harness (to shift
sensor (for MTT890D)), wire harness (to sidestand
switch).
D. Route the rear wheel sensor lead over the wire
harness.
E. Insert the joint coupler into the rib of the battery
box.
F. Route the rear brake light switch lead between the
wire harness and joint coupler. (between clamp
and rear brake light switch coupler)
G. Route the wire harness to the front side of the rear
brake light switch lead.
H. For MTT890D
I. Route the sub-wire harness (neutral switch) to the
rear of the wire harness (to rectifier/regulator
coupler). (for MTT890D)
2-34
CABLE ROUTING
Top view 2
18
19
K 1,A
20,M 17
2
3
C
2
C 19 16
15,J
14
12 22,O 21,N
4,B
C
5,D
13,I
6
7
12,H 8
9
G
2
E
11,F
2
L
10
2-35
CABLE ROUTING

2. Battery box
3. Battery
4. Brake light relay
5. Heater relay
6. Rear turn signal light coupler (left)
7. Rear turn signal light coupler (right)
8. License plate light coupler
9. Tail/brake light coupler
10. Tail/brake light lead
11. YDT coupler
12. Bonda
13. Seat heater coupler
14. Starter relay coupler
15. Starter relay
16. Coupler cover
17. Radiator fan motor relay
18. ABS ECU coupler
19. Wire harness
21. Starter relay lead
22. Positive battery lead
A. Insert the rear wheel sensor coupler into the hole
of the battery box.
B. Insert the brake light relay until it stops the rib
stopper on the battery box.
C. Insert the projection on the wire harness holder
into the hole in the battery box.
D. Heater relay contacts the stopper on the battery
box.
E. Route the tail/brake light lead, rear turn signal light
lead and license plate light lead to the wire guide
on the battery box.
F. YDT coupler contacts the stopper on the battery
box.
G. Route the wire harness to the wire guide on the
battery box.
H. Point the end of the bonda to the guide on the
battery box.
I. Insert the seat heater coupler into the rib of the
battery box.
J. Starter relay contacts the stopper on the battery
box.
K. Point the open ends of the coupler cover along the
wire harness.
Insert the coupler cover open ends between the
wire harnesses.
L. The leads may be routed in any order.
M. Route the starter motor lead on the inside of the
holder.
N. Route the starter relay lead under the positive
battery lead.
O. Bend the positive battery lead as shown in the
illustration and fit it between the fuse and the
battery.
2-36
CABLE ROUTING
Front brake hose (right side view)
2
10
6
9,D
1 2
2
B 2 1
8 C 7 2
2
1
6
7
1
E
5 3
F
2 1 6
11 E
4
5
2-37
CABLE ROUTING
1. Brake hose (brake hose joint to front brake caliper

(left))
2. Brake hose (front brake master cylinder to brake
hose joint)
3. Front fork
4. Front brake caliper assembly (right)
5. Front fender
6. Bracket
7. Frame
8. Brake hose joint
9. Front wheel sensor lead
10. Front brake hose holder
11. Brake hose (front brake caliper (left) to front brake
caliper (right))
A. 17 mm (0.67 in)
B. Fit the metal fitting for the front brake hose to the
recess of the brake hose joint.
C. Install the brake hose between the stoppers on the
brake hose joint.
D. Insert the grommet of the front wheel sensor lead.
E. Make sure the holder is engaged by 2 or more
notches. Engage the claws so that they face
toward the rear of the vehicle.
F. Fit the holder between the ribs on the front fender.
2-38
CABLE ROUTING
Rear brake hose (right side view)
4 N 6
K 2,L
O
4 M
3
8
C D
4
2,G H
3 I
B
J 5
E
1 2 A 3 6
T F 7
2,S
3 H
3 6 7,Q
I R
2 P
3 2
U 10
I
2-39
CABLE ROUTING
1. Rear wheel sensor

3. Rear brake hose (hydraulic unit to rear brake
caliper)
4. Brake fluid reservoir hose
5. Rear brake hose bracket
6. Rear brake hose (rear brake master cylinder to
hydraulic unit)
8. Rear fender
9. Brake fluid reservoir bracket
10. Swingarm
A. Fasten the rear brake hose with the holder at the
hose protector on the rear brake hose.
B. Fasten the rear wheel sensor lead with the holder
at the white tape on the rear wheel sensor lead.
C. Align the white paint mark on the rear brake hose
(hydraulic unit to rear brake caliper) and white tape
on the rear wheel sensor lead, and then fasten the
rear wheel sensor lead and rear brake hose
(hydraulic unit to rear brake caliper) with the holder.
D. Fasten the grommet on the rear wheel sensor lead
with the bracket.
E. Fasten the rear brake light switch lead at the gray
tape with the holder.
F. 70 mm (2.76 in)
G. Fasten the grommet of the rear wheel sensor lead
with the holder.
H. 45°
I. Outward
J. Route the rear wheel sensor lead on the outside of
the rear brake hose (hydraulic unit to rear brake
caliper).
K. Face the catch of the holder upward.
L. Route the rear wheel sensor lead on the outside of
caliper).
M. Insert the holder of the brake fluid reservoir hose
into the hole in the brake fluid reservoir bracket.
N. Fasten the brake fluid reservoir hose with the
holder at the hose protector on the reservoir hose.
Face the catch of holder forward.
O. Face the catch of the holder downward.
P. Face the catch of the holder rearward, and then
close the holder until three clicks or more are
heard.
Q. Route the rear brake light switch lead on the
outside of the rear brake hose (rear brake master
cylinder to hydraulic unit).
R. Route the rear wheel sensor lead and rear brake
hose (hydraulic unit to rear brake caliper) through
the guide.
S. Route the rear wheel sensor lead on the outside of
caliper).
T. Face the catch of the holder outward, and then
close the holder until three clicks or more are
heard.
U. Route the rear wheel sensor lead along the rear
brake hose (hydraulic unit to rear brake caliper).
Position the rear wheel sensor lead within the
range shown in the illustration.
2-40
CABLE ROUTING
Fuel tank (left side view)
2
3
6 5 4
1
1
7
H
C 5 9
4,G
4 5,B
8
5,F
D 4
2-41
CABLE ROUTING
1. Fuel tank
2. Frame
3. Fuel pump
6. Fuel hose
7. White paint mark
8. Projection
9. Yellow paint mark
A. To engine
B. Insert the fuel tank drain hose up to the section where
the fuel tank pipe increases in diameter. Install it so
that the paint mark faces the front.
C. Align the hose clamp with the paint mark on the fuel
tank drain hose and install it. Make sure not to install
the hose clamp on the raised portion of the hose
fitting.
D. Face the tip of the hose clamp rearward from the
central axis of the fuel tank breather hose.
E. Face the tip of the hose clamp forward from the
central axis of the fuel tank drain hose.
F. Install the fuel tank drain hose on the projection side
of the fuel tank.
G. Insert the fuel tank breather hose up to the section
where the fuel tank pipe increases in diameter. Install
it so that the paint mark faces the rear.
H. Align the hose clamp with the paint mark on the fuel
tank breather hose and install it. Make sure not to
install the hose clamp on the raised portion of the
hose fitting.
2-42
CABLE ROUTING
Main switch (left side view)
1
A
B
3
4
4 1
2-43
CABLE ROUTING
1. Wire harness
3. Bracket
4. Frame
A. Insert the projection on the wire harness holder into
the hole in the bracket.
B. Insert the projection on the wire harness holder into
the rib of the frame.
2-44
CABLE ROUTING
Radiator (front side view)
5 L N
J K M N N
6
O
1
P Q
I
H
A
B
2
R 7 3 F E D
8
U T S
2-45
CABLE ROUTING
1. Radiator
3. Thermostat assembly
5. Radiator cap
6. Coolant reservoir hose
7. Water jacket joint
A. Install the radiator outlet hose completely onto the
radiator pipe.
B. Face the white paint mark on the radiator outlet
hose outward.
C. Face the screw head of the hose clamp inward.
D. Point the ends of the hose clamp toward the yellow
paint mark on the radiator outlet hose.
E. Align the yellow paint mark on the radiator outlet
hose with the rib on the thermostat assembly.
F. Install the radiator outlet hose completely onto the
rib of the thermostat assembly.
G. Face the white paint mark on the radiator hose
(cylinder head to radiator) forward.
H. Install the radiator hose (cylinder head to radiator)
completely onto the radiator pipe.
I. Point the ends of the hose clamp downward.
J. Point the ends of the hose clamp inward. Make
sure not to install the hose clamp on the raised
portion of the hose fitting.
K. Install the coolant reservoir hose completely onto
the radiator.
L. Hose clamp fixed position details.
M. Make sure not to install the hose clamp on the
raised portion of the hose fitting.
N. 3 mm (0.12 in) or more
O. 0–1 mm (0–0.04 in)
P. Hose plug-in section
Q. Make sure not to install the hose clamp on the
R. Install the radiator inlet hose completely onto the
radiator.
S. Install the radiator inlet hose completely onto the
rib of the water jacket joint.
T. Align the yellow paint mark on the radiator inlet
hose with the rib on the water jacket joint.
U. Face the screw head of the hose clamp upward.
V. Face the white paint mark on the radiator inlet
hose outward.
2-46
CABLE ROUTING
Canister (left side view)
12,F
1 2
3,A
12
6
I E
7
L 6,7
K 8
11,J
11 10,D 9,C B
6 7 G
H
2-47
CABLE ROUTING
1. Wire harness
canister)
3. Wire harness (to purge cut valve solenoid)
5. Purge cut valve solenoid
6. Sidestand switch lead
10. Plastic locking tie
12. Clutch cable
A. Route the wire harness (to purge cut valve
solenoid) to the rear side of the stator coil lead,
sidestand switch lead and shift sensor lead (for
MTT890D).
B. Route the shift sensor lead to the outside of the
fuel tank drain hose and canister breather hose.
(for MTT890D)
C. Route the fuel tank drain hose to the rear side of
the stator coil lead, sidestand switch lead and shift
sensor lead (for MTT890D). Route the fuel tank
drain hose to the outside of the canister purge
hose (purge cut valve solenoid to canister).
D. Fasten the side stand switch lead and shift sensor
lead (for MTT890D) with plastic locking tie at the
gray tape on the side stand switch lead and shift
sensor lead (for MTT890D).
E. Route the stator coil assembly lead, shift sensor
lead (for MTT890D) and sidestand switch lead on
outside of the vehicle of the clutch cable and
canister purge hose (purge cut valve solenoid to
canister).
F. Route the clutch cable between the cylinder head
and the bracket.
G. Face the end of the plastic locking tie outward and
cut off the excess.
H. Outside of the vehicle
I. Inside of the vehicle
J. Route the stator coil assembly lead to the front of
the vehicle and fix the gray tape part with a plastic
locking tie.
K. Fix the plastic locking tie is located 20–30 mm
(0.79–1.18 in) away from the plastic locking tie
“10”. Face the locking part of the plastic locking tie
forward. Face the end of the plastic locking tie
inward and do not cut off the excess.
L. Forward
2-48
CABLE ROUTING
Radiator (right side view)
F
G H
I
2
1
3
A
B
4
E D
C
2-49
CABLE ROUTING
1. Radiator fan cover

2. Radiator fan motor lead
4. Radiator
A. Route the radiator hose (cylinder head to radiator)
through the notch of the radiator fan cover.
B. Route the radiator fan motor lead through the
notch of the radiator fan cover.
C. Insert the radiator hose (cylinder head to radiator)
until it contacts the cylinder head.
D. 0–2 mm (0–0.08 in)
E. Point the end of clamp rearward.
F. Hose clamp fixed position details.
G. Make sure not to install the hose clamp on the
H. 3 mm (0.12 in) or more
I. Hose plug-in section
2-50
CABLE ROUTING
Front brake hose (left side view)

F
3
G E
2
D
3,C
A 6 H F
3 3
I
G E
3 5
J B
2-51
CABLE ROUTING
1. Brake hose (front brake master cylinder to brake hose

joint)
2. Brake hose (brake hose joint to front brake caliper
(left))
4. Brake hose (front brake caliper (left) to front brake
caliper (right))
5. Front brake caliper assembly (left)
6. Reflector bracket
7. Front fork
A. Face the white paint mark on the hose outward.
B. Install the holder with contacted the front fork leg.
C. Make the front wheel sensor lead to follow the brake
hose (brake hose joint to front brake caliper (left))
without slacking.
D. Route the front wheel sensor lead to the front side of
the brake hose with the holder at the white tape on
the front wheel sensor lead. Face the catch of holder
forward. Make sure the holder is engaged by 3 or
more notches.
E. 45°
F. Left side of the vehicle
G. Front side of the vehicle
H. Insert the grommet of the front wheel sensor lead.
I. Route the front wheel sensor lead to the front side of
the brake hose with the holder at the white tape on
the front wheel sensor lead. Fasten the protector of
the brake hose with the holder. Face the catch of
holder forward. Make sure the holder is engaged by 3
or more notches.
J. Fasten the front wheel sensor lead with the holder at
the white tape on the front wheel sensor lead.
2-52
CABLE ROUTING
Air filter case and throttle bodies (left side view)

G H I E J
K
3
L
L
L
O N M
Q P
A B
2
F
E
D C
2-53
CABLE ROUTING
1. Throttle body
2. Cylinder head breather hose
hose joint)
A. Install the cylinder head breather hose completely
onto the air filter case joint. Face the yellow paint
mark on the cylinder head breather hose to the left.
B. Yellow paint mark
C. 5–7 mm (0.20–0.28 in)
D. 1–3 mm (0.04–0.12 in)
E. White paint mark
F. Install the cylinder head breather hose completely
onto the cylinder head joint. Face the white paint
mark on the cylinder head breather hose to the
right.
G. 123°
H. 105°
I. 10°
J. Install the canister purge hose completely onto the
purge cut valve solenoid.
K. Point the ends of the hose clamp upward.
L. Face the bolt head to the position as shown in the
illustration.
M. Point the ends of the hose clamp forward.
N. Install the canister purge hose completely onto the
hose joint.
O. Install the purge hoses completely onto the hose
joint and throttle body.
P. Point the ends of the hose clamp to the left.
Q. Point the ends of the hose clamp to the right.
2-54
CABLE ROUTING
IMU (top view)
1 2 3 4 9
8 7,B 6 A 5
10
7,C 3
2-55
CABLE ROUTING
1. Bracket
2. Positive battery lead
3. IMU (Inertial Measurement Unit)
4. IMU coupler
5. Battery box
6. Wire harness (to starter relay)
8. Starter relay
9. Wire harness
10. Negative battery lead
A. Do not contact the starter motor lead with the bracket.
B. Route the starter motor lead to the lower side of the
bracket.
C. When inserting the clamp into the battery box, pass
the starter motor lead through the left side of the rib
on the battery box. After inserting the clamp into the
battery box, the starter motor lead may come off the
rib on the battery box.
2-56
CABLE ROUTING
Canister
C
2,A
B
77 E F G 8
G
I
6 5 H D
2-57
CABLE ROUTING
1. Frame
2. Fuel tank breather hose (fuel tank to canister)
3. Canister
canister)
hose joint)
A. Face the white paint mark on the fuel tank breather
hose (fuel tank to canister) upward.
B. Point the ends of the hose clamp downward.
C. Face the yellow paint mark on the canister purge
hose (purge cut valve solenoid to canister) upward.
D. Install the fuel tank breather hose (fuel tank to
canister), canister breather hose and canister
purge hose (purge cut valve solenoid to canister)
completely onto the canister.
E. Point the ends of the hose clamp upward.
F. Face the blue paint mark on the canister purge
hose (purge cut valve solenoid to canister) upward.
G. Install the canister purge hoses (purge cut valve
solenoid to canister and purge cut valve solenoid
to hose joint) completely onto the purge cut valve
solenoid.
H. Point the ends of the hose clamp rearward.
I. Fit the fuel tank drain hose into the canister holder
as shown in the illustration.
2-58
CABLE ROUTING
ABS ECU (Electronic Control Unit) (top and left side view)
A
1 2 3 4 5
B
C
D
6 7 8 5
4
7
9
2-59
CABLE ROUTING
1. Brake hose (front brake master cylinder to brake hose

joint)
2. Brake hose (brake hose joint to front brake calipers)
3. Brake hose joint
4. Hydraulic unit brake pipe (brake hose joint to
hydraulic unit)
5. Hydraulic unit brake pipe (hydraulic unit to brake hose
joint)
6. Battery box
7. Rear brake hose (hydraulic unit to rear brake caliper)
8. Rear brake hose (rear brake master cylinder to
hydraulic unit)
9. Bracket
A. 79°
B. 89°
C. 77°
D. 78°
E. Forward
2-60
CABLE ROUTING
Oil cooler and thermostat (front side view)
1 A B C D
I
E
H 4
G A F G A F
J N K K
O
M M
2-61
CABLE ROUTING
1. Water jacket joint

2. Water pump inlet hose
3. Thermostat assembly
4. Oil cooler
5. Oil cooler outlet hose
6. Oil cooler inlet hose
A. Install the hose clamp with its end facing the front.
B. Face the white paint mark on the oil cooler outlet
hose forward and insert until the hose stops.
C. Align the yellow paint mark on the water pump inlet
hose with the rib on the thermostat assembly, and
insert until the hose stops.
D. Install the hose clamp with its end facing the rear.
E. Install the hose clamp with its end the screw head
facing the down.
F. Fit the clip at a position more than 1 mm (0.04 in)
from the end of the hose, and do not ride on the
spool.
G. Face the yellow paint mark on the hoses forward,
insert them up to the step where the thick part of pipe.
H. Install the hose clamp with its end facing the right.
I. Align the white paint mark on the oil cooler inlet hose
with the rib on the water jacket joint, and insert until
the hose stops.
J. Hose clamp fixed position details.
K. 3 mm (0.12 in) or more
L. 0–1 mm (0–0.04 in)
M. Hose plug-in section
N. Make sure not to install the hose clamp on the raised
O. Make sure not to install the hose clamp on the raised
2-62
CABLE ROUTING
Water pump (left side view)
1 2 A
B C
F
2-63
CABLE ROUTING
1. Water pump inlet hose

2. Water pump assembly
4. Radiator
A. Align the white paint mark on the water pump inlet
hose with the rib on the water pump and insert until
the hose stops.
B. Hose clamp fixed position details.
C. 3 mm (0.12 in) or more
D. 0–1 mm (0–0.04 in)
E. Hose plug-in section
F. Make sure not to install the hose clamp on the raised
2-64
CABLE ROUTING
2-65
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL ........................................................................................................ 3-4
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUGS ............................................................. 3-5
ADJUSTING THE VALVE CLEARANCE .................................................. 3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-8
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-8
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-10
CHECKING THE CYLINDER HEAD BREATHER HOSE .......................3-10
CHECKING THE EXHAUST SYSTEM....................................................3-10
CHECKING THE CANISTER .................................................................. 3-11
3
CHECKING THE PURGE CUT VALVE SOLENOID ...............................3-11
ADJUSTING THE EXHAUST GAS VOLUME .........................................3-11
REPLACING THE AIR FILTER ELEMENT ............................................. 3-11
ADJUSTING THE CLUTCH LEVER FREE PLAY................................... 3-12
CHECKING THE BRAKE OPERATION .................................................. 3-13
CHECKING THE BRAKE FLUID LEVEL................................................. 3-13
ADJUSTING THE FRONT DISC BRAKE................................................ 3-13
CHECKING THE FRONT BRAKE PADS ................................................ 3-14
ADJUSTING THE REAR DISC BRAKE .................................................. 3-14
CHECKING THE REAR BRAKE PADS .................................................. 3-14
CHECKING THE FRONT BRAKE HOSES ............................................. 3-15
CHECKING THE REAR BRAKE HOSE .................................................. 3-15
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)......................... 3-15
CHECKING THE WHEELS ..................................................................... 3-16
CHECKING THE TIRES..........................................................................3-16
CHECKING THE WHEEL BEARINGS ....................................................3-17
CHECKING THE SWINGARM OPERATION ..........................................3-17
LUBRICATING THE SWINGARM PIVOT ............................................... 3-18
DRIVE CHAIN SLACK............................................................................. 3-18
LUBRICATING THE DRIVE CHAIN ........................................................ 3-19
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-19
LUBRICATING THE STEERING HEAD.................................................. 3-20
CHECKING THE CHASSIS FASTENERS .............................................. 3-20
LUBRICATING THE BRAKE LEVER ......................................................3-20
LUBRICATING THE CLUTCH LEVER....................................................3-20
LUBRICATING THE PEDAL ................................................................... 3-20
ADJUSTING THE SHIFT PEDAL............................................................ 3-20
CHECKING THE SIDESTAND................................................................3-20
LUBRICATING THE SIDESTAND........................................................... 3-20
CHECKING THE CENTERSTAND ......................................................... 3-21
LUBRICATING THE CENTERSTAND ....................................................3-21
CHECKING THE SIDESTAND SWITCH................................................. 3-21
CHECKING THE FRONT FORK ............................................................. 3-21
ADJUSTING THE FRONT FORK LEGS (for MTT890) ........................... 3-21
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-22
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for MTT890)........................................................................................... 3-22
ADJUSTING THE FRONT FORK LEGS AND REAR SHOCK
ABSORBER (for MTT890D) ................................................................... 3-23
CHECKING THE CONNECTING ARM AND RELAY ARM.....................3-25
CHECKING THE ENGINE OIL LEVEL....................................................3-25
CHANGING THE ENGINE OIL ...............................................................3-25
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-26
CHECKING THE COOLANT LEVEL.......................................................3-28
CHECKING THE COOLING SYSTEM ....................................................3-28
CHANGING THE COOLANT................................................................... 3-28
CHECKING THE FRONT BRAKE LIGHT SWITCH ................................3-30
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-30
CHECKING AND LUBRICATING THE CABLES .................................... 3-30
CHECKING THE THROTTLE GRIP........................................................ 3-31
CHECKING AND CHARGING THE BATTERY....................................... 3-31
CHECKING THE FUSES ........................................................................3-31
ADJUSTING THE HEADLIGHT BEAM ...................................................3-31
ADJUSTING THE CORNERING LIGHT BEAM (for MTT890D).............. 3-31
PERIODIC MAINTENANCE
EAS20022
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.
TIP
• Items marked with an asterisk should be performed by your Yamaha dealer because these items re-
quire special tools, data, and technical skills.
• From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
• The annual checks must be performed every year, except if a distance-based maintenance is
performed instead.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
NO. ITEM JOB CHECK
1000 km 10000 km 20000 km 30000 km 40000 km
(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
GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
NO. ITEM JOB CHECK
1000 km 10000 km 20000 km 30000 km 40000 km
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Perform dynamic inspection

1 * Diagnostic sys- using Yamaha diagnostic tool. √ √ √ √ √ √
tem check
• Check the error codes.
2 * Air filter element • Replace. Every 40000 km (24000 mi)
• Check operation.
3 Clutch √ √ √ √ √
• Adjust.
• Check operation, fluid level,
and for fluid leakage.
4 * Front brake √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check operation, fluid level,
5 * Rear brake and for fluid leakage. √ √ √ √ √ √
• Replace brake pads if neces-
sary.
3-1
ODOMETER READING
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 for cracks or damage. √ √ √ √ √
6 * Brake hoses
• Replace. Every 4 years
7 * Brake fluid • Change. Every 2 years
• Check runout and for dam-
8 * Wheels age. √ √ √ √
• Check tread depth and for
damage.
9 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
10 * Wheel bearings √ √ √ √
or damage.
• Check operation and for ex-
cessive play. √ √ √ √
Swingarm pivot
11 *
bearings • Lubricate with lithium-soap- Every 50000 km (30000 mi)
based grease.
• Check chain slack, alignment
and condition. Every 1000 km (600 mi) and after washing the motorcycle, riding in the
12 Drive chain • Adjust and lubricate chain
with a special O-ring chain lu- rain or riding in wet areas
bricant thoroughly.
• Check bearing assemblies for
looseness. √ √ √
13 * Steering bearings
• Moderately repack with lithi- √ √
um-soap-based grease.
• Make sure that all nuts, bolts
14 * Chassis fasteners and screws are properly tight- √ √ √ √ √
ened.
Brake lever pivot • Lubricate with silicone
15 √ √ √ √ √
shaft grease.
Brake pedal pivot • Lubricate with lithium-soap-
16 shaft based grease. √ √ √ √ √
17 Clutch lever pivot • Lubricate with lithium-soap- √ √ √ √ √

shaft based grease.
Shift pedal pivot • Lubricate with lithium-soap-
18 √ √ √ √ √
shaft based grease.
19 Sidestand • Lubricate with molybdenum √ √ √ √ √
disulfide grease.
20 Centerstand • Lubricate with lithium-soap- √ √ √ √ √
based grease.
• Check operation and replace
21 * Sidestand switch if necessary. √ √ √ √ √ √
• Check operation and for oil

22 * Front fork leakage. √ √ √ √
Shock absorber • Check operation and for oil

23 * leakage. √ √ √ √
assembly • Replace if necessary.
Rear suspension
relay arm and
24 * connecting arm • Check operation. √ √ √ √
pivoting points
• Change (warm engine before
25 Engine oil draining). √ √ √ √ √ √
• Check oil level and vehicle for
oil leakage.
26 Engine oil filter • Replace. √ √ √

cartridge
3-2
ODOMETER READING
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 coolant level and vehi-
√ √ √ √ √
27 * Cooling system cle for coolant leakage.
• Change. Every 3 years
28 * Front and rear • Check operation. √ √ √ √ √ √

brake switches
Moving parts and
29 * • Lubricate. √ √ √ √ √
cables
30 * Throttle grip • Lubricate throttle grip housing √ √ √ √ √
tube guides.
Lights, signals • Check operation.
31 * and switches • Adjust headlight beam. √ √ √ √ √ √
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
areas.
• 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
EAS32024 EAS30619
CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE

YAMAHA DIAGNOSTIC TOOL The following procedure applies to all of the fuel,
Use the YDT and check the vehicle according to drain and breather hoses.
the following procedure. 1. Remove:
1. Remove: • Rider seat
• Passenger seat • Rubber cover
Refer to “GENERAL CHASSIS (1)” on page Refer to “GENERAL CHASSIS (1)” on page
4-1. 4-1.
2. Remove the protective cap, and then connect • Fuel tank bracket cover
the YDT to the coupler. • Side cover
Refer to “YDT” on page 9-2. Refer to “GENERAL CHASSIS (2)” on page
4-5.
Yamaha diagnostic tool USB • Front side cowling assembly
90890-03267 • Fuel tank side cover assembly
Yamaha diagnostic tool (A/I) Refer to “GENERAL CHASSIS (3)” on page
90890-03264
4-14.
• Fuel tank
TIP
Refer to “FUEL TANK” on page 7-1.
• Yamaha diagnostic tool (A/I) (90890-03264) in- 2. Check:
cludes YDT sub harness (6P) (90890-03266). • Fuel hose “1”
• If you already have Yamaha diagnostic tool (A/ • Fuel tank breather hose “2”
I) (90890-03262), YDT sub harness (6P) • Fuel tank drain hose “3”
(90890-03266) is separately required. Cracks/damage → Replace.
3. Check: Loose connection → Connect properly.
ECA14940
• DTC
NOTICE
TIP
Make sure the fuel tank breather hose is rout-
Use the “Diagnosis of malfunction” function of ed correctly.
the YDT to check the DTC. For information
about using the YDT, refer to the operation man- TIP
ual that is included with the tool. Before removing the fuel hoses, place a few
DTC No. is displayed → Check and repair the rags in the area under where it will be removed.
probable cause of the malfunction.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-52.
4. Perform:
• Dynamic inspection
TIP
Use the “Dynamic inspection” function of the
2
YDT version 3.0 and after to perform the dynam- 1 3
ic inspection. For information about using the
YDT, refer to the operation manual that is includ- 3. Install:
ed with the tool. • Fuel tank
5. Install: • Fuel tank side cover assembly
• Passenger seat • Front side cowling assembly
Refer to “GENERAL CHASSIS (1)” on page Refer to “GENERAL CHASSIS (3)” on page
4-1. 4-14.
• Side cover
3-4
• Fuel tank bracket cover 5. Clean:

Refer to “GENERAL CHASSIS (2)” on page • Spark plug
4-5. (with a spark plug cleaner or wire brush)
• Rubber cover 6. Measure:
• Rider seat • Spark plug gap “a”
Refer to “GENERAL CHASSIS (1)” on page (with a wire thickness gauge)
4-1. Out of specification → Regap.
EAS30620
Spark plug gap
CHECKING THE SPARK PLUGS 0.8–0.9 mm (0.031–0.035 in)
The following procedure applies to all of the
spark plugs.
1. Remove:
• Rider seat
• Rubber cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
• Fuel tank bracket cover
• Side cover
4-5. G088879
• Front side cowling assembly 7. Install:

• Fuel tank side cover assembly • Spark plug
Refer to “GENERAL CHASSIS (3)” on page • Ignition coil
4-14.
• Fuel tank Spark plug
Refer to “FUEL TANK” on page 7-1. 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
• Air filter case

Refer to “GENERAL CHASSIS (4)” on page TIP
4-24. Before installing the spark plug, clean the spark
2. Remove: plug and gasket surface.
• Ignition coil
8. Install:
• Spark plug
ECA13320 • Air filter case
NOTICE Refer to “GENERAL CHASSIS (4)” on page
Before removing the spark plugs, blow away 4-24.
any dirt accumulated in the spark plug wells • Fuel tank
with compressed air to prevent it from falling Refer to “FUEL TANK” on page 7-1.
into the cylinders. • Fuel tank side cover assembly
• Front side cowling assembly
3. Check: Refer to “GENERAL CHASSIS (3)” on page
• Spark plug type 4-14.
Incorrect → Change. • Side cover
Manufacturer/model
NGK/LMAR9A-9 Refer to “GENERAL CHASSIS (2)” on page
4-5.
4. Check: • Rubber cover
• Electrode “1” • Rider seat
Damage/wear → Replace the spark plug. Refer to “GENERAL CHASSIS (1)” on page
• Insulator “2” 4-1.
Abnormal color → Replace the spark plug. EAS30622
Normal color is medium-to-light tan. ADJUSTING THE VALVE CLEARANCE

valves.
3-5
TIP b. When piston #1 is at TDC on the compres-

Valve clearance adjustment should be made on sion stroke, align the TDC mark “a” on the
a cold engine, at room temperature. generator rotor with the generator rotor
cover mark “b”.
1. Remove:
• Rider seat b
• Rubber cover
Refer to “GENERAL CHASSIS (1)” on page a
4-1.
• Side cover
4-5.
• Fuel tank side cover assembly TIP
TDC on the compression stroke can be found
4-14.
when the camshaft lobes are turned away from
• Fuel tank
each other.
• Air filter case c. Measure the valve clearance with a thick-
Refer to “GENERAL CHASSIS (4)” on page ness gauge.
4-24.
• Radiator Thickness gauge
Refer to “RADIATOR” on page 6-3. 90890-03268
2. Remove: Feeler gauge set
YU-26900-9
• Ignition coil
• Spark plug
TIP
• Cylinder head cover
• Cylinder head cover gasket • If the valve clearance is incorrect, record the
Refer to “CAMSHAFTS” on page 5-17. measured reading.
3. Remove: • Measure the valve clearance in the following
• Timing mark accessing bolt “1” sequence.
• Crankshaft end cover “2”
Valve clearance measuring sequence
2 Cylinder #1 → #2 → #3
1
4. Measure:
• Valve clearance
Out of specification → Adjust. G088882
A. Front
Valve clearance (cold)
Intake d. To measure the valve clearances of the
0.11–0.20 mm (0.0043–0.0079 in) other cylinders, starting with cylinder #1 at
Exhaust TDC, turn the crankshaft counterclock-
0.28–0.32 mm (0.0110–0.0126 in) wise as specified in the following table.
a. Turn the crankshaft counterclockwise.
3-6
c. Check the thickness of the current valve

B pad.
TIP
The thickness “a” of each valve pad is marked in
D hundredths of millimeters on the side that touch-
es the valve lifter.
C D
Example:
D If the valve pad is marked “158”, the pad
thickness is 1.58 mm (0.062 in).
B. Degrees that the crankshaft is turned
counterclockwise
C. Cylinder a
D. Combustion cycle
Cylinder #2 240°
Cylinder #3 480°
5. Remove:
• Camshaft G088885
TIP d. Calculate the sum of the values obtained

• Refer to “CAMSHAFTS” on page 5-17. in steps (b) and (c) to determine the re-
• When removing the timing chain and cam- quired valve pad thickness and the valve
shafts, fasten the timing chain with a wire to re- pad number.
trieve it if it falls into the crankcase. Example:
1.58 mm (0.062 in) + 0.05 mm (0.002 in) =
6. Adjust:
1.63 mm (0.064 in)
• Valve clearance
The valve pad number is 163.
a. Remove the valve lifter and the valve pad
e. Round off the valve pad number according
with a valve lapper.
to the following table, and then select the
Valve lapper (ø14) suitable valve pad.
90890-04101 Last digit Rounded value
Valve lapper (ø14) 0, 1, 2 0
YM-A8998
3, 4, 5, 6 5
TIP 7, 8, 9 10
• Cover the timing chain opening with a rag to
TIP
prevent the valve pad from falling into the
crankcase. Refer to the following table for the available
• Make a note of the position of each valve lifter valve pads.
and valve pad so that they can be installed in Valve pad range Nos. 150–240
the correct place.
1.50–2.40 mm
Valve pad thickness
b. Calculate the difference between the (0.0590–0.0944 in)
specified valve clearance and the mea- 25 thicknesses in 0.05
sured valve clearance. Available valve pads mm (0.002 in) incre-
Example: ments
Specified valve clearance = 0.11–0.20
Example:
mm (0.004–0.008 in)
Valve pad number = 163
Measured valve clearance = 0.25 mm
Rounded value = 165
(0.010 in)
New valve pad number = 165
0.25 mm (0.010 in) - 0.20 mm (0.008 in) =
f. Install the new valve pad and the valve lift-
0.05 mm (0.002 in)
er.
3-7
TIP
Engine idling speed
• Lubricate the valve pad with molybdenum di- 1200–1400 r/min
sulfide oil.
• Lubricate the valve lifter (Top side) with molyb- 3. Check:
denum disulfide oil. • ISC (idle speed control) learning value
• Lubricate the valve lifter (Outer side) with en- “00” or “01” → Check the intake system.
gine oil. “02” → Clean the throttle bodies.
• Install the valve lifter and the valve pad in the Refer to “CHECKING AND CLEANING THE
correct place. THROTTLE BODIES” on page 7-8.
• The valve lifter must turn smoothly when rotat- a. Connect the YDT.
ed by hand. Use the diagnostic code number “67”.
g. Install the exhaust and intake camshafts, Refer to “DIAGNOSTIC CODE: SENSOR
timing chain and camshaft caps. OPERATION TABLE” on page 9-79.
b. Check the ISC (idle speed control) leaning
Camshaft cap bolt value.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
EAS30797
SYNCHRONIZING THE THROTTLE BODIES

TIP
TIP
• Refer to “CAMSHAFTS” on page 5-17.
Before synchronizing the throttle bodies, check
• Lubricate the camshaft lobes and camshaft
the following items:
journals.
• Valve clearance
• First, install the exhaust camshaft.
• Spark plug
• Align the camshafts marks with the camshaft
• Air filter element
cap marks.
• Throttle body joint
• Turn the crankshaft counterclockwise several
• Fuel hose
full turns to seat the parts.
• Exhaust system
h. Measure the valve clearance again. • Breather hose
i. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
Checking the throttle body synchronization
adjustment steps until the specified clear-
1. Stand the vehicle on a level surface.
ance is obtained.
TIP
7. Install:
• All removed parts Place the vehicle on a suitable stand.
TIP 2. Remove:
For installation, reverse the removal procedure. • Rider seat
• Rubber cover
EAS31017 Refer to “GENERAL CHASSIS (1)” on page
CHECKING THE ENGINE IDLING SPEED 4-1.
TIP • Fuel tank bracket cover
Prior to checking the engine idling speed, the • Side cover
throttle body synchronization should be adjusted Refer to “GENERAL CHASSIS (2)” on page
properly, the air filter element should be clean, 4-5.
and the engine should have adequate compres- • Front side cowling assembly
sion. • Fuel tank side cover assembly
1. Start the engine and let it warm up for several 4-14.
minutes. • Fuel tank
2. Check: Refer to “FUEL TANK” on page 7-1.
• Engine idling speed • Air filter case
Out of specification → Go to next step. Refer to “GENERAL CHASSIS (4)” on page
4-24.
3-8
3. Remove: Adjusting the throttle body synchronization

• Service hose cap “1” 1. Adjust:
• Throttle body synchronization
1 1 a. Start the engine, warm it up for several
minutes, and then let it run at the specified
engine idling speed.
Engine idling speed

1200–1400 r/min
b. Using the throttle body that has the bypass

air screw “1” with a white paint mark as the
standard, adjust the other throttle bodies
4. Install:
by turning its bypass air screw in or out.
• Vacuum gauge “1” ECA21300
NOTICE
Vacuum gauge
90890-03094 Do not turn the bypass air screw (white paint
Vacuummate mark) of the throttle body that is the stan-
YU-44456 dard. Otherwise, the engine may run roughly
at idle and the throttle bodies may not oper-
ate properly.
1 TIP
• Turn the bypass air screw using the carburetor
angle driver.
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
• If a bypass air screw was removed, turn the
screw in fully and be sure to synchronize the
5. Install: throttle bodies.
• Air filter case • If the throttle body synchronization can not be
Refer to “GENERAL CHASSIS (4)” on page adjusted using the bypass air screw, clean or
4-24. replace the throttle bodies.
• Fuel tank • The difference in vacuum pressure between
Refer to “FUEL TANK” on page 7-1. the throttle bodies should not exceed 1.3 kPa
6. Check: (10 mmHg).
• Throttle body synchronization
a. Start the engine, warm it up for several Carburetor angle driver 2
minutes, and then let it run at the specified 90890-03173
engine idling speed.
Engine idling speed

1200–1400 r/min
b. Check the vacuum pressure.
Difference in vacuum pressure

between the cylinders 1
0–1.3 kPa (10 mmHg, 0.4 inHg)
If out of specification → Adjust the throttle

body synchronization.
3-9
2. Stop the engine and remove the measuring • Air filter case
equipment. Refer to “GENERAL CHASSIS (4)” on page
3. Install: 4-24.
• Service hose cap 2. Check:
4. Install: • Cylinder head breather hose “1”
• Air filter case Cracks/damage → Replace.
Refer to “GENERAL CHASSIS (4)” on page Loose connection → Connect properly.
4-24. ECA14920
• Fuel tank NOTICE

Refer to “FUEL TANK” on page 7-1. Make sure the cylinder head breather hose is
• Fuel tank side cover assembly routed correctly.
4-14. 1
• Side cover
4-5.
• Rubber cover
• Rider seat
4-1. 3. Install:
EAS30798 • Air filter case
CHECKING THE THROTTLE BODY JOINTS Refer to “GENERAL CHASSIS (4)” on page
1. Remove: 4-24.
• Throttle body • Fuel tank
Refer to “THROTTLE BODIES” on page 7-6. Refer to “FUEL TANK” on page 7-1.
2. Check: • Fuel tank side cover assembly
• Throttle body joint • Front side cowling assembly
Cracks/damage → Replace. Refer to “GENERAL CHASSIS (3)” on page
3. Install: 4-14.
• Throttle body • Side cover
Refer to “THROTTLE BODIES” on page 7-6. • Fuel tank bracket cover
EAS30623
CHECKING THE CYLINDER HEAD 4-5.

BREATHER HOSE • Rubber cover
1. Remove: • Rider seat
• Rider seat Refer to “GENERAL CHASSIS (1)” on page
• Rubber cover 4-1.
Refer to “GENERAL CHASSIS (1)” on page EAS30625
4-1. CHECKING THE EXHAUST SYSTEM

• Fuel tank bracket cover 1. Check:
• Side cover • Muffler assembly “1”
Refer to “GENERAL CHASSIS (2)” on page Cracks/damage → Replace.
4-5. • Gasket “2”
• Front side cowling assembly Exhaust gas leaks → Replace.
• Fuel tank side cover assembly 2. Check:
Refer to “GENERAL CHASSIS (3)” on page Tightening torque
4-14. • Exhaust pipe nut “3”
• Fuel tank • Muffler bolt “4”
3-10
• Rider seat
Exhaust pipe nut Refer to “GENERAL CHASSIS (1)” on page
20 N·m (2.0 kgf·m, 15 lb·ft) 4-1.
T.
R.
Muffler bolt
20 N·m (2.0 kgf·m, 15 lb·ft) EAS33546
CHECKING THE PURGE CUT VALVE

SOLENOID
4
2 Refer to “CHECKING THE PURGE CUT VALVE
SOLENOID” on page 7-5.
EAS30799
ADJUSTING THE EXHAUST GAS VOLUME

1 TIP
• Be sure to set the CO density level to standard,
4 and then adjust the exhaust gas volume.
3 • To adjust the exhaust gas volume, use the CO
adjustment mode of the YDT. For more infor-
EAS31922
CHECKING THE CANISTER mation, refer to the operation manual of the

1. Remove: YDT.
• Rider seat 1. Remove the protective cap, and then connect
• Rubber cover the YDT to coupler.
Refer to “GENERAL CHASSIS (1)” on page Refer to “YDT” on page 9-2.
4-1.
• Fuel tank bracket cover Yamaha diagnostic tool USB
• Side cover 90890-03267
Refer to “GENERAL CHASSIS (2)” on page Yamaha diagnostic tool (A/I)
4-5. 90890-03264
• Fuel tank side cover assembly TIP
Refer to “GENERAL CHASSIS (3)” on page • Yamaha diagnostic tool (A/I) (90890-03264) in-
4-14. cludes YDT sub harness (6P) (90890-03266).
• Fuel tank • If you already have Yamaha diagnostic tool (A/
Refer to “FUEL TANK” on page 7-1. I) (90890-03262), YDT sub harness (6P)
2. Check: (90890-03266) is separately required.
• Canister
• Canister purge hose EAS30628
• Fuel tank breather hose REPLACING THE AIR FILTER ELEMENT

• Canister breather hose 1. Remove:
Cracks/damage → Replace. • Rider seat
Loose connection → Connect properly. • Rubber cover
Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS (1)” on page
3. Install: 4-1.
• Fuel tank • Fuel tank bracket cover
Refer to “FUEL TANK” on page 7-1. • Side cover
• Fuel tank side cover assembly Refer to “GENERAL CHASSIS (2)” on page
• Front side cowling assembly 4-5.
Refer to “GENERAL CHASSIS (3)” on page • Front side cowling assembly
4-14. • Fuel tank side cover assembly
• Side cover Refer to “GENERAL CHASSIS (3)” on page
• Fuel tank bracket cover 4-14.
Refer to “GENERAL CHASSIS (2)” on page • Fuel tank
4-5. Refer to “FUEL TANK” on page 7-1.
• Rubber cover 2. Remove:
• ECU (Engine Control Unit) “1”
3-11
• Air filter case cover “2” 5. Install:

Refer to “GENERAL CHASSIS (4)” on page • Fuel tank
4-24. Refer to “FUEL TANK” on page 7-1.
• Fuel tank side cover assembly
1
2 Refer to “GENERAL CHASSIS (3)” on page
4-14.
• Side cover
4-5.
• Rubber cover
• Rider seat
3. Check: Refer to “GENERAL CHASSIS (1)” on page
• Air filter element “1” 4-1.
• Air filter seal
Damage → Replace.
EAS30629
ADJUSTING THE CLUTCH LEVER FREE

TIP PLAY
• Replace the air filter element every 40000 km 1. Check:
(24000 mi) of operation. • Clutch lever free play “a”
• The air filter needs more frequent service if you Out of specification → Adjust.
are riding in unusually wet or dusty areas.
Clutch lever free play
1 5.0–10.0 mm (0.20–0.39 in)
4. Install:
G088887
• Air filter case cover 2. Adjust:
• ECU (Engine Control Unit) • Clutch lever free play
Refer to “REPLACING THE ECU (Engine
Control Unit)” on page 8-43. Handlebar side
ECA20710
a. Turn the adjusting bolt “1” until the speci-
NOTICE fied clutch lever free play is obtained.
Never operate the engine without the air filter
element installed. Unfiltered air will cause 1
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
synchronization, leading to poor engine per-
formance and possible overheating.
TIP
When installing the air filter element into the air G088888
filter case cover, make sure that the sealing sur-
faces are aligned to prevent any air leaks.
3-12
TIP
Front brake
If the specified clutch lever free play cannot be Specified brake fluid
obtained on the handlebar side of the cable, use DOT 4
the adjusting nut on the engine side. Rear brake
Specified brake fluid
Engine side DOT 4
a. Loosen the locknut “1”. EWA13090
b. Turn the adjusting nut “2” until the speci- WARNING

fied clutch lever free play is obtained. • Use only the designated brake fluid. Other
c. Tighten the locknut “1”. brake fluids may cause the rubber seals to
Clutch cable locknut deteriorate, causing leakage and poor
7 N·m (0.7 kgf·m, 5.2 lb·ft) brake performance.
T.
• Refill with the same type of brake fluid that

R.
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
2 the brake fluid and could cause vapor lock.
ECA13540
1
NOTICE
Brake fluid may damage painted surfaces
EAS30801 and plastic parts. Therefore, always clean up
CHECKING THE BRAKE OPERATION any spilt brake fluid immediately.
1. Check:
• Brake operation TIP
Brake not working properly → Check the In order to ensure a correct reading of the brake
brake system. fluid level, make sure the top of the brake fluid
Refer to “FRONT BRAKE” on page 4-41 and reservoir is horizontal.
“REAR BRAKE” on page 4-54.
EAS30630
TIP
ADJUSTING THE FRONT DISC BRAKE
Drive on the dry road, operate the front and rear 1. Adjust:
brakes separately and check to see if the brakes • Front brake lever position
are operating properly. (distance “a” from the throttle grip to the brake
lever)
EAS30632
CHECKING THE BRAKE FLUID LEVEL

TIP
• Place the vehicle on a suitable stand. a
• Make sure the vehicle is upright.
2. Check:
• Brake fluid level
Below the minimum level mark → Add the
G088889
specified brake fluid to the proper level.
a. Push the brake lever forward.
b. Turn the adjusting dial “1” until the brake
lever is in the desired position.
3-13
c. Align the appropriate setting on the adjust- EAS30631
ADJUSTING THE REAR DISC BRAKE

ing dial with the mark “a” on the brake le-
1. Adjust:
ver.
• Brake pedal position
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the speci-
fied brake pedal position is obtained.
EWA18830
WARNING
1 a After adjusting the brake pedal position,
check that the end of the adjusting bolt “a” is
visible through the hole “b”.
G088890 c. Tighten the locknut “1” to specification.
EWA17050
WARNING Rear brake master cylinder lock-

• After adjusting the brake lever position, nut
T.
R.
18 N·m (1.8 kgf·m, 13 lb·ft)
make sure the pin on the brake lever holder
is firmly inserted in the hole in the adjusting EWA17030
dial. WARNING
• A soft or spongy feeling in the brake lever A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake can indicate the presence of air in the brake
system. Before the vehicle is operated, the system. Before the vehicle is operated, the
air must be removed by bleeding the brake air must be removed by bleeding the brake
system. Air in the brake system will consid- system. Air in the brake system will consid-
erably reduce brake performance resulting erably reduce braking performance.
in loss of control and possibly cause an ac- ECA13510
cident. Therefore, check and if necessary, NOTICE
bleed the brake system.
After adjusting the brake pedal position,
ECA13490
make sure there is no brake drag.
NOTICE
After adjusting the brake lever position,
make sure there is no brake drag.
EAS30633
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the a
brake pads. 2
1. Operate the brake.
2. Check: b
1
• Front brake pad
Wear indicators “1” almost touch the brake 2. Adjust:
disc → Replace the brake pads as a set. • Rear brake light switch
Refer to “FRONT BRAKE” on page 4-41. Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-30.
EAS30634
CHECKING THE REAR BRAKE PADS

1 1 brake pads.
1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicator grooves “1” almost disap-
peared → Replace the brake pads as a set.
3-14
Refer to “REAR BRAKE” on page 4-54. ECA22640
NOTICE
• Bleed the brake system in the following or-
der.
• 1st step: Front brake master cylinder
• 2nd step: Front brake calipers
1 1 • 3rd step: Rear brake caliper
EWA16530
WARNING
Bleed the ABS whenever:
• the system is disassembled.
EAS30635 • a brake hose is loosened, disconnected or
CHECKING THE FRONT BRAKE HOSES replaced.
The following procedure applies to all of the • the brake fluid level is very low.
brake hoses and brake hose holders. • brake operation is faulty.
1. Check:
• Brake hose TIP
Cracks/damage/wear → Replace. • Be careful not to spill any brake fluid or allow
2. Check: the brake fluid reservoir to overflow.
• Brake hose holder • When bleeding the ABS, make sure that there
Loose → Tighten the holder bolt. is always enough brake fluid before applying
3. Hold the vehicle upright and apply the brake the brake. Ignoring this precaution could allow
several times. air to enter the ABS, considerably lengthening
4. Check: the bleeding procedure.
• Brake hose • If bleeding is difficult, it may be necessary to let
Brake fluid leakage → Replace the damaged the brake fluid settle for a few hours.
hose. • Repeat the bleeding procedure when the tiny
Refer to “FRONT BRAKE” on page 4-41. bubbles in the hose have disappeared.
EAS30636 1. Bleed:
CHECKING THE REAR BRAKE HOSE • ABS
1. Check: a. Fill the brake fluid reservoir to the proper
• Brake hose level with the specified brake fluid.
Cracks/damage/wear → Replace. b. Install the brake fluid reservoir diaphragm.
2. Check: c. Connect a clear plastic hose “1” tightly to
• Brake hose holder the bleed screw “2”.
Loose Connection → Tighten the holder bolt.
A
3. Hold the vehicle upright and apply the rear
brake several times.
4. Check:
• Brake hose 1
Brake fluid leakage → Replace the damaged
hose.
2
Refer to “REAR BRAKE” on page 4-54.
EAS30893
BLEEDING THE HYDRAULIC BRAKE

SYSTEM (ABS)
EWA14000
WARNING
Always bleed the brake system when the
brake related parts are removed.
3-15
l. Tighten the bleed screw to specification.

B
Front brake master cylinder
bleed screw
T.
R.
5 N·m (0.5 kgf·m, 3.7 lb·ft)
Brake caliper bleed screw
2 5 N·m (0.5 kgf·m, 3.7 lb·ft)
m. Fill the brake fluid reservoir to the proper

1 level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
C
LEVEL” on page 3-13.
EWA13110
1 WARNING
2
After bleeding the hydraulic brake system,
check the brake operation.
EAS30638
CHECKING THE WHEELS

The following procedure applies to both of the
wheels.
1. Check:
A. Front brake master cylinder • Wheel
B. Front brake caliper (left/right) Damage/out-of-round → Replace.
C. Rear brake caliper EWA13260
WARNING
d. Place the other end of the hose into a con-
tainer. Never attempt to make any repairs to the
e. Slowly apply the brake several times. wheel.
f. Fully squeeze the brake lever or fully de- TIP
press the brake pedal and hold it in posi- After a tire or wheel has been changed or re-
tion. placed, always balance the wheel.
g. Loosen the bleed screw.
TIP EAS30640
Loosening the bleed screw will release the pres- CHECKING THE TIRES
sure and cause the brake lever to contact the The following procedure applies to both of the
throttle grip or the brake pedal to fully extend. tires.
1. Check:
h. Tighten the bleed screw and then release • Tire air pressure
the brake lever or brake pedal. Out of specification → Regulate.
i. Repeat steps (e) to (h) until all of the air EWA13181
bubbles have disappeared from the brake WARNING

fluid in the plastic hose. • The tire pressure should only be checked
j. Check the operation of the hydraulic unit. and regulated when the tire temperature
Refer to “HYDRAULIC UNIT OPERA- equals the ambient air temperature.
TION TESTS” on page 4-70. • The tire pressure and the suspension must
ECA17061
NOTICE
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
Make sure that the main switch is turned to cessories) and the anticipated riding
“OFF” before checking the operation of the speed.
hydraulic unit. • Operation of an overloaded vehicle could
k. After operating the ABS, repeat steps (e) cause tire damage, an accident or an injury.
to (i), and then fill the brake fluid reservoir NEVER OVERLOAD THE VEHICLE.
to the proper level with the specified brake
fluid.
3-16
Tire air pressure (measured on Rear tire

cold tires) Size
1 person 180/55ZR17M/C (73W)
Front Manufacturer/model
250 kPa (2.50 kgf/cm², 36 psi) BRIDGESTONE/BATTLAX
Rear SPORT TOURING T32R
290 kPa (2.90 kgf/cm², 42 psi)
2 persons EWA13210
Front WARNING
250 kPa (2.50 kgf/cm², 36 psi) New tires have a relatively low grip on the
Rear road surface until they have been slightly
290 kPa (2.90 kgf/cm², 42 psi) worn. Therefore, approximately 100 km
Maximum load should be traveled at normal speed before
193 kg (425 lb) any high-speed riding is done.
* Maximum load: Total weight of rider, pas-
senger, cargo and accessories TIP
For tires with a direction of rotation mark “1”:
2. Check: • Install the tire with the mark pointing in the di-
• Tire surfaces rection of wheel rotation.
Damage/wear → Replace the tire. • Align the mark “2” with the valve installation
EWA13190
point.
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re- 1
place the tire immediately.
2
Wear limit (front)
1.6 mm (0.06 in)
Wear limit (rear)
1.6 mm (0.06 in)
EWA14090 G088891
WARNING EAS30641
After extensive tests, the tires listed below CHECKING THE WHEEL BEARINGS
have been approved by Yamaha Motor Co., The following procedure applies to all of the
Ltd. for this model. The front and rear tires wheel bearing.
should always be by the same manufacturer 1. Check:
and of the same design. No guarantee con- • Wheel bearing
cerning handling characteristics can be giv- Refer to “CHECKING THE FRONT WHEEL”
en if a tire combination other than one on page 4-28 and “CHECKING THE REAR
approved by Yamaha is used on this vehicle. WHEEL” on page 4-36.
EAS30802
Front tire CHECKING THE SWINGARM OPERATION
Size 1. Check:
120/70ZR17M/C (58W) • Swingarm operation
Manufacturer/model Swingarm not working properly → Check the
BRIDGESTONE/BATTLAX
swingarm.
SPORT TOURING T32F
Refer to “SWINGARM” on page 4-126.
2. Check:
• Swingarm excessive play
Refer to “SWINGARM” on page 4-126.
3-17
EAS30643
LUBRICATING THE SWINGARM PIVOT 1

1. Lubricate:
• Dust cover a
• Pivot shaft
• Bearing 2
• Oil seal
• Collar
Recommended lubricant
Lithium-soap-based grease
Refer to “INSTALLING THE SWINGARM” on 1 d

page 4-128.
EAS31923
c
DRIVE CHAIN SLACK
2 b
Checking the drive chain slack
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over. ECA20870
NOTICE
ECA13550
NOTICE Improper drive chain slack will overload the

A drive chain that is too tight will overload engine as well as other vital parts of the mo-
the engine and other vital parts, and one that torcycle and can lead to chain slippage or
is too loose can skip and damage the swing- breakage. If the drive chain slack is more
arm or cause an accident. Therefore, keep than the specified limit, the chain can dam-
the drive chain slack within the specified lim- age the frame, swingarm, and other parts. To
its. prevent this from occurring, keep the drive
chain slack within the specified limits.
1. Shift the transmission into the neutral posi-
tion.
Adjusting the drive chain slack
2. Check: EWA13120
• Drive chain slack WARNING
Out of specification → Adjust.
TIP no danger of it falling over.
• Measure the distance “a” between the rib end
1. Loosen:
on the drive chain guide “1” and the center
• Wheel axle nut
point of the drive chain “2”.
Refer to “REAR WHEEL” on page 4-33.
• The center point “b” of the drive chain is ap-
2. Adjust:
prox. 53 mm (2.09 in) “c” forward from the edge
• Drive chain slack
“d” of the drive chain guide.
a. Loosen both locknuts “1”.
b. Turn both adjusting bolts “2” until the spec-
Drive chain slack (Mainstand) ified drive chain slack is obtained.
45.0–50.0 mm (1.77–1.97 in)
Drive chain slack limit (Main-
stand)
55.0 mm (2.17 in)
3-18
EAS30645
CHECKING AND ADJUSTING THE

2 STEERING HEAD
1 1. Stand the vehicle on a level surface.
EWA13120
WARNING
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
TIP front wheel is elevated.
• To maintain the proper wheel alignment, adjust 2. Check:
both sides evenly. • Steering head
• There should be no clearance between the ad- Grasp the bottom of the front fork legs and
justing block and adjusting bolt. gently rock the front fork.
c. Tighten the wheel axle nut to specification. Blinding/looseness → Adjust the steering
head.
Rear wheel axle nut 3. Remove:
105 N·m (10.5 kgf·m, 77 lb·ft) • Upper bracket
T.
R.
4. Adjust:
d. Tighten the locknuts to specification. • Steering head
a. Remove the lock washer “1”, the upper
Chain puller adjusting bolt lock-
nut ring nut “2”, and the rubber washer “3”.
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft)
EAS30803
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
G088892
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean- b. Loosen the lower ring nut “4” and then
ing, high-pressure washing, certain solvents, tighten it to specification with a steering
and the use of a coarse brush can damage nut wrench “5”.
these O-rings. Therefore, use only kerosene to TIP
clean the drive chain. Wipe the drive chain dry • Set the torque wrench at a right angle to the
and thoroughly lubricate it with engine oil or steering nut wrench.
chain lubricant that is suitable for O-ring chains. • Move the steering to the left and right a couple
Do not use any other lubricants on the drive of times to check that it moves smoothly.
chain since they may contain solvents that could
damage the O-rings.
Chain lubricant suitable for O-
ring chains
G088893
3-19
EAS30646
Steering nut wrench LUBRICATING THE STEERING HEAD

90890-01403 1. Lubricate:
Exhaust flange nut wrench • Upper bearing
YU-A9472 • Lower bearing
• Bearing race
Lower ring nut (initial tightening Recommended lubricant
torque) Lithium-soap-based grease
T.
R.
52 N·m (5.2 kgf·m, 38 lb·ft)

EAS31186
c. Loosen the lower ring nut completely, then CHECKING THE CHASSIS FASTENERS
tighten it to specification. Make sure that all nuts, bolts, and screws are
EWA13140
properly tightened.
WARNING
Refer to “CHASSIS TIGHTENING TORQUES”
Do not overtighten the lower ring nut. on page 2-12.
EAS30804
Lower ring nut (final tightening LUBRICATING THE BRAKE LEVER
torque)
Lubricate the pivoting point and metal-to-metal
T.
R.
14 N·m (1.4 kgf·m, 10 lb·ft)

moving parts of the lever.
d. Check the steering head for looseness or Recommended lubricant
binding by turning the front fork all the way Silicone grease
in both directions. If any binding is felt, re-
move the lower bracket and check the up- EAS30805
per and lower bearings. LUBRICATING THE CLUTCH LEVER

Refer to “STEERING HEAD” on page Lubricate the pivoting point and metal-to-metal
4-112. moving parts of the lever.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”. Recommended lubricant
g. Finger tighten the upper ring nut, then Lithium-soap-based grease
align the slots of both ring nuts. If neces-
EAS30649
sary, hold the lower ring nut and tighten LUBRICATING THE PEDAL
the upper ring nut until their slots are
Lubricate the pivoting point and metal-to-metal
aligned.
moving parts of the pedal.
h. Install the lock washer “1”.
TIP Recommended lubricant
Make sure the lock washer tabs “a” sit correctly Lithium-soap-based grease
in the ring nut slots “b”.
EAS30851
ADJUSTING THE SHIFT PEDAL

Refer to “ADJUSTING THE SHIFT PEDAL” on
page 4-135.
EAS30650
CHECKING THE SIDESTAND

1. Check:
• Sidestand operation
Check that the sidestand moves smoothly.
G088894
Rough movement → Repair or replace.
5. Install: EAS30651
• Upper bracket LUBRICATING THE SIDESTAND

Refer to “HANDLEBAR” on page 4-74. Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the side-
stand.
3-20
EAS30806
Recommended lubricant ADJUSTING THE FRONT FORK LEGS (for

Molybdenum disulfide grease MTT890)
EAS30856 front fork legs.
CHECKING THE CENTERSTAND EWA13120
1. Check: WARNING
• Centerstand operation Securely support the vehicle so that there is
Check that the centerstand moves smoothly. no danger of it falling over.
Rough movement → Repair or replace.
EAS30857 Spring preload
LUBRICATING THE CENTERSTAND EWA17040
Lubricate the pivoting point and metal-to-metal WARNING

moving parts of the centerstand. Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
Recommended lubricant dling and loss of stability.
Lithium-soap-based grease ECA13590
NOTICE
EAS30652
CHECKING THE SIDESTAND SWITCH Never go beyond the maximum or minimum

Refer to “ELECTRICAL COMPONENTS” on adjustment positions.
page 8-39. 1. Adjust:
EAS30653
• Spring preload
CHECKING THE FRONT FORK a. Turn the adjusting bolt “1” in direction “a”
1. Stand the vehicle on a level surface. or “b”.
EWA13120
WARNING Direction “a”

Securely support the vehicle so that there is Spring preload is increased (suspen-
no danger of it falling over. sion is harder).
Direction “b”
2. Check: Spring preload is decreased (suspen-
• Inner tube sion is softer).
Damage/scratches → Replace.
• Front fork leg
Oil leaks between inner tube and outer tube 1 1
→ Replace the oil seal.
Refer to “FRONT FORK (for MTT890)” on
page 4-85 or refer to “FRONT FORK (for
MTT890D)” on page 4-97.
3. Hold the vehicle upright and apply the front a b a b
brake.
4. Check:
• Front fork operation
Push down hard on the handlebar several
TIP
times and check if the front fork rebounds
smoothly. The spring preload setting is determined by
Rough movement → Repair. measuring the distance “c” shown in the illustra-
Refer to “FRONT FORK (for MTT890)” on tion. The shorter distance “c” is, the higher the
page 4-85 or refer to “FRONT FORK (for spring preload; the longer distance “c” is, the
MTT890D)” on page 4-97. lower the spring preload.
3-21
differences in production, the actual number of

clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of
each damping force adjusting mechanism and
c
to modify the specifications as necessary.
• When turning the damping force adjusting bolt
in direction “a”, the 0 click position and the 1
click position may be the same.
1
Spring preload a b
Adjustment value (Soft)
19.0 mm (0.75 in) (MTT890)
Adjustment value (STD)
16.0 mm (0.63 in) (MTT890)
Adjustment value (Hard)
4.0 mm (0.16 in) (MTT890)
Rebound damping (right side only)

ECA13590 EAS30808
NOTICE CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
Never go beyond the maximum or minimum
Refer to “CHECKING THE REAR SHOCK AB-
adjustment positions.
SORBER ASSEMBLIES (for MTT890)” on page
1. Adjust: 4-117 or refer to “CHECKING THE REAR
• Rebound damping SHOCK ABSORBER ASSEMBLY (for
a. Turn the adjusting screw “1” in direction MTT890D)” on page 4-121.
“a” or “b”.
EAS30655
ADJUSTING THE REAR SHOCK ABSORBER

Direction “a”
Rebound damping is increased (sus- ASSEMBLY (for MTT890)
EWA13120
pension is harder). WARNING
Direction “b”
Rebound damping is decreased (sus- Securely support the vehicle so that there is
pension is softer). no danger of it falling over.
Spring preload
Rebound damping ECA13590
Adjustment value from the start NOTICE

position (Soft) Never go beyond the maximum or minimum
11 (MTT890)
Adjustment value from the start
position (STD) 1. Adjust:
6 (MTT890) • Spring preload
Adjustment value from the start a. Adjust the spring preload with the special
position (Hard) wrench “1” and extension bar “2” included
1 (MTT890) in the owner’s tool kit.
* Start position: With the adjusting screw b. Turn the adjusting ring “3” in direction “a”
fully turned in direction “a” or “b”.
c. Align the desired position on the adjusting
TIP ring with the stopper “4”.
• Although the total number of clicks of a damp-
ing force adjusting mechanism may not exactly
match the above specifications due to small
3-22
Direction “a” Rebound damping

Spring preload is increased (suspen- Adjustment value from the start
sion is harder). position (Soft)
Direction “b” 2 1/2 (MTT890)
Spring preload is decreased (suspen- Adjustment value from the start
sion is softer). position (STD)
1 (MTT890)
Adjustment value from the start
Spring preload position (Hard)
Adjustment value (Soft) 0 (MTT890)
1 (MTT890) * Start position: With the adjusting screw
Adjustment value (STD) fully turned in direction “a”
4 (MTT890)
Adjustment value (Hard) TIP
7 (MTT890)
Although the total number of turns of a damping
force adjusting mechanism may not exactly
21 match the above specifications due to small dif-
1 76543
2 ferences in production, the actual number of
a 4 turns always represents the entire adjusting
range. To obtain a precise adjustment, it would
be advisable to check the number of turns of
each damping force adjusting mechanism and
3
b to modify the specifications as necessary.
Rebound damping
ECA13590
NOTICE b a
Never go beyond the maximum or minimum 1
1. Adjust:
• Rebound damping
a. Turn the adjusting screw “1” in direction
EAS33552
“a” or “b”. ADJUSTING THE FRONT FORK LEGS AND
REAR SHOCK ABSORBER (for MTT890D)
Direction “a”
Rebound damping is increased (sus-
pension is harder). front fork legs and rear shock absorber.
EWA12313
Direction “b” WARNING
Rebound damping is decreased (sus-
pension is softer). Be sure to stop the vehicle before making
any setting changes to the multi-function
display. Changing settings while riding can
distract the operator and increase the risk of
an accident.
Damping force
Within each preload setting there are 2 damping
force settings: “SUS-MODE A-1” and “SUS-
MODE A-2”.
3-23
SUS-MODE A-1: Sport setting with increased

damping force, suitable for smoother road con-
1
ditions
SUS-MODE A-2: Comfort setting with softer b
a
damping force, suitable for rougher road condi-
tions
EWA21170
WARNING
Do not change the suspension mode while 1
1
the vehicle is moving.
TIP Spring preload
The current “SUS-MODE” setting is saved when Minimum (soft):
the vehicle is turned off. 0 turn(s) in direction “a”
Standard:
1. Adjust: 2 turn(s) in direction “a”
• Damping force Maximum (hard):
a. Turn the main switch to “ON”. 10 turn(s) in direction “a”
b. Use the “MODE” switch to select “SUS- * With the adjusting nut fully turned in di-
MODE”. rection “b”
c. Use “MODE up/down” switches to select
“SUS-MODE A-1” or “SUS-MODE A-2”.
Spring preload of the rear shock absorber
Spring preload of the front fork legs assembly
ECA13590
EWA17040
WARNING NOTICE
Always adjust both front fork legs evenly. Never go beyond the maximum or minimum
Uneven adjustment can result in poor han- adjustment positions.
dling and loss of stability. 1. Adjust:
ECA13590 • Spring preload
NOTICE a. Turn the adjusting knob “1” in direction “a”
Never go beyond the maximum or minimum or “b”.
Direction “a”
1. Adjust: Spring preload is increased (suspen-
• Spring preload sion is harder).
a. Turn the adjusting bolt “1” in direction “a” Direction “b”
or “b”. Spring preload is decreased (suspen-
sion is softer).
Direction “a”
Spring preload is increased (suspen-
sion is harder).
Direction “b” a
Spring preload is decreased (suspen-
sion is softer).
1
b
3-24
Spring preload Recommended brand

Minimum (soft): YAMALUBE
1 click(s) in direction “a” SAE viscosity grades
Standard: 10W-40
11 click(s) in direction “a” Recommended engine oil grade
Maximum (hard): API service SG type or higher,
24 click(s) in direction “a” JASO standard MA
* With the adjusting nut fully turned in di- ECA13361
rection “b” NOTICE
TIP • Engine oil also lubricates the clutch and the

wrong oil types or additives could cause
When turning the spring preload adjuster in di-
clutch slippage. Therefore, do not add any
rection “b”, the 0 click position and the 1 click po-
chemical additives or use engine oils with a
sition may be the same.
grade of “CD” or higher and do not use oils
labeled “ENERGY CONSERVING II”.
EAS30809
CHECKING THE CONNECTING ARM AND • Do not allow foreign materials to enter the
RELAY ARM crankcase.
Refer to “CHECKING THE CONNECTING ARM TIP
AND RELAY ARM” on page 4-117. Before checking the engine oil level, wait a few
EAS30656 minutes until the oil has settled.
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface. 4. Start the engine, warm it up for several min-
utes, and then turn it off.
TIP
5. Check the engine oil level again.
• Place the vehicle on a suitable stand.
TIP
• Make sure the vehicle is upright.
Before checking the engine oil level, wait a few
2. Start the engine, warm it up for several min- minutes until the oil has settled.
3. Check: EAS30657
• Engine oil level CHANGING THE ENGINE OIL

The engine oil level should be between the 1. Start the engine, warm it up for several min-
minimum level mark “a” and maximum level utes, and then turn it off.
mark “b”. 2. Place a container under the engine oil drain
Below the minimum level mark → Add the bolt.
recommended engine oil to the proper level. 3. Remove:
• Engine oil filler cap “1”
• Engine oil drain bolt “2”
• Gasket “3”
1
a
b
3-25
7. Fill:
• Crankcase
(with the specified amount of the recom-
mended engine oil)
Engine oil quantity

2 3 Quantity (disassembled)
3.50 L (3.70 US qt, 3.08 Imp.qt)
Oil change
2.80 L (2.96 US qt, 2.46 Imp.qt)
With oil filter removal
4. Drain: 3.20 L (3.38 US qt, 2.82 Imp.qt)
• Engine oil
(completely from the crankcase) 8. Install:
5. If the oil filter cartridge is also to be replaced, • Engine oil filler cap
perform the following procedure. (along with the O-ring New )
a. Remove the oil filter cartridge “1” with an 9. Start the engine, warm it up for several min-
oil filter wrench “2”. utes, and then turn it off.
10.Check:
Oil filter wrench • Engine
90890-01426
(for engine oil leaks)
Oil filter wrench
YU-38411 11.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
EAS30810
MEASURING THE ENGINE OIL PRESSURE

1. Check:
• Engine oil level
Below the minimum level mark “a” → Add the
recommended engine oil to the proper level.
2 1
b. Lubricate the O-ring of the new oil filter

cartridge with a thin coat of engine oil.
ECA25890
NOTICE
Make sure the O-ring is positioned correctly
in the groove of the oil filter cartridge.
c. Tighten the new oil filter cartridge to spec- a
ification with an oil filter wrench.
2. Start the engine, warm it up for several min-
Oil filter cartridge utes, and then turn it off.
17 N·m (1.7 kgf·m, 13 lb·ft) ECA13410
T.
R.
NOTICE
6. Install: When the engine is cold, the engine oil will
• Engine oil drain bolt have a higher viscosity, causing the engine
(along with the gasket New ) oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
Engine oil drain bolt warming up the engine.
43 N·m (4.3 kgf·m, 32 lb·ft)
T.
3. Remove:
R.
• Oil pressure switch joint bolt “1”
3-26
• Oil pressure switch joint (with the oil pressure 6. Start the engine, warm it up for several min-
switch) “2” utes.
EWA12980 ECA13410
WARNING NOTICE
The engine, muffler and engine oil are ex- When the engine is cold, the engine oil will
tremely hot. have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
7. Measure:
• Engine oil pressure
(at the following conditions)
2
Oil pressure
1 200.0 kPa/5000 r/min (2.00 kgf/
cm²/5000 r/min, 29.0 psi/5000 r/
min)
4. Install:
• Oil pressure gauge joint 18 mm “1” Out of specification → Check.
Engine oil pressure Possible causes
Oil pressure gauge joint 18 mm • Faulty oil pump
90890-04176 • Clogged oil filter
YU-04176 Below specification • Leaking oil passage
• Broken or damaged
oil seal
Oil pressure switch joint bolt
• Faulty oil filter
10 N·m (1.0 kgf·m, 7.4 lb·ft) Above specification
T.
• Oil viscosity too high

R.
8. Remove:
• Oil pressure gauge
• Adapter C
1 • Oil pressure switch joint bolt
• Oil pressure switch joint (with the O-ring)
2
9. Install:
• O-ring “1” New
• Oil pressure switch joint (with the oil pressure
switch) “2”
5. Install:
• Oil pressure gauge “1” Oil pressure switch joint bolt
• Adapter C “2” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Oil pressure gauge set

90890-03120
3
2 1 New
3-27
EAS30811
• Oil cooler outlet hose “9”
CHECKING THE COOLANT LEVEL
• Water jacket joint “10”
• Oil cooler inlet hose “11”
TIP • Oil cooler “12”
• Place the vehicle on a suitable stand. Cracks/damage → Replace.
• Make sure the vehicle is upright. Refer to “RADIATOR” on page 6-3, “OIL
2. Check: COOLER” on page 6-7, “THERMOSTAT” on
• Coolant level page 6-9, and “WATER PUMP” on page
The coolant level should be between the 6-11.
maximum level mark “a” and minimum level
1 2
mark “b”.
recommended coolant to the proper level.
4
a
10 5
b 6
8
11
ECA21281
NOTICE 9
• Adding water instead of coolant dilutes the 7
antifreeze concentration of the coolant. If 12
water is used instead of coolant; check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if dis- EAS30813
tilled water is not available, soft water may CHANGING THE COOLANT
be used. 1. Remove:
• Front side cowling assembly (right)
3. Start the engine, warm it up for several min- Refer to “GENERAL CHASSIS (3)” on page
utes, and then turn it off. 4-14.
4. Check: • Radiator cap “1”
• Coolant level EWA13030
TIP WARNING
Before checking the coolant level, wait a few A hot radiator is under pressure. Therefore,
minutes until it settles. do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
EAS30812 be blown out, which could cause serious in-
CHECKING THE COOLING SYSTEM jury. When the engine has cooled, open the
1. Check: radiator cap as follows:
• Radiator “1” Place a thick rag or a towel over the radiator
• Water pump inlet hose “2” cap and slowly turn the radiator cap counter-
• Thermostat housing “3” clockwise toward the detent to allow any re-
• Thermostat “4” sidual pressure to escape. When the hissing
• Thermostat cover “5” sound has stopped, press down on the radi-
• Radiator outlet hose “6” ator cap and turn it counterclockwise to re-
• Water pump “7” move.
• Radiator inlet hose “8”
3-28
1 2
2. Remove: 6. Drain:
• Coolant reservoir bolt • Coolant
• Coolant reservoir cover “1” (from the engine and radiator)
• Coolant reservoir “2” 7. Install:
• Collar • Water pump drain bolt
Refer to “RADIATOR” on page 6-3. • Copper washer New
Water pump drain bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
8. Install:
• Collar
• Coolant reservoir
• Coolant reservoir cover
1 • Coolant reservoir bolt
2
Refer to “RADIATOR” on page 6-3.
3. Remove:
Coolant reservoir bolt (M5)
• Coolant reservoir cap “1”
0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
T.
R.
1 Coolant reservoir bolt (M6)

9 N·m (0.9 kgf·m, 6.6 lb·ft)
LOCTITE®
9. Fill:
• Cooling system
mended coolant)
Recommended antifreeze
4. Drain: High-quality ethylene glycol anti-
• Coolant freeze containing corrosion
(from the coolant reservoir) inhibitors for aluminum engines
Mixing ratio
5. Remove:
1:1 (antifreeze:water)
• Water pump drain bolt “1” Radiator (including all routes)
• Copper washer “2” 1.72 L (1.82 US qt, 1.51 Imp.qt)
Coolant reservoir (up to the maxi-
mum level mark)
0.28 L (0.30 US qt, 0.25 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
3-29
EWA13040 EAS30814
WARNING CHECKING THE FRONT BRAKE LIGHT

• If coolant splashes in your eyes, thorough- SWITCH
ly wash them with water and consult a doc- Refer to “ELECTRICAL COMPONENTS” on
tor. page 8-39.
• If coolant splashes on your clothes, quickly EAS30659
wash it away with water and then with soap ADJUSTING THE REAR BRAKE LIGHT
and water. SWITCH
• If coolant is swallowed, induce vomiting TIP
and get immediate medical attention. The rear brake light switch is operated by move-
ECA21291
ment of the brake pedal. The rear brake light
NOTICE switch is properly adjusted when the brake light
• Adding water instead of coolant dilutes the comes on just before the braking effect starts.
antifreeze concentration of the coolant. If
1. Check:
water is used instead of coolant; check,
• Rear brake light operation timing
and if necessary, correct the antifreeze
Incorrect → Adjust.
concentration of the coolant.
2. Adjust:
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
a. Hold the main body “1” of the rear brake
be used.
light switch so that it does not rotate and
• If coolant comes into contact with painted
turn the adjusting nut “2” until the rear
surfaces, immediately wash them with wa-
brake light comes on at the proper time.
ter.
• Do not mix different types of antifreeze.
10.Install:
• Radiator cap
11.Fill: 1
• Coolant reservoir 2
(with the recommended coolant to the maxi-
mum level mark “a”)
EAS30660
a CHECKING AND LUBRICATING THE

CABLES
The following procedure applies to all of the in-
ner and outer cables.
EWA13270
WARNING
Damaged outer cable may cause the cable to
12.Install: corrode and interfere with its movement. Re-
• Coolant reservoir cap place damaged outer cable and inner cables
13.Start the engine, warm it up for several min- as soon as possible.
utes, and then turn it off. 1. Check:
14.Check: • Outer cable
• Coolant level Damage → Replace.
Refer to “CHECKING THE COOLANT LEV- 2. Check:
EL” on page 3-28. • Cable operation
TIP Rough movement → Lubricate.
Before checking the coolant level, wait a few
minutes until the coolant has settled.
3-30
a. Turn the adjusting screw “1”.

Engine oil or a suitable cable lu-
bricant
TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit- a
able lubricating device.
EAS30815
CHECKING THE THROTTLE GRIP

1. Check:
• Throttle grip movement
Rough movement → Lubricate or replace the
defective part(s).
Suitable cable lubricant
TIP
1
With the engine stopped, turn the throttle grip
slowly and release it. Make sure that the throttle
EAS33553
grip turns smoothly and returns properly when ADJUSTING THE CORNERING LIGHT BEAM
released. (for MTT890D)
Repeat this check with the handlebar turned all EWA13120
the way to the left and right. WARNING

EAS30816
CHECKING AND CHARGING THE BATTERY
Refer to “CHECKING AND CHARGING THE TIP
BATTERY” on page 8-43. • Adjust the cornering light beam on a level sur-
EAS30662
face.
CHECKING THE FUSES • To turn on the cornering light, use the diagno-
Refer to “CHECKING THE FUSES” on page sis function of the YDT.
8-42. 1. Preparation:
EAS30124 a. Draw a perpendicular line “a” on the wall
ADJUSTING THE HEADLIGHT BEAM on which the headlights and cornering
EWA13120
lights are projected. Draw a line “b” on the
WARNING
floor that is perpendicular to the wall on
Securely support the vehicle so that there is which the light is projected, starting from
no danger of it falling over. line “a”.
TIP
Adjust the headlight beams on a level surface.
a
1. Adjust:
• Headlight low beam (vertically)
TIP
To adjust the headlight low beam (vertically), in- b
sert a crosshead screwdriver “a” into hole on the
headlight unit cover and turn the adjusting
screw.
3-31
b. Place the vehicle perpendicular to line “a” cornering light beam from the reference
and line “b” so that the distance between point “f” to the upper left at 35° as shown
the wall and the center of the headlight is in the illustration.
1 m (39.37 in).
g
a 35º f
e
h
h = 136 mm (5.35 in)

TIP
• Before adjusting the cornering light beam, ad-
just the headlight low beam to the proper
height.
• Adjust the cut-off line of the headlight low beam
(vertically) so that it is slightly below the line “e”
b of the headlight low beam.
• Draw a right triangle as shown in the illustration
1m (39,37 in) and make an angle of 35°.
c. Ride on the vehicle without lowering the

centerstand or sidestand.
70mm (2.76 in)
d. Measure height “c” from the floor to the

center “d” of the headlight.
35º
100mm (3.94 in)

f. Remove the passenger seat “1”. If some-
c one is using the passenger seat, remove
the tail/brake light cover “2”.
1
d d 2
g. Remove the protective cap, and then con-

nect the YDT to the YDT coupler “i”.
e. Draw a horizontal line “e” on the wall at the If someone is using the passenger seat,
height of the headlight “c”. Place the refer- route the YDT sub-harness “j” under the
ence point “f” at 136 mm (5.35 in) above grab bar “3”.
line “e”. Draw the reference line “g” for the
3-32
i
3
Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264
TIP
• Yamaha diagnostic tool (A/I) (90890-03264) in-
cludes YDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/ 1
I) (90890-03262), YDT sub harness (6P)
b. Align cut-off line “l” of the cornering light
(90890-03266) is separately required.
with cornering light reference line “g”
h. Install the passenger seat.
i. Ride on the vehicle without lowering the
centerstand or sidestand.
j. Start the YDT and display the diagnosis
function screen. g
k. Select “CLCU” and “code No. 98”. l
l. Click “Actuator Check”, and then turn on
the cornering light.
TIP
• When the cornering light is turned on with the
YDT, only the left cornering light is turned on. c. Remove the YDT coupler.
• When the cornering light is turned on with the d. Install the passenger seat and tail/brake
YDT, the cornering light turns on for 10 minutes light cover.
and then turns off.
Tail/brake light
• When the cornering light is turned on with the
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
YDT, the cornering light turns off when another

R.
function is selected.
2. Adjust:
• Cornering light beam (vertically)
TIP
To adjust the cornering light beam (vertically), in-
sert a phillips screwdriver into the hole “k” on the
headlight front cover and turn the adjusting
screw.
a. Turn the adjusting screw “1”
3-33
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

INSTALLING THE IMU..............................................................................4-2
INSTALLING THE SEATS......................................................................... 4-2
GENERAL CHASSIS (2) ................................................................................. 4-5

REMOVING THE SIDE COVER AND FUEL TANK BRACKET
COVER ................................................................................................... 4-11
REMOVING THE TAIL/BRAKE LIGHT COVER...................................... 4-11
REMOVING THE SADDLEBAG BRACKET COVER ..............................4-11
INSTALLING THE SADDLEBAG BRACKET (for MTT890D).................. 4-12
INSTALLING THE SADDLEBAG BRACKET COVER............................. 4-12
INSTALLING THE TAIL/BRAKE LIGHT COVER .................................... 4-12
INSTALLING THE SIDE COVER AND FUEL TANK BRACKET
COVER ................................................................................................... 4-13
GENERAL CHASSIS (3) ............................................................................... 4-14

REMOVING THE FRONT SIDE COWLING ASSEMBLY .......................4-20
REMOVING THE FUEL TANK TOP COVER..........................................4-20
REMOVING THE FUEL TANK SIDE COVER ASSEMBLY ....................4-20
INSTALLING THE FUEL TANK SIDE COVER ASSEMBLY ................... 4-21
4
INSTALLING THE FUEL TANK TOP COVER ........................................ 4-21
INSTALLING THE FRONT SIDE COWLING ASSEMBLY ......................4-22
REMOVING THE FRONT COVER.......................................................... 4-22
INSTALLING THE FRONT COVER ........................................................ 4-22
ADJUSTING THE WINDSHIELD HEIGHT.............................................. 4-23
GENERAL CHASSIS (4) ............................................................................... 4-24
FRONT WHEEL............................................................................................. 4-26

REMOVING THE FRONT WHEEL.......................................................... 4-28
DISASSEMBLING THE FRONT WHEEL................................................ 4-28
CHECKING THE FRONT WHEEL .......................................................... 4-28
ASSEMBLING THE FRONT WHEEL......................................................4-29
MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR
ROTOR................................................................................................... 4-30
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-30
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-30
REAR WHEEL ...............................................................................................4-33

REMOVING THE REAR WHEEL ............................................................ 4-36
DISASSEMBLING THE REAR WHEEL .................................................. 4-36
CHECKING THE REAR WHEEL............................................................. 4-36
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-36
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .........4-36
ASSEMBLING THE REAR WHEEL ........................................................ 4-37
MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR
ROTOR................................................................................................... 4-37
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-38
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-38
FRONT BRAKE ............................................................................................. 4-41

INTRODUCTION .....................................................................................4-47
CHECKING THE FRONT BRAKE DISCS............................................... 4-47
REPLACING THE FRONT BRAKE PADS .............................................. 4-47
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-49
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-49
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-49
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-49
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-50
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-51
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-51
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-51
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-51
REAR BRAKE ...............................................................................................4-54

ADJUSTING THE FOOTREST POSITION ............................................. 4-60
INTRODUCTION .....................................................................................4-60
CHECKING THE REAR BRAKE DISC....................................................4-60
REPLACING THE REAR BRAKE PADS................................................. 4-61
REMOVING THE REAR BRAKE CALIPER ............................................4-62
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-62
CHECKING THE REAR BRAKE CALIPER............................................. 4-62
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-63
INSTALLING THE REAR BRAKE CALIPER...........................................4-63
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-64
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-64
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-64
INSTALLING THE BRAKE LIGHT SWITCH ...........................................4-64
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-65
ABS (ANTI-LOCK BRAKE SYSTEM)........................................................... 4-66

REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-68
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-68
CHECKING THE BRAKE PIPES............................................................. 4-68
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-69
HYDRAULIC UNIT OPERATION TESTS................................................ 4-70
CHECKING THE ABS WARNING LIGHT ............................................... 4-73
HANDLEBAR ................................................................................................4-74
ADJUSTING THE HANDLEBAR POSITION...........................................4-78
REMOVING THE HANDLEBAR..............................................................4-79
CHECKING THE HANDLEBAR ..............................................................4-79
INSTALLING THE HANDLEBAR ............................................................ 4-79
ASSEMBLING THE HANDLEBAR LEAD WIRES ASSEMBLY
(LEFT) (for MTT890D) ............................................................................4-81
ASSEMBLING THE HANDLEBAR LEAD WIRES ASSEMBLY
(RIGHT) (for MTT890D) .........................................................................4-83
FRONT FORK (for MTT890) .........................................................................4-85

REMOVING THE FRONT FORK LEGS.................................................. 4-90
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-90
CHECKING THE FRONT FORK LEGS .................................................. 4-91
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-92
INSTALLING THE FRONT FORK LEGS ................................................ 4-96
FRONT FORK (for MTT890D) ...................................................................... 4-97

REMOVING THE FRONT FORK LEGS................................................4-102
DISASSEMBLING THE FRONT FORK LEGS ......................................4-102
CHECKING THE FRONT FORK LEGS ................................................4-105
ASSEMBLING THE FRONT FORK LEGS ............................................4-105
INSTALLING THE FRONT FORK LEGS ..............................................4-110
STEERING HEAD........................................................................................4-112
REMOVING THE LOWER BRACKET...................................................4-114
CHECKING THE STEERING HEAD .....................................................4-114
INSTALLING THE STEERING HEAD ...................................................4-115
INSTALLING THE HORN......................................................................4-115
REAR SHOCK ABSORBER ASSEMBLY (for MTT890)............................4-116

HANDLING THE REAR SHOCK ABSORBER ......................................4-117
DISPOSING OF A REAR SHOCK ABSORBER ...................................4-117
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................4-117
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES
(for MTT890).........................................................................................4-117
CHECKING THE CONNECTING ARM AND RELAY ARM...................4-117
INSTALLING THE RELAY ARM............................................................4-117
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ...............4-118
REAR SHOCK ABSORBER ASSEMBLY (for MTT890D) .........................4-119

HANDLING THE REAR SHOCK ABSORBER ......................................4-121
DISPOSING OF A REAR SHOCK ABSORBER ...................................4-121
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................4-121
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY
(for MTT890D) ......................................................................................4-121
CHECKING THE CONNECTING ARM AND RELAY ARM...................4-121
INSTALLING THE RELAY ARM............................................................4-121
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ...............4-122
ADJUSTING THE ANGULAR POSITION SENSOR POSITION ...........4-123
CHECKING THE VEHICLE AFTER INSTALLING THE REAR
SHOCK ABSORBER ASSEMBLY (for MTT890D) ...............................4-124
SWINGARM.................................................................................................4-126
REMOVING THE SWINGARM..............................................................4-128
CHECKING THE SWINGARM ..............................................................4-128
INSTALLING THE SWINGARM ............................................................4-128
CHAIN DRIVE..............................................................................................4-130
REMOVING THE DRIVE CHAIN...........................................................4-132
CHECKING THE DRIVE CHAIN ...........................................................4-132
CHECKING THE DRIVE SPROCKET...................................................4-133
CHECKING THE REAR WHEEL SPROCKET......................................4-133
CHECKING THE REAR WHEEL DRIVE HUB ......................................4-133
INSTALLING THE DRIVE CHAIN .........................................................4-133
ADJUSTING THE SHIFT PEDAL..........................................................4-135
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the seats, battery and IMU
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1
6
2 2.2 N•m (0.22 kgf•m, 1.6 lb•ft)
T.R
.
8
4 9 7
11
12 (4) 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
(4)
S (4) 10
Order Job/Parts to remove Q’ty Remarks

1 Passenger seat 1
2 Seat lock stopper 1
3 Rider seat 1
4 Rider seat height position adjuster 1
5 Rubber cover 1
6 Battery holding bracket 1
7 Negative battery lead 1 Disconnect.
8 Positive battery lead 1 Disconnect.
9 Battery 1
10 IMU bottom cover 1
11 IMU (Inertial Measurement Unit) 1
12 IMU coupler 1
4-1
GENERAL CHASSIS (1)
EAS31636
INSTALLING THE IMU IMU bolt

ECA27350
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
NOTICE
R.
• Do not perform angle adjustment of the IMU
and battery box by pinching the washer
and related parts.
• When installing the IMU, apply a thin coat of
silicone grease onto the washer and collar
S
where they contact the IMU grommet. 1
• When installing the IMU, use only a genuine
bolt and washer, and tighten the bolt to the
specified torque. 2
• Pay attention not to expose the IMU to
strong shocks, such as striking or drop- S
ping it.
• Do not place any foreign objects in and
around the battery box. S
• Do not obstruct breather opening “a” of the
IMU.
• Do not clean the breather opening and do
not blow it with compressed air.
• When replacing the collar or grommet, re-
S
place all four collars and grommets.
• Use only the specified genuine YAMAHA EAS30125
battery. Using a different battery may cause INSTALLING THE SEATS

the IMU to fail and the engine to stall. 1. Install:
• Rider seat height position adjuster “1”
• Rider seat “2”
a TIP
The rider seat height can be adjusted to one of
two positions to suit the rider’s preference.
To install the rider seat in the high posi-

tion
a. Insert the projection “a” on the rider seat
height position adjuster “1” into the grom-
1. Install: met “b”.
• IMU (Inertial Measurement Unit) “1”
a. Connect the IMU coupler “2” to the IMU.
b. Install the grommets, collars, IMU “1”, a
1
washers, IMU nuts and IMU bolts, and
then tighten the bolts to specification.
TIP
Apply a thin coat of silicone grease onto the col-
lars and washers where contacting the grom- b a
mets.
b. Remove the rubber cover.
Recommended lubricant TIP
Silicone grease
Do not lose the rubber cover.
4-2
GENERAL CHASSIS (1)
c. Insert the projection “c” on the front of the

h 3
rider seat “2” into the seat holder “d”. g
d 2
c
c d
e
d c. Insert the projection “i” on the front of the

rider seat “2” into the seat holder “j”.
d. Align the projection “e” on the bottom of
the rider seat with the “H” position slot “f”, 2
and then push the rear of the seat down to j
lock it in place as shown. i
e j
f d. Align the projection “k” on the bottom of

the rider seat with the “L” position slot “l”,
and then push the rear of the seat down to
lock it in place as shown.
To install the rider seat in the low position
a. Insert the projection “a” on the rider seat
height position adjuster “1” into the grom-
met “b”.
k
1 l
a
2. Install:
• Seat lock stopper “1”
b • Passenger seat “2”
a a. Insert the projections “a” on the seat lock
stopper “1” into the hole “b”.
b. Insert the projection “c” on the rubber cov-
er “3” into the slit “d”.
Insert the projection “e” on the rubber cov- 1
er “3” into the hole “f”.
Insert the projections “g” on the rubber b
cover “3” into the holes “h”.
4-3
GENERAL CHASSIS (1)
b. Insert the parts “c” on the rear of the pas-

senger seat “2” into the seat holders “d”
and then push the front of the seat down to
lock it in place.
2 d
4-4
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the rear side covers (for MTT890)
25 N•m (2.5 kgf•m, 18 lb•ft)
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
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
7
.
LT 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
5
1
4
LT
3 8
1
8
8
8
9
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
3.0 N•m (0.30 kgf•m, 2.2 lb•ft) 6

T.R
.
10
4.3 N•m (0.43 kgf•m, 3.2 lb•ft)
T.R
.

Passenger seat/Rider seat 4-1.
1 Fuel tank bracket cover bolt 2
2 Side cover (left) 1
3 Side cover (right) 1
4 Fuel tank bracket cover 1
5 Tail/brake light cover 1
6 Saddlebag bracket cover (left) 1
7 Saddlebag bracket cover (right) 1
8 Damper 4
9 Rear side cover (left) 1
10 Seat lock key cylinder bracket 1
11 Rear side cover (right) 1
4-5
GENERAL CHASSIS (2)
Removing the rear side covers (for MTT890)

25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
12
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
LT 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
13 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
14 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
17
20
16
LT 15
19
18
17
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

21
T.R
.
4.3 N•m (0.43 kgf•m, 3.2 lb•ft)

T.R
.

12 Grab bar 1
13 Rider seat support (left) 1
14 Rider seat support (right) 1
15 Seat bracket 1
16 Passenger seat lock assembly 1
17 Seat lock cable 1 Disconnect.
18 Passenger seat lock bracket 1
19 Rider seat lock assembly 1
20 Rider seat lock bracket 1
21 Seat lock key cylinder 1
4-6
GENERAL CHASSIS (2)
Removing the rear side covers (for MTT890D)

2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
T.R
.
.
45 N•m (4.5 kgf•m, 33 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
7
.
LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
12 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
9
1 5
LT 1
3
45 N•m (4.5 kgf•m, 33 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
10
2
8
3.0 N•m (0.30 kgf•m, 2.2 lb•ft) 11
T.R
.
6
4.3 N•m (0.43 kgf•m, 3.2 lb•ft)
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.

1 Fuel tank bracket cover bolt 2
2 Side cover (left) 1
3 Side cover (right) 1
4 Fuel tank bracket cover 1
5 Tail/brake light cover 1
6 Saddlebag bracket cover (left) 1
7 Saddlebag bracket cover (right) 1
8 Saddlebag bracket (left) 1
9 Saddlebag bracket (right) 1
10 Rear side cover (left) 1
11 Seat lock key cylinder bracket 1
12 Rear side cover (right) 1
4-7
GENERAL CHASSIS (2)
Removing the rear side covers (for MTT890D)

T.R
T.R
.
.
45 N•m (4.5 kgf•m, 33 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft) 13
T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
14
15 17
18
21
LT
16
19
20
45 N•m (4.5 kgf•m, 33 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
18
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)
T.R
.
4.3 N•m (0.43 kgf•m, 3.2 lb•ft) 22

T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.

13 Grab bar 1
14 Rider seat support (left) 1
15 Rider seat support (right) 1
16 Seat bracket 1
17 Passenger seat lock assembly 1
18 Seat lock cable 1 Disconnect.
19 Passenger seat lock bracket 1
20 Rider seat lock assembly 1
21 Rider seat lock bracket 1
22 Seat lock key cylinder 1
4-8
GENERAL CHASSIS (2)
Removing the tail/brake light and mudguard assembly
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
3
1 5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
6
4
5
9
10
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Grab bar 4-5.
1 Tail/brake light coupler 1 Disconnect.
2 Tail/brake light bracket 1
3 Tail/brake light 1
4 Rear turn signal light cover 2 Disconnect.
5 License plate light coupler 1 Disconnect.
6 Mudguard assembly 1
7 Lower tail cover 1
8 Rectifier/regulator cover 1
9 Rectifier/regulator coupler 1 Disconnect.
10 Rectifier/regulator 1
4-9
GENERAL CHASSIS (2)
Disassembling mudguard assembly
T.R
T.R
.
.
4 LT
(4)
(4) 5
6
3 8
7
1
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
2
2.3 N•m (0.23 kgf•m, 1.7 lb•ft)
T.R
.

1 Mudguard assembly bracket 1
2 Cover 1
3 Mudguard assembly stay 1
4 Stay 2
5 Rear turn signal light 2
6 License plate light 1
7 Damper 1
8 Rear reflector 1
4-10
GENERAL CHASSIS (2)
EAS33568
REMOVING THE SIDE COVER AND FUEL TIP

TANK BRACKET COVER The type of quick fasteners “f” on the fuel tank
1. Remove: side and the type of quick fasteners “g” on the
• Side cover (left) side are different.
• Side cover (right)
a. Remove the fuel tank bracket cover bolt f
“a” and collar.
g
a
g
EAS33569
REMOVING THE TAIL/BRAKE LIGHT COVER

1. Remove:
• Tail/brake light cover “1”
b. Pull out the side cover (left) “1” forward a. Remove the bolts, and then remove the
and downward, and then unhook the pro- tail/brake light cover.
jection “b” on the side cover from the slit b. Pull the tail/brake light cover to the rear,
“c” on the fuel tank. and then unhook the projections “a” on the
Unhook the projections “d” on the side tail/brake light cover from the slits “b” on
cover from the slits “e” on the fuel tank the rear side cover.
bracket cover. c. Unhook the projection “c” on the tail/brake
Unhook the projection “f” on the side cover light cover from the slits “d” on the rear
from the slit “g” on the fuel tank bracket side cover.
cover.
TIP b
This procedure applies to both the side cover. d a 1
b
d
c
EAS33570
REMOVING THE SADDLEBAG BRACKET

COVER
saddlebag bracket cover.
e d 1. Remove:
c • Saddlebag bracket cover (left) “1”
a. Remove the quick fasteners, and then re-
move the saddlebag bracket cover (left).
b b. Pull the saddlebag bracket cover (left) to
f the outside, and then unhook the projec-
tion “a” on the saddlebag bracket cover
g (left) from the hole “b” on the rear side cov-
er (left).
c. Remove the quick fasteners, and then re-
move the fuel tank bracket cover.
4-11
GENERAL CHASSIS (2)
c. Unhook the projection “c” on the saddle- EAS33571
INSTALLING THE SADDLEBAG BRACKET

bag bracket cover (left) from the hole “d”
COVER
on the rear side cover (left).
d. Unhook the projections “e” on the saddle-
saddlebag bracket cover.
bag bracket cover (left) from the holes “f”
1. Install:
• Saddlebag bracket cover (left) “1”
e. Unhook the projection “g” on the saddle-
a. Install the saddlebag bracket cover (left) to
bag bracket cover (left) from the hole “h”
the inside, and then fit the projection “a” on
the saddlebag bracket cover (left) to the
A f h g e hole “b” on the rear side cover (left).
d b. Fit the projection “c” on the saddlebag
c bracket cover (left) to the hole “d” on the
b
rear side cover (left).
1 c. Fit the projection “e” on the saddlebag
bracket cover (left) to the hole “f” on the
a rear side cover (left).
d. Fit the projection “g” on the saddlebag
bracket cover (left) to the hole “h” on the
rear side cover.
B f h g f
e A h g e
d d
c c
b b
1 1
a a
A. MTT890
B. MTT890D B f h g
e
EAS32541
d
INSTALLING THE SADDLEBAG BRACKET c
b
(for MTT890D)
The following procedure applies to both of the 1
saddlebag bracket.
1. Install: a
• Saddlebag bracket (left) “1”
TIP
Align the hole in the saddlebag bracket with the A. MTT890
hole in the frame using the screwdriver bit “a” of B. MTT890D
the owner’s tool kit. e. Install the quick fasteners.
EAS33572
INSTALLING THE TAIL/BRAKE LIGHT

COVER
a
1. Install:
• Tail/brake light cover “1”
1 a. Fit the projections “a” on the tail/brake light
cover into the slits “b” on the rear side cov-
er.
1 a
4-12
GENERAL CHASSIS (2)
b. Fit the projections “c” on the tail/brake light

cover into the slits “d” on the rear side cov- f e
er. d
c. Install the rear side cover bolts.
Rear side cover bolt c

1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.
g
R.
h
b
d a 1
b
i
d
c
EAS33573
INSTALLING THE SIDE COVER AND FUEL

TANK BRACKET COVER
1. Install: c. Install the collar and fuel tank bracket cov-
• Fuel tank bracket cover er bolt “j”.
• Side cover (left)
Fuel tank bracket cover bolt
• Side cover (right)
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
a. Install the fuel tank bracket cover, and

R.
then install the quick fasteners.

TIP j
The type of quick fasteners “a” on the fuel tank
side and the type of quick fasteners “b” on the
side are different.
b. Fit the projection “c” on the side cover into

the hole “d” on the fuel tank.
Fit the projections “e” on the side cover
into the slits “f” on the fuel tank bracket
cover.
Fit the projection “g” on the side cover into
the slit “h” on the fuel tank bracket cover.
TIP
• This procedure applies to both the side cover.
• Make sure that the side cover projection “i” is
inside the fuel tank bracket cover.
4-13
GENERAL CHASSIS (3)
EAS20156
GENERAL CHASSIS (3)

Removing the front side cowling assemblies and headlight cover
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
6 1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
T.R
.
.
5
1
3 4
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1 Front side cowling assembly (left) 1
2 Front side cowling assembly (right) 1
3 Headlight cover 1
4 Front side cowling (left) 1
5 Front side cowling inner panel (left) 1
6 Front side cowling (right) 1
7 Front side cowling inner panel (right) 1
4-14
GENERAL CHASSIS (3)
Removing the fuel tank top cover and fuel tank side cover assemblies
9 N•m (0.9 kgf•m, 6.6 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
T.R
.
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
4
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
7
2 9 N•m (0.9 kgf•m, 6.6 lb•ft)

3
T.R
.
8
6
5 9
1
10 13
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
11
12
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

Front side cowling assembly 4-14.
1 Fuel tank top cover 1
2 Fuel tank side cover assembly (left) 1
3 Fuel tank side cover assembly (right) 1
4 Fuel tank side cover upper panel (left) 1
5 Fuel tank side cover inner panel (left) 1
6 Air scoop (left) 1
7 Fuel tank side cover (left) 1
8 Fuel tank side cover front panel (left) 1
9 Fuel tank side cover upper panel (right) 1
10 Fuel tank side cover inner panel (right) 1
11 Air scoop (right) 1
12 Fuel tank side cover (right) 1
13 Fuel tank side cover front panel (right) 1
4-15
GENERAL CHASSIS (3)
Removing the windshield
3
2
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
4
0.5 N•m (0.05 kgf•m, 0.37 lb•ft)

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.

1 Windshield 1
2 Front cover assembly 1
3 Front cover Inner panel 1
4 Front cover bracket 1
4-16
GENERAL CHASSIS (3)
Removing the headlight assembly and meter assembly
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
.
8 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9
5
2
1 11
10
4
3 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
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Front side cowling assembly/Fuel tank top cov- Refer to “GENERAL CHASSIS (3)” on page
er/Fuel tank side cover assembly 4-14.
1 Front turn signal light coupler (left) 1 Disconnect.
2 Front turn signal light coupler (right) 1 Disconnect.
3 Auxiliary light coupler 1 Disconnect.
for MTT890D
4 CLCU (cornering light control unit) coupler 1 Disconnect.
5 Auxiliary light assembly 1
6 Meter assembly coupler 1 Disconnect.
7 Meter assembly 1
8 Meter assembly bracket 1
9 Meter assembly inner panel 1
10 Auxiliary DC jack coupler 1 Disconnect.
11 Auxiliary DC jack 1
4-17
GENERAL CHASSIS (3)
Removing the headlight assembly and meter assembly
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

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
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
16
17
14
12
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
15
13 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

12 Headlight assembly coupler 1 Disconnect.
13 Wire harness 1
14 Headlight assembly 1
15 Sub-wire harness (headlight control unit) 1
16 Band 1
17 Headlight control unit 1
4-18
GENERAL CHASSIS (3)
Disassembling the auxiliary light assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1 Auxiliary light cover 1
2 Front turn signal light (left) 1
3 Front turn signal light (right) 1
4-19
GENERAL CHASSIS (3)
EAS31360
REMOVING THE FRONT SIDE COWLING

ASSEMBLY a 1
front side cowling assembly.
1. Remove:
• Front side cowling assembly (left) “1”
a. Remove the front side cowling assembly
bolt “a” and quick fasteners “b”.
b. Unhook the hole “b” on the fuel tank top

a cover from the projection “c” on the fuel
tank.
1
c. Unhook the projections “d” on the fuel tank
top cover from the holes “e” on the fuel
b tank side cover assembly.
d. Unhook the projections “f” on the fuel tank
top cover from the holes “g” on the fuel
tank side cover assembly.
b. Pull the front side cowling assembly (left)
e. Unhook the projections “h” on the fuel tank
to the outside.
top cover from the holes “i” on the fuel tank
c. Unhook the projection “c” on the front side
side cover assembly.
cowling assembly (left) from the grommet
“d” on the fuel tank side cover assembly h f d
(left).
d. Unhook the projection “e” on the front side b
cowling assembly (left) from the grommet
“f” on the headlight cover. f
e. Unhook the projection “g” on the front side
cowling assembly (left) from the grommet d
“h” on the headlight cover.
f. Unhook the projection “i” on the front side g
e
cowling assembly (left) from the hole “j” on
the radiator side bracket (left). h
d c
e i
f
h g
i g
e c
j i
EAS33574
EAS31102
REMOVING THE FUEL TANK SIDE COVER
REMOVING THE FUEL TANK TOP COVER ASSEMBLY
1. Remove: The following procedure applies to both of the
• Fuel tank top cover “1” fuel tank side cover assembly.
a. Remove the quick fasteners “a”, and then 1. Remove:
pull the fuel tank top cover forward. • Fuel tank side cover assembly (left) “1”
a. Remove the fuel tank side cover assembly
bolts “a” and collar “b”.
4-20
GENERAL CHASSIS (3)
c. Install the fuel tank side cover assembly

b bolts “e”, collar “f”, and then tighten the
bolts to specification.
a Fuel tank side cover assembly
a bolt
T.
R.
1 9 N·m (0.9 kgf·m, 6.6 lb·ft)
a f
b. Pull the fuel tank side cover assembly

(left) to the outside. e
c. Unhook the projection “c” on the fuel tank e
side cover assembly (left) from the grom-
met “d” on the fuel tank.
d. Unhook the hole “e” on the fuel tank side
e
cover assembly (left) from the projection
“f” on the fuel tank bracket.
EAS31103
INSTALLING THE FUEL TANK TOP COVER

f 1. Install:
e • Fuel tank top cover
a. Fit the projections “a” on the fuel tank top
cover into the holes “b” on the fuel tank
side cover assembly.
b. Fit the projections “c” on the fuel tank top
cover into the holes “d” on the fuel tank
d
c side cover assembly.
c. Fit the projections “e” on the fuel tank top
EAS33575
cover into the holes “f” on the fuel tank side
INSTALLING THE FUEL TANK SIDE COVER
cover assembly.
ASSEMBLY
d. Fit the hole “g” on the fuel tank top cover
into the projection “h” on the fuel tank.
fuel tank side cover assembly.
1. Install: e c a
• Fuel tank side cover assembly (left)
a. Fit the projection “a” on the fuel tank side g
cover assembly (left) into the grommet “b”
on the fuel tank. c
b. Fit the hole “c” on the fuel tank side cover
assembly (left) into the projection “d” on a
the fuel tank bracket.
d
b
d e
c
f
b
a f d
b h
4-21
GENERAL CHASSIS (3)
e. Install the quick fasteners. b. Move the front cover “1” to the highest po-
sition, remove the front cover bolt “3”, and
EAS31361
INSTALLING THE FRONT SIDE COWLING then remove the cover.

ASSEMBLY TIP
The following procedure applies to both of the For information about adjusting the height of the
front side cowling assembly. front cover, refer to “ADJUSTING THE WIND-
1. Install: SHIELD HEIGHT” on page 4-23.
• Front side cowling assembly (left)
a. Install the projection “a” on the front side
cowling assembly (left) into the hole “b” on
the radiator bracket (left). 1
b. Fit the projection “c” on the front side cowl-
ing assembly (left) into the grommet “d” on
the fuel tank side cover assembly (left).
c. Fit the projection “e” on the front side cowl-
ing assembly (left) into the grommet “f” on
the headlight cover. 3
d. Fit the projection “g” on the front side cowl-
EAS31399
ing assembly (left) into the grommet “h” on INSTALLING THE FRONT COVER
the headlight cover. 1. Install:
d c • Front cover “1”
e a. Install the front cover bolts “2”. (temporari-
f
ly tighten)
h g
1
b a
e. Install the front side cowling assembly bolt

and quick fasteners.
f. Tighten the bolts to specification. 2
Front side cowling assembly bolt b. Move the front cover “1” to the lowest po-
9 N·m (0.9 kgf·m, 6.6 lb·ft) sition, and then install and tighten the front
T.
R.
cover bolt “3” to specification.

EAS31398
REMOVING THE FRONT COVER Front cover bolt

1. Remove: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
• Windshield
2. Remove:
• Front cover “1”
a. Remove the front cover bolt “2”.
1
1
3
c. Move the front cover “1” to the highest po-

sition, and then tighten the front cover
2
bolts “2”.
4-22
GENERAL CHASSIS (3)
Front cover bolt

6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
2
2. Install:
• Windshield
EAS31383
ADJUSTING THE WINDSHIELD HEIGHT

1. Adjust:
• Windshield height position
a. To change the position of the windshield,
lift up the windshield lock lever “1” and
slide the windshield “2” up or down. Re-
lease the lock lever when finished.
TIP
Make sure the windshield and lock lever are
properly secured before riding.
4-23
GENERAL CHASSIS (4)
EAS20157
GENERAL CHASSIS (4)

Removing the SCU (Suspension Control Unit) (for MTT890D)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Front side cowling assembly (left)/Fuel tank side Refer to “GENERAL CHASSIS (3)” on page
cover assembly (left) 4-14.
Clutch cable Refer to “CLUTCH” on page 5-47.
1 SCU bracket 1
2 SCU coupler 1 Disconnect.
3 SCU (Suspension Control Unit) 1
4 Band 1
4-24
GENERAL CHASSIS (4)
Removing the air filter case
1.6 N•m (0.16 kgf•m, 1.2 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
5
(10)
1
New 2
3 9
6
6
2.8 N•m (0.28 kgf•m, 2.1 lb•ft)
6
T.R
.
8 2.8 N•m (0.28 kgf•m, 2.1 lb•ft)

T.R
.

Fuel tank bracket cover 4-5.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 ECU (Engine Control Unit) 1
2 ECU coupler 3 Disconnect.
3 Intake air temperature sensor 1 Disconnect.
4 Air filter case cover 1
5 Air filter element 1
6 Air filter case joint clamp screw 3 Loosen.
7 Air induction system hose 1 Disconnect.
8 Cylinder head breather hose 1 Disconnect.
9 Air filter case 1
4-25
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake discs
3
2 35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
72 N•m (7.2 kgf•m, 53 lb•ft)
.
T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
18 N•m (1.8 kgf•m, 13 lb•ft)
.
T.R
.
1
6
New 2
8 LT
LT
(5)
5 3
1
4
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
9
7 N•m (0.7 kgf•m, 5.2 lb•ft)
LT
T.R
.
New
(5)
7
9 18 N•m (1.8 kgf•m, 13 lb•ft)
8
T.R
.

1 Front brake caliper 2
2 Reflector bracket 2
3 Reflector 2
4 Front wheel sensor 1
5 Wheel axle pinch bolt 1 Loosen.
6 Wheel axle 1
7 Front wheel 1
8 Collar 2
9 Front brake disc 2
4-26
FRONT WHEEL
Disassembling the front wheel
2 New
3
4
LT
3
New 2
New
1 (5)
8 N・m (0.8 kgf・m, 5.9 lb・ft)

1 Front wheel sensor rotor 1
2 Oil seal 2
3 Wheel bearing 2
4 Spacer 1
4-27
FRONT WHEEL
EAS31148
• Wheel bearing
REMOVING THE FRONT WHEEL
ECA20981
a. Clean the surface of the front wheel hub.
NOTICE b. Remove the oil seals “1” with a flat-head
• Keep any type of magnets (including mag- screwdriver.
netic pick-up tools, magnetic screwdrivers, TIP
etc.) away from the front wheel sensor or To prevent damaging the wheel, place a rag “2”
front wheel sensor rotor; otherwise, the between the screwdriver and the wheel surface.
sensor or rotor may be damaged, resulting
in improper performance of the ABS sys- 2
tem.
• Do not drop the front wheel sensor rotor or
subject it to shocks.
• If any solvent gets on the front wheel sen- 1
sor rotor, wipe it off immediately.
EWA13120
WARNING G088896
Securely support the vehicle so that there is c. Remove the wheel bearings with a gener-
no danger of it falling over. al bearing puller.
2. Remove: EAS30147
• Brake caliper (left) CHECKING THE FRONT WHEEL

• Brake caliper (right) 1. Check:
• Front wheel sensor • Wheel axle
ECA21440
Roll the wheel axle on a flat surface.
NOTICE Bends → Replace.
• Do not apply the brake lever when remov- EWA13460
ing the brake calipers. WARNING

• Be sure not to contact the sensor electrode Do not attempt to straighten a bent wheel ax-
to any metal part when removing the front le.
wheel sensor from the sensor housing. 2. Check:
3. Elevate: • Tire
• Front wheel • Front wheel
TIP Damage/wear → Replace.
Place the vehicle on a maintenance stand so Refer to “CHECKING THE TIRES” on page
that the front wheel is elevated. 3-16 and “CHECKING THE WHEELS” on
page 3-16.
4. Loosen: 3. Measure:
• Wheel axle pinch bolt • Radial wheel runout “1”
5. Remove: • Lateral wheel runout “2”
• Wheel axle Over the specified limits → Replace.
• Front wheel
Radial wheel runout limit
EAS31149
1.0 mm (0.04 in)
DISASSEMBLING THE FRONT WHEEL
ECA21340
Lateral wheel runout limit
NOTICE 0.5 mm (0.02 in)
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
1. Remove:
• Oil seal
4-28
FRONT WHEEL
TIP
2 Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
1
“3” and outer race “4” are pressed at the same
time, and then press the bearing until the inner
race makes contact with the spacer “5”.
G088897
4. Check:
• Wheel bearing
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
• Oil seal
Damage/wear → Replace.
G088899
EAS31150
d. Install the new oil seals.
ASSEMBLING THE FRONT WHEEL
ECA21340
2. Install:
NOTICE • Front wheel sensor rotor
• Do not drop the wheel sensor rotor or sub- Wheel sensor rotor bolt
ject it to shocks. 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
• If any solvent gets on the wheel sensor ro- LOCTITE®

tor, wipe it off immediately.
ECA17200
1. Install: NOTICE
• Wheel bearing New Replace the wheel sensor rotor bolts with
• Oil seal New new ones.
a. Install the new wheel bearing (left side).
ECA18110 TIP
NOTICE Install the wheel sensor rotor with the stamped
Do not contact the wheel bearing inner race mark “1” facing outward.
“1” or balls “2”. Contact should be made
only with the outer race “3”.
TIP
1
Use a socket “4” that matches the diameter of
the wheel bearing outer race.
G088900
3. Measure:
• Wheel sensor rotor runout
Out of specification → Correct the wheel sen-
sor rotor runout or replace the wheel sensor
rotor.
G088898
Refer to “MAINTENANCE OF THE FRONT
b. Install the spacer. WHEEL SENSOR AND SENSOR ROTOR”
c. Install the new wheel bearing (right side). on page 4-30.
Wheel sensor rotor runout limit

0.25 mm (0.01 in)
4-29
FRONT WHEEL
EAS31151
a. Hold the dial gauge at a right angle against
MAINTENANCE OF THE FRONT WHEEL
the wheel sensor rotor surface.
SENSOR AND SENSOR ROTOR
ECA21070
b. Measure the wheel sensor rotor runout.
NOTICE
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
• The front wheel sensor cannot be disas-
sembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
• Keep any type of magnets (including mag- G088902
netic pick-up tools, magnetic screwdrivers,
c. If the runout is above specification, re-
etc.) away from the front wheel sensor or
front wheel sensor rotor. move the sensor rotor from the wheel, ro-
• Do not drop or shock the wheel sensor or tate it by two or three bolt holes, and then
install it.
the wheel sensor rotor.
1. Check: Wheel sensor rotor bolt
• Front wheel sensor “1” T.
R.
8 N·m (0.8 kgf·m, 5.9 lb·ft)
Cracks/bends/distortion → Replace. LOCTITE®
Iron powder/dust → Clean. ECA17200
NOTICE
Replace the wheel sensor rotor bolts with
new ones.
d. If the runout is still above specification, re-
1 place the wheel sensor rotor.
EAS30152
ADJUSTING THE FRONT WHEEL STATIC

BALANCE
TIP
2. Check:
• After replacing the tire, wheel or both, the front
• Front wheel sensor rotor
wheel static balance should be adjusted.
Cracks/damage/scratches → Replace the
• Adjust the front wheel static balance with the
front wheel sensor rotor.
brake disc installed.
Iron powder/dust/solvent → Clean.
• Refer to “ADJUSTING THE WHEEL STATIC
TIP BALANCE” in “BASIC INFORMATION” (sepa-
• The wheel sensor rotor is installed on the inner rate volume).
side of the wheel hub.
• When cleaning the wheel sensor rotor, be 1. Remove:
careful not to damage the surface of the sensor • Balancing weight(s)
rotor. 2. Find:
• Front wheel’s heavy spot
3. Measure: 3. Adjust:
• Wheel sensor rotor runout • Front wheel static balance
Out of specification → Clean the installation 4. Check:
surface of the wheel sensor rotor and correct • Front wheel static balance
the wheel sensor rotor runout, or replace the
wheel sensor rotor. EAS31327
INSTALLING THE FRONT WHEEL (FRONT

Wheel sensor rotor runout limit BRAKE DISCS)
0.25 mm (0.01 in) 1. Install:
• Front brake disc
4-30
FRONT WHEEL
Front brake disc bolt

18 N·m (1.8 kgf·m, 13 lb·ft) a
T.
R.
LOCTITE® b
ECA19150
NOTICE
Replace the brake disc bolts with new ones.
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern. 6. Install:
• Front wheel sensor
2. Check:
• Front brake disc Front wheel sensor bolt
Refer to “CHECKING THE FRONT BRAKE 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
DISCS” on page 4-47.
3. Lubricate: ECA21020
• Oil seal lip NOTICE

Make sure there are no foreign materials in
Recommended lubricant the front wheel sensor rotor and front wheel
Lithium-soap-based grease sensor. Foreign materials cause damage to
the front wheel sensor rotor and front wheel
4. Install: sensor.
• Collar
• Front wheel TIP
• Wheel axle When installing the front wheel sensor, check
5. Tighten: the wheel sensor lead for twists.
• Wheel axle
7. Measure:
• Wheel axle pinch bolt
• Distance “a”
Front wheel axle (between the wheel sensor rotor “1” and
72 N·m (7.2 kgf·m, 53 lb·ft) wheel sensor “2”)
T.
Out of specification → Check the wheel bear-

R.
Front wheel axle pinch bolt

23 N·m (2.3 kgf·m, 17 lb·ft) ing for looseness, and the front wheel sensor
and sensor rotor installation conditions
ECA19760
(warpage caused by overtorque, wrong in-
NOTICE
stallation direction, rotor decentering, LOC-
Before tightening the wheel axle, push down TITE® on the mounting surface of the rotor,
hard on the handlebars several times and deformation caused by an impact during ser-
check if the front fork rebounds smoothly. vice and caught foreign materials). If there is
TIP any defective part, repair or replace the de-
fective part.
Check that wheel axle end “a” is flush with front
fork surface “b” and then tighten the wheel axle Distance “a” (between the wheel
pinch bolt. If wheel axle end “a” is not flush with sensor rotor and front wheel sen-
surface “b”, align the ends manually or with a sor)
plastic hammer. 0.6–1.8 mm (0.02–0.07 in)
TIP
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
places in one rotation of the front wheel. Do not
4-31
FRONT WHEEL
turn the front wheel while the thickness gauge is

installed. This may damage the front wheel sen-
sor rotor and the front wheel sensor.
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
a
1
2
2
1
G088903
8. Install:
• Front brake caliper
Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-32
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel
1 10
9
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
105 N•m (10.5 kgf•m, 77 lb•ft)

T.R
.
4
5
8
LS
3 2 2 3
6
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.

Rear brake caliper Refer to “REAR BRAKE” on page 4-54.
1 Rear wheel sensor 1
2 Locknut 2 Loosen.
3 Adjusting bolt 2 Loosen.
4 Wheel axle nut 1
5 Washer 1
6 Wheel axle 1
7 Adjusting block (left) 1
8 Adjusting block (right) 1
9 Brake caliper bracket 1
10 Rear wheel 1
4-33
REAR WHEEL
Removing the brake disc and rear wheel sprocket

30 N・m (3.0 kgf・m, 22 lb・ft) 8 N・m (0.8 kgf・m, 5.9 lb・ft)
LT
(5) New LT
13
(5) 1
2 6 LS
12
11 New 80 N・m (8.0 kgf・m, 59 lb・ft)
10
9
4
LS
3
(5)
7 New
New 8
LS

1 Rear wheel sensor rotor 1
2 Rear brake disc 1
3 Bracket 1
4 Rear wheel sprocket 1
5 Collar 1
6 Collar 1
7 Oil seal 1
8 Bearing 1
9 Rear wheel drive hub 1
10 Collar 1
11 Oil seal 1
12 Rear wheel drive hub damper 5
13 Rear wheel 1
4-34
REAR WHEEL
Disassembling the rear wheel
1 New
2

1 Oil seal 1
2 Wheel bearing 1
3 Spacer 1
4 Wheel bearing 1
4-35
REAR WHEEL
EAS30910 EAS31154
REMOVING THE REAR WHEEL DISASSEMBLING THE REAR WHEEL

ECA21030 ECA21340
NOTICE NOTICE
• Keep any type of magnets (including mag- • Do not drop the wheel sensor rotor or sub-
netic pick-up tools, magnetic screwdrivers, ject it to shocks.
etc.) away from the rear wheel sensor or • If any solvent gets on the wheel sensor ro-
rear wheel sensor rotor; otherwise, the sen- tor, wipe it off immediately.
sor or rotor may be damaged, resulting in 1. Remove:
improper performance of the ABS system. • Oil seal
• Do not drop the rear wheel sensor rotor or • Wheel bearing
subject it to shocks. Refer to “DISASSEMBLING THE FRONT
• If any solvent gets on the rear wheel sensor WHEEL” on page 4-28.
rotor, wipe it off immediately.
EAS30159
1. Stand the vehicle on a level surface. CHECKING THE REAR WHEEL
EWA13120
WARNING 1. Check:
• Wheel axle
• Wheel bearing
• Oil seal
TIP Refer to “CHECKING THE FRONT WHEEL”
Place the vehicle on the suitable so that the rear on page 4-28.
wheel is elevated. 2. Check:
• Tire
2. Remove: • Rear wheel
• Rear brake caliper Damage/wear → Replace.
• Rear wheel sensor Refer to “CHECKING THE TIRES” on page
ECA21040
NOTICE
3-16 and “CHECKING THE WHEELS” on
page 3-16.
• Do not depress the brake pedal when re- 3. Measure:
moving the brake caliper. • Radial wheel runout
• Be sure not to contact the sensor electrode • Lateral wheel runout
to any metal part when removing the rear Refer to “CHECKING THE FRONT WHEEL”
wheel sensor from the rear brake caliper on page 4-28.
bracket.
EAS30160
3. Loosen: CHECKING THE REAR WHEEL DRIVE HUB
• Locknut 1. Check:
• Adjusting bolt • Rear wheel drive hub
4. Remove: Cracks/damage → Replace.
• Wheel axle nut • Rear wheel drive hub damper
• Washer Damage/wear → Replace.
• Wheel axle
• Rear wheel EAS30161
• Brake caliper bracket CHECKING AND REPLACING THE REAR

ECA21400 WHEEL SPROCKET
NOTICE 1. Check:
Be sure to remove the rear wheel sensor be- • Rear wheel sprocket
fore removing the brake caliper bracket, oth- More than 1/4 tooth “a” wear → Replace the
erwise the sensor could be damaged. drive sprocket, the rear wheel sprocket and
the drive chain as a set.
TIP Bent teeth → Replace the drive sprocket, the
Push the rear wheel forward and remove the rear wheel sprocket and the drive chain as a
drive chain from the rear wheel sprocket. set.
4-36
REAR WHEEL
G088904 G088898
b. Correct b. Install the spacer.

1. Drive chain roller c. Install the new wheel bearing (left side).
2. Rear wheel sprocket TIP
2. Replace: Place a suitable washer “1” between the socket
• Rear wheel sprocket “2” and the bearing so that both the inner race
a. Remove the rear wheel sprocket nuts and “3” and outer race “4” are pressed at the same
the rear wheel sprocket. time, and then press the bearing until the inner
b. Clean the rear wheel drive hub with a race makes contact with the spacer “5”.
clean cloth, especially the surfaces that
contact the sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket nut

80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
TIP
Tighten the rear wheel sprocket nuts in stages
and in a crisscross pattern. G088899
d. Install the new oil seals.

EAS30163
ASSEMBLING THE REAR WHEEL EAS31156

ECA21340 MAINTENANCE OF THE REAR WHEEL
NOTICE SENSOR AND SENSOR ROTOR
ECA21060
• Do not drop the wheel sensor rotor or sub-
NOTICE
ject it to shocks.
• If any solvent gets on the wheel sensor ro- • Handle the ABS components with care
tor, wipe it off immediately. since they have been accurately adjusted.
Keep them away from dirt and do not sub-
1. Install:
ject them to shocks.
• Wheel bearing New • The rear wheel sensor cannot be disassem-
• Oil seal New bled. Do not attempt to disassemble it. If
a. Install the new wheel bearing (right side). faulty, replace with a new one.
ECA18110
• Keep any type of magnets (including mag-
NOTICE netic pick-up tools, magnetic screwdrivers,
Do not contact the wheel bearing inner race etc.) away from the rear wheel sensor or
“1” or balls “2”. Contact should be made rear wheel sensor rotor.
only with the outer race “3”. • Do not drop or shock the wheel sensor or
the wheel sensor rotor.
TIP
Use a socket “4” that matches the diameter of 1. Check:
the wheel bearing outer race. • Rear wheel sensor
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR”
on page 4-30.
4-37
REAR WHEEL
2. Check: • Wheel axle

• Rear wheel sensor rotor • Washer
Refer to “MAINTENANCE OF THE FRONT • Wheel axle nut
WHEEL SENSOR AND SENSOR ROTOR” TIP
on page 4-30. • Do not install the brake caliper.
3. Measure: • Align the projection “a” in the swingarm with the
• Wheel sensor rotor runout slot “b” of the brake caliper bracket.
Refer to “MAINTENANCE OF THE FRONT • Install the adjusting block (left) so that projec-
WHEEL SENSOR AND SENSOR ROTOR” tion “c” faces to the front of the vehicle.
on page 4-30. • Install the adjusting block (right) with the cham-
EAS30164 fered “d” facing the inside.
ADJUSTING THE REAR WHEEL STATIC
BALANCE
TIP
• After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
b
• Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
a
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-30. A
EAS31157
c
INSTALLING THE REAR WHEEL (REAR
BRAKE DISC)
1. Install:
• Rear brake disc
Rear brake disc bolt

30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
LOCTITE®
ECA19150 B
NOTICE
Replace the brake disc bolts with new ones.
TIP
d
crisscross pattern.
2. Check:
• Rear brake disc
Refer to “CHECKING THE REAR BRAKE A. Left side
DISC” on page 4-60. B. Right side
3. Lubricate:
• Oil seal lip 5. Install:
• Rear brake caliper
Recommended lubricant • Rear brake caliper bolt
Lithium-soap-based grease 6. Adjust:
4. Install: Refer to “DRIVE CHAIN SLACK” on page
• Brake caliper bracket 3-18.
• Rear wheel
• Adjusting block
4-38
REAR WHEEL
ECA21080
Drive chain slack (Mainstand) NOTICE

45.0–50.0 mm (1.77–1.97 in) Make sure there are no foreign materials in
Drive chain slack limit (Main- the rear wheel sensor rotor and rear wheel
stand) sensor. Foreign materials cause damage to
55.0 mm (2.17 in)
the rear wheel sensor rotor and rear wheel
sensor.
7. Tighten:
• Wheel axle nut TIP
• Rear brake caliper bolt When installing the rear wheel sensor, check the
rear wheel sensor lead for twists.
Rear wheel axle nut
105 N·m (10.5 kgf·m, 77 lb·ft) 9. Measure:
T.
R.
Rear brake caliper bolt (front) • Distance “a”

27 N·m (2.7 kgf·m, 20 lb·ft) (between the wheel sensor rotor “1” and rear
Rear brake caliper bolt (rear) wheel sensor “2”)
22 N·m (2.2 kgf·m, 16 lb·ft) Out of specification → Check the wheel bear-
LOCTITE®
ing for looseness, and the rear wheel sensor
EWA13500 and sensor rotor installation conditions
WARNING (warpage caused by overtorque, wrong in-
Make sure the brake hose is routed properly. stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
TIP deformation caused by an impact during ser-
When tightening the wheel axle nut, there vice and caught foreign materials). If there is
should be no clearance “a” between the adjust- any defective part, repair or replace the de-
ing block “1” and adjusting bolt “2”. fective part.
A
a Distance “a” (between the wheel
sensor rotor and rear wheel sen-
sor)
0.6–1.7 mm (0.02–0.07 in)
TIP
Measure the distance between the rear wheel
2 1 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-
B
a sor rotor and the rear wheel sensor.
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
1 2
1
A. Left side
2
B. Right side 2
8. Install:
• Rear wheel sensor
a
Rear wheel sensor bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft) 1
G088906
T.
R.
4-39
REAR WHEEL
10.Check (for MTT890D):

• SUS. Sensor Calibration
Refer to “CHECKING THE VEHICLE AFTER
INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY (for MTT890D)” on page
4-124.
4-40
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
6 5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
9
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
5
4
3
2
1
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.

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
6 Front wheel sensor lead 1
8 Reflector 1
9 Bleed screw 1
4-41
FRONT BRAKE
Removing the front brake master cylinder

1.1 N•m (0.11 kgf•m, 0.81 lb•ft) 1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
T.R
.
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
1
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
4
10 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
5 2
6
8
9
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

New
T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
T.R
T.R
.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-15.
1 Rearview mirror (right) 1 Left-hand threads
2 Brake fluid reservoir cap stopper 1
3 Brake fluid reservoir cap 1
4 Brake fluid reservoir diaphragm holder 1
5 Brake fluid reservoir diaphragm 1
6 Brake fluid reservoir 1
7 Brake fluid reservoir hose 1
8 Handguard upper bracket (right) 1
9 Handguard (right) 1
10 Grip end (right) 1
4-42
FRONT BRAKE
Removing the front brake master cylinder

1.1 N•m (0.11 kgf•m, 0.81 lb•ft) 1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
T.R
.
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
18
17
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
12
15
11 16 New
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
15
T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft) 14

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 13

T.R
.
T.R
T.R
.

11 Handguard lower bracket (right) 1
12 Brake lever 1
13 Front brake light switch 1
14 Brake hose union bolt 1
15 Brake hose gasket 2
Brake hose (front brake master cylinder to brake
16 1
hose joint)
17 Front brake master cylinder holder 1
18 Front brake master cylinder 1
4-43
FRONT BRAKE
Disassembling the front brake master cylinder
5 N・m (0.5 kgf・m, 3.7 lb・ft)
3
BF
4
1 New
BF
1 New

1 Brake master cylinder kit 1
2 Bleed screw 1
3 Cap 1
4 Brake master cylinder body 1
4-44
FRONT BRAKE
Removing the front brake calipers
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
3 New
8
4 6
2 New
1
30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.

Drain.
Brake fluid Refer to“BLEEDING THE HYDRAULIC
3 Brake hose gasket 1 Left side only
Brake hose (front brake caliper (left) to front
4 1
brake caliper (right))
Brake hose (brake hose joint to front brake cali-
5 1 Left side only
per (left))
7 Reflector 1
4-45
FRONT BRAKE
Disassembling the front brake calipers

5 N・m (0.5 kgf・m, 3.7 lb・ft)
FW
D 8
7 New
New 6
BF
2 New 5
1
6
New 7
S
S
7
6 New
New
5
BF
6 New
7 New

1 Brake pad clip 2
2 Brake pad pin 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Bleed screw 1
4-46
FRONT BRAKE
EAS30168
INTRODUCTION
EWA14101
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake G098641
system is disconnected, the entire brake
system must be disassembled, drained, 3. Measure:
cleaned, properly filled, and bled after reas- • Brake disc thickness
sembly. Measure the brake disc thickness at a few dif-
• Never use solvents on internal brake com- ferent locations.
ponents. Out of specification → Replace.
• Use only clean or new brake fluid for clean- Brake disc thickness limit
ing brake components. 4.0 mm (0.16 in)
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean 4. Replace:
up any spilt brake fluid immediately. • Brake disc
• Avoid brake fluid coming into contact with Refer to “FRONT WHEEL” on page 4-26.
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING Front brake disc bolt
THE EYES: 18 N·m (1.8 kgf·m, 13 lb·ft)
T.
R.
• Flush with water for 15 minutes and get im- LOCTITE®

mediate medical attention. ECA19150
NOTICE
EAS30169
CHECKING THE FRONT BRAKE DISCS Replace the brake disc bolts with new ones.
The following procedure applies to both brake TIP
discs.
1. Check:
crisscross pattern.
• Front brake disc
Damage/galling → Replace. EAS30170
2. Measure: REPLACING THE FRONT BRAKE PADS
• Brake disc runout The following procedure applies to both brake
Out of specification → Replace. calipers.
Brake disc runout limit (as mea- TIP
sured on wheel) When replacing the brake pads, it is not neces-
0.10 mm (0.0039 in) sary to disconnect the brake hose or disassem-
ble the brake caliper.
a. Place the vehicle on a maintenance stand
1. Remove:
so that the front wheel is elevated.
• Brake pad clip “1”
b. Remove the brake caliper.
• Brake pad pin “2”
c. Hold the dial gauge at a right angle against
• Brake pad spring “3”
the brake disc surface.
d. Measure the runout 1.5 mm (0.06 in) be-
low the edge of the brake disc.
4-47
FRONT BRAKE
b. Loosen the bleed screw and push the

3 brake caliper pistons into the brake caliper
with your finger.
1
2
2
1
2. Remove:
• Brake pad “1”
c. Tighten the bleed screw.
Brake caliper bleed screw

5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
1 d. Install the brake pads and brake pad
spring.
TIP
The arrow mark “a” on the brake pad spring
3. Measure: must point in the direction of disc rotation.
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness limit

0.5 mm (0.02 in)
a
6. Install:
• Brake pad pin
• Brake pad clip
Front brake caliper bolt

4. Remove: 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
• Brake caliper bolt

5. Install: 7. Check:
• Brake pad • Brake fluid level
• Brake pad spring Below the minimum level mark → Add the
TIP
Always install new brake pads and new brake
pad spring as a set.
8. Check:
a. Connect a clear plastic hose “1” tightly to • Brake lever operation
the bleed screw “2”. Put the other end of Soft or spongy feeling → Bleed the brake sys-
the hose into an open container. tem.
Refer to “BLEEDING THE HYDRAULIC
4-48
FRONT BRAKE
EAS30724 EAS30173
REMOVING THE FRONT BRAKE CALIPERS CHECKING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the The following procedure applies to both of the
brake calipers. brake calipers.
TIP Recommended brake component
Before removing the brake caliper, drain the replacement schedule
brake fluid from the entire brake system. Brake pads If necessary
1. Remove: Piston seals Every two years
• Brake hose union bolt Piston dust seals Every two years
• Brake hose gasket
Brake hoses Every four years
• Brake hose (front brake caliper (left) to front
brake caliper (right)) Every two years and
Brake fluid whenever the brake is
• Brake hose (brake hose joint to front brake disassembled
caliper (left))
TIP 1. Check:
Put the end of the brake hose into a container • Brake caliper piston
and pump out the brake fluid carefully. Rust/scratches/wear → Replace the brake
caliper pistons.
EAS30172
• Brake caliper cylinder
DISASSEMBLING THE FRONT BRAKE Scratches/wear → Replace the brake caliper
CALIPERS assembly.
The following procedure applies to both of the • Brake caliper body
brake calipers. Cracks/damage → Replace the brake caliper
1. Remove: assembly.
• Brake caliper piston • Brake fluid delivery passages
• Brake caliper piston dust seal (brake caliper body)
• Brake caliper piston seal Obstruction → Blow out with compressed air.
EWA13611
a. Secure the inner side brake caliper pis-
tons with a piece of wood “a”. WARNING
b. Blow compressed air into the brake hose Whenever a brake caliper is disassembled,
joint opening “b” to force out the outer side replace the brake caliper piston dust seals
pistons from the brake caliper. and brake caliper piston seals.
EWA17060
WARNING EAS30174
• Never try to pry out the brake caliper pis- ASSEMBLING THE FRONT BRAKE
tons. CALIPERS
EWA16560
• Do not loosen the bolts “4”. WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
4 with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
seals to swell and distort.
a b • Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
c. Remove the brake caliper piston dust
seals and brake caliper piston seals. Specified brake fluid
d. Repeat the previous steps to force out the DOT 4
inner side pistons from the brake caliper.
4-49
FRONT BRAKE
EAS30175
2. Remove:
INSTALLING THE FRONT BRAKE CALIPERS
3. Install:
brake calipers.
• Brake pad
1. Install:
• Brake pad spring
• Front brake caliper “1”
• Brake pad pin
(temporarily)
• Brake pad clip
• Brake hose gasket New • Front brake caliper
• Brake hose (front brake caliper (left) to front
brake caliper (right)) “2” Front brake caliper bolt
• Brake hose (brake hose joint to front brake 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
caliper (left)) “3”
• Brake hose union bolt “4” Refer to “REPLACING THE FRONT BRAKE
PADS” on page 4-47.
Front brake caliper bolt 4. Fill:
35 N·m (3.5 kgf·m, 26 lb·ft) • Brake master cylinder reservoir
T.
R.
(with the specified amount of the specified

EWA13531
WARNING
brake fluid)
Proper brake hose routing is essential to in- Specified brake fluid
sure safe vehicle operation. DOT 4
ECA21410
EWA13090
NOTICE
WARNING
• When installing the brake hose onto the
• Use only the designated brake fluid. Other
brake caliper “1”, make sure the brake pipe
brake fluids may cause the rubber seals to
“a” touches the projection “b” on the brake
deteriorate, causing leakage and poor
caliper.
brake performance.
• Install the brake pipe “c” so that it is
aligned with the brake pipe “a”.
A may result in a harmful chemical reaction,
b leading to poor brake performance.
2
a will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
4
ECA13540
NOTICE
1 Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
B any spilt brake fluid immediately.
c 3 5. Bleed:
2 • Brake system
4 Refer to “BLEEDING THE HYDRAULIC
a BRAKE SYSTEM (ABS)” on page 3-15.
b 6. Check:
1 Below the minimum level mark → Add the
A. Right side
B. Left side
4-50
FRONT BRAKE
7. Check: EAS30181
ASSEMBLING THE FRONT BRAKE MASTER

• Brake lever operation
CYLINDER
Soft or spongy feeling → Bleed the brake sys- EWA13520
tem. WARNING
Refer to “BLEEDING THE HYDRAULIC • Before installation, all internal brake com-
BRAKE SYSTEM (ABS)” on page 3-15. ponents should be cleaned and lubricated
EAS30179 with clean or new brake fluid.
REMOVING THE FRONT BRAKE MASTER • Never use solvents on internal brake com-
CYLINDER ponents.
TIP
Before removing the front brake master cylinder, Specified brake fluid
drain the brake fluid from the entire brake sys- DOT 4
tem.
EAS30182
1. Disconnect: INSTALLING THE FRONT BRAKE MASTER
• Brake light switch connector CYLINDER
(from the front brake light switch) 1. Install:
2. Remove: • Front brake master cylinder
• Brake hose union bolt • Front brake master cylinder holder
• Brake hose (front brake master cylinder to Front brake master cylinder hold-
brake hose joint) er bolt
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft)

TIP
To collect any remaining brake fluid, place a TIP
container under the master cylinder and the end
• Install the front brake master cylinder holder
of the brake hose.
with the “UP” mark “a” facing up.
EAS30725
• Align the end of the front brake master cylinder
CHECKING THE FRONT BRAKE MASTER holder with the punch mark “b” on the handle-
CYLINDER bar.
1. Check: • First, tighten the upper bolt, then the lower bolt.
• Brake master cylinder
Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed air.
2. Check:
• Brake master cylinder kit b
3. Check:
• Brake master cylinder reservoir a
• Brake master cylinder reservoir diaphragm 2. Install:
holder
• Brake hose gasket New
Cracks/damage → Replace.
• Brake hose (front brake master cylinder to
• Brake master cylinder reservoir diaphragm
brake hose joint)
• Brake hose union bolt
4. Check:
• Brake hose Front brake hose union bolt
Cracks/damage/wear → Replace. 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
4-51
FRONT BRAKE
EWA13531
WARNING 3
Proper brake hose routing is essential to in-
sure safe vehicle operation.
TIP
• When installing the brake hose onto the master
cylinder, make sure the projection “a” on the
brake hose touches the projection “b” on the a
master cylinder.
• Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts 4. Tighten:
(e.g., wire harness, cables, leads). Correct if • Handguard lower bracket bolt
necessary. • Handguard upper bracket bolt
Handguard lower bracket bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
a Handguard upper bracket bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
b 5. Tighten:
• Grip end bolt
Grip end bolt

17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
3. Install: 6. Fill:
• Handguard lower bracket (right) • Brake master cylinder reservoir
• Handguard lower bracket bolt “1” (temporary) (with the specified amount of the specified
• Handguard upper bracket (right) brake fluid)
• Handguard upper bracket bolt “2” (tempo-
rary) Specified brake fluid
• Grip end (right) “3” DOT 4
• Handguard (right) EWA13540
• Grip end bolt “4” (temporary) WARNING
TIP • Use only the designated brake fluid. Other
There should be 1–3 mm (0.04–0.12 in) of clear- brake fluids may cause the rubber seals to
ance “a” between the throttle grip and the grip deteriorate, causing leakage and poor
end. brake performance.
2 may result in a harmful chemical reaction,
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
4 ing point of the brake fluid and could cause
vapor lock.
1 ECA13540
NOTICE
any spilt brake fluid immediately.
4-52
FRONT BRAKE
7. Bleed:
• Brake system
8. Check:
9. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
4-53
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads
9
*
5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
3
S
8
S
7 2
6 1
LT
S
6
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
5 17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
4 2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

S
T.R
.
* Three Bond No. 1521

1 Screw plug 1
2 Brake pad retaining bolt 1
3 Rear brake caliper 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad insulator 2
8 Bleed screw 1
9 Brake caliper bracket assembly 1
4-54
REAR BRAKE
Removing the rear brake master cylinder
5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
LS
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
3
4
5
6
7
30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
.
1
2
New
28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.
LT
LT
23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.

Rider seat 4-1.
Drain.
Brake fluid Refer to“BLEEDING THE HYDRAULIC
1 Passenger footrest (right) 1
2 Brake fluid reservoir bracket 1
3 Brake fluid reservoir cap 1
4 Brake fluid reservoir diaphragm holder 1
5 Brake fluid reservoir diaphragm 1
6 Brake fluid reservoir 1
7 Brake fluid reservoir hose 1
4-55
REAR BRAKE
Removing the rear brake master cylinder
5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
11 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
LS
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
14
30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
.
15
8 16
New 9 10
12
13
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
LT
LT
23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.

Rear brake hose (rear brake master cylinder to
10 1
hydraulic unit)
11 Rear brake light switch coupler 1 Disconnect.
12 Footrest assembly (right) 1
13 Rear brake master cylinder assembly 1
14 Rear brake light switch 1
15 Rear brake light switch bracket 1
16 Brake pedal 1
4-56
REAR BRAKE
Disassembling the rear brake master cylinder
New
BF
New
New BF
18 N・m (1.8 kgf・m, 13 lb・ft)

1 Brake master cylinder yoke 1
2 Brake master cylinder kit 1
3 Hose joint 1
4 Bushing 1
5 Brake master cylinder body 1
4-57
REAR BRAKE
Removing the rear brake caliper
30 N・m (3.0 kgf・m, 22 lb・ft)
New 2
3
LT
S
4
22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.

Drain.
Rear brake hose (hydraulic unit to rear brake
3 1
caliper)
4 Rear brake caliper 1
4-58
REAR BRAKE
Disassembling the rear brake caliper
S
5 N・m (0.5 kgf・m, 3.7 lb・ft)
BF
17 N・m (1.7 kgf・m, 13 lb・ft)
2.5 N・m (0.25 kgf・m, 1.8 lb・ft)

1 Screw plug 1
2 Brake pad retaining bolt 1
3 Brake pad 2
4 Brake pad shim 2
5 Brake pad insulator 2
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Bleed screw 1
4-59
REAR BRAKE
EAS33521
• If any connection on the hydraulic brake
ADJUSTING THE FOOTREST POSITION
system is disconnected, the entire brake
1. Check:
system must be disassembled, drained,
• Footrest position
cleaned, properly filled, and bled after reas-
TIP sembly.
The rider footrests can be adjusted to one of two • Never use solvents on internal brake com-
positions. From the factory, the footrests are in ponents.
the low position. • Use only clean or new brake fluid for clean-
2. Adjust: ing brake components.
a. Remove the footrest assembly (left and • Brake fluid may damage painted surfaces
right) “1”. and plastic parts. Therefore, always clean
b. Adjust the footrest position (low or high po- up any spilt brake fluid immediately.
sition). • Avoid brake fluid coming into contact with
c. Install the footrest assembly (left and the eyes as it can cause serious injury.
right). FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
Footrest assembly bolt • Flush with water for 15 minutes and get im-
28 N·m (2.8 kgf·m, 21 lb·ft) mediate medical attention.
T.
R.
EAS30184
A
CHECKING THE REAR BRAKE DISC
1. Check:
• Rear brake disc
Damage/galling → Replace.
2. Measure:
1 • Brake disc runout
Out of specification → Replace.
Refer to “CHECKING THE FRONT BRAKE
B Brake disc runout limit (as mea-

sured on wheel)
0.15 mm (0.0059 in)
1
3. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Refer to “CHECKING THE FRONT BRAKE
A. Left side DISCS” on page 4-47.
B. Right side
Brake disc thickness limit
EAS30183 4.5 mm (0.18 in)
INTRODUCTION
EWA14101
4. Replace:
WARNING
• Brake disc
Disc brake components rarely require disas- Refer to “REAR WHEEL” on page 4-33.
sembly. Therefore, always follow these pre-
ventive measures: Rear brake disc bolt
• Never disassemble brake components un- 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
less absolutely necessary. LOCTITE®
4-60
REAR BRAKE
EAS30185
REPLACING THE REAR BRAKE PADS Brake caliper bleed screw

TIP 5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- d. Install the brake pad insulators and brake
ble the brake caliper. pad shims onto each brake pads.
TIP
1. Measure:
Apply silicone grease between the brake pad in-
• Brake pad wear limit “a”
sulator and brake pad shim.
Out of specification → Replace the brake
pads as a set. ECA14150
NOTICE
Brake pad lining thickness limit • Do not allow grease to contact the brake
1.0 mm (0.04 in) pads.
• Remove any excess grease.
e. Install the brake pads and brake pad
spring.
TIP
a
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
piston.
a
2. Install:
• Brake pad insulator
• Brake pad shim
(onto the brake pad)
• Brake pad spring
(into the rear brake caliper)
• Brake pad
TIP
3. Lubricate:
Always install new brake pads, brake pad insu- • Rear brake caliper bolt
lators, brake pad shims, and brake pad spring as
a set. Recommended lubricant
Silicone grease
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of ECA14150
the hose into an open container. NOTICE

b. Loosen the bleed screw and push the • Do not allow grease to contact the brake
brake caliper piston into the brake caliper pads.
with your finger. • Remove any excess grease.
1 4. Install:
2
• Brake pad retaining bolt
• Screw plug
c. Tighten the bleed screw.
4-61
REAR BRAKE
• Never try to pry out the brake caliper pis-

Rear brake caliper bolt (front) ton.
27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
Rear brake caliper bolt (rear)

22 N·m (2.2 kgf·m, 16 lb·ft)
LOCTITE®
Rear brake pad retaining bolt
17 N·m (1.7 kgf·m, 13 lb·ft)
Rear brake caliper screw plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
5. Check: a
Below the minimum level mark → Add the b. Remove the brake caliper piston dust seal
specified brake fluid to the proper level. and brake caliper piston seal.
LEVEL” on page 3-13. EAS30188
6. Check: CHECKING THE REAR BRAKE CALIPER

• Brake pedal operation Recommended brake component
Soft or spongy feeling → Bleed the brake sys- replacement schedule
tem. Brake pads If necessary
Piston seal Every two years
Piston dust seal Every two years
EAS30186
REMOVING THE REAR BRAKE CALIPER Brake hoses Every four years
TIP Every two years and
Brake fluid whenever the brake is
Before disassembling the brake caliper, drain disassembled
the brake fluid from the entire brake system.
1. Check:
1. Remove:
• Brake caliper piston
Rust/scratches/wear → Replace the brake
caliper piston.
• Rear brake hose (hydraulic unit to rear brake
• Brake caliper cylinder
caliper)
Scratches/wear → Replace the brake caliper
TIP assembly.
Put the end of the brake hose into a container • Brake caliper body
and pump out the brake fluid carefully. Cracks/damage → Replace the brake caliper
assembly.
EAS30187
DISASSEMBLING THE REAR BRAKE (brake caliper body)
CALIPER Obstruction → Blow out with compressed air.
1. Remove: EWA13601
• Brake caliper piston WARNING

• Brake caliper piston dust seal Whenever a brake caliper is disassembled,
• Brake caliper piston seal replace the brake caliper piston dust seal
a. Blow compressed air into the brake hose and brake caliper piston seal.
joint opening “a” to force out the piston
from the brake caliper. 2. Check:
EWA13550 • Rear brake caliper bracket
WARNING Cracks/damage → Replace.
• Cover the brake caliper piston with a rag. Refer to “REAR WHEEL” on page 4-33.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
4-62
REAR BRAKE
EAS30189
3. Install:
ASSEMBLING THE REAR BRAKE CALIPER
EWA17080
• Brake pad insulator
WARNING • Brake pad shim
• Before installation, all internal brake com- (onto the brake pad)
ponents should be cleaned and lubricated • Brake pad spring
with clean or new brake fluid. (into the rear brake caliper)
• Never use solvents on internal brake com- • Brake pad
ponents as they will cause the brake caliper • Rear brake caliper
piston dust seal and brake caliper piston Refer to “REPLACING THE REAR BRAKE
seal to swell and distort. PADS” on page 4-61.
• Whenever a brake caliper is disassembled, Rear brake caliper bolt (front)
replace the brake caliper piston dust seal 27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
and brake caliper piston seal. Rear brake caliper bolt (rear)
22 N·m (2.2 kgf·m, 16 lb·ft)
Specified brake fluid LOCTITE®
DOT 4 Rear brake pad retaining bolt
17 N·m (1.7 kgf·m, 13 lb·ft)
EAS30190 Rear brake caliper screw plug
INSTALLING THE REAR BRAKE CALIPER 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
1. Install:
• Rear brake caliper 4. Fill:
(temporarily) • Brake fluid reservoir
• Brake hose gasket New (with the specified amount of the specified
• Rear brake hose (hydraulic unit to rear brake brake fluid)
caliper) Specified brake fluid
• Brake hose union bolt DOT 4
Rear brake hose union bolt EWA13090
30 N·m (3.0 kgf·m, 22 lb·ft) WARNING

T.
R.
EWA13531
WARNING brake fluids may cause the rubber seals to
Proper brake hose routing is essential to in- deteriorate, causing leakage and poor
sure safe vehicle operation. brake performance.
ECA19080
NOTICE
When installing the brake hose onto the leading to poor brake performance.
brake caliper “1”, make sure the brake pipe • When refilling, be careful that water does
“a” passes between the projections “b” on not enter the brake fluid reservoir. Water
the brake caliper. will significantly lower the boiling point of
ECA13540
b NOTICE
a and plastic parts. Therefore, always clean up
1 5. Bleed:
• Brake system
2. Remove: BRAKE SYSTEM (ABS)” on page 3-15.
4-63
REAR BRAKE
6. Check: EAS30195
ASSEMBLING THE REAR BRAKE MASTER

CYLINDER
Below the minimum level mark → Add the EWA13520
specified brake fluid to the proper level. WARNING

Refer to “CHECKING THE BRAKE FLUID • Before installation, all internal brake com-
LEVEL” on page 3-13. ponents should be cleaned and lubricated
7. Check: with clean or new brake fluid.
• Brake pedal operation • Never use solvents on internal brake com-
Soft or spongy feeling → Bleed the brake sys- ponents.
tem.
DOT 4
EAS30193
REMOVING THE REAR BRAKE MASTER 1. Install:

CYLINDER • Brake master cylinder kit New
1. Remove:
• Brake hose union bolt EAS33564
INSTALLING THE BRAKE LIGHT SWITCH

1. Install:
• Rear brake hose (rear brake master cylinder
• Rear brake pedal “1”
to hydraulic unit)
• Rear brake light switch bracket “2”
TIP
• Rear brake light switch “3”
To collect any remaining brake fluid, place a TIP
container under the master cylinder and the end
• Point the end “a” and “b” of the springs inward.
of the brake hose.
• Point the end “c” of the spring rearward.
EAS30194
• Position the rear brake light switch lead within
CHECKING THE REAR BRAKE MASTER the range “d” shown in the illustration.
CYLINDER
1. Check:
3
• Brake master cylinder 2
a b
(brake master cylinder body)
Obstruction → Blow out with compressed air. 1
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace. c
3. Check:
• Brake fluid reservoir
• Brake fluid reservoir diaphragm holder
• Brake fluid reservoir diaphragm
4. Check:
• Brake hose d
• Brake fluid reservoir hose
Cracks/damage/wear → Replace.
d = 30°
4-64
REAR BRAKE
EAS30196
INSTALLING THE REAR BRAKE MASTER
CYLINDER
will significantly lower the boiling point of
1. Install:
• Brake hose gasket New ECA13540
• Rear brake hose (rear brake master cylinder NOTICE
to hydraulic unit)
• Brake fluid reservoir hose
Rear brake hose union bolt 3. Bleed:
30 N·m (3.0 kgf·m, 22 lb·ft) • Brake system
T.
R.
EWA13531
WARNING BRAKE SYSTEM (ABS)” on page 3-15.
4. Check:
Proper brake hose routing is essential to in-
sure safe vehicle operation.
ECA14160
NOTICE
When installing the brake hose onto the LEVEL” on page 3-13.
brake master cylinder, make sure the brake 5. Adjust:
pipe touches the projection “a” as shown. • Brake pedal position
Refer to “ADJUSTING THE REAR DISC
a BRAKE” on page 3-14.
6. Adjust:
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-30.
2. Fill:
• Brake fluid reservoir
(with the specified amount of the specified
brake fluid)

DOT 4
EWA13090
WARNING
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
4-65
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS20032

Removing the hydraulic unit assembly
7 N•m (0.7 kgf•m, 5.2 lb•ft)
1
T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft) 16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
T.R
.
New 2 4
3
New 2
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)
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
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
D
FW
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.

Rider seat/Battery 4-1.
Air filter case 4-24.
Drain.
2 Gasket 4
Brake hose (brake hose joint to front brake cali-
3 1 Disconnect.
per (left))
Brake hose (front brake master cylinder to brake
4 1 Disconnect.
hose joint)
4-66
Removing the hydraulic unit assembly

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
T.R
6
.
New
5
New
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
11 16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
7
10
8
14
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9
13
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 12

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
D
FW
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.

Hydraulic unit brake pipe (brake hose joint to hy-
5 1
draulic unit)
Hydraulic unit brake pipe (hydraulic unit to brake
6 1
hose joint)
7 Brake hose joint 1
8 Rear wheel sensor lead 1
9 Bracket 1
Rear brake hose (rear brake master cylinder to
10 1 Disconnect.
hydraulic unit)
Rear brake hose (hydraulic unit to rear brake
11 1 Disconnect.
caliper)
12 ABS ECU coupler 1 Disconnect.
13 Hydraulic unit bracket 1
14 Hydraulic unit assembly 1
4-67
EAS30197
REMOVING THE HYDRAULIC UNIT TIP

ASSEMBLY • Do not operate the brake lever and brake pedal
ECA21091 while removing the brake hoses.
NOTICE • Do not bend the brake pipe when loosening the
Unless necessary, avoid removing and in- brake pipe flare nuts.
stalling the brake hoses of the hydraulic unit ECA19800
assembly. NOTICE
EWA13930 • When removing the brake hoses and brake
WARNING pipes, cover the area around the hydraulic
Refill with the same type of brake fluid that is unit assembly to catch any spilt brake fluid.
already in the system. Mixing fluids may re- Do not allow the brake fluid to contact other
sult in a harmful chemical reaction, leading parts.
to poor braking performance. • Before disconnecting the brake pipes from
ECA18241 the hydraulic unit assembly, do not lift up
NOTICE or move the brake pipes.
• Handle the ABS components with care 3. Remove:
since they have been accurately adjusted. • Hydraulic unit assembly “1”
Keep them away from dirt and do not sub- TIP
ject them to shocks. To avoid brake fluid leakage and to prevent for-
• Do not turn the main switch to “ON” when eign materials from entering the hydraulic unit
removing the hydraulic unit assembly. assembly, insert a rubber plug “a” or a bolt (M10
• Do not clean with compressed air. × 1.0) into each brake hose union bolt hole.
• Do not reuse the brake fluid.
ECA19810
• Brake fluid may damage painted surfaces
NOTICE
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. When using a bolt, do not tighten the bolt un-
• Do not allow any brake fluid to contact the til the bolt head touches the hydraulic unit.
couplers. Brake fluid may damage the cou- Otherwise, the brake pipe seating surface
plers and cause bad contacts. could be deformed.
• If the union bolts for the hydraulic unit as-
sembly have been removed, be sure to
tighten them to the specified torque and
bleed the brake system. a
1. Disconnect:
• ABS ECU coupler “1”
TIP 1
While pushing the portion “a” of the ABS ECU
coupler, pull the lock lever “2” up to release the
lock.
EAS30198
CHECKING THE HYDRAULIC UNIT

ASSEMBLY
2 1. Check:
a
• Hydraulic unit assembly
1 Cracks/damage → Replace the hydraulic unit
assembly and the brake pipes that are con-
nected to the assembly as a set.
EAS30935
CHECKING THE BRAKE PIPES

2. Remove: brake pipes.
• Brake hose
4-68
1. Check: ECA19820
• Brake pipe end (flare nut) NOTICE

Damage → Replace the hydraulic unit as- If the brake pipe flare nut does not turn easi-
sembly, brake pipes, and related parts as a ly, replace the hydraulic unit assembly,
set. brake pipes, and related parts as a set.
EAS30200 TIP
INSTALLING THE HYDRAULIC UNIT Do not bend the brake pipe when tightening the
ASSEMBLY brake pipe flare nuts.
1. Install:
• Hydraulic unit assembly 5. Install:
ECA21371
• Gasket New
NOTICE • Brake hose union bolt “1”
Do not remove the rubber plugs or bolts • Brake hose (brake hose joint to front brake
(M10 × 1.0) installed in the brake hose union caliper (left))
bolt holes before installing the hydraulic unit • Brake hose (front brake master cylinder to
assembly. brake hose joint)
Refer to “CABLE ROUTING” on page 2-13.
TIP
TIP
Do not allow any foreign materials to enter the
hydraulic unit assembly, brake hoses or brake After holding the protrusion “a” (17 mm (0.67 in))
pipes when installing the hydraulic unit assem- on the brake hose joint with an appropriate tool,
bly. tighten the brake hose union bolts to the speci-
fied torque.
a. Install the hydraulic unit assembly “1” on
the hydraulic unit bracket “2”.
Front brake hose union bolt
b. Tighten the hydraulic unit assembly bolt 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
“3”, and bolt “4” to the specified torque in

R.
this order.
1
Hydraulic unit assembly bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
a
3
6. Connect:
• ABS ECU coupler “1”
TIP
2 4 Connect the ABS ECU coupler, and then push
2. Remove: the lock lever “a” of the coupler in the direction of
• Rubber plugs or bolt (M10 × 1.0) the arrow shown.
3. Install:
• Hydraulic unit brake pipe
4. Tighten: 1
• Hydraulic unit brake pipe flare nut a
Hydraulic unit brake pipe flare

nut
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft)
4-69
7. Fill: The hydraulic unit operation can be tested using

• Brake fluid reservoir the following two methods.
(with the specified amount of the specified • Brake line routing confirmation: this test
brake fluid) checks the function of the ABS after the sys-
tem was disassembled, adjusted, or serviced.
Specified brake fluid • ABS reaction-force confirmation: this test gen-
DOT 4 erates the same reaction-force pulsating action
EWA17280
that is generated in the brake lever and brake
WARNING pedal when the ABS is activated.
Brake line routing confirmation
brake fluids may cause the rubber seals to EWA13120
deteriorate, causing leakage and poor WARNING

brake performance. Securely support the vehicle so that there is
• Refill with the same type of brake fluid that no danger of it falling over.
may result in a harmful chemical reaction, TIP
leading to poor brake performance. • For the brake line routing confirmation, use the
• When refilling, be careful that water does diagnosis of function of the YDT.
not enter the brake master cylinder reser- • Before performing the brake line routing confir-
voir or brake fluid reservoir. Water will sig- mation, make sure that no malfunctions have
nificantly lower the boiling point of the been detected in the ABS ECU and that the
brake fluid and could cause vapor lock. wheels are not rotating.
ECA13540
1. Place the vehicle on a suitable stand.
NOTICE
2. Turn the main switch to “OFF”.
Brake fluid may damage painted surfaces 3. Remove:
and plastic parts. Therefore, always clean up • Rider seat
any spilt brake fluid immediately. Refer to “GENERAL CHASSIS (1)” on page
8. Bleed: 4-1.
• Brake system 4. Check:
Refer to “BLEEDING THE HYDRAULIC • Battery voltage
BRAKE SYSTEM (ABS)” on page 3-15. Lower than 12.8 V → Charge or replace the
9. Check the operation of the hydraulic unit ac- battery.
cording to the brake lever and the brake ped-
al response. (Refer to “HYDRAULIC UNIT Battery voltage
OPERATION TESTS” on page 4-70.) Higher than 12.8 V
ECA14770
NOTICE TIP
Always check the operation of the hydraulic If the battery voltage is lower than 12.8 V, charge
unit according to the brake lever and the the battery, and then perform brake line routing
brake pedal response. confirmation.
10.Delete the DTC. (Refer to “SELF-DIAGNOS- 5. Removing the protective cap, and then con-
TIC FUNCTION AND DIAGNOSTIC CODE nect the YDT to the YDT coupler (6P).
TABLE” on page 9-52.)
11.Perform a trial run. (Refer to “CHECKING Yamaha diagnostic tool USB
THE ABS WARNING LIGHT” on page 4-73.) 90890-03267
EAS30930 90890-03264
HYDRAULIC UNIT OPERATION TESTS
The reaction-force pulsating action generated in TIP
the brake lever and brake pedal when the ABS • Yamaha diagnostic tool (A/I) (90890-03264) in-
is activated can be tested when the vehicle is cludes YDT sub harness (6P) (90890-03266).
stopped.
4-70
• If you already have Yamaha diagnostic tool (A/ TIP

I) (90890-03262), YDT sub harness (6P) “ON” and “OFF” on the tool screen indicate
(90890-03266) is separately required. when the brakes are being applied and released
Refer to “YDT” on page 9-2. respectively.
6. Start the YDT and display the diagnosis of ECA17371
function screen. NOTICE

7. Select code No. 2, “Brake line routing confir- • Check that the pulse is felt in the brake le-
mation”. ver, brake pedal, and again in the brake le-
8. Click “Actuator Check”, and then operate the ver, in this order.
brake lever “1” and brake pedal “2” simulta- • If the pulse is felt in the brake pedal before
neously. it is felt in the brake lever, check that the
TIP brake hoses and brake pipes are connected
• The hydraulic unit operates 1 second after the correctly to the hydraulic unit assembly.
brake lever and brake pedal are operated si- • If the pulse is hardly felt in either the brake
multaneously and continues for approximately lever or brake pedal, check that the brake
5 seconds. hoses and brake pipes are connected cor-
• The operation of the hydraulic unit can be con- rectly to the hydraulic unit assembly.
firmed using the indicator. 10.If the operation of the hydraulic unit is normal,
On: The hydraulic unit is operating. delete all of the DTC.
Flashing: The conditions for operating the hy-
draulic unit have not been met. ABS reaction-force confirmation
Off: The brake lever and brake pedal are not EWA13120
being operated. WARNING

1 no danger of it falling over.
TIP
• For the ABS reaction-force confirmation, use
the diagnosis of function of the YDT. For more
information, refer to the operation manual of
the YDT.
• Before performing the ABS reaction-force con-
G088909 2 firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
9. Check: wheels are not rotating.
• Hydraulic unit operation
Click “Actuator Check”, a single pulse will be 1. Place the vehicle on a suitable stand.
generated in the brake lever “1”, brake pedal 2. Turn the main switch to “OFF”.
“2”, and again in the brake lever “1”, in this or- 3. Remove:
der. • Rider seat
1 4-1.
4. Check:
• Battery voltage
Lower than 12.8 V → Charge or replace the
battery.
Battery voltage
Higher than 12.8 V
G088911 2
4-71
TIP 9. A reaction-force pulsating action is generated

If the battery voltage is lower than 12.8 V, charge in the brake lever “1” and continues for a few
the battery, and then perform ABS reaction- seconds.
force confirmation. TIP
• The reaction-force pulsating action consists of
5. Removing the protective cap, and then con-
quick pulses.
nect the YDT to the YDT coupler (6P).
• Be sure to continue operating the brake lever
Yamaha diagnostic tool USB and brake pedal even after the pulsating action
90890-03267 has stopped.
Yamaha diagnostic tool (A/I) • “ON” and “OFF” on the tool screen indicate
90890-03264 when the brakes are being applied and re-
leased respectively.
TIP
• Yamaha diagnostic tool (A/I) (90890-03264) in-
1
cludes YDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/
Refer to “YDT” on page 9-2.
6. Start the YDT and display the diagnosis of
function screen.
G088913
7. Select code No. 1, “ABS reaction-force con-
firmation”. 10.After the pulsating action has stopped in the
8. Click “Actuator Check”, and then operate the brake lever, it is generated in the brake pedal
brake lever “1” and brake pedal “2” simulta- “1” and continues for a few seconds.
neously. TIP
TIP • The reaction-force pulsating action consists of
• The hydraulic unit operates 1 second after the quick pulses.
brake lever and brake pedal are operated si- • Be sure to continue operating the brake lever
multaneously and continues for approximately and brake pedal even after the pulsating action
5 seconds. has stopped.
• The operation of the hydraulic unit can be con- • “ON” and “OFF” on the tool screen indicate
firmed using the indicator. when the brakes are being applied and re-
On: The hydraulic unit is operating. leased respectively.
Flashing: The conditions for operating the hy-
draulic unit have not been met.
Off: The brake lever and brake pedal are not
being operated.
1
G088914
11.After the pulsating action has stopped in the

brake pedal, it is generated in the brake lever
and continues for a few seconds.
G088909 2
TIP
• The reaction-force pulsating action consists of
quick pulses.
4-72
• “ON” and “OFF” on the tool screen indicate

when the brakes are being applied and re-
leased respectively.
ECA17371
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 YDT from the YDT coupler, and
then install the protective cap.
14.Turn the main switch to “ON”.
15.Set the stop/run/start switch to “ ”.
16.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage → Replace the hydraulic
unit, brake pipes, and related parts as a set.
17.If the operation of the hydraulic unit is normal,
delete all of the DTC.
EAS30202
CHECKING THE ABS WARNING LIGHT

After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 5 km/h
(3 mi/h) or performing a trial run.
4-73
HANDLEBAR
EAS20033
HANDLEBAR
Removing the handlebar
7 N•m (0.7 kgf•m, 5.2 lb•ft) 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
1
T.R
.
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
2 * 6
3
5 LS
LS
LS 7
17 N•m (1.7 kgf•m, 13 lb•ft) * **

T.R
.
LS 8
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
9
* T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
4
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
10
**
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
*for MTT890
**for MTT890D

Front brake master cylinder Refer to “FRONT BRAKE” on page 4-41.
1 Rearview mirror (left) 1
2 Handguard upper bracket (left) 1
3 Handguard (left) 1
4 Grip end (left) 1
5 Handguard lower bracket 1
6 Throttle grip 1 MTT890
7 Throttle grip 1 MTT890D
8 Handlebar switch (right) 1
9 Handlebar grip 1 MTT890
10 Handlebar grip 1 MTT890D
4-74
HANDLEBAR
Removing the handlebar

T.R
T.R
.
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
*
LS
LS
17
16 LS
17 N•m (1.7 kgf•m, 13 lb•ft) 18 * **

T.R
.
15 12
LS 14
13 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
11
* 3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
19
**
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
*for MTT890
**for MTT890D

11 Handlebar switch (left) 1
12 Handlebar switch holder 2
13 Clutch switch 1
14 Clutch cable 1 Disconnect.
15 Clutch lever 1
16 Clutch lever holder 1
17 Upper handlebar holder 2
18 Handlebar 1
19 Lower handlebar holder 2
4-75
HANDLEBAR
Removing the handlebar lead wires assemblies (for MTT890D)
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
8
2
7 6
1
2
3
5

Front brake master cylinder Refer to “FRONT BRAKE” on page 4-41.
Throttle grip/Handlebar switch (right)/Handle- Refer to “HANDLEBAR” on page 4-74.
bar grip/Clutch lever holder
1 Clutch switch coupler 1 Disconnect.
Sub-wire harness coupler (front fork solenoid
2 2 Disconnect.
(left))
3 Grip warmer coupler (left) 1 Disconnect.
4 Handlebar lead wires assembly (left) 1
5 Corrugated tube (left) 1 Part No. BAP-82351-00
6 Grip warmer lead (left) 1
7 Sub-wire harness (front fork solenoid (left)) 1
8 Clutch switch lead 1
4-76
HANDLEBAR
Removing the handlebar lead wires assemblies (for MTT890D)
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
12
9
14
15
9 16
10
11
13

Sub-wire harness coupler (front fork solenoid
9 2 Disconnect.
(right))
10 Grip warmer coupler (right) 1 Disconnect.
11 Handlebar switch coupler (right) 3 Disconnect.
12 Handlebar lead wires assembly (right) 1
13 Corrugated tube (right) 1 Part No. BAP-82352-00
14 Grip warmer lead (right) 1
15 Sub-wire harness (front fork solenoid (right)) 1
16 Handlebar switch lead (right) 1
4-77
HANDLEBAR
EAS31396
ADJUSTING THE HANDLEBAR POSITION 1

1. Check: 2
• Handlebar position
TIP
The handlebar position can be adjusted in two
positions to suit the rider’s preference.
d. Loosen the lower handlebar holder nuts.

e. Adjust the handlebar position by rotating
both of the lower handlebar holders “1” in
180°.
1 1
2. Adjust:
• Handlebar position
a. Remove the plastic locking tie “a” from the
clutch cable, handlebar switch lead (left),
clutch switch lead, horn lead, sub-wire
harness (front fork solenoid (left))
(MTT890D), grip warmer lead (left)
(MTT890D) and the lower handlebar hold- f. Install the handlebar “1” and upper han-
er (left). dlebar holders “2”.
b. Remove the plastic locking tie “b” from the
Upper handlebar holder bolt
front brake light switch lead, handlebar 22 N·m (2.2 kgf·m, 16 lb·ft)
T.
switch lead (right), sub-wire harness (front

R.
fork solenoid (right)) (MTT890D), grip ECA18300
warmer lead (right) (MTT890D) and the NOTICE

lower handlebar holder (right). First, tighten the bolts on the front side of the
A B
handlebar holder, and then on the rear side.
TIP
b b
• Align the punch mark “a” on the handlebar with
the left side upper surface of the lower handle-
bar holder (left) “3”.
• The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
a ward.
a
b
A. MTT890 1 a
B. MTT890D
c. Remove the upper handlebar holders “1”
and handlebar “2”.
3
g. Tighten the lower handlebar holder nuts.
4-78
HANDLEBAR
EAS30204
Lower handlebar holder nut CHECKING THE HANDLEBAR

40 N·m (4.0 kgf·m, 30 lb·ft) 1. Check:
T.
R.
• Handlebar
h. Fasten the front brake light switch lead, Bends/cracks/damage → Replace.
handlebar switch lead (right), sub-wire EWA13690
harness (front fork solenoid (right)) WARNING

(MTT890D) and grip warmer lead (right) Do not attempt to straighten a bent handle-
(MTT890D) to the lower handlebar holder bar as this may dangerously weaken it.
(right) with a plastic locking tie. (Refer to
“CABLE ROUTING” on page 2-13.) EAS30205
i. Fasten the clutch cable, handlebar switch INSTALLING THE HANDLEBAR

lead (left), clutch switch lead, horn lead, 1. Stand the vehicle on a level surface.
EWA13120
sub-wire harness (front fork solenoid (left)) WARNING
(MTT890D) and grip warmer lead (left)
(MTT890D) to the lower handlebar holder
(left) with a plastic locking tie. (Refer to
“CABLE ROUTING” on page 2-13.) 2. Install:
TIP • Lower handlebar holder
(temporarily)
Route the clutch cable to the inside of the han-
• Handlebar “1”
dlebar switch lead (left), clutch switch lead, horn
• Upper handlebar holder “2”
lead, sub-wire harness (front fork solenoid (left))
(MTT890D) and grip warmer lead (left) Upper handlebar holder bolt
(MTT890D). (Refer to “CABLE ROUTING” on 22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.
page 2-13.)
ECA18300
EAS30203
NOTICE
REMOVING THE HANDLEBAR First, tighten the bolts on the front side of the
1. Stand the vehicle on a level surface. handlebar holder, and then on the rear side.
EWA13120
WARNING TIP
Securely support the vehicle so that there is • Align the punch mark “a” on the handlebar with
no danger of it falling over. the left side upper surface of the lower handle-
2. Remove: bar holder (left) “3”.
• Handlebar grip “1” • The upper handlebar holders should be in-
stalled with the punch marks “b” facing for-
TIP
ward.
Blow compressed air between the handlebar
(left) and the handlebar grip, and gradually push b
the grip off the handlebar. 1
3 a 2
3. Tighten:
G088916
• Lower handlebar holder nut
Lower handlebar holder nut

40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
4-79
HANDLEBAR
4. Install: • Front brake master cylinder assembly

• Handlebar switch (right) Refer to “FRONT BRAKE” on page 4-41.
• Throttle grip 6. Install:
• Clutch lever holder “1”
Handlebar switch screw • Clutch cable
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
Clutch lever holder pinch bolt

a. Fit the slot “a” in the throttle grip “1” into the 11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
projection “b” in the handlebar switch
(right, front side) “2” and the throttle grip TIP
onto the handlebar “3”. • Align the rear corner of the clutch lever holder
2 b a 1 with the punch mark “a” on the handlebar.
• Make sure that the leaf spring “b” on the clutch
lever holder does not contact the handlebar.
1
a
b
3 1 a
b. Make sure that the throttle grip “1” turns

smoothly.
1
b
c. Install the handlebar switch (right, rear

side) “4”. 7. Install:
TIP • Handlebar grip
Align the projection “c” on the handlebar switch a. Apply a thin coat of rubber adhesive onto
(right, rear side) with the hole “d” in the handle- the end of the handlebar (left).
bar “3”. b. Side the handlebar grip over the end of the
handlebar (left).
3 d c. Wipe off any excess rubber adhesive with
c a clean rag.
EWA13700
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
8. Install:
• Handguard lower bracket (left)
4 • Handguard lower bracket bolt “1” (temporary)
• Handguard upper bracket (left)
5. Install:
• Handguard upper bracket bolt “2” (tempo-
• Handguard (right)
rary)
4-80
HANDLEBAR
• Grip end (left) “3”

• Handguard (left) Handlebar switch holder screw
• Rearview mirror (left) “4” (temporary) 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
• Grip end bolt “5” (temporary) Handlebar switch screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
TIP
There should be 1–3 mm (0.04–0.12 in) of clear- TIP
ance “a” between the handlebar grip and the grip Align the projection “a” on the handlebar switch
end. (left) with the hole “b” in the handlebar.
4 2 b
5
1
a
12.Check:
3 • Clutch lever
TIP
Make sure that the handlebar switch (left) and
clutch lever are not in contact when you pull the
clutch lever.
a 13.Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
9. Tighten: FREE PLAY” on page 3-12.
• Handguard lower bracket bolt
• Handguard upper bracket bolt Clutch lever free play
• Rearview mirror (left) 5.0–10.0 mm (0.20–0.39 in)
Handguard lower bracket bolt EAS33585
7 N·m (0.7 kgf·m, 5.2 lb·ft) ASSEMBLING THE HANDLEBAR LEAD

T.
WIRES ASSEMBLY (LEFT) (for MTT890D)

R.
Handguard upper bracket bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft) 1. Install:
Rearview mirror (left) • Clutch switch lead “1”
17 N·m (1.7 kgf·m, 13 lb·ft) • Grip warmer lead (left) “2”
• Sub-wire harness (front fork solenoid (left))
10.Tighten: “3”
• Grip end bolt TIP
Grip end bolt Align the blue tapes “b” of each lead wires and,
17 N·m (1.7 kgf·m, 13 lb·ft) wrap the clutch switch lead “1”, grip warmer lead
T.
R.
(left) “2”, and sub-wire harness (front fork sole-

11.Install: noid (left)) “3” with the black tape “a” as shown in
• Handlebar switch holder the illustration.
• Handlebar switch screw (left)
4-81
HANDLEBAR
A a
2
b
4 1
d
3
1
A. To clutch switch and handlebar grip. e
2. Install:
• Corrugated tube 2
a. Put the clutch switch lead, grip warmer
lead (left), sub-wire harness (front fork so- d
lenoid (left)) into the corrugated tube.
TIP
Position the blue tapes “b” on each leads to the
inside the end of the corrugated tube “a” as f
shown in the illustration.
A
a d
3
g
b
A. To handlebar switch (right) and handlebar

grip. 1. Clutch switch
2. Handlebar grip
b. Wrap the entire corrugated tube with the 3. Sub-wire harness coupler (front fork solenoid
black tape “c”. (left front fork side)
TIP 4. Corrugated tube
• Cover the lead wire from the end of the corru- d. Blue tape
gated tube to 20 mm (0.79 in) with the back e. 235 mm (9.25 in)
tape “c”. (both ends) f. 375 mm (14.76 in)
• Make sure that the distances “e”, “f”, “g” are as g. 90 mm (3.54 in)
shown in the illustration. 3. Install:
• Plastic locking tie
c TIP
• Install the plastic locking tie to the corrugated
tube as shown in the illustration.
• Face the projection “a” and the projection “b” in
opposite directions.
• Cut off the excess end of the plastic locking tie
20mm(0.79in) to 3 mm (0.12 in) or less.
4-82
HANDLEBAR
A A
30-50mm(1.18-1.97in) a
175-185mm(6.89-7.28in)
b
b
a
A. To Clutch switch and handlebar grip. A. To handlebar switch (right) and throttle grip.
EAS33586 b. Wrap the entire corrugated tube with black
ASSEMBLING THE HANDLEBAR LEAD tape “c”.
WIRES ASSEMBLY (RIGHT) (for MTT890D) TIP
1. Install:
• Cover the lead wire from the end of the corru-
• Handlebar switch lead (right) “1”
gated tube to 20 mm (0.79 in) with back tape
• Grip warmer lead (right) “2”
“c”. (both ends)
• Sub-wire harness (front fork solenoid (right))
• Make sure that the distances “e”, “f”, “g” are as
“3”
TIP
Align the blue tapes “b” of each lead wires and,
wrap the handlebar switch lead (right) “1”, grip
warmer lead (right) “2”, and sub-wire harness
c
(front fork solenoid (right)) “3” with the black tape
“a” as shown in the illustration.
A 20
a mm
b 1 (0.
79
in)
3 2
A. To handlebar switch (right) and throttle grip.

2. Install:
• Corrugated tube
a. Put the handlebar switch lead (right), grip
warmer lead (left), sub-wire harness (front
fork solenoid (left)) into the corrugated
tube.
TIP
Position the blue tapes “b” on each leads to the
inside the end of the corrugated tube “a” as
4-83
HANDLEBAR
A
a
b
1
4
175-185mm(6.89-7.28in)
30-50mm(1.18-1.97in)
d A. To handlebar switch (right) and throttle grip.
d
f 2
d 3
1. Handlebar switch (right)

2. Throttle grip
3. Sub-wire harness coupler (front fork solenoid
(right front fork side)
4. Corrugated tube
d. Blue tape
e. 260 mm (10.24 in)
f. 275 mm (10.83 in)
g. 90 mm (3.54 in)
3. Install:
• Plastic locking tie
TIP
• Install the plastic locking tie to the corrugated
tube as shown in the illustration.
• Face the projection “a” and the projection “b” in
opposite directions.
• Cut off the excess end of the plastic locking tie
to 3 mm (0.12 in) or less.
4-84
FRONT FORK (for MTT890)
EAS20034

Removing the front fork legs
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
2
3
23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.
1 5
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-26.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Cap bolt 1 Loosen.
4 Lower bracket pinch bolt 2 Loosen.
5 Front fork leg 1
4-85
Disassembling the front fork leg (left)

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
1 13 New
LS 15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
New 2
6
3
12 New
11
10 New
LS New
8 New
7 New LT
New
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

1 Cap bolt 1
2 O-ring 1
3 Washer 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Dust seal 1
8 Oil seal clip 1
9 Outer tube 1
10 Oil seal 1
11 Washer 1
12 Outer tube bushing 1
13 Inner tube bushing 1
4-86

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
New
LS 15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
New
17
16
New
New
LS 15 New
New
New LT
New 14
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

14 Damper rod assembly bolt 1
15 Copper washer 1
16 Damper rod assembly 1
17 Inner tube 1
4-87
Disassembling the front fork leg (right)

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
1 14 New
LS 15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
New 2
6
3
10
7
5
13 New
12
11 New
LS New
9 New
8 New LT
New
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

1 Cap bolt 1
2 O-ring 1
3 Washer 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Damper adjusting rod 1
8 Dust seal 1
9 Oil seal clip 1
10 Outer tube 1
11 Oil seal 1
12 Washer 1
4-88

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
New
LS 15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
New
19
18
New
New
LS New 17 New
New LT
15
16 New
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

15 Wheel axle pinch bolt 1
17 Copper washer 1
19 Inner tube 1
4-89
EAS30206
• Spacer “3”
REMOVING THE FRONT FORK LEGS
• Locknut “4”
a. Press down on the spacer with the fork
front fork legs.
spring compressor “5”.
TIP b. Install the rod holder “6” between the lock-
Each front fork leg is equipped with a spring pre- nut “4” and the washer “2”.
load adjusting bolt, the fork leg (right) is
equipped with a rebound damping force adjust- Fork spring compressor
ing screw. Pay attention not to mistake the right 90890-01441
and left. Fork spring compressor
YM-01441
1. Stand the vehicle on a level surface. Rod holder
EWA13120
90890-01434
WARNING Damper rod holder double ended
Securely support the vehicle so that there is YM-01434
TIP
TIP
Use the side of the rod holder that is marked “B”.
Place the vehicle on a maintenance stand so
that the front wheel is elevated.
2. Remove:
Refer to “FRONT BRAKE” on page 4-41.
• Front wheel
Refer to “FRONT WHEEL” on page 4-26.
3. Loosen:
• Upper bracket pinch bolt “1”
• Cap bolt “2”
• Lower bracket pinch bolt “3”
EWA13640
c. Hold the cap bolt and loosen the locknut.
WARNING d. Remove the cap bolt.
Before loosening the upper and lower brack- e. Remove the rod holder and fork spring
et pinch bolts, support the front fork leg. compressor.
f. Remove the washer, spacer and locknut.
2. Drain:
2 • Fork oil
TIP
1 Stroke the damper rod assembly “1” several
times while draining the fork oil.
3
4. Remove:
• Front fork leg
EAS30207
DISASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the G088919
front fork legs.
1. Remove: 3. Remove:
• Cap bolt “1” • Dust seal “1”
(from the damper rod assembly) • Oil seal clip “2”
• Washer “2” (with a flat-head screwdriver)
4-90
ECA19100
NOTICE
Do not scratch the outer tube.
1
1
EAS30208
2 CHECKING THE FRONT FORK LEGS

G088920 The following procedure applies to both of the
4. Remove: front fork legs.
• Outer tube 1. Check:
a. Hold the front fork leg horizontally. • Inner tube
b. Securely clamp the brake caliper bracket • Outer tube
in a vise with soft jaws. Bends/damage/scratches → Replace.
EWA13650
c. Separate the outer tube from the inner
WARNING
tube by pulling the outer tube forcefully but
carefully. Do not attempt to straighten a bent inner
ECA19880 tube as this may dangerously weaken it.
NOTICE
2. Measure:
Excessive force will damage the bushings. • Fork spring free length “a”
Damaged bushings must be replaced. Out of specification → Replace.
Fork spring free length limit

268.9 mm (10.59 in)
5. Remove:
• Damper rod assembly bolt
• Damper rod assembly G088921
TIP 3. Check:
While holding the damper rod with the damper • Damper rod
rod holder “1”, loosen the damper rod assembly Damage/wear → Replace.
bolt. Obstruction → Blow out all of the oil passag-
es with compressed air.
ECA19110
Damper rod holder (ø27)
NOTICE
90890-01423
Damping rod holder • The front fork leg has a very sophisticated
YM-01423 internal construction, which are particular-
ly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
4-91
4. Check:
• Cap bolt “1” Front fork damper rod assembly
Cracks/damage → Replace. bolt
T.
R.
23 N·m (2.3 kgf·m, 17 lb·ft)
LOCTITE®
TIP
While holding the damper rod assembly with the
damper rod holder “1”, tighten the damper rod
assembly bolt.

90890-01423
Damping rod holder
EAS30209 YM-01423
ASSEMBLING THE FRONT FORK LEGS
front fork legs.
EWA17090
WARNING
• Note that the amount of the fork oil is differ- 1
ent in the left and right front fork legs. Make
sure to fill each of the left and right front
fork legs with the specified amount of the
fork oil.
• If both front fork legs are not filled with the
specified amount of the fork oil, it may
3. Lubricate:
cause poor handling and a loss of stability.
• Inner tube’s outer surface
TIP
Recommended oil
• When assembling the front fork leg, be sure to
Yamaha Suspension Oil 01
replace the following parts:
–Inner tube bushing 4. Install:
–Outer tube bushing
• Dust seal “1” New
–Oil seal
–Oil seal clip • Oil seal clip “2” New
–Dust seal • Oil seal “3” New
–Copper washer • Washer “4”
–O-ring • Outer tube bushing “5” New
–Damper rod assembly bolt
• Inner tube bushing “6” New
• Before assembling the front fork leg, make ECA19170
sure all of the components are clean. NOTICE

1. Install: Make sure the numbered side of the oil seal
• Damper rod assembly faces bottom side.
ECA22560
NOTICE TIP
Allow the damper rod assembly to slide • Before installing the oil seal, lubricate its lips
slowly down the inner tube. Be careful not to with lithium-soap-based grease.
damage the inner tube. • Lubricate the outer surface of the inner tube
with fork oil.
2. Tighten: • Before installing the oil seal, cover the top of
• Damper rod assembly bolt the front fork leg with a plastic bag to protect
(along with the copper washer New ) the oil seal during installation.
4-92
3 New
New 5 4 2
New 6 1
1 New
2 New
G088924
8. Install:
• Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
G088922 1
5. Install:
• Outer tube
(to the inner tube)
6. Install:
• Outer tube bushing “1” G088925
• Washer “2”
9. Install:
(with the fork seal driver “3”)
• Dust seal “1”
Fork seal driver (with the fork seal driver “2”)
90890-01442
Adjustable fork seal driver (36–46 Fork seal driver
mm) 90890-01442
YM-01442 Adjustable fork seal driver (36–46
mm)
YM-01442
2 2
1
1
G088923
7. Install: G088926
• Oil seal “1”
10.Install:
(with the fork seal driver “2”)
• Rod puller “1”
Fork seal driver • Rod puller attachment (M10) “2”
90890-01442 (onto the damper rod “3”)
Adjustable fork seal driver (36–46
mm)
YM-01442
4-93
Rod puller
90890-01437
Universal damping rod bleeding
tool set
YM-A8703
Rod puller attachment (M10 long)
90890-01578
tool set
G088929
YM-A8703
13.Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual
air.
14.Measure:
• Front fork leg oil level “a”
(from the top of the outer tube, with the outer
G088927 tube fully compressed and without the fork
11.Fill: spring)
• Front fork leg Out of specification → Correct.
mended fork oil) Level (left)
96 mm (3.8 in)
Recommended oil Level (right)
Yamaha Suspension Oil 01 97 mm (3.8 in)
Quantity (left)
493.0 cm³ (16.67 US oz, 17.39
Imp.oz)
Quantity (right)
a
479.0 cm³ (16.19 US oz, 16.89
Imp.oz)
ECA14230
NOTICE
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on G088930
front fork performance. 15.Install:
• When disassembling and assembling the • Fork spring
front fork leg, do not allow any foreign ma- • Spacer
terial to enter the front fork. • Locknut
12.After filling the front fork leg, slowly stroke the • Damper adjusting rod (damper rod assem-
damper rod “1” up and down (at least ten bly)
times) to distribute the fork oil. • Washer
TIP • Cap bolt
Be sure to stroke the damper rod slowly be- (along with the O-ring New )
cause the fork oil may spurt out. a. Remove the rod puller and rod puller at-
tachment.
b. Install the fork spring.
4-94
TIP
Install the fork spring with the smaller diameter
“a” facing up “A”.
i. Remove the rod puller and rod puller at-

tachment.
j. Position the locknut “3” as distance “b”.
G088931
(front fork leg (right) only)
c. Install the locknut all the way onto the
damper rod assembly. Distance “b”
d. Install the rod puller and rod puller attach- 12 mm (0.47 in)
ment.
e. Install the spacer and washer.
f. Install the fork spring compressor. 3
g. Press down on the spacer with the fork b
spring compressor “1”.
h. Pull up the rod puller and install the rod
holder “2” between the locknut “3” and the
washer “4”.
Rod puller
90890-01437
tool set k. Set the cap bolt distance “c” to specifica-
YM-A8703 tion. (front fork leg (right) only)
Rod puller attachment (M10 long)
90890-01578 Distance “c”
Universal damping rod bleeding 13 mm (0.51 in)
tool set
YM-A8703
90890-01441
YM-01441
Rod holder
90890-01434
Damper rod holder double ended c
YM-01434
TIP l. Install the damper adjusting rod and cap

Use the side of the rod holder that is marked “B”. bolt, and then finger tighten the cap bolt.
EWA13670
WARNING
Always use a new cap bolt O-ring.
m. Hold the cap bolt “5” and tighten the lock-
nut “3” to specification.
4-95
Front fork cap bolt locknut

15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
2. Tighten:
Lower bracket pinch bolt

n. Remove the rod holder and fork spring 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
compressor.
16.Install: • Cap bolt “2”
• Cap bolt
(to the outer tube) Front fork cap bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
TIP T.
R.
• Temporarily tighten the cap bolt. • Upper bracket pinch bolt “3”
• When to tighten the cap bolt to the specified
torque is after installing the front fork leg to the Upper bracket pinch bolt
vehicle and tightening the lower bracket pinch 26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
bolts.
EAS30210
2
INSTALLING THE FRONT FORK LEGS
front fork legs. 3
1. Install:
• Front fork leg 1
Temporarily tighten the upper and lower
bracket pinch bolts.
Installed length (from the top of 3. Check:

the outer tube) “a” • Cable routing
211.5 mm (8.33 in)
TIP
EWA13680 Make sure the brake hoses, clutch cable, and
WARNING handlebar switch leads are routed properly. Re-
Make sure the brake hoses are routed prop- fer to “CABLE ROUTING” on page 2-13.
erly. 4. Adjust:
TIP • Spring preload
When installing the front fork, set the outer tube • Rebound damping
with the specified length “a” from the top of the • Compression damping
outer tube to the top of the lower bracket. Refer to “ADJUSTING THE FRONT FORK
LEGS (for MTT890)” on page 3-21.
4-96
FRONT FORK (for MTT890D)
EAS20169

Removing the front fork legs
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
2
3
4
23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.
1 6
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-26.
1 Front fender 1
2 Front fork solenoid coupler 1 Disconnect.
3 Upper bracket pinch bolt 1 Loosen.
4 Cap bolt 1 Loosen.
5 Lower bracket pinch bolt 2 Loosen.
6 Front fork leg 1
4-97

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
11 New
28 N•m (2.8 kgf•m, 21 lb•ft)

1
T.R
.
LS
LS
New
New 2
3
7
10 New
9
8 New
LS
6 New New
5 New LT
New
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

1 Cap bolt 1
2 O-ring 1
3 Guide 1
4 Fork spring 1
5 Dust seal 1
6 Oil seal clip 1
7 Outer tube 1
8 Oil seal 1
9 Washer 1
4-98

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
New
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
LS
LS
New 15
New
16
New
14
New
LS
New 13 New
New LT
New 12
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

13 Copper washer 1
15 O-ring 1
16 Inner tube 1
4-99

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
New
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
1
LS
New
LS
New 2
3
7
10 New
9
8 New
LS New
6 New
5 New LT
New
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

1 Cap bolt 1
2 O-ring 1
3 Guide 1
4 Fork spring 1
5 Dust seal 1
6 Oil seal clip 1
7 Outer tube 1
8 Oil seal 1
9 Washer 1
4-100

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
New
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
LS
New 16
LS
New
17
15
New
New
LS 14 New
New
New LT
12
13 New
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

12 Wheel axle pinch bolt 1
14 Copper washer 1
16 O-ring 1
17 Inner tube 1
4-101
EAS31648 EAS31649
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 fork legs. front fork legs.
TIP 1. Remove:
Pay attention not to mistake the right and left. • Cap bolt “1”
• Fork spring
1. Stand the vehicle on a level surface. • Guide
EWA13120
a. Remove the cap bolt “1” using the front
WARNING
fork hexagonal cap bolt wrench “2”.
TIP
Hold the cap bolt “1” and turn the outer tube to
TIP remove the cap bolt “1”.
that the front wheel is elevated. Front fork hexagonal cap bolt
2. Remove: wrench 42mm
90890-01906
Front fork hexagonal cap bolt
Refer to “FRONT BRAKE” on page 4-41. wrench 42mm
• Front wheel YM-01906
• Front fender
3. Loosen: 1
• Upper bracket pinch bolt “1” 2
• Cap bolt “2”
EWA13640
WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
TIP
Loosen the cap bolt “2” using the front fork hex- b. Install the fork spring compression tool “3”
agonal cap bolt wrench “4”. on the guide. Press down on the guide
with the fork spring compression tool “3”.
c. Install the damper rod holder “4” into the
Front fork hexagonal cap bolt slit “a” on the damper rod assembly.
wrench 42mm Press down the fork spring compression
90890-01906
tool while holding the damper rod assem-
wrench 42mm bly.
YM-01906
Fork spring compression tool
29mm
90890-01907
2 Fork spring compression tool
29mm
4 YM-01907
1 90890-01908
3 Damper rod holder 18.5mm
YM-01908
4. Remove:
• Front fork leg
4-102
b
3
a a
d. Hold the width across flats “a” on the cap g. Remove the damper rod holder and fork
bolt “1” and loosen the lock nut “b”. spring compression tool.
ECA27320
h. Remove the guide and fork spring.
NOTICE 2. Drain (front fork assembly (left)):
Do not turn the cap bolt. Turning the cap bolt • Fork oil
may twist and damage the internal lead. TIP
Stroke the damper rod assembly “1” several
1 times while draining the fork oil.
a
1
e. Lift the cap bolt “1” and disconnect the

front fork solenoid inner coupler “a”.
3. Drain (front fork assembly (right)):
1 • Fork oil
TIP
Connect the fork solenoid power supply tool, ac-
a tivate the front fork solenoid and stroke the
damper rod assembly.
a. Connect the damper rod assembly and
cap bolt with the front fork solenoid inner
coupler “a”.
f. Cover the front fork solenoid inner coupler b. Connect the front fork solenoid coupler
“a” with a plastic bag to protect from fork and the fork solenoid power supply tool
oil. “1”. Turn on the fork solenoid power sup-
ECA27300
NOTICE ply tool “1” and stroke the damper rod as-
sembly.
• Make sure that fork oil does not enter the
front fork solenoid inner coupler as this
could cause a malfunction.
• Do not put fork oil in the hole “b” of the
a 1
4-103
• Oil seal clip “2”

Fork solenoid power supply tool (with a flat-head screwdriver)
(6V) ECA19100
90890-01909 NOTICE
Fork solenoid power supply tool Do not scratch the outer tube.
(6V)
YM-01909
1
TIP
• Install four AA batteries in the fork solenoid
power supply tool.
• If you do not have a fork solenoid power supply
tool (90890-01909), connect a DC 6V power
supply to the front fork solenoid coupler.
2
c. Disconnect the front fork solenoid inner G088920
coupler from the front fork solenoid power 5. Remove:

supply tool. • Outer tube
d. Cover the front fork solenoid inner coupler a. Hold the front fork leg horizontally.
“a” with a plastic bag to protect from fork b. Securely clamp the brake caliper bracket
oil. in a vise with soft jaws.
ECA27300
NOTICE
c. Separate the outer tube from the inner
tube by pulling the outer tube forcefully but
• Make sure that fork oil does not enter the carefully.
front fork solenoid inner coupler as this ECA19880
could cause a malfunction. NOTICE

• Do not put fork oil in the hole “b” of the Excessive force will damage the bushings.
damper rod assembly. Damaged bushings must be replaced.
e. Drain the fork oil 6. Remove:

• Damper rod assembly bolt
• Damper rod assembly
1 TIP
While holding the damper rod with the damper
rod holder “1”, loosen the damper rod assembly
bolt.

90890-01423
f. Repeat steps (a) to (e) until the fork oil is Damping rod holder
completely drained from front fork leg. YM-01423
4. Remove:
• Dust seal “1”
4-104
4. Check:
• Cap bolt
1 EAS31651
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
EWA17090
WARNING
• Note that the amount of the fork oil is differ-
EAS31650 ent in the left and right front fork legs. Make
CHECKING THE FRONT FORK LEGS sure to fill each of the left and right front
The following procedure applies to both of the fork legs with the specified amount of the
front fork legs. fork oil.
1. Check: • If both front fork legs are not filled with the
• Inner tube specified amount of the fork oil, it may
• Outer tube cause poor handling and a loss of stability.
Bends/damage/scratches → Replace.
EWA13650 TIP
WARNING • When assembling the front fork leg, be sure to
Do not attempt to straighten a bent inner replace the following parts:
tube as this may dangerously weaken it. –Inner tube bushing
–Outer tube bushing
2. Measure:
–Oil seal
• Fork spring free length “a”
–Oil seal clip
–Dust seal
Fork spring free length limit –Copper washer
277.6 mm (10.93 in) –O-ring
–Damper rod assembly bolt
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Damper rod assembly
ECA22560
NOTICE
Allow the damper rod assembly to slide
slowly down the inner tube. Be careful not to
G088921
damage the inner tube.
3. Check: 2. Tighten:
• Damper rod • Damper rod assembly bolt
Damage/wear → Replace. (along with the copper washer New )
Obstruction → Blow out all of the oil passag-
es with compressed air. Front fork damper rod assembly
ECA19110 bolt
T.
R.
NOTICE 23 N·m (2.3 kgf·m, 17 lb·ft)

• The front fork leg has a very sophisticated LOCTITE®
internal construction, which are particular-
ly sensitive to foreign material. TIP
• When disassembling and assembling the While holding the damper rod assembly with the
front fork leg, do not allow any foreign ma- damper rod holder “1”, tighten the damper rod
terial to enter the front fork. assembly bolt.
4-105

90890-01423
Damping rod holder
YM-01423
1 G088922
5. Install:
• Outer tube
(to the inner tube)
6. Install:
• Outer tube bushing “1”
3. Lubricate: • Washer “2”
• Inner tube’s outer surface (with the fork seal driver “3”)
Recommended oil Fork seal driver

Yamaha Suspension Oil 01 90890-01442
4. Install: mm)
YM-01442
• Dust seal “1” New
• Oil seal clip “2” New
• Oil seal “3” New
• Washer “4”
• Outer tube bushing “5” New 3
• Inner tube bushing “6” New
ECA19170 2
NOTICE
1
Make sure the numbered side of the oil seal
faces bottom side. G088923
TIP 7. Install:
• Before installing the oil seal, lubricate its lips • Oil seal “1”
with lithium-soap-based grease. (with the fork seal driver “2”)
• Lubricate the outer surface of the inner tube
Fork seal driver
with fork oil.
90890-01442
• Before installing the oil seal, cover the top of Adjustable fork seal driver (36–46
the front fork leg with a plastic bag to protect mm)
the oil seal during installation. YM-01442
3 New
New 5 4
2
New 6
1 New 1
2 New
G088924
4-106
8. Install: • When disassembling and assembling the

• Oil seal clip “1” front fork leg, do not allow any foreign ma-
TIP terial to enter the front fork.
Adjust the oil seal clip so that it fits into the outer TIP
tube’s groove. Fasten the damper rod assembly with a string to
prevent it from falling in to the front fork leg.
G088925
9. Install:
• Dust seal “1” a. Cover the front fork solenoid inner coupler
(with the fork seal driver “2”) “a” with a plastic bag to protect from fork
Fork seal driver oil.
ECA27300
90890-01442 NOTICE
mm) • Make sure that fork oil does not enter the
YM-01442 front fork solenoid inner coupler as this
could cause a malfunction.
• Do not put fork oil in the hole “b” of the
2
b
1 a
G088926
10.Fill:
• Front fork leg (left)
(with the specified amount of the recom- b. Fill the front fork leg with fork oil.
mended fork oil) c. Slowly stroke the damper rod “1” up and
Recommended oil down (at least ten times) to distribute the
Yamaha Suspension Oil 01 fork oil.
Quantity (left) TIP
373.0 cm³ (12.61 US oz, 13.16 • Be sure to stroke the damper rod slowly be-
Imp.oz) cause the fork oil may spurt out.
ECA14230
• Stroke so that it does not completely fit into the
NOTICE outer tube in the end of the damper rod assem-
bly.
Other oils may have an adverse effect on
front fork performance.
4-107
1 b
11.Fill: b. Fill the front fork leg with fork oil.

• Front fork leg (right) c. Connect the damper rod assembly and
(with the specified amount of the recom- cap bolt with the front fork solenoid inner
mended fork oil) coupler “a”.
d. Connect the front fork solenoid coupler
Recommended oil and the fork solenoid power supply tool
Yamaha Suspension Oil 01 “1”.
Quantity (right)
362.0 cm³ (12.24 US oz, 12.77
Imp.oz)
ECA14230
NOTICE
a 1
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
Fork solenoid power supply tool
TIP (6V)
Fasten the damper rod assembly with a string to 90890-01909
prevent it from falling in to the front fork leg. Fork solenoid power supply tool
(6V)
YM-01909
TIP
• Install four AA batteries in the fork solenoid
power supply tool.
• If you do not have a fork solenoid power supply
tool (90890-01909), connect a DC 6V power
supply to the front fork solenoid coupler.
e. Turn on the fork solenoid power supply
a. Cover the front fork solenoid inner coupler tool and slowly stroke the damper rod “1”
“a” with a plastic bag to protect from fork up and down (at least ten times) to distrib-
oil. ute the fork oil.
ECA27300 TIP
NOTICE • Be sure to stroke the damper rod slowly be-
• Make sure that fork oil does not enter the cause the fork oil may spurt out.
front fork solenoid inner coupler as this • Stroke so that it does not completely fit into the
could cause a malfunction. outer tube in the end of the damper rod assem-
• Do not put fork oil in the hole “b” of the bly.
4-108
a 2
1
f. Disconnect the front fork solenoid coupler 1. Damper rod assembly

and remove the fork solenoid power sup- 2. Damper rod holder
ply tool. 3. Fork oil
Disconnect the front fork solenoid inner
coupler and remove the cap bolt. 14.Install:
g. Cover the front fork solenoid inner coupler • Fork spring
with a plastic bag to protect from fork oil. • Guide
12.Before measuring the fork oil level, wait ten • Cap bolt
minutes until the oil has settled and the air a. Install the fork spring and guide.
bubbles have dispersed. b. Install the fork spring compression tool on
the guide.
TIP
c. Press down on the guide with the fork
Be sure to bleed the front fork leg of any residual spring compression “1”.
air.
TIP
13.Measure: Do not pinch the front fork solenoid inner coupler
• Front fork leg oil level “a” in the fork spring.
(from the top of the damper rod assembly,
with the outer tube fully compressed and d. Install the damper rod holder “2” into the
without the fork spring) slit “a” on the damper rod assembly.
Out of specification → Correct. Fork spring compression tool
29mm
Level (left)
90890-01907
133 mm (5.2 in)
Fork spring compression tool
Level (right)
29mm
133 mm (5.2 in)
YM-01907
TIP 90890-01908
Install the damper rod holder “2” to the damper Damper rod holder 18.5mm
rod assembly “1” as shown in the illustration. YM-01908

90890-01908
YM-01908 1
a
e. Connect the front fork solenoid inner cou-

pler and install the cap bolt.
4-109
EWA13670
WARNING 3
Always use a new cap bolt O-ring. 5
f. Hold the width across flats “a” on the cap

bolt “3” and tighten the lock nut “b”.
ECA27320
NOTICE
Do not turn the cap bolt. Turning the cap bolt
may twist and damage the internal lead.
Front fork cap bolt locknut

28 N·m (2.8 kgf·m, 21 lb·ft)
wrench 42mm
T.
R.
90890-01906
3
wrench 42mm
YM-01906
a
15.Install:
• Cap bolt
b (to the outer tube)
TIP
• Temporarily tighten the cap bolt.
g. Adjust the cap bolt distance “c” to specifi-
torque is after installing the front fork leg to the
cation.
vehicle and tightening the lower bracket pinch
Distance “c” bolts.
43 mm (1.69 in)
EAS31652
INSTALLING THE FRONT FORK LEGS

TIP
Turn the spring preload adjusting bolt “4” to ad- front fork legs.
just the cap bolt distance “c”. 1. Install:
• Front fork leg
4
Temporarily tighten the upper and lower
bracket pinch bolts.
Installed length (from the top of

c the outer tube) “a”
208.5 mm (8.21 in)
EWA13680
WARNING
Make sure the brake hoses are routed prop-
h. Install the cap bolt “3” to outer tube using erly.
the front fork hexagonal cap bolt wrench
“5”. TIP
TIP When installing the front fork, set the outer tube
• Hold the cap bolt “3” and turn the outer tube to with the specified length “a” from the top of the
temporarily tighten the cap bolt “3”. outer tube to the top of the lower bracket.
torque is after installing the front fork leg to the
vehicle and tightening the lower bracket pinch
bolts.
4-110
a 55 - 65° a 55 - 65° a
1 1
2. Tighten: 3. Check:
• Lower bracket pinch bolt “1” • Cable routing
TIP
23 N·m (2.3 kgf·m, 17 lb·ft) Make sure the brake hoses, clutch cable, and
T.
handlebar switch leads are routed properly. Re-

R.
• Cap bolt “2” fer to “CABLE ROUTING” on page 2-13.

4. Adjust:
Front fork cap bolt
• Spring preload
23 N·m (2.3 kgf·m, 17 lb·ft)
T.
• Rebound damping
R.
• Upper bracket pinch bolt “3” • Compression damping

Refer to “ADJUSTING THE FRONT FORK
TIP
LEGS AND REAR SHOCK ABSORBER (for
Tighten the cap bolt “2” using the front fork hex- MTT890D)” on page 3-23.
agonal cap bolt wrench.

wrench 42mm
90890-01906
wrench 42mm
YM-01906
Upper bracket pinch bolt

26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
3
1
TIP
When installing the front fork legs, make sure
that the spring preload adjusting nut “a” on the
cap bolts “1” are positioned within the angle
range shown in the illustration.
4-111
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
110 N•m (11 kgf•m, 81 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
.
8
9
1st 52 N•m (5.2 kgf•m, 38 lb•ft)
T.R
*2nd 14 N•m (1.4 kgf•m, 10 lb•ft)

.
10
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
7
2
5
31
FWD LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
* Loosen the lower ring nut completely, and then tighten it to specification.

Handlebar Refer to “HANDLEBAR” on page 4-74.
Front fork legs page 4-85 or “FRONT FORK (for
MTT890D)” on page 4-97.
1 Horn coupler 2
2 Horn 1
3 Bracket 1
4 Front brake hose bracket 1
5 Horn lead 1
6 Horn bracket 1
7 Lower bracket cap 1
8 Clutch cable 1
9 Handlebar switch lead (left) 1
Grip warmer lead (left)/Clutch switch lead/Sub-
10 1
wire harness (front fork solenoid (left))
4-112
STEERING HEAD
Removing the lower bracket

12
110 N•m (11 kgf•m, 81 lb•ft)
T.R
.
14
16 15
T.R
T.R
.
.
13
1st 52 N•m (5.2 kgf•m, 38 lb•ft) 17
T.R
*2nd 14 N•m (1.4 kgf•m, 10 lb•ft) 18

.
19
23
22 20 11
LS
24
25
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
21
25
23
FWD LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
* Loosen the lower ring nut completely, and then tighten it to specification.

11 Cable holder 1
12 Front brake hose 1
13 Handlebar switch lead (right) 1
14 Front brake hose holder 1
15 Steering stem nut 1
16 Upper bracket 1
17 Lock washer 1
18 Upper ring nut 1
19 Rubber washer 1
20 Lower ring nut 1
21 Lower bracket 1
22 Bearing cover 1
23 Lower bearing dust seal 1
24 Upper bearing 1
25 Lower bearing 1
4-113
STEERING HEAD
EAS30213
• Bearing race
REMOVING THE LOWER BRACKET
Damage/pitting → Replace the bearings and
EWA13120
bearing races as a set.
WARNING 3. Replace:
Securely support the vehicle so that there is • Bearing
no danger of it falling over. • Bearing race
a. Remove the bearing races from the steer-
2. Remove: ing head pipe “1” with a long rod “2” and
• Upper ring nut “1” hammer.
• Rubber washer b. Remove the bearing race “3” from the low-
• Lower ring nut “2” er bracket with a floor chisel “4” and ham-
• Lower bracket mer.
EWA13730
c. Install a new dust seal and new bearing
WARNING
races.
Securely support the lower bracket so that ECA14270
there is no danger of it falling. NOTICE
TIP If the bearing race is not installed properly,

the steering head pipe could be damaged.
• Hold the lower ring nut with ring nut wrench “3”,
and then remove the upper ring nut with the TIP
steering nut wrench “4”. • Always replace the bearings and bearing races
• Remove the lower ring nut with the steering nut as a set.
wrench. • Whenever the steering head is disassembled,
replace the dust seal.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
4 3 G088933
G088932 2
EAS30214
CHECKING THE STEERING HEAD G088934

1. Wash:
4. Check:
• Bearing
• Upper bracket
• Bearing race
• Lower bracket
Recommended cleaning solvent (along with the steering stem)
Kerosene Bends/cracks/damage → Replace.
2. Check:
• Bearing
4-114
STEERING HEAD
EAS30216
INSTALLING THE STEERING HEAD Upper bracket pinch bolt

1. Lubricate: 26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
• Upper bearing
• Lower bearing EAS33565
INSTALLING THE HORN

Recommended lubricant 1. Install:
Lithium-soap-based grease • Horn “1”
2. Install: Horn bolt
• Lower ring nut “1” 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Rubber washer “2”
• Upper ring nut “3” TIP
• Lock washer “4” • Fit the projection “a” on the horn bracket with
Refer to “CHECKING AND ADJUSTING the notch “b” in the bracket.
THE STEERING HEAD” on page 3-19. • Fit the projection “c” on the bracket with the
notch “d” in the horn.
b
d
G088935
1
3. Install: c a
• Upper bracket
• Washer
• Steering stem nut
TIP
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
page 4-85 or “FRONT FORK (for MTT890D)”
on page 4-97.
TIP
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
• Steering stem nut
Steering stem nut

110 N·m (11 kgf·m, 81 lb·ft)
T.
R.
6. Tighten:
• Lower bracket pinch bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
• Upper bracket pinch bolt
4-115
REAR SHOCK ABSORBER ASSEMBLY (for MTT890)
EAS20036

Removing the rear shock absorber assembly
2 44 N•m (4.4 kgf•m, 32 lb•ft)
T.R
.
7
44 N•m (4.4 kgf•m, 32 lb•ft)
T.R
.
2 5
LS
1
9 New 4
3
6
New 9 LS
LS
9 New 10 10
LS
10
6 7
45 N•m (4.5 kgf•m, 33 lb•ft)
1
LS
T.R
.
5 11 8 11 New
4 11 11 New
7 LS
44 N•m (4.4 kgf•m, 32 lb•ft)
T.R
.

1 Rear shock absorber assembly lower nut/Bolt 1/1
Rear shock absorber assembly upper nut/
2 1/1/1
Washer/Bolt
3 Rear shock absorber assembly 1
4 Relay arm nut/Bolt 1/1
5 Connecting arm upper nut/Bolt 1/1
6 Relay arm 2
7 Connecting arm lower nut/Collar/Bolt 1/1/1
8 Connecting arm 1
9 Collar/Oil seal/Bearing 1/2/1
4-116
EAS30826
HANDLING THE REAR SHOCK ABSORBER TIP

EWA13740 • Place the vehicle on a suitable stand so that
WARNING the rear wheel is elevated.
This rear shock absorber contains highly • When removing the bolt, hold the swingarm so
compressed nitrogen gas. Before handling that it does not drop down.
the rear shock absorber, read and make sure
you understand the following information. EAS30220
The manufacturer cannot be held responsi- CHECKING THE REAR SHOCK ABSORBER
ble for property damage or personal injury ASSEMBLIES (for MTT890)
that may result from improper handling of 1. Check:
the rear shock absorber. • Rear shock absorber rod
• Do not tamper or attempt to open the rear Bends/damage → Replace the rear shock
shock absorber. absorber assembly.
• Do not subject the rear shock absorber to • Rear shock absorber assembly
an open flame or any other source of high Gas leaks/oil leaks → Replace the rear shock
heat. High heat can cause an explosion due absorber assembly.
to excessive gas pressure. • Spring
• Do not deform or damage the rear shock • Bushing
absorber in any way. Rear shock absorber Damage/wear → Replace the rear shock ab-
damage will result in poor damping perfor- sorber assembly.
mance. • Bolt
Bends/damage/wear → Replace.
EAS31632
EAS30221
DISPOSING OF A REAR SHOCK ABSORBER CHECKING THE CONNECTING ARM AND
1. Gas pressure must be released before dis- RELAY ARM
posing of a rear shock absorber. To release 1. Check:
the gas pressure, drill a 2–3 mm (0.08–0.12 • Connecting arm
in) hole through the rear shock absorber at a • Relay arm
point 20–25 mm (0.79–0.98 in) from its end Damage/wear → Replace.
as shown. 2. Check:
EWA13760
WARNING • Bearing
Damage/pitting → Replace.
Wear eye protection to prevent eye damage
3. Check:
from released gas or metal chips. • Collar
20-25 mm
(0.79-0.98 in) EAS30222
INSTALLING THE RELAY ARM

1. Lubricate:
• Collar
• Oil seal New
Lithium-soap-based grease
EAS30219 2. Install:
REMOVING THE REAR SHOCK ABSORBER • Bearing “1”
ASSEMBLY (to the connecting arm and swingarm)
1. Stand the vehicle on a level surface. • Oil seal “2” New
EWA13120
WARNING (connecting arm and swingarm)

4-117
• Rear shock absorber assembly upper nut

Installed depth “a” TIP
4 mm (0.16 in)
Installed depth “b” • Install the rear shock absorber assembly upper
0–1.0 mm (0–0.04 in) bolt from the left.
• Align the surface “a” on the frame with the sur-
TIP face “b” on the rear shock absorber assembly
• When installing the oil seals “2” to the relay upper bolt.
arm, face the character stamp of the oil seals
outside.
• Install the connecting arm upper bolt and relay
arm bolt from the left.
a
3 3
1 5
b
New 2 2 New 2. Install:
• Rear shock absorber assembly lower bolt
b b
a a • Rear shock absorber assembly lower nut
1 TIP
5
New 2 2 New • Install the rear shock absorber assembly lower
A b b B bolt from the left.
a a • When installing the rear shock absorber as-
sembly, lift up the swingarm.
4
3. Tighten:
a a • Rear shock absorber assembly upper nut
b b • Rear shock absorber assembly lower nut
Rear shock absorber assembly

New 2 2 New upper nut
T.
1
R.
44 N·m (4.4 kgf·m, 32 lb·ft)

3. Relay arm Rear shock absorber assembly
4. Connecting arm lower nut
5. Swingarm 44 N·m (4.4 kgf·m, 32 lb·ft)
A. Left side
B. Right side
3. Tighten:
• Connecting arm upper bolt
• Relay arm bolt
Connecting arm upper bolt

45 N·m (4.5 kgf·m, 33 lb·ft)
T.
R.
Relay arm bolt

45 N·m (4.5 kgf·m, 33 lb·ft)
EAS30225
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Install:
• Rear shock absorber assembly
• Rear shock absorber assembly upper bolt
4-118
REAR SHOCK ABSORBER ASSEMBLY (for MTT890D)
EAS20233

T.R
T.R
.
.
1 44 N•m (4.4 kgf•m, 32 lb•ft)
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
.
2
LS
7 6 8
3
4 44 N•m (4.4 kgf•m, 32 lb•ft)
T.R
5
.
9
LT
New
New
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft) New
T.R
.
LS
LS
LS New
LS
New
LS
New
28 N•m (2.8 kgf•m, 21 lb•ft)
T.R
.
44 N•m (4.4 kgf•m, 32 lb•ft)

T.R
.

T.R
T.R
.

Fuel tank/Canister Refer to “FUEL TANK” on page 7-1.
1 Ground lead 2
2 Angular position sensor coupler 1 Disconnect.
3 Locknut (angular position sensor side) 1
4 Locknut (swingarm side) 1 Left-hand threads
5 Angular position sensor rod 1
6 Angular position sensor 1
7 Angular position sensor bracket 1
8 Angular position sensor rod joint (upper) 1
9 Angular position sensor rod joint (lower) 1
4-119

T.R
T.R
.
.
T.R
.
T.R
.
18 20
LS
13 44 N•m (4.4 kgf•m, 32 lb•ft)
T.R
.
LT
22 New 14
19 15
New 16
18 11 LS 17
7 N•m (0.7 kgf•m, 5.2 lb•ft) New 23
T.R
23
.
LS
LS
10 20
LS New 23
17 24
LS
14 24
12 14 21 New
15 20 24 New
LS
28 N•m (2.8 kgf•m, 21 lb•ft) 16
T.R
.
44 N•m (4.4 kgf•m, 32 lb•ft)

T.R
.

T.R
T.R
.

10 Gas cylinder 1
11 Gas cylinder bracket 1
12 Passenger footrest (left) 1
13 Rear shock absorber assembly solenoid coupler 1 Disconnect.
14 Connecting arm upper nut/Bolt 1/1
15 Rear shock absorber assembly lower nut/Bolt 1/1
16 Relay arm nut/Bolt 1/1
17 Relay arm 2
Rear shock absorber assembly upper nut/
18 1/1/1
Washer/Bolt
19 Rear shock absorber assembly 1
20 Connecting arm lower nut/Collar/Bolt 1/1/1
21 Connecting arm 1
4-120
EAS31912
HANDLING THE REAR SHOCK ABSORBER TIP

EWA13740 • Place the vehicle on a suitable stand so that
WARNING the rear wheel is elevated.
This rear shock absorber contains highly • When removing the bolt, hold the swingarm so
compressed nitrogen gas. Before handling that it does not drop down.
the rear shock absorber, read and make sure
you understand the following information. EAS31305
The manufacturer cannot be held responsi- CHECKING THE REAR SHOCK ABSORBER
ble for property damage or personal injury ASSEMBLY (for MTT890D)
that may result from improper handling of 1. Check:
the rear shock absorber. • Rear shock absorber rod
• Do not tamper or attempt to open the rear Bends/damage → Replace the rear shock
shock absorber. absorber assembly.
• Do not subject the rear shock absorber to • Rear shock absorber assembly
an open flame or any other source of high Gas leaks/oil leaks → Replace the rear shock
heat. High heat can cause an explosion due absorber assembly.
to excessive gas pressure. • Spring
• Do not deform or damage the rear shock • Bushing
absorber in any way. Rear shock absorber Damage/wear → Replace the rear shock ab-
damage will result in poor damping perfor- sorber assembly.
mance. • Hose
Cracks/damage/wear → Replace the rear
EAS30729 shock absorber assembly.
DISPOSING OF A REAR SHOCK ABSORBER • Bolt
1. Gas pressure must be released before dis- Bends/damage/wear → Replace.
posing of a rear shock absorber. To release
EAS31916
the gas pressure, drill a 2–3 mm (0.08–0.12 CHECKING THE CONNECTING ARM AND
in) hole through the flat portion of the gas cyl- RELAY ARM
inder and rear shock absorber at a point 20– 1. Check:
25 mm (0.79–0.98 in) from its end of flange • Connecting arm
as shown. • Relay arm
EWA13760
WARNING Damage/wear → Replace.

2. Check:
Wear eye protection to prevent eye damage • Bearing
from released gas or metal chips.
Damage/pitting → Replace.
3. Check:
20-25 mm • Collar
(0.79-0.98 in) Damage/scratches → Replace.
EAS31917
INSTALLING THE RELAY ARM

1. Lubricate:
• Collar
• Oil seal New
EAS31304 Lithium-soap-based grease
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY 2. Install:
1. Stand the vehicle on a level surface. • Bearing “1”
EWA13120
(to the connecting arm and swingarm)
WARNING
(connecting arm and swingarm)
4-121
• Rear shock absorber assembly upper nut

Installed depth “a” TIP
4 mm (0.16 in)
Installed depth “b” • Install the rear shock absorber assembly upper
0–1.0 mm (0–0.04 in) bolt from the left.
• Align the surface “a” of the frame with the sur-
TIP face “b” of the rear shock absorber assembly
• When installing the oil seals “2” to the relay upper bolt.
arm, face the character stamp of the oil seals
outside.
• Install the connecting arm upper bolt and relay
arm bolt from the left.
a
3 3
1 5
b
New 2 2 New 2. Install:
• Rear shock absorber assembly lower bolt
b b
a a • Rear shock absorber assembly lower nut
1 TIP
5
New 2 2 New • Install the rear shock absorber assembly lower
A b b B bolt from the left.
a a • When installing the rear shock absorber as-
sembly, lift up the swingarm.
4
3. Tighten:
a a • Rear shock absorber assembly upper nut
b b • Rear shock absorber assembly lower nut
Rear shock absorber assembly

New 2 2 New upper nut
T.
1
R.
44 N·m (4.4 kgf·m, 32 lb·ft)

3. Relay arm Rear shock absorber assembly
4. Connecting arm lower nut
5. Swingarm 44 N·m (4.4 kgf·m, 32 lb·ft)
A. Left side
B. Right side 4. Install:
• Passenger footrest (left)
3. Tighten: • Gas cylinder bracket
• Connecting arm upper bolt • Gas cylinder
• Relay arm bolt
Passenger footrest bolt
Connecting arm upper bolt 28 N·m (2.8 kgf·m, 21 lb·ft)
T.
R.
45 N·m (4.5 kgf·m, 33 lb·ft) Gas cylinder bolt

T.
R.
Relay arm bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft)

45 N·m (4.5 kgf·m, 33 lb·ft)
TIP
EAS31366
INSTALLING THE REAR SHOCK Install the gas cylinder punch mark “a” toward
ABSORBER ASSEMBLY the inside of the vehicle.
1. Install:
• Rear shock absorber assembly
• Rear shock absorber assembly upper bolt
4-122
a b
5. Install:
• Angular position sensor rod joint (upper) “1” 1
• Angular position sensor rod joint (lower) “2”
• Angular position sensor rod “3” c 4
• Locknut “4” 3 c
TIP
• Install the angular position sensor rod joint
(lower) onto the swingarm, make sure the pro- d 2
jection “a” on the angular position sensor rod e
joint (lower) touches the projection “b” on the
swingarm. d. 39 mm (1.54 in)
• The locknut (swingarm side) has left-hand e. 17°
threads.
• Install the locknut with groove “c” facing in-
ward.
• Be sure to place the angular position sensor
rod and bracket “f” of angular position sensor 3
rod joint are in parallel.
• The allowable twist angular position sensor rod
“3” joints is ±5°.
f
Angular position sensor rod joint
bolt
T.
6. Adjust:
R.
10 N·m (1.0 kgf·m, 7.4 lb·ft)

Locknut (angular position sen- • Installed angular position sensor rod length
sor side) Refer to “ADJUSTING THE ANGULAR PO-
7 N·m (0.7 kgf·m, 5.2 lb·ft) SITION SENSOR POSITION” on page
Locknut (swingarm side) 4-123.
7 N·m (0.7 kgf·m, 5.2 lb·ft) 7. Check:
Left-hand threads • SUS. Sensor Calibration
Angular position sensor bracket Refer to “CHECKING THE VEHICLE AFTER
bolt INSTALLING THE REAR SHOCK ABSORB-
7 N·m (0.7 kgf·m, 5.2 lb·ft) ER ASSEMBLY (for MTT890D)” on page
LOCTITE®
4-124.
EAS33566
ADJUSTING THE ANGULAR POSITION

SENSOR POSITION
TIP
The angular sensor position is determined by
the installed angular position sensor rod length.
4-123
1. Measure: EAS33567
CHECKING THE VEHICLE AFTER

• Installed angular position sensor rod length
INSTALLING THE REAR SHOCK
“a”
ABSORBER ASSEMBLY (for MTT890D)
Incorrect → Adjust.
1. Check:
Installed angular position sensor • SUS. Sensor Calibration
rod length“a” TIP
114.0–116.0 mm (4.49–4.57 in) • Perform “SUS. Sensor Calibration” with all
parts installed.
• When performing the sensor calibration, place
the vehicle on the centerstand and there
should be no weight on the vehicle.
• If the following parts are removed, perform
a “SUS. Sensor Calibration”.
Rear shock absorber assembly/Angular posi-
tion sensor/Angular position sensor bracket/
Angular position sensor rod joint bolt (upper)/
Swingarm/Rear fender/Relay arm/Connecting
arm/Angular position sensor rod joint (lower)/
2. Adjust: Angular position sensor rod/Angular position
• Installed angular position sensor rod length sensor rod joint (upper)/Angular position sen-
a. Loosen both locknuts “1”. sor rod locknut/Rear wheel
b. Turn the angular position sensor rod “2” • If you loosen the angular position sensor
until the specified installed angular posi- bracket bolts, perform “SUS. Sensor Calibra-
tion sensor rod length is obtained. tion”.
a. Place the vehicle on the centerstand.
b. Turn the main switch to “ON”.
1 c. Use the wheel switch “1” to select settings
2 MENU icon “2”, and then push select the
wheel switch.
c. Tighten both locknuts.

TIP 1
• The locknut (swingarm side) has left-hand
threads.
• Be sure to place the angular position sensor
rod joints in parallel. The allowable twist of the
angular position sensor rod joints is ±5°.
Locknut (angular position sen-

sor side)
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

Locknut (swingarm side)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Left-hand threads
2
d. Make sure the installed angular position
sensor rod length is within specification. d. The menu screen will be displayed, and
select “SUS. Sensor Calibration”.
4-124
MENU
Exit
Display Setting
Manual TCS Setting
Vehicle Setting
Shift Indicator
km/h
e. Select “Execute” and after approx. 5 sec-

onds the result of the calibration (success/
failed) will be displayed.
SUS. Sensor Calibration
Result : .....
Execute
km/h
f. If “success” is displayed. → Complete.

If “failed” is displayed. → Reinstall.
4-125
SWINGARM
EAS20037
SWINGARM
Removing the swingarm
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
LS
LS
New
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
LS
LS
New
105 N•m (10.5 kgf•m, 77 lb•ft)

T.R
.
*for MTT890

Rear brake caliper Refer to “REAR BRAKE” on page 4-54.
Rear wheel Refer to “REAR WHEEL” on page 4-33.
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY (for MTT890)” on page 4-116 and
Relay arm nut/Bolt “REAR SHOCK ABSORBER ASSEMBLY
(for MTT890D)” on page 4-119.
for MTT890D
Angular position sensor rod joint (lower) Refer to “REAR SHOCK ABSORBER AS-
SEMBLY (for MTT890D)” on page 4-119.
4-126
SWINGARM
Removing the swingarm
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
*
5 3
LS
LS 8
7 10 12 New
LS
10
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9
13
8
11 LS
2
LS
New 12 6
1
105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
*for MTT890

1 Pivot shaft nut 1
2 Washer 1
3 Pivot shaft 1
4 Swingarm 1
5 Rear fender 1
6 Drive chain guide 1
7 Cable holder 1
8 Dust cover 2
9 Collar 1
10 Bearing 2
11 Collar 1
12 Oil seal 2
13 Bearing 1
4-127
SWINGARM
EAS30226 EWA13770
REMOVING THE SWINGARM WARNING

1. Stand the vehicle on a level surface. Do not attempt to straighten a bent pivot
EWA13120
WARNING shaft.
Securely support the vehicle so that there is 3. Wash:
no danger of it falling over. • Pivot shaft
• Dust cover
TIP • Collar
that the rear wheel is elevated. Recommended cleaning solvent
Kerosene
2. Measure:
• Swingarm side play 4. Check:
• Swingarm vertical movement • Dust cover “1”
a. Measure the tightening torque of the pivot • Oil seal “2”
shaft nut. Damage/wear → Replace.
• Collar “3”
Pivot shaft nut
105 N·m (10.5 kgf·m, 77 lb·ft)
T.
• Bearing “4”
R.
b. Check the swingarm side play “A” by mov- Damage/pitting → Replace.

ing the swingarm from side to side. • Collar “5”
If the swingarm has side-to-side play, Damage/scratches → Replace.
check the collars, bearings, and dust cov- 4 1
ers.
4
c. Check the swingarm vertical movement 2
“B” by moving the swingarm up and down. 5
If the swingarm vertical movement is not
smooth or if there is binding, check the piv-
ot shaft, collar, bearings, and dust covers. 2 4 3
1
B
EAS30228
A
INSTALLING THE SWINGARM
1. Lubricate:
• Dust cover
• Pivot shaft
• Bearing
G088936 • Oil seal New
3. Remove: • Collar
• Swingarm
EAS30227 Lithium-soap-based grease
CHECKING THE SWINGARM
1. Check: 2. Install:
• Swingarm • Bearing “1”
Bends/cracks/damage → Replace. (to the swingarm)
2. Check: • Oil seal “2” New
• Pivot shaft (to the swingarm)
Roll the pivot shaft on a flat surface.
Bends → Replace.
4-128
SWINGARM
Installed depth “a” Drive chain slack (Mainstand)

0–1.0 mm (0–0.039 in) 45.0–50.0 mm (1.77–1.97 in)
Installed depth “b” Drive chain slack limit (Main-
4 mm (0.157 in) stand)
Installed depth “c” 55.0 mm (2.17 in)
0.2–1.0 mm (0.008–0.039 in)
6. Check (for MTT890D):
TIP • SUS. Sensor Calibration
When installing the oil seals to the swingarm, Refer to “CHECKING THE VEHICLE AFTER
face the character stamp of the oil seals outside. INSTALLING THE REAR SHOCK ABSORB-
ER ASSEMBLY (for MTT890D)” on page
4-124.
b
1
New 2 2 N
New
A B
a a
c 1 1 c
A B
A. Left side
B. Right side
3. Install:
• Swingarm
• Pivot shaft
Relay arm nut

45 N·m (4.5 kgf·m, 33 lb·ft)
T.
R.
Pivot shaft nut

105 N·m (10.5 kgf·m, 77 lb·ft)
4. Install:
• Rear wheel
Refer to “REAR WHEEL” on page 4-33.
5. Adjust:
Refer to “DRIVE CHAIN SLACK” on page
3-18.
4-129
CHAIN DRIVE
EAS20038
CHAIN DRIVE
Removing the drive chain
4.3 N•m (0.43 kgf•m, 3.2 lb•ft)
T.R
.
160 N•m (16 kgf•m, 118 lb•ft)
1
T.R
.
14 N•m (1.4 kgf•m, 10 lb•ft)
LT
LT
T.R
.
* 5 LT
LT
LT
New
9
LT
7 LS 10
2 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
6 LS
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
8 4
7 N•m (0.7 kgf•m, 5.2 lb•ft)
11
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) LS

3
T.R
.
LT
LS LT
LT
10
28 N•m (2.8 kgf•m, 21 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
.
.
*for MTT890D

for MTT890D
1 Sidestand switch 1
2 Shift rod locknut (shift arm side) 1
3 Shift rod locknut (shift pedal side) 1 Left-hand threads
4 Shift rod 1 for MTT890
for MTT890D
5 Shift sensor coupler 1 Disconnect.
6 Shift rod locknut (shift sensor side) 1 for MTT890D
7 Shift sensor 1 for MTT890D
8 Shift rod 1 for MTT890D
9 Shift arm 1
10 Shift rod joint 2
11 Shift pedal 1
4-130
CHAIN DRIVE
Removing the drive chain
4.3 N•m (0.43 kgf•m, 3.2 lb•ft)
T.R
.
14
160 N•m (16 kgf•m, 118 lb•ft)
T.R
.
14 N•m (1.4 kgf•m, 10 lb•ft)
LT
LT
T.R
.
12
* LT
LT 17
LT
16
New 15
13
LT
LS
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
LS
8 N•m (0.8 kgf•m, 5.9 lb•ft)
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) LS

T.R
.
LT
LS LT
LT
28 N•m (2.8 kgf•m, 21 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
T.R
.
.
*for MTT890D

12 Drive sprocket cover 1
13 Drive chain guide 1
14 Drive chain 1
15 Drive sprocket nut 1
16 Washer 1
17 Drive sprocket 1
4-131
CHAIN DRIVE
EAS30229
b. Calculate the 15-link section length “a” of
REMOVING THE DRIVE CHAIN
the 15-link section of the drive chain using
EWA13120
the following formula.
WARNING Drive chain 15-link section length “a” =
Securely support the vehicle so that there is (length “b” between pin inner sides +
no danger of it falling over. length “c” between pin outer sides)/2
TIP
2. Straighten the drive sprocket nut ribs “a”.
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a different
location each time.
3. Loosen:
• Drive sprocket nut
TIP
G088937
Loosen the drive sprocket nut while pressing the
brake pedal.
4. Remove:
• Drive chain
ECA17410
NOTICE
Be sure to put on safety goggles when work-
ing.
TIP
G088938
Cut the drive chain with the drive chain cut & riv-
et tool. 2. Check:
• Drive chain
Drive chain cut & rivet tool Stiffness → Clean and lubricate or replace.
90890-01550
YM-01550
EAS30230
CHECKING THE DRIVE CHAIN

1. Measure:
• 15-link section length “a” of the drive chain
Out of specification → Replace the drive
chain. G088939
3. Clean:
15-link length limit • Drive chain
239.3 mm (9.42 in)
a. Wipe the drive chain with a clean cloth.
a. Measure the length “b” between the inner b. Put the drive chain in kerosene and re-
move any remaining dirt.
sides of the pins and the length “c” be-
tween the outer sides of the pins on a 15- c. Remove the drive chain from the kerosene
link section of the drive chain as shown in and completely dry it.
the illustration.
4-132
CHAIN DRIVE
ECA19090
NOTICE
• This vehicle has a drive chain with small
rubber O-rings “1” between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean
the drive chain. High-pressure methods
could force dirt or water into the drive
chain’s internals, and solvents will deterio- G088943
rate the O-rings. A coarse brush can also 5. Lubricate:

damage the O-rings. Therefore, use only • Drive chain
kerosene to clean the drive chain.
• Do not soak the drive chain in kerosene for Recommended lubricant
more than ten minutes, otherwise the O- Chain lubricant suitable for O-
rings can be damaged. ring chains
EAS30231
CHECKING THE DRIVE SPROCKET

1. Check:
• Drive sprocket
More than 1/4 tooth “a” wear → Replace the
drive sprocket, the rear wheel sprocket and
the drive chain as a set.
Bent teeth → Replace the drive sprocket, the
rear wheel sprocket and the drive chain as a
G088940
set.
G088941 G088904
4. Check: b. Correct
• O-ring “1” 1. Drive chain roller
Damage → Replace the drive chain. 2. Drive sprocket
• Drive chain roller “2”
Damage/wear → Replace the drive chain.
EAS30232
CHECKING THE REAR WHEEL SPROCKET

• Drive chain side plate “3” Refer to “CHECKING AND REPLACING THE
Damage/wear/cracks → Replace the drive REAR WHEEL SPROCKET” on page 4-36.
chain.
EAS30233
CHECKING THE REAR WHEEL DRIVE HUB

Refer to “CHECKING THE REAR WHEEL
DRIVE HUB” on page 4-36.
EAS30234
INSTALLING THE DRIVE CHAIN

1. Install:
• Drive chain
4-133
CHAIN DRIVE
ECA17410
NOTICE
Be sure to put on safety goggles when work-
ing.
TIP
Install the drive chain joint with the drive chain
cut & rivet tool.

90890-01550
Drive chain cut & rivet tool 2. Lubricate:
YM-01550 • Drive chain
a. When press fitting the connecting plate Recommended lubricant

“1”, make sure the space “a” between the Chain lubricant suitable for O-
end of the connecting pin “2” and the con- ring chains
necting plate is 1.2–1.4 mm (0.05–0.06
3. Install:
in).
• Drive sprocket
• Washer “1”
• Drive sprocket nut “2” New
Drive sprocket nut

160 N·m (16 kgf·m, 118 lb·ft)
T.
R.
LOCTITE®
TIP
• Thoroughly clean all the drive sprocket nut
seat and threads of drive axle.
b. After riveting, make sure the diameter be- • While applying the rear brake, tighten the drive
tween the edges “b” of the connecting pin sprocket nut.
“2” is 5.7–6.0 mm (0.22–0.24 in). • Install washer “1” with the “OUT” mark “a” fac-
ing out.
• Stake the drive sprocket nut “2” at cutouts “b”
in the drive axle securely.
1
c. After riveting, make sure the space “c”,
which is inside of the connecting link “3” b
and inside of the connecting plate “1”, is a
14.35–14.55 mm (0.565–0.573 in).
4-134
CHAIN DRIVE
A 1 B 1
a a
3 2
c c
3
1 b 1 b
b
4. Install: A. MTT890
• Shift arm “1” B. MTT890D
TIP a. 24 mm (0.94 in)
b. 24.4 mm (0.96 in)
Before installing, make sure to align the mark “a”
of the shift shaft with the punch mark “b” of the 6. Adjust:
shift arm. • Installed shift rod length
Refer to “ADJUSTING THE SHIFT PEDAL”
Shift arm bolt on page 4-135.
14 N·m (1.4 kgf·m, 10 lb·ft) 7. Adjust:
T.
R.

Refer to “DRIVE CHAIN SLACK” on page
3-18.
b
Drive chain slack (Mainstand)
45.0–50.0 mm (1.77–1.97 in)
Drive chain slack limit (Main-
stand)
55.0 mm (2.17 in)
1 a
ECA13550
NOTICE
5. Install: A drive chain that is too tight will overload
• Shift rod joint “1” the engine and other vital parts, and one that
• Shift sensor “2” (MTT890D) is too loose can skip and damage the swing-
• Shift rod “3” arm or cause an accident. Therefore, keep
TIP the drive chain slack within the specified lim-
• Install the shift rod joint and shift sensor in the its.
direction shown in the illustration.
• The allowable twist of the shift rod joint and EAS31729
shift sensor is ±5°. ADJUSTING THE SHIFT PEDAL

• Install the shift rod so that the side “c” faces up- TIP
ward as shown in the illustration. The shift pedal position is determined by the in-
stalled shift rod length.
Shift rod joint bolt 1. Measure:
10 N·m (1.0 kgf·m, 7.4 lb·ft) • Installed shift rod length “a”
T.
R.
LOCTITE® Incorrect → Adjust.

Shift sensor locknut
7 N·m (0.7 kgf·m, 5.2 lb·ft) Installed shift rod length
236.4–238.4 mm (9.31–9.39 in)
4-135
CHAIN DRIVE
A B
a a
A. MTT890
B. MTT890D
2. Adjust:
• Installed shift rod length
a. Loosen both locknuts “1”.
b. Turn the shift rod “2” until the specified in-
stalled shift rod length is obtained.
A B
1
2
1
2
1
1
A. MTT890
B. MTT890D
c. Tighten both locknuts.
TIP
• The shift rod locknut (shift pedal side) has left-
hand threads.
• Be sure to place the shift rod joints in parallel.
The allowable twist of the shift rod joints is ±5°.
Shift rod locknut (shift arm side)

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Shift rod locknut (shift sensor

side) (MTT890D)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Shift rod locknut (shift pedal
side)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Left-hand threads
d. Make sure the installed shift rod length is

within specification.
4-136
CHAIN DRIVE
4-137
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

ENGINE OIL LUBRICATION CHART .......................................................5-1
LUBRICATION DIAGRAMS ...................................................................... 5-2
ENGINE INSPECTION .................................................................................... 5-7

MEASURE THE COMPRESSION PRESSURE........................................ 5-7
ENGINE REMOVAL ........................................................................................5-9

REMOVING THE ENGINE ...................................................................... 5-14
INSTALLING THE ENGINE..................................................................... 5-14
CAMSHAFTS.................................................................................................5-17
REMOVING THE CAMSHAFTS..............................................................5-20
CHECKING THE CAMSHAFTS ..............................................................5-21
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .........5-22
CHECKING THE TIMING CHAIN GUIDES............................................. 5-22
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-22
INSTALLING THE CAMSHAFTS ............................................................ 5-23
CYLINDER HEAD.......................................................................................... 5-27

REMOVING THE CYLINDER HEAD.......................................................5-28
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................. 5-28
CHECKING THE CYLINDER HEAD .......................................................5-28
INSTALLING THE CYLINDER HEAD .....................................................5-28
5
VALVES AND VALVE SPRINGS.................................................................. 5-30
REMOVING THE VALVES...................................................................... 5-32
CHECKING THE VALVES AND VALVE GUIDES ..................................5-32
CHECKING THE VALVE SEATS ............................................................ 5-34
CHECKING THE VALVE SPRINGS........................................................ 5-35
CHECKING THE VALVE LIFTERS ......................................................... 5-35
INSTALLING THE VALVES .................................................................... 5-35
GENERATOR AND STARTER CLUTCH......................................................5-37

REMOVING THE GENERATOR ............................................................. 5-40
REMOVING THE STARTER CLUTCH ...................................................5-40
CHECKING THE STARTER CLUTCH ....................................................5-40
INSTALLING THE STARTER CLUTCH .................................................. 5-41
INSTALLING THE GENERATOR............................................................ 5-41
ELECTRIC STARTER ...................................................................................5-43

CHECKING THE STARTER MOTOR .....................................................5-45
ASSEMBLING THE STARTER MOTOR................................................. 5-45
INSTALLING THE STARTER MOTOR ...................................................5-46
CLUTCH ........................................................................................................5-47
REMOVING THE CLUTCH ..................................................................... 5-51
CHECKING THE FRICTION PLATES.....................................................5-52
CHECKING THE CLUTCH PLATES .......................................................5-52
CHECKING THE CLUTCH SPRINGS.....................................................5-53
CHECKING THE CLUTCH HOUSING ....................................................5-53
CHECKING THE CLUTCH BOSS........................................................... 5-54
CHECKING THE PRESSURE PLATE ....................................................5-54
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-54
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-54
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-54
INSTALLING THE CLUTCH.................................................................... 5-54
SHIFT SHAFT................................................................................................5-57
CHECKING THE SHIFT SHAFT ............................................................. 5-58
CHECKING THE STOPPER LEVER ......................................................5-58
INSTALLING THE SHIFT SHAFT ........................................................... 5-58
OIL PUMP...................................................................................................... 5-59

CHECKING THE SPROCKET AND CHAIN............................................5-61
CHECKING THE OIL PUMP ................................................................... 5-61
CHECKING THE RELIEF VALVE ........................................................... 5-61
ASSEMBLING THE OIL PUMP...............................................................5-61
INSTALLING THE OIL PUMP .................................................................5-61
OIL PAN ........................................................................................................5-63

REMOVING THE OIL PAN...................................................................... 5-64
CHECKING THE OIL STRAINER ........................................................... 5-64
INSTALLING THE OIL PAN .................................................................... 5-64
CRANKCASE ................................................................................................5-65
DISASSEMBLING THE CRANKCASE....................................................5-67
CHECKING THE CRANKCASE ..............................................................5-67
ASSEMBLING THE CRANKCASE.......................................................... 5-67
INSTALLING THE OIL PRESSURE SWITCH.........................................5-69
INSTALLING THE GEAR POSITION SENSOR...................................... 5-69
CONNECTING RODS AND PISTONS .......................................................... 5-71

REMOVING THE CONNECTING RODS AND PISTONS.......................5-72
CHECKING THE CYLINDER AND PISTON ...........................................5-72
CHECKING THE PISTON RINGS........................................................... 5-73
CHECKING THE PISTON PIN ................................................................5-73
CHECKING THE CONNECTING RODS................................................. 5-74
INSTALLING THE CONNECTING ROD AND PISTON .......................... 5-77
CRANKSHAFT AND BALANCER SHAFT ...................................................5-81
REMOVING THE CRANKSHAFT AND BALANCER SHAFT.................. 5-82
CHECKING THE OIL NOZZLES ............................................................. 5-82
CHECKING THE CRANKSHAFT ............................................................ 5-82
CHECKING THE BALANCER SHAFT ....................................................5-84
INSTALLING THE CRANKSHAFT .......................................................... 5-85
INSTALLING THE BALANCER ASSEMBLY...........................................5-86
TRANSMISSION............................................................................................ 5-87
REMOVING THE TRANSMISSION ........................................................ 5-92
CHECKING THE SHIFT FORKS............................................................. 5-92
CHECKING THE SHIFT DRUM ASSEMBLY..........................................5-93
CHECKING THE TRANSMISSION ......................................................... 5-93
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..............................5-93
INSTALLING THE TRANSMISSION .......................................................5-94
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20298

EAS32362
ENGINE OIL LUBRICATION CHART
16
15
14
13
12 12 12
11
7
6 2
4 3
5 1
8 8 8
10
1. Oil strainer 16. Exhaust camshaft

2. Oil pump
3. Relief valve
4. Oil cooler
5. Oil filter cartridge
6. Main gallery
8. Mission shower
9. Main axle
10. Drive axle
11. Crankshaft
12. Oil nozzle
13. Balancer shaft
14. Timing chain tensioner
15. Intake camshaft
5-1
EAS32363
LUBRICATION DIAGRAMS
3 5
2
1
1. Oil filter cartridge union bolt
3. Oil delivery pipe
4. Drive axle
5. Main axle
5-2
2 3
10
9 7
7
8
1. Timing chain tensioner

2. Intake camshaft
3. Exhaust camshaft
4. Balancer shaft
5. Crankshaft
6. Oil cooler
7. Oil strainer
8. Oil drain bolt
9. Oil pump driven sprocket
5-3
5
4
2 1
1. Oil cooler
4. Oil strainer
5. Oil pump
5-4
1. Balancer shaft
2. Crankshaft
4. Main axle
5. Drive axle
6. Oil gallery bolt
5-5
3
4 5
8
1. Cylinder head
2. Intake camshaft
3. Exhaust camshaft
4. Oil passage to the cylinder head
5. Oil passage to the clutch chamber
6. Oil return passage from the cylinder head
7. Crankshaft
8. Main gallery
5-6
ENGINE INSPECTION
EAS20041
ENGINE INSPECTION Compression gauge

90890-03081
EAS30249
Engine compression tester
MEASURE THE COMPRESSION PRESSURE YU-33223
The following procedure applies to all of the cyl- Compression gauge extension
inders. 122mm
TIP 90890-04136
Insufficient compression pressure will result in a Compression gauge extension
loss of performance. 122mm
YM-04136
1. Measure:
• Valve clearance
Out of specification → Adjust. 1
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
2. Start the engine, warm it up for several min- 2
3. Remove:
• Rider seat/Rubber cover
4-1.
• Fuel tank bracket cover 5. Measure:
Refer to “GENERAL CHASSIS (2)” on page • Compression pressure
4-5. Out of specification → Refer to steps (c) and
• Front side cowling assembly (d).
• Fuel tank top cover
• Fuel tank side cover assembly Compression pressure
Refer to “GENERAL CHASSIS (3)” on page 1365–1758 kPa/600 r/min (13.7–
17.6 kgf/cm²/600 r/min, 194.3–
4-14.
250.1 psi/600 r/min)
• Fuel tank
Refer to “FUEL TANK” on page 7-1. a. Set the main switch to “ON”.
• Air filter case b. With the throttle wide open, crank the en-
Refer to “GENERAL CHASSIS (4)” on page gine until the reading on the compression
4-24. gauge stabilizes.
• Ignition coil EWA17100
• Spark plug WARNING

Refer to “CAMSHAFTS” on page 5-17. To prevent sparking the plug, remove all ig-
ECA13340
nition coil couplers and fuel injector cou-
NOTICE
plers before cranking the engine.
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumulat- TIP
ed in the spark plug wells to prevent it from The difference in compression pressure be-
falling into the cylinders. tween cylinders should not exceed 100 kPa (1
4. Install: kg/cm², 15 psi).
• Compression gauge “1” c. If the compression pressure is above the
• Extension “2” maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
5-7
ENGINE INSPECTION
Refer to the following table.

Compression pressure (with oil applied into the
cylinder)
Reading Diagnosis
Piston ring(s) wear or
Higher than without oil
damage → Repair.
Piston, valves, cylinder
Same as without oil head gasket possibly
defective → Repair.
6. Install:
• Spark plug
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
7. Install:
• Ignition coil
Refer to “CAMSHAFTS” on page 5-17.
• Air filter case
4-24.
• Fuel tank
• Fuel tank side cover assembly
4-14.
4-5.
• Rider seat/Rubber cover
4-1.
5-8
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler and exhaust pipe
20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
.
*
New 3
20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
.
20 N•m (2.0 kgf•m, 15 lb•ft) 4

T.R
.
25 N•m (2.5 kgf•m, 18 lb•ft)

T.R
.
* YAMAHA GREASE “G”

Take the vehicle off the centerstand, and
Centerstand then put the sidestand down.
Radiator bracket Refer to “RADIATOR” on page 6-3.
1 O2 sensor coupler 1 Disconnect.
2 Muffler assembly 1
3 Exhaust gasket 3
Remove the O2 sensor only when neces-
4 O2 sensor 1
sary.
5-9
ENGINE REMOVAL
Disconnecting the leads and hoses
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
.

Rider seat/Rubber cover 4-1.
Canister/Purge cut valve solenoid Refer to “FUEL TANK” on page 7-1.
Throttle bodies Refer to “THROTTLE BODIES” on page 7-6.
Radiator Refer to “RADIATOR” on page 6-3.
Shift rod/Drive sprocket/Sidestand switch Refer to “CHAIN DRIVE” on page 4-130.
5-10
ENGINE REMOVAL
Disconnecting the leads and hoses
6
8
7 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1
9
4
2
5
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

2 Starter motor lead 1 Disconnect.
3 Ignition coil coupler 3 Disconnect.
4 Coolant temperature sensor coupler 1 Disconnect.
5 Neutral switch coupler 1 Disconnect.
6 Gear position sensor coupler 1 Disconnect.
7 Crankshaft position sensor coupler 1 Disconnect.
8 Stator coil coupler 1 Disconnect.
9 Oil pressure switch connector 1 Disconnect.
5-11
ENGINE REMOVAL
Removing the engine

T.R
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
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
.
105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
25 N•m (2.5 kgf•m, 18 lb•ft) 5
T.R
.
2
2 3
1
2 6
4
45 N•m (4.5 kgf•m, 33 lb•ft)
T.R
.
9
1 25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
45 N•m (4.5 kgf•m, 33 lb•ft)

T.R
.
7 60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
LT
LT
8
55 N•m (5.5 kgf•m, 41 lb•ft) 10 55 N•m (5.5 kgf•m, 41 lb•ft)
T.R
T.R
.

Engine mounting bolt (right front upper side)/
1 1/1
Engine mounting bolt (left front upper side)
Engine bracket bolt (right)/Engine bracket bolt
2 2/2
(left)
3 Engine bracket (right) 1
4 Engine bracket (left) 1
5 Engine mounting nut (rear lower side) 1
6 Pivot shaft nut 1 Loosen.
7 Centerstand bolt (right) 1
8 Centerstand bolt (left) 1
9 Engine mounting bolt (rear lower side) 1
10 Centerstand 1
5-12
ENGINE REMOVAL
Removing the engine

T.R
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 55 N•m (5.5 kgf•m, 41 lb•ft)
12
T.R
.
13 18
14 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
105 N•m (10.5 kgf•m, 77 lb•ft)
T.R
.
25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
18
16
45 N•m (4.5 kgf•m, 33 lb•ft)

15
T.R
.
25 N•m (2.5 kgf•m, 18 lb•ft)

T.R
.
45 N•m (4.5 kgf•m, 33 lb•ft)

T.R
.
60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
LT
17
LT

T.R
T.R
.

11 Engine mounting nut (rear upper side) 1
12 Engine mounting bolt (right front lower side) 1
13 Collar 1
14 Collar 1
15 Engine mounting bolt (left front lower side) 1
16 Engine mounting bolt (rear upper side) 1
17 Engine 1
18 Engine mounting adjust bolt 2
5-13
ENGINE REMOVAL
EAS30250
• Engine mounting bolt (rear upper side) “7”
REMOVING THE ENGINE
1. Loosen: TIP
• Engine mounting adjust bolt (rear) It is not necessary to pass the centerstand
TIP
bracket “a” through the engine mounting bolt
(rear lower side) “6”.
Loosen the engine mounting adjust bolts with
the pivot shaft wrench “1” and pivot shaft wrench
adapter “2”.
Pivot shaft wrench

90890-01518
YM-01518
Pivot shaft wrench adapter
90890-01476 6
a
5. Install:
1 • Engine mounting bolt (left front lower side) “8”
(temporarily tighten)
6. Install:
• Collar “9”
2 • Collar “10”
• Engine mounting bolt (right front lower side)
“11”
7. Tighten:
• Engine mounting adjust bolt (lower) “1”
TIP
• Tighten the engine mounting adjust bolt to
specification with the pivot shaft wrench and
pivot shaft wrench adapter.
• Make sure that the flange on the engine
1 mounting adjust bolt contacts the engine.
2
Engine mounting adjust bolt
(lower)
T.
R.
EAS30251
7 N·m (0.7 kgf·m, 5.2 lb·ft)
INSTALLING THE ENGINE
1. Install:
• Engine mounting adjust bolt (lower) “1” Pivot shaft wrench
(temporarily tighten) 90890-01518
• Engine mounting adjust bolt (upper) “2” Frame spanner socket
(temporarily tighten) YM-01518
2. Install: Pivot shaft wrench adapter
• Centerstand “3” 90890-01476
• Centerstand bolt (left) “4”
8. Install:
• Centerstand bracket
• Centerstand bolt (right) “5”
(temporarily tighten) TIP
3. Install: Remove the engine mounting bolt (rear lower
• Engine side) “6”. Reinstall the engine mounting bolt
4. Install: (rear lower side) “6” through the centerstand
• Engine mounting bolt (rear lower side) “6” bracket “a”.
5-14
ENGINE REMOVAL
Pivot shaft wrench

90890-01518
YM-01518
6 Pivot shaft wrench adapter
90890-01476
13.Tighten:
a • Engine mounting nut (rear upper side) “14”
9. Tighten: Engine mounting nut (rear upper

• Engine mounting nut (rear lower side) “12” side)
T.
R.
• Centerstand bolt “4”, “5” 45 N·m (4.5 kgf·m, 33 lb·ft)
Engine mounting nut (rear lower 14.Install:

side) • Engine bracket (left) “15”
T.
R.
55 N·m (5.5 kgf·m, 41 lb·ft) • Engine bracket bolt (left) “16”

Centerstand bolt (temporarily tighten)
55 N·m (5.5 kgf·m, 41 lb·ft) • Engine mounting bolt (left front upper side)
LOCTITE® “17”
10.Tighten:
15.Install:
• Engine mounting bolt (left front lower side) “8”
• Engine bracket (right) “18”
• Engine mounting bolt (right front lower side)
• Engine bracket bolt (right) “19”
“11”
Engine mounting bolt (left front • Engine mounting bolt (right front upper side)
lower side) “20”
T.
R.
60 N·m (6.0 kgf·m, 44 lb·ft) (temporarily tighten)

Engine mounting bolt (right front 16.Tighten:
lower side) • Engine bracket bolt (left) “16”
60 N·m (6.0 kgf·m, 44 lb·ft) • Engine mounting bolt (left front upper side)
“17”
11.Tighten: • Engine bracket bolt (right) “19”
• Pivot shaft nut “13” • Engine mounting bolt (right front upper side)
“20”
Pivot shaft nut
105 N·m (10.5 kgf·m, 77 lb·ft) Engine bracket bolt (left)
T.
R.
25 N·m (2.5 kgf·m, 18 lb·ft)

T.
12.Tighten:
R.
Engine mounting bolt (left front

• Engine mounting adjust bolt (upper) “2” upper side)
TIP 45 N·m (4.5 kgf·m, 33 lb·ft)
• Tighten the engine mounting adjust bolt to Engine bracket bolt (right)
specification with the pivot shaft wrench and 25 N·m (2.5 kgf·m, 18 lb·ft)
pivot shaft wrench adapter. Engine mounting bolt (right front
upper side)
• Make sure that the flange on the engine
45 N·m (4.5 kgf·m, 33 lb·ft)
mounting adjust bolt contacts the engine.
Engine mounting adjust bolt (up-

per)
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
5-15
ENGINE REMOVAL
11 10
9 6
14
2
19
12
18 1
20
16 13
15
17
8
5
3 4
5-16
CAMSHAFTS
EAS20043
CAMSHAFTS
Removing the cylinder head cover
10 N•m (1.0 kgf•m, 7.4 lb•ft)

1
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
2 2 2
3 3 3
New 5
* 13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.
* Three Bond No. 1541C®

1 Ignition coil coupler 3 Disconnect.
2 Ignition coil 3
3 Spark plug 3
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (top side) 1
5-17
CAMSHAFTS
Removing the camshafts
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

(8)
T.R
.
E
(4)
8 9 6 (4)
5 New
4 7
9
9 9
10
(7) 11
1 2 3 New T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft)

M
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Crankshaft end cover/Timing mark accessing Refer to “GENERATOR AND STARTER
bolt CLUTCH” on page 5-37.
1 Holder 2
2 Timing chain cover 1
3 Timing chain cover gasket 1
4 Timing chain tensioner 1
5 Timing chain tensioner gasket 1
6 Intake camshaft cap 1
7 Exhaust camshaft cap 1
8 Camshaft cap 1
9 Dowel pin 6
10 Intake camshaft 1
11 Exhaust camshaft 1
5-18
CAMSHAFTS
Removing the camshafts
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

(8)
T.R
.
E
(4)
(4)
New
12
14
(7) 13
New T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft)

M
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
15 16 17
.

12 Intake camshaft sprocket 1
13 Exhaust camshaft sprocket 1
14 Timing chain bolt 1
15 Dowel pin 1
16 Timing chain guide (intake side) 1
17 Timing chain 1
5-19
CAMSHAFTS
EAS30256
• Exhaust camshaft cap
REMOVING THE CAMSHAFTS ECA13720
1. Remove: NOTICE
• Timing mark accessing bolt “1” To prevent damage to the cylinder head,
• Crankshaft end cover “2” camshafts or camshaft caps, loosen the
camshaft cap bolts in stages and in a criss-
2 cross pattern, working from the outside in.
1 5. Remove:
• Intake camshaft “1”
• Exhaust camshaft “2”
TIP
To prevent the timing chain from falling into the
crankcase, fasten it with a wire “3”.
2. Align: 2
• Mark “a” on the generator rotor
(with the generator rotor cover mark “b”)
b. When piston #1 is at BTDC125° on the
compression stroke, align the BTDC125°
mark “a” on the generator rotor with the
generator rotor cover mark “b”.
TIP 1
BTDC125° on the compression stroke can be
found when the camshaft lobes are turned away
from each other.
3
6. Remove:
• Camshaft sprocket “1”
TIP
3. Remove: Use the camshaft wrench “2” and loosen the
• Timing chain tensioner “1” camshaft sprocket bolt.
• Timing chain tensioner gasket
Camshaft wrench
90890-04162
Camshaft wrench
YM-04162
4. Remove:
• Camshaft cap
• Intake camshaft cap
5-20
CAMSHAFTS
4. Measure:
• Camshaft-journal-to-camshaft-cap clearance
Out of specification → Measure the camshaft
1 journal diameter.
2
Camshaft-journal-to-camshaft-
cap clearance limit
0.080 mm (0.0032 in)
a. Install the camshaft into the cylinder head

(without the camshaft caps).
EAS30257 b. Position strip of Plastigauge® “1” onto the
CHECKING THE CAMSHAFTS camshaft journal as shown.
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re- 1
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions

Lobe height limit (Intake) G088947
35.590 mm (1.4012 in)
c. Install the dowel pins and camshaft caps.
Lobe height limit (Exhaust)
35.620 mm (1.4024 in) Refer to “INSTALLING THE CAM-
SHAFTS” on page 5-23.
TIP
Do not turn the camshaft when measuring the
camshaft journal-to-camshaft cap clearance
with the Plastigauge®.
d. Remove the camshaft caps, and then
measure the width of the Plastigauge®
“1”.
G088946
1
3. Measure:
• Camshaft runout
Camshaft runout limit

0.030 mm (0.0012 in)
G088948
5. Measure:
• Camshaft journal diameter “a”
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter

24.459–24.472 mm (0.9630–
0.9635 in)
5-21
CAMSHAFTS
a. Using the valve spring compressor “1”,

push and insert timing chain tensioner rod
“2” into the timing chain tensioner housing.
TIP
Push the timing chain tensioner rod in direction
“a”, and turn the timing chain tensioner body “3”
in direction “b” until the circlip fits into the groove.
G088949 a
1
EAS30258
CHECKING THE TIMING CHAIN AND

CAMSHAFT SPROCKET
1. Check: 2
• Timing chain
Damage/stiffness → Replace the timing
chain and camshaft and camshaft sprocket b 3
as a set.
2. Check:
• Camshaft sprocket
More than 1/4 tooth wear “a” → Replace the
camshaft sprockets and the timing chain as a 1
set.
1
a
b
b. Lock the timing chain tensioner rod by set-
ting the circlip “4” to groove “5” while push-
2
ing the timing chain tensioner rod.
G088950
a. 1/4 tooth 4
b. Correct
1. Timing chain
2. Camshaft sprocket
5
EAS30265
CHECKING THE TIMING CHAIN GUIDES

1. Check:
• Timing chain guide (intake side)
• Timing chain guide (top side) c. Push the timing chain tensioner rod “c”.
Damage/wear → Replace the defective d. If the circlip does not unlock even though
part(s). you press the timing chain tensioner rod in
the “c” direction, rotate the timing chain
EAS30266 tensioner rod clockwise.
CHECKING THE TIMING CHAIN TENSIONER e. Make sure that the timing chain tensioner
1. Check: rod comes out “d” of the timing chain ten-
• Timing chain tensioner sioner housing smoothly. If there is rough
Cracks/damage/rough movement → Re- movement, replace the timing chain ten-
place. sioner.
5-22
CAMSHAFTS
• Tighten the camshaft sprocket bolt with the

camshaft wrench “3”.
c
Camshaft wrench
90890-04162
Camshaft wrench
YM-04162
d
1 2
a
B7N
N
EAS30269
B7
INSTALLING THE CAMSHAFTS
1. Remove:
• Timing mark accessing bolt “1”
2 a
1
2. Align:
• Mark “a” on the generator rotor
(with the generator rotor cover mark “b”)
b. When piston #1 is at BTDC125°, align the 4. Install:
mark “a” on the generator rotor with the • Exhaust camshaft “1”
generator rotor cover mark “b”. • Intake camshaft “2”
TIP
b Make sure the punch mark “a” on each camshaft
faces up.
a
2 a
3. Install:
• Intake camshaft sprocket “1” a
• Exhaust camshaft sprocket “2” 1
Camshaft sprocket bolt 5. Install:

24 N·m (2.4 kgf·m, 18 lb·ft) • Camshaft cap
T.
R.
• Intake camshaft cap

TIP • Exhaust camshaft cap
• Install the camshaft projection “a” at the posi-
tion shown in the illustration.
5-23
CAMSHAFTS
TIP TIP
• Make sure each camshaft cap is installed in its Tighten the camshaft cap bolts in stage and in a
original place. Refer to the identification marks crisscross pattern, working from the inner caps
as follows: out.
“IL”: Intake left side camshaft cap mark ECA17430
“EL”: Exhaust left side camshaft cap mark NOTICE

• Make sure the arrow mark “a” on each cam- • Lubricate the camshaft cap bolts with the
shaft points toward the right side of the engine. engine oil.
• The camshaft cap bolts must be tightened
a evenly or damage to the cylinder head,
IL
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
1
EL
a
6. Tighten:
• Camshaft cap bolt “1”
Camshaft cap bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
1
TIP
8. Check:
Tighten the camshaft cap bolts in the tightening
• Camshaft punch mark “a”
sequence as shown.
Make sure the camshaft punch mark “a” on
ECA17430
the camshaft is aligned with the camshaft cap
NOTICE alignment mark “b”.
• Lubricate the camshaft cap bolts with the
engine oil. b
a
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result. b
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
a
8 5 9. Install:
2 3 • Timing chain tensioner gasket New
• Timing chain tensioner
4 1 a. Using the valve spring compressor “1”,
push and insert timing chain tensioner rod
6 7 “2” into the timing chain tensioner housing.
TIP
7. Tighten: Push the timing chain tensioner rod in direction
• Camshaft cap bolt “1” “a”, and turn the timing chain tensioner body “3”
in direction “b” until the circlip fits into the groove.
Camshaft cap bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
5-24
CAMSHAFTS
• Camshaft punch mark “c”

a Make sure the camshaft punch mark “c” on
1
the camshaft is aligned with the camshaft cap
alignment mark “d”.
Out of alignment → Adjust.
Refer to the installation steps above.
2
b
b 3
a
d
c
b. Lock the timing chain tensioner rod by set- d

ting the circlip “4” into groove “5” while
pushing the timing chain tensioner rod.
c
4
13.Measure:
• Valve clearance
5 Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
14.Install:
• Timing mark accessing bolt “1”
c. Install the timing chain tensioner to the cyl-
inder block. Timing mark accessing bolt
T.
R.
Always use a new gasket.

Timing chain tensioner bolt Crankshaft end cover
10 N·m (1.0 kgf·m, 7.4 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
T.
R.
R.
d. Turn the crankshaft clockwise several

times to release the timing chain tensioner 2
rod.
10.Turn: 1
• Crankshaft
(several turns counterclockwise)
11.Confirm the timing chain tension properly.
12.Check:
• Mark “a”
Make sure the mark “a” on the generator rotor
is aligned with the generator rotor cover mark
“b”.
5-25
CAMSHAFTS
15.Install:
• Timing chain guide (top side)
• Cylinder head cover gasket “1” New
• Cylinder head cover
Cylinder head cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Apply Three Bond No. 1541C® onto the mat- 1
ing surfaces of the cylinder head cover and cyl-
inder head cover gasket.
• After installing the cylinder head cover gasket
“1” to the cylinder head cover, cut off the “a”
section.
1 New
16.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.
5-26
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
(8) 1st 20 N・m (2.0 kgf・m, 15 lb・ft)
2nd 30 N・m (3.0 kgf・m, 22 lb・ft)
E
10 N・m (1.0 kgf・m, 7.4 lb・ft) 15 N・m (1.5 kgf・m, 11 lb・ft)
*3rd
Specified angle 120°
15 N・m (1.5 kgf・m, 11 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
New 3 New
4
2
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque and the
specified angle.

Engine Refer to “ENGINE REMOVAL” on page 5-9.
Intake camshaft Refer to “CAMSHAFTS” on page 5-17.
Exhaust camshaft Refer to “CAMSHAFTS” on page 5-17.
Timing chain Refer to “CAMSHAFTS” on page 5-17.
1 Coolant temperature sensor 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5 Timing chain guide (exhaust side) 1
5-27
CYLINDER HEAD
EAS30276
REMOVING THE CYLINDER HEAD Warpage limit

1. Remove: 0.10 mm (0.0039 in)
• Intake camshaft
• Exhaust camshaft
Refer to “REMOVING THE CAMSHAFTS”
on page 5-20.
2. Remove:
• Cylinder head bolt (M6) (×4)
TIP
• Loosen the bolts in the proper sequence as
shown. G088955
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove them. a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
Thickness gauge
5 11 9 7 90890-03268
1 4
Feeler gauge set
YU-26900-9
3 2 4
8 10 12 6 1 2
8
EAS30278
CHECKING THE TIMING CHAIN GUIDE

(EXHAUST SIDE)
1. Check:
• Timing chain guide (exhaust side) G088957
b. Measure the warpage.
EAS30277
c. If the limit is exceeded, resurface the cylin-
CHECKING THE CYLINDER HEAD der head as follows.
1. Eliminate: d. Place a 400–600 grit wet sandpaper on
• Combustion chamber carbon deposits the surface plate and resurface the cylin-
(with a rounded scraper) der head using a figure-eight sanding pat-
TIP tern.
Do not use a sharp instrument to avoid damag- TIP
ing or scratching: To ensure an even surface, rotate the cylinder
• Spark plug bore threads head several times.
• Valve seats
2. Check: EAS30282
• Cylinder head INSTALLING THE CYLINDER HEAD

Damage/scratches → Replace. 1. Install:
• Cylinder head water jacket • Timing chain guide (exhaust side) “1”
Mineral deposits/rust → Eliminate. • Cylinder head gasket “2” New
3. Measure: • Dowel pin “3”
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
5-28
CYLINDER HEAD
• Intake camshaft
3 2 New Refer to “INSTALLING THE CAMSHAFTS”
on page 5-23.
3
2. Install:
• Cylinder head
• Cylinder head bolt (M9) (×8) New
TIP
• Pass the timing chain through the timing chain
cavity.
• Lubricate the cylinder head bolt (M9) thread
and mating surface with engine oil.
3. Tighten:
• Cylinder head bolt “1”–“8”
• Cylinder head bolt “9”–“12”
Cylinder head bolt “1”–“8”

1st: 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
2nd: 30 N·m (3.0 kgf·m, 22 lb·ft)

*3rd: 15 N·m (1.5 kgf·m, 11 lb·ft)
Cylinder head bolt “9”–“12”
10 N·m (1.0 kgf·m, 7.4 lb·ft)
* Following the tightening order, loosen the

bolt one by one and then retighten it to the
specified torque and the specified angle.
TIP
Tighten the cylinder head bolts “1”–“8” in the
tightening sequence as shown and torque them
in 3 stages.
8 2 4 6
12 9
10 11 4
5 3 1 7
8
4. Install:
• Exhaust camshaft
5-29
VALVES AND VALVE SPRINGS
EAS20045

Removing the valves and valve springs
10
11 E
E
12
13 M M
14
M
New M
1
2
3
4
5
7 New
8
9
6

Cylinder head Refer to “CYLINDER HEAD” on page 5-27.
1 Intake valve lifter 6
2 Intake valve pad 6
3 Intake valve cotter 12
4 Intake valve spring retainer 6
5 Intake valve spring 6
6 Intake valve 6
7 Intake valve stem seal 6
8 Intake valve spring seat 6
9 Intake valve guide 6
10 Exhaust valve lifter 6
11 Exhaust valve pad 6
12 Exhaust valve cotter 12
13 Exhaust valve spring retainer 6
14 Exhaust valve spring 6
5-30
Removing the valves and valve springs
E
E
M M
M
New 16
M
17
New
18
15

15 Exhaust valve 6
16 Exhaust valve stem seal 6
17 Exhaust valve spring seat 6
18 Exhaust valve guide 6
5-31
EAS30283
REMOVING THE VALVES Valve spring compressor

The following procedure applies to all of the 90890-04200
valves and related components. Valve spring compressor
TIP YM-04019
Before removing the internal parts of the cylinder Valve spring compressor attach-
ment (ø23)
head (e.g., valves, valve springs, valve seats),
90890-04179
make sure the valves properly seal. Valve spring compressor adapt-
1. Remove: er (ø23)
• Valve lifter YM-04179
• Valve pad
TIP
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
• Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
G088959
Refer to “CHECKING THE VALVE SEATS”
on page 5-34. 4. Remove:
a. Pour a clean solvent “a” into the intake and • Valve spring retainer
exhaust ports. • Valve spring
b. Check that the valves properly seal. • Valve
TIP • Valve stem seal
• Valve spring seat
There should be no leakage at the valve seat “1”.
TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place.
EAS30284
CHECKING THE VALVES AND VALVE

GUIDES
valves and valve guides.
1. Measure:
G088958
• Valve-stem-to-valve-guide clearance
3. Remove: Out of specification → Replace the valve
• Valve cotter guide.
TIP • Valve-stem-to-valve-guide clearance =
Remove the valve cotters by compressing the Valve guide inside diameter “a” -
valve spring with the valve spring compressor Valve stem diameter “b”
“1” and the valve spring compressor attachment
“2”. Valve-stem-to-valve-guide clear-
ance limit (intake)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance limit (exhaust)
0.100 mm (0.0039 in)
5-32
G088960 G088963
a. Valve guide position

c. After installing the valve guide, bore the
valve guide with the valve guide reamer
“3” to obtain the proper valve-stem-to-
valve-guide clearance.
G088961
2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
G088964
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven. TIP
a. Remove the valve guide with the valve After replacing the valve guide, reface the valve
guide remover “1”. seat.
Valve guide remover (ø4.5)

90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø4.5)
90890-04117
Valve guide installer (4.5 mm)
YM-04117
G088962 Valve guide reamer (ø4.5)
90890-04118
b. Install the new valve guide with the valve Valve guide reamer (4.5 mm)
guide installer “2” and valve guide remov- YM-04118
er “1”.
3. Eliminate:
Valve guide position • Carbon deposits
13.3–13.7 mm (0.52–0.54 in)
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5-33
5. Measure: a. Apply blue layout fluid “b” onto the valve

• Valve stem runout face.
Out of specification → Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.020 mm (0.0008 in) G088967
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
d. Measure the valve seat contact width.
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
removed.
G088965
4. Lap:
EAS30285
CHECKING THE VALVE SEATS • Valve face

The following procedure applies to all of the • Valve seat
valves and valve seats. TIP
1. Eliminate: After replacing the cylinder head or replacing the
• Carbon deposits valve and valve guide, the valve seat and valve
(from the valve face and valve seat) face should be lapped.
2. Check:
a. Apply a coarse lapping compound “a” to
• Valve seat
the valve face.
Pitting/wear → Replace the cylinder head. ECA13790
3. Measure: NOTICE
• Valve seat contact width “a” Do not let the lapping compound enter the
Out of specification → Replace the cylinder gap between the valve stem and the valve
head. guide.
Valve seat contact width limit (in-
take)
1.6 mm (0.06 in)
Valve seat contact width limit (ex-
haust)
1.8 mm (0.07 in)
G088968
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and
valve seat are evenly polished, then clean
G088966 off all of the lapping compound.
5-34
TIP 1. Measure:
For the best lapping results, lightly tap the valve • Valve spring free length “a”
seat while rotating the valve back and forth be- Out of specification → Replace the valve
tween your hands. spring.
Free length limit (intake)

37.34 mm (1.47 in)
Free length limit (exhaust)
35.89 mm (1.41 in)
G088969
e. Apply a fine lapping compound to the

valve face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from G088971
the valve face and valve seat.
EAS30287
g. Apply blue layout fluid “b” onto the valve
CHECKING THE VALVE LIFTERS
face.
valve lifters.
1. Check:
• Valve lifter
Damage/scratches → Replace the valve lift-
ers and cylinder head.
EAS30288
INSTALLING THE VALVES

G088967 valves and related components.
h. Install the valve into the cylinder head. 1. Deburr:
i. Press the valve through the valve guide • Valve stem end
and onto the valve seat to make a clear (with an oil stone)
impression.
j. Measure the valve seat contact width “c”
again. If the valve seat width is out of spec-
ification, reface and lap the valve seat.
G088972
2. Lubricate:
• Valve stem
• Valve stem seal
G088970 (with the recommended lubricant)
EAS30286
CHECKING THE VALVE SPRINGS
Molybdenum disulfide oil
valve springs.
5-35
3. Install: 5. To secure the valve cotters onto the valve

• Valve spring seat “1” stem, lightly tap the valve tip with a soft-face
• Valve stem seal “2” New hammer.
ECA13800
• Valve “3” NOTICE
• Valve spring “4”
• Valve spring retainer “5” Hitting the valve tip with excessive force
(into the cylinder head) could damage the valve.
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
G088975
6. Lubricate:
• Valve pad
(with the recommended lubricant)
G088973
Molybdenum disulfide oil
b. Smaller pitch
• Valve lifter
4. Install: (with the recommended lubricant)
• Valve cotter
TIP Recommended lubricant
Engine oil
Install the valve cotters by compressing the
valve spring with the valve spring compressor 7. Install:
“1” and the valve spring compressor attachment • Valve pad
“2”. • Valve lifter
TIP
Valve spring compressor
• The valve lifter must move smoothly when ro-
90890-04200
Valve spring compressor tated with a finger.
YM-04019 • Each valve lifter and valve pad must be rein-
Valve spring compressor attach- stalled in its original position.
ment (ø23)
90890-04179
Valve spring compressor adapt-
er (ø23)
YM-04179
G088959
5-36
GENERATOR AND STARTER CLUTCH
EAS20140

Removing the stator coil, generator rotor and starter clutch
E
E
New
E New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
75 N・m (7.5 kgf・m, 55 lb・ft) (3) New
New
32 N・m (3.2 kgf・m, 24 lb・ft) LT
15 N・m (1.5 kgf・m, 11 lb・ft)
*
LT
(6)
(3)
12 N・m (1.2 kgf・m, 8.9 lb・ft)
LT
New
11 N・m (1.1 kgf・m, 8.1 lb・ft)
LT LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)
* YAMAHA bond No. 1215 (Three bond No. 1215®)

Water pump Refer to “WATER PUMP” on page 6-11.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-25.
5-37
E
E
New
E New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
75 N・m (7.5 kgf・m, 55 lb・ft) (3) New
6 New 1
32 N・m (3.2 kgf・m, 24 lb・ft) 2
LT
15 N・m (1.5 kgf・m, 11 lb・ft)
4
*
LT
(6)
5 (3)
12 N・m (1.2 kgf・m, 8.9 lb・ft)
LT
3 New
11 N・m (1.1 kgf・m, 8.1 lb・ft)
LT LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1 Stator coil coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Holder (fuel tank overflow hose) 3
4 Bracket 1
5 Generator cover 1
6 Generator cover gasket 1
5-38
E
15
14
13
E 7
11
12 7
10
E
E
New
E New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
18
T.R
.
75 N・m (7.5 kgf・m, 55 lb・ft) (3) New
32 N・m (3.2 kgf・m, 24 lb・ft) LT New
15 N・m (1.5 kgf・m, 11 lb・ft)
17
*
LT
(6) 16 8 (3)
12 N・m (1.2 kgf・m, 8.9 lb・ft)
LT
New 9
11 N・m (1.1 kgf・m, 8.1 lb・ft)
LT LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)

7 Dowel pin 2
8 Stator coil lead holder 1
Stator coil assembly (stator coil/crankshaft posi-
9 1
tion sensor)
10 Generator rotor 1
11 Starter clutch 1
12 Starter clutch gear 1
13 Woodruff key 1
14 Starter clutch idle gear shaft 1
15 Starter clutch idle gear 1
16 Crankshaft end cover 1
17 Timing mark accessing bolt 1
18 Water pump outlet pipe 1
5-39
EAS30867
REMOVING THE GENERATOR

1. Remove:
• Generator rotor bolt “1”
• Washer 1
TIP 2
While holding the generator rotor “2” with the
sheave holder “3”, loosen the generator rotor
bolt.
Sheave holder EAS30868
90890-01903 REMOVING THE STARTER CLUTCH

Primary clutch holder 1. Remove:
YS-01880-A • Starter clutch bolt
• Starter clutch
TIP
While holding the generator rotor “1” with the
sheave holder “2”, loosen the starter clutch
bolts.
3 Sheave holder
90890-01903
2 Primary clutch holder
1 YS-01880-A
2. Remove:
• Generator rotor “1” 1
(with the flywheel puller “2”) 2
• Woodruff key
ECA13880
NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller set center bolt and the crank-
shaft.
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
Heavy duty puller Burrs/chips/roughness/wear → Replace the
YU-33270-B defective part(s).
3. Check:
• Starter clutch gear contact surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
5-40
a. Install the starter clutch gear “1” onto the

generator rotor “2” and hold the generator 2
rotor. 3
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be re-
placed.
c. When turning the starter clutch gear coun-
terclockwise “B”, it should turn freely, oth-
erwise the starter clutch is faulty and must EAS30872
be replaced. INSTALLING THE GENERATOR
1 1. Install:
A • Woodruff key
• Generator rotor
• Washer New
• Generator rotor bolt
TIP
• Clean the tapered portion of the crankshaft and
B the generator rotor hub.
2
G088978 • When installing the generator rotor, make sure
EAS30871
the woodruff key is properly seated in the key-
INSTALLING THE STARTER CLUTCH way of the crankshaft.
1. Install: • Lubricate the washer with engine oil.
• 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)
T.
• Generator rotor bolt “1”

R.
LOCTITE®
Generator rotor bolt
T.
R.
• Install the starter clutch so that the side of the

starter clutch roller assembly with the arrow TIP
mark “a” is toward the generator rotor “2”. While holding the generator rotor “2” with the
• While holding the generator rotor with the sheave holder “3”, tighten the generator rotor
sheave holder “3”, tighten the starter clutch bolt.
bolts.
Sheave holder
Sheave holder 90890-01903
90890-01903 Primary clutch holder
Primary clutch holder YS-01880-A
YS-01880-A
3
1
2
2 1
5-41
3. Apply:
• Sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No. 1215

90890-85505
Three bond No. 1215®
G088980
4. Install:
• Generator cover gasket New
• Generator cover
Generator cover bolt “1”

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
LOCTITE®
Generator cover bolt “2”
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
5. Connect:
• Stator coil coupler
• Crankshaft position sensor coupler
TIP
To route the stator coil lead, refer to “CABLE
ROUTING” on page 2-13.
5-42
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
New
2
1
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Purge cut valve solenoid Refer to “FUEL TANK” on page 7-1.
Throttle bodies Refer to “THROTTLE BODIES” on page 7-6.
1 Starter motor lead 1 Disconnect.
2 Starter motor 1
3 Canister holder 1
5-43
ELECTRIC STARTER
Disassembling the starter motor

11 N•m (1.1 kgf•m, 8.1 lb•ft)
7
New
6
3
4
5 New
5 New
1 New
New
5 N•m (0.5 kgf•m, 3.7 lb•ft)

1 O-ring 1
2 Starter motor front cover 1
3 Starter motor yoke 1
4 Armature assembly 1
5 Gasket 2
6 Brush holder set 1
7 Starter motor rear cover 1
5-44
ELECTRIC STARTER
EAS30325
CHECKING THE STARTER MOTOR Brush overall length limit

1. Check: 6.5 mm (0.26 in)
• Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Mica undercut “a”
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth)

0.70 mm (0.03 in)
G088989
TIP 5. Check:
The mica of the commutator must be undercut to • Gear teeth
ensure proper operation of the commutator. Damage/wear → Replace the starter motor
assembly.
6. Check:
• Bearing
• Oil seal
Damage/wear → Replace the starter motor
assembly.
EAS30326
ASSEMBLING THE STARTER MOTOR

1. Install:
G088986
• Brush holder set
3. Check: • Insulator “1”
• Armature assembly TIP
a. Connect the digital circuit tester and check Install the insulator as shown in the illustration.
the continuity.
Digital circuit tester (CD732) 1

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
b. If there is no continuity, replace the starter

motor.
2. Install:
• Starter motor rear cover “1”
• Starter motor yoke “2”
• Starter motor front cover “3”
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front and
rear cover.
4. Measure:
• Brush length “a”
Out of specification → Replace the brush
holder set.
5-45
ELECTRIC STARTER
b a b
1 2 3
EAS30327
INSTALLING THE STARTER MOTOR

1. Install:
• Canister holder
• Starter motor
• Starter motor bolt
TIP
Tighten the starter motor bolts in the tightening
sequence as shown.
Starter motor bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
2. Connect:
• Starter motor lead
Starter motor lead nut

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
5-46
CLUTCH
EAS20055
CLUTCH
Removing the clutch cover
1
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
5
.
5
New
6 4 New
(8) 3
2 LS
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Drain.
page 3-25.
2 Cover 1
3 Clutch cover 1
4 Clutch cover gasket 1
5 Dowel pin 2
6 Oil filler cap 1
5-47
CLUTCH
Removing the pull lever shaft
4 New
8
7
New 6
5
E
LS
3
1 New 2

1 Circlip 1
2 Pull lever 1
3 Pull lever spring 1
4 Circlip 1
5 Pull lever shaft 1
6 Oil seal 1
7 Bearing 1
8 Bearing 1
5-48
CLUTCH
Removing the clutch
125 N•m (12.5 kgf•m, 92 lb•ft)
11 10
E
New
11
6 10 12
14 13
6
4 5
E 3
2 7
10 N•m (1.0 kgf•m, 7.4 lb•ft)
1

Oil pump driven sprocket Refer to “OIL PUMP” on page 5-59.
1 Pressure plate 1 1
2 Clutch spring 3
3 Pressure plate 2 1
4 Pull rod 1
5 Bearing 1
6 Friction plate 2 3 Inside diameter: 126 mm (4.96 in)
7 Clutch plate 1 1 Inside diameter: 116 mm (4.57 in)
8 Clutch plate 2 7 Inside diameter: 105 mm (4.13 in)
9 Friction plate 1 6 Inside diameter: 119 mm (4.69 in)
10 Clutch damper spring 1
11 Clutch damper spring seat 1
12 Clutch boss nut 1
13 Conical spring washer 1
14 Washer 1
5-49
CLUTCH
Removing the clutch
125 N•m (12.5 kgf•m, 92 lb•ft)
22
21
20
19 E
18
17
16
E 15
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)

15 Clutch boss 1
16 Thrust plate 1
17 Clutch housing 1
18 Oil pump drive chain 1
19 Bearing 1
20 Spacer 1
21 Thrust plate 1
22 Thrust plate 1
5-50
CLUTCH
EAS30346
4. Remove:
REMOVING THE CLUTCH
• Friction plate 2 “1”
1. Remove:
• Cover “1”
• Clutch cover “2”
• Gasket
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
1
1 5. Remove:
• Clutch plate 1 “1”
• Clutch plate 2
• Friction plate 1
• Clutch damper spring
• Clutch damper spring seat
2. Remove:
• Oil pump driven sprocket “1”
Refer to “OIL PUMP” on page 5-59.
6. Straighten the clutch boss nut rib “a”.
1
3. Remove:
• Clutch spring bolt “1”
• Pressure plate 1 “2”
• Clutch spring G088992
• Pressure plate 2 “3”
• Pull rod “4” 7. Loosen:
• Clutch boss nut “1”
4 TIP
While holding the clutch boss “2” with the univer-
1
sal clutch holder “3”, loosen the clutch boss nut.
Clutch holder
3 1 90890-04199
Universal clutch holder
2 YM-91042
5-51
CLUTCH
3 1
2
G088993
8. Remove:
A. Friction plate 1
• Clutch boss nut
B. Friction plate 2
• Conical spring washer
• Washer EAS30349
• Clutch boss CHECKING THE CLUTCH PLATES

• Thrust plate The following procedure applies to all of the
• Clutch housing clutch plates.
• Oil pump drive chain 1. Check:
• Clutch plate 1, 2
Damage → Replace the clutch plates as a
EAS30348
CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric- set.
tion plates. 2. Measure:
1. Check: • Clutch plate 1, 2 thickness
• Friction plate 1, 2 (with a surface plate and thickness gauge)
Damage/wear → Replace the friction plates Out of specification → Replace the clutch
as a set. plates as a set.
2. Measure: Thickness gauge
• Friction plate 1, 2 thickness 90890-03268
Out of specification → Replace the friction Feeler gauge set
plates as a set. YU-26900-9
TIP
Measure the friction plate at four places. Clutch plate 1 thickness
2.18–2.42 mm (0.086–0.095 in)
Friction plate 1 thickness Warpage limit
2.92–3.08 mm (0.115–0.121 in) 0.10 mm (0.004 in)
Wear limit Clutch plate 2 thickness
2.82 mm (0.111 in) 1.90–2.10 mm (0.075–0.083 in)
Friction plate 2 thickness Warpage limit
2.92–3.08 mm (0.115–0.121 in) 0.10 mm (0.004 in)
Wear limit
2.82 mm (0.111 in) 3. Measure:
• Assembly width “a” of the friction plates and
clutch plates
Out of specification → Adjust.
Assembly width
42.7–43.5 mm (1.68–1.71 in)
TIP
• Perform the thickness measurement without
applying the oil.
• This step should be performed only if the fric-
tion plates and clutch plates were replaced.
5-52
CLUTCH
• To measure the total width of the friction plates 1. Check:

and clutch plates, combine 9 friction plates and • Clutch spring
8 clutch plates as shown. Damage → Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length
a Out of specification → Replace the clutch
springs as a set.
a Clutch spring free length limit
42.53 mm (1.67 in)
EAS30352
CHECKING THE CLUTCH HOUSING

a. Assembly width adjusted by clutch plate 2 1. Check:
“1” and “2”. • Clutch housing dogs
b. Select the clutch plate 2 from the following Damage/pitting/wear → Deburr the clutch
table. housing dogs or replace the clutch housing.
Clutch plate 2 “1” TIP
Pitting on the clutch housing dogs will cause er-
BR9-16324-00 1.6 mm (0.063 in)
ratic clutch operation.
5VY-16325-00 2.0 mm (0.079 in) STD
4B1-16325-00 2.3 mm (0.091 in)
Clutch plate 2 “2”

BR9-16324-00 1.6 mm (0.063 in)
5VY-16325-00 2.0 mm (0.079 in) STD
4B1-16325-00 2.3 mm (0.091 in)
TIP
G088994
When adjusting the clutch assembly width [by
replacing the clutch plate(s)], be sure to replace 2. Check:
the clutch plate 2 “1” first. • Oil pump drive sprocket “1”
After replacing the clutch plate 2 “1”, if specifica- Cracks/damage/wear → Replace the oil
tions cannot be met, replace the clutch plate 2 pump drive chain and clutch housing as a set.
“2”.
1
2 1 3. Check:
• Bearing
EAS30351 Damage/wear → Replace the bearing and
CHECKING THE CLUTCH SPRINGS clutch housing.
clutch springs.
5-53
CLUTCH
EAS30353
2. Check:
CHECKING THE CLUTCH BOSS
• Pull rod bearing
1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the clutch EAS30363
boss. INSTALLING THE CLUTCH

TIP
1. Install:
• Oil pump drive chain “1”
Pitting on the clutch boss splines will cause er-
• Clutch housing “2”
ratic clutch operation.
TIP
Install the oil pump drive chain onto the oil pump
drive sprocket “a”.
G088995
EAS30354
CHECKING THE PRESSURE PLATE a 1

1. Check:
• Pressure plate 1 2. Install:
• Pressure plate 2 • Thrust plate
Cracks/damage → Replace. • Clutch boss “1”
• Bearing • Washer
Damage/wear → Replace. • Conical spring washer “2”
EAS30356
• Clutch boss nut “3” New
CHECKING THE PRIMARY DRIVE GEAR
Clutch boss nut
1. Check:
125 N·m (12.5 kgf·m, 92 lb·ft)
T.
• Primary drive gear

R.
Damage/wear → Replace the crankshaft and

TIP
clutch housing as a set.
Excessive noise during operation → Replace • Install the conical spring washer on the main
the crankshaft and clutch housing as a set. axle with the “OUT” mark “a” facing away from
the vehicle.
EAS30357 • While holding the clutch boss “1” with the uni-
CHECKING THE PRIMARY DRIVEN GEAR versal clutch holder “4”, tighten the clutch boss
1. Check: nut.
• Primary driven gear • Stake the clutch boss nut at cutouts “b” in the
Damage/wear → Replace the clutch housing main axle.
and crankshaft as a set.
Excessive noise during operation → Replace
Clutch holder
the clutch housing and crankshaft as a set.
90890-04199
EAS30358 Universal clutch holder
CHECKING THE PULL LEVER SHAFT AND YM-91042
PULL ROD
1. Check:
• Pull lever shaft pinion gear teeth
• Pull rod teeth
Damage/wear → Replace the pull rod and
pull lever shaft as a set.
5-54
CLUTCH
3 New Clutch spring bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
4 1
2 Oil pump driven sprocket bolt

15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
LOCTITE®
a TIP
• Tighten the clutch spring bolts in stages and in
a crisscross pattern.
b • Apply lithium-soap-based grease onto the pull
rod.
• Position the pull rod so that the teeth “a” face
towards the hole “b”. Then, install the clutch
cover.
3. Install: 1
• Clutch damper spring seat
• Clutch damper spring
• Friction plate 2 1
• Clutch plate 2
• Friction plate 1
• Clutch plate 1
TIP
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Install the last friction plate “1” offset from the
other friction plates “2”, making sure to align a
projection on the friction plate with the punch a
mark “a” on the clutch housing.
2
b
5. Install:
2
• Dowel pin
• Clutch cover gasket New
a • Clutch cover
• Cover
1
Clutch cover bolt
4. Install: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
• Pull rod
R.
• Pressure plate 2 TIP

• Clutch spring
• Apply engine oil onto the bearing.
• Pressure plate 1
• Tighten the clutch cover bolts in stages and in
• Clutch spring bolt “1”
a crisscross pattern.
5-55
CLUTCH
6. Install: 8. Adjust:
• Pull lever • Clutch lever free play
TIP Refer to “ADJUSTING THE CLUTCH LEVER
• Install the pull lever with the “O” mark facing to- FREE PLAY” on page 3-12.
ward lower side.
Clutch lever free play
• When installing the pull lever, push the pull le- 5.0–10.0 mm (0.20–0.39 in)
ver and check that the punch mark “a” on the
pull lever aligns with the mark “b” on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.
a
b
7. Connect:
• Clutch cable “1”
TIP
• For the clutch cable “1”, turn the nut “2” in fully
and then adjust the length “a” by using the nut
“3” so that the cable length is 47.1–54.8 mm
(1.85–2.16 in).
• Measure the length while keeping the measur-
ing surface “b” parallel.
• After installing the clutch cable, bend the pro-
jection “c” on the pull lever.
c
a
2
3
b
1
5-56
SHIFT SHAFT
EAS20057
SHIFT SHAFT
Removing the shift shaft and stopper lever
E
13
12 New
2
LS 1 New
LT
LT
22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.
8 3
New 11
4
5
6
7
E 9 E
10
E

Clutch assembly Refer to “CLUTCH” on page 5-47.
Shift arm Refer to “CHAIN DRIVE” on page 4-130.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Circlip 1
6 Washer 1
7 Stopper lever 1
8 Stopper lever spring 1
9 Collar 1
10 Shift shaft spring 1
11 Shift shaft spring stopper 1
12 Oil seal 1
13 Bearing 1
5-57
SHIFT SHAFT
EAS30377
CHECKING THE SHIFT SHAFT TIP

1. Check: Lubricate the oil seal lips with lithium-soap-
• Shift shaft based grease.
Bends/damage/wear → Replace.
• Shift shaft spring
• Collar 2
EAS30378
CHECKING THE STOPPER LEVER

1. Check:
• Stopper lever
Bends/damage → Replace. 1
Roller turns roughly → Replace the stopper
lever.
EAS30381
INSTALLING THE SHIFT SHAFT

1. Install:
• Shift shaft spring stopper “1”
• Shift shaft assembly
• Stopper lever spring “2”
Shift shaft spring stopper

22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.
LOCTITE®
TIP
• Hook the end of the shift shaft spring “3” onto
the shift shaft spring stopper “1”.
• Hook the ends of the stopper lever spring “2”
onto the stopper lever “4” and the crankcase
boss “5”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
3
1
4
5
2. Install:
• Bearing
• Oil seal New
• Washer “1”
• Circlip “2” New
5-58
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump
LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
1
T
LL
T
15 N•m (1.5 kgf•m, 11 lb•ft)

T.R
.
LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.

Clutch cover Refer to “CLUTCH” on page 5-47.
1 Oil pump driven sprocket 1
2 Oil pump assembly 1
5-59
OIL PUMP
Disassembling the oil pump
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.
6
1
3
8
2
4
5
9
E
9

1 Oil pump cover 1
2 Oil pump shaft 1
3 Pin 1
4 Oil pump inner rotor 1
5 Oil pump outer rotor 1
6 Washer 1
7 Spring 1
8 Relief valve 1
9 Dowel pin 2
5-60
OIL PUMP
EAS30336
CHECKING THE SPROCKET AND CHAIN

1. Check:
• Oil pump drive sprocket
Refer to “CHECKING THE CLUTCH HOUS- 1
ING” on page 5-53.
2. Check:
• Oil pump drive chain 2
Damage/stiffness → Replace the oil pump
drive chain and oil pump drive sprocket
(clutch housing) as a set.
EAS30342
EAS30337 ASSEMBLING THE OIL PUMP

CHECKING THE OIL PUMP 1. Lubricate:
1. Check: • Inner rotor
• Oil pump driven sprocket • Outer rotor
Cracks/damage/wear → Replace the oil • Oil pump shaft
pump drive chain and oil pump driven sprock-
et as a set. Recommended lubricant
• Oil pump housing Engine oil
• Oil pump cover
• Oil pump shaft 2. Install:
• Oil pump inner rotor • Outer rotor “1”
• Oil pump outer rotor • Inner rotor “2”
Cracks/damage/wear → Replace the oil • Pin “3”
pump assembly. • Oil pump cover “4”
2. Check: • Oil pump cover screw
• Oil pump operation Oil pump cover screw
Rough movement → Replace the oil pump 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
assembly.
TIP
Align the pin “3” in the oil pump shaft with the
groove in the inner rotor “2”.
2
1
G088997 4
EAS30338
CHECKING THE RELIEF VALVE

1. Check:
• Relief valve “1”
• Spring “2” 3. Check:
Damage/wear → Replace the oil pump as- • Oil pump operation
sembly. Refer to “CHECKING THE OIL PUMP” on
page 5-61.
EAS30343
INSTALLING THE OIL PUMP

1. Install:
• Oil pump “1”
• Oil pump bolt “2”
5-61
OIL PUMP
Oil pump bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Oil pump driven sprocket bolt

15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
LOCTITE®
ECA20940
NOTICE
After installing the oil pump drive chain and
driven sprocket, make sure the oil pump
turns smoothly.
TIP
• 1RC mark of the oil pump driven sprocket is in-
stalled at oil pump side.
• Install the oil pump drive chain onto the oil
pump driven sprocket.
2
3
2 1
5-62
OIL PAN
EAS20177
OIL PAN
Removing the oil pan
43 N•m (4.3 kgf•m, 32 lb•ft)

T.R
.
New
New 2
New
(15)
LT
LT
LT
3
13 N•m (1.3 kgf•m, 9.6 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
T.R
.

Muffler assembly Refer to “ENGINE REMOVAL” on page 5-9.
Drain.
page 3-25.
1 Oil pan 1
2 Oil pan gasket 1
3 Oil strainer 1
5-63
OIL PAN
EAS31068
REMOVING THE OIL PAN

1. Remove:
• Oil pan
• Oil pan gasket
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
EAS31069
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS31070
INSTALLING THE OIL PAN

1. Install:
• Oil pan gasket New
• Oil pan
Oil pan bolt

13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
LOCTITE®
TIP
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
2. Install:
• Gasket New
• Engine oil drain bolt
Engine oil drain bolt

43 N·m (4.3 kgf·m, 32 lb·ft)
T.
R.
5-64
CRANKCASE
EAS20059
CRANKCASE
Separating the crankcase
T.R
10 N•m (1.0 kgf•m, 7.4 lb•ft) 1st 25 N•m (2.5 kgf•m, 18 lb•ft)
.
New 20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
*2nd
.
1st 25 N•m (2.5 kgf•m, 18 lb•ft) Specified angle 60°
16 N•m (1.6 kgf•m, 12 lb•ft) New (2)
T.R
*2nd
.
22 N•m (2.2 kgf•m, 16 lb•ft)

Specified angle 60° (4)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) E 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft) (6) New

T.R
.
E E E 13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
(2)
(2) **
E
LS
(12)
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
E
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
LS
LS
E

T.R
.
LT
LT
New
LT
LT
T
LL
T 12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
T.R
T.R
.
specified angle.
** YAMAHA Bond No. 1215B®

Engine Refer to “ENGINE REMOVAL” on page 5-9.
Cylinder head Refer to “CYLINDER HEAD” on page 5-27.
Water pump Refer to “WATER PUMP” on page 6-11.
Oil cooler Refer to “OIL COOLER” on page 6-7.
Water jacket joint Refer to “OIL COOLER” on page 6-7.
Thermostat assembly Refer to “THERMOSTAT” on page 6-9.
Refer to “GENERATOR AND STARTER
Starter clutch CLUTCH” on page 5-37.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-43.
Clutch housing Refer to “CLUTCH” on page 5-47.
Oil strainer Refer to “OIL PAN” on page 5-63.
5-65
CRANKCASE
Separating the crankcase

10 N•m (1.0 kgf•m, 7.4 lb•ft) 1st 25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
T.R
*2nd
.
1st 25 N•m (2.5 kgf•m, 18 lb•ft) Specified angle 60°
16 N•m (1.6 kgf•m, 12 lb•ft) New (2)
T.R
*2nd
.
22 N•m (2.2 kgf•m, 16 lb•ft)

Specified angle 60° (4)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) E 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft) (6) New 3

T.R
.
4
E E E 13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
(2)
(2) **
E
LS
(12)
8 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
2 E
9 9
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
9
1
LS
5 LS
E

T.R
.
7
LT
LT
New
LT
LT
6 T
LL
T 12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
T.R
T.R
.
specified angle.
** YAMAHA Bond No. 1215B®

1 Oil filter cartridge 1
2 Oil filter cartridge union bolt 1
3 Oil pressure switch 1
4 Oil pressure switch joint 1
5 Gear position sensor 1
6 Neutral switch 1
7 Clutch cable holder 1
8 Lower crankcase 1
9 Dowel pin 3
5-66
CRANKCASE
EAS30389 EAS30390
DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE

1. Place the engine upside down. 1. Thoroughly wash the crankcase halves in a
2. Remove: mild solvent.
• Crankcase bolt (×31) 2. Thoroughly clean all the gasket surfaces and
TIP crankcase mating surfaces.
• Loosen each bolt 1/4 of a turn at a time, in stag- 3. Check:
es and in a crisscross pattern. After all of the • Crankcase
bolts are fully loosened, remove them. Cracks/damage → Replace.
• Loosen the bolts in the proper sequence as • Oil delivery passages
shown. Obstruction → Blow out with compressed air.
• The numbers embossed on the crankcase in- EAS30397
dicate the crankcase tightening sequence. ASSEMBLING THE CRANKCASE

1. Lubricate:
• Crankshaft journal bearing inner surface
13 12 7
11 8 Recommended lubricant
10 9
17 Engine oil
23 20
22 21 2. Apply:
25 31 29 27 • Sealant
(onto the crankcase mating surfaces)
14 24 28 30 26
Yamaha bond No. 1215
90890-85505
19 6 16 Three bond No. 1215®
15
2 TIP
• Do not allow any sealant to come into contact
1 3 4 5 18
with the oil gallery or crankshaft journal bear-
ings, or balancer shaft journal bearings.
• Make sure that the sealant does not get into
31 the groove “a” in the crankcase.
3. Remove:
• Lower crankcase
ECA13900
NOTICE
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
4. Remove:
• Dowel pin
5. Remove:
• Crankshaft journal lower bearing
• Balancer shaft journal bearing
(from the lower crankcase)
TIP
Identify the position of each part very carefully so
a
5-67
CRANKCASE
3. Install:
• Dowel pin
4. Set the shift drum assembly and transmission
19 20 25
gears in the neutral position. 21
5. Install: 22 23 24
15 9 12
• Lower crankcase “1”
(onto the upper crankcase “2”) 10 11
ECA13980
NOTICE 7 1 3 5
Before tightening the crankcase bolts, make 18 8 4 2 6
sure the transmission gears shift correctly
when the shift drum assembly is turned by
26 16
hand. 17
13
30
1
31 29 28 27 14
2
31
7. Tighten:
• Crankcase bolt “1”–“8”
Crankcase bolts “1”–“6”

6. Install: 1st: 25 N·m (2.5 kgf·m, 18 lb·ft)
T.
R.
• Crankcase bolt (×31) *2nd: 16 N·m (1.6 kgf·m, 12 lb·ft)

TIP Specified angle 60°
• Lubricate the bolts “1”–“8” thread, mating sur- Crankcase bolts “7”–“8”
faces and washers with engine oil. 1st: 25 N·m (2.5 kgf·m, 18 lb·ft)
• Lubricate the bolts “9”–“12” thread, mating sur- *2nd: 20 N·m (2.0 kgf·m, 15 lb·ft)
faces and O-rings with engine oil. Specified angle 60°
• Lubricate the bolts “13”–“31” thread and mat-
* Following the tightening order, loosen the
ing surfaces with engine oil.
bolt one by one and then retighten it to the
• M9 × 100 mm (3.94 in) bolt with washer: “7”, specified torque and the specified angle.
EWA16610
“8” New WARNING
• M9 × 85 mm (3.35 in) bolt with washer: “1”–
If the bolt is tightened more than the speci-
“6” New fied angle, do not loosen the bolt and then re-
• M8 × 78 mm (3.07 in) bolt with new O-ring: tighten it. Instead, replace the bolt with a new
“9”–“12” one and perform the procedure again.
• M8 × 60 mm (2.36 in) bolt: “13”, “14”
ECA20890
• M6 × 85 mm (3.35 in) bolt: “18” NOTICE
• M6 × 65 mm (2.56 in) bolt: “15”, “16”
• M6 × 65 mm (2.56 in) bolt: “26” Do not use a torque wrench to tighten the
• M6 × 50 mm (1.97 in) bolt: “17”, “19”–“21”, bolt to the specified angle.
“23”–“25”, “27”–“31” TIP
• M6 × 40 mm (1.57 in) bolt: “22” Tighten the bolts in the tightening sequence cast
on the crankcase.
5-68
CRANKCASE
EAS31071
INSTALLING THE OIL PRESSURE SWITCH

1. Install:
• Oil pressure switch “1”
• Oil pressure switch lead “2”
Oil pressure switch

7 1 3 5 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
Oil pressure switch lead bolt
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
8 4 2 6 TIP
• Apply Three Bond No. 1215B® to the threads
“a” of the oil pressure switch. However, do not
apply Three Bond No. 1215B® to the portion
“b” of the oil pressure switch.
• Install the oil pressure switch lead so that it is
routed within the range shown in the illustra-
tion.
8
8. Tighten:
• Crankcase bolt “9”–“31” 1
22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.

24 N·m (2.4 kgf·m, 18 lb·ft) a
b
10 N·m (1.0 kgf·m, 7.4 lb·ft)
TIP 2
Tighten the bolts in the tightening sequence cast
on the crankcase.
26°
19 20 25
21 1
22 23 24
15 9 12
10 11
EAS31658
INSTALLING THE GEAR POSITION SENSOR

ECA22630
18 NOTICE
To prevent damage to the gear position sen-
26 16 sor, keep magnets (including any pickup tool
17 13 with a magnet, magnetized screwdrivers,
etc.) away from the gear position sensor.
30
1. Install:
31 29 28 27 14
• O-ring New
• Gear position sensor “1”
23
5-69
CRANKCASE
Gear position sensor bolt

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
LOCTITE®
TIP
• Lubricate the O-ring with lithium-soap-based
grease.
• Fit the end “a” of the shift drum assembly into
the opening “b” in the gear position sensor “1”.
a
b
5-70
CONNECTING RODS AND PISTONS
EAS20132

Removing the connecting rods and pistons
New 1st 20 N•m (2.0 kgf•m, 15 lb•ft)
2nd Specified angle 180˚
M 1
6 New
E 3
5
4
New 3 10
9
8

Lower crankcase Refer to “CRANKCASE” on page 5-65.
1 Connecting rod cap 3
2 Big end lower bearing 3
3 Piston pin clip 6
4 Piston pin 3
5 Piston 3
6 Connecting rod 3
7 Big end upper bearing 3
8 Top ring 3
9 2nd ring 3
10 Oil ring 3
5-71
EAS30745
REMOVING THE CONNECTING RODS AND TIP

PISTONS When removing a piston ring, open the end gap
The following procedure applies to all of the con- with your fingers and lift the other side of the ring
necting rods and pistons. over the piston crown.
1. Remove:
• Connecting rod cap
• Connecting rod
• Big end bearing
TIP
• Identify the position of each big end bearing so
• After removing the connecting rods and con-
necting rod caps, care should be taken not to
G088999
damage the mating surfaces of the connecting
rods and connecting rod caps. EAS30747
CHECKING THE CYLINDER AND PISTON

2. Remove: 1. Check:
• Piston pin clip • Piston wall
• Piston pin “1” • Cylinder wall
• Piston “2” Vertical scratches → Replace the cylinder,
ECA13810
NOTICE and replace the piston and piston rings as a

set.
Do not use a hammer to drive the piston pin
2. Measure:
out.
• Piston-to-cylinder clearance
TIP a. Measure cylinder bore “C” with the cylin-
• For reference during installation, put identifica- der bore gauge.
tion marks on the piston crown. TIP
• Before removing the piston pin, deburr the pis- Measure cylinder bore “C” by taking side-to-side
ton pin clip groove and the piston pin bore ar- and front-to-back measurements of the cylinder.
ea. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the Bore
piston pin puller set “3”. 78.000–78.010 mm (3.0709–
3.0713 in)
Piston pin puller set Wear limit
90890-01304 78.060 mm (3.0732 in)
Piston pin puller
YU-01304 “C” = maximum of D1, D2, D3, D4, D5, D6
2 1
G088998 3 G089000
3. Remove: b. If out of specification, replace the cylinder,

• Top ring and replace the piston and piston rings as
• 2nd ring a set.
• Oil ring
5-72
c. Measure piston skirt diameter “b” with the

micrometer.
Piston
Diameter
77.975–77.990 mm (3.0699–
3.0705 in)
G089002
2. Install:
a • Piston ring
(into the cylinder)
b
TIP
Use the piston crown to level the piston ring near
bottom of cylinder, where cylinder wear is low-
G089001
est.
a. 9.0 mm (0.35 in) from the bottom edge of the 3. Measure:
piston
• Piston ring end gap
d. If out of specification, replace the piston Out of specification → Replace the piston
and piston rings as a set. ring.
e. Calculate the piston-to-cylinder clearance TIP
with the following formula. The oil ring expander spacer’s end gap cannot
Piston-to-cylinder clearance = Cylinder bore “C” - be measured. If the oil ring rail’s gap is exces-
Piston skirt diameter “b” sive, replace all three piston rings.
Piston-to-cylinder clearance Top ring

0.010–0.035 mm (0.0004–0.0014 End gap limit
in) 0.50 mm (0.0197 in)
2nd ring
f. If out of specification, replace the cylinder, End gap limit
and replace the piston and piston rings as 1.15 mm (0.0453 in)
a set.
EAS30748
CHECKING THE PISTON RINGS a

1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
b
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston G089003
ring grooves and piston rings. a. Bottom of cylinder

b. Upper of cylinder
Top ring
EAS30749
Side clearance limit
CHECKING THE PISTON PIN
0.115 mm (0.0045 in)
2nd ring The following procedure applies to all of the pis-
Side clearance limit ton pins.
0.115 mm (0.0045 in)
5-73
1. Check: ECA13930
• Piston pin NOTICE

Blue discoloration/grooves → Replace the Do not interchange the big end bearings and
piston pin and then check the lubrication sys- connecting rods. To obtain the correct
tem. crankshaft-pin-to-big-end-bearing clear-
2. Measure: ance and prevent engine damage, the big
• Piston pin outside diameter “a” end bearings must be installed in their origi-
Out of specification → Replace the piston pin. nal positions.
a. Clean the big end bearings, crankshaft
Piston pin outside diameter limit
16.970 mm (0.6681 in) pins, and the inside of the connecting rods
halves.
b. Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap with
the connecting rod big end metal installer
“1”.
TIP
• From the 3 types, choose the connecting rod
big end metal installer “1” that fits exactly, and
install it to the connecting rod and connecting
G089004
rod cap as shown in the illustration.
3. Measure: • Align the projections “a” on the big end bear-
• Piston pin bore inside diameter “b” ings with the notches “b” in the connecting rod
Out of specification → Replace the piston. and connecting rod cap.
• Push the big end bearing “2” down and install it
Piston pin bore inside diameter to the connecting rod and connecting rod cap.
limit
17.043 mm (0.6710 in)
Connecting rod big end bearing
installer
90890-04193
installer
YM-04193
1
b
G089005
EAS30750
CHECKING THE CONNECTING RODS

1. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
1
Out of specification → Replace the big end
bearings.
Oil clearance
0.027–0.051 mm (0.0011–0.0020
in)

connecting rods.
5-74
a b
b
1
a
TIP
Install by carrying out the following procedures in
order to assemble in the most suitable condition.
e. Tighten the connecting rod bolt while
checking that the sections shown “a” and
1 “b” are flush with each other by touching
the surface.
2
Connecting rod bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
c. Put a piece of Plastigauge® “1” on the

crankshaft pin. TIP
To install the big end bearing, care should be
taken not to install it at an angle and the position
1
should not be out of alignment.
a
b
G089008
d. Assemble the connecting rod halves.

ECA18390
NOTICE
Tighten the connecting rod bolts using the
plastic-region tightening angle method. Al- a. Side machined face
ways install new bolts. b. Thrusting faces
TIP f. Loosen the connecting rod bolt, remove

• Clean the connecting rod bolts and lubricate the connecting rod and connecting rod
the bolt threads and seats with molybdenum cap and install these parts to the crank-
disulfide oil. shaft with the big end bearing kept in the
• Make sure that the projection “a” on the con- current condition.
necting rod cap faces the same direction as the TIP
“Y” mark “b” on the connecting rod. • Do not move the connecting rod or crankshaft
• After installing the big end bearing, assemble until the clearance measurement has been
the connecting rod and connecting rod cap completed.
without installing them onto the crankshaft. • Make sure that the projection “a” on the con-
necting rod cap faces the same direction as the
“Y” mark “b” on the connecting rod.
5-75
• Make sure the “Y” marks “b” on the connecting EWA16610
rods face towards the left side of the crank- WARNING

shaft. If the bolt is tightened more than the speci-
fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
b one and perform the procedure again.
ECA20890
NOTICE
Do not use a torque wrench to tighten the
bolt to the specified angle.
a j. After the installation, check that the sec-
tion shown “a” is flush with each other by
touching the surface.
g. Tighten the connecting rod bolts with a
torque wrench.
Connecting rod bolt (1st)

20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
h. Put a mark “1” on the corner of the con-

necting rod bolt “2” and the connecting rod
cap “3”. a
k. Remove the connecting rod and big end

bearings.
l. Measure the compressed Plastigauge®
width “e” on the crankshaft pin. If the
crankshaft-pin-to-big-end-bearing clear-
ance is out of specification, select replace-
ment big end bearings.
i. Tighten the connecting rod bolts further to

reach the specified angle 180°.
Connecting rod bolt (final)

T.
e
R.
G089010
2. Select:
• Big end bearing (P1–P3)
TIP
• The numbers “A” stamped into the crankshaft
web and the numbers “1” on the connecting
180˚ rods are used to determine the replacement
big end bearings sizes.
• “P1”–“P3” refer to the bearings shown in the
crankshaft illustration.
5-76
For example, if the connecting rod “P1” and 1. Install:

the crankshaft web “P1” numbers are 5 and 2 • Big end bearing
respectively, then the bearing size for “P1” is: • Connecting rod cap
(onto the connecting rod)
“P1” (connecting rod) - “P1” (crankshaft)
TIP
=5-2
= 3 (brown) • Be sure to reinstall each big end bearing in its
original place.
• From the 3 types, choose the connecting rod
Bearing color code big end metal installer “1” that fits exactly, and
Code 1
install it to the connecting rod and connecting
Blue
Code 2 rod cap as shown in the illustration.
Black • Align the projections “a” on the big end bear-
Code 3 ings with the notches “b” in the connecting rods
Brown and connecting rod caps.
Code 4 • Push the big end bearing “2” down and install it
Green to the connecting rod and connecting rod cap.
• Make sure that the projection “c” on the con-
necting rod cap faces the same direction as the
“Y” mark “d” on the connecting rod.
P3 Connecting rod big end bearing

installer
P1 P2 90890-04193
installer
YM-04193
A P1 P 2 P3 1
a
b
1
EAS30751
INSTALLING THE CONNECTING ROD AND

PISTON
The following procedure applies to all of the con-
necting rods and pistons.
5-77
a
b
1
a. Side machined face

b. Thrusting faces
d
e. Loosen the connecting rod bolt, remove
the connecting rod and connecting rod
cap and install these parts to the crank-
shaft with the big end bearing kept in the
current condition.
c 3. Install:
• Oil ring expander “1”
• Lower oil ring rail “2”
2. Tighten: • Upper oil ring rail “3”
• Connecting rod bolt New • 2nd ring “4”
ECA18390
• Top ring “5”
NOTICE (into the piston)
Tighten the connecting rod bolts using the TIP
plastic-region tightening angle method. Al- Be sure to install the piston rings so that the
ways install new bolts. manufacturer’s marks or numbers “a” face up.
TIP
Install by carrying out the following procedures in
order to assemble in the most suitable condition.
a. Replace the connecting rod bolts with new
ones.
b. Clean the connecting rod bolts and lubri-
cate the bolt threads and seats with mo-
lybdenum disulfide oil.
c. After installing the big end bearing, as-
semble the connecting rod and connecting
rod cap without installing them onto the 4. Install:
crankshaft. • Piston “1”
d. Tighten the connecting rod bolt while (onto the respective connecting rod “2”)
checking that the sections shown “a” and • Piston pin “3”
“b” are flush with each other by touching • Piston pin clip “4” New
the surface.
TIP
Connecting rod bolt • Apply engine oil onto the piston pin.
30 N·m (3.0 kgf·m, 22 lb·ft) • Make sure that the “Y” mark “a” on the connect-
T.
R.
ing rod faces left when the punch mark “b” on

TIP the piston is pointing up as shown.
To install the big end bearing, care should be • Make sure that the clip ends “c” are positioned
taken not to install it at an angle and the position away from the cutout “d” in the piston as shown
should not be out of alignment. in the illustration.
5-78
• Reinstall each piston into its original cylinder.

Engine oil
a 4 New
8. Install:
2 1 • Piston assembly “1”
(into the cylinder “2” and onto the crankshaft
pin)
3
b Piston installing tool
New 4
90890-04161
G089013 Piston installing tool
YM-04161
ECA21490
NOTICE
If the projection “a” of the piston installing
tool damages, you cannot use it. Please han-
dle with care.
c
d TIP
Fit the projection “a” of the piston installing tool
4 New “3” and blunt-edged part “b” of the cylinder, fix
5. Lubricate: the position of the piston installing tool, and then
• Piston push the piston up to the cylinder.
• Piston ring
• Cylinder 2
(with the recommended lubricant) 2
b
Recommended lubricant a 1
Engine oil
6. Offset: 3
• Piston ring end gap
3 1
90˚ 9. Install:
b,e c
• Connecting rod cap
• Connecting rod bolt
TIP
90˚
• Make sure the “Y” marks “a” on the connecting
rods face towards the left side of the crank-
a,d shaft.
45˚ • Make sure that the projection “b” on the con-
a. Top ring necting rod cap faces the same direction as the
b. 2nd ring “Y” mark “a” on the connecting rod.
c. Upper oil ring rail • Apply Molybdenum disulfide oil to the bolt
d. Oil ring expander threads and seats.
e. Lower oil ring rail
A. Exhaust side
7. Lubricate:
• Crankshaft pin
• Connecting rod big end bearing inner surface
5-79
EWA16610
a WARNING
If the bolt is tightened more than the speci-
fied angle, do not loosen the bolt and then re-
tighten it. Instead, replace the bolt with a new
one and perform the procedure again.
ECA20890
b
NOTICE
Do not use a torque wrench to tighten the
bolt to the specified angle.
10.Tighten:
d. After the installation, check that the sec-
• Connecting rod bolt
tion shown “a” is flush with each other by
TIP
touching the surface.
Tighten the connecting rod bolts using the fol- EWA17120
lowing procedure. WARNING
a. Tighten the connecting rod bolts with a If the connecting rod and cap are not flush
torque wrench. with each other, remove the connecting rod
bolts and big end bearing and restart from
Connecting rod bolt (1st) step (1). In this case, make sure to replace
20 N·m (2.0 kgf·m, 15 lb·ft) the connecting rod bolts.
T.
R.
b. Put a mark “1” on the corner of the con-

necting rod bolt “2” and the connecting rod
cap “3”.
c. Tighten the connecting rod bolts further to

reach the specified angle 180°.
Connecting rod bolt (final)

T.
R.
180˚
5-80
CRANKSHAFT AND BALANCER SHAFT
EAS20178

Removing the crankshaft and balancer shaft
4
New 7
New
7
E
6 2
1
2
E
3
E
3

Refer to “REMOVING THE CONNECTING
Connecting rod RODS AND PISTONS” on page 5-72.
1 Balancer shaft 1
2 Balancer shaft journal lower bearing 2
3 Balancer shaft journal upper bearing 2
4 Crankshaft 1
5 Crankshaft journal lower bearing 4
6 Crankshaft journal upper bearing 4
7 Oil nozzle 3
5-81
EAS31171
• Crankshaft pin surfaces
REMOVING THE CRANKSHAFT AND
• Bearing surfaces
BALANCER SHAFT
Scratches/wear → Replace the crankshaft.
1. Remove:
3. Measure:
• Balancer shaft “1”
• Crankshaft-journal-to-crankshaft-journal-
• Balancer shaft journal bearing
bearing clearance
• Crankshaft assembly “2”
Out of specification → Replace the crank-
• Crankshaft journal bearing
shaft journal bearings.
TIP
Identify the position of each balancer shaft jour- Journal oil clearance
nal bearings and crankshaft journal bearings so 0.013–0.037 mm (0.0005–0.0015
that it can be reinstalled in its original place. in)
ECA13920
2 NOTICE
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
their original positions.
1
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions
EAS31174
of the crankcase.
CHECKING THE OIL NOZZLES
b. Place the upper crankcase upside down
The following procedure applies to all of the oil
on a bench.
nozzles.
c. Install the crankshaft journal upper bear-
1. Check:
ings “1” and the crankshaft into the upper
• Oil nozzle
crankcase.
Damage/wear → Replace the oil nozzle.
• Oil passage TIP
Obstruction → Blow out with compressed air. Align the projections “a” on the crankshaft jour-
nal upper bearings with the notches “b” in the up-
EAS31075
per crankcase.
CHECKING THE CRANKSHAFT
1. Measure:
• Crankshaft runout
Out of specification → Replace the crank- 1
shaft.
a
Runout limit b
0.030 mm (0.0012 in)
G089019
d. Put a piece of Plastigauge® “1” on each

crankshaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
G089017
2. Check:
• Crankshaft journal surfaces
5-82
4. Select:
1 • Crankshaft journal bearing (J1–J4)
TIP
• The numbers “A” stamped into the crankshaft
web and the numbers “B” stamped into the
lower crankcase are used to determine the re-
placement crankshaft journal bearing sizes.
• “J1”–“J4” refer to the bearings shown in the
G089020 crankshaft and lower crankcase illustration.
e. Install the crankshaft journal lower bear- For example, if the crankcase “J1” and crank-
ings “1” into the lower crankcase and as- shaft web “J1” numbers are 7 and 2 respec-
semble the crankcase halves. tively, then the bearing size for “J1” is:
TIP
“J1” (crankcase) - “J1” (crankshaft web) -1
• Align the projections “a” of the crankshaft jour-
=7-2-1
nal lower bearings with the notches “b” in the = 4 (green)
lower crankcase.
• Do not move the crankshaft until the clearance
measurement has been completed. Bearing color code
Code 0
White
Code 1
Blue
1 Code 2
a Black
Code 3
b
Brown
Code 4
Green
G089019
f. Tighten the bolts to specification in the

tightening sequence cast on the crank-
case.
Refer to “CRANKCASE” on page 5-65.
g. Remove the lower crankcase and the J1 J2 J3 J4
crankshaft journal lower bearings.
h. Measure the compressed Plastigauge®
width “a” on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-
journal-bearing clearance is out of specifi-
cation, select replacement crankshaft A J1 J2 J3 J4
journal bearings.
G089021
5-83
a. Clean the balancer shaft journal bearings,

balancer shaft journals, and bearing por-
tions of the crankcase.
b. Place the upper crankcase upside down
on a bench.
c. Install the balancer shaft journal upper
bearings “1” and the balancer shaft into
the upper crankcase.
TIP
B J1 J2 J3 J4
Align the projections “a” on the balancer shaft
EAS31076 journal upper bearings with the notches “b” in the
CHECKING THE BALANCER SHAFT upper crankcase.
1. Measure:
• Balancer shaft runout
Out of specification → Replace the balancer
shaft. 1
a
Balancer shaft runout limit
0.030 mm (0.0012 in) b
G089019
d. Put a piece of Plastigauge® “1” on each

balancer shaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
the balancer shaft journal.
2. Check:
• Balancer shaft journal surfaces
• Bearing surfaces
Scratches/wear → Replace the balancer
shaft. 1
3. Measure:
• Balancer shaft journal-to-balancer shaft bear-
ing clearance
Out of specification → Replace the balancer
shaft journal bearings. e. Install the balancer shaft journal lower
bearings “1” into the lower crankcase and
Balancer shaft journal to balanc- assemble the crankcase halves.
er shaft bearing clearance TIP
0.023–0.047 mm (0.0009–0.0019
in) • Align the projections “a” of the balancer shaft
journal lower bearings with the notches “b” in
ECA18400 the crankcase.
NOTICE • Do not move the balancer shaft until the clear-
Do not interchange the balancer shaft jour- ance measurement has been completed.
nal bearings. To obtain the correct balancer
shaft-journal-to-balancer shaft-journal-bear-
ing clearance and prevent engine damage,
the balancer shaft journal bearings must be
installed in their original positions.
5-84
Bearing color code

Code 1
1 Blue
a Code 2
Black
b Code 3
Brown
Code 4
Green
G089019
Code 5
f. Tighten the bolts to specification in the Yellow
tightening sequence cast on the crank-
case. Refer to “CRANKCASE” on page
5-65.
g. Remove the lower crankcase and the bal-
ancer shaft journal lower bearings.
h. Measure the compressed Plastigauge® J1 J2
width “a” 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.
a J1 J2
4. Select:
• Balancer shaft journal bearing (J1–J2)
TIP
• The numbers “A” stamped into the balancer
shaft web and the numbers “B” stamped into
the lower crankcase are used to determine the
replacement balancer shaft journal bearing siz-
es.
• “J1”–“J2” refer to the bearings shown in the bal-
B J1 J2
ancer shaft and lower crankcase illustration.
EAS31077
For example, if the crankcase “J1” and bal- INSTALLING THE CRANKSHAFT
ancer shaft web “J1” numbers are 5 and 2 re- 1. Install:
spectively, then the bearing size for “J1” is: • Crankshaft journal upper bearing
(into the upper crankcase)
“J1” (crankcase) - “J1” (balancer shaft web)
• Crankshaft journal lower bearing
=5-2
= 3 (brown) (into the lower crankcase)
• Crankshaft
5-85
TIP
b a
• Align the projections “a” on the crankshaft jour-
nal bearings “1” with the notches “b” in the
crankcase.
• Be sure to install each crankshaft journal bear-
ings in its original place.
1
a
b
G089019
EAS31172
INSTALLING THE BALANCER ASSEMBLY

1. Install:
• Balancer shaft journal upper bearing
(into the upper crankcase)
• Balancer shaft journal lower bearing
(into the lower crankcase)
TIP
• Align the projections “a” on the balancer shaft
journal bearings “1” with the notches “b” in the
crankcases.
• Be sure to install each balancer shaft journal
bearing in its original place.
1
a
b
G089019
2. Install:
• Balancer shaft
TIP
Install by aligning the crankshaft match mark “a”
and the balancer shaft match mark “b”.
5-86
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
E
12 N•m (1.2 kgf•m, 8.9 lb•ft)
2 New
LT 4 New 1
LT E
5 9
13 3
LT E
10
14 N•m (1.4 kgf•m, 10 lb•ft) E
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)

0.5 N•m (0.05 kgf•m, 0.37 lb•ft)
11 8
E
8
E
8
7
6
8
12 6
LT E LT 10 N•m (1.0 kgf•m, 7.4 lb•ft)

Shift shaft Refer to “SHIFT SHAFT” on page 5-57.
1 Drive axle assembly 1
2 Oil seal 1
3 Bearing 1
4 Circlip 1
5 Washer 1
6 Shift drum retainer 2
7 Shift fork guide bar 2 1
8 Spring 4
9 Shift fork-L 1
10 Shift fork-R 1
11 Shift fork guide bar 1 1
12 Shift drum assembly 1
13 Shift fork-C 1
5-87
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
E 19 12 N•m (1.2 kgf•m, 8.9 lb•ft)

New
LT New
14 18
LT E
LT E
14 N•m (1.4 kgf•m, 10 lb•ft) E

17
New
16
15
10 N•m (1.0 kgf•m, 7.4 lb•ft)
0.5 N•m (0.05 kgf•m, 0.37 lb•ft)
E
E
LT E LT 10 N•m (1.0 kgf•m, 7.4 lb•ft)

14 Main axle assembly 1
15 Oil delivery pipe 1
16 O-ring 1
17 Oil nozzle 1
18 Bearing cover plate 1
19 Bearing 1
5-88
TRANSMISSION
Disassembling the main axle assembly
14
E 9 New
10
13
11
12
15
M
1
2
M M
3
4
M
5
6
New 7
M
8
M
M

1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Collar 1
6 Washer 1
7 Circlip 1
8 3rd pinion gear 1
9 Circlip 1
10 Washer 1
11 5th pinion gear 1
12 Collar 1
13 Bearing housing 1
14 Bearing 1
15 Main axle 1
5-89
TRANSMISSION
Disassembling the drive axle assembly
M 6
New 5
M 4
3
2
M
1
M
New
14
15
New
12 13
11 M
10
9
M
8
7
M
New

1 1st wheel gear 1
2 Collar 1
3 5th wheel gear 1
4 Circlip 1
5 Washer 1
6 3rd wheel gear 1
7 Collar 1
8 Toothed lock washer 1
9 Toothed lock washer retainer 1
10 4th wheel gear 1
11 Collar 1
12 Washer 1
13 Circlip 1
14 6th wheel gear 1
15 Circlip 1
5-90
TRANSMISSION
Disassembling the drive axle assembly
New
M
18
17
M
M 16
New
New
M
19
20
M
22 21 New

16 Washer 1
17 2nd wheel gear 1
18 Collar 1
19 Collar 1
20 Bearing 1
21 Circlip 1
22 Drive axle 1
5-91
TRANSMISSION
EAS30430
REMOVING THE TRANSMISSION 2 4

1. Remove: 1
• Drive axle assembly “1”
3
• Shift drum retainer “2”
• Shift fork guide bar 2
• Spring
• Shift fork-L
• Shift fork-R
• Spring
• Shift drum assembly EAS30431
CHECKING THE SHIFT FORKS

• Shift fork-C
The following procedure applies to all of the shift
1 forks.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the
shift fork.
2
2. Remove:
• 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. G089022
2. Check:
1 2 • Shift fork guide bar 2
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
EWA12840
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3
b. Tighten the bolts until they contact the 3. Check:
crankcase surface. • Shift fork movement
c. Continue tightening the bolts until the main (along the shift fork guide bar)
axle assembly comes free from the upper Rough movement → Replace the shift forks
crankcase. and shift fork guide bar as a set.
3. Remove:
• Oil delivery pipe “1”
• Oil nozzle “2”
• Bearing cover plate “3”
• Bearing “4”
G089023
5-92
TRANSMISSION
EAS30432
CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
• Shift drum groove 1
Damage/scratches/wear → Replace the shift
drum assembly.
• Shift drum segment “1”
Damage/wear → Replace the shift drum as-
sembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
3. Check:
sembly.
• Transmission gear
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
G089024
EAS30433
CHECKING THE TRANSMISSION

1. Measure:
• Main axle runout
(with a centering device and dial gauge “1”) G089025
Out of specification → Replace the main axle.
4. Check:
Main axle runout limit • Transmission gear engagement
0.08 mm (0.0032 in) (each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
1 5. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• Circlip
Bends/damage/looseness → Replace.
EAS30435
2. Measure: ASSEMBLING THE MAIN AXLE AND DRIVE
• Drive axle runout AXLE
(with a centering device and dial gauge “1”) 1. Install:
Out of specification → Replace the drive axle. • Toothed washer “1”
Drive axle runout limit • Circlip “2” New
0.08 mm (0.0032 in) TIP
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the toothed washer
and gear.
• Align the opening between the ends “b” of the
circlip with a groove “c” in the axle.
5-93
TRANSMISSION
• Install the circlip so that a spline “d” is in the A

center of the gap between the circlip ends “e” 1
as shown. 2
2
1
B c
1
2 b
b 1
2
b
A. Main axle
c B. Drive axle
EAS30438
INSTALLING THE TRANSMISSION

e 1. Install:
• Bearing “1”
• Bearing cover plate “2”
• Oil nozzle “3”
• Oil delivery pipe “4”
TIP
• Face the seal side of bearing to the outside.
d • Install bearing cover plate “2” with the “OUT”
mark “a” facing out.
A. Main axle
B. Drive axle Bearing cover plate screw
2. Install: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
LOCTITE®
• Toothed lock washer retainer “1”
Oil nozzle
• Toothed lock washer “2” 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
TIP
• With the toothed lock washer retainer in the 3
groove “a” in the axle, align the projection on 1 a
4
the retainer with an axle spline, and then install
the toothed lock washer.
2
• Be sure to align the projection on the toothed
lock washer that is between the alignment
marks “b” with the alignment mark “c” on the re-
tainer. 2
2. Install:
• Main axle assembly “1”
5-94
TRANSMISSION
• Bearing housing “2”

Shift drum retainer bolt
Main axle bearing housing bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
14 N·m (1.4 kgf·m, 10 lb·ft) LOCTITE®
T.
R.
LOCTITE®
TIP
• Install shift fork-R into the groove “a” in the 5th
wheel gear and shift fork-L into the groove “b”
2 1 in the 6th wheel gear on the drive axle.
• Face the seal side of bearing “4” to the outside.
• Install the shift drum retainer with its “OUT”
mark “c” facing outward.
• Make sure that the projection “d” on the drive
axle assembly is inserted into the slot in the
crankcase.
• Make sure that the drive axle bearing circlips
3. Install: “5” is inserted into the grooves “e” in the upper
• Shift fork-C “1” crankcase.
• Shift drum assembly “2”
• Spring
• Shift fork guide bar 1 “3” a b 6
TIP
• The embossed marks on the shift forks should
face towards the right side of the engine and be 4
in the following sequence: “R”, “C”, “L”.
• Carefully position the shift forks so that they 5 5
New New
are installed correctly into the transmission
gears. e
1 2 d e
• Install shift fork-C into the groove “a” in the 3rd
pinion gear on the main axle. 3
c
a c
2
3
5. Check:
1
• Transmission
4. Install: Rough movement → Repair.
• Shift fork-R “1” TIP
• Shift fork-L “2”
Oil each gear, shaft, and bearing thoroughly.
• Spring
• Shift drum retainer “3”
• Bearing “4”
• Circlip “5” New
• Oil seal New
• Drive axle assembly “6”
5-95
COOLING SYSTEM
COOLING SYSTEM DIAGRAMS .................................................................... 6-1
RADIATOR ...................................................................................................... 6-3

CHECKING THE RADIATOR.................................................................... 6-5
INSTALLING THE RADIATOR..................................................................6-5
OIL COOLER...................................................................................................6-7
CHECKING THE OIL COOLER ................................................................6-8
INSTALLING THE OIL COOLER .............................................................. 6-8
THERMOSTAT ................................................................................................6-9
CHECKING THE THERMOSTAT............................................................ 6-10
INSTALLING THE THERMOSTAT ASSEMBLY ..................................... 6-10
WATER PUMP...............................................................................................6-11
DISASSEMBLING THE WATER PUMP.................................................. 6-13
CHECKING THE WATER PUMP ............................................................ 6-13
ASSEMBLING THE WATER PUMP........................................................ 6-13
6
COOLING SYSTEM DIAGRAMS
EAS20299
1. Water pump
2. Thermostat
3. Radiator
6-1
1 2 3
4
1. Water jacket
2. Thermostat
3. Water pump
4. Oil cooler
5. Coolant reservoir
6-2
RADIATOR
EAS20063
RADIATOR
Removing the radiator
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
.
LT 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
5
LT
6 7
1 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
4
LT
LT 3
LT
2
T.R
T.R
.
.
0.5 N•m (0.05 kgf•m, 0.37 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
.
T.R
.
T.R
.

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-28.
1 Coolant reservoir hose 1 Disconnect.
2 Coolant reservoir cover 1
3 Coolant reservoir 1
4 Coolant reservoir holder 1
5 Coolant reservoir cap 1
6 Coolant reservoir breather hose 1
7 Radiator cap 1
8 Radiator fan motor coupler 1 Disconnect.
6-3
RADIATOR
Removing the radiator
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
.
17
LT 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
18
8 N•m (0.8 kgf•m, 5.9 lb•ft) 14
T.R
.
12 LT
19
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9
20
LT
LT 15
11
LT 16
13
T.R
T.R
.
.
0.5 N•m (0.05 kgf•m, 0.37 lb•ft) 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) 10 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
T.R
.

9 Radiator hose (cylinder head to radiator) 1 Disconnect.
10 Radiator inlet hose 1 Disconnect.
11 Radiator outlet hose 1 Disconnect.
12 O2 sensor lead 1
13 Oil pressure switch lead 1

14 Wire harness 1
15 Radiator 1
16 Radiator bracket 1
17 Radiator fan cover 1
18 Radiator fan 1
19 Radiator side bracket (left) 1
20 Radiator side bracket (right) 1
6-4
RADIATOR
EAS30439
CHECKING THE RADIATOR

1. Check:
• Radiator fin
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head G089029
screwdriver. b. Apply specified pressure to the radiator

cap and then, make sure to check the
specified pressure for at least 10 seconds.
If it is not keep the pressure, replace it.
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-27.
EAS30440
G089028
INSTALLING THE RADIATOR
2. Check: 1. Install:
• Radiator hose • All removed parts
Cracks/damage → Replace. 2. Fill:
3. Measure: • Cooling system
• Radiator cap valve opening pressure (with the specified amount of the recom-
Below the specified pressure → Replace the mended coolant)
radiator cap. Refer to “CHANGING THE COOLANT” on
page 3-28.
Radiator cap valve opening pres- 3. Check:
sure • Cooling system
107.9–137.3 kPa (1.08–1.37 kgf/ Leaks → Repair or replace any faulty part.
cm², 15.6–19.9 psi)
a. Attach the radiator cap tester “1” and radi-
a. Install the radiator cap tester “1” and radiator cap tester adapter “2” to the radiator.
ator cap tester adapter “2” to the radiator Radiator cap tester
cap “3”. 90890-01325
Mityvac cooling system tester kit
Radiator cap tester YU-24460-A
90890-01325 Radiator cap tester adapter
Mityvac cooling system tester kit 90890-01352
YU-24460-A Pressure tester adapter
Radiator cap tester adapter YU-33984
90890-01352
Pressure tester adapter
YU-33984
G089031 1
6-5
RADIATOR
b. Apply the specified pressure.
Cooling system leak test pres-

sure
137.3 kPa (1.37 kgf/cm², 19.9
psi)
ECA24270
NOTICE
• Do not apply such a high pressure as ex-
ceeds the test pressure.
• Make sure that a checkup after the cylinder
head gasket is replaced is made after 3 min-
utes of warm-up.
• Make sure that coolant is filled up to the up-
per level beforehand.
4. Check:
• Pressure value
No stay for 5 to 10 seconds at the test pres-
sure value → Repair.
• Radiator
• Radiator hose connections
Coolant leaks → Repair or replace.
• Radiator hose
Bulges → Replace.
EWA19090
WARNING
When the radiator cap tester is removed,
coolant will spout; therefore, cover it with a
cloth beforehand.
6-6
OIL COOLER
EAS20064
OIL COOLER
Removing the oil cooler
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
LT
LS
New
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
LT 3
1
2
4 LT
New LT
LS
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.

Coolant reservoir Refer to “RADIATOR” on page 6-3.
Drain.
page 3-28.
Drain.
page 3-25.
1 Radiator inlet hose 1
2 Oil cooler inlet hose 1
3 Oil cooler outlet hose 1
4 Oil cooler 1
5 Water jacket joint 1
6-7
OIL COOLER
EAS30441
Refer to “INSTALLING THE RADIATOR” on
CHECKING THE OIL COOLER
page 6-5.
1. Check:
5. Measure:
• Oil cooler
• Radiator cap valve opening pressure
Below the specified pressure → Replace the
2. Check:
radiator cap.
• Oil cooler inlet hose
Refer to “CHECKING THE RADIATOR” on
• Oil cooler outlet hose
page 6-5.
EAS30442
INSTALLING THE OIL COOLER

1. Clean:
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• O-ring New
• Oil cooler
• Oil cooler bolt “1”
Oil cooler bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
TIP
• Before installing the oil cooler, apply lithium-
soap-based grease to the O-ring.
• Make sure the O-ring is positioned properly.
3. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-28.
• Crankcase
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” on
page 3-25.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
6-8
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat assembly
7
2
6
LS
4
New 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)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Drain.
page 3-28.
1 O2 sensor lead 1
2 Oil cooler outlet hose 1

3 Radiator outlet hose 1
4 Water pump inlet hose 1
5 Thermostat cover 1
6 Thermostat 1
7 Thermostat housing 1
6-9
THERMOSTAT
EAS30443
4. Measure:
CHECKING THE THERMOSTAT
• Radiator cap valve opening pressure
1. Check:
Below the specified pressure → Replace the
• Thermostat
radiator cap.
When the water temperature in the specified
Refer to “CHECKING THE RADIATOR” on
value, the thermostat does not fully open. →
page 6-5.
Replace.
Valve opening temperature

80.0–84.0 °C (176.00–183.20 °F)
a. Suspend the thermostat “1” in a container

“2” filled with water.
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the ther-
mostat and thermometer’s indicated tem-
perature.
G089032
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
• Thermostat housing
EAS30445
INSTALLING THE THERMOSTAT

ASSEMBLY
1. Install:
• Thermostat
2. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-28.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-5.
6-10
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
New
LS
New
1 LS
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Drain.
page 3-28.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1
6-11
WATER PUMP
Disassembling the water pump
5
6
9
10
4 7
E 2
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1 Water pump housing cover 1
2 O-ring 1
3 Circlip 1
4 Water pump driven gear 1
5 Pin 1
6 Washer 1
7 Impeller shaft 1
8 Mechanical seal 1
9 Bearing 1
10 Oil seal 1
6-12
WATER PUMP
EAS30446 EAS30447
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Mechanical seal (housing side) “1” • Water pump housing cover “1”
TIP • Impeller shaft “2”
Remove the mechanical seal (housing side) Cracks/damage/wear → Replace.
from the inside of the water pump housing “2”. • Water pump housing “3”
Cracks/damage/wear → Replace the water
pump assembly.
3
2
1
1 2
2. Remove:
• Bearing “1” 2. Check:
• Oil seal “2” • Bearing
TIP Rough movement → Replace.
Remove the oil seal and bearing from the out- 3. Check:
side of the water pump housing “3”. • Water pump inlet hose
EAS30448
ASSEMBLING THE WATER PUMP

1. Install:
2 • Bearing “2” New
(into the water pump housing “3”)
1 3 Installed depth “a”
0.5–1.0 mm (0.02–0.04 in)
3. Remove:
• Mechanical seal (impeller side) “1” TIP
(from the impeller, with a thin, flat-head Install the oil seal with a socket that matches its
screwdriver) outside diameter.
TIP
Do not scratch the impeller shaft.
2 3
a
2. Install:
G089034
• Mechanical seal (housing side) “1” New
6-13
WATER PUMP
ECA20330
NOTICE
Never lubricate the mechanical seal (hous-
ing side) surface with oil or grease.
TIP
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it
touches the water pump housing.
G089035
Mechanical seal installer

90890-04078
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058
2. Water pump housing

3. Mechanical seal installer
4. Middle driven shaft bearing driver
A. Push down
3. Install:
• Mechanical seal (impeller side) “1” New
ECA20340
NOTICE
Make sure the mechanical seal (impeller
side) is flush with the impeller.
TIP
• Before installing the mechanical seal (impeller
side), apply tap water or coolant onto its outer
surface.
• If the top of the mechanical seal is dirty, clean
it.
6-14
WATER PUMP
6-15
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-4
REMOVING THE FUEL PUMP .................................................................7-4
CHECKING THE FUEL PUMP BODY.......................................................7-4
CHECKING THE FUEL PUMP OPERATION............................................7-4
CHECKING THE PURGE CUT VALVE SOLENOID .................................7-5
INSTALLING THE FUEL PUMP................................................................7-5
INSTALLING THE FUEL TANK.................................................................7-5
THROTTLE BODIES .......................................................................................7-6

CHECKING THE INJECTORS (BEFORE REMOVING) ........................... 7-8
REMOVING THE FUEL HOSE (FUEL RAIL SIDE) ..................................7-8
REMOVING THE INJECTORS .................................................................7-8
CHECKING THE INJECTORS ..................................................................7-8
CHECKING AND CLEANING THE THROTTLE BODIES.........................7-8
REPLACING THE THROTTLE BODIES ................................................. 7-10
INSTALLING THE INJECTORS ..............................................................7-10
CHECKING THE INJECTOR PRESSURE.............................................. 7-10
CHECKING THE FUEL PRESSURE ......................................................7-11
INSTALLING THE FUEL HOSE (FUEL RAIL SIDE) ...............................7-12
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-12
7
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
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
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.R
.
(4)
New 9 1
5 4
7 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
3
(4) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.

Rider seat 4-1.
Side covers/Fuel tank bracket cover 4-5.
er/Fuel tank side cover assemblies 4-14.
1 Fuel tank bracket bolt 4
2 Fuel hose connector 1 Disconnect.
3 Fuel pump coupler 1 Disconnect.
4 Fuel tank breather hose 1 Disconnect.
5 Fuel tank drain hose 1 Disconnect.
6 Fuel tank 1
7 Fuel pump bracket 1
8 Fuel pump 1
9 Fuel pump gasket 1
7-1
FUEL TANK
Removing the fuel tank

6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
11
T.R
.
13
13
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
12
10
12
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
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft) 14

T.R
.
(4)
New 15
16
16
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
(4) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

T.R
.

10 Fuel tank cap 1
11 Fuel tank top cover bracket 1
12 Fuel tank side cover assembly bracket (left) 1
13 Fuel tank side cover assembly bracket (right) 1
14 Fuel tank bracket 1
15 Fuel tank bracket 1
16 Rider seat height position adjuster bracket 2
7-2
FUEL TANK
Removing the canister
7
2
6

1 Fuel tank breather hose (fuel tank to canister) 1
Canister purge hose (purge cut valve solenoid
2 1
to canister)
3 Fuel tank drain hose 1
4 Canister breather hose 1
5 Canister 1
6 1 Disconnect.
to hose joint)
7 Purge cut valve solenoid coupler 1 Disconnect.
8 Purge cut valve solenoid 1
7-3
FUEL TANK
EAS30450
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the 1 c
fuel tank cap with a pump.
2. Remove:
• Rider seat
4-1.
• Side cover
4-5.
• Fuel tank top cover a
• Fuel tank side cover assembly b
4-14.
• Fuel tank bracket bolt
3. Disconnect: b
• Fuel hose (fuel tank side) “1”
• Fuel pump coupler “2”
• Fuel tank breather hose “3”
• Fuel tank drain hose “4” 4. Remove:
• Fuel tank
TIP
Do not set the fuel tank down so that the instal-
lation surface of the fuel pump is directly under
the tank. Be sure to lean the fuel tank in an up-
right position.
2
EAS30451
3 REMOVING THE FUEL PUMP
1 4 1. Remove:
EWA17320 • Fuel pump
WARNING ECA14721
NOTICE
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres- • Do not drop the fuel pump or give it a
sure in the fuel lines could cause fuel to strong shock.
spurt out when removing the hose. • Do not touch the base section of the fuel
ECA17490
sender.
NOTICE
EAS30454
Be sure to disconnect the fuel hose by hand. CHECKING THE FUEL PUMP BODY
Do not forcefully disconnect the hose with 1. Check:
tools. • Fuel pump body
TIP Obstruction → Clean.
Cracks/damage → Replace fuel pump as-
• While pushing the ends “a” of the fuel hose
sembly.
connector cover “1” in direction “b”, slide the
fuel hose connector cover in direction “c”, and EAS30455
then remove the hose from the fuel pump. CHECKING THE FUEL PUMP OPERATION
• Before removing the hose, place a few rags in 1. Check:
the area under where it will be removed. • Fuel pump operation
• It is prohibited to wear the cotton work gloves Refer to “CHECKING THE FUEL PRES-
or equivalent coverings. SURE” on page 7-11.
7-4
FUEL TANK
EAS33542 ECA17500
CHECKING THE PURGE CUT VALVE NOTICE

SOLENOID When installing the fuel hose, make sure that
1. Check: it is securely connected, and that the fuel
• Canister purge hose hose connector cover on the fuel hose is in
Loose connection → Connect properly. the correct position, otherwise the fuel hose
Cracks/damage/wear → Replace. will not be properly installed.
2. Check:
• Purge cut valve solenoid resistance TIP
Refer to “CHECKING THE PURGE CUT • Install the fuel hose onto the fuel pump secure-
VALVE SOLENOID” on page 8-51. ly, and slide the fuel hose connector cover “1”
EAS30456
in the direction shown in the illustration.
INSTALLING THE FUEL PUMP • It is prohibited to wear the cotton work gloves
1. Install: or equivalent coverings.
• Fuel pump gasket New
• Fuel pump
• Fuel pump bracket
• Fuel pump bolt 1
Fuel pump bolt

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
TIP
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket. 2. Connect:
• Install the fuel pump gasket so that the lip side • Fuel tank drain hose
turns to the inside of the fuel tank. • Fuel tank breather hose
• Install the fuel pump as shown in the illustra- • Fuel pump coupler
tion.
• Install the fuel pump projection “a” toward the
fuel tank slot “b”.
• Align the projection “a” on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
4 b
1
2
3
a
A. Forward
EAS30457
INSTALLING THE FUEL TANK

1. Connect:
• Fuel hose (fuel tank side)
7-5
THROTTLE BODIES
EAS20070
THROTTLE BODIES
Removing the throttle bodies
11
2
6 10
7
8 (3)
LT
3
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
4
5
3 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.

1 Fuel hose 1
2 Intake air pressure sensor 1 coupler 1 Disconnect.
3 Intake air pressure sensor 2 coupler 1 Disconnect.
4 Injector coupler 3 Disconnect.
5 Throttle servo motor coupler 1 Disconnect.
6 Throttle position sensor coupler 1 Disconnect.
7 1 Disconnect.
to hose joint)
8 Throttle body joint clamp screw 3 Loosen.
9 Throttle body assembly 1
10 Throttle body joint 1
11 Throttle body joint 1
7-6
THROTTLE BODIES
Removing the injectors

3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft) 1

New
T.R
.
New
New
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
New 2
4 New
6 2 2
New
3
6
8
5
6
6
7
6
7
6
9
8
8
9

1 Fuel rail 1
2 Injector 3
3 Intake air pressure sensor 2 1
4 Intake air pressure sensor 1 1
5 Throttle position sensor 1
6 Negative pressure hose 6
7 Hose joint 2
8 Canister purge hose 4
9 Hose joint 2
7-7
THROTTLE BODIES
EAS30475 EAS30476
CHECKING THE INJECTORS (BEFORE REMOVING THE INJECTORS

REMOVING) EWA17330
1. Check: WARNING
• Injector • Check the injectors in a well-ventilated area
Use the diagnostic code numbers “36”–“38”. free of combustible materials. Make sure
Refer to “DIAGNOSTIC CODE: ACTUATOR that there is no smoking or use of electric
OPERATION TABLE” on page 9-83. tools in the vicinity of the injectors.
• Be careful when disconnecting the fuel
EAS31158
hose. Any remaining pressure in the fuel
REMOVING THE FUEL HOSE (FUEL RAIL
hose may cause the fuel to spray out. Place
SIDE)
a container or rag under the hose to catch
1. Remove:
any fuel that spills. Always clean up any
• Fuel tank
spilt fuel immediately.
Refer to “REMOVING THE FUEL TANK” on
• Turn the main switch to “OFF” and discon-
page 7-4.
nect the negative battery lead from the bat-
2. Remove:
tery terminal before removing the injectors.
• Fuel hose (fuel rail side)
ECA17490
1. Remove:
NOTICE • Fuel rail
Be sure to disconnect the fuel hose by hand. a. Remove the fuel rail bolts.
Do not forcefully disconnect the hose with
EAS30477
tools. CHECKING THE INJECTORS
TIP 1. Check:
• While pushing the ends “a” of the fuel hose • Injector
connector cover “1” in direction “b”, slide the Obstruction → Replace and check the fuel
fuel hose connector cover in direction “c”, and pump/fuel supply system.
then remove the hose from the fuel pump. Deposit → Replace.
• Before removing the hose, place a few rags in Damage → Replace.
the area under where it will be removed. 2. Check:
• It is prohibited to wear the cotton work gloves • Injector resistance
or equivalent coverings. Refer to “CHECKING THE FUEL INJEC-
TORS” on page 8-51.
EAS30769
1 c CHECKING AND CLEANING THE THROTTLE
BODIES
TIP
Clean the throttle bodies only if they cannot be
synchronized using the bypass air screws. Be-
fore cleaning the throttle bodies, check the fol-
lowing items:
• Valve clearance
• Spark plug
a
• Throttle body joint
b • Fuel hose
• Exhaust system
• Cylinder head breather hose
EWA17340
b WARNING
If the throttle bodies are subjected to strong
shocks or dropped during cleaning, replace
them as a set.
7-8
THROTTLE BODIES
1. Check: c. Hold the throttle valves in the open posi-

• Throttle bodies tion.
Cracks/damage → Replace the throttle bod- EWA15940
ies as a set. WARNING

2. Clean: When cleaning the throttle bodies, be careful
• Throttle bodies not to injure yourself on the throttle valves or
ECA21540 other components of the throttle bodies.
NOTICE ECA20380
• Observe the following precautions; other- NOTICE

wise, the throttle bodies may not operate • Do not open the throttle valves by supply-
properly. ing electrical power to the throttle bodies.
• Do not subject the throttle bodies to exces- • Do not use tools to open the throttle valves
sive force. or to keep them in the open position.
• Clean the throttle bodies in the recom- • Do not open the throttle valves quickly.
mended cleaning solvent.
• Do not use any caustic carburetor cleaning
solution.
• Do not apply cleaning solvent directly to
any plastic parts, sensors, or seals.
• Be careful not to remove the white paint
mark that identifies the standard throttle
body.
• Do not turn the bypass air screws “a”; oth-
erwise, the throttle body synchronization
will be affected.
d. Apply the recommended cleaning solvent
to the throttle valves and the inside of the
Recommended cleaning solvent
Yamaha Oil & Brake Cleaner throttle bodies to remove any carbon de-
posits.
TIP
• Do not allow any cleaning solvent to enter the
opening for the injectors.
• Do not apply any cleaning solvent to the por-
tions of the throttle valve shafts between the
throttle bodies.
a e. Remove the carbon deposits from the in-

side of each throttle body in a downward
a direction, from the air filter case side of the
throttle body to the engine side.
a. Place the throttle bodies on a flat surface ECA17590
with the air filter case side facing up. NOTICE

b. Install the caps (895-14169-00) onto the • Do not use a tool, such as a wire brush, to
hose fittings “a”. remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
aged.
• 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-
tween the throttle valve shaft and the throt-
tle body.
a
a
a
7-9
THROTTLE BODIES
f. After removing the carbon deposits, clean 5. Place the vehicle on a maintenance stand so
the inside of the throttle bodies with the that the rear wheel is elevated.
recommended cleaning solvent, and then 6. Check:
dry the throttle bodies using compressed • Engine idling speed
air. Start the engine, warm it up, and then mea-
g. Make sure that there are no carbon de- sure the engine idling speed.
posits or other foreign materials in any of
the passages “a” in each throttle body or in Engine idling speed
the space “b” between the throttle valve 1200–1400 r/min
shaft and the throttle body.
EAS30480
A a B a INSTALLING THE INJECTORS

ECA19400
NOTICE
• Always use new O-rings.
• When installing the injectors, do not allow
any foreign material to enter or adhere to
the injectors, fuel rails, or O-rings.
• Be careful not to twist or pinch the O-rings
b when installing the injectors.
• When installing the injector, install it at the
A. Air filter case side same position as the removed cylinder.
B. Throttle body joint side • If an injector is subject to strong shocks or
excessive force, replace it.
3. Install the throttle bodies.
4. Reset: 1. Install a new seal onto the end of each injec-
• ISC (idle speed control) learning values tor.
Use the diagnostic code number “67”. 2. Install the injectors to the fuel rail, making
Refer to “DIAGNOSTIC CODE: SENSOR sure to install them in the correct direction.
OPERATION TABLE” on page 9-79. 3. Install the injector assemblies to the throttle
5. Adjust: bodies.
• Throttle bodies synchronizing Fuel rail bolt
Out of specification → Replace the throttle 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
bodies.
R.
Refer to “SYNCHRONIZING THE THROT- 4. Check the injector pressure after the injectors
TLE BODIES” on page 3-8. are installed.
EAS31160
Refer to “CHECKING THE INJECTOR
REPLACING THE THROTTLE BODIES PRESSURE” on page 7-10.
1. Remove the throttle bodies from the vehicle. EAS30481
2. Install a new throttle bodies to the vehicle. CHECKING THE INJECTOR PRESSURE
3. Reset: TIP
• ISC (idle speed control) learning values
• After installing the injectors, perform the follow-
Use the diagnostic code number “67”.
ing steps to check the injector pressure.
Refer to “DIAGNOSTIC CODE: SENSOR
• Do not allow any foreign materials to enter the
OPERATION TABLE” on page 9-79.
fuel lines.
• A/F control learning value
Use the diagnostic code number “87”. 1. Check:
Refer to “DIAGNOSTIC CODE: SENSOR • Injector pressure
OPERATION TABLE” on page 9-79. a. Connect the fuel injector pressure adapter
4. Adjust: “1” to the fuel rail joint “2”, and then con-
• Throttle bodies synchronizing nect an air compressor “3” to the adapter.
Refer to “SYNCHRONIZING THE THROT- b. Connect the pressure gauge “4” to the fuel
TLE BODIES” on page 3-8. injector pressure adapter “1”.
7-10
THROTTLE BODIES

Pressure gauge Refer to “GENERAL CHASSIS (2)” on page
90890-03153 4-5.
Pressure gauge • Front side cowling assembly
YU-03153
Fuel injector pressure adapter
90890-03210 • Fuel tank side cover assembly
Fuel injector pressure adapter Refer to “GENERAL CHASSIS (3)” on page
YU-03210 4-14.
2. Check:
• Fuel pressure
a. Remove the fuel bracket bolt and hold up
the fuel tank.
b. Disconnect the fuel hose “1” from the fuel
pump.
Refer to “REMOVING THE FUEL TANK”
on page 7-4.
EWA17320
WARNING
G089041 Cover fuel hose connections with a cloth
c. Close the valve on the fuel injector pres- when disconnecting them. Residual pres-
sure adapter. sure in the fuel lines could cause fuel to
d. Apply air pressure with the air compres- spurt out when removing the hose.
sor. ECA17490
e. Open the valve on the fuel injector pres- NOTICE

sure adapter until the specified air pres- Be sure to disconnect the fuel hose by hand.
sure is reached. Do not forcefully disconnect the hose with
tools.
Specified air pressure
490 kPa (5.0 kgf/cm², 71.1 psi)
ECA17600
1
NOTICE
Never exceed the specified air pressure or
damage could occur.
f. Close the valve on the fuel injector pres-
sure adapter.
g. Check that the specified air pressure is
held at least one minute.
Pressure drops → Check the pressure c. Connect the pressure gauge “2” and fuel
gauge and adapter. pressure adapter “3” to the fuel hose.
Check the seals and O-rings and then re-
Pressure gauge
install. 90890-03153
Out of specification → Replace the fuel in- Pressure gauge
jectors. YU-03153
EAS30482
Fuel pressure adapter
CHECKING THE FUEL PRESSURE 90890-03176
1. Remove: Fuel pressure adapter
• Rider seat YM-03176
• Rubber cover
4-1.
• Side cover
7-11
THROTTLE BODIES
EAS30485
ADJUSTING THE THROTTLE POSITION

3 SENSOR
ECA17540
2 NOTICE
• 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.
1. Check:
d. Start the engine. • Throttle position sensor
e. Measure the fuel line pressure. Refer to “DIAGNOSTIC CODE: SENSOR
Faulty → Replace the fuel pump. OPERATION TABLE” on page 9-79.
Fuel line pressure (at idle) 2. Adjust:
300–390 kPa (3.0–3.9 kgf/cm², • Throttle position sensor angle
43.5–56.6 psi) TIP
Before adjusting the throttle position sensor, the
EAS31159
throttle bodies must be removed.
INSTALLING THE FUEL HOSE (FUEL RAIL
SIDE) a. Temporary tighten the throttle position
1. Connect: sensor screws “1”.
• Fuel hose (fuel rail side) b. Check that the throttle valves are fully
ECA17500 closed.
NOTICE c. Connect the throttle position sensor to the
When installing the fuel hose, make sure that wire harness.
it is securely connected, and that the fuel d. Remove the protective cap, and then con-
hose connector cover on the fuel hose is in nect the YDT to coupler.
the correct position, otherwise the fuel hose
will not be properly installed. Yamaha diagnostic tool USB
90890-03267
TIP Yamaha diagnostic tool (A/I)
• Install the fuel hose onto the fuel pump secure- 90890-03264
ly, and slide the fuel hose connector cover “1”
in the direction shown in the illustration. TIP
• It is prohibited to wear the cotton work gloves • Yamaha diagnostic tool (A/I) (90890-03264) in-
or equivalent coverings. cludes YDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/
1 e. Diagnostic code number “01” is selected.
f. Adjust the position of the throttle position
sensor angle so that 11–21 can appear in
the YDT screen.
g. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
Throttle position sensor screw

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
7-12
THROTTLE BODIES
7-13
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
ENGINE STOPPING DUE TO SIDESTAND OPERATION.......................8-3
TROUBLESHOOTING ..............................................................................8-4
ELECTRIC STARTING SYSTEM .................................................................... 8-7

CIRCUIT DIAGRAM .................................................................................. 8-7
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-9
TROUBLESHOOTING ............................................................................8-10
CHARGING SYSTEM....................................................................................8-12
CIRCUIT DIAGRAM ................................................................................ 8-12
LIGHTING SYSTEM ......................................................................................8-15

CIRCUIT DIAGRAM ................................................................................ 8-15
SIGNALING SYSTEM ...................................................................................8-19

CIRCUIT DIAGRAM ................................................................................ 8-19
COOLING SYSTEM....................................................................................... 8-27

CIRCUIT DIAGRAM ................................................................................ 8-27
FUEL PUMP SYSTEM...................................................................................8-31

CIRCUIT DIAGRAM ................................................................................ 8-31
GRIP WARMER SYSTEM (for MTT890D)....................................................8-35

CIRCUIT DIAGRAM ................................................................................ 8-35
8
ELECTRICAL COMPONENTS...................................................................... 8-39
CHECKING THE SWITCHES .................................................................8-41
CHECKING THE FUSES ........................................................................8-42
REPLACING THE ECU (Engine Control Unit) ........................................ 8-43
CHECKING AND CHARGING THE BATTERY....................................... 8-43
CHECKING THE RELAYS ...................................................................... 8-43
CHECKING THE RELAY UNIT (DIODE) ................................................ 8-45
CHECKING THE IGNITION COILS......................................................... 8-46
CHECKING THE IGNITION SPARK GAP............................................... 8-46
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 8-47
CHECKING THE STARTER MOTOR OPERATION ...............................8-47
CHECKING THE STATOR COIL ............................................................ 8-47
CHECKING THE RECTIFIER/REGULATOR ..........................................8-48
CHECKING THE HORN..........................................................................8-48
CHECKING THE FUEL SENDER ........................................................... 8-48
CHECKING THE FUEL LEVEL WARNING LIGHT .................................8-49
CHECKING THE RADIATOR FAN MOTOR ...........................................8-49
CHECKING THE COOLANT TEMPERATURE SENSOR.......................8-49
CHECKING THE THROTTLE SERVO MOTOR ..................................... 8-50
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................8-50
CHECKING THE FUEL INJECTORS......................................................8-51
CHECKING THE PURGE CUT VALVE SOLENOID ...............................8-51
CHECKING THE GRIP WARMERS (for MTT890D) ...............................8-52
CHECKING THE SOLENOID (FRONT FORK/REAR SHOCK
ABSORBER ASSEMBLY) (for MTT890D).............................................. 8-52
D
EAS30490
EAS20072
Sb Sb
A E
R/W R/W R/W R/W
4 R/W
R R O
56
R/W O R/W
R
R 59 (B)
R
CIRCUIT DIAGRAM
R
R/W
Y/R P/B O/G Gy/R O W/R G L Br/Y R/W O 57
R W Br/R Br/R Gy/R Gy/R
3 27 41 Lg/R L/B G/B R/B B Y W Y/R Gy/R R/W
R/L G/Y B B/L Br O/G
OFF 59 (B)
ON R,W R
R/G Y/R Y/B L/W R/L B/W B/W W/B B Y/B
Br/L Br/L B
Br W R L/W R (B) (B)
IGNITION SYSTEM
R/W
Br/L B B B W L/W R L/B L Sb B Sb/W 58
O/G O/G R/W
28 Sb L 59 (B)
L/B
D
Sb L/Y
R/W R/W L/B

R/W 37 Sb
R R/L L/B
39 B
R/W B/W W/G W/B OFF 45
RUN
R R B R/W START L/W R/L Y/G W/G L/B B B B
(B) L L/Y
(B)
44 L/Y L L/Y
W/B W/G B/W R/W L/W B 48
R/W B W
L/B L/B L/B L/B L/B L/W L/W L/W L/WL/W
L/W L/WL/W L/W B B B L/B L/B L/B L/B L/B Y/L O/W Lg/L P/W P V L L Gy
48 L/B
48 L/W B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
L/B L/W L/Y L/W Lg/B G/W G/W W/G W/Y
R
R
(B)
R/L R/L R/L R/L R/L

R 48
Br/L 12 55
Br/L Br/L B Gy Gy
L/W Gy B 53
B/L B/L L/B L/B L/W Gy B/L B/L
Gy B/L
8-1
(B)
B/L
R/L B/W
71
L/W L/B
B/W L/W L/B R/L
(B)
B
L/W
L/B
B/W
B/W B/W B B
B
B/W
B/W
B
B
B
IGNITION SYSTEM
IGNITION SYSTEM
3. Main switch
4. Main fuse
12.Ignition fuse 1
27.Battery
28.Frame ground
37.Handlebar switch (right)
39.Stop/run/start switch
41.Relay unit
44.Neutral switch
45.Sidestand switch
48.Joint coupler
53.Crankshaft position sensor
55.ECU (Engine Control Unit)
56.Ignition coil #1
57.Ignition coil #2
58.Ignition coil #3
59.Spark plug
71.IMU (Inertial Measurement Unit)
A. Wire harness (MTT890D)
E. Sub-wire harness (neutral switch) (MTT890D)
8-2
IGNITION SYSTEM
EAS30491
ENGINE STOPPING DUE TO SIDESTAND OPERATION

When the engine is running and the transmission is in gear, the engine will stop if the sidestand is
moved down. This is because the electric current from the ECU does not flow to the ignition coils or fuel
injectors when the neutral switch or sidestand switch is open. However, the engine continues to run
under the following conditions:
• The transmission is in gear (the neutral switch is open) and the sidestand is up (the sidestand switch
circuit is closed).
• The transmission is in neutral (the neutral switch is closed) and the sidestand is down (the sidestand
switch circuit is open).
2
9 5
8
6
11 10
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse 1
5. Stop/run/start switch
6. Ignition coil
7. Spark plug
9. Relay unit (diode)
10. Sidestand switch
11. Neutral 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/Rider seat
2. Front side cowling assemblies (left and right)
3. Fuel tank
4. Air filter case
1. Check the fuses. NG →

(Main, and ignition 1)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-42.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-43.
OK ↓
3. Check the spark plugs. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plugs.
PLUGS” on page 3-5.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 8-46.
NG ↓
5. Check the ignition coils. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coils.
TION COILS” on page 8-46.
OK ↓
6. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on
page 8-47.
OK ↓
7. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch/immobilizer unit.
SWITCHES” on page 8-41.
OK ↓
8-4
IGNITION SYSTEM
8. Check the stop/run/start switch. NG →

Refer to “CHECKING THE Replace the handlebar switch (right).
OK ↓
9. Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
10.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
11.Check the relay unit (diode). NG →
Refer to “CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)” on page 8-45.
OK ↓
12.Check the entire ignition system’s NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 8-1.
OK ↓
Replace the ECU or IMU.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-43.
8-5
IGNITION SYSTEM
8-6
D
EAS30493
EAS20073
Sb Sb
A E
R/W R
R/W L/W
R
(B)
4 30
R/W
R R
R L/W
CIRCUIT DIAGRAM
R
R RR B
3 R W Br/R Br/R
27 29 41 W WR
OFF
ON R,W R
Br/L Br/L B
Br W R L/W R 42
Br/L B B W L/W R L/B L Sb B Sb/W
28 R B Sb L
L/W L/B
D
B Sb
R/W R/W L/W L/B

R/W 37 Sb
R B/Y L/B
R R/L
R/W
39 B
34 B/Y Y/B Y/B B/Y B/W W/G W/B OFF 45
RUN
R OFF R B R/W START
ON L/Y L/W Y/W L/Y L/W R/L Y/G W/G L/B B B B
L/W (B) (B) L B W L/W
(B) (B) L/Y
B 44 L/Y L L/Y B/Y B/Y B B/Y W L/W W W L/W
W/B W/G B/W R/W L/W B
L/Y 48 48 48
R/W B W
ELECTRIC STARTING SYSTEM
R
R
Br/L 12
Br/L Br/L
8-7
B
B
B
B
3. Main switch
4. Main fuse
12.Ignition fuse 1
27.Battery
28.Frame ground
29.Starter motor
30.Starter relay
34.Clutch switch
41.Relay unit
42.Starting circuit cut-off relay
44.Neutral switch
45.Sidestand switch
48.Joint coupler
A. Wire harness (MTT890D)
8-8
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to “ON” and the “ ” side of the stop/run/start switch is pushed, the starter
motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the
sidestand switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met, the starting circuit cut-off relay
is closed and the engine can be started by pressing the “ ” side of the stop/run/start switch.
12
11
4
6 6
10
6
6
7 a
6
8 9 10
b
a. WHEN THE TRANSMISSION IS IN NEUTRAL

b. WHEN THE SIDESTAND IS UP AND THE
CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse 1
5. Starting circuit cut-off relay
6. Relay unit (diode)
7. Clutch switch
8. Sidestand switch
9. Neutral switch
11. Starter relay
12. Starter motor
8-9
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
3. Fuel tank
4. Air filter case
5. Canister

(Main, and ignition 1)
ES” on page 8-42.
OK ↓
page 8-43.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step (5).
8-47.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-45.
OK ↓
5. Check the relay unit (starting circuit NG →
cut-off relay).
Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 8-43.
OK ↓
6. Check the relay unit (diode). NG →
OK ↓
7. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
8-10

OK ↓
OK ↓
10.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
11.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
12.Check the stop/run/start switch. NG →
OK ↓
13.Check the entire starting system’s NG →
wiring. Properly connect or repair the starting sys-
page 8-7.
OK ↓
The starting system circuit is OK.
8-11
CHARGING SYSTEM
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
B
B
B
R
28
27
R
R
R
W W W
B
B
R
W W W
B
WWW
2
R
1
B W R
W W
(Dgy)
R
R
1. AC magneto
2. Rectifier/regulator
4. Main fuse
27.Battery
28.Frame ground
8-12
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
3. Fuel tank
4. Air filter case
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 8-42.
OK ↓
page 8-43.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator coil assembly.
COIL” on page 8-47.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-48.
OK ↓
5. Check the entire charging system’s NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 8-12.
OK ↓
The charging system circuit is OK.
8-13
CHARGING SYSTEM
8-14
A C
Y/B R/Y R/Y Y/B

R/G R/G R/L B W/Y W/Y B R/W R/G R/G
B B B B
EAS30498
EAS20075
W/L Br/L Br/R G B B B B G Br/R Br W/L
R/Y Y Y R/Y
(B) (B)
A B A D
4 L/W L/B W/R G/B G/Y G/Y G/B W/R L/B L/W
R R W/B W W/G Br/Y B B Br/YW/G W W/B
R
R (B) (B)
R R
A B
3 R W Br/R Br/R
27
OFF
ON R,W R Sb/W Lg B/W G/O G/L G/L G/OB/W Lg Sb/W
Br/L Br/L B
Y G/W B/R B/G Br/Y Br/Y B/G B/R G/W Y
Br/L B B
Br/R
28 A B
CIRCUIT DIAGRAM
B
LIGHTING SYSTEM
48
9 L/W L/WL/W L/W B B B L/B L/B L/B L/B
Y Y Y
R/L YY Y B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R
L/R
R Br/R L/R
R L/R
10 L/R
L/R
48
Br/L 13
Br/L Br/L R/Y
R/Y R/Y
R/Y
B L/R
B/R
91 L/R
L/R
B B/R L/R B
(B)
Y/B Y/B Y/B
Y/B
L/R Y/B
Y/B 48
L/R
8-15
92 SET L
FREE 95 75
RES ON FREE UP OFF L/R
HI
W/R G/B Y/W O/W G/L Br/L LO OFF PUSH (N) ON R
PASS DOWN N
W/G B W/Y W/L L Y Y/B PUSH R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W
FREE B/W L
G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G
(Gy) B W/G
(Gy)
Y
Br/L G/L O/W Y/W G/B W/R R/L A R/W
Y/B Y L/R W/L W/Y B G/Y
(Gy)
80
B
B
B
B R/Y Y/B Y B R/Y

L/R
C C C C C C B/W A B/W
B B B B B B B/W L B R/Y Y/B Y B R/Y
B B/W 110
L/R
48
G/R 107
BB
111 90
L/R B B G/R Y A Y
B L Y Y L/R 108 109
B B
(Gy)
B B R/Y B Y/B Y B R/Y 88
B B
(B)
LIGHTING SYSTEM
LIGHTING SYSTEM
3. Main switch
4. Main fuse
9. Ignition fuse 2
10.Signaling system fuse
13.Headlight fuse
27.Battery
28.Frame ground
48.Joint coupler
75.Meter assembly
80.Multi-function meter
88.Meter light
90.High beam indicator light
91.Auxiliary light
92.Handlebar switch (left)
95.Dimmer/pass switch
107.Headlight control unit
108.Headlight (high beam)
109.Headlight (low beam)
110.Tail/brake light
111.License plate light
A. Wire harness
B. Sub-wire harness (meter)
D. Sub-wire harness (headlight control unit)
8-16
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, auxiliary light, high beam indicator light, taillight, license light
or meter light.
TIP
3. Fuel tank
4. Air filter case

(Main, headlight, ignition 2, and sig-
naling system) Replace the fuse(s).
ES” on page 8-42.
OK ↓
page 8-43.
OK ↓
OK ↓
4. Check the dimmer/pass switch. NG →
The dimmer switch is faulty. Replace the
Refer to “CHECKING THE
handlebar switch (left).
OK ↓
5. Check the entire lighting system’s NG →
wiring. Properly connect or repair the lighting sys-
page 8-15.
OK ↓
Replace the meter assembly, headlight
assembly, tail/brake light, license plate
light or auxiliary light.
8-17
LIGHTING SYSTEM
8-18
A B D

W/L Br/L Br/R G B B B B G Br/R Br W/L Sb Sb
G/L G/L
EAS30500
EAS20076
(B) (B)
A B A C A E
L/W L/B W/R G/B G/Y G/Y G/B W/R L/B L/W
W/B W W/G Br/Y B B Br/YW/G W W/B
(B) (B)
A B
Sb/W Lg B/W G/O G/L G/L G/OB/W Lg Sb/W

A B
CIRCUIT DIAGRAM
4
R R
R/W
R
R
R R
Y/R P/B O/G Gy/R O W/R G L Br/Y R/W

R W Br/R Br/R
3 27 Lg/R L/B G/B R/B B Y W Y/R
41 Sb/W
SIGNALING SYSTEM
OFF R/L G/Y B B/L Br

ON R,W R
Br/L Br/L B
Br W R L/W R (B) (B)
B B B G/W W L/W R L/B L Sb B Sb/W L L
Br/L L
Br/R
28 35 Sb
Y/B G/W G/W Y/B
D
OFF Y/W G/Y G/Y Y/W
B B ON Sb
(B)
(B)
G/Y
B/L B/L
L G/W B/L 49 G/W G/W
Sb L L
R/L B G/W B (B)
G/Y G/W
(B)
Br G
R/W 36 G Br G/Y Y/B
R OFF Y B Lg/B Lg/L 46
ON
(B) (B)
B Y
44 B
Lg/B
9 L/W L/WL/W L/W B B B L/B L/B L/B L/B L/B Y/L O/W Lg/L P/W P V L L Gy
R/L
48 L/B L/B
48 B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
L/W L/W L/Y L/W Lg/B G/W G/W W/G W/Y
L/R
R Br/R L/R
R L/R
10 L/R (B)
L/R
R 48
Br/L 12 55
8-19
Br/L Br/L
B/L B/L
R/B B/L
14 G/W G/W
B/L
L/R 54 G/W B/L
L/R
(B)
Sb/W
A
Sb/W B/L
L/R G/W L/R L/R

Sb/W
17 B
92 SET L 48
FREE
75
HI B B B B B
L/R W/R G/B Y/W O/W G/L Br/L LO
96 OFF PUSH (N) 100 ON R
L/R Lg/B PASS DOWN 101 N
FREE L/R B B/W Br/L L 78
(Gy) B W/G
(L) (B)
(Gy) 77
112 B Br/L W/L W/Y
Br/L G/L O/W Y/W G/B W/R B L/R Br/L R/L A R/W
B Y/B Y L/R W/L W/Y B G/Y
Y L/R (L) (B) 79 L/W W/G G Y L R/B Br L/W B/W
(Gy) 97 R G/O W/Y L B W Y L/B B
Lg/B Y B
B A B (B)
G/W A G/W 80
L/W A L/W B/L V L R/B
G/L A G/L L/B A L/B
(B)
W/Y W/Y
B
L/W W
R W B B B/L L/B B
B W/Y A W/Y W V V 67
B W/L A W/L 73 R L
B Br/L A Br 82 (B)
Y G/L
B/W A B/W B/W B/W B B
B B B B B B B/W L G/L
B B/W 110 Br/B
Br/W W
Br/B Br/W Br/R A Br/R 84 85 B 69
48 G A G
Ch Ch Br/R G
G/L W B
B
106 105 B B/W
Ch Ch a
B Ch B Ch
104 103 G/L
B L Y Y L/R B W
B B B
B B Ch Br/R B B Ch G B
B B B
Br/B B Br/W B
B A A (B) 102
B (B) B B B B/W
B/W
B
B
B
B/W
B
SIGNALING SYSTEM
SIGNALING SYSTEM
3. Main switch
4. Main fuse
9. Ignition fuse 2
12.Ignition fuse 1
14.ABS ECU fuse
17.Brake light fuse
27.Battery
28.Frame ground
35.Front brake light switch
36.Rear brake light switch
41.Relay unit
44.Neutral switch
46.Fuel sender
48.Joint coupler
49.Gear position sensor
54.Coolant temperature sensor
67.ABS ECU
69.Rear wheel sensor
73.Shift sensor (MTT890D)
75.Meter assembly
77.Neutral indicator light
78.Oil pressure and coolant temperature warning
light
79.Auxiliary system warning light
82.Fuel level warning light
84.Turn signal indicator light (left)
85.Turn signal indicator light (right)
96.Horn switch
97.Horn
100.Hazard switch
101.Turn signal switch
102.Oil pressure switch
103.Rear turn signal light (right)
104.Rear turn signal light (left)
105.Front turn signal light (right)
106.Front turn signal light (left)
112.Brake light relay
A. Wire harness
C. Sub-wire harness (oil pressure switch)
8-20
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
3. Fuel tank
4. Air filter case

(Main, ignition 1, ignition 2, ABS
ECU signaling system, and brake
light.)
ES” on page 8-42.
OK ↓
page 8-43.
OK ↓
OK ↓
4. Check the entire signaling sys- NG →
tem’s wiring. Properly connect or repair the signaling
page 8-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system” on
page 8-21.
Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
Refer to “CHECKING THE Replace the handlebar switch (left).
OK ↓
8-21
SIGNALING SYSTEM
2. Check the horn. NG →

Refer to “CHECKING THE HORN” Replace the horn.
on page 8-48.
OK ↓
page 8-19.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
3. Check the brake light relay. NG →
Refer to “CHECKING THE RE- Replace the brake light relay.
OK ↓
page 8-19.
OK ↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal switch. NG →
OK ↓
2. Check the hazard switch. NG →
OK ↓
8-22
SIGNALING SYSTEM

page 8-19.
OK ↓
Replace the meter assembly or turn
signal light.
The neutral indicator light fails to come on.

OK ↓
2. Check the relay unit (diode). NG →
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The oil pressure and coolant temperature warning light fails to come on, when the main switch is set to
“ON”.
tem’s wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19
OK ↓
2. Disconnect the oil pressure switch NG →
lead from the oil pressure switch,
and then check whether the oil
pressure and coolant temperature Replace the meter assembly.
warning light come on when the
lead is connected to the engine
ground.
OK ↓
Replace the oil pressure switch.
8-23
SIGNALING SYSTEM
The oil pressure and coolant temperature warning light remains on, or the oil pressure warning icon
flashes after the engine is started.
page 8-19.
OK ↓
2. Measure the engine oil pressure. NG →
Refer to “MEASURING THE EN- Check the engine oil leakage, oil viscosity,
GINE OIL PRESSURE” on page oil seal, oil filter, or oil pump.
3-26.
OK ↓
Replace the oil pressure switch.
The fuel level warning light fails to come on.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 8-48.
OK ↓
page 8-19.
OK ↓
The oil pressure and coolant temperature warning light fails to come on.
1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-49.
OK ↓
page 8-19.
OK ↓
Replace the ECU or meter assembly.
8-24
SIGNALING SYSTEM
QSS (Quick Shift System) does not operate. (for MTT890D)

1. Check that the MIL does not come NG →
Repair the faulty parts.
on.
OK ↓
2. Check that the QSS is working un- NG → Check the QSS operating conditions ex-
der normal QSS operating condi- plained in the owner’s manual and operate
tions. the QSS accordingly.
OK ↓
3. Make sure that the QSS is effective. NG →
Activate the QSS. (Set the QSS to a set-
(Check whether the “QS ” icon ting other than “OFF”.)
is displayed at the top of the meter.)
OK ↓
4. Are you operating while the NG →
Operate while the “QS ” icon is lit.
“QS ” icon is lit?
OK ↓
5. Is the transmission gear display NG →
Repair the gear position sensor.
normal?
OK ↓
6. Check the connection of the cou- NG →
pler between the gear position sen- Connect the gear position sensor coupler.
sor and the ECU.
OK ↓
7. Are the clutch and neutral switches NG →
Repair the switch if it is not normal.
normal?
OK ↓
8. Check the shift sensor value in the NG →
diagnostic mode.
2.5 V when the shift pedal is not be-
ing operated.
Replace the shift sensor.
4.5 V when the shift pedal is
pressed fully in.
0.5 V when the shift pedal is
pushed fully up.
OK ↓
page 8-19.
OK ↓
Replace the ECU.
8-25
SIGNALING SYSTEM
The speedometer fails to operate.

1. Check the rear wheel sensor. NG →
Execute the diagnostic mode.
(Code “07”)
Replace the rear wheel sensor.
Refer to “DIAGNOSTIC CODE:
SENSOR OPERATION TABLE” on
page 9-79.
OK ↓
2. Check the entire wheel sensor wir- NG →
Properly connect or repair the wheel sen-
ing.
sor wiring.
Refer to TIP.
OK ↓
Replace the hydraulic unit assembly,
ECU, meter assembly.
TIP
Repair or replace if there is an open or short circuit.
• Between rear wheel sensor coupler and ABS ECU coupler.
(white–white)
(black–black)
• Between ABS ECU coupler and ECU coupler.
(white/yellow–white/yellow)
• Between joint coupler and meter assembly coupler.
(blue/white–blue/white)
(blue/black–blue/black)
8-26
EAS30502
EAS20077
4
R R
R/W
R
R
R R
CIRCUIT DIAGRAM

R W Br/R Br/R
ON R,W R
Br/L Br/L B
(B) (B)
Br/L B B
COOLING SYSTEM
28
B
L/W R
R
L/W 5
L/W
R/W
R G/Y L/W
G/Y R
B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
RR L/Y L/W Lg/B G/W G/W W/G W/Y
R
R
R (B)
R 48
Br/L 12 55
Br/L Br/L
B/L
B/L
G/W G/W
B/L
54
8-27
G/W B/L
(B)
B/L
G/Y
23
R L/W
L/W
L
113 B/W B/W B B
B B
L/W L
B/W
B/W
B
B
B
COOLING SYSTEM
COOLING SYSTEM
3. Main switch
4. Main fuse
12.Ignition fuse 1
23.Radiator fan motor fuse
27.Battery
28.Frame ground
48.Joint coupler
113.Radiator fan motor
8-28
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
TIP
3. Fuel tank
4. Air filter case

(Main, ignition 1, and radiator fan
motor) Replace the fuse(s).
ES” on page 8-42.
OK ↓
page 8-43.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor(s).
TOR FAN MOTOR” on page 8-49.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK ↓
6. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-49.
OK ↓
8-29
COOLING SYSTEM
7. Check the entire cooling system’s NG →

wiring. Properly connect or repair the cooling sys-
page 8-27.
OK ↓
Replace the ECU.
8-30
EAS30513
EAS20081
R R/L R/L R/W R
4
R R
R/W
R
R
CIRCUIT DIAGRAM
R R

R W Br/R Br/R
41 R Br
ON R,W R
Br/L Br/L B
Br W R L/W R 43 (B) (B)
Br/L B B B W L/W R L/B L Sb B Sb/W
28 R L/W L/W
R/L
FUEL PUMP SYSTEM
R/W R/W
R/W 37 R/L B G/W B
R R/L R/L
39 (B)
R/W B/W W/G W/B OFF

RUN
R R B R/W START 47
L/W R/L Y/G W/G
Br B
W/B W/G B/W R/W L/W
6 R/W B W
R
R L/B Y/L O/W Lg/L P/W P V L L Gy

L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
R L/Y L/W Lg/B G/W G/W W/G W/Y
R
R
R (B)
Br/L 12 55
Br/L Br/L
8-31
B
B
B/W B/W B B
B/W
B/W
B
B
B
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
3. Main switch
4. Main fuse
6. Fuel injection system fuse
12.Ignition fuse 1
27.Battery
28.Frame ground
41.Relay unit
43.Fuel pump relay
47.Fuel pump
8-32
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
3. Fuel tank

(Main, ignition 1, and fuel injection
system) Replace the fuse(s).
ES” on page 8-42.
OK ↓
page 8-43.
OK ↓
OK ↓
4. Check the stop/run/start switch. NG →
OK ↓
5. Check the relay unit (fuel pump re- NG →
lay).
Replace the relay unit.
Refer to “CHECKING THE RE-
OK ↓
6. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PUMP OPERATION” on page 7-4.
OK ↓
7. Check the entire fuel pump sys- NG →
tem’s wiring. Properly connect or repair the fuel pump
page 8-31.
OK ↓
Replace the ECU.
8-33
FUEL PUMP SYSTEM
8-34
A

EAS31007
EAS20167
(B) (B)
A B
(B) (B)
A B

4
R R
R/W A B
R
CIRCUIT DIAGRAM
R
R R

R W Br/R Br/R
ON R,W R
Br/L Br/L B
(B) (B)
Br/L B B
Br/R
28
BB
R/G
W/G W W/B
37
R R/L
38
R/W B/W W/G W/B OFF
RUN
R R B R/W START Y/G W/G
B/W
W/B W/G B/W
R/W B W
R L/B L/B L/B L/B L/B L/W L/W L/W L/WL/W
R/G
R 8 9 L/W L/WL/W L/W B B B L/B L/B L/B L/B L/B Y/L O/W Lg/L P/W P V L L Gy
R/L
48 L/B L/B
RR L/B L/W L/W L/Y L/W Lg/B G/W G/W W/G W/Y
R Br/R
R
R (B)
R 48 Br/Y Br B
Br/L 12 55 Br/Y
B Br Br/Y B
Br/Y Br/Y Br/Y 63
Br/L Br/L
L/B L/W L/W Br/Y
L/B (B) (B)
B
Br/Y W L B B B
8-35
Br/Y B
GRIP WARMER SYSTEM (for MTT890D)
L W
64
(Gy) (Gy)
75
R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W
R/G G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G
R
(Gy)
21
R/L A R/W
W/B A W/B
W A W
W/G A W/G
80
L/W A L/W
L/B A L/B
L/W
L/B

B B B B B B B/W
B/W
L/W L/W B
48 L/B
R/G 74 R/G L/B
B
B/W B (R)
B/W
B/W
B
B
B
B
3. Main switch
4. Main fuse
8. Backup fuse 2
9. Ignition fuse 2
12.Ignition fuse 1
21.Backup fuse 1
27.Battery
28.Frame ground
38.Menu switch
48.Joint coupler
63.Grip warmer (left)
64.Grip warmer (right)
74.YDT coupler
75.Meter assembly
A. Wire harness
8-36
EAS31008
TROUBLESHOOTING
TIP
The grip warmers do not become warm at all.

1. Check that the MIL (Malfunction in- NG →
Perform the troubleshooting for fault code
dicator light) is on and that “Err” is
No. U0155 (FI). Refer to “U0155 or Err
displayed in the multi-function me-
(FI)” on page 9-302.
ter display.
OK ↓
2. Check that the grip warmers are not NG → Adjust the temperature levels of the grip
turned off. warmer settings.
OK ↓
(Main, ignition 1, ignition 2, backup
1 and backup 2) Replace the fuse(s).
ES” on page 8-42.
OK ↓
page 8-43.
OK ↓
5. Check that the engine is started. NG → Start the engine.
OK ↓
6. Check the grip warmers. NG →
Refer to “CHECKING THE GRIP
Replace the handlebar grip or throttle grip.
WARMERS (for MTT890D)” on
page 8-52.
OK ↓
7. Check the entire grip warmer sys- NG →
tem wiring. Properly connect or replace the wiring har-
page 8-35.
OK ↓
8-37
8. Execute the diagnostic mode (code NG →

Replace the ECU. Refer to “REPLACING
No. 57) to turn on the grip warmers,
THE ECU (Engine Control Unit)” on page
and then check that they become
8-43.
warm.
OK ↓
The grip warmers are abnormally hot while the engine is idling.
1. Check that the temperature level of NG →
Adjust the temperature levels of the grip
the low grip warmer setting is set to
warmer settings.
lowest temperature.
OK ↓
Replace the ECU. Refer to “REPLAC-
ING THE ECU (Engine Control Unit)”
on page 8-43.
The grip warmers do not become very warm while the vehicle is traveling.
1. Check that the temperature level of NG →
Adjust the temperature levels of the grip
the high grip warmer setting is set
warmer settings.
to highest temperature.
OK ↓
2. Check that the engine trouble warn- NG →
Perform the troubleshooting for fault code
ing light is on and that fault code
No. “P0500 (FI), P1500”. Refer to “P0500
No. P0500 (FI) is displayed in the
Yamaha diagnostic tool display. (FI), P1500” on page 9-200.
OK ↓
Replace the ECU. Refer to “REPLAC-
ING THE ECU (Engine Control Unit)”
on page 8-43.
The temperature levels of the grip warmer settings cannot be changed.

1. Check the wire harness between NG →
Properly connect or replace the wiring har-
the handlebar switch (right) and the
ness.
meter assembly.
OK ↓
Replace the meter assembly or han-
dlebar switch (right).
8-38
ELECTRICAL COMPONENTS
EAS20089
1 2
3
21 4
5
20
19 6
8
18
9
17
16
13 10
15 14
11
12
1. ECU (Engine Control Unit) 19. Headlight control unit

2. Fuel pump 20. Intake air temperature sensor
3. Relay unit 21. Clutch switch
5. Fuse box
6. Brake light relay
7. Starter relay
8. Angular position sensor (MTT890D)
9. Gear position sensor
10. Shift sensor (MTT890D)
11. Sidestand switch
12. AC magneto
13. Crankshaft position sensor
14. O2 sensor
16. Front wheel sensor
17. SCU (Suspension Control Unit) (MTT890D)
18. Horn
8-39
3
2
4
7
6
1 5
8
21
9
10
20
11
19
18
12
17
15 13
16 14
1. ABS ECU (Electronic Control Unit) 21. Rectifier/regulator
2. Throttle servo motor
3. Intake air pressure sensor 2
5. Throttle position sensor
6. Injector
7. Accelerator position sensor
9. CLCU (cornering light control unit) (MTT890D)
10. Main switch/Immobilizer unit
11. Ignition coil
12. Radiator fan motor
13. Coolant temperature sensor
14. Starter motor
16. Neutral switch
17. Rear brake light switch
19. IMU (Inertial Measurement Unit)
20. Battery
8-40
EAS30549
CHECKING THE SWITCHES

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
TIP
Refer to “CHECKING THE SWITCHES” in “BASIC INFORMATION” (separate volume).
1 Y/W O/W
10
W/R G/B Y/W O/W G/L Br/L
PUSH W/G B W/Y W/L L Y Y/B Y/B L/W B/Y L/Y
FREE OFF B/Y Y/B
ON L/Y L/W
2 G/L Y/W Br/L

SET
FREE
RES 11
G/W G/Y Y/W Y/B
3 HI
Y Y/B Y
OFF
Y/B G/W
Y/W G/Y
ON
LO
PASS
4 L/R B/W
12
ON
OFF B/W W/G W/B
R/L R/W L/W B
OFF R B R/W
L/R B
RUN
START
5 W/G B
L/W R/L
FREE
PUSH
6 G/B B W/R 13
UP
(N) R,W Br/L Br/R
R,W
DOWN ON Br/R
Br/L
OFF
7 L Br/L
OFF
ON
Br/L 14
8 W/L L/R W/Y
R
N
L
15
Br B G Y G Br
OFF
Y B
ON
1. Cruise control power switch 15. Rear brake light switch

2. Cruise control setting switch
3. Dimmer/pass switch
4. Horn switch
5. Mode switch
6. Select switch
7. Hazard switch
8. Turn signal switch
9. Sidestand switch
10. Clutch switch
13. Main switch
14. Neutral switch
8-41
EAS30551
CHECKING THE FUSES Amperage

Fuses Q’ty
The following procedure applies to all of the fus- rating
es. Auxiliary DC jack
2A 1
ECA13680 “TERMINAL 2”
NOTICE
Backup 1 7.5 A 1
To avoid a short circuit, always set the main
Backup 2 15 A 1
switch to “OFF” when checking or replacing
a fuse. Electronic throttle valve 7.5 A 1
ABS motor 30 A 1
1. Remove:
• Rider seat ABS ECU 7.5 A 1
Refer to “GENERAL CHASSIS (1)” on page ABS solenoid 15 A 1
4-1. Cruise control 2A 1
• Fuse box cover
Seat heater 7.5 A 1
2. Check:
• Fuse Accessory 2A 1
a. Connect the digital circuit tester to the fuse SCU (for MTT890D) 7.5 A 1
and check the continuity. Spare fuse 30 A 1
TIP Spare fuse 15 A 1
Set the digital circuit tester selector to “ Ω ”. Spare fuse 10 A 1
Spare fuse 7.5 A 1
Digital circuit tester (CD732)
Spare fuse 2A 1
90890-03243
Model 88 Multimeter with ta- EWA13310
chometer WARNING
YU-A1927 Never use a fuse with an amperage rating
other than that specified. Improvising or us-
b. If the digital circuit tester indicates “O.L”, ing a fuse with the wrong amperage rating
replace the fuse. may cause extensive damage to the electri-
3. Replace: cal system, cause the lighting and ignition
• Blown fuse systems to malfunction and could possibly
a. Set the main switch to “OFF”. cause a fire.
b. Install a new fuse of the correct amperage
rating. 4. Install:
c. Set on the switches to verify if the electri- • Fuse box cover
cal circuit is operational. • Rider seat
d. If the fuse immediately blows again, check Refer to “GENERAL CHASSIS (1)” on page
the electrical circuit. 4-1.
ECA27250
Amperage NOTICE
Fuses Q’ty
rating
• Be careful not to lose or damage the fuse
Main 50 A 1 box cover. If the fuse box cover is lost or
Headlight 7.5 A 1 damaged, replace it with a new one.
Signaling system 7.5 A 1
• Be sure to install the fuse box cover. Water
may get inside the fuse box and cause mal-
Ignition 1 10 A 1 function.
Ignition 2 7.5 A 1
Radiator fan motor 15 A 1
Brake light 2A 1
Fuel injection system 7.5 A 1
Auxiliary DC jack 1
2A 1
“TERMINAL 1”
8-42
EAS31006
3. Remove:
REPLACING THE ECU (Engine Control Unit)
• Battery
1. Turn the main switch to “OFF”.
2. Replace the ECU (Engine Control Unit).
4-1.
TIP 4. Check:
Fix the ECU “1” with the claw of air filter case • Battery charge
cover “2” properly. 5. Charge:
• Battery
6. Install:
• Battery
4-1.
7. Connect:
• Battery lead
2
(to the battery terminals)
ECA26980
1 NOTICE
First, connect the positive battery lead, and
3. Clean the throttle bodies and reset the ISC
then the negative battery lead.
(idle speed control) learning value.
Refer to “CHECKING AND CLEANING THE 8. Check:
THROTTLE BODIES” on page 7-8. • Battery terminal
4. Check: Dirt → Clean with a wire brush.
• Engine idling speed Loose connection → Connect properly.
Start the engine, warm it up, and then mea- 9. Lubricate:
sure the engine idling speed. • Battery terminal
Engine idling speed Recommended lubricant

1200–1400 r/min Dielectric grease
EAS30552 10.Install:
CHECKING AND CHARGING THE BATTERY • Rider seat
ECA22960
NOTICE
4-1.
Use only the specified genuine YAMAHA bat-
tery. Using a different battery may cause the EAS30553
CHECKING THE RELAYS

IMU to fail and the engine to stall.
Check each switch for continuity with the digital
TIP circuit tester. If the continuity reading is incor-
Refer to “CHECKING AND CHARGING THE rect, replace the relay.
BATTERY” in “BASIC INFORMATION” (sepa-
rate volume). Digital circuit tester (CD732)
90890-03243
1. Remove: Model 88 Multimeter with ta-
• Rider seat chometer
Refer to “GENERAL CHASSIS (1)” on page YU-A1927
4-1.
2. Disconnect: 1. Disconnect the relay from the wire harness.
• Battery lead 2. Connect the digital circuit tester (Ω) and bat-
(from the battery terminals) tery (12 V) to the relay terminal as shown.
ECA13700 Check the relay operation.
NOTICE Out of specification → Replace.
First, disconnect the negative battery lead,
and then the positive battery lead.
8-43
Starter relay 2. Negative battery terminal

3. Positive tester probe
3
4. Negative tester probe
Result
Continuity
R/W L/W (between “3” and “4”)
1 2 Radiator fan motor relay

4
1. Positive battery terminal
2. Negative battery terminal L/W
3. Positive tester probe L/W
R G/Y
Relay operation
Continuity
(between “3” and “4”)
Relay unit (starting circuit cut-off relay) 2. Negative battery terminal
Result
Continuity
Br W R L/W R
W L/W R L/B L Sb B Sb/W
Brake light relay
First step:
2. Negative battery terminal
Result B Y Lg/B
Continuity
(between “3” and “4”) L/R
Relay unit (fuel pump relay) 1. Positive tester probe

3 2 1 4 Result
Continuity
Br W R L/W R
8-44
Second step:
No continuity
Positive tester probe
sky blue “1”
Negative tester probe
black “2”
Continuity
B Y Lg/B
black “2”
L/R Negative tester probe
sky blue “1”
No continuity
1. Positive battery terminal Positive tester probe
2. Negative battery terminal sky blue “1”
blue “3”
Continuity
Result blue “3”
No continuity Negative tester probe
(between “3” and “4”) sky blue “1”
No continuity
EAS30795 Positive tester probe
CHECKING THE RELAY UNIT (DIODE) sky blue “1”
1. Check: Negative tester probe
• Relay unit (diode) sky blue/white “4”
Out of specification → Replace. Continuity
Digital circuit tester (CD732) sky blue/white “4”
90890-03243 Negative tester probe
Model 88 Multimeter with ta- sky blue “1”
chometer No continuity
YU-A1927 Positive tester probe
blue/black “5”
TIP Negative tester probe
blue “3”
The digital circuit tester readings are shown in
Continuity
the following table. Positive tester probe
blue “3”
blue/black “5”
Br W R L/W R
a. Disconnect the relay unit coupler from the

wire harness.
b. Connect the digital circuit tester (Ω) to the
relay unit terminal as shown.
8-45
c. Check the relay unit (diode) for continuity.

d. Check the relay unit (diode) for no continu- Digital circuit tester (CD732)
ity. 90890-03243
EAS30558 chometer
CHECKING THE IGNITION COILS YU-A1927
The following procedure applies to all of the igni-
tion coils. • Negative tester probe
1. Check: Ignition coil terminal “1”
• Primary coil resistance • Positive tester probe
Out of specification → Replace. Spark plug terminal “2”
Primary coil resistance

1.19–1.61 Ω 1
a. Disconnect the ignition coil coupler from

the ignition coil.
ignition coil as shown.

2
90890-03243 G089047
Model 88 Multimeter with ta- b. Measure the secondary coil resistance.

chometer
YU-A1927 EAS30556
CHECKING THE IGNITION SPARK GAP

• Positive tester probe 1. Check:
Ignition coil terminal “1” • Ignition spark gap
• Negative tester probe Out of specification → Perform the ignition
Ignition coil terminal “2” system troubleshooting, starting with step (5).
Refer to “TROUBLESHOOTING” on page
1 8-4.
2
Minimum ignition spark gap
6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
G089046 a. Remove the ignition coil from the spark
c. Measure the primary coil resistance. plug.
2. Check: b. Connect the ignition checker “1” as
• Secondary coil resistance shown.
Ignition checker
Secondary coil resistance 90890-06754
8.50–11.50 kΩ Oppama pet–4000 spark checker
YM-34487
a. Connect the digital circuit tester (Ω) to the
ignition coil as shown.
8-46
Gy B
G089048
2. Ignition coil b. Measure the crankshaft position sensor

resistance.
c. Turn the main switch to “ON”.
d. Measure the ignition spark gap “a”. EAS30562
e. Crank the engine by pushing the “ ” side CHECKING THE STARTER MOTOR
of the stop/run/start switch and gradually OPERATION
increase the spark gap until a misfire oc- 1. Check:
curs. • Starter motor operation
Does not operate → Perform the electric
EAS30560
starting system troubleshooting, starting with
CHECKING THE CRANKSHAFT POSITION step (4).
SENSOR Refer to “TROUBLESHOOTING” on page
1. Disconnect: 8-10.
• Crankshaft position sensor coupler a. Connect the positive battery terminal “1”
(from the wire harness) and starter motor lead “2” with a jumper
2. Check: lead “3”.
• Crankshaft position sensor resistance EWA13810
Out of specification → Replace the crank- WARNING

shaft position sensor. • A wire that is used as a jumper lead must
have at least the same capacity of the bat-
Crankshaft position sensor resis-
tery lead, otherwise the jumper lead may
tance
228–342 Ω burn.
• This check is likely to produce sparks,
a. Connect the digital circuit tester (Ω) to the therefore, make sure no flammable gas or
crankshaft position sensor coupler as fluid is in the vicinity.
shown.

90890-03243
chometer
YU-A1927
• Positive tester probe

black “1”
G089054
• Negative tester probe
gray “2” b. Check the starter motor operation.
EAS30566
CHECKING THE STATOR COIL

1. Disconnect:
• Stator coil coupler
(from the wire harness)
8-47
2. Check:
• Stator coil resistance Digital circuit tester (CD732)
Out of specification → Replace the stator coil. 90890-03243
Stator coil resistance chometer
0.152–0.228 Ω YU-A1927
a. Connect the digital circuit tester to the sta-

tor coil coupler as shown.

90890-03243
Model 88 Multimeter with ta- 2
chometer
YU-A1927
1
white “1”
• Negative tester probe 1. Positive tester probe
white “2” 2. Negative tester probe
b. Start the engine and let it run at approxi-
white “1” mately 5000 r/min.
• Negative tester probe c. Measure the rectifier/regulator input volt-
white “3” age.
EAS30569
white “2”
CHECKING THE HORN
• Negative tester probe 1. Check:
white “3” • Horn sound
Faulty sound → Replace.
EAS30573
CHECKING THE FUEL SENDER

1 2 3 1. Disconnect:
• Fuel pump coupler
W W W (from the fuel pump)
2. Remove:
• Fuel tank
3. Remove:
• Fuel pump
(from the fuel tank)
b. Measure the stator coil resistance.
4. Check:
EAS30680 • Fuel sender resistance
CHECKING THE RECTIFIER/REGULATOR Out of specification → Replace the fuel pump
1. Check: assembly.
• Charging voltage
Out of specification → Replace the rectifier/ Sender unit resistance (full)
regulator. 9.0–11.0 Ω
Refer to “CHECKING THE STATOR COIL” Sender unit resistance (empty)
on page 8-47. 213.0–219.0 Ω
Charging voltage a. Connect the digital circuit tester (Ω) to the

above 14 V at 5000 r/min fuel sender terminals as shown.
a. Connect the digital circuit tester (AC V) to

the battery terminal as shown.
8-48
Digital circuit tester (CD732) 1

90890-03243
chometer
YU-A1927
• Positive tester probe →

Fuel sender terminal “1”
• Negative tester probe →
Fuel sender terminal “2”
EAS30577
CHECKING THE RADIATOR FAN MOTOR

1. Check:
• Radiator fan motor
Faulty/rough movement → Replace.
a. Disconnect the radiator fan motor coupler
2 from the wire harness.
b. Connect the battery (DC 12 V) as shown.
1 • Positive tester probe
blue “1”
• Negative tester probe
b. Move the fuel sender float to maximum “3” black “2”
and minimum “4” level position.
EAS30574 c. Measure the radiator fan motor move-

CHECKING THE FUEL LEVEL WARNING ment.
LIGHT
EAS30578
This model is equipped with a self-diagnosis de-
CHECKING THE COOLANT TEMPERATURE
vice for the fuel level detection circuit.
SENSOR
1. Check:
1. Remove:
• Fuel level warning light “1”
• Coolant temperature sensor
(Turn the main switch to “ON”.)
Refer to “CYLINDER HEAD” on page 5-27.
Warning light comes on for a few seconds, EWA14130
then goes off → Warning light is OK. WARNING

Warning light does not come on → Replace • Handle the coolant temperature sensor
the meter assembly. with special care.
Warning light flashes eight times, then goes • Never subject the coolant temperature sen-
off for 3 seconds in a repeated cycle (mal- sor to strong shocks. If the coolant tem-
function detected in fuel sender) → Replace perature sensor is dropped, replace it.
the fuel pump assembly.
2. Check:
• Coolant temperature sensor resistance
8-49
a. Connect two C-size batteries to the throttle

Coolant temperature sensor re- servo motor terminals “1” as shown.
sistance ECA17660
2513–2777 Ω at 20 °C (2513– NOTICE

2777 Ω at 68 °F) Do not use a 12 V battery to operate the throt-
Coolant temperature sensor re-
tle servo motor.
sistance
210–221 Ω at 100 °C (210–221 Ω TIP
at 212 °F) Do not use old batteries to operate the throttle
servo motor.
a. Connect the digital circuit tester (Ω) to the
coolant temperature sensor as shown.

90890-03243
chometer
YU-A1927 1 1
b. Immerse the coolant temperature sensor 3V
“1” in a container filled with coolant “2”.
TIP
EAS30594
Make sure the coolant temperature sensor ter- CHECKING THE INTAKE AIR
minals do not get wet. TEMPERATURE SENSOR
c. Place a thermometer “3” in the coolant. 1. Remove:
• Intake air temperature sensor
EWA14110
3 WARNING
1 • Handle the intake air temperature sensor
with special care.
• Never subject the intake air temperature
sensor to strong shocks. If the intake air
temperature sensor is dropped, replace it.
2
2. Check:
G089056
• Intake air temperature sensor resistance
d. Heat the coolant or let it cool down to the Out of specification → Replace.
specified temperatures.
e. Measure the coolant temperature sensor Intake air temperature sensor re-
resistance. sistance
3. Install: 5400–6600 Ω at 0 °C (5400–6600
• Coolant temperature sensor Ω at 32 °F)
Intake air temperature sensor re-
Coolant temperature sensor sistance
15 N·m (1.5 kgf·m, 11 lb·ft) 290–390 Ω at 80 °C (290–390 Ω
T.
at 176 °F)
R.
EAS30592
CHECKING THE THROTTLE SERVO MOTOR a. Connect the digital circuit tester (Ω) to the
1. Remove: intake air temperature sensor terminal as
• Air filter case shown.
4-24.
90890-03243
2. Check: Model 88 Multimeter with ta-
• Throttle valve operation chometer
Throttle valves do not fully open → Replace YU-A1927
the throttle bodies.
8-50
b. Immerse the intake air temperature sen-

sor “1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.
3
1 c. Measure the fuel injector resistance.
EAS32604
CHECKING THE PURGE CUT VALVE

SOLENOID
2 1. Check:
G089057 • Purge cut valve solenoid resistance
d. Slowly heat the water, then let it cool down
to the specified temperature. Solenoid resistance
e. Measure the intake air temperature sen- 22–26 Ω
sor resistance.
3. Install: a. Disconnect the purge cut valve solenoid
• Intake air temperature sensor coupler from the wire harness.
EAS30681
b. Connect the digital circuit tester to the
CHECKING THE FUEL INJECTORS purge cut valve solenoid terminals as
The following procedure applies to all of the fuel shown.
injectors.
1. Remove:
90890-03243
• Fuel injector Model 88 Multimeter with ta-
Refer to “THROTTLE BODIES” on page 7-6. chometer
2. Check: YU-A1927
• Fuel injector resistance
Out of specification → Replace the fuel injec- • Positive tester probe →
tor. Purge cut valve solenoid terminal “1”
Resistance Purge cut valve solenoid terminal “2”
12.0 Ω
2 1
a. Disconnect the fuel injector coupler from
the fuel injector.
fuel injector coupler as shown.
R/W Y/R

90890-03243
chometer
YU-A1927
c. Measure the purge cut valve solenoid re-
sistance.
• Positive tester probe →
Injector terminal “1”
Injector terminal “2”
8-51
EAS31016
CHECKING THE GRIP WARMERS (for Solenoid resistance

MTT890D) 4.0–4.6 Ω
grip warmers. a. Disconnect the front fork solenoid coupler
1. Check: or rear shock absorber assembly solenoid
• Grip warmer resistance coupler from the wire harness.
Out of specification → Replace the handlebar b. Connect the digital circuit tester to the
grip or throttle grip. purge cut valve solenoid terminals as
shown.
Grip warmer resistance (L)
6.3–7.7 Ω (MTT890D) Digital circuit tester (CD732)
Grip warmer resistance (R) 90890-03243
6.3–7.7 Ω (MTT890D) Model 88 Multimeter with ta-
chometer
a. Disconnect the grip warmer coupler from YU-A1927
the wire harness.
b. Connect the digital circuit tester (Ω) to the • Positive tester probe →
grip warmer coupler as shown. Solenoid terminal “1”
Digital circuit tester (CD732) Solenoid terminal “2”
90890-03243
Model 88 Multimeter with ta- A B
chometer
YU-A1927
2 1 1 2
• Positive tester probe → B W W B
Black “1”
Black “2”
A. Front fork
B. Rear shock absorber assembly
A B
2 1 2 1
Br L W
A. Grip warmer coupler (left)

B. Grip warmer coupler (right)
c. Measure the grip warmer resistance.
EAS33554
CHECKING THE SOLENOID (FRONT FORK/

REAR SHOCK ABSORBER ASSEMBLY) (for
MTT890D)
1. Check:
• Solenoid resistance
Out of specification → Replace the damper
rod assembly or rear shock absorber assem-
bly.
8-52
8-53
SELF DIAGNOSTIC
SELF-DIAGNOSTIC FUNCTION..................................................................... 9-1

GLOSSARY............................................................................................... 9-1
OUTLINE ...................................................................................................9-1
CHECKING THE WARNING LIGHT .........................................................9-1
YDT ...........................................................................................................9-2
PARTS CONNECTED TO THE ECU ........................................................9-3
PARTS CONNECTED TO THE ABS ECU................................................ 9-3
PARTS CONNECTED TO THE SCU (for MTT890D) ............................... 9-4
PRECAUTIONS FOR ROAD TEST .......................................................... 9-4
COPE WITH THE MIL FLASHING ............................................................ 9-4
SYSTEM DIAGRAM ........................................................................................9-5

ECU CIRCUIT DIAGRAM..........................................................................9-5
ECU COUPLER LAYOUT ......................................................................... 9-7
FUEL INJECTION SYSTEM............................................................................9-9

CIRCUIT DIAGRAM .................................................................................. 9-9
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-11
[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS
NOT NORMAL........................................................................................ 9-12
[B] THE MIL DOES NOT COME ON, BUT THE ENGINE
OPERATION IS NOT NORMAL ............................................................. 9-12
IMMOBILIZER SYSTEM................................................................................ 9-13

CIRCUIT DIAGRAM ................................................................................ 9-13
SYSTEM OUTLINE ................................................................................. 9-15
PART REPLACEMENT AND KEY CODE REGISTRATION
REQUIREMENTS...................................................................................9-15
HOW TO CHECK DTC............................................................................9-20
CRUISE CONTROL SYSTEM ....................................................................... 9-21

CIRCUIT DIAGRAM ................................................................................ 9-21
CRUISE CONTROL CIRCUIT OPERATION...........................................9-23
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 9-24
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-25
[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR
LIGHT ..................................................................................................... 9-26
[B-1] DIAGNOSIS USING THE DTC .......................................................9-26
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES...... 9-26
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED........................... 9-26
[C-1] ERASING THE DTC ....................................................................... 9-26
[C-2] FINAL CHECK ................................................................................ 9-27
9
ABS (Anti-lock Brake System) .................................................................... 9-29
CIRCUIT DIAGRAM ................................................................................ 9-29
ABS COMPONENTS CHART .................................................................9-31
ABS COUPLER LOCATION CHART ......................................................9-32
MAINTENANCE OF THE ABS ECU .......................................................9-33
ABS TROUBLESHOOTING OUTLINE....................................................9-33
[A] CHECKING THE ABS WARNING LIGHT..........................................9-36
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............. 9-36
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................9-36
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 9-36
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE ........................ 9-36
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE ........................ 9-37
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................... 9-37
[B-2] DIAGNOSIS USING THE DTC .......................................................9-37
[B-3] DELETING THE DTC ..................................................................... 9-38
[C-1] FINAL CHECK ................................................................................ 9-38
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM

(for MTT890D) ..............................................................................................9-39
CIRCUIT DIAGRAM ................................................................................ 9-39
MAINTENANCE OF THE SCU (Suspension Control Unit) .....................9-41
CORNERING LIGHT SYSTEM (for MTT890D) ............................................9-47

CIRCUIT DIAGRAM ................................................................................ 9-47
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........9-52

DTC TABLE............................................................................................. 9-52
SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION
SYSTEM)................................................................................................9-57
SELF-DIAGNOSTIC FUNCTION TABLE (FOR IMMOBILIZER
SYSTEM)................................................................................................9-71
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS
(Anti-lock Brake System)) ....................................................................... 9-71
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ELECTRONICALLY
ADJUSTABLE SUSPENSION SYSTEM (for MTT890D)) ......................9-75
SELF-DIAGNOSTIC FUNCTION TABLE (FOR CORNERING LIGHT
SYSTEM (for MTT890D)) ....................................................................... 9-78
COMMUNICATION ERROR WITH THE METER ................................... 9-79
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 9-79
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................9-83
EVENT CODE TABLE...................................................................................9-85
30_EVENT ..................................................................................................... 9-87

70_EVENT ..................................................................................................... 9-89
B1000 ............................................................................................................9-90
B1001 ............................................................................................................9-91
C0044 ............................................................................................................9-92
C0520 (FI) ...................................................................................................... 9-93

C0520 (SCU).................................................................................................. 9-97

C0520 (CLCU) .............................................................................................9-100

TROUBLESHOOTING ..........................................................................9-100
C100A ..........................................................................................................9-103
C100B ..........................................................................................................9-108
C100D ..........................................................................................................9-113
C100F ..........................................................................................................9-116
C1007 ..........................................................................................................9-119
P0030...........................................................................................................9-120
P00D1, P2195..............................................................................................9-124
P0105...........................................................................................................9-128
P0106...........................................................................................................9-130
P0107, P0108 ..............................................................................................9-132

P0110...........................................................................................................9-136
P0111...........................................................................................................9-138
P0112, P0113 ..............................................................................................9-141

P0115...........................................................................................................9-145
P0116...........................................................................................................9-146
P0117, P0118 ..............................................................................................9-149

P0122, P0123, P0222, P0223, P2135 .........................................................9-153

P0132...........................................................................................................9-158
P0133...........................................................................................................9-161
OUTLINE ...............................................................................................9-161
FAIL-SAFE SYSTEM.............................................................................9-161
P0134...........................................................................................................9-163
P0201...........................................................................................................9-165
P0202...........................................................................................................9-168
P0203...........................................................................................................9-171
P0300, P0301, P0302, P0303 .....................................................................9-174
OUTLINE ...............................................................................................9-174
FAIL-SAFE SYSTEM.............................................................................9-175
P0335...........................................................................................................9-178
P0351...........................................................................................................9-181
P0352...........................................................................................................9-185
P0353...........................................................................................................9-189
P0458...........................................................................................................9-193
P0480...........................................................................................................9-197
P0500 (FI), P1500........................................................................................9-200

P0500 (CLCU) .............................................................................................9-212

P0560 (FI), P0563........................................................................................9-213

P0560 (SCU)................................................................................................9-214
P0564...........................................................................................................9-215
P056C ..........................................................................................................9-221
P0601...........................................................................................................9-228
P0606...........................................................................................................9-229
P062F ..........................................................................................................9-230
P0638...........................................................................................................9-232
P0657...........................................................................................................9-236
P0914...........................................................................................................9-240
P0915...........................................................................................................9-242
P0916, P0917 ..............................................................................................9-244

P1004...........................................................................................................9-248
P1600...........................................................................................................9-250
P1601...........................................................................................................9-254
P1602...........................................................................................................9-258
P1606, P1607 ..............................................................................................9-261

P1608...........................................................................................................9-265
P1609...........................................................................................................9-267
P1806, P1807 ..............................................................................................9-269

P2122, P2123, P2127, P2128, P2138 .........................................................9-273

P2158 (FI) ....................................................................................................9-277
P2158 (SCU)................................................................................................9-281
U0100 (SCU)................................................................................................9-285
U0100 (CLCU) .............................................................................................9-288

U0121 ..........................................................................................................9-291
U0125 (FI) ....................................................................................................9-294

U0125 (SCU)................................................................................................9-297
U0125 (CLCU) .............................................................................................9-299

U0155 or Err (FI) .........................................................................................9-302

U0155 or Err (SCU).....................................................................................9-305

U0401 ..........................................................................................................9-308
U0432 ..........................................................................................................9-311
51_IMMOBILIZER .......................................................................................9-314
52_IMMOBILIZER .......................................................................................9-315
53_IMMOBILIZER .......................................................................................9-316
54_IMMOBILIZER .......................................................................................9-318
55_IMMOBILIZER .......................................................................................9-319
56_IMMOBILIZER .......................................................................................9-320
11_ABS .......................................................................................................9-322
12_ABS .......................................................................................................9-323
13, 26_ABS .................................................................................................9-324

14, 27_ABS .................................................................................................9-325

15_ABS .......................................................................................................9-326
16_ABS .......................................................................................................9-328
21_ABS .......................................................................................................9-330
31_ABS .......................................................................................................9-331
33_ABS .......................................................................................................9-333
34_ABS .......................................................................................................9-335
41_ABS .......................................................................................................9-336
42_ABS .......................................................................................................9-337
43, 45_ABS .................................................................................................9-338
44, 46_ABS .................................................................................................9-339

51_ABS .......................................................................................................9-340
53_ABS .......................................................................................................9-341
55_ABS .......................................................................................................9-343
56_ABS .......................................................................................................9-344
57_ABS .......................................................................................................9-345
62_ABS .......................................................................................................9-349
68_ABS .......................................................................................................9-350
89_ABS .......................................................................................................9-351
90_ABS .......................................................................................................9-353
91_ABS .......................................................................................................9-355
SELF-DIAGNOSTIC FUNCTION
EAS20437
EAS33142
GLOSSARY
Word Description
MIL
MIL is an indicator light that comes on when a control unit determines a malfunc-
(Malfunction indicator
tion.
light)
DTC
DTC is a code that is saved within a control unit’s memory when the control unit
(Diagnostic trouble
determines a malfunction.
code)
Pending DTC Pending DTC is a code that is saved within a control unit’s memory when the con-
(Pending diagnostic trol unit detects an abnormal condition. If the abnormal condition continues, a
trouble code) malfunction may be determined.
Driving cycle is the duration from the main switch being turned on, OBD require-
Driving cycle
ments are met, and until the main switch is turned off.
FFD FFD is the data of all signal sensors saved at the moment a malfunction is deter-
(Freeze frame data) mined.
Current malfunction A DTC for an unrecovered, current malfunction.
Recovered malfunc-
A DTC for a previously determined but now recovered malfunction.
tion
Pending abnormality Abnormal condition that is detected but not yet determined to be a malfunction.
Threshold Threshold is a point set to detect if the output from sensors are abnormal or not.
OBD
Self-diagnostic system is equipped in a control unit for the emission control sys-
(On-board diagnos-
tem.
tics)
GST
Generic diagnostic tool that complies with OBD standards.
(Generic scan tool)
YDT
(Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles.
tool)
EAS32858
OUTLINE
The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat-
ing normally. If this function detects a malfunction in the system, it immediately operates the system
under substitute characteristics and illuminates the warning light to alert the rider that a malfunction has
occurred in the system. Once a malfunction has been detected, a DTC is stored in the memory of the
control unit.
EAS32859
CHECKING THE WARNING LIGHT

The warning light comes on after the main switch has been set to “ON”. Refer to the following table for
lighting up time.
If the warning light still comes on, refer to a check item of a troubleshooting of each system, check and
repair it. If the warning light does not come on, the warning light (LED) may be defective.
TIP
• This engine equips self-diagnostic function. It’s controlled delicately for detecting defective and mal-
function of the exhaust emission control system. Therefor, the vehicle modifying, poor maintenance,
and improper using of the vehicle may also become the cause of the MIL come on. These events may
cause the occurrence of the warning light coming on without malfunction.
• Reprogramming of the ECU software.
• Using the electrical accessory which may affect the ECU.
9-1
• Using the incorrect specification of spark plug and fuel injector. Using the third party accessories such
as suspension and exhaust system.
• Change of specifications of drive chain, sprocket, wheel and tire.
• Removing or modifying the O2 sensor, the exhaust system part (catalyst, etc.).
• Poor maintenance of the drive chain and tire air pressure.
• Incorrect brake pedal height, rear brake dragging.
• Excessive opening and closing of the throttle grip, frequently used of burnout, wheelie and half clutch.
• Air mixture by fuel supply badness.
2 3 4 1
ABS
System Lighting up warning light Lighting time

FUEL INJECTION SYSTEM MIL “1” 2.0 seconds*1
About 0.15 sec-
IMMOBILIZER SYSTEM Immobilizer system indicator light “2”
onds
ABS (Anti-lock Brake System) ABS warning light “3” *2
CRUISE CONTROL SYSTEM MIL “1” 2.0 seconds
ELECTRONICALLY ADJUST-
ABLE SUSPENSION SYS- Auxiliary system warning light “4” 2.0 seconds
TEM (for MTT890D)
TIP
*1: If the MIL flashed, refer to “COPE WITH THE MIL FLASHING” on page 9-4.
*2: The ABS warning light goes off when the vehicle is judged to normal with running.
EAS32806
YDT
This model uses the YDT to identify malfunctions.
For information about using the YDT, refer to the operation manual that is included with the tool.

90890-03267
90890-03264
TIP
• Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-
03266) is separately required.
• A GST can also be used to identify malfunctions.
9-2
Connecting the YDT

Remove the protective cap, and then connect the YDT to the coupler “1”.
EAS32864
PARTS CONNECTED TO THE ECU

The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • O2 sensor
• Injector #1 • ABS ECU (Electronic Control Unit)
• Injector #2 • Throttle servo motor
• Injector #3 • Relay unit
• Clutch switch • Starter relay
• Ignition coil #1 • Purge cut valve solenoid
• Ignition coil #2 • Brake light relay
• Ignition coil #3 • Radiator fan motor relay
• Throttle position sensor • Meter assembly
• Intake air pressure sensor 1 • Immobilizer unit
• Intake air pressure sensor 2 • Headlight control unit
• Coolant temperature sensor • Handlebar switch (left and right)
• Gear position sensor • IMU (Inertial Measurement Unit)
• Shift sensor • Grip warmer (left and right)
• Intake air temperature sensor • SCU (Suspension Control Unit) (for MTT890D)
• Fuel pump • CLCU (cornering light control unit) (for MTT890D)
EAS32918
PARTS CONNECTED TO THE ABS ECU

The following parts are connected to the hydraulic unit assembly (ABS ECU).
parts beforehand.
• Meter assembly • Handlebar switch (left)
• IMU (Inertial Measurement Unit) • Brake light relay
• ECU (Engine Control Unit) • SCU (Suspension Control Unit) (for MTT890D)
• Front wheel sensor • CLCU (cornering light control unit) (for MTT890D)
• Rear wheel sensor
9-3
EAS32865
PARTS CONNECTED TO THE SCU (for MTT890D)

The following parts are connected to the SCU.
parts beforehand.
• Front fork solenoid (left) • ECU (Engine Control Unit)
• Front fork solenoid (right) • Hydraulic unit assembly (ABS ECU)
• Rear shock absorber assembly solenoid • Meter assembly
• Angular position sensor • IMU (Inertial Measurement Unit)
EAS33137
PRECAUTIONS FOR ROAD TEST

EWA20860
WARNING
When test riding the vehicle, always comply with local traffic regulations.
EAS33283
COPE WITH THE MIL FLASHING

With the vehicle is running, the MIL flashes by the process of the misfire (P0300/P0301/P0302/P0303)
detection procedure but no DTC is sometimes stored. In this case, question the customer about the
conditions when the problem occurred, and do the troubleshooting.
Refer to “P0300, P0301, P0302, P0303” on page 9-174.
9-4
SYSTEM DIAGRAM
EAS20387
SYSTEM DIAGRAM
EAS32920
ECU CIRCUIT DIAGRAM

A
B 29 16
4. Electronic throttle valve fuse
26 39. Injector #1
18. Fuel pump relay
32 15
15. Engine stop 19. Fuel 40. Injector #2
switch pump 14
5. Backup fuse 2
41. Injector #3
6. Ignition
fuse 1 16. Starter 20. Neutral 41
relay indicator light 64 42. Immobilizer unit
7. Main
switch
96
21. Starting circuit
M 17. Starter cut-off relay
3. Main motor 18 A
fuse
23. Stop/run/ 22. Clutch 43. Throttle servo motor
2. Battery start switch switch 95
1
80
24. Sidestand 25. Neutral
switch switch
10
7. Main 26. Rectifier/regulator 34
switch 44. Ignition coil #1
33 B
27. Cruise control fuse
8. Ignition 9. Signaling 28. Cruise control power switch 9
fuse 2 system fuse 66
29. Cruise control setting switch (SET–)
45. Ignition coil #2
C 83
10. Brake light 30. Cruise control setting switch (SET+)
fuse 82 8
22. Clutch 11. Front brake 12. Rear brake
11. Front brake 67
switch light switch light switch
light switch 1. ECU (Engine
98 Control Unit) 46. Ignition coil #3
12. Rear brake
72
light switch 7
31. Crankshaft position sensor
76
17
13. Brake 69
light relay 25
14. 68 50. Grip 51. Grip

Tail/brake 33. Intake air pressure sensor 1 warmer (left) warmer (right)
light 102 40
34. Coolant temperature sensor 86
52. Purge cut C
35. Intake air temperature sensor 71
valve solenoid
73 27
36. Shift sensor
103 53. Radiator
37. Gear position sensor fan motor
89
38. O2 sensor 84 19
5
88
28
37
54. Dimmer switch
43
55. Pass switch
47. Throttle
position sensor
56 56. Headlight
49 control unit
45
35
42
48. Accelerator 51
position sensor 54
57. Meter assembly
57
36 77 58. CAN communication
49. ABS ECU (Electronic Control Unit)
105 circuit
107 61
9-5
SYSTEM DIAGRAM
1. ECU (Engine Control Unit) 54.Dimmer switch

2. Battery 55.Pass switch
3. Main fuse 56.Headlight control unit
4. Electronic throttle valve fuse 57.Meter assembly
5. Backup fuse 2 58.CAN communication circuit
6. Ignition fuse 1
7. Main switch
8. Ignition fuse 2
9. Signaling system fuse
10.Brake light fuse
14.Tail/brake light
15.Engine stop switch
16.Starter relay
17.Starter motor
18.Fuel pump relay
19.Fuel pump
20.Neutral indicator light
22.Clutch switch
24.Sidestand switch
25.Neutral switch
26.Rectifier/regulator
27.Cruise control fuse
28.Cruise control power switch
29.Cruise control setting switch (SET-)
30.Cruise control setting switch (SET+)
32.Intake air pressure sensor 2
35.Intake air temperature sensor
36.Shift sensor
38.O2 sensor
39.Injector #1
40.Injector #2
41.Injector #3
42.Immobilizer unit
43.Throttle servo motor
44.Ignition coil #1
45.Ignition coil #2
46.Ignition coil #3
47.Throttle position sensor
48.Accelerator position sensor
49.ABS ECU (Electronic Control Unit)
52.Purge cut valve solenoid
53.Radiator fan motor
9-6
SYSTEM DIAGRAM
EAS33369
ECU COUPLER LAYOUT
1 2 3 4 5 6 7 8 9 35 36 37 38 39 40 41
10 11 12 13 14 15 16 17 42 43 44 45 46 47 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
18 19 20 21 22 23 24 25 48 49 50 51 52 53 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92
26 27 28 29 30 31 32 33 34 54 55 56 57 58 59 60 93 94 95 96 97 98 99 100101102103104105106107108
Wire harness Wire harness

No. Connected parts No. Connected parts
color color
1 Throttle servo motor Y/R 29 Fuel pump relay L/W
2 — — 30 — —
3 — — 31 — —
4 — — Fuel pump relay, Fuel
32 R/L
pump
5 O2 sensor P/B
33 Ground B/W
6 — — 34 Ground B/W
7 Ignition coil #3 O/G Accelerator position
35 W/R
8 Ignition coil #2 Gy/R sensor
9 Ignition coil #1 O ABS ECU (Electronic

36 G
Control Unit)
10 Throttle servo motor Lg/R
Throttle position sen-
11 — — 37 L
sor
12 — — 38 — —
13 — — 39 — —
14 Injector #3 L/B Grip warmer (left),
40 Br/Y
15 Injector #2 G/B Grip warmer (right)
16 Injector #1 R/B 41 Ignition fuse 1 R/W
17 Ground B Accelerator position
42 Y
sensor
Electronic throttle
18 R/L Throttle position sen-
valve fuse 43 W
sor
Radiator fan motor re-
19 G/Y 44 — —
lay
20 — — Accelerator position
45 Y/R
sensor
21 — —
46 — —
22 — —
47 — —
23 — —
48 — —
24 — —
Throttle position sen-
25 Ground B 49 B/L
sor
26 Backup fuse 2 R/G 50 — —
Purge cut valve sole- Accelerator position
27 Y/R 51 Br
noid sensor
Dimmer/pass switch, 52 — —
28 Y/B
Headlight control unit
53 — —
9-7
SYSTEM DIAGRAM
Wire harness Wire harness

No. Connected parts No. Connected parts
color color
Accelerator position O2 sensor
54 W/B 84 Gy/G
sensor
55 — — 85 — —
Throttle position sen- Intake air tempera-
56 B 86 Br/W
sor ture sensor
Accelerator position 87 — —
57 Y/B
sensor 88 Ground B/L
58 — — 89 Gear position sensor B/L
59 — — 90 — —
60 — — 91 — —
CAN communication 92 — —
61 L/B
circuit
93 — —
62 — —
94 — —
63 — —
Clutch switch, Side-
64 Immobilizer unit Y/L 95 L/Y
stand switch
65 — — Starting circuit cut-off
96 L/W
Cruise control power relay
66 O/W
switch 97 — —
Rear brake light Brake light relay, Rear
67 Lg/L 98 Lg/B
switch brake light switch
Intake air pressure 99 — —
68 P/W
sensor 1
100 — —
Intake air pressure
69 P 101 — —
sensor 2
70 — — Coolant temperature
102 G/W
sensor
71 Shift sensor V
103 Gear position sensor G/W
Intake air pressure
sensor 1, Intake air 104 — —
72 L
pressure sensor 2, ABS ECU (Electronic
Shift sensor 105 W/G
Control Unit)
73 Gear position sensor L 106 — —
74 — — ABS ECU (Electronic
107 W/Y
75 — — Control Unit)
Crankshaft position 108 — —
76 Gy
sensor
CAN communication
77 L/W
circuit
78 — —
79 — —
Starting circuit cut-off
80 B/Y
relay, Clutch switch
81 — —
Cruise control setting
82 Br/L
switch (RES+)
Cruise control setting
83 G/L
switch (SET–)
9-8
A C D
Y/B R/Y R/Y Y/B

B B B B Sb Sb
EAS32871
EAS20440
R/Y Y Y R/Y
(B) (B)
A B A D A E
(B) (B)
A B

R R/L R/L R/L R/L

A B R/W R R/W R/W R/W
CIRCUIT DIAGRAM
R/W L/W
(B)
4 30 R/W
R/W 56
R R O
R/W O R/W
R L/W R/L
R 59 (B)
R L/W
R
R/W
Y/R P/B O/G Gy/R O W/R G L Br/Y R/W O 57
R W Br/R Br/R Gy/R Gy/R
3 27 Lg/R L/B G/B R/B B Y W Y/R Gy/R R/W
41 R Br O/G
OFF R/L G/Y B B/L Br 59
R,W R (B)
ON R/G Y/R Y/B L/W R/L B/W B/W W/B B Y/B
Br/L Br/L B
42 43 Br W R L/W R (B) (B)
R/W
B B B W L/W R L/B L Sb B Sb/W L L 58
Br/L L
O/G O/G R/W
Br/R LL
28 B Sb L R L/W L/W 59 (B)
L/B
D
BBB Sb L/Y R/B R/L
B/Y
FUEL INJECTION SYSTEM
(Gy) 60
R/G
R/B R/B R/L
R B/Y G/W B/L B/L
37 L/B L G/W B/L G/W G/W G/B G/B R/L
R R/W R/W R/L B G/W B 49 L L
R/W Sb
L/B (B) 61
R 34 35 Y/B G/W R R/L (B) R/L W/R G/B R/L
L/W 5 R/W
B/Y Y/B
OFF
39 W/R Y/G W/B
OFF Y/W G/Y B Y/R
L/W ON L/Y L/W ON 40 W/B Y/R Y/B (Gy)
R/W (B) B/W W/G W/B OFF 45
R G/Y L/W (B) RUN W/G Y/B Y L/B L/B R/L
G/Y R R B R/W START 47
G/Y L/W R/L Y/G W/G (B) B B Br
L/Y G/W Y/B (B) L L/Y B L/W 62
L/Y B/Y B/Y L/W L L/B R/L
Y/B B/Y G/Y Y/W Br W/B W/R 44 B B/L
Br R/W L/W Y/B Y/R Y B B/L P/W L 50
Y/W L/Y W/B W/G B/W Br W/R 48 48 48 P/W P/W (Gy)
L/B B
6 7 (B) R/W B W Y/R W/B (Dl)
(B) (B)
R R/L Y/B Y
R/G L/Y L L/Y B/Y B B/Y L/W W W L/W L
B/L P L 51 B/L
R (B) P P L/B Y/L O/W Lg/L P/W P V L L Gy
8 9 (Dl)
R/L L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
R/W R B B P/B P/B
RR L/Y L/W Lg/B G/W G/W W/G W/Y
R B/L W L Gy/G Gy/G
Br/R L/R
R
R 10 (B)
L/W L/WL/W L/W B B B L/B L/B L/B L/B R P/B B B
R/L R/L R/L R/L R/L B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R Gy/G B/L W L 52
R (B) Br/Y Br B
9-9
(B) 55
G/Y Br/Y
Br/L 12 L/B L/B L/B L/B L/B L/W L/W L/W L/WL/W B Br Br/Y B
Br/Y Br/Y Br/Y 63
Br/L Br/L Br G B Gy Gy
36 Gy B 53 Br/Y
R/B G Br Gy B/L B/L (B) (B)
OFF Y B
48 L/B L/B
48 L/W
48
B
14 ON L/B L/W L/W G/W G/W
(B) Gy B/L B/L Br/Y W L B B B
B Y
(B) Br/Y B
B/L B/L B/L B/L L/B L/W L/W 54 L W
Lg/B G/W B/L 64
B/L B/L B/L B/L L/B L/B L/W
G/Y Y/B
(B) (Gy) (Gy)
Lg/B Lg/L
W B/L L B
(B)
Y/B Y/B Y/B (B)

L L
B/L
B B
B/L Br/W Br/W W W 65
L/R G/W Y/B
Y/B 48 B/L B/L
17 70
75 Br/W B/L
Lg/R Lg/R
(B) Y/R Y/R 66
Lg/B R/L B/W
Lg/B R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W Y/B
G/Y
R/G G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G Y/R Lg/R
R 71
(Gy) (B)
21
R/L A R/W
L/W L/B
B/W L/W L/B R/L L/W W/G G Y L R/B Br L/W B/W
(B) R G/O W/Y L B W Y L/B B

Lg/B
72 (B)
R/W Y/R Y/R
80
R/W Y/R
L/W A L/W R/B
L/B A L/B
(B)
B W/G W/G Y Y W
W/Y W/Y Br Br B 68
B
L/W W
B/L V L R W B B B/L L/B B
W V V 67 W B
73 R L
(B) (B)
B/W B Y/B B
C C C Br Y
83 B/W A B/W B/W B/W B B
B B B B B B B/W B Y/B B
B B/W
W
L/W L/W B B 69
48 L/B
107 R/G 74 R/G L/B
B
W B
BB B B/W
(R)
B 108 109 B W
B R/Y B Y/B Y B R/Y

(B) B
B/W
B/W
B
B
B B/W
B
3. Main switch 74.YDT coupler

4. Main fuse 75.Meter assembly
5. Radiator fan motor relay 80.Multi-function meter
6. Fuel injection system fuse 83.Malfunction indicator light
7. Electronic throttle valve fuse 107.Headlight control unit
8. Backup fuse 2 108.Headlight (high beam)
9. Ignition fuse 2 109.Headlight (low beam)
A. Wire harness
12.Ignition fuse 1
14.ABS ECU fuse
D. Sub-wire harness (headlight control unit)
17.Brake light fuse
21.Backup fuse 1
27.Battery
28.Frame ground
30.Starter relay
34.Clutch switch
41.Relay unit
43.Fuel pump relay
44.Neutral switch
45.Sidestand switch
47.Fuel pump
48.Joint coupler
52.O2 sensor
56.Ignition coil #1
57.Ignition coil #2
58.Ignition coil #3
59.Spark plug
60.Injector #1
61.Injector #2
62.Injector #3
65.Throttle position sensor
66.Throttle servo motor
67.ABS ECU
68.Front wheel sensor
70.Intake air temperature sensor
72.Purge cut valve solenoid
9-10
EAS32917
BASIC PROCESS FOR TROUBLESHOOTING

This section describes the basic process about fuel injection system troubleshooting.
But because a work procedure varies depending to symptom and DTC, check and repair it according
to applicable troubleshooting.
When turning the main switch to No Does the MIL (LED) work No
Check the MIL (LED).
“ON”, does the MIL come on? properly?
Yes Yes
Yes [B] Perform the checking with the

The MIL goes off after 2 seconds?
diagnostic mode.
No
Still on / flash. *2
[A] Check the DTC.
*1
Delete the DTC.
Are DTCs displayed on the screen No

after performs the problem Temporary failure.
verification?
Yes
Do the troubleshooting according

to the DTCs of “malfunction”.
Check the DTCs of “malfunction”

are not displayed on the screen.
Finished.
*1. For P0133, P0300, P0301, P0302, P0303

*2. For except P0133, P0300, P0301, P0302, P0303
9-11
EAS33147
[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS NOT NORMAL
1. Check the DTC of “malfunction” using the YDT.
2. Delete the DTC using the YDT. (Only for *1)
3. Check and repair the malfunction according to applicable DTC troubleshooting.
4. Turn the main switch from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed.
TIP
• If another DTC is displayed, repeat steps (1) to (4) until no DTC is displayed.
• Turning the main switch to “OFF” will not erase the malfunction history.
EAS33148
[B] THE MIL DOES NOT COME ON, BUT THE ENGINE OPERATION IS NOT NORMAL
1. Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode.
Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-79 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-83.
01: Throttle position sensor signal 1 (throttle angle)
13: Throttle position sensor signal 2 (throttle angle)
14: Accelerator position sensor signal 1 (throttle angle)
15: Accelerator position sensor signal 2 (throttle angle)
30: Cylinder-#1 ignition coil
36: Injector #1
37: Injector #2
38: Injector #3
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
engine.
9-12
A D

W/L Br/L Br/R G B B B B G Br/R Br W/L Sb Sb
EAS32885
EAS20442
(B) (B)
A B A E
(B) (B)
A B
33 R/G B B R/G
R/W Lg Y/L Y/L Lg R Sb/W Lg B/W G/O G/L G/L G/OB/W Lg Sb/W
R/W Y G/W B/R B/G Br/Y Br/Y B/G B/R G/W Y
Lg R/G R B Y/L
A B
CIRCUIT DIAGRAM
4 Y/L
R R
R/W
R
R
R R

R W Br/R Br/R
ON R,W R
Br/L Br/L B
(B) (B)
Br/L B B
Br/R
IMMOBILIZER SYSTEM
28
B
R
R/W
R
R/L
48 L/B L/B
R Br/R
R
R (B)
R 48
Br/L 12 55
Br/L Br/L
9-13
L/B L/W L/W
L/B
Lg
A
Lg
Lg
75
76
R R/G
(Gy)
21
R/L A R/W
R/G 80
R/G R/G R/G A R/G
R/G R/G A R/G
L/W A L/W
L/B A L/B
L/W
L/B

B B B B B B B/W
B/W
L/W L/W B
48 L/B
R/G 74 R/G L/B
B
B (R)
B
B
B/W
B/W
B
B
B
B
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
3. Main switch
4. Main fuse
9. Ignition fuse 2
12.Ignition fuse 1
21.Backup fuse 1
27.Battery
28.Frame ground
33.Immobilizer unit
48.Joint coupler
74.YDT coupler
75.Meter assembly
76.Immobilizer system indicator light
A. Wire harness
E. Sub-wire harness (neutral switch)
(MTT890D)
9-14
IMMOBILIZER SYSTEM
EAS32886
SYSTEM OUTLINE
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 (installed in the red key bow)
• 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 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 re-
placed.
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.
EAS32887
PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS

In the course of use, you may encounter the following cases where replacement of parts and registra-
tion of code re-registering/standard keys are required.
TIP
Each standard key is registered during production, therefore re-registering at purchase is not neces-
sary.
9-15
IMMOBILIZER SYSTEM
Parts to be replaced
Main switch/
Accessory Key registration re-
immobilizer unit Standard
ECU lock* and quirement
Main Immobilizer key
key
switch unit
Standard key is lost √ New standard key
All keys have been lost
Code re-registering
(including code re-reg- √ √ √ √
key and standard keys
istering key)
Code re-registering
ECU is defective √
Immobilizer unit is de- Code re-registering
√ √ √ √
fective key and standard keys
Code re-registering
Main switch is defective √ √ √ √
Accessory lock* is de-
√ Not required
fective
* Accessory locks mean the seat lock and fuel tank cap.
Code re-registering key registration:

When the immobilizer unit or ECU is replaced, the code re-registering key must be registered to the
unit.
To register a code re-registering key:
1. Turn the main switch to “ON” with the code re-registering key.
TIP
Check that the immobilizer system indicator light comes on for one second, then goes off. When the
immobilizer system indicator light goes off, the code re-registering key has been registered.
2. Check that the engine can be started.
3. Register the standard key, following the instructions in the section below.
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.
Standby mode
a. Main switch “ON” d. LED off

b. Main switch “OFF” e. Standby mode on
c. LED on f. Standby mode off
9-16
IMMOBILIZER SYSTEM
Standard key registration:

Standard key registration is required when a standard key is lost and needs to be replaced, or when
the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
TIP
Do not start the engine with a standard key that has not been registered. If the main switch is turned
“ON” with a standard key that has not been registered, the immobilizer system indicator light flashes to
indicate DTC “52”. (Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR IMMOBILIZER SYS-
TEM)” on page 9-71).
1. Check that the immobilizer system indicator light signals the standby mode.
2. Using the code re-registering key, turn the main switch to “ON”, then “OFF”, and then remove the
key within 5 seconds.
3. Insert the first standard key to be registered into the main switch, then turn the key to “ON” within 5
seconds to activate the key registration mode.
TIP
The existing standard key code is erased from the memory when the key registration mode is activated.
When the key registration mode is activated, the immobilizer system indicator light flashes rapidly.
4. While the indicator light is flashing, turn the main switch to “OFF”, remove the key, and within 5 sec-
onds, insert the second standard key to be registered into the main switch.
TIP
If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is regis-
tered, the registration mode is deactivated. If this occurs, the second standard key cannot be registered,
and steps (2) to (4) need to be repeated to register both standard keys.
5. Turn the main switch to “ON”.
TIP
When the indicator light goes off, the registration is complete.
6. Check that the engine can be started with the two registered standard keys.
Standard key registration
a. Main switch “ON” A. Registration of the second standard key is

b. Main switch “OFF” complete.
c. LED on B. Immobilizer system indicator light stops flashing
d. LED off when the registration of the second standard
key is complete.
e. Less than 5.0 s
f. Code re-registering key
g. First standard key
h. Second standard key
i. Registration mode
9-17
IMMOBILIZER SYSTEM
Voiding the standard key code:

If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard
key. Standard key registration erases the stored standard key code from the memory, thus disabling
the lost standard key. To re-register, refer to “Standard key registration”.
Standard key code voiding method
a. Main switch “ON” A. If the immobilizer system indicator light stops

b. Main switch “OFF” flashing 5 seconds after the first standard key is
c. LED on registered, the second standard key cannot be
registered.
d. LED off
e. Less than 5.0 s
f. Code re-registering key
g. Remaining standard key
h. Registration mode
9-18
IMMOBILIZER SYSTEM
EAS32888
TROUBLESHOOTING
When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor
flashes.
(Main, ignition 1, ignition 2 and
backup 1) Replace the fuse(s).
ES” on page 8-42.
OK ↓
page 8-43.
OK ↓
OK ↓
4. Check the entire immobilizer sys- NG →
tem wiring. Properly connect or repair the immobilizer
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 9-13.
OK ↓
• Check the condition of the each im-
mobilizer system circuits.
• Refer to “SELF-DIAGNOSTIC
FUNCTION TABLE (FOR IMMOBI-
LIZER SYSTEM)” on page 9-71.
9-19
IMMOBILIZER SYSTEM
EAS32889
HOW TO CHECK DTC

When a system malfunction occurs, the DTC is indicated in the meter display and the immobilizer sys-
tem indicator light flashes at the same time. The pattern of flashing also shows the DTC.
Immobilizer system indicator light DTC indication

Digit of 10: Cycles of 1 sec. ON and 1.5 sec. OFF.
Digit of 1: Cycles of 0.5 sec. ON and 0.5 sec. OFF.
Example: DTC 52
a. Light on
b. Light off
9-20
A

EAS32875
EAS20441
(B) (B)
A B
(B) (B)
A B

A B
CIRCUIT DIAGRAM
4
R R
R/W
R
R
R R

R W Br/R Br/R L/B Y/L O/W Lg/L P/W P V L L Gy
OFF L/W B/Y Br/L G/L Gy/G Br/W B/L B/L R/L G/Y B B/L Br
ON R,W R
L/Y L/W Lg/B G/W G/W W/G W/Y R/G Y/R Y/B L/W R/L B/W B/W W/B B Y/B
Br/L Br/L B
(B) (B)
B B (B) L L
Br/L L
Br/R
28
B
B/L B/L
L G/W B/L 49 G/W G/W
L L
Y/B G/W Y/W G/Y Y/B
37 (B)
R R/L W/R
CRUISE CONTROL SYSTEM
W/R Y/G Br W/R W/B

Br G 40 W/B Y/R Y/R W/B Y/R
R/W 34 35 Y/B G/W G/W Y/B 36 OFF Y/B
B/Y Y/B Y/B B/Y G Br G/Y Y/B W/G Y/B Y/B Y
R/W RUN Y
R OFF OFF Y/W G/Y G/Y Y/W OFF Y B Lg/B Lg/L START
ON L/Y L/W Y/W L/Y ON ON Y/G W/G (B) Br
(B) (B) (B)
L/W (B) (B) (B) B Y (B)
Br W/B W/R
G/Y Y/B Y/B Y/R Y
Y/W Lg/B Lg/L
9 L/W L/WL/W L/W B B B L/B L/B L/B L/B

R/L
48 L/B L/B
48 L/W B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R
RR L/B L/W L/W
R Br/R L/R
R
R 10
R 48
Br/L 12 55
Br/L Br/L
9-21
B/L L/B L/W L/W
B/L L/B
B/L
L/R G/W Y/W

17 18 Y/B
92 SET L
R/W Y/W 75
94 FREE
HI
Lg/B W/R G/B Y/W O/W G/L Br/L 93 LO OFF PUSH (N) ON R
Lg/B PASS DOWN N
FREE B/W L
R (Gy) B W/G
(Gy)
21 O/W Br/L
Br/L G/L O/W Y/W G/B W/R G/L R/L A R/W G/L
Y/B Y L/R W/L W/Y B G/Y
O/W
Br/L
(Gy) Lg/L
Lg/B
80
L/W A L/W B/L V L
L/B A L/B
(B)
L/W
R W B B B/L L/B
73 W V V
R L
(B)
83 B/W A B/W B/W B/W B B

B B B B B B B/W
B/W
L/W L/W B
48 L/B
R/G 74 R/G L/B
B
B (R)
86 87
B
B/W
B/W
B
B
B
B
3. Main switch
4. Main fuse
9. Ignition fuse 2
12.Ignition fuse 1
17.Brake light fuse
18.Cruise control fuse
21.Backup fuse 1
27.Battery
28.Frame ground
34.Clutch switch
48.Joint coupler
74.YDT coupler
75.Meter assembly
83.Malfunction indicator light
86.Cruise control system indicator light
87.Cruise control setting indicator light
93.Cruise control power switch
94.Cruise control setting switch
A. Wire harness
9-22
EAS32876
CRUISE CONTROL CIRCUIT OPERATION
6. Ignition 7. Cruise control 8. Cruise control

fuse 1 fuse power switch
9.Cruise control
setting switch
12.Clutch 10.Front brake 11.Rear brake

switch light switch light switch
4. Signaling 5. Brake 14.ECU (Engine
system light Control Unit)
fuse fuse
13. Accelerator
position sensor
3. Ignition
fuse 2
16. Cruise control system indicator light

15.Multi-function
meter
17. Cruise control setting indicator light
2. Main
fuse
1. Battery
1. Battery
2. Main fuse
3. Ignition fuse 2
4. Signaling system fuse
5. Brake light fuse
6. Ignition fuse 1
7. Cruise control fuse
8. Cruise control power switch
9. Cruise control setting switch
11. Rear brake light switch
12. Clutch switch
13. Accelerator position sensor
15. Multi-function meter
16. Cruise control system indicator light
17. Cruise control setting indicator light
9-23
EAS32877
BASIC INSTRUCTIONS FOR TROUBLESHOOTING

TIP
4. Do the final check.
EWA17420
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.
9-24
EAS32878
BASIC PROCESS FOR TROUBLESHOOTING

When turning the main switch to No
Check the MIL (LED).
“ON”, does the MIL come on?
Yes
The MIL goes off after 2 Yes

seconds?
No
[A] Push the cruise control Fails to come on • The cruise control power switch is
power switch, and check defective.
the cruise control system
Flashes
• The cruise control system fuse is
indicator light.
blown.
Return to [A].
• The ECU is defective.
Comes on
[B-1] Diagnosis using the DTC. [C-1] Delete the DTC. Return to [A].
[B-2] Check the malfunction

history using the malfunction Yes
mode of the YDT.
Is there any malfunction
history?
No
[B-3] Is there automatic Yes Explain the conditions for

deactivation history for the automatically deactivating the
cruise control system? cruise control system to the
customer.
No
OK
[C-2] Final check.
DTC No. is not displayed.
Finished.
9-25
EAS32879
[A] CHECKING THE CRUISE CONTROL SYSTEM INDICATOR LIGHT

Turn the main switch, and then push the cruise control power switch.
1. The cruise control system indicator light does not come on.
• Check the control power switch for continuity. Refer to “CHECKING THE SWITCHES” on page
8-41. If there is no continuity, replace the handlebar switch (left).
• Check the fuse for continuity. Refer to “CHECKING THE FUSES” on page 8-42. If the cruise con-
trol system fuse is blown, replace the fuse.
• Check for continuity between the orange/white terminal of the handlebar switch coupler (left) and
orange/white terminal of the ECU (engine control unit) coupler. If there is no continuity, the wire
harness is defective. Replace the wire harness.
2. The cruise control system indicator light flashes. [B-1]
3. The cruise control system indicator light come on. [B-2]
EAS32880
[B-1] DIAGNOSIS USING THE DTC

1. Information for the DTCs from the cruise control system is contained in the following table. Refer to
this table for troubleshooting.
DTC table
DTC No. Symptom Check point
P056C No normal signals from the switch are re- • Wire harness (ECU coupler and front or rear
ceived by the ECU. brake light switch coupler)
• Signaling system fuse and brake light fuses
• Connection of the ECU coupler, rear brake light
switch coupler, brake light relay coupler and
handlebar switch coupler (right)
• Accelerator position sensor
• Front brake light switch
• Rear brake light switch
P0564 No normal signals from the switch are re- • Wire harness (ECU coupler and handlebar
ceived by the ECU. switch coupler (left))
• Ignition fuse 1 and cruise control system fuse
• Cruise control setting switch
EAS32881
[B-2] DIAGNOSIS USING THE MALFUNCTION HISTORY CODES

Check the malfunction history using the malfunction mode of the YDT.
• Malfunction history is displayed on the YDT. [B-1]
• Malfunction history is not displayed on the YDT. [B-3]
EAS32882
[B-3] MALFUNCTION HISTORY IS NOT DISPLAYED

Use the YDT to check whether automatic deactivation history for the cruise control system exists.
1. There is automatic deactivation history for the cruise control system.
• Explain the conditions for automatically deactivating the cruise control system to the customer.
• For information about the conditions for automatically deactivating the cruise control system.
TIP
If you do not have a YDT, the automatic deactivation history cannot be checked. Therefore, explain the
automatic deactivation function of the cruise control system to the customer and explain that this is not
a malfunction.
EAS32883
[C-1] ERASING THE DTC

1. Delete the DTC using the malfunction of the YDT, and check that the MIL goes off.
9-26
EAS32884
[C-2] FINAL CHECK

EWA17441
WARNING
When maintenance or checks have been performed on components related to the cruise control
system, be sure to perform a final check before delivering the vehicle to the customer.
1. Check the front brake lever and rear brake pedal operation.
2. Check the rear brake light switch.
Refer to “CHECKING THE SWITCHES” on page 8-41.
3. Execute the diagnostic mode (No. 82 and 83) to check the operation of the front brake light switch,
rear brake light switch, and accelerator position sensor.
Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-79.
4. Execute the diagnostic mode (No. 80 and 81) to check the operation of the cruise control setting
switch.
5. Delete the DTCs.
Refer to “DTC TABLE” on page 9-52.
6. Check the operation of the cruise control system.
Test ride the vehicle and confirm that the cruise control system is operating normally.
9-27
9-28
A
EAS32890
EAS20443
(B) (B)
A B
(B) (B)
A B

A B
CIRCUIT DIAGRAM
4
R R
R/W
R
R R
R R

R W Br/R Br/R
ON R,W R
Br/L Br/L B
(B) (B)
Br/L B B B
Br/R
28
B B
G/W G/Y
Br G
R/W 35 Y/B G/W G/W Y/B 36 G Br G/Y Y/B
ABS (Anti-lock Brake System)
R OFF Y/W G/Y G/Y Y/W OFF Y B Lg/B Lg/L

ON ON
(B) (B)
(B) B Y (B)
G/Y
Lg/B
R/L
48 L/B L/B
L/R
R Br/R L/R
R L/R
R 10 (B)
L/R
R/L R/L R/L R/L R/L
R 48
Br/L 12 55
Br/L Br/L
9-29
L/B L/B L/W L/W
R/B L/B L/B L/W L/W
14
L/R G/W
17
75
R L/W
R/L B/W
19 20 L/R Lg/B R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W
R
R 71
(Gy)
21 112
R/L A R/W
B L/W L/B
Y Y L/R L/W W/G G Y L R/B Br L/W B/W
B/W L/W L/B R/L
Lg/B Y B
(B)
80 G G R
L L/W
L/W A L/W R/B
L/B A L/B
W/G W/G Y Y W
W/Y W/Y Br Br B 68
B
L/W W
L/B B
B 67 W B
B/W Y L/W
L/B Br Y
B B B B B B B/W L G/O
B B/W 110 Y
L
W
L/W L/W B B 69
48 L/B
R/G 74 R/G L/B
B
W B
B B B/W
(R)
B L Y Y L/R B W
B B
B
B
G/O A G/O B/W
B/W
89 B
B
B B/W
B
3. Main switch
4. Main fuse
9. Ignition fuse 2
12.Ignition fuse 1
14.ABS ECU fuse
17.Brake light fuse
19.ABS solenoid fuse
20.ABS motor fuse
21.Backup fuse 1
27.Battery
28.Frame ground
48.Joint coupler
67.ABS ECU
68.Front wheel sensor
74.YDT coupler
75.Meter assembly
89.ABS warning light
A. Wire harness
9-30
EAS32891
ABS COMPONENTS CHART

4
5
1
11
7
8
10
1. Meter assembly
2. Hydraulic unit assembly (ABS ECU)
3. Fuse box (ABS motor fuse, ABS ECU fuse, ABS
solenoid fuse)
4. YDT coupler
6. Rear wheel sensor rotor
7. Rear brake caliper
8. Front brake caliper (left)
9. Front wheel sensor
10. Front wheel sensor rotor
11. Front brake caliper (right)
9-31
EAS32892
ABS COUPLER LOCATION CHART
1 2
L/W B
R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W R/G L/B
(Gy) (R)
Br Y W B
3
4 L/W W/G G Y L R/B Br L/W B/W
R G/O W/Y L B W Y L/B B
W B B W
(B)
1. Meter assembly coupler

2. YDT coupler
3. ABS ECU coupler
5. Front wheel sensor coupler
9-32
EAS32893
MAINTENANCE OF THE ABS ECU
Checking the ABS ECU

1. Check:
• Terminals “1” of the hydraulic unit assembly (ABS ECU)
Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off → Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
1 2
EAS33284
ABS TROUBLESHOOTING OUTLINE

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 9-38.
ABS operation when the ABS warning light comes on

1. The ABS warning light remains on → ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 10 km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h)). → ABS operation is normal.
3. The ABS warning light flashes → ABS operation is normal.
• Refer to “[C-1] FINAL CHECK” on page 9-38.
Self-diagnosis with the ABS ECU

The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”. It
also checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they
are detected, it is possible to check the recorded malfunction data by utilizing the YDT when the ABS
ECU has entered the self-diagnosis mode.
9-33
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned to “ON”. During this test, a “clicking” noise can be heard from under the seat,
and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and
pedal, but these do not indicate a malfunction.
Special precautions for handling and servicing a vehicle equipped with ABS
ECA17620
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 DTC when the service is
finished. (This is because the past DTC will be displayed again if another malfunction occurs.)
EAS32895

TIP
4. Do the final check.
EWA17420
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.
9-34
Fails to
[A] Turn the main switch to “ON”, come on [A-1] Does only the ABS Yes • The ABS warning light (LED) is
and check the ABS warning warning light fail to defective. Return to [A].
light. come on? • The wire harness is grounded
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly 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.
Cannot
[A-3] The ABS warning light comes communicate Yes • The ABS ECU fuse is blown.
[A-4] Only the ABS ECU
on. • The ABS ECU coupler is Return to [A].
fails to communicate.
Connect the YDT, and then disconnected.
execute functional diagnosis. • The wire harness is defective.
Can the YDT communicate • The hydraulic unit assembly
with the ABS ECU? is defective.
Can communicate
No
[A-5] ABS ECU and FI ECU Yes • The connection with the YDT is
defective. Return to [A].
fail to communicate.
• The wire harness is defective.
[B-1] Check for ABS DTC in the Yes [B-2] Diagnose by the DTC. [B-3] Delete the DTC.
screen for the YDT. Return to [A].
Execute diagnosis of
malfunction.
Are DTC displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect. Refer to
“[C-1] FINAL CHECK”.
[C-1] Perform the final checks. • The brake hoses and brake
No
Were all of the final checks pipes are not connected Return to [A].
completed normally? correctly.
The ABS warning light does
Yes not go off when the light is
(The ABS warning light checked. Refer to “[C-1]
goes off when the light is FINAL CHECK”.
checked.) • The malfunction is not
corrected.
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The ABS warning light circuit in
the hydraulic unit assembly is
defective.
Finished.
9-35
EAS32897
[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS32898
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the green/orange terminal of the ABS ECU coupler
and green/orange terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS32899
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
• If there is no continuity, replace the main switch/immobilizer unit.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-43.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-42.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 9-29.
• If the meter assembly circuit is open, replace the wire harness.
EAS32900
[A-3] THE ABS WARNING LIGHT COMES ON

Connect the YDT to the YDT coupler and execute functional diagnosis. (For information about how to
execute functional diagnosis, refer to the operation manual that is included with the tool.)
Check that communication with the ABS ECU is possible.
• Only the ABS ECU fails to communicate. [A-4]
• ABS ECU and FI ECU fail to communicate. [A-5]
• Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
EAS32901
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE

1. ABS ECU fuse
• Check the ABS ECU fuse for continuity.
• If the ABS ECU fuse is blown, replace the fuse.
9-36
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 4-69.
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 red/black terminal
of the ABS ECU coupler.
Check for continuity between black terminal of the ABS ECU coupler and the ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler.
Check for continuity between blue/white terminal of the ABS ECU coupler and blue/white terminal
of the YDT coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the YDT coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS32902
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE

1. YDT
Check that the YDT is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler.
Check for continuity between blue/white terminal of the ABS ECU coupler and blue/white terminal
of the YDT coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the YDT coupler. (CANL)
EAS32903
[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the YDT is connected to the YDT coupler, the DTC will be displayed on the computer screen.
• A DTC is displayed. [B-2]
• A DTC is not displayed. [C-1]
EAS32904
[B-2] DIAGNOSIS USING THE DTC

This model uses the YDT to identify malfunctions.
For information about using the YDT, refer to the operation manual that is included with the tool.

90890-03267
90890-03264
TIP
Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the
vehicle.
Once all the work is complete, delete the DTCs. [B-3]
TIP
Do the final check after terminating the connection with the YDT and turning the main switch off. [C-1]
9-37
EAS33339
[B-3] DELETING THE DTC

To delete the DTCs, use the YDT. For information about deleting the DTCs, refer to the operation man-
ual of the YDT.
Check that all the displayed DTCs are deleted.

90890-03267
90890-03264
TIP
EAS32905
[C-1] FINAL CHECK

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.
Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.
Checking procedures
1. Check the brake fluid level in the front brake master cylinder reservoir and the rear brake master
cylinder reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-13.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS)” on page 4-30 and “IN-
STALLING THE REAR WHEEL (REAR BRAKE DISC)” on page 4-38.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-70.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the DTCs.
Refer to “[B-3] DELETING THE DTC” on page 9-38.
5. Checking the ABS warning light.
Confirm the ABS warning light go off.
If the ABS warning light does not come on or does not go off, refer to “[A] CHECKING THE ABS
WARNING LIGHT” on page 9-36.
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/orange terminal of the ABS ECU coupler and green/orange ter-
minal of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.
9-38
A E F
EAS32914
EAS20446
Gy/R Gy/L Gy/L Gy/R G/L G/R G/R G/L
(B) (B)
(B) (B)
A B A F A G
(B) (B)
A B

A B
CIRCUIT DIAGRAM
4
R R
R/W
R
R
R R

R W Br/R Br/R
ON R,W R
Br/L Br/L B
(B) (B)
Br/L B B B
Br/R
28
B B
R/W
R
R/L
48 L/B L/B L/B
RR L/B L/W L/W L/W L/Y L/W Lg/B G/W G/W W/G W/Y
R Br/R
R
R (B)
R/L R/L R/L R/L R/L

R R/L
48
Br/L 12 55
Br/L Br/L
L/B L/B L/W L/W
R/B L/B L/B L/W L/W
14
9-39
75
R/L B/W
R 71
(Gy)
21 119
R/B R/L A R/W
L/W L/B
79 B/W L/W L/B R/L L/W W/G G Y L R/B Br L/W B/W
(B)
L/W A L/W R/B

L/B A L/B
B
L/W
L/B
67
B/W L/W
R/L L/B
B B B B B B B B/W
R/B B/W
Gy/R E Gy/R W L/W L/W B

B W Gy/R Gy/L 48 L/B
Gy/L E Gy/L B 114 R/G 74 R/G L/B
(B) B
B B B/W
(R)
G/R F G/R W
B W G/R G/L B
G/L F G/L B 115 B
(B)
B
118 P/R P/R W
W B P/L P/R B/W
P/L P/L B 116 B/W
B
B
(Gy)
B B/W
B
W/R W/R P
W/G W/G W 117 P W B W/B W/G W/R
W/B W/B B
(B)
L/W
L/B
G/R B R/B R/L Gy/L

G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
(B)
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for MTT890D)
MTT890D)
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for
MTT890D)
3. Main switch
4. Main fuse
9. Ignition fuse 2
12.Ignition fuse 1
14.ABS ECU fuse
21.Backup fuse 1
27.Battery
28.Frame ground
48.Joint coupler
67.ABS ECU
74.YDT coupler
75.Meter assembly
79.Auxiliary system warning light
114.Front fork solenoid (left)
115.Front fork solenoid (right)
116.Rear shock absorber assembly solenoid
117.Angular position sensor
118.SCU (Suspension Control Unit)
119.SCU fuse
A. Wire harness
F. Sub-wire harness (front fork solenoid (left))
G. Sub-wire harness (front fork solenoid (right))
9-40
MTT890D)
EAS32915
MAINTENANCE OF THE SCU (Suspension Control Unit)
Checking the SCU (Suspension Control Unit)

1. Check:
• Terminals “1” of the SCU
Cracks/damages → Replace the SCU.
• Terminals “2” of the SCU couplers
Connection defective, contaminated, come-off → Replace or clean.
TIP
If the SCU couplers are clogged with mud or dirt, clean with compressed air.
11
EAS32916

TIP
EAS33576
TROUBLESHOOTING
“SUS-MODE” is not indicated on the meter.
Item
Calibration of angular position sensor is not executed.
Fail-safe system
• Able to start engine
• Able to drive vehicle
Procedure
TIP
If more than one DTC (SCU) is detected at the same time, perform troubleshooting first.
9-41
MTT890D)
1. Calibration is not executed with the meter.
• Execute the calibration with the meter.
Refer to “CHECKING THE VEHICLE AFTER INSTALLING THE REAR SHOCK ABSORBER AS-
• Turn the main switch to “ON”, and then check the “SUS-MODE” on the meter.
Is the “SUS-MODE” indicated?

YES
→ Service is complete.
NO
Go to step 2.
2. Installed condition of angular position sensor.
• Check for looseness or pinching.
Is check result OK?

YES
→ Go to step 3.
NO
a. Reinstall or adjustment the sensor.
b. Execute the calibration with the meter.
c. Turn the main switch to “ON”, and then check the “SUS-MODE” on the meter.

YES
NO
→ Go to step 3.
3. Connection of angular position sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).
Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.

YES
NO
→ Go to step 4.
4. Connection of SCU coupler.
9-42
MTT890D)
pins).

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Wire harness continuity.
• Disconnect the angular position sensor coupler “1” and SCU coupler “2”.
• Open circuit check
white/red–white/red
Between angular position sensor coupler “1” and
white/green–white/green
SCU coupler “2”
white/black–white/black
1 2 G/R B R/B R/L Gy/L

G/L W/G W/R Gy/R
W/B W/G W/R W/B L/W P/L
L/B P/R
Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.

YES
NO
→ Go to step 6.
• Short circuit check
9-43
MTT890D)
TIP
Disconnect the SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for MTT890D)” on page 9-4.
Ground short circuit check “A”
white/red–ground
white/green–ground
ground
white/black–ground
Lines short circuit check “B”

white/red–any other coupler terminal
Angular position sensor coupler “1” white/green–any other coupler terminal
white/black–any other coupler terminal
SCU coupler “2” white/green–any other coupler terminal
A B
1 1 2
G/R B R/B R/L Gy/L
W/B W/G W/R W/B W/G W/R G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
Is resistance ∞ Ω?
YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
6. Defective angular position sensor.
• Replace the angular position sensor.

YES
NO
9-44
MTT890D)
→ Go to step 7.
7. Malfunction in SCU.
• Replace the SCU.
Refer to “MAINTENANCE OF THE SCU (Suspension Control Unit)” on page 9-41.

YES
NO
→ Go to step 2.
9-45
MTT890D)
9-46
EAS33577
EAS20805
CIRCUIT DIAGRAM
4
R R
R/W
R
R
R R

R W Br/R Br/R
ON R,W R
Br/L Br/L B
(B) (B)
Br/L B B B
28
B
R/W
R
L/B L/B L/B L/B L/B L/W L/WL/W L/WL/W
48 L/B
48 L/W L/W B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
RR L/B L/B L/W L/Y L/W Lg/B G/W G/W W/G W/Y
R
R
R (B)
R/L R/L R/L R/L R/L

R 48
Br/L 12 13 55
Br/L Br/L
R/Y R/Y L/R L/B L/W L/W
L/B L/B L/W
L/R B L/WL/B
R Br W
120
B L/R R B
L/W L/B W Br
(B)
9-47
R/L B/W
R/G
R 71
21
L/W L/B
B/W L/W L/B R/L
CORNERING LIGHT SYSTEM (for MTT890D)
(B)
B
L/W
L/B
B/W
B/W B/W B B
B B B B B B B/W
L/W L/W B
48 L/B
R/G 74 R/G L/B
B
BB (R)
B/W
B/W
B
B
B
B
3. Main switch
4. Main fuse
12.Ignition fuse 1
13.Headlight fuse
21.Backup fuse 1
27.Battery
28.Frame ground
48.Joint coupler
74.YDT coupler
120.CLCU (cornering light control unit)
9-48
EAS32913
The cornering light is not comes on when riding the corner.

TIP
EAS33579
TROUBLESHOOTING
Abnormal CLCU, but DTC is not stored in the memory of the CLCU.
Item
Abnormal connection of CLCU coupler or CLCU can not receive normal signal from IMU
Fail-safe system
Procedure
1. Locate the malfunction.
• Check YDT for “CLCU” indication.
Is the “CLCU” indicated?

YES
→ Go to step 5.
NO
→ Go to step 2.
2. Connection of CLCU coupler.
pins).

YES
→ Go to step 4.
NO
b. Riding the vehicle, and check the cornering light comes on.
Is it correct condition?
YES
NO
→ Go to step 3.
• Disconnect the headlight fuse holder “1”, CLCU coupler “2” and YDT coupler “3”.
Between head light fuse holder “1” and CLCU cou-
red/yellow–blue/red
pler “2”
Between CLCU coupler “2” and ground black–black
9-49
blue/white–blue/white
Between CLCU coupler “2” and YDT coupler “3”
blue/black–blue/black
3
2 L/W B
B L/R R/G L/B
L/W L/B
Is resistance 0 Ω?
YES
NO
YES
NO
→ Go to step 4.
blue/red–ground
Between CLCU coupler “2” and ground blue/white–ground
blue/black–ground

blue/red–any other coupler terminal
blue/white–any other coupler terminal
CLCU coupler “2”
blue/black–any other coupler terminal
black–any other coupler terminal
YDT coupler “3”
A B
2 2 3
B L/R B L/R L/W B
L/W L/B L/W L/B R/G L/B
YES
→ Go to step 4.
9-50
NO
YES
NO
→ Go to step 4.
4. Defective CLCU.
• Replace the auxiliary light assembly.
• Riding the vehicle, and check the cornering light comes on.
5. Abnormal front wheel sensor.
• Repair the DTC (P2158 (FI)).
Refer to “P2158 (FI)” on page 9-277.
• Turn the main switch to “ON”, and then execute the diagnostic mode. (Code 16)
• Rotate the front wheel by hand and check that the indicated value increases.
Is that value increased?

YES
NO
→ Go to step 6.
6. Defective CLCU.
9-51
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20551

EAS33149
DTC TABLE
Fail-safe system
Diagnostic
DTC Symptom Starting the Driving the code
engine vehicle
Front wheel sensor (intermittent pulses or no
“11_ABS” — — —
pulses)
Rear wheel sensor (intermittent pulses or no
“12_ABS” — — —
pulses)
“13,
Front wheel sensor (abnormal pulse period) — — —
26_ABS”
“14,
Rear wheel sensor (abnormal pulse period) — — —
27_ABS”
“15_ABS” Front wheel sensor (open or short circuit) — — —
“16_ABS” Rear wheel sensor (open or short circuit) — — —
Hydraulic unit assembly (defective solenoid
“21_ABS” — — —
drive circuit)
“30_EVENT” Overturn detected. Unable Unable 17
Hydraulic unit assembly (defective ABS sole-
“31_ABS” — — —
noid power circuit)
Hydraulic unit assembly (abnormal ABS mo-
“33_ABS” — — —
tor power supply)
Hydraulic unit assembly (short circuit in ABS
“34_ABS” — — —
motor power supply circuit)
Front wheel ABS (intermittent wheel speed
“41_ABS” — — —
pulses or incorrect depressurization)
Rear wheel ABS (intermittent wheel speed
“42_ABS” — — —
pulses or incorrect depressurization)
“43,
Front wheel sensor (missing pulses) — — —
45_ABS”
“44,
Rear wheel sensor (missing pulses) — — —
46_ABS”
Vehicle system power supply (voltage of
“51_ABS” — — —
ABS ECU power supply is high)
“51_IMMO- Code cannot be transmitted between the key
— — —
BILIZER” and the immobilizer unit.
“52_IMMO- Codes between the key and immobilizer unit
— — —
BILIZER” do not match.
Vehicle system power supply (voltage of
“53_ABS” — — —
ABS ECU power supply is low)
“53_IMMO- Codes cannot be transmitted between the
— — —
BILIZER” ECU and the immobilizer unit.
“54_IMMO- Codes transmitted between the ECU and the
— — —
BILIZER” immobilizer unit do not match.
Hydraulic unit assembly (defective ABS
“55_ABS” — — —
ECU)
“55_IMMO-
Key code registration malfunction. — — —
BILIZER”
9-52
Fail-safe system
Diagnostic
engine vehicle
Hydraulic unit assembly (abnormal internal
“56_ABS” — — —
circuit)
“56_IMMO-
Unidentified code is received. — — —
BILIZER”
Vehicle CAN communication line or power
“57_ABS” — — —
source of vehicle system
Power supply voltage failure in pressure sen-
“62_ABS” — — —
sor
Defective hydraulic unit assembly (defective
“68_ABS” — — —
front pressure sensor)
Engine forcibly stops when the vehicle is left
“70_EVENT” Able/Unable Able/Unable —
idling for a long period.
CAN communication (between meter as-
“89_ABS” — — —
sembly and hydraulic unit assembly)
CAN communication (between ECU and hy-
“90_ABS” — — —
draulic unit assembly)
CAN communication (between IMU and hy-
“91_ABS” — — —
draulic unit assembly)
“B1000” Internal malfunction in CLCU. Able Able —
Error is detected while reading or writing of
“B1001” Able Able —
data.
“C0044” Abnormal ABS Able Able —
ECU: no normal signals or malfunction sig-
“C0520 (FI)” Able/Unable Able/Unable —
nals are received from the IMU.
“C0520 SCU: no normal signals or malfunction sig-
Unable Able/Unable —
(SCU)” nals are received from the IMU.
“C0520 (CL- CLCU: no normal signals or malfunction sig-
Able Able —
CU)” nals are received from the IMU.
Abnormal front fork compression damping
“C100A” Able Able —
adjustment
Abnormal front fork rebound damping adjust-
“C100B” Able Able —
ment
Abnormal rear shock absorber compression
“C100D” Able Able —
damping adjustment
“C100F” Abnormal angular position sensor Able Able —
“C1007” Abnormality inside SCU Able Able —
O2 sensor heater: defective heater controller
“P0030” Able Able —
detected.
[P00D1] O2 sensor: heater performance de-
“P00D1,
terioration Able Able —
P2195”
[P2195] O2 sensor: open circuit detected.
Intake air pressure sensor 1: signal out of
“P0105” Able Able 03
range
Intake air pressure sensor 1: clogging of
hose or sensor disconnection
9-53
Fail-safe system
Diagnostic
engine vehicle
[P0107] Intake air pressure sensor 1: ground
“P0107, short circuit detected.
Able Able 03
P0108” [P0108] Intake air pressure sensor 1: open
or power short circuit detected.
“P0110” Intake air temperature sensor: signal stuck Able Able —
Intake air temperature sensor: signal out of
range
[P0112] Intake air temperature sensor:
“P0112, ground short circuit detected.
Able Able 05
P0113” [P0113] Intake air temperature sensor: open
“P0115” Coolant temperature sensor: signal stuck Able Able —
Coolant temperature sensor: signal out of
range
[P0117] Coolant temperature sensor: ground
Able Able 06
P0118” [P0118] Coolant temperature sensor: open
[P0122] Throttle position sensor: ground
short circuit detected.
[P0123] Throttle position sensor: open or
“P0122,
power short circuit detected.
P0123,
[P0222] Throttle position sensor: open or
P0222, Able/Unable Able/Unable 01, 13
ground short circuit detected.
P0223,
[P0223] Throttle position sensor: power
P2135”
[P2135] Throttle position sensor: output volt-
age deviation error.
O2 sensor: short circuit detected (power
“P0132” Able Able —
short circuit).
“P0133” O2 sensor: response delay Able Able —
“P0134” O2 sensor: signal stuck Able Able —
Able Able
(depending on (depending on
“P0201” Injector #1: malfunction in injector #1. the number of the number of 36
faulty cylin- faulty cylin-
ders) ders)
Able Able
ders) ders)
Able Able
ders) ders)
“P0300, [P0300] Misfire in multiple cylinders
P0301, [P0301] Misfire in cylinder #1
Able/Unable Able/Unable —
P0302, [P0302] Misfire in cylinder #2
P0303” [P0303] Misfire in cylinder #3
9-54
Fail-safe system
Diagnostic
engine vehicle
Crankshaft position sensor: no normal sig-
“P0335” nals are received from the crankshaft posi- Unable Unable —
tion sensor.
Able Able
Cylinder-#1 ignition coil: open or short circuit (depending on (depending on
“P0351” detected in the primary lead of the cylinder- the number of the number of 30
#1 ignition coil. faulty cylin- faulty cylin-
ders) ders)
Able Able
ders) ders)
Able Able
ders) ders)
Purge cut valve solenoid: open circuit detect-
ed.
Radiator fan motor relay: open or short cir-
cuit detected.
[P0500] Rear wheel sensor: no normal sig-
nals are received from the rear wheel sen-
sor.
“P0500 (FI),
[P1500] Neutral switch: open or short circuit Able Able 07, 21
P1500”
is detected.
[P1500] Clutch switch: open or short circuit
is detected.
“P0500 (CL-
Charging voltage is abnormal. Able Able —
CU)”
[P0560] Charging voltage is abnormal.
“P0560 (FI),
[P0563] Vehicle system power voltage out of Able Able —
P0563”
range
“P0560
Abnormal SCU power supply voltage. Able Able 09
(SCU)”
Cruise control setting switch “RES+”: open
or short circuit is detected.
“P0564” Able Able 80, 81
Cruise control setting switch “SET–”: open or
short circuit is detected.
Front brake light switch: open or short circuit
is detected.
“P056C” Able Able 82, 83
Rear brake light switch: open or short circuit
is detected.
Internal malfunction in ECU. (When this mal-
“P0601” function is detected in the ECU, the DTC Unable Unable —
might not appear on the tool display.)
Internal malfunction in ECU. (When this mal-
“P0606” function is detected in the ECU, the DTC Able/Unable Able/Unable —
might not appear on the tool display.)
9-55
Fail-safe system
Diagnostic
engine vehicle
EEPROM DTC: an error is detected while
“P062F” Able/Unable Able/Unable 60
reading or writing on EEPROM.
“P0638” YCC-T drive system: malfunction detected. Able/Unable Able/Unable —
Fuel system voltage: incorrect voltage sup-
“P0657” Able Able 09, 50
plied to the fuel injector and fuel pump.
“P0914” Gear position sensor: signal stuck Able Able —
“P0915” Gear position sensor: signal out of range Able Able —
[P0916] Gear position sensor: open or
“P0916, ground short circuit detected.
Able Able —
P0917” [P0917] Gear position sensor: power short
circuit detected.
Intake air pressure sensor 1 and intake air
“P1004” pressure sensor 2: output voltage deviation Able Able 03, 04
error.
Lean angle sensor: open or short circuit de-
“P1600” Unable Unable 17
tected.
Sidestand switch: open or short circuit of the
“P1601” Unable Unable 20
blue/yellow lead of the ECU is detected.
Malfunction in ECU internal circuit (malfunc-
“P1602” Able/Unable Able/Unable —
tion of ECU power cut-off function).
[P1606] Intake air pressure sensor 2: ground
Able Able 04
P1607” [P1607] Intake air pressure sensor 2: open
Intake air pressure sensor 2: signal out of
range
Intake air pressure sensor 2: clogging of
hose or sensor disconnection
[P1806] Shift sensor: open or ground short
“P1806, circuit detected.
Able Able 95
P1807” [P1807] Shift sensor: power short circuit de-
tected.
[P2122] Accelerator position sensor: open or
ground short circuit detected.
“P2122, [P2123] Accelerator position sensor: power
P2123, short circuit detected.
P2127, [P2127] Accelerator position sensor: open or Able/Unable Able/Unable 14, 15
P2128, ground short circuit detected.
P2138” [P2128] Accelerator position sensor: power
[P2138] Deviation error
Front wheel sensor: no normal signals are
“P2158 (FI)” Able Able 16
received from the front wheel sensor.
“P2158 Front wheel sensor: no normal signals are
Able Able —
(SCU)” received from the front wheel sensor.
“U0100 Abnormal CAN communication (between
Able Able —
(SCU)” ECU and SCU)
“U0100 (CL- Abnormal CAN communication (between
Able Able —
CU)” ECU and CLCU)
9-56
Fail-safe system
Diagnostic
engine vehicle
Abnormal CAN communication (between
“U0121” Able Able —
ABS ECU and SCU)
Signals cannot be transmitted between the
“U0125 (FI)” Unable Able/Unable —
ECU and the IMU.
“U0125 Abnormal CAN communication (between
Able Able —
(SCU)” IMU and SCU)
“U0125 (CL- Abnormal CAN communication (between
Able Able —
CU)” IMU and CLCU)
Multi-function meter: signals cannot be
“U0155 or
transmitted between the ECU and the meter Able Able —
Err (FI)”
assembly.
“U0155 or Abnormal CAN communication (between
Able Able —
Err (SCU)” meter assembly and SCU)
CAN communication: SCU is received ab-
normal data from ECU.
CAN communication: SCU is received ab-
normal data from IMU.
EAS33028
SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

TIP
For details of the DTC, refer to “BASIC PROCESS FOR TROUBLESHOOTING” on page 9-11.
Probable cause of Fail-safe system op-

DTC Item Vehicle symptom
malfunction eration
30_EVEN Overturn detected. • The vehicle has
T overturned.
• Installed condition of
— —
IMU.
• Defective IMU.
• Malfunction in ECU.
70_EVEN Engine forcibly stops • Allow to idle for a
T when the vehicle is long period of time.
— —
left idling for a long • Malfunction in ECU.
period.
C0520 ECU: no normal sig- • Defective IMU cou- Engine cannot be Engine cannot be
nals or malfunction pler or ECU coupler. started (depending on started (depending on
signals are received • Open or short cir- the circumstances). the circumstances).
from the IMU. cuit in wire harness
between IMU and
ECU.
• Improperly installed
IMU.
• Malfunction in IMU.
9-57

malfunction eration
P0030 O2 sensor heater: de- • Open circuit in wire (When the O2 sensor Display only (If the O2
fective heater control- harness. does not operate be- sensor does not oper-
ler detected. • Disconnected cou- cause the exhaust ate, O2 feedback is
pler. temperature is low) not carried out.)
• Defective O2 sensor Increased exhaust Cruise control system
heater controller emissions. cannot be operated.
(Malfunction in Fuel learning cannot
ECU). be carried out.
• Broken or discon-
nected lead in O2
sensor heater.
P00D1 O2 sensor: heater • Improperly installed Increased exhaust O2 feedback is not
performance deterio- O2 sensor. emissions. carried out.
ration • Defective coupler O2 learning is not car-
between O2 sensor ried out.
and ECU. QSS is not carried
• Open or short cir- out.
cuit in wire harness Cruise control system
between O2 sensor cannot be operated.
and ECU.
• Incorrect fuel pres-
sure.
• Defective O2 sensor.
P0105 Intake air pressure • Defective coupler Engine idling speed is Intake air pressure is
sensor 1: signal out of between intake air unstable. fixed to 101.3 [kPa].
range pressure sensor and Engine response is Intake air pressure
ECU. poor. difference is fixed to 0
• Open or short cir- Loss of engine power. [kPa].
cuit in wire harness Increased exhaust α–N is fixed.
between intake air emissions. Fuel is not cut off due
pressure sensor and to the intake air pres-
ECU. sure difference.
• Defective intake air O2 feedback is not
pressure sensor. carried out.
• Malfunction in ECU. ISC feedback is not
carried out.
ISC learning is not
carried out.
QSS is not carried
out.
Cruise control system
cannot be operated.
9-58

malfunction eration
P0106 Intake air pressure • Intake air pressure Engine idling speed is Intake air pressure is
sensor 1: clogging of sensor 1 hose is not high. fixed to 101.3 [kPa].
hose or sensor dis- installed. Engine idling speed is Intake air pressure
connection • Intake air pressure unstable. difference is fixed to 0
sensor 1 hose is not Engine response is [kPa].
installed correctly poor. α–N is fixed.
(Detached, clogged, Loss of engine power. Fuel is not cut off due
kinked or pinching). Increased exhaust to the intake air pres-
• Intake air pressure emissions. sure difference.
sensor 1 hole is O2 feedback is not
clogged, or intake carried out.
air pressure sensor ISC feedback is not
1 is not installed cor- carried out.
rectly. ISC learning is not
carried out.
QSS is not carried
out.
cannot be operated.
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure is
P0108 pressure sensor 1: of the intake air pres- unstable. fixed to 101.3 [kPa].
ground short circuit sure sensor 1 circuit Engine response is Intake air pressure
detected. (0.5 V or less) poor. difference is fixed to 0
[P0108] Intake air [P0108] High voltage Loss of engine power. [kPa].
pressure sensor 1: of the intake air pres- Increased exhaust α–N is fixed.
open or power short sure sensor 1 circuit emissions. Fuel is not cut off due
circuit detected. (4.8 V or more) to the intake air pres-
• Defective coupler sure difference.
between intake air O2 feedback is not
pressure sensor 1 carried out.
and ECU. ISC feedback is not
• Open or short cir- carried out.
cuit in wire harness ISC learning is not
between intake air carried out.
pressure sensor 1 QSS is not carried
and ECU. out.
• Defective intake air Cruise control system
pressure sensor 1. cannot be operated.
P0110 Intake air tempera- • Improperly installed Engine is difficult to The intake air tem-
ture sensor: signal intake air tempera- start. perature is fixed to 20
stuck ture sensor. Increased exhaust [°C].
• Defective intake air emissions. O2 sensor heater driv-
temperature sensor. Engine idling speed is ing is not carried out.
• Malfunction in ECU. unstable. O2 feedback is not
carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
QSS is not carried
out.
cannot be operated.
9-59

malfunction eration
P0111 Intake air tempera- • Defective coupler Engine is difficult to The intake air tem-
ture sensor: signal out between intake air start. perature is fixed to 20
of range temperature sensor Increased exhaust [°C].
and ECU. emissions. O2 sensor heater driv-
• Open or short cir- Engine idling speed is ing is not carried out.
cuit in wire harness unstable. O2 feedback is not
between intake air carried out.
temperature sensor ISC feedback is not
and ECU. carried out.
• Improperly installed ISC learning is not
intake air tempera- carried out.
ture sensor. QSS is not carried
• Defective intake air out.
temperature sensor. Cruise control system
• Malfunction in ECU. cannot be operated.
P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tem-
P0113 temperature sensor: of the intake air tem- start. perature is fixed to 20
ground short circuit perature sensor circuit Increased exhaust [°C].
detected. (0.1 V or less) emissions. O2 sensor heater driv-
[P0113] Intake air [P0113] High voltage Engine idling speed is ing is not carried out.
temperature sensor: of the intake air tem- unstable. O2 feedback is not
open or power short perature sensor circuit carried out.
circuit detected. (4.8 V or more) ISC feedback is not
• Defective coupler carried out.
between intake air ISC learning is not
temperature sensor carried out.
and ECU. QSS is not carried
between intake air cannot be operated.
temperature sensor
and ECU.
intake air tempera-
ture sensor.
• Defective intake air
temperature sensor.
P0115 Coolant temperature • Defective coolant Engine is difficult to The radiator fan motor
sensor: signal stuck temperature sensor. start. relay is on only when
• Malfunction in ECU. Increased exhaust the vehicle is traveling
emissions. at low speeds.
Engine idling speed is O2 feedback is not
unstable. carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
The coolant tempera-
ture is fixed to 60 [°C].
QSS is not carried
out.
cannot be operated.
9-60

malfunction eration
P0116 Coolant temperature • Defective coupler Engine is difficult to The radiator fan motor
sensor: signal out of between coolant start. relay is on only when
range temperature sensor Increased exhaust the vehicle is traveling
and ECU. emissions. at low speeds.
• Open or short cir- Engine idling speed is O2 feedback is not
cuit in wire harness unstable. carried out.
between coolant ISC feedback is not
temperature sensor carried out.
and ECU. ISC learning is not
• Improperly installed carried out.
coolant temperature The coolant tempera-
sensor. ture is fixed to 60 [°C].
• Defective coolant QSS is not carried
temperature sensor. out.
• Malfunction in ECU. Cruise control system
cannot be operated.
P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan motor
P0118 perature sensor: of the coolant tem- start. relay is on only when
ground short circuit perature sensor circuit Increased exhaust the vehicle is traveling
detected. (0.1 V or less) emissions. at low speeds.
[P0118] Coolant tem- [P0118] High voltage Engine idling speed is O2 feedback is not
perature sensor: open of the coolant tem- unstable. carried out.
or power short circuit perature sensor circuit ISC feedback is not
detected. (4.9 V or more) carried out.
• Defective coupler ISC learning is not
between coolant carried out.
temperature sensor The coolant tempera-
and ECU. ture is fixed to 60 [°C].
• Open or short cir- QSS is not carried
cuit in wire harness out.
between coolant Cruise control system
temperature sensor cannot be operated.
and ECU.
coolant temperature
sensor.
• Defective coolant
temperature sensor.
9-61

malfunction eration
P0122 [P0122] Throttle posi- [P0122, P0222] Low Engine idling speed is Change in the throttle
P0123 tion sensor: ground voltage of the throttle high. opening is 0 (transient
P0222 short circuit detected. position sensor circuit Engine idling speed is control is not carried
P0223 [P0123] Throttle posi- (0.25 V or less) unstable. out).
P2135 tion sensor: open or [P0123, P0223] High Engine response is D–j is fixed.
power short circuit de- voltage of the throttle poor. Throttle opening is
tected. position sensor circuit Loss of engine power. fixed to 125 [°].
[P0222] Throttle posi- (4.75 V or more) Deceleration is poor. O2 feedback is not
tion sensor: open or [P2135] Difference in Increased exhaust carried out.
ground short circuit output voltage 1 and emissions. Fuel is not cut off due
detected. output voltage 2 of the Vehicle cannot be to the throttle open-
[P0223] Throttle posi- throttle position sen- driven. ing.
tion sensor: power sor Output is restricted.
short circuit detected. • Defective coupler ISC feedback is not
[P2135] Throttle posi- between throttle po- carried out.
tion sensor: output sition sensor and ISC learning is not
voltage deviation er- ECU. carried out.
ror. • Open or short cir- O2 sensor heater driv-
cuit in wire harness ing is not carried out.
between throttle po- QSS is not carried
sition sensor and out.
ECU. Cruise control system
• Improperly installed cannot be operated.
throttle position sen-
sor.
• Defective throttle po-
sition sensor.
P0132 O2 sensor: deteriora- High voltage of the O2 Increased exhaust O2 feedback is not
tion detected sensor circuit (4.8 V emissions. carried out.
or more) O2 feedback learning
• Improperly installed is not carried out.
O2 sensor. QSS is not carried
• Defective coupler out.
between O2 sensor Cruise control system
and ECU. cannot be operated.
• Open or short cir-
cuit in wire harness
between O2 sensor
and ECU.
sure.
P0133 O2 sensor: response • Defective O2 sensor. Increased exhaust
delay • Malfunction in fuel emissions.
system. —
• Malfunction in ex-
haust system.
P0134 O2 sensor: signal • Defective engine Increased exhaust QSS is not carried
stuck condition. emissions. out.
• Improperly installed Cruise control system
O2 sensor. cannot be operated.
sure.
9-62

malfunction eration
P0201 [P0201] Injector #1: • Defective coupler Loss of engine power. O2 feedback is not
P0202 malfunction in injec- between injector Engine is difficult to carried out.
P0203 tor #1. and ECU. start. ISC feedback is not
[P0202] Injector #2: • Open or short cir- Engine cannot be carried out.
malfunction in injec- cuit in wire harness started. ISC learning is not
tor #2. between injector Engine stops. carried out.
[P0203] Injector #3: and ECU. Engine idling speed is QSS is not carried
malfunction in injec- • Defective injector. unstable. out.
tor #3. • Malfunction in ECU. Increased exhaust Cruise control system
• Improperly installed emissions. cannot be operated.
injector.
P0300 Misfire in multiple cyl- • Ignition system mal- Engine is difficult to
inders function/abnormal start.
• Fuel system mal- Loss of engine power.
function/abnormal Engine idling speed is
unstable. —
Engine response is
poor.
Increased exhaust
emissions.
P0301 Misfire in cylinder #1 • Ignition system mal- Engine is difficult to
function/abnormal start.
unstable. —
Engine response is
poor.
Increased exhaust
emissions.
unstable. —
Engine response is
poor.
Increased exhaust
emissions.
unstable. —
Engine response is
poor.
Increased exhaust
emissions.
9-63

malfunction eration
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor: no normal between crankshaft started. ISC feedback is not
signals are received position sensor and carried out.
from the crankshaft ECU. ISC learning is not
position sensor. • Open or short cir- carried out.
between crankshaft cannot be operated.
position sensor and
ECU.
crankshaft position
sensor.
• Malfunction in gen-
erator rotor.
• Defective crank-
shaft position sen-
sor.
P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. O2 feedback is not
P0352 ignition coil: open or between ignition coil Loss of engine power. carried out.
P0353 short circuit detected and ECU. Engine is difficult to ISC feedback is not
in the primary lead of • Open or short cir- start. carried out.
the cylinder-#1 igni- cuit in wire harness Engine cannot be ISC learning is not
tion coil. between ignition coil started. carried out.
[P0352] Cylinder-#2 and ECU. Engine idling speed is QSS is not carried
ignition coil: open or • Improperly installed unstable. out.
short circuit detected ignition coil. Increased exhaust Cruise control system
in the primary lead of • Defective ignition emissions. cannot be operated.
the cylinder-#2 igni- coil.
tion coil. • Malfunction in ECU.
[P0353] Cylinder-#3
ignition coil: open or
short circuit detected
in the primary lead of
the cylinder-#3 igni-
tion coil.
P0458 Purge cut valve sole- • Open or short cir- Vapor gas cannot be Closing side on purge
noid: open circuit de- cuit in wire harness. purged from canister. cut valve solenoid is
tected. • Defective purge cut fixed.
valve solenoid.
P0480 Radiator fan motor re- • Open or short cir- Engine is difficult to Radiator fan motor re-
lay: open or short circuit in wire harness. start. lay is off all the time.
cuit detected. • Disconnected cou- Loss of engine power. O2 feedback is not
pler. Engine overheats. carried out.
• Defective radiator Increased exhaust ISC feedback is not
fan motor relay. emissions. carried out.
• Defective radiator ISC learning is not
fan motor relay con- carried out.
troller (Malfunction Cruise control system
in ECU). cannot be operated.
9-64

malfunction eration
P0500 [P0500] Rear wheel • Open or short cir- Vehicle speed is not Vehicle speed dis-
P1500 sensor: no normal cuit in wire harness displayed on the me- played on the meter =
signals are received between rear wheel ter. 0 [km/h]
from the rear wheel sensor and ABS [P1500] Indication of O2 feedback is not
sensor. ECU. the neutral indicator carried out.
[P1500] Neutral • Open or short cir- light is incorrect. Fuel cut-off control
switch: open or short cuit in wire harness Engine idling speed is when the rear wheel
circuit is detected. between ABS ECU unstable. sensor or neutral
[P1500] Clutch switch: and ECU. Traction control does switch malfunctions is
open or short circuit is • [P1500] Open or not work. carried out.
detected. short circuit in wire ISC feedback is not
harness between carried out.
neutral switch and ISC learning is not
ECU. carried out.
• [P1500] Open or Traction control does
short circuit in wire not work.
harness between [P0500] QSS is not
clutch switch and carried out.
• Defective rear wheel cannot be operated.
sensor.
• [P1500] Defective
neutral switch.
• [P1500] Defective
clutch switch.
• [P1500] Improper
adjustment of clutch
lever.
P0560 Charging voltage is • Battery over-dis- Engine is difficult to O2 feedback is not
abnormal. charging (broken or start. carried out.
disconnected lead in Increased exhaust
charging system). emissions.
• Battery over-dis- Battery performance
charging (defective has deteriorated or
rectifier/regulator). battery is defective.
P0563 Vehicle system power • Battery overcharg- Engine is difficult to O2 feedback is not
voltage out of range ing (defective rectifi- start. carried out.
er/regulator). Increased exhaust
• Battery overcharg- emissions.
ing (broken or dis- Battery performance
connected lead in has deteriorated or
rectifier/regulator battery is defective.
wire harness).
P0564 Cruise control setting • Open or short cir- Cruise control system Cruise control system
switch “RES+”: open cuit in wire harness. cannot be operated. cannot be operated.
or short circuit is de- • Defective cruise
tected. control setting
Cruise control setting switch.
switch “SET–”: open • Malfunction in ECU.
or short circuit is de-
tected.
P056C Cruise control cancel-
ing switch: open or
short circuit is detect-
ed.
9-65

malfunction eration
P0601 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be
ECU. (When this mal- started. started.
function is detected in Cruise control system
the ECU, the DTC cannot be operated.
might not appear on
the tool display.)
P0606 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be
ECU. (When this mal- started. started.
function is detected in Engine response is Ignition and injection
the ECU, the DTC poor. are not carried out.
might not appear on Loss of engine power. Judgment for other
the tool display.) DTCs is not carried
out.
Load control is not
carried out. (The relay
unit, radiator fan mo-
tor relay, and other re-
lays are all turned off.)
The CO adjustment
mode and diagnostic
mode cannot be acti-
vated.
Output is restricted.
cannot be operated.
P062F EEPROM DTC: an er- • CO adjustment val- Increased exhaust CO adjustment value
ror is detected while ue is not properly emissions. for the faulty cylinder
reading or writing on written. Engine cannot be = 0 (default value)
EEPROM. • ISC learning value is started or is difficult to ISC learning values =
not properly written. start. Default values.
• O2 feedback learn- Engine idling speed is OBD memory value is
ing value is not unstable. initialized.
properly written. OBD memory value is Initialization of O2
• OBD memory value not correct. feedback learning val-
is not properly writ- ue.
ten. Cruise control system
P0638 YCC-T drive system: • Defective coupler Engine response is O2 feedback is not
malfunction detected. between throttle ser- poor. carried out.
vo motor and ECU. Loss of engine power. YCC-T evacuation is
• Open or short cir- Engine idling speed is activated.
cuit in wire harness unstable. Output is restricted.
between throttle ser- ISC feedback is not
vo motor and ECU. carried out.
• Defective throttle ISC learning is not
servo motor. carried out.
• Throttle servo mo- QSS is not carried
tor is stuck (mecha- out.
nism or motor). Cruise control system
• Blown electric throt-
tle valve fuse.
9-66

malfunction eration
P0657 Fuel system voltage: • Open or short cir- Engine is difficult to Monitor voltage = 12
incorrect voltage sup- cuit in wire harness start. [V]
plied to the fuel injec- between relay unit Increased exhaust O2 feedback is not
tor and fuel pump. and ECU. emissions. carried out.
• Open circuit in wire Cruise control system
harness between cannot be operated.
battery and ECU.
• Defective relay unit.
P0914 Gear position sensor: • Improperly installed Improper display for QSS is not carried
signal stuck gear position sen- position. out.
sor. Engine response is Cruise control system
• Defective gear posi- poor. cannot be operated.
tion sensor.
P0915 Gear position sensor: • Defective coupler Improper display for Maintains the gear
signal out of range between gear posi- position. position value at the
tion sensor and Engine response is previous value.
ECU. poor. QSS is not carried
• Open or power short out.
circuit in wire har- Engine brake man-
ness between gear agement: control
position sensor and mode is fixed.
ECU. Engine brake man-
• Improperly installed agement: control val-
gear position sen- ue is fixed.
sor. Cruise control system
• Defective gear posi- cannot be operated.
tion sensor.
P0916 [P0916] Gear posi- [P0916] Low voltage Improper display for Maintains the gear
P0917 tion sensor: open or of the gear position position. position value at the
ground short circuit sensor circuit (0.2 V Engine response is previous value.
detected. or less) poor. QSS is not carried
[P0917] Gear posi- [P0917] High voltage out.
tion sensor: power of the gear position Engine brake man-
short circuit detected. sensor circuit (4.8 V agement: control
or more) mode is fixed.
• Defective coupler Engine brake man-
between gear posi- agement: control val-
tion sensor and ue is fixed.
• Open or power short cannot be operated.
circuit in wire har-
ness between gear
position sensor and
ECU.
gear position sen-
sor.
• Defective gear posi-
tion sensor.
9-67

malfunction eration
P1004 Intake air pressure • Intake pressure sen- Engine is difficult to Intake air pressure is
sensor 1 and intake sor 1 hose or intake start. fixed to 101.3 [kPa].
air pressure sensor 2: pressure sensor 2 Engine idling speed is Intake air pressure
output voltage devia- hose is detached, unstable. difference is fixed to 0
tion error. clogged, kinked or Increased exhaust [kPa].
bent. emissions. Atmospheric pres-
• Defective intake air Loss of engine power. sure is fixed to 101.3
pressure sensor 1 or [kPa].
intake air pressure α–N is fixed.
sensor 2. Fuel is not cut off due
• Malfunction in ECU. to the intake air pres-
sure difference.
O2 feedback is not
carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
cannot be operated.
P1600 Lean angle sensor: • Open or short cir- Engine cannot be Engine cannot be
open or short circuit cuit in wire harness. started. started.
detected. • Malfunction in IMU. Cruise control system
P1601 Sidestand switch: • Defective coupler Engine cannot be Engine is forcefully
open or short circuit of between relay unit started. stopped (the injector
the blue/yellow lead of and ECU. output is stopped).
the ECU is detected. • Open or short cir- Cruise control system
cuit in wire harness cannot be operated.
between relay unit
and ECU.
• Defective coupler
between sidestand
switch and relay
unit.
between sidestand
switch and relay
unit.
• Defective sidestand
switch.
P1602 Malfunction in ECU • Open or short cir- Engine idling speed is O2 feedback learning
internal circuit (mal- cuit in wire harness unstable. is not carried out.
function of ECU pow- between ECU and Engine idling speed is O2 feedback learning
er cut-off function). battery. high. value is not written.
• Open or short cir- Increased exhaust Cruise control system
cuit in wire harness emissions. cannot be operated.
between ECU and Engine is difficult to
main switch. start.
• Blown backup fuse.
9-68

malfunction eration
P1606 [P1606] Intake air • Defective coupler Engine is difficult to α–N is fixed.
P1607 pressure sensor 2: between intake air start. Intake air pressure
P1608 ground short circuit pressure sensor 2 Increased exhaust difference is fixed to 0
detected. and ECU. emissions. [kPa].
[P1607] Intake air • Open or short cir- Insufficient power at Atmospheric pres-
pressure sensor 2: cuit in wire harness high altitudes. sure is fixed to 101.3
open or power short between intake air Engine idling speed is [kPa].
circuit detected. pressure sensor 2 unstable. Fuel is not cut off due
[P1608] Intake air and ECU. to the intake air pres-
pressure sensor 2: • Improperly installed sure difference.
signal out of range. intake air pressure O2 feedback is not
sensor 2. carried out.
• Defective intake air ISC feedback is not
pressure sensor 2. carried out.
• Malfunction in ECU. ISC learning is not
carried out.
P1609 Intake air pressure • Intake air pressure Engine idling speed is Intake air pressure
sensor 2: clogging of sensor 2 hose is not high. difference is fixed to 0
hose or sensor dis- installed. Engine idling speed is [kPa].
connection • Intake air pressure unstable. α–N is fixed.
sensor 2 hose is not Loss of engine power. Fuel is not cut off due
installed correctly to the intake air pres-
(Detached, clogged, sure difference.
kinked or pinching). Atmospheric pres-
• Intake air pressure sure is fixed to 101.3
sensor 2 hole is [kPa].
clogged, or intake O2 feedback is not
air pressure sensor carried out.
is not installed cor-
rectly.
P1806 [P1806] Shift sensor: • Defective coupler Unable to carry out QSS is not carried
P1807 open or ground short between shift sensor QSS. out.
circuit detected. and ECU. (If this abnormality oc-
[P1807] Shift sensor: • Open or power short curs during actual
power short circuit de- circuit in wire har- shifting, the operation
tected. ness between shift will be carried out until
sensor and ECU. the process is com-
• Improperly installed pleted.)
shift sensor.
• Defective shift sen-
sor.
9-69

malfunction eration
P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in acceler-
P2123 position sensor: open voltage of the acceler- poor. ator opening (tran-
P2127 or ground short cir- ator position sensor Loss of engine power. sient control is not
P2128 cuit detected. circuit (0.25 V or less) Engine idling speed is carried out).
P2138 [P2123] Accelerator [P2123, P2128] High unstable. Accelerator opening is
position sensor: pow- voltage of the acceler- fixed to 0[°].
er short circuit detect- ator position sensor O2 feedback is not
ed. circuit (4.75 V or carried out.
[P2127] Accelerator more) YCC-T evacuation is
position sensor: open [P2138] Difference in activated.
or ground short cir- output voltage 1 and Fuel cut is prohibited
cuit detected. output voltage 2 of the by accelerator open-
[P2128] Accelerator accelerator position ing.
position sensor: pow- sensor Output is restricted.
er short circuit detect- • Defective coupler ISC feedback is not
ed. between accelera- carried out.
[P2138] Deviation er- tor position sensor ISC learning is not
ror and ECU. carried out.
• Open or short cir- QSS is not carried
cuit in wire harness out.
between accelera- Cruise control system
tor position sensor cannot be operated.
and ECU.
accelerator position
sensor.
• Defective accelera-
tor position sensor.
P2158 Front wheel sensor: • Open or short cir- Traction control does Traction control does
no normal signals are cuit in wire harness not work. not work.
received from the between front wheel Traction control sys- Cruise control system
front wheel sensor. sensor and ABS tem indicator on the cannot be operated.
ECU. meter comes on.
• Defective front Traction control sys-
wheel sensor. tem switch is dis-
• Malfunction in ABS abled. (Traction
ECU. control system indica-
• Malfunction in ECU. tor on the meter goes
OFF.)
P2195 O2 sensor: open cir- • Low voltage of the Increased exhaust O2 feedback is not
cuit detected. O2 sensor circuit emissions. carried out.
(0.18–0.49 V). O2 feedback learning
• Improperly installed is not carried out.
O2 sensor. QSS is not carried
• Defective coupler out.
between O2 sensor Cruise control system
and ECU. cannot be operated.
between O2 sensor
and ECU.
sure.
9-70

malfunction eration
U0125 Signals cannot be • Defective IMU cou- Engine cannot be Engine cannot be
transmitted between pler or ECU coupler. started. started.
the ECU and the IMU. • Open or short cir- Cruise control system
cuit in wire harness cannot be operated.
between IMU and
ECU.
EAS33029
SELF-DIAGNOSTIC FUNCTION TABLE (FOR IMMOBILIZER SYSTEM)

TIP
For details of the DTC, refer to “HOW TO CHECK DTC” on page 9-20.
DTC Item
51 Immobilizer unit: Code cannot be transmitted between the key and the immobilizer unit.
52 Immobilizer unit: Codes between the key and immobilizer unit do not match.
53 Immobilizer unit: Codes cannot be transmitted between the ECU and the immobilizer unit.
54 Immobilizer unit: Codes transmitted between the ECU and the immobilizer unit do not match.
55 Immobilizer unit: Key code registration malfunction.
56 ECU: Unidentified code is received.
EAS33286
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))

TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-34.
DTC Item Symptom Check point

11 Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the front wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
12 Rear wheel sensor (intermit- Rear wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the rear wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) rear wheel
rotor
• Defective rear wheel sen-
of the sensor
9-71

13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
front wheel
rotor
of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered
27* mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
rear wheel
rotor
of the sensor
15 Front wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the front wheel sen- the front wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
sor or hydraulic unit as-
sembly
16 Rear wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the rear wheel sen- the rear wheel sensor and
sor. the hydraulic unit assembly
rear wheel sensor and the
sor or hydraulic unit as-
sembly
21 Hydraulic unit assembly (de- Solenoid drive circuit in the • Defective hydraulic unit as-
fective solenoid drive circuit) hydraulic unit assembly is sembly
open or short-circuited.
31 Hydraulic unit assembly (de- Power is not supplied to the • Blown ABS solenoid fuse
fective ABS solenoid power solenoid circuit in the hy- • Defective coupler between
circuit) draulic unit assembly. the battery and the hydrau-
lic unit assembly
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
9-72

33 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS motor fuse
normal ABS motor power motor circuit in the hydraulic • Defective coupler between
supply) unit assembly. the battery and the hydrau-
lic unit assembly
unit assembly
sembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS motor the motor power supply cir- sembly
power supply circuit) cuit in the hydraulic unit as-
sembly.
41 Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- front wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. front wheel
• Front wheel will not recover • Front brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
42 Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- rear wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. rear wheel
• Rear wheel will not recover • Rear brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
43* Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
45* pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) front wheel
rotor
of the sensor
44* Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
46* pulses) not received properly. (Miss- around the rear wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) rear wheel
rotor
of the sensor
9-73

51 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Disconnected battery ter-
supply is high) lic unit assembly is too high. minal
• Defective charging system
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lic unit assembly is too low. the battery and the hydrau-
lic unit assembly
unit assembly
55 Hydraulic unit assembly (de- Abnormal data is detected in • Defective hydraulic unit as-
fective ABS ECU) the hydraulic unit assembly. sembly
56 Hydraulic unit assembly (ab- Abnormality detected in of • Defective hydraulic unit as-
normal internal circuit) hydraulic unit assembly. sembly
57 Vehicle CAN communication Short-circuit in CAN commu- • Short-circuit in CAN com-
line or power source of vehi- nication line or the voltage munication line
cle system that supplies the hydraulic • Defective battery
unit assembly is too low. • Defective coupler between
battery and hydraulic unit
assembly
• Wire harness between bat-
tery and hydraulic unit is in-
terrupted or has short-
circuited
62 Power supply voltage failure Abnormality detected in • Defective hydraulic unit as-
in pressure sensor pressure sensor power sup- sembly
ply circuit of hydraulic unit
assembly.
68 Defective hydraulic unit as- Abnormality detected in In case of electrical interlock-
sembly (defective front pres- pressure sensor circuit at ing brake
sure sensor) front caliper side of hydrau- • Defective front brake line
lic unit assembly. • Defective hydraulic unit as-
sembly
89 CAN communication (be- Transmitted data from the • Defective coupler between
tween meter assembly and meter cannot be normally re- meter assembly and hy-
hydraulic unit assembly) ceived. draulic unit assembly
• Harness is broken or short-
circuit between meter as-
sembly and hydraulic unit
assembly
• Defective meter assembly
sembly
90 CAN communication (be- Transmitted data from the FI • Defective coupler between
tween ECU and hydraulic ECU cannot be normally re- FI ECU and hydraulic unit
unit assembly) ceived. assembly
circuit between FI ECU and
• Defective FI ECU
sembly
9-74

91 CAN communication (be- Transmitted data from the • Defective coupler between
tween IMU and hydraulic unit IMU cannot be normally re- IMU and hydraulic unit as-
assembly) ceived. sembly
circuit between IMU and
• Defective IMU
sembly
* The DTC number varies according to the vehicle conditions.
EAS33288
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ELECTRONICALLY ADJUSTABLE SUSPENSION

SYSTEM (for MTT890D))
TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-41.
DTC Item Probable cause of Vehicle symptom

Fail-safe system operation
malfunction
C0044 Abnormal ABS • Power supply volt- • “SUS-MODE” system
age failure in pres- adjustments cannot be
sure sensor. performed.
—
• Defective hydraulic • The damping preset
unit assembly. value is fixed at the
maximum position.
C0520 SCU: normal sig- • Defective IMU cou- • “SUS-MODE” system
nal or malfunc- pler or ECU coupler. adjustments cannot be
tion signals are • Open or short circuit performed.
received from the in wire harness be- • The damping preset
IMU. tween IMU and value is fixed at the
—
ECU. maximum position.
IMU.
C100A Abnormal front • Defective connec- • “SUS-MODE” system
fork compression tion of wire harness, adjustments can not be
damping adjust- front fork solenoid, performed.
ment and SCU coupler. • The damping preset
• Defective connec- value is fixed at the
tion of sub-wire har- maximum position.
ness coupler.
• Open or short circuit
—
in wire harness con-
tinuity.
• Defective connec-
tion inside of front
fork solenoid cou-
pler.
• Open circuit inside
of solenoid harness.
9-75

malfunction
C100B Abnormal front • Defective connec- • “SUS-MODE” system
fork rebound tion of wire harness, adjustments can not be
damping adjust- front fork solenoid, performed.
ment and SCU coupler. • The damping preset
• Defective connec- value is fixed at the
tion of sub-wire har- maximum position.
ness coupler.
—
tinuity.
tion inside of front
fork solenoid cou-
pler.
• Open circuit inside
of solenoid harness.
C100D Abnormal rear • Defective connec- • “SUS-MODE” system
shock absorber tion of wire harness, adjustments can not be
rebound damp- rear shock absorb- performed.
ing adjustment er assembly sole- • The damping preset
noid, and SCU value is fixed at the
coupler. maximum position.
—
tion of sub-wire har-
ness coupler.
tinuity.
• Defective solenoid.
• Malfunction in SCU.
C100F Abnormal angu- • Improperly installed • “SUS-MODE” system
lar position sen- angular position adjustments can not be
sor sensor. performed.
• Defective connec- • The damping preset
tion of wire harness, value is fixed at the
angular position maximum position.
sensor, and SCU
—
coupler.
tinuity.
• Defective angular
position sensor.
C1007 Abnormality in- • Malfunction in SCU. • “SUS-MODE” system
side SCU adjustments can not be
performed.
—
• The damping preset
value is fixed at the
maximum position.
P0560 Abnormal SCU • Battery overcharg- • “SUS-MODE” system
power supply volt- ing (defective rectifi- adjustments cannot be
age er/regulator). performed.
• Battery overcharg- • The damping preset
—
ing (broken or dis- value is fixed at the
connected lead in maximum position.
rectifier/regulator
wire harness).
9-76

malfunction
P2158 Abnormal front • Open or short circuit • “SUS-MODE” system
wheel sensor in wire harness be- adjustments cannot be
tween front wheel performed.
sensor and ABS • The damping preset
ECU. value is fixed at the
—
• Defective front maximum position.
wheel sensor.
• Malfunction in ABS
ECU.
U0100 Abnormal CAN • Defective connec- • “SUS-MODE” system
communication tion of wire harness, adjustments cannot be
(between ECU ECU, and SCU cou- performed.
and SCU) plers. • The damping preset
—
• Wire harness conti- value is fixed at the
nuity. maximum position.
(between ABS ABS ECU, and SCU performed.
ECU and SCU) couplers. • The damping preset
• Wire harness conti- value is fixed at the —
• Malfunction in ABS
ECU.
(between IMU IMU, and SCU cou- performed.
and SCU) plers. • The damping preset
—
• Wire harness conti- value is fixed at the
(between meter meter assembly, performed.
assembly and and SCU couplers. • The damping preset
SCU) • Wire harness conti- value is fixed at the —
• Malfunction in meter
assembly.
U0401 CAN communica- • Defective connec- • “SUS-MODE” system
tion: SCU is re- tion of wire harness, adjustments cannot be
ceived abnormal ECU, and SCU cou- performed.
data from ECU. pler. • The damping preset
• Open or short circuit value is fixed at the
—
in wire harness be- maximum position.
tween SCU and
ECU.
9-77

malfunction
U0432 CAN communica- • Defective connec- • “SUS-MODE” system
tion: SCU is re- tion of wire harness, adjustments cannot be
ceived abnormal IMU, and SCU cou- performed.
data from IMU. pler. • The damping preset
• Open or short circuit value is fixed at the
—
in wire harness be- maximum position.
tween SCU and
IMU.
EAS33580
SELF-DIAGNOSTIC FUNCTION TABLE (FOR CORNERING LIGHT SYSTEM (for MTT890D))

malfunction eration
B1000 Abnormal inside CL- • Malfunction in CL- Cornering light is not —
CU. CU. comes on.
B1001 Error is detected while • Malfunction in CL- A difference is reflect- —
reading or writing of CU. ed on a lighting start
data. angle in left and right.
C0520 CLCU: malfunction • Defective connec- Cornering light is not —
signals are received tion of wire harness, comes on.
from IMU or normal IMU and CLCU cou-
signals can not be re- pler.
ceived from IMU. • Open or short cir-
continuity between
IMU and CLCU.
IMU.
• Malfunction in CL-
CU.
P0500 No normal signals are Refer to “P0500” in Cornering light is not —
received from the “SELF-DIAGNOSTIC comes on.
wheel sensor or open FUNCTION TABLE
circuit neutral switch (FOR FUEL INJEC-
or open or short cir- TION SYSTEM)” on
cuit clutch switch. page 9-57.
U0100 Abnormal CAN com- • Defective connec- Cornering light is not —
munication (between tion of wire harness, comes on.
ECU and CLCU) ECU and CLCU
coupler.
continuity between
ECU and CLCU.
CU.
9-78

malfunction eration
U0125 Abnormal CAN com- • Defective connec- Cornering light is not —
munication (between tion of wire harness, comes on.
IMU and CLCU) IMU and CLCU cou-
pler.
continuity between
IMU and CLCU.
CU.
EAS33030
COMMUNICATION ERROR WITH THE METER

malfunction eration
U0155 [U0155 (FI)] Multi- Communication be- Defective meter dis- MAP changeover:
(YDT) function meter: sig- tween the ECU and play. State is fixed.
Err (multi- nals cannot be trans- the meter is not possi- Traction control does Traction control does
function mitted between the ble not work. not work.
meter dis- ECU and the multi- • Defective meter cou- Meter switch input:
play) function meter. pler and ECU cou- OFF is fixed.
pler QSS is not carried
cuit in the wire har- Cruise control system
ness between the cannot be operated.
meter and the ECU
• Defective meter
• Defective ECU
EAS33031
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor sig-
nal 1
• Fully closed position 11–21 Check with throttle valves ful-
ly closed.
• Fully open position 96–107 Check with throttle valves ful-
ly open.
03 Intake air pressure 1 Displays the intake air pres- Operate the throttle while
sure. pushing the “ ” side of the
stop/run/start switch. (If the
display value changes, the
performance is OK.)
04 Intake air pressure 2 Displays the intake air pres- Operate the throttle while
sure. pushing the “@” side of the
stop/run/start switch. (If the
display value changes, the
performance is OK.)
05 Intake air temperature Displays the intake air tem- Compare the actually mea-
perature. sured air temperature with
the tool display value.
9-79
Diagnostic
code No.
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
air temperature. with the tool display value.
When engine is hot: Displays
current coolant temperature.
07 Rear wheel vehicle speed Rear wheel speed pulse Check that the number in-
pulses 0–999 creases when the rear wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
09 (FI) Fuel system voltage Fuel system voltage Set the stop/run/start switch
(battery voltage) Approximately 12.0 to “ ”, and then compare
the actually measured bat-
tery voltage with the tool dis-
play value. (If the actually
measured battery voltage is
low, recharge the battery.)
09 (SCU) SCU system voltage SCU system voltage Set the stop/run/start switch
(battery voltage) Approximately 12.0 to “ ”, and then compare
the actually measured bat-
tery voltage with the tool dis-
play value. (If the actually
measured battery voltage is
low, recharge the battery.)
13 Throttle position sensor sig-
nal 2
• Fully closed position 9–23 Check with throttle valves ful-
ly closed.
• Fully open position 93–109 Check with throttle valves ful-
ly open.
14 Accelerator position sensor
signal 1
• Fully closed position 14–18 Check with throttle grip fully
closed position.
• Fully open position 82–92 Check with throttle grip fully
open position.
• Turn the throttle grip past 7–12
the closed position in the
deceleration direction.
15 Accelerator position sensor
signal 2
• Fully closed position 14–18 Check with throttle grip fully
closed position.
• Fully open position 82–92 Check with throttle grip fully
open position.
• Turn the throttle grip past 7–12
deceleration direction.
9-80
Diagnostic
code No.
16 Front wheel vehicle speed Front wheel speed pulse Check that the number in-
pulses 0–999 creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
17 Bank angle display Displays the bank angle in in- Check that 0–5° is displayed
crements of 5° when the vehicle is vertical
• 0–5° (vehicle is vertical) and that the displayed value
• Less than 30° (when the increases as the vehicle con-
sidestand is used) tinues to incline.
20 Sidestand switch Extend and retract the side-
stand (with the transmission
• Sidestand retracted ON
in gear).
• Sidestand extended OFF
21 Neutral switch and clutch Operate the transmission,
switch clutch lever, and sidestand.
• Transmission is in neutral ON
• Transmission is in gear or OFF
the clutch lever released
• 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
60 EEPROM DTC display —
• No history 00
• No malfunctions detected
(If the DTC P062F is indi-
cated, the ECU is defec-
tive.)
• History exists 01–03 (CO adjustment val-
ue)
• (If more than one cylinder is
defective, the display alter-
nates every two seconds to
show all the detected cylin-
der numbers.
When all cylinder numbers
are shown, the display re-
peats the same process.)
Except 00–03 (EEPROM
data error for corresponding
learning/memory values)
9-81
Diagnostic
code No.
67 ISC (Idle Speed Control) 00 To erase the ISC (Idle Speed
learning condition display ISC (Idle Speed Control) Control) learning data, push
ISC (Idle Speed Control) learning data has been the “Operation” button 3
learning data erasure erased. times in 5 seconds.
01
It is not necessary to erase
the ISC (Idle Speed Control)
learning data.
02
It is necessary to erase the
ISC (Idle Speed Control)
learning data.
70 Control number 0–254 [-] —
80 Cruise control setting switch Push and release the
“RES+” “RES+” side of the cruise
control setting switch.
• Switch is pushed ON
• Switch is released OFF
81 Cruise control setting switch Push and release the “SET-”
“SET-” side of the cruise control set-
ting switch.
• Switch is pushed ON
• Switch is released OFF
82 Cruise control cancel circuit Operate the clutch lever,
brake lever, brake pedal, and
• Clutch lever is squeezed ON
throttle grip.
• Clutch lever is released OFF
• Brake lever is squeezed ON
• Brake lever is released OFF
• Brake pedal is depressed ON
• Brake pedal is released OFF
• Throttle grip is turned past ON
deceleration direction
• Throttle grip is released OFF
83 Front brake light switch and Operate the brake lever and
rear brake light switch brake pedal.
• Brake lever is squeezed ON
• Brake lever is released OFF
• Brake pedal is depressed ON
• Brake pedal is released OFF
87 O2 feedback learning data 00 To erase the O2 feedback
erasure O2 feedback learning data learning data, push the “Op-
has been erased. eration” button 3 times in 5
01 seconds.
O2 feedback learning data
has not been erased.
9-82
Diagnostic
code No.
95 Shift sensor Check the sensor condition
by operating the shift pedal.
• Shift sensor output voltage 0.2–4.8 [V]
display
• With no shift weighting in- Approx. 2.5 [V]
put
• Shift up weighting Changes to the low side
• Shift down weighting Changes to the high side
EAS33032
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Cylinder-#1 ignition coil Actuates the cylinder-#1 igni- Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. • Connect an ignition check-
The “check” indicator on the er.
YDT screen come on each
time the ignition coil is actu-
ated.
ated.
ated.
36 Injector #1 Actuates the injector #1 five Disconnect the fuel pump
times at one-second inter- coupler before doing this
vals. procedure.
The “check” indicator on the Check that injector #1 is ac-
YDT screen come on each tuated five times by listening
time the fuel injector is actu- for the operating sound.
ated.
vals. procedure.
ated.
vals. procedure.
ated.
9-83
Diagnostic
Item Actuation Procedure
code No.
46 Purge cut valve solenoid Actuates the purge cut valve Check that the purge cut
solenoid five times at one- valve solenoid is actuated
second intervals. five times by listening for the
The “check” indicator on the operating sound.
time the intake solenoid is
actuated.
50 Main relay Actuates the relay unit five Check that the relay unit is
times at one-second inter- actuated five times by listen-
vals. ing for the operating sound.
The “check” indicator on the
time the relay is actuated.
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
seconds intervals. times by listening for the op-
The “check” indicator on the erating sound.
time the relay is actuated.
52 Headlight relay Actuates the headlight five Check that the headlight
times at five-seconds inter- comes on five times.
vals.
The “check” indicator on the
time the headlight is actuat-
ed.
57 Grip warmer Turns on the grip warmers Check that the grip warmers
for 2 minutes. become warm.
66 Bank angle fine adjustment Click the “Actuator Check” CLCU memorize the last ad-
button, the bank angle is justment value that the ad-
change as follows. justment start from this
0° → 2° → 4° → -2° → -4° → adjusting value.
0° Factory standard is 0°.
98 Cornering light comes on Comes on the cornering light The cornering light goes off
(left side only) for 10 minutes. click the “Actuator Check”
button or select other self-di-
agnostic function.
9-84
EVENT CODE TABLE
EAS20707
EVENT CODE TABLE

TIP
The event code numbers listed below cannot be displayed on the meter. To display the event code
numbers, use the YDT.
No. Item Symptom Possible causes Note

192 Intake air pres- Brief abnormality de- Same as for DTC num- Perform the inspection
sure sensor 1 tected in the intake air ber P0107 and P0108 items listed for DTC num-
pressure sensor ber P0107 and P0108.
193 Throttle position Brief abnormality de- Same as for DTC num- Perform the inspection
sensor tected in the throttle ber P0122, P0123, items listed for DTC num-
position sensor P0222 and P0223 ber P0122, P0123, P0222
and P0223.
195 Sidestand switch Brief abnormality de- Same as for DTC num- Perform the inspection
tected in the ECU ber P1601 items listed for DTC num-
(blue/yellow) input ber P1601.
line
196 Coolant tempera- Brief abnormality de- Same as for DTC num- Perform the inspection
ture sensor tected a in the coolant ber P0117 and P0118 items listed for DTC num-
temperature sensor ber P0117 and P0118.
197 Intake air tem- Brief abnormality de- Same as for DTC num- Perform the inspection
perature sensor tected in the intake air ber P0112 and P0113 items listed for DTC num-
temperature sensor ber P0112 and P0113.
199 Intake air pres- Brief abnormality de- Same as for DTC No. Perform the inspection
sure sensor 2 tected in the intake air P1606 and P1607 items listed for DTC No.
pressure sensor 2 P1606 and P1607.
207 Accelerator posi- Brief abnormality de- Same as for DTC num- Perform the inspection
tion sensor tected in the acceler- ber P2122, P2123, items listed for DTC num-
ator position sensor P2127 and P2128 ber P2122, P2123, P2127
and P2128.
220 Gear position Brief abnormality de- Same as for DTC num- Perform the inspection
sensor tected in the gear po- ber P0916 and P0917 items listed for DTC num-
sition sensor ber P0916 and P0917.
240 O2 sensor During O2 feedback, • Open or short circuit in • If a DTC is occurring, re-
(Stuck at the up- the adjustment is the wire harness be- spond to that first.
per limit for ad- maintained at the up- tween the sensor and * Rarely, Code 240 occurs
justment) per limit ECU even when the system is
• Drop in fuel pressure functioning properly.
• Clogged fuel injector
• Fault in sensor
• Malfunction in ECU
• Malfunction in the fuel
injection system
241 O2 sensor During O2 feedback, • Open or short circuit in • If a DTC is occurring, re-
(Stuck at the low- the adjustment is the wire harness be- spond to that first.
er limit for adjust- maintained at the low- tween the sensor and * Rarely, Code 241 occurs
ment) er limit ECU even when the system is
• Drop in fuel pressure functioning properly.
• Clogged fuel injector
• Fault in sensor
• Malfunction in the fuel
injection system
9-85
EVENT CODE TABLE
No. Item Symptom Possible causes Note

242 ISC During idling, the ad- Idling engine speed is • Implement diagnosis
(Stuck at the up- justment is main- slow mode D67, and check the
per limit for ad- tained at the upper • Clogged throttle body ISC maintenance request.
justment) limit • Poorly adjusted clutch • If a DTC is occurring, re-
cable spond to that first.
• Malfunction in the fuel * Rarely, Code 242 occurs
injection system even when the system is
• Dirty or worn spark functioning properly.
plug
• Malfunction in the bat-
tery
243 ISC During idling, the ad- Idling engine speed is • If a DTC is occurring, re-
(Stuck at the low- justment is main- fast spond to that first.
er limit for adjust- tained at the lower • Poorly adjusted clutch * Rarely, Code 243 occurs
ment) limit cable even when the system is
• Malfunction in the fuel functioning properly.
injection system
• Dirty or worn spark
plug
tery
244 Poor starting/in- Poor starting/inability • No gasoline • If a DTC is occurring, re-
ability to start to start detected • Malfunction in the fuel spond to that first.
injection system * Rarely, Code 244 occurs
• Dirty or worn spark even when the system is
plug functioning properly.
tery
245 Engine stop Engine stop detected • No gasoline • If a DTC is occurring, re-
• Poorly adjusted clutch spond to that first.
cable * Rarely, Code 245 occurs
• Malfunction in the fuel even when the system is
injection system functioning properly.
• Dirty or worn spark
plug
tery
246 Cruise control Automatic turning off The cruise control sys- The automatic turning off of
of the cruise control tem will automatically the cruise control system
system detected turn off under the follow- does not indicate a mal-
ing conditions: function in the system.
• Unable to maintain the
set cruising speed
when traveling up a
steep slope
• Wheel slip detected
• Engine stalls
• Sidestand is extended
• Engine stop switch is
set to the position
251 Shift sensor Brief abnormality de- Same as for DTC num- Perform the inspection
tected in the shift sen- ber P1806 and P1807 items listed for DTC num-
sor ber P1806 and P1807.
9-86
30_EVENT
EAS20552
30_EVENT
EAS33033
TROUBLESHOOTING
Item
Overturn detected.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle
Procedure
1. The vehicle has overturned.
• Raise the overturned vehicle vertically and check again.
• Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.
Is the MIL on?

YES
→ Go to step 2.
NO
→ Service is completed.
2. Installed condition of IMU.
• Check the installed direction and condition of the sensor.
Refer to “GENERAL CHASSIS (1)” on page 4-1.
• Check the grommet for cracks.
Is check result OK?

YES
→ Go to step 3.
NO
a. Fix the IMU installation condition.
b. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.
Is the MIL on?

YES
→ Go to step 3.
NO
3. Defective IMU.
• Execute the diagnostic mode. (Code 17)
• Check that 0°–5° is displayed when the vehicle is vertical and that the displayed value increases as
the vehicle continues to incline.
Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the IMU.
b. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.
Is the MIL on?

YES
9-87
30_EVENT
→ Go to step 4.
NO
4. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-43.
9-88
70_EVENT
EAS20554
70_EVENT
EAS33034
TROUBLESHOOTING
Item
Engine forcibly stops when the vehicle is left idling for a long period.
Procedure
TIP
If another error code is displayed at the same time, check the other error code first and repair it.
1. Allow to idle for a long period.
• Turn the main switch to “OFF”.
• Check whether it is possible to start the engine.
Can the engine starting?

YES
NO
→ Go to step 2.
9-89
B1000
EAS20555
B1000
EAS33035
TROUBLESHOOTING
Item
Internal malfunction in CLCU.
Fail-safe system
Procedure
1. Malfunction in CLCU.
• Replace the CLCU.
9-90
B1001
EAS20556
B1001
EAS33036
TROUBLESHOOTING
Item
Error is detected while reading or writing of data
Fail-safe system
Procedure
1. Writing error for leaning angle fine adjustment value
• Execute diagnostic code 66.
YES
NO
→ Go to step 2.
9-91
C0044
EAS20559
C0044
EAS33039
TROUBLESHOOTING
Item
Abnormal ABS
Fail-safe system
Procedure
1. Abnormal ABS
• Check the items of DTCs 62, 68 and 69 for the ABS.
Refer to “[B-2] DIAGNOSIS USING THE DTC” on page 9-37.
• Turn the main switch to “OFF” and back to “ON”, and then check the auxiliary system warning light.
Is the warning light comes on 2 seconds and goes off?

YES
NO
→ Refer to the item corresponding to the DTC.
9-92
C0520 (FI)
EAS20689
C0520 (FI)
EAS33319
TROUBLESHOOTING
Item
ECU: no normal signals or malfunction signals are received from the IMU.
Fail-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle
Procedure
1. Connection of IMU coupler.
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.
Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of ECU coupler.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the ECU coupler “1”, IMU coupler “2” and ignition fuse 1 holder “3”.
Between ignition fuse 1 holder “3” coupler and IMU
red/blue–red/blue
coupler “2”
9-93
C0520 (FI)
Between IMU coupler “2” and ECU coupler “1”
Between IMU coupler “2” and ground black/white–ground
3 2
B/W L/W L/B R/L
1
L/B Y/L O/W Lg/L P/W P V L L Gy
L/Y L/W Lg/B G/W G/W W/G W/Y
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
blue/black–ground
Between IMU coupler “2” and ground blue/white–ground
red/blue–ground

ECU coupler “1”
IMU coupler “2” blue/white–any other coupler terminal
red/blue–any other coupler terminal
9-94
C0520 (FI)
A B
2 1
B/W L/W L/B R/L
2
B/W L/W L/B R/L
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
5. Defective IMU.
• Replace the IMU.
• Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.
9-95
C0520 (FI)
YES
NO
→ Go to step 6.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.
9-96
C0520 (SCU)
EAS20664
C0520 (SCU)
EAS33290
TROUBLESHOOTING
Item
SCU: no normal signals or malfunction signals are received from the IMU.
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, and then check the auxiliary system warning light.
Is the warning light comes on for 2 seconds and goes off?

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Disconnect the SCU coupler “1”, IMU coupler “2” and ignition fuse 1 holder “3”.
red/blue–red/blue
coupler “2”
Between IMU coupler “2” and SCU coupler “1”
9-97
C0520 (SCU)
3 2 1
B/W L/W L/B R/L G/R B R/B R/L Gy/L
G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 4.
TIP
blue/black–ground
red/blue–ground

SCU coupler “1”
A B
1
2 2
G/R B R/B R/L Gy/L
B/W L/W L/B R/L G/L W/G W/R Gy/R B/W L/W L/B R/L
W/B L/W P/L
L/B P/R
9-98
C0520 (SCU)
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective IMU.
• Turn the main switch to “ON”, and then check the auxiliary system warning light.

YES
NO
→ Go to step 6.
• Replace the SCU, and complete the service.
9-99
C0520 (CLCU)
EAS20795
C0520 (CLCU)
EAS33555
TROUBLESHOOTING
Item
CLCU: no normal signals or malfunction signals are received from the IMU.
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO
YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
YES
NO
→ Go to step 3.
• Disconnect the CLCU coupler “1”, IMU coupler “2” and ignition fuse 1 holder “3”.
red/blue–red/blue
coupler “2”
Between IMU coupler “2” and CLCU coupler “1”
9-100
C0520 (CLCU)
2 1
B/W L/W L/B R/L B L/R
L/W L/B
Is resistance 0 Ω?
YES
NO
YES
NO
→ Go to step 4.
blue/black–ground
red/white–ground

A B
2 1 2
B/W L/W L/B R/L B L/R B/W L/W L/B R/L
L/W L/B
YES
→ Go to step 4.
NO
9-101
C0520 (CLCU)

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO
YES
NO
→ Go to step 5.
5. Defective IMU.
YES
NO
→ Go to step 6.
• Replace the auxiliary light assembly, and complete the service.
9-102
C100A
EAS20796
C100A
EAS33556
TROUBLESHOOTING
Item
Abnormal front fork compression damping adjustment
Fail-safe system
Procedure
1. Connection of front fork solenoid coupler (left side) and sub-wire harness (front fork solenoid (left))
coupler.
pins).

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness or sub-wire harness (front fork solenoid
(left)) coupler.
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the front fork solenoid coupler “1”, sub-wire harness (front fork solenoid (left)) coupler “2”
and SCU coupler “3”.
9-103
C100A
Between front fork solenoid coupler “1” and sub-wire gray/red–gray/red

harness (front fork solenoid (left)) coupler “2” gray/blue–gray/blue
Between sub-wire harness (front fork solenoid (left)) gray/red–gray/red
coupler “2” and SCU coupler “3” gray/blue–gray/blue
3 G/R B R/B R/L Gy/L

G/L W/G W/R Gy/R
1 2 W/B L/W P/L
Gy/R Gy/L Gy/L Gy/R Gy/R Gy/L
L/B P/R
Is resistance 0 Ω?
YES
NO
a. Replace the wire harness or sub-wire harness (front fork solenoid (left)).
of the YDT.

YES
NO
→ Go to step 4.
TIP
gray/red–ground
Between front fork solenoid coupler “1” and ground
gray/blue–ground
gray/red–ground
Between SCU coupler “3” and ground
gray/blue–ground

gray/red–any other coupler terminal
Front fork solenoid coupler “1”
gray/blue–any other coupler terminal
gray/red–any other coupler terminal
SCU coupler “3”
gray/blue–any other coupler terminal
9-104
C100A
A B
1 3 1 3
G/R B R/B R/L Gy/L G/R B R/B R/L Gy/L
Gy/R Gy/L G/L W/G W/R Gy/R Gy/R Gy/L G/L W/G W/R Gy/R
W/B L/W P/L W/B L/W P/L
L/B P/R L/B P/R
YES
→ Go to step 4.
NO
a. Replace the wire harness or sub-wire harness (front fork solenoid (left)).
of the YDT.

YES
NO
→ Go to step 4.
4. Connection of front fork solenoid inside coupler (left side).
pins).

YES
→ Go to step 5.
NO
a. Connect the coupler securely or replace the cap bolt or damper rod assembly.
of the YDT.

YES
NO
→ Go to step 5.
• Disconnect the front fork solenoid coupler “1” and front fork solenoid inside coupler “2”.
Between front fork solenoid coupler (front fork side) white–white
“1” and front fork solenoid inside coupler “2” black–black
9-105
C100A
1 2
B W W B
Is resistance 0 Ω?
YES
NO
a. Replace the cap bolt.
of the YDT.

YES
NO
→ Go to step 6.
Line short circuit check
white–any other coupler terminal
Front fork solenoid coupler (front fork side) “1”
B W
YES
→ Go to step 6.
NO
of the YDT.

YES
NO
→ Go to step 6.
9-106
C100A
6. Defective solenoid.
• Check the solenoid resistance.
Refer to “CHECKING THE SOLENOID (FRONT FORK/REAR SHOCK ABSORBER ASSEMBLY)
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the damper rod assembly.
of the YDT.

YES
NO
→ Go to step 7.
9-107
C100B
EAS20797
C100B
EAS33557
TROUBLESHOOTING
Item
Abnormal front fork rebound damping adjustment
Fail-safe system
Procedure
1. Connection of front fork solenoid coupler (right side) and sub-wire harness (front fork solenoid
(right)) coupler.
pins).

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness or sub-wire harness (front fork solenoid
(right)) coupler.
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the front fork solenoid coupler “1”, sub-wire harness (front fork solenoid (right)) coupler
“2” and SCU coupler “3”.
9-108
C100B
Between front fork solenoid coupler “1” and sub-wire green/red–green/red

harness (front fork solenoid (right)) coupler “2” green/blue–green/blue
Between sub-wire harness (front fork solenoid green/red–green/red
(right)) coupler “2” and SCU coupler “3” green/blue–green/blue

G/L W/G W/R Gy/R
1 2 W/B L/W P/L
G/R G/L G/R G/L G/L G/R
L/B P/R
Is resistance 0 Ω?
YES
NO
a. Replace the wire harness or sub-wire harness (front fork solenoid (right)).
of the YDT.

YES
NO
→ Go to step 4.
TIP
green/red–ground
Between front fork solenoid coupler “1” and ground
green/blue–ground
green/red–ground
green/blue–ground

green/red–any other coupler terminal
Front fork solenoid coupler “1”
green/blue–any other coupler terminal
green/red–any other coupler terminal
SCU coupler “3”
9-109
C100B
A B
1 3 1 3
G/R G/L G/L W/G W/R Gy/R G/R G/L G/L W/G W/R Gy/R
L/B P/R L/B P/R
YES
→ Go to step 4.
NO
a. Replace the wire harness or sub-wire harness (front fork solenoid (right)).
of the YDT.

YES
NO
→ Go to step 4.
4. Connection of front fork solenoid inside coupler (right side).
pins).

YES
→ Go to step 5.
NO
a. Connect the coupler securely or replace the cap bolt or damper rod assembly.
of the YDT.

YES
NO
→ Go to step 5.
• Disconnect the front fork solenoid coupler “1” and front fork solenoid inside coupler “2”.
Between front fork solenoid coupler (front fork side) white–white
“1” and front fork solenoid inside coupler “2” black–black
9-110
C100B
1 2
B W W B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 6.
Line short circuit check
Front fork solenoid coupler (front fork side) “1”
B W
YES
→ Go to step 6.
NO
of the YDT.

YES
NO
→ Go to step 6.
9-111
C100B
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the damper rod assembly.
of the YDT.

YES
NO
→ Go to step 7.
9-112
C100D
EAS20798
C100D
EAS33558
TROUBLESHOOTING
Item
Abnormal rear shock absorber compression damping adjustment
Fail-safe system
Procedure
1. Connection of rear shock absorber solenoid coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the rear shock absorber solenoid coupler “1” and SCU coupler “2”.
Between rear shock absorber solenoid coupler “1” pink/red–pink/red
and SCU coupler “2” pink/blue–pink/blue
9-113
C100D

G/L W/G W/R Gy/R
1 W/B L/W P/L
P/L P/R
L/B P/R
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Between rear shock absorber solenoid coupler “1” pink/red–ground
and ground pink/blue–ground

pink/red–any other coupler terminal
Rear shock absorber solenoid coupler “1”
pink/blue–any other coupler terminal
pink/red–any other coupler terminal
SCU coupler “2”
pink/blue–any other coupler terminal
A B
1 1 2
G/R B R/B R/L Gy/L
P/L P/R P/L P/R G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
YES
→ Go to step 4.
9-114
C100D
NO
of the YDT.

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the rear shock absorber assembly.
of the YDT.

YES
NO
→ Go to step 5.
9-115
C100F
EAS20799
C100F
EAS33559
TROUBLESHOOTING
Item
Abnormal angular position sensor
Fail-safe system
Procedure
1. Installed condition of angular position sensor.
• Check the installed condition of the sensor.
Refer to “ADJUSTING THE ANGULAR POSITION SENSOR POSITION” on page 4-123.
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or adjusting the angular position sensor.
of the YDT.

YES
NO
→ Go to step 2.
2. Connection of angular position sensor coupler.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
pins).
9-116
C100F
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the angular position sensor coupler “1” and SCU coupler “2”.
white/red–white/red
white/green–white/green
SCU coupler “2”
white/black–white/black
1 2 G/R B R/B R/L Gy/L

G/L W/G W/R Gy/R
W/B W/G W/R W/B L/W P/L
L/B P/R
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 5.
TIP
white/red–ground
ground
white/black–ground
9-117
C100F

Angular position sensor coupler “1” white/green–any other coupler terminal
SCU coupler “2” white/green–any other coupler terminal
A B
1 1 2
G/R B R/B R/L Gy/L
W/B W/G W/R W/B W/G W/R G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
5. Defective angular position sensor.
• Replace the angular position sensor.
Refer to “ADJUSTING THE ANGULAR POSITION SENSOR POSITION” on page 4-123.
of the YDT.

YES
NO
→ Go to step 6.
9-118
C1007
EAS20566
C1007
EAS33046
TROUBLESHOOTING
Item
Abnormality inside SCU
Fail-safe system
Procedure
• The warning light is comes on for 2 seconds and goes off.
9-119
P0030
EAS20397
P0030
EAS33134
TROUBLESHOOTING
Item
O2 sensor heater: defective heater controller detected.
Fail-safe system
Procedure
TIP
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0112, P0113, P0122, P0123, P0222, P0223, P2135
1. Connection of O2 sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Start the engine, and then check the condition of the DTC.

YES
NO
→ Go to step 2.
TIP
For this check, also set the stop/run/start switch to “ON”.
pins).

YES
→ Go to step 3.
NO
9-120
P0030

of the YDT.

YES
NO

YES
NO
→ Go to step 3.
TIP
• Disconnect the O2 sensor coupler “1”, ECU coupler “2” and ignition fuse 1 holder “3”.
Between O2 sensor coupler “1” and ECU coupler “2” pink/black–pink/black
Between O2 sensor coupler “1” and ignition fuse 1
red–red
holder “3”
3 1 2
Y/R P/B O/G Gy/R O
R P/B
Lg/R L/B G/B R/B B
Gy/G B/L
R/L G/Y B
R/G Y/R Y/B L/W R/L B/W B/W
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO

YES
9-121
P0030
NO
→ Go to step 4.
TIP
TIP
Between O2 sensor coupler “1” and ground red–ground
pink/black–ground

O2 sensor coupler “1” red–any other coupler terminal
pink/black–any other coupler terminal
ECU coupler “2” pink/black–any other coupler terminal
A B
1 1
R P/B R P/B 2
Gy/G B/L Gy/G B/L
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
R/L G/Y B
YES
→ Go to step 4.
NO
of the YDT.

YES
NO

YES
NO
→ Go to step 4.
TIP
9-122
P0030
4. Defective O2 sensor.
• Replace the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-9.
of the YDT.

YES
NO

YES
NO
→ Go to step 5.
TIP
9-123
P00D1, P2195
EAS20660
P00D1, P2195
EAS33115
TROUBLESHOOTING
Item
• [P00D1] O2 sensor: heater performance deterioration
• [P2195] O2 sensor: open circuit detected.
Fail-safe system
Procedure
TIP
• P0030
1. Installed condition of O2 sensor.
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the O2 sensor.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-124
P00D1, P2195

pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor coupler “1”, ECU coupler “2” and ignition fuse 1 holder “3”.
gray/green–gray/green
Between O2 sensor coupler “1” and ECU coupler “2” pink/black–pink/black
black/blue–black/blue
Between O2 sensor coupler “1” and ignition fuse 1
red–red
holder “3”
2
1 Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
R P/B
R/L G/Y B
Gy/G B/L
2
Is resistance 0 Ω?
YES
NO

YES
9-125
P00D1, P2195
NO
→ Go to step 5.
TIP
gray/green–ground
Between O2 sensor coupler “1” and ground pink/black–ground
black/blue–ground
red–ground

gray/green–any other coupler terminal
O2 sensor coupler “1” pink/black–any other coupler terminal
black/blue–any other coupler terminal
red–any other coupler terminal
ECU coupler “2” pink/black–any other coupler terminal
A B
1
R P/B
1 Gy/G B/L
R P/B
Gy/G B/L
2 2
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B L/B Y/L O/W Lg/L P/W P V L L Gy
R/L G/Y B L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
R/G Y/R Y/B L/W R/L B/W B/W L/Y L/W Lg/B G/W G/W W/G W/Y
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-126
P00D1, P2195
5. Check fuel pressure.

• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-11.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the fuel pump.
Refer to “INSTALLING THE FUEL PUMP” on page 7-5.

YES
NO
→ Go to step 6.
a. Replace the O2 sensor.

YES
NO
→ Go to step 7.
9-127
P0105
EAS20420
P0105
EAS32838
TROUBLESHOOTING
Item
Intake air pressure sensor: signal out of range
Fail-safe system
Procedure
TIP
• P0107, P0108
1. Connection of intake air pressure sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
2. Defective intake air pressure sensor.
• Replace the intake air pressure sensor.
Refer to “THROTTLE BODIES” on page 7-6.
of the YDT.

YES
NO
→ Go to step 3.
3. Defective wire harness.
• Replace the wire harness.
of the YDT.

YES
9-128
P0105
NO
→ Go to step 4.
9-129
P0106
EAS20421
P0106
EAS32840
TROUBLESHOOTING
Item
Intake air pressure sensor 1: clogging of hose or sensor disconnection
Fail-safe system
Procedure
TIP
• P0105, P0107, P0108, P0122, P0123, P0222, P0223, P0335, P1606, P1607, P1608, P1609, P2135
1. Installed condition of intake air pressure sensor 1 hose.
• Check for detached, clogged, kinked or pinching.
Is check result OK?

YES
→ Go to step 2.
NO
a. Repair or replace the intake air pressure sensor 1 hose.
b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then
check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
2. Defective intake air pressure sensor 1.
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
At sea level 101 kPa (757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea level Approx. 90 kPa (675.1 mmHg, 26.6 inHg)
• When engine is cranking: Make sure that the indication value changes.
Is check result OK?

YES
NO
a. Replace the intake air pressure sensor 1.
c. Confirm the “Recovered” condition, then go to step 3.
9-130
P0106
9-131
P0107, P0108
EAS20567
P0107, P0108
EAS33047
TROUBLESHOOTING
Item
• [P0107] Intake air pressure sensor 1: ground short circuit detected.
• [P0108] Intake air pressure sensor 1: open or power short circuit detected.
Fail-safe system
Procedure
1. Connection of intake air pressure sensor 1 coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the intake air pressure sensor 1 coupler “1” and ECU coupler “2”.
9-132
P0107, P0108
[P0108] blue–blue
Between ECU coupler “2” and intake air pressure
[P0107, P0108] pink/white–pink/white
sensor 1 coupler “1”
[P0108] black/blue–black/blue
2
1
L/B Y/L O/W P/W P V L L Gy
B/L P/W L L/W B/Y Br/L Gy/G Br/W B/L B/L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Between intake air pressure sensor 1 coupler “1” blue–ground
and ground pink/white–ground

[P0108] blue–any other coupler terminal
[P0108] black/blue–any other coupler terminal
ECU coupler “2”
[P0107, P0108] pink/white–any other coupler termi-
nal
Intake air pressure sensor 1 coupler “1”
[P0107, P0108] pink/white–any other coupler termi-
nal
9-133
P0107, P0108
A B
1 1 2
B/L P/W L B/L P/W L
L/W B/Y Br/L Gy/G Br/W B/L B/L
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of intake air pressure sensor 1.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the sensor.
of the YDT.

YES
NO
→ Go to step 5.
dicated.
Approx. 101 kPa (757.6 mmHg, 29.8 inHg), approx.
At sea level
3.64 V
1000 m (3300 ft) above sea level
3.30 V
9-134
P0107, P0108

3.00 V
2.70 V
Is check result OK?

YES
→ Go to step 6.
NO
of the YDT.

YES
NO
→ Go to step 6.
9-135
P0110
EAS20426
P0110
EAS32845
TROUBLESHOOTING
Item
Intake air temperature sensor: signal stuck
Fail-safe system
Procedure
TIP
• Perform this procedure when the engine is cold.
• If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0111, P0112, P0113, P0115, P0116, P0117, P0118, P0335, P0500, P2122, P2123, P2127, P2128,
P2138
1. Installed condition of intake air temperature sensor.
• Check the dirt around the intake air temperature sensor.
Is check result OK?

YES
→ Go to step 2.
NO
a. Clean around the intake air temperature sensor, then reinstall it.
b. Turn the main switch to “ON”, then heat the intake air temperature sensor using warm water or hot
air.

YES
NO
→ Go to step 2.
2. Defective intake air temperature sensor.
• Measure and note the intake air temperature sensor resistance at ambient temperature.
• Heat the intake air temperature sensor using warm water or hot air, and measure the intake air tem-
perature sensor resistance, then compare the noted resistance at ambient temperature.
Is the resistance change?

YES
→ Go to step 3.
NO
a. Replace the intake air temperature sensor.
b. Turn the main switch to “ON”, then heat the intake air temperature sensor using warm water or hot
air.

YES
9-136
P0110
NO
→ Go to step 3.
9-137
P0111
EAS20425
P0111
EAS32844
TROUBLESHOOTING
Item
Intake air temperature sensor: signal out of range
Fail-safe system
Procedure
TIP
• P0112, P0113
1. Connection of intake air temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO
b. Execute the diagnostic mode. (Code 05)
• When engine is cold: Displayed temperature is close to the ambient temperature.
Is check result OK?

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
Is check result OK?

YES
NO
→ Go to step 3.
9-138
P0111

Is check result OK?

YES
→ Go to step 4.
NO
a. Reinstall the sensor.
Is check result OK?

YES
NO
→ Go to step 4.
• Check the intake air temperature sensor.
Refer to “CHECKING THE INTAKE AIR TEMPERATURE SENSOR” on page 8-50.
5.4–6.6 kΩ at 0 °C (5.4–6.6 kΩ at 32 °F)
Intake air temperature sensor resistance
0.29–0.39 kΩ at 80 °C (0.29–0.39 kΩ at 176 °F)
Is check result OK?

YES
→ Go to step 5.
NO
c. Submerge the intake air temperature sensor in a container filled with water at 0 °C (32 °F).
• The displayed temperature is close to the 0 °C (32 °F)
Is check result OK?

YES
NO
→ Go to step 5.
• Submerge the intake air temperature sensor in a container of 0 °C (32 °F) water.
• The displayed temperature is close to the 0 °C (32 °F)
Is check result OK?

YES
NO
→ Go to step 6.
9-139
P0111
9-140
P0112, P0113
EAS20568
P0112, P0113
EAS33048
TROUBLESHOOTING
Item
• [P0112] Intake air temperature sensor: ground short circuit detected.
• [P0113] Intake air temperature sensor: open or power short circuit detected.
Fail-safe system
Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of intake air temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the intake air temperature sensor coupler “1” and ECU coupler “2”.
9-141
P0112, P0113

Between ECU coupler “2” and intake air tempera- [P0112, P0113] brown/white–brown/white
ture sensor coupler “1” [P0113] black/blue–black/blue

1 L/W B/Y Br/L Gy/G Br/W B/L B/L
Br/W B/L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Between intake air temperature sensor coupler “1”
[P0112, P0113] brown/white–ground
and ground

[P0112, P0113] brown/white–any other coupler ter-
intake air temperature sensor coupler “1” minal
[P0113] black–any other coupler terminal
[P0112, P0113] brown/white–any other coupler ter-
ECU coupler “2” minal
9-142
P0112, P0113
A B
1 1 2
Br/W B/L Br/W B/L
YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
• The displayed temperature is not close to the ambient temperature → Check the intake air tempera-
ture sensor.
Is check result OK?
9-143
P0112, P0113
YES
→ Go to step 6.
NO
of the YDT.

YES
NO
→ Go to step 6.
9-144
P0115
EAS20424
P0115
EAS32843
TROUBLESHOOTING
Item
Coolant temperature sensor: signal stuck
Fail-safe system
Procedure
TIP
• P0116, P0117, P0118, P0335, P0500, P2122, P2123, P2127, P2128, P2138
1. Defective coolant temperature sensor.
• Measure and note the coolant temperature sensor resistance at ambient temperature.
• Start the engine and warm-up the vehicle.
• Measure the coolant temperature sensor resistance at engine warmed-up, then compare the noted
resistance at ambient temperature.

YES
→ Go to step 2.
NO
a. Allow the engine to cool to ambient temperature, then replace the coolant temperature sensor.
b. Turn the main switch to “ON”, then start the engine and warm-up the vehicle.

YES
NO
→ Go to step 2.
9-145
P0116
EAS20423
P0116
EAS32842
TROUBLESHOOTING
Item
Coolant temperature sensor: signal out of range
Fail-safe system
Procedure
TIP
• P0117, P0118
1. Connection of coolant temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO
Is check result OK?

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
Is check result OK?

YES
NO
→ Go to step 3.
9-146
P0116
3. Installed condition of coolant temperature sensor.

Is check result OK?

YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
→ Go to step 4.
• Check the coolant temperature sensor resistance.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR” on page 8-49.
2.513–2.777 kΩ at 20 °C (2.513–2.777 kΩ at 68 °F)
Coolant temperature sensor resistance 0.210–0.221 kΩ at 100 °C (0.210–0.221 kΩ at 212
°F)
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the coolant temperature sensor.
c. Submerge the coolant temperature sensor in a container filled with water at 20 °C (68 °F) and 100
°C (212 °F).
• Displayed temperature is close to the 20 °C (68 °F) and 100 °C (212 °F).
Is check result OK?

YES
NO
→ Go to step 5.
• Submerge the coolant temperature sensor in a container filled with water at 20 °C (68 °F) and 100
°C (212 °F).
• Displayed temperature is close to the 20 °C (68 °F) and 100 °C (212 °F).
Is check result OK?

YES
9-147
P0116
NO
→ Go to step 6.
9-148
P0117, P0118
EAS20569
P0117, P0118
EAS33049
TROUBLESHOOTING
Item
• [P0117] Coolant temperature sensor: ground short circuit detected.
• [P0118] Coolant temperature sensor: open or power short circuit detected.
Fail-safe system
Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of coolant temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the coolant temperature sensor coupler “1” and ECU coupler “2”.
9-149
P0117, P0118

Between coolant temperature sensor coupler “1” [P0117, P0118] green/white–green/white
and ECU coupler “2” [P0118] black/blue–black/blue

G/W B/L
Is resistance 0 Ω?
YES
→ Go to step “Short circuit check”.
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Between coolant temperature sensor coupler “1”
[P0117, P0118] green/white–ground
and ground

[P0117, P0118] green/white–any other coupler ter-
Coolant temperature sensor coupler “1” minal
[P0118] black–any other coupler terminal
[P0117, P0118] green/white–any other coupler ter-
ECU coupler “2” minal
9-150
P0117, P0118
A B
1 1 2
G/W B/L G/W B/L
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of coolant temperature sensor.
Is check result OK?

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
• The displayed temperature is not close to the ambient temperature → Check the coolant tempera-
ture sensor.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR” on page 8-49.
Is check result OK?
9-151
P0117, P0118
YES
→ Go to step 6.
NO
a. Replace the coolant temperature sensor.
of the YDT.

YES
NO
→ Go to step 6.
9-152
P0122, P0123, P0222, P0223, P2135
EAS20570
P0122, P0123, P0222, P0223, P2135

EAS33050
TROUBLESHOOTING
Item
• [P0122] Throttle position sensor: ground short circuit detected.
• [P0123] Throttle position sensor: open or power short circuit detected.
• [P0222] Throttle position sensor: open or ground short circuit detected.
• [P0223] Throttle position sensor: power short circuit detected.
• [P2135] Throttle position sensor: output voltage deviation error.
Fail-safe system
Procedure
TIP
If a DTC other than P2135 is detected, perform troubleshooting first (P0122, P0123, P0222, P0223).
1. Connection of throttle position sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
9-153
P0122, P0123, P0222, P0223, P2135
→ Go to step 3.
• Disconnect the throttle position sensor coupler “1” and ECU coupler “2”.
[P0122, P0123, P0222, P0223, P2135] white–white
Between throttle position sensor coupler “1” and [P0123, P0223] black/blue–black/blue
ECU coupler “2” [P0122, P0222] blue–blue
[P0122, P0123, P0222, P0223, P2135] black–black
1 2
W/R G L Br/Y R/W
Y W Y/R
W B/L L B
B/L Br
W/B B Y/B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
[P0122, P0123, P0222, P0223, P2135] white–
ground
Between throttle position sensor coupler “1” and
[P0122, P0222] blue–ground
ground
[P0122, P0123, P0222, P0223, P2135] black–
ground
9-154
P0122, P0123, P0222, P0223, P2135

[P0122, P0123, P0222, P0223, P2135] white–any
other coupler terminal
[P0123, P0223] black/blue–any other coupler termi-
Throttle position sensor coupler “1” nal
[P0122, P0222] blue–any other coupler terminal
[P0122, P0123, P0222, P0223, P2135] black–any
[P0122, P0123, P0222, P0223, P2135] white–any
[P0123, P0223] black/blue–any other coupler termi-
ECU coupler “2” nal
[P0122, P0222] blue–any other coupler terminal
[P0122, P0123, P0222, P0223, P2135] black–any
A B
1 1 2
W/R G L Br/Y R/W
Y W Y/R
W B/L L B W B/L L B
B/L Br
W/B B Y/B
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of throttle position sensor.
Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 7-12.
Is check result OK?

YES
9-155
P0122, P0123, P0222, P0223, P2135
→ Go to step 5.
NO
a. Reinstall or adjust the sensor.
of the YDT.

YES
NO
→ Go to step 5.
5. Defective throttle position sensor.
• Check throttle position sensor signal 1.
When the throttle valves are fully closed 11–21
When throttle valves are fully open 96–107
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the throttle position sensor.
of the YDT.

YES
NO
→ Go to step 6.
6. Defective throttle position sensor.
• Check throttle position sensor signal 2.
When throttle valves are fully open 93–109
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the throttle position sensor.
of the YDT.

YES
NO
→ Go to step 7.
9-156
P0122, P0123, P0222, P0223, P2135
9-157
P0132
EAS20571
P0132
EAS33051
TROUBLESHOOTING
Item
O2 sensor: short circuit detected (power short circuit).
Fail-safe system
Procedure
Is check result OK?

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
pins).
9-158
P0132
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor coupler “1” and ECU coupler “2”.
Between O2 sensor coupler “1” and ECU coupler “2” gray/green–gray/green

R P/B L/Y L/W Lg/B G/W G/W W/G W/Y
Gy/G B/L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 5.
TIP
Between O2 sensor coupler “1” and ground gray/green–ground
9-159
P0132

O2 sensor coupler “1” gray/green–any other coupler terminal
ECU coupler “2”
A B
1 1 2
R P/B R P/B
Gy/G B/L Gy/G B/L L/B Y/L O/W Lg/L P/W P V L L Gy
YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
of the YDT.

YES
NO
→ Go to step 6.
9-160
P0133
EAS20767
P0133
• O2 sensor: deterioration detected
EAS33291
OUTLINE
Explanation of detection method
The O2 sensor detects the oxygen concentration in the exhaust gas, converts it into an electrical signal,
and sends it to the ECU. The ECU determines whether there is any deterioration by comparing the out-
put value from the O2 sensor with a predetermined threshold value such as response time. When the
ECU determines that there is an O2 sensor deterioration, the DTC is stored in ECU and MIL comes on.
Frequency of detection Once per driving cycle
Malfunction determination If an abnormality is detected in three consecutive driving cycles, the mal-
method function is confirmed and the MIL comes on.
Driving condition Flat road, no overloading, and no acceleration or deceleration
Type of detection result Complete, Incomplete
Requirement for detection

Duration 400 seconds or more
O2 feedback Carried out
Vehicle speed 40–60 km/h (25–37 mph)
Gear position No condition specified
Engine speed No condition specified
Fuel correction value The O2 feedback correction amount is within a certain range.
Related sensor for detection

O2 sensor, intake air pressure sensor, coolant temperature sensor (or engine temperature sensor),
front wheel sensor, rear wheel sensor, crankshaft position sensor, and throttle position sensor
Storing DTC
Once an abnormality has been detected, a pending DTC is stored in the memory of the ECU. Then, if
the abnormality is detected in the next two driving cycles, the MIL comes on and the DTC and FFD are
stored. If the vehicle is judged to be operating normally for three consecutive driving cycles, the MIL
goes off. However, the DTC, pending DTC, and FFD will not be deleted even if a battery terminal is
disconnected.
Reproduction test
Perform the test using the driving pattern according to the detection method.
EWA20860
WARNING
EAS33153
FAIL-SAFE SYSTEM
9-161
P0133
EAS32813
TROUBLESHOOTING
TIP
• DTC except P0133
1. Connect the YDT to check and delete the DTC stored in the ECU.
2. Perform the reproduction test under the following conditions, then go to step 3.
Reproduction test conditions
60
40
D
B
E F
C
G
A. Speed [km/h] E. 5 min.
B. Time [min] F. Total: 15 min.
C. Start the engine G. Stop the engine
D. Idle (warm up)
3. Connect the YDT and check if the pending DTC is displayed.
Is pending DTC displayed?

Yes
→ Delete the pending DTC, then go to step 4.
No
→ Check the readiness status.
Readiness status is “Complete”.
→ Check the coupler between the ECU and O2 sensor for any abnormality. If there is no abnormality,
temporary connection failure is considered to be the cause, so finish the troubleshooting.
Readiness status is “Incomplete”
→ Reproduction test is required again because the reproduction is not completed.
Go to step 2.
4. Replace the O2 sensor, then go to step 5.
5. Perform reproduction test and connect the YDT.
Check that the pending DTC is not detected and readiness status is “Complete”. Then complete the
troubleshooting.
9-162
P0134
EAS20414
P0134
EAS32834
TROUBLESHOOTING
Item
O2 sensor: signal stuck
Fail-safe system
Procedure
TIP
1. P0030
2. P00D1, P2195
3. P0105, P0106, P0107, P0108, P0110, P0111, P0112, P0113, P0115, P0116, P0117, P0118,
P0122, P0123, P0132, P0134, P0201, P0202, P0203, P0222, P0223, P0335, P0351, P0352,
P0353, P0480, P0500, P0560, P0563, P0606, P062F, P0638, P0657, P0606, P1004, P1500,
P1600, P2122, P2123, P2127, P2128, P2135, P2138
4. P0300, P0301, P0302, P0303
1. Engine condition.
• Check the idling condition and check the engine sound while racing the engine.
Is check result OK?

YES
→ Go to step 2.
NO
a. Check the ignition spark gap.
Refer to “CHECKING THE IGNITION SPARK GAP” on page 8-46.
b. Test ride the vehicle according to the test-ride conditions for the O2 deterioration diagnosis.
Refer to step 2 in “TROUBLESHOOTING” on page 9-162.
At this time, do not check the malfunction diagnosis status (readiness).

YES
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO
a. Reinstall the O2 sensor.
9-163
P0134

YES
NO
→ Go to step 3.
3. Check fuel pressure.
• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-11.
Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the fuel pump.
Refer to “INSTALLING THE FUEL PUMP” on page 7-5.

YES
NO
→ Go to step 4.

YES
NO
→ Go to step 5.
9-164
P0201
EAS20574
P0201
EAS33054
TROUBLESHOOTING
Item
Injector #1: malfunction in injector #1.
Fail-safe system
• Able to start engine (depending on the number of faulty cylinders)
• Able to drive vehicle (depending on the number of faulty cylinders)
Procedure
1. Connection of injector #1 coupler.
pins).

YES
→ Go to step 2.
NO
Is it hear operating sound?

YES
→ Go to step 6.
NO
→ Go to step 2.
2. Defective injector #1.
• Measure the injector resistance.
Refer to “CHECKING THE FUEL INJECTORS” on page 8-51.
Is check result OK?

YES
→ Go to step 3.
NO
a. Replace the injector #1.

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-165
P0201
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
• Disconnect the injector #1 coupler “1”, ECU coupler “2” and relay unit coupler “3”.
Between injector #1 coupler “1” and ECU coupler
red/black–red/black
“2”
Between injector #1 coupler “1” and relay unit cou-
red/blue–red
pler “3”
1
R/B R/L
2 3
Y/R P/B O/G Gy/R O
Br W R L/W R
Lg/R L/B G/B R/B B
R/L G/Y B
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
TIP
red/black–ground
Between injector #1 coupler “1” and ground
red/blue–ground
9-166
P0201

red/black–any other coupler terminal
Injector #1 coupler “1”
ECU coupler “2” red/black–any other coupler terminal
Relay unit coupler “3” red–any other coupler terminal
A B
1 1 2
Y/R P/B O/G Gy/R O
R/B R/L R/B R/L
Lg/R L/B G/B R/B B
R/L G/Y B
3
Br W R L/W R
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
• Start the engine and let it idle for approximately 5 seconds.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.
9-167
P0202
EAS20575
P0202
EAS33055
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-168
P0202
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
• Disconnect the injector #2 coupler “1”, ECU coupler “2” and relay unit coupler “3”.
green/black–green/black
“2”
red/blue–red
pler “3”
1
G/B R/L
2 3
Y/R P/B O/G Gy/R O
Br W R L/W R
Lg/R L/B G/B R/B B
R/L G/Y B
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
TIP
green/black–ground
red/blue–ground
9-169
P0202

green/black–any other coupler terminal
ECU coupler “2” green/black–any other coupler terminal
A B
1 1 2
Y/R P/B O/G Gy/R O
G/B R/L G/B R/L
Lg/R L/B G/B R/B B
R/L G/Y B
3
Br W R L/W R
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-170
P0203
EAS20576
P0203
EAS33056
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-171
P0203
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
• Disconnect the injector #3 coupler “1”, ECU coupler “2” and relay unit coupler “3”
“2”
red/blue–red
pler “3”
1
L/B R/L
2 3
Y/R P/B O/G Gy/R O
Br W R L/W R
Lg/R L/B G/B R/B B
R/L G/Y B
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
TIP
blue/black–ground
red/blue–ground
9-172
P0203

ECU coupler “2” blue/black–any other coupler terminal
A B
1 1 2
Y/R P/B O/G Gy/R O
L/B R/L L/B R/L
Lg/R L/B G/B R/B B
R/L G/Y B
3
Br W R L/W R
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-173
P0300, P0301, P0302, P0303
EAS20773
P0300, P0301, P0302, P0303

• [P0300] Misfire in multiple cylinders
• [P0301] Misfire in cylinder #1
EAS33318
OUTLINE
Explanation of detection method

The ECU monitors the consistency of the crankshaft rotation by crankshaft position sensor, and if the
angular velocity fluctuates irregularly, the ECU determines that there is a misfire. Two kinds of misfire
judgment are performed according to the number of misfire occurrences and the threshold value.
* Catalyst damage
• The number of misfires per 200 revolutions of the crankshaft exceeds the threshold value, and it is
detected that the exhaust gas damages the catalyst, the DTC is stored in the ECU and the MIL starts
flashing.
* Exhaust gas deterioration
• The number of misfires per 1000 revolutions of the crankshaft exceeds the threshold value, and it is
detected that the exhaust gas does not damage the catalyst but affect the exhaust gas emission level,
the DTC is stored in the ECU and the MIL comes on.
Frequency of detection Always
Time required for detection Always
• Catalyst damage
When an abnormality is detected three times in one driving cycle, it is de-
termined to be a pending abnormality and the MIL starts flashing. If this
cycle occurs in three consecutive driving cycles, the malfunction is deter-
Malfunction determination mined and the MIL comes on.
method • Exhaust gas deterioration
If an abnormality is detected four times within one driving cycle, it is deter-
mined to be a pending abnormality. The MIL does not flash at this time. If
this cycle occurs in three consecutive driving cycles, the malfunction is de-
termined and the MIL comes on.
Driving condition No excessive acceleration or deceleration
Type of detection result Complete, Incomplete
Requirement for detection

Duration Refer to the conversion table of steady driving time.
Engine starting time No condition specified
O2 feedback No condition specified
Vehicle speed No condition specified
Gear position No condition specified
Engine speed 2300–6500 r/min
Related sensors for detection

Intake air pressure sensor, coolant temperature sensor (or engine temperature sensor), front wheel
sensor, rear wheel sensor, crankshaft position sensor, and throttle position sensor
9-174
P0300, P0301, P0302, P0303
Storing DTC
Once an abnormality has been detected, a pending DTC is stored in the memory of the ECU. Then, if
the abnormality is detected in the next two driving cycles, the MIL comes on and the DTC and FFD are
stored. If the vehicle is judged to be operating normally for three consecutive driving cycles, the MIL
goes off. However, the DTC, pending DTC, and FFD will not be deleted even if a battery terminal is
disconnected.
Reproduction test
Operate the vehicle according to the engine speed, vehicle speed, and gear position in the FFD. Con-
firm the operating time in the conversion table of steady driving time according to the engine speed in
the FFD. Do not accelerate or decelerate excessively during the reproduction test. Continue to operate
the vehicle even if the vehicle cannot be operated at a constant speed due to the operating environ-
ment.
EWA20860
WARNING
EAS33154
FAIL-SAFE SYSTEM
EAS32820
TROUBLESHOOTING
TIP
• If more than one DTC is detected at the same time, perform troubleshooting of DTCs listed below first
DTC except P0300, P0301, P0302, P0303
• If more than one misfire DTC has been detected at the same time, open each FFD and check the total
ECU energization time at the time of failure or event, and refer to the latest FFD.
• How to identify the most recent FFD.
Total energization time of 00:25:30 is newer than 00:10:55 of FFD.
1. Connect the YDT and check the DTC stored in the ECU.
DTC is displayed
→ Check the engine speed, vehicle speed and gear position of FFD.
Delete DTC, then go to step 2.
Pending DTC is displayed
→ Confirm the engine speed, vehicle speed and gear position to the customer when the customer
feels an abnormality.
Delete pending DTC, then go to step 2.
DTC and pending DTC are not displayed.
feels an abnormality
Go to step 2.
2. Perform the reproduction test under the following conditions, then go to step 3.
ECA26950
NOTICE
If the MIL flashes during the reproduction test, immediately decelerate or reduce the engine
speed. Otherwise, the catalyst could be damaged.
9-175
P0300, P0301, P0302, P0303
Reproduction test condition
B
D F
E
A. Speed [km/h] E. Steady driving time

B. Time [min] F. Stop the engine
C. Vehicle speed of FFD
D. Start the engine
Conversion table of steady driving time

Engine speed (r/min) Time (sec.)
2000 240
3000 160
4000 120
5000 96
6000 80
7000 70
8000 60
9000 54
10000 48
3. Connect the YDT and check if the pending DTC is displayed.
Is the pending DTC displayed?

Yes
→ Delete the pending DTC, then go to step 4.
No
feels an abnormality.
Go to step 2.
If the pending DTC is not displayed after several reproduction test, go to step 4.
4. Check the ignition system
9-176
P0300, P0301, P0302, P0303
Is the inspection result OK?

Yes
→ Go to step 5.
No
→Repair or replace the defective part, then go to step 6.
5. Check the following parts. If defective, replace the parts and go to step 6.
• Intake air pressure sensor
• Coolant temperature sensor (or Engine temperature sensor)
• Speed sensor
• Crankshaft position sensor
• Throttle position sensor
• Gear position sensor
6. Perform a reproduction test and connect the YDT.
Check that the pending DTC is not detected, then complete the troubleshooting.
9-177
P0335
EAS20578
P0335
EAS33058
TROUBLESHOOTING
Item
Crankshaft position sensor: no normal signals are received from the crankshaft position sensor.
Fail-safe system
Procedure
1. Connection of crankshaft position sensor coupler.
pins).

YES
→ Go to step 2.
NO
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
2. Connection of wire harness ECU coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Disconnect the crankshaft position sensor coupler “1” and ECU coupler “2”.
Between crankshaft position sensor coupler “1” and gray–gray
ECU coupler “2” black/blue–black/blue
9-178
P0335
2
1
Gy B/L L/B Y/L O/W Lg/L P/W P V L L Gy
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 4.
TIP
Between crankshaft position sensor coupler “1” and
gray–ground
ground

Crankshaft position sensor coupler “1”
gray–any other coupler terminal
ECU coupler “2”
gray–any other coupler terminal
A B
1 1 2
Gy B/L
Gy B/L
9-179
P0335
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of crankshaft position sensor.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective crankshaft position sensor.
• Check the crankshaft position sensor.
Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page 8-47.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the crankshaft position sensor.

YES
NO
→ Go to step 6.
9-180
P0351
EAS20580
P0351
EAS33060
TROUBLESHOOTING
Item
Cylinder-#1 ignition coil: open or short circuit detected in the primary lead of the cylinder-#1 ignition coil.
Fail-safe system
Procedure
1. Connection of cylinder-#1 ignition coil coupler.
pins).

YES
→ Go to step 2.
NO
b. Start the engine and let it idle for approximately 5 seconds.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Disconnect the cylinder-#1 ignition coil coupler “1” and ECU coupler “2”.
Between cylinder-#1 ignition coil coupler “1” and
orange–orange
ECU coupler “2”
9-181
P0351
2 1
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
O R/W
R/L G/Y B
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 4.
TIP
orange–ground
ground

Cylinder-#1 ignition coil coupler “1” orange–any other coupler terminal
ECU coupler “2” orange–any other coupler terminal
A B
1 1 2
Y/R P/B O/G Gy/R O
O R/W O R/W
Lg/R L/B G/B R/B B
R/L G/Y B
9-182
P0351
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of cylinder-#1 ignition coil.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the ignition coil.

YES
NO
→ Go to step 5.
5. Defective cylinder-#1 ignition coil.
• Measure the primary coil resistance of the cylinder-#1 ignition coil.
Refer to “CHECKING THE IGNITION COILS” on page 8-46.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the cylinder-#1 ignition coil.

YES
NO
→ Go to step 6.
• Confirm that spark plug does not sparking.
9-183
P0351
9-184
P0352
EAS20581
P0352
EAS33061
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
gray/red–gray/red
ECU coupler “2”
9-185
P0352
2 1
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
Gy/R R/W
R/L G/Y B
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 4.
TIP
gray/red–ground
ground

Cylinder-#2 ignition coil coupler “1” gray/red–any other coupler terminal
ECU coupler “2” gray/red–any other coupler terminal
A B
1 1 2
Y/R P/B O/G Gy/R O
Gy/R R/W Gy/R R/W
Lg/R L/B G/B R/B B
R/L G/Y B
9-186
P0352
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
9-187
P0352
9-188
P0353
EAS20582
P0353
EAS33062
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3
NO

YES
NO
→ Go to step 3.
orange/green–orange/green
ECU coupler “2”
9-189
P0353
2 1
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
O/G R/W
R/L G/Y B
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 4.
TIP
orange/green–ground
ground

Cylinder-#3 ignition coil coupler “1” orange/green–any other coupler terminal
ECU coupler “2” orange/green–any other coupler terminal
A B
1 1 2
O/G R/W O/G R/W Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
R/L G/Y B
9-190
P0353
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
9-191
P0353
9-192
P0458
EAS20785
P0458
EAS33528
TROUBLESHOOTING
Item
Purge cut valve solenoid: open circuit detected.
Fail-safe system
Procedure
1. Connection of purge cut valve solenoid coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the ignition fuse 2 holder “1”, purge cut valve solenoid coupler “2”, ECM coupler “3” and
main switch coupler “4”.
9-193
P0458
Between ignition fuse 2 holder “1” and purge cut

red/white–red/white
valve solenoid coupler “2”
Between purge cut valve solenoid coupler “2” and
yellow/red–yellow/red
ECU coupler “3”
Between main switch coupler “4” and ignition fuse 2
brown/red–brown/red
holder “1”
4 1 2 3
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
R/L G/Y B
Br/R R/W Y/R R/G Y/R Y/B L/W R/L B/W B/W
R
Br/L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Between purge cut valve solenoid coupler “2” and red/white–ground
ground yellow/red–ground
Between main switch coupler “4” and ground brown/red–ground

red/white–any other coupler terminal
Purge cut valve solenoid coupler “2”
yellow/red–any other coupler terminal
ECU coupler “3” yellow/red–any other coupler terminal
Main switch coupler “4” brown/red–any other coupler terminal
9-194
P0458
A B
2 4 2 4 Br/R
R
R/W Y/R Br/L Br/R R/W Y/R R
Br/L
3
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
R/L G/Y B
YES
→Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of purge cut valve solenoid.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the purge cut valve solenoid.
of the YDT.

YES
NO
→ Go to step 5.
5. Defective purge cut valve solenoid.
9-195
P0458

YES
NO
→ Check the purge cut valve solenoid.
Refer to “CHECKING THE PURGE CUT VALVE SOLENOID” on page 8-51.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the purge cut valve solenoid.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction
mode of the YDT.

YES
NO
→ Go to step 6.
9-196
P0480
EAS20585
P0480
EAS33065
TROUBLESHOOTING
Item
Radiator fan motor relay: open or short circuit detected.
Fail-safe system
Procedure
1. Connection of radiator fan motor relay coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the radiator fan motor relay “1”, ECU coupler “2” and ignition fuse 1 holder “3”.
Between radiator fan motor relay “1” and ignition
red–red
fuse 1 holder “3”
9-197
P0480
Between radiator fan motor relay “1” and ECU cou-

green/yellow–green/yellow
pler “2”
1
3 L/W
L/W
R G/Y
2
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
R/L G/Y B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
green/yellow–ground
Between radiator fan motor relay “1” and ground
red–ground

green/yellow–any other coupler terminal
Radiator fan motor relay “1”
ECU coupler “2” green/yellow–any other coupler terminal
A B
1 L/W
1
R
L/W
G/Y
L/W 2
L/W
R G/Y Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
R/L G/Y B
YES
9-198
P0480
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective radiator fan motor relay.
• Replace the radiator fan motor relay.
of the YDT.

YES
NO
→ Go to step 5.
9-199
P0500 (FI), P1500
EAS20674
P0500 (FI), P1500

EAS33303
TROUBLESHOOTING
Item
• Rear wheel sensor: no normal signals are received from the rear wheel sensor.
• Neutral switch: open or short circuit is detected.
• Clutch switch: open or short circuit is detected.
Fail-safe system
Procedure
TIP
• In case P0500 is detected, or both P0500 and P1500 are detected, proceed from step 1.
• P0335
• DTCs P0500 or P0500 and P1500 detected.
a. Execute the diagnostic mode. (Code 07)
b. Rotate the rear wheel by hand and check that the indicated value increases.

YES
→ Go to step 21.
NO
→ Go to step 2.
TIP
Perform the procedure from step 2 to step 7 and step 21.
• DTC P1500 detected.
When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF
Is check result OK?

YES
→ Go to step “b. Execute the diagnostic mode. (Code 21)”.
NO
→ Go to step 8.
TIP
Perform the procedure from step 8 to step 14 and step 21.
When the transmission is in gear with the clutch lever squeezed and the side-
ON
stand retracted
9-200
P0500 (FI), P1500
Is check result OK?

YES
→ Go to step 21.
NO
→ Go to step 15.
TIP
Perform the procedure from step 15 to step 21.
2. Connection of rear wheel sensor coupler.
pins).

YES
→ Go to step 3.
NO
c. Rotate the rear wheel by hand and check that the indicated value increases.

YES
→ Go to step 21.
NO
→ Go to step 3.
3. Connection of ABS ECU coupler.
pins).

YES
→ Go to step 4.
NO

YES
→ Go to step 21.
NO
→ Go to step 4.
pins).

YES
→ Go to step 5.
9-201
P0500 (FI), P1500
NO

YES
→ Go to step 21.
NO
→ Go to step 5.
• Disconnect the rear wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
Between rear wheel sensor coupler “1” and ABS black–black
ECU coupler “2” white–white
Between ABS ECU coupler “2” and ECU coupler “3” white/yellow–white/yellow
2
1
B W
L/W W/G G Y L R/B Br L/W B/W 3
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 21.
NO
→ Go to step 6.
TIP
9-202
P0500 (FI), P1500

black–ground
Between ABS ECU coupler “2” and ground white–ground
white/yellow–ground

Rear wheel sensor coupler “1”
ABS ECU coupler “2” white–any other coupler terminal
white/yellow–any other coupler terminal
ECU coupler “3” white/yellow–any other coupler terminal
A B
2 1 2
B W
L/W W/G G Y L R/B Br L/W B/W

YES
→ Go to step 6.
NO

YES
→ Go to step 21.
NO
→ Go to step 6.
• Replace the ECU.
• Rotate the rear wheel by hand and check that the indicated value increases.

YES
9-203
P0500 (FI), P1500
→ Go to step 21.
NO
→ Go to step 7.
7. Malfunction in ABS ECU.
• Replace the ABS ECU and go to step 21.
8. Connection of neutral switch coupler and sub-wire harness (for MTT890D).
pins).

YES
→ Go to step 9.
NO
a. Connect the coupler securely or replace the wire harness or sub-wire harness (for MTT890D).

Is it correct indication?
YES
→ Go to step 21.
NO
→ Go to step 9.
pins).

YES
→ Go to step 10.
NO

YES
→ Go to step 21.
NO
→ Go to step 10.
10.Wire harness continuity.
• Disconnect the relay unit coupler “1”, ECU coupler “2” and neutral switch connector “3”.
Between relay unit coupler “1” and ECU coupler “2” black–black/yellow
9-204
P0500 (FI), P1500
Between relay unit coupler “1” and neutral switch

sky blue–sky blue
connector “3”
1
Br W R L/W R
2
3
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 21.
NO
→ Go to step 11 (for MTT890D) or step 12 (for MTT890).
TIP
black–ground
Between relay unit coupler “1” and ground
sky blue–ground

Relay unit coupler “1”
sky blue–any other coupler terminal
ECU coupler “2” black/yellow–any other coupler terminal
9-205
P0500 (FI), P1500
A B
1
Br W R L/W R
1
Br W R L/W R
W L/W R L/B L Sb B Sb/W 2

YES
NO

YES
→ Go to step 21.
NO
11.Sub-wire harness continuity (neutral switch) (for MTT890D).
• Remove the sub-wire harness (neutral switch)
Between neutral switch connector and sub-wire har-
sky blue–sky blue
ness coupler
9-206
P0500 (FI), P1500
Sb
Sb
Is resistance 0 Ω?
YES
→ Go to step 12.
NO
a. Replace the sub-wire harness (neutral switch).

YES
→ Go to step 21.
NO
→ Go to step 12.
12.Defective neutral switch.
• Check the neutral switch.
• Refer to “CHECKING THE SWITCHES” on page 8-41.
Is check result OK?

YES
→ Go to step 13.
NO
a. Replace the neutral switch.

YES
→ Go to step 21.
NO
→ Go to step 13.
9-207
P0500 (FI), P1500
13.Faulty shift drum (neutral detection area).

• Check the shift drum.
Refer to “CHECKING THE SHIFT DRUM ASSEMBLY” on page 5-93.
Is check result OK?

YES
→ Go to step 14.
NO
→ Replace the shift drum and go to step 21.
Refer to “TRANSMISSION” on page 5-87.
14.Malfunction in ECU.
15.Clutch lever adjustment.
• Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-12.
When the clutch lever is released with the transmission in gear and when the
OFF
sidestand is retracted
When the clutch lever is squeezed with the transmission in gear and when the
ON
YES
→ Go to step 21.
NO
→ Go to step 16.
16.Connection of clutch switch coupler.
pins).

YES
→ Go to step 17.
NO
OFF
ON
YES
→ Go to step 21.
NO
→ Go to step 17.
9-208
P0500 (FI), P1500
17.Connection of ECU coupler.

pins).

YES
→ Go to step 18.
NO
OFF
ON
YES
→ Go to step 21.
NO
→ Go to step 18.
18.Wire harness continuity.
• Disconnect the ECU coupler “2”, relay unit coupler “1” and clutch switch coupler “3”.
Between ECU coupler “2” and relay unit coupler “1” black/yellow–black
Between clutch switch coupler “3” and relay unit black/yellow–black
coupler “1” blue/yellow–blue
1
Br W R L/W R
3 2
Y/B B/Y
Y/W L/Y
Is resistance 0 Ω?
YES
NO
9-209
P0500 (FI), P1500

OFF
ON
YES
→ Go to step 21.
NO
→ Go to step 19.
TIP
black–ground
blue–ground

blue–any other coupler terminal
ECU coupler “2” black/yellow–any other coupler terminal
black/yellow–any other coupler terminal
Clutch switch coupler “3”
blue/yellow–any other coupler terminal
A B
1
Br W R L/W R
1
Br W R L/W R
W L/W R L/B L Sb B Sb/W 2 3
Y/B B/Y
L/B Y/L O/W Lg/L P/W P V L L Gy Y/W L/Y
YES
→ Go to step 19.
NO
9-210
P0500 (FI), P1500

OFF
ON
YES
→ Go to step 21.
NO
→ Go to step 19.
19.Defective clutch switch.
• Check the clutch switch.
Is check result OK?

YES
→ Go to step 20.
NO
a. Replace the clutch switch.
Refer to “HANDLEBAR” on page 4-74.
OFF
ON
YES
→ Go to step 21.
NO
→ Go to step 20.
21.Delete the DTC and check that the MIL goes off.
• Turn the main switch to “ON”, and then rotate the rear 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).
then delete the DTC. Delete this DTC even if it has a condition of “Detected”.
9-211
P0500 (CLCU)
EAS20800
P0500 (CLCU)
EAS33560
TROUBLESHOOTING
Item
• Rear wheel sensor: no normal signals are received from the rear wheel sensor.
• Neutral switch: open or short circuit is detected.
• Clutch switch: open or short circuit is detected.
Fail-safe system
Procedure
Refer to “P0500 (FI), P1500” on page 9-200.
9-212
P0560 (FI), P0563
EAS20675
P0560 (FI), P0563

EAS33304
TROUBLESHOOTING
Item
• [P0560] Charging voltage is abnormal.
• [P0563] Vehicle system power voltage out of range
Fail-safe system
Procedure
TIP
• P0335
1. Malfunction in charging system.
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-12.
Is check result OK?

YES
→ Repeat step 1.
NO
a. Defective rectifier/regulator or AC magneto → Replace.
b. Defective connection in the charging system circuit → Properly connect or replace the wire har-
ness.
c. Start the engine and let it idle for approximately 5 seconds.
d. Check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Repeat step 1.
9-213
P0560 (SCU)
EAS20593
P0560 (SCU)
EAS33073
TROUBLESHOOTING
Item
Charging voltage is abnormal.
Fail-safe system
Procedure
1. Malfunction in charging system.
Is check result OK?

YES
→ Repeat step 1.
NO
a. Defective rectifier/regulator or AC magneto → Replace.
b. Defective connection in the charging system circuit → Properly connect or replace the wire har-
ness.
c. Start the engine and let it idle for approximately 5 seconds.
d. Check the condition of the auxiliary system warning light.
9-214
P0564
EAS20594
P0564
EAS33074
TROUBLESHOOTING
Item
• Cruise control setting switch “RES+”: open or short circuit is detected.
• Cruise control setting switch “SET–”: open or short circuit is detected.
Fail-safe system
Procedure
1. Connection of ECU coupler, handlebar switch coupler (left) and main switch coupler.
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, and then push the “RES+” side and “SET–”side of the cruise control
setting switch.

YES
NO
→ Go to step 2.
When the cruise control setting switch “RES+” is pushed ON
When the cruise control setting switch is released OFF
Is check result OK?

YES
→ Go to “b. Execute the diagnostic mode. (Code 81)”.
NO
→ Go to step 3.
TIP
Perform the procedure from step 3 to step 5, and from step 9 to step 10.
When the cruise control setting switch “SET–” is pushed ON
When the cruise control setting switch is released OFF
c. Confirm that it is defective.

d. Go to step 6.
9-215
P0564
TIP
3. Check the fuse.
• Check the ignition fuse 1 and cruise control fuse.
Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the fuse.
c. Push and release the “RES+” side of the cruise control setting switch, and then check the condition
of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the ignition fuse 1 holder “4”, cruise control fuse holder “1”, handlebar switch coupler
(left) “2” and ECU coupler “3”.
Between ignition fuse 1 holder “4” and cruise control
red–red/white
fuse holder “1”
Between cruise control fuse holder “1” and handle-
yellow/white–yellow/white
bar switch coupler (left) “2”
Between handlebar switch coupler (left) “2” and
brown/blue–brown/blue
ECU coupler “3”

4 1 2 L/Y L/W Lg/B G/W G/W W/G W/Y
Br/L G/L O/W Y/W G/B W/R
Y/B Y L/R W/L W/Y B W/G
Is resistance 0 Ω?
YES
NO
9-216
P0564

YES
NO
→ Go to step 5.
TIP
Between handlebar switch coupler (left) “2” and brown/blue–ground
ground yellow/white–ground

brown/blue–any other coupler terminal
Handlebar switch coupler (left) “2”
yellow/white–any other coupler terminal
ECU coupler “3” brown/blue–any other coupler terminal
A B
2 2 3
Br/L G/L O/W Y/W G/B W/R Br/L G/L O/W Y/W G/B W/R
Y/B Y L/R W/L W/Y B W/G Y/B Y L/R W/L W/Y B W/G L/B Y/L O/W Lg/L P/W P V L L Gy
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective cruise control setting switch.
• Replace the handlebar switch (left).
• Turn the main switch to “ON”.
9-217
P0564
• Push the “RES+” side and “SET–” side of the cruise control setting switch, and then check the con-
dition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 9.
6. Check the fuse. (main fuse, ignition fuse 1 and cruise control fuse)
Is check result OK?

YES
→ Go to step 7.
NO
c. Push and release the “SET–” side of the cruise control setting switch, and then check the condition

YES
NO
→ Go to step 7.
• Disconnect the main fuse holder “4”, ignition fuse 1 holder “5”, main switch coupler “6”, cruise control
fuse holder “1”, handlebar switch coupler (left) “2” and ECU coupler “3”.
Between main fuse holder “4” and main switch cou-
red–red
pler “6”
holder “5”
Between ignition fuse 1 holder “5” and cruise control
red–red/white
fuse holder “1”
Between cruise control fuse holder “1” and handle-
yellow/white–yellow/white
bar switch coupler (left) “2”
Between handlebar switch coupler (left) “2” and
green/blue–green/blue
ECU coupler “3”
4 3

6 L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
Br/R
R 2 L/Y L/W Lg/B G/W G/W W/G W/Y
Br/L
Br/L G/L O/W Y/W G/B W/R
5 1 Y/B Y L/R W/L W/Y B W/G
9-218
P0564
Is resistance 0 Ω?
YES
NO
c. Push and “SET–” side of the cruise control setting switch, and then check the condition of the DTC
using the malfunction mode of the YDT.

YES
NO
→ Go to step 8.
TIP
Between handlebar switch coupler (left) “2” and green/blue–ground
ground yellow/white–ground
red–ground
Between main switch coupler “6” and ground
brown/blue–ground

Handlebar switch coupler (left) “2”
yellow/white–any other coupler terminal
ECU coupler “3” green/blue–any other coupler terminal
Main switch coupler “6”
brown/blue–any other coupler terminal
A B
2 6 2 3
Br/L G/L O/W Y/W G/B W/R R Br/L G/L O/W Y/W G/B W/R
Br/R
Y/B Y L/R W/L W/Y B W/G Br/L Y/B Y L/R W/L W/Y B W/G L/B Y/L O/W Lg/L P/W P V L L Gy
6
Br/R R
Br/L
YES
→ Go to step 8.
NO
9-219
P0564

c. Push and “SET–” side of the cruise control setting switch, and then check the condition of the DTC
using the malfunction mode of the YDT.

YES
NO
→ Go to step 8.
8. Defective cruise control setting switch.
• Replace the handlebar switch (left).
• Push the “RES+” side and “SET–” side of the cruise control setting switch, and then check the con-
dition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 9.
9-220
P056C
EAS20595
P056C
EAS33075
TROUBLESHOOTING
Item
• Front brake light switch: open or short circuit is detected.
• Rear brake light switch: open or short circuit is detected.
Fail-safe system
Procedure
a. Execute the diagnostic mode. (Code 82, 83)
When the front brake is applied ON
When the front brake is not applied OFF
Is check result OK?

YES
→ Go to “b. Execute the diagnostic mode. (Code 82, 83)”.
NO
→ Go to step 2.
TIP
Perform the procedure from step 2 to step 5, and from step 10 to step 11.
b. Execute the diagnostic mode. (Code 82, 83)
When the rear brake is applied ON
When the rear brake is not applied OFF
c. Confirm that it is defective.

d. Go to step 6.
TIP
2. Connection of ECU coupler, front brake light switch coupler, brake light relay coupler and main
switch coupler.
pins).

YES
→ Go to step 3.
NO
c. Operate the front brake lever, and then check the condition of the DTC using the malfunction mode
of the YDT.

YES
9-221
P056C
NO
→ Go to step 3.
3. Check the fuse. (signaling system fuse and brake light fuse)
Is check result OK?

YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the brake light fuse holder “1”, front brake light switch coupler “2”, rear brake light switch
coupler “3”, brake light relay coupler “4” and ECU coupler “5”.
Between brake light fuse holder “1” and front brake
green/white–green/white
light switch coupler “2”
Between front brake light switch coupler “2” and rear
brake light switch coupler “3”
Between rear brake light switch coupler “3” and
light green/black–light green/black
brake light relay coupler “4”
Between brake light relay coupler “4” and ground black–ground
Between brake light relay coupler “4” and ECU cou-
pler “5”
2
G/W Y/B
G/Y Y/W
1 5
4
L/R L/B Y/L O/W Lg/L P/W P V L L Gy
3 Lg/B Y B L/Y L/W Lg/B G/W G/W W/G W/Y
G/Y Y/B
Lg/B Lg/L
Is resistance 0 Ω?
YES
NO
9-222
P056C

of the YDT.

YES
NO
→ Go to step 5.
TIP
Between brake light relay coupler “4” and ground light green/black–ground
Between front brake light switch coupler “2” and green/white–ground
ground green/yellow–ground

Brake light relay coupler “4” light green/black–any other coupler terminal
green/white–any other coupler terminal
Front brake light switch coupler “2”
Rear brake light switch coupler “3”
light green/black–any other coupler terminal
ECU coupler “5” light green/black–any other coupler terminal
A B
2 5
G/W Y/B
4 2 4 G/Y Y/W L/B Y/L O/W Lg/L P/W P V L L Gy
L/R L/W B/Y Br/L G/L Gy/G Br/W B/L B/L

G/W Y/B L/R
G/Y Y/W
Lg/B Y B Lg/B Y B
3
G/Y Y/B
Lg/B Lg/L
YES
→ Go to step 5.
NO
of the YDT.

YES
9-223
P056C

NO
→ Go to step 5.
5. Defective front brake light switch.
• Replace the front brake light switch.
Refer to “FRONT BRAKE” on page 4-41.
• Operate the front brake lever, and then check the condition of the DTC using the malfunction mode
of the YDT.

YES
NO
→ Go to step 10.
6. Connection of wire harness ECU coupler, rear brake light switch coupler, brake light relay coupler
and main switch coupler.
pins).

YES
→ Go to step 7.
NO
c. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction mode
of the YDT.

YES
NO
→ Go to step 7.
7. Check the fuse. (signaling system fuse and brake light fuse)
Is check result OK?

YES
→ Go to step 8.
NO
of the YDT.

YES
NO
→ Go to step 8.
9-224
P056C

• Disconnect the brake light fuse holder “1”, front brake light switch coupler “2”, rear brake light switch
coupler “3”, brake light relay coupler “4” and ECU coupler “5”.
Between brake light fuse holder “1” and front brake
light switch coupler “2”
Between front brake light switch coupler “2” and rear
brake light switch coupler “3”
Between rear brake light switch coupler “3” and
brake light relay coupler “4”
Between brake light relay coupler “4” and ground black–ground
Between brake light relay coupler “4” and ECU cou-
pler “5”
2
G/W Y/B
G/Y Y/W
1 5
4
L/R L/B Y/L O/W Lg/L P/W P V L L Gy
3 Lg/B Y B L/Y L/W Lg/B G/W G/W W/G W/Y
G/Y Y/B
Lg/B Lg/L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 9.
TIP
Between brake light relay coupler “4” and ground light green/black–ground
Between rear brake light switch coupler “3” and green/yellow–ground
ground light green/black–ground
9-225
P056C

Brake light relay coupler “4” light green/black–any other coupler terminal
green/white–any other coupler terminal
Front brake light switch coupler “2”
Rear brake light switch coupler “3”
light green/black–any other coupler terminal
ECU coupler “5” light green/black–any other coupler terminal
A B
2 5
4 3 4
G/W Y/B
L/R G/Y Y/B G/Y Y/W L/B Y/L O/W Lg/L P/W P V L L Gy
Lg/B Lg/L L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
L/R
Lg/B Y B L/Y L/W Lg/B G/W G/W W/G W/Y
Lg/B Y B
3
G/Y Y/B
Lg/B Lg/L
YES
→ Go to step 9.
NO
of the YDT.

YES
NO
→ Go to step 9.
9. Defective rear brake light switch.
• Replace the rear brake light switch.
Refer to “REAR BRAKE” on page 4-54.
Is check result OK?

YES
→ Go to step 10.
NO
a. Turn the main switch to “ON”.
b. Operate the rear brake pedal, and then check the condition of the DTC using the malfunction mode
of the YDT.

YES
NO
9-226
P056C
→ Go to step 10.
9-227
P0601
EAS20676
P0601
EAS33305
TROUBLESHOOTING
Item
Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear
on the tool display.)
Fail-safe system
Procedure
• Check that the MIL does not come on.
9-228
P0606
EAS20677
P0606
EAS33306
TROUBLESHOOTING
Item
Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear
on the tool display.)
Fail-safe system
Procedure
1. Check and repair for simultaneous malfunction.
• Check the items of DTCs P0122, P0123, P0222, P0223 and P2135, if they are detected at the same
time, correct the P0122, P0123, P0222, P0223 and P2135 first.
of the YDT.

YES
NO
→ Go to step 2.
• Check that the MIL does not come on.
9-229
P062F
EAS20598
P062F
EAS33078
TROUBLESHOOTING
Item
EEPROM DTC: an error is detected while reading or writing on EEPROM.
Fail-safe system
Procedure
• Execute the diagnostic mode (Code 60)
00
Go to step 6.
01
Go to step 2.
02
Go to step 3.
03
Go to step 4.
Except 00–03
Go to step 5.
2. “01” is indicated in diagnostic mode (Code 60). EEPROM data error for adjustment of CO concen-
tration of cylinder #1.
• Change the CO concentration of cylinder #1, and rewrite in EEPROM.
Refer to “ADJUSTING THE EXHAUST GAS VOLUME” on page 3-11.
• After this adjustment is made, turn the main switch to “OFF”.
of the YDT.

YES
NO
a. Repeat step 1.
b. If the same number is indicated, go to item 7.
of the YDT.

YES
NO
a. Repeat step 1.
9-230
P062F
of the YDT.

YES
NO
a. Repeat step 1.
5. Except “00-03” is indicated in diagnostic mode Code 60). EEPROM data error for corresponding
learning/memory values.
• Turn the main switch to “OFF”.
of the YDT.

YES
NO
a. Repeat step 1.
9-231
P0638
EAS20599
P0638
EAS33079
TROUBLESHOOTING
Item
YCC-T drive system: malfunction detected.
Fail-safe system
Procedure
1. Connection of throttle servo motor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
3. Check the electronic throttle valve fuse.
Is check result OK?

YES
→ Go to step 4.
9-232
P0638
NO
a. Replace the electronic throttle valve fuse.
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the throttle servo motor coupler “1”, ECU coupler “2” and electronic throttle valve fuse
holder “3”.
Between throttle servo motor coupler “1” and ECU yellow/red–yellow/red
coupler “2” light green/red–light green/red
Between ECU coupler “2” and electronic throttle
red/blue–red/blue
valve fuse holder “3”
1
3 Y/R Lg/R
2 Y/R P/B O/G Gy/R O

Lg/R L/B G/B R/B B
R/L G/Y B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 5.
TIP
yellow/red–ground
Between ECU coupler “2” and ground light green/red–ground
red/blue–ground
9-233
P0638

Throttle servo motor coupler “1”
light green/red–any other coupler terminal
ECU coupler “2” light green/red–any other coupler terminal
A B
2 1
Y/R P/B O/G Gy/R O Y/R Lg/R
Lg/R L/B G/B R/B B
R/L G/Y B
2
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
R/L G/Y B
YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
5. Defective throttle bodies.
• Check the throttle bodies.
Refer to “CHECKING THE THROTTLE SERVO MOTOR” on page 8-50.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the throttle bodies.
Refer to “REPLACING THE THROTTLE BODIES” on page 7-10.
of the YDT.

YES
NO
→ Go to step 6.
9-234
P0638
9-235
P0657
EAS20601
P0657
EAS33081
TROUBLESHOOTING
Item
Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
Fail-safe system
Procedure
TIP
• P0335
1. Connection of relay unit coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-236
P0657

• Disconnect the fuel injection system fuse holder “1”, relay unit coupler “2”, ignition fuse 1 holder “3”,
handlebar switch (right) coupler “4” and ECU coupler “5”.
Between fuel injection system fuse holder “1” and
brown–brown
relay unit coupler “2”
Between ignition fuse 1 holder “3” and handlebar
red–red/white
switch (right) coupler “4”
Between handlebar switch (right) coupler “4” and re-
red/white–red
lay unit coupler “2”
red–red/blue
Between relay unit coupler “2” and ECU coupler “5”
1 2
Br W R L/W R
5
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
4 R/L G/Y B
3 W/B W/G B/W
4 R/W L/W
R/W B W
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 4.
TIP
brown–ground
Between relay unit coupler “2” and ground blue/white–ground
red–ground
Between handlebar switch (right) coupler “4” and red/white–ground
ground red/white–ground
9-237
P0657

brown–any other coupler terminal
Relay unit coupler “2” blue/white–any other coupler terminal
Handlebar switch (right) coupler “4”
ECU coupler “5”
A B
2 2 5
Br W R L/W R Br W R L/W R
Y/R P/B O/G Gy/R O
W L/W R L/B L Sb B Sb/W W L/W R L/B L Sb B Sb/W
Lg/R L/B G/B R/B B
R/L G/Y B
4 4 4
W/B W/G B/W 4 R/W L/W W/B W/G B/W R/W L/W
R/W B W R/W B W
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Defective relay unit.
• Check the operating sound of the relay.
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the relay unit.

YES
NO
→ Go to step 5.
9-238
P0657
5. Defective relay unit.

Is the fuel system voltage less than 3V?

YES
a. Replace the relay unit.

YES
NO
→ Go to step 6.
NO
→ Go to step 6.
9-239
P0914
EAS20417
P0914
EAS32837
TROUBLESHOOTING
Item
Gear position sensor: signal stuck
Fail-safe system
Procedure
TIP
• P0335, P0500, P0915, P0916, P0917, P1500
1. Installed condition of gear position sensor.
Is check result OK?

YES
→ Go to step 2.
NO
b. Make sure that the position of each gear is correctly displayed on the meter.
Is check result OK?

YES
NO
→ Go to step 2.
2. Defective gear position sensor.
• Disconnect the gear position sensor coupler.
• Measure the gear position sensor resistance.
• Shift the transmission to each position.

YES
→ Go to step 3.
NO
9-240
P0914
a. Replace the gear position sensor.

Is check result OK?

YES
NO
→ Go to step 3.
9-241
P0915
EAS20416
P0915
EAS32836
TROUBLESHOOTING
Item
Gear position sensor: signal out of range
Fail-safe system
Procedure
TIP
• P0916, P0917
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
NO
→ Go to step 2.
2. Connection of gear position sensor coupler.
pins).

YES
→ Go to step 3.
NO
Is check result OK?

YES
NO
→ Go to step 3.
9-242
P0915
pins).

YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
→ Go to step 4.
• Replace the gear position sensor.
• Make sure that the position of each gear is correctly displayed on the meter.
Is check result OK?

YES
NO
→ Go to step 5.
Is check result OK?

YES
NO
→ Go to step 6.
9-243
P0916, P0917
EAS20611
P0916, P0917
EAS33091
TROUBLESHOOTING
Item
• [P0916] Gear position sensor: open or ground short circuit detected.
• [P0917] Gear position sensor: power short circuit detected.
Fail-safe system
Procedure
1. Connection of gear position sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the gear position sensor coupler “1” and ECU coupler “2”.
9-244
P0916, P0917
Between gear position sensor coupler “1” and ECU
coupler “2”
blue–blue
2
1 L/B Y/L O/W Lg/L P/W P V L L Gy
L G/W B/L L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Between gear position sensor coupler “1” and green/white–ground
ground blue–ground

Gear position sensor coupler “1” green/white–any other coupler terminal
ECU coupler “2” green/white–any other coupler terminal
9-245
P0916, P0917
A B
1 1 2
L G/W B/L L G/W B/L
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO
9-246
P0916, P0917
a. Replace the gear position sensor.

of the YDT.

YES
NO
→ Go to step 6.
9-247
P1004
EAS20786
P1004
EAS33529
TROUBLESHOOTING
Item
Intake air pressure sensor 1 and intake air pressure sensor 2: output voltage deviation error.
Fail-safe system
Procedure
TIP
• P0105, P0106, P0108, P0335, P0606
dicated.
At sea level
3.64 V
3.30 V
3.00 V
2.70 V
Is check result OK?

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
dicated.
At sea level
3.64 V
3.30 V
3.00 V
9-248
P1004

2.70 V
Is check result OK?

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
9-249
P1600
EAS20613
P1600
EAS33093
TROUBLESHOOTING
Item
Lean angle sensor: open or short circuit detected.
Fail-safe system
Procedure
TIP
• U0125
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-250
P1600

Between ECU coupler “1” and IMU coupler “2”
Between ignition fuse 1 holder “3” and IMU coupler
red/blue–red/blue
“3”
3 2
B/W L/W L/B R/L
1
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 4.
TIP
Disconnect the ECU and IMU related connectors before checking.
blue/white–ground
Between IMU coupler “2” and ground blue/black–ground
red/blue–ground

ECU coupler “1”
black/black–any other coupler terminal
IMU coupler “2”
black/white–any other coupler terminal
9-251
P1600
A B
2 1
B/W L/W L/B R/L
2
B/W L/W L/B R/L
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO
b. Turn the main switch to “ON.

YES
NO
→ Go to step 5.
5. Defective IMU.
• Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
• Check the condition of the DTC using the malfunction mode of the YDT.
9-252
P1600
YES
NO
→ Go to step 6.
9-253
P1601
EAS20614
P1601
EAS33094
TROUBLESHOOTING
Item
Sidestand switch: open or short circuit of the blue/yellow lead of the ECU is detected.
Fail-safe system
Procedure
1. Connection of sidestand switch coupler.
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, and then extend and retract the sidestand.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
3. Connection of relay unit coupler.
pins).
9-254
P1601

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the relay unit coupler “1”, ECU coupler “2” and sidestand switch coupler “3”.
Between relay unit coupler “1” and ECU coupler “2” blue–blue/yellow
Between relay unit coupler “1” and sidestand switch
coupler “3”
3 1 2
Br W R L/W R
L/B B W L/W R L/B L Sb B Sb/W L/B Y/L O/W Lg/L P/W P V L L Gy
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 5.
TIP
blue–ground
blue/black–ground
9-255
P1601

ECU coupler “2” blue/yellow–any other coupler terminal
Sidestand switch coupler “3” blue/black–any other coupler terminal
A B
1 Br W R L/W R
1 Br W R L/W R
2
W L/W R L/B L Sb B Sb/W W L/W R L/B L Sb B Sb/W L/B Y/L O/W Lg/L P/W P V L L Gy
3 L/B B
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective sidestand switch.
• Shift the transmission into gear.
Sidestand retracted ON
Sidestand extended OFF
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the sidestand switch.

YES
NO
9-256
P1601
→ Go to step 6.
9-257
P1602
EAS20615
P1602
EAS33095
TROUBLESHOOTING
Item
Malfunction in ECU internal circuit (malfunction of ECU power cut-off function).
Fail-safe system
Procedure
1. Installed condition of battery leads.
• Check the installed condition of the battery and battery leads (loose bolts).
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the battery leads.
of the YDT.

YES
NO
→ Go to step 2.
2. Connection of starter relay coupler.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
3. Check the backup fuse.
Is check result OK?

YES
→ Go to step 4.
NO
9-258
P1602

of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the battery terminal “1”, backup fuse 2 holder “2”, ECU coupler “3”, main switch coupler
“4” and ignition fuse 1 holder “5”.
Between battery terminal “1” and backup fuse 2
red–red
holder “2”
Between backup fuse 2 holder “2” and ECU coupler
red/green–red/green
“3”
holder “5”
Between ignition fuse 1 holder “5” and ECU coupler
red–red/white
“3”
1
3
Y/R P/B O/G Gy/R O
2 Lg/R
R/L G/Y
L/B G/B R/B B
B
4 R
5
Br/R
Br/L
3
W/R G L Br/Y R/W
Y W Y/R
B/L Br
W/B B Y/B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 5.
TIP
9-259
P1602

Between battery terminal “1” and ground red–ground
red/green–ground
Between ECU coupler “3” and ground
red/white–ground
Between main switch coupler “4” and ground brown/blue–ground

red/green–any other coupler terminal
ECU coupler “3”
Main switch coupler “4” brown/blue–any other coupler terminal
A B
1 3 3 3
Y/R P/B O/G Gy/R O
Lg/R L/B G/B R/B B
Lg/R L/B G/B R/B B Y W Y/R
R/L G/Y B
R/L G/Y B B/L Br
4 3
R
Br/R
Br/L
W/R G L Br/Y R/W 4 Br/R
R
Y W Y/R Br/L
B/L Br
W/B B Y/B
YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
9-260
P1606, P1607
EAS20787
P1606, P1607
EAS33530
TROUBLESHOOTING
Item
• [P1606] Intake air pressure sensor 2: ground short circuit detected.
• [P1607] Intake air pressure sensor 2: open or power short circuit detected.
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the intake air pressure sensor 2 coupler “1” and ECU coupler “2”.
9-261
P1606, P1607
[P1607] blue–blue
Between ECU coupler “2” and intake air pressure
[P1606, P1607] pink–pink
sensor 2 coupler “1”
[P1607] black/blue–black/blue
2
B/L P L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Between intake air pressure sensor 2 coupler “1” [P1607] blue–ground
and ground [P1606, P1607] pink–ground

ECU coupler “2” [P1607] black/blue–any other coupler terminal
[P1606, P1607] pink–any other coupler terminal
Intake air pressure sensor 2 coupler “1” [P1607] black/blue–any other coupler terminal
[P1606, P1607] pink–any other coupler terminal
9-262
P1606, P1607
A B
1 1 2
B/L P L B/L P L
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of intake air pressure sensor 2.
Is check result OK?

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
dicated.
At sea level
3.64 V
3.30 V
3.00 V
9-263
P1606, P1607

2.70 V
Is check result OK?

YES
→ Go to step 6.
NO
of the YDT.

YES
NO
→ Go to step 6.
9-264
P1608
EAS20788
P1608
EAS33531
TROUBLESHOOTING
Item
Intake air pressure sensor 2: signal out of range
Fail-safe system
Procedure
TIP
• P1606, P1607
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
• Replace the intake air pressure sensor 2.
of the YDT.

YES
NO
→ Go to step 3.
of the YDT.

YES
9-265
P1608
NO
→ Go to step 4.
9-266
P1609
EAS20789
P1609
EAS33532
TROUBLESHOOTING
Item
Intake air pressure sensor 2: clogging of hose or sensor disconnection
Fail-safe system
Procedure
TIP
• P0122, P0123, P0222, P0223, P0335, P1606, P1607, P1608, P2135
1. Installed condition of intake air pressure sensor 2 hose.
• Check for detached, clogged, kinked or pinching.
Is check result OK?

YES
→ Go to step 2.
NO
a. Repair or replace the intake air pressure sensor 2 hose.
b. Start the engine and let it idle for approximately 5 seconds, and then check the condition of the
DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
dicated.
At sea level 101 kPa (757.6 mmHg, 29.8 inHg)
Is check result OK?

YES
NO
a. Replace the intake air pressure sensor.
Refer to “THROTTLE BODIES” on page 7-6
c. Confirm the “Recovered” condition, then go to step 3.
9-267
P1609
9-268
P1806, P1807
EAS20623
P1806, P1807
EAS33103
TROUBLESHOOTING
Item
• [P1806] Shift sensor: open or ground short circuit detected.
• [P1807] Shift sensor: power short circuit detected.
Fail-safe system
Procedure
1. Connection of shift sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
3. Wire harness continuity
• Disconnect the shift sensor coupler “1” and ECU coupler “2”.
9-269
P1806, P1807
blue–blue
Between shift sensor coupler “1” and ECU coupler
violet–violet
“2”
2
B/L V L L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
violet–ground
Between shift sensor coupler “1” and ground
blue–ground

Shift sensor coupler “1” violet–any other coupler terminal
ECU coupler “2” violet–any other coupler terminal
9-270
P1806, P1807
A B
1 1 2
B/L V L B/L V L
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of shift sensor.
Is check result OK?

YES
→ Go to step 5.
NO
Refer to “CHAIN DRIVE” on page 4-130.
of the YDT.

YES
NO
→ Go to step 5.
5. Defective shift sensor.
• Execute the diagnostic mode. (Code D95)
Shift sensor output voltage display 0.2–4.8 [V]
With no shift weighting input Approx. 2.5 [V]
Shift up weighting Changes to the low side
Shift down weighting Changes to the high side
Is check result OK?
9-271
P1806, P1807
YES
→ Go to step 6.
NO
a. Replace the shift sensor.
Refer to “CHAIN DRIVE” on page 4-130.
of the YDT.

YES
NO
→ Go to step 6.
9-272
P2122, P2123, P2127, P2128, P2138
EAS20632
P2122, P2123, P2127, P2128, P2138

EAS33112
TROUBLESHOOTING
Item
• [P2122] Accelerator position sensor: open or ground short circuit detected.
• [P2123] Accelerator position sensor: power short circuit detected.
• [P2127] Accelerator position sensor: open or ground short circuit detected.
• [P2128] Accelerator position sensor: power short circuit detected.
• [P2138] Deviation error
Fail-safe system
• Able/unable to start engine
• Able/unable to drive vehicle
Procedure
TIP
If a DTC other than P2138 is indicated, perform troubleshooting first (P2122, P2123, P2127, or P2128).
1. Connection of accelerator position sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
9-273
P2122, P2123, P2127, P2128, P2138
→ Go to step 3.
• Disconnect the accelerator position sensor coupler “1” and ECU coupler “2”.
[P2122, P2127] yellow/red–yellow/red
[P2122, P2127] white/red–white/red
[P2122, P2123, P2127, P2128, P2138] yellow–yel-
Between accelerator position sensor coupler “1” and low
ECU coupler “2” [P2123, P2128] white/black–white/black
[P2123, P2128] yellow/black–yellow/black
[P2122, P2123, P2127, P2128, P2138] brown–
brown
1 2
Br W/R W/R G L Br/Y R/W
Y/R W/B Y W Y/R
Y/B Y B/L Br
W/B B Y/B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
[P2122, P2123, P2127, P2128, P2138] brown–
ground
Between accelerator position sensor coupler “1” and [P2122, P2127] white/red–ground
ground [P2122, P2127] yellow/red–ground
[P2122, P2123, P2127, P2128, P2138] yellow–
ground
9-274
P2122, P2123, P2127, P2128, P2138

[P2122, P2123, P2127, P2128, P2138] brown–any
[P2122, P2127] white/red–any other coupler termi-
nal
[P2122, P2127] yellow/red–any other coupler termi-
nal
Accelerator position sensor coupler “1”
[P2122, P2123, P2127, P2128, P2138] yellow–any
[P2123, P2128] yellow/black–any other coupler ter-
minal
[P2123, P2128] white/black–any other coupler ter-
minal
[P2122, P2123, P2127, P2128, P2138] brown–any
[P2122, P2127] white/red–any other coupler termi-
nal
[P2122, P2127] yellow/red–any other coupler termi-
nal
ECU coupler “2”
[P2122, P2123, P2127, P2128, P2138] yellow–any
[P2123, P2128] yellow/black–any other coupler ter-
minal
[P2123, P2128] white/black–any other coupler ter-
minal
A B
1 1 2
Br W/R Br W/R W/R G L Br/Y R/W
Y/R W/B Y/R W/B Y W Y/R
Y/B Y Y/B Y B/L Br
W/B B Y/B
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective accelerator position sensor.
• Execute the diagnostic mode. (Code 14) (Accelerator position sensor signal 1.)
9-275
P2122, P2123, P2127, P2128, P2138

When the throttle valves are fully open 82–92
Turn the throttle grip past the closed position in the deceleration direction. 7–12
• Execute the diagnostic mode. (Code 15) (Accelerator position sensor signal 2.)
When the throttle valves are fully open 82–92
Turn the throttle grip past the closed position in the deceleration direction. 7–12
Is check result OK?

YES
→ Go to step 5.
NO
→ Replace the handlebar switch (right).
Refer to “HANDLEBAR” on page 4-74.

YES
NO
→ Go to step 5.
9-276
P2158 (FI)
EAS20633
P2158 (FI)
EAS33113
TROUBLESHOOTING
Item
Front wheel sensor: no normal signals are received from the front wheel sensor.
Fail-safe system
Procedure
1. Connection of front wheel sensor coupler.
pins).

YES
→ Go to step 2.
NO
c. Rotate the front wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
pins).
9-277
P2158 (FI)

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the front wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
Between front wheel sensor coupler “1” and ABS brown–brown
ECU coupler “2” yellow–yellow
Between ABS ECU coupler “2” and ECU coupler “3” white/green–white/green
1 2 3
Br Y L/W W/G G Y L R/B Br L/W B/W
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 5.
TIP
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE ABS
ECU” on page 9-3.
9-278
P2158 (FI)

brown–ground
Between ABS ECU coupler “2” and ground yellow–ground

Front wheel sensor coupler “1”
yellow–any other coupler terminal
ABS ECU coupler “2” yellow–any other coupler terminal
white/green–any other coupler terminal
ECU coupler “3” white/green–any other coupler terminal
A B
1
Br Y
2 2 3
L/W W/G G Y L R/B Br L/W B/W L/W W/G G Y L R/B Br L/W B/W L/B Y/L O/W Lg/L P/W P V L L Gy
R G/O W/Y L B W Y L/B B R B L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
G/O W/Y L B W Y L/B
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective front wheel sensor.
• Replace the front wheel sensor.

YES
9-279
P2158 (FI)

NO
→ Go to step 6.

YES
NO
→ Go to step 7.
• Replace the ABS ECU.
Refer to “REMOVING THE HYDRAULIC UNIT ASSEMBLY” on page 4-68.
• Go to step 8, and complete the service.
• Turn the main switch to “ON”, and then rotate the front 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).
9-280
P2158 (SCU)
EAS20634
P2158 (SCU)
EAS33114
TROUBLESHOOTING
Item
Front wheel sensor: no normal signals are received from the front wheel sensor.
Fail-safe system
Procedure
1. Connection of front wheel sensor coupler.
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “OFF” and back to “ON”, and then check the auxiliary system warning light.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
pins).

YES
9-281
P2158 (SCU)
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the front wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
Between front wheel sensor coupler “1” and ABS brown–brown
ECU coupler “2” yellow–yellow
Between ABS ECU coupler “2” and ECU coupler “3” white/green–white/green
1 2 3
Br Y L/W W/G G Y L R/B Br L/W B/W
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 5.
TIP
ECU” on page 9-3.
brown–ground
Between ABS ECU coupler “2” and ground yellow–ground
9-282
P2158 (SCU)

Front wheel sensor coupler “1”
ABS ECU coupler “2” yellow–any other coupler terminal
white/green–any other coupler terminal
ECU coupler “3” white/green–any other coupler terminal
A B
1
Br Y
2 2 3
L/W W/G G Y L R/B Br L/W B/W L/W W/G G Y L R/B Br L/W B/W L/B Y/L O/W Lg/L P/W P V L L Gy
R G/O W/Y L B W Y L/B B R B L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
G/O W/Y L B W Y L/B
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective front wheel sensor.
• Replace the front wheel sensor.

YES
NO
→ Go to step 6.
9-283
P2158 (SCU)

YES
NO
→ Go to step 7.
• Replace the ABS ECU.
9-284
U0100 (SCU)
EAS20801
U0100 (SCU)
EAS33124
TROUBLESHOOTING
Item
Abnormal CAN communication (between ECU and SCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1” and ECU coupler “2”.
Between SCU coupler “1” and ECU coupler “2”
1 G/R B R/B R/L Gy/L 2

G/L W/G W/R Gy/R
W/B L/W P/L L/B Y/L O/W Lg/L P/W P V L L Gy
L/B P/R L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
Is resistance 0 Ω?
YES
NO
9-285
U0100 (SCU)
YES
NO
→ Go to step 3.
TIP
Disconnect the ECU and SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE SCU
blue/white–ground
blue/black–ground

SCU coupler “1”
ECU coupler “2”
A B
1 1
G/L W/G W/R Gy/R G/L W/G W/R Gy/R
L/B P/R L/B P/R

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-286
U0100 (SCU)
9-287
U0100 (CLCU)
EAS20802
U0100 (CLCU)
EAS33561
TROUBLESHOOTING
Item
Abnormal CAN communication (between ECU and CLCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO
YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
YES
NO
→ Go to step 3.
Between CLCU coupler “1” and ECU coupler “2”
9-288
U0100 (CLCU)
1
B L/R 2
L/W L/B
Is resistance 0 Ω?
YES
NO
YES
NO
→ Go to step 4.
TIP
blue/white–ground
Between CLCU coupler “1” and ground
blue/black–ground

ECU coupler “2”
9-289
U0100 (CLCU)
A B
1 1
B L/R B L/R
L/W L/B L/W L/B

YES
→ Go to step 4.
NO
YES
NO
→ Go to step 4.
YES
NO
→ Go to step 5.
• Riding the vehicle, and check the cornering light.
9-290
U0121
EAS20646
U0121
EAS33126
TROUBLESHOOTING
Item
Abnormal CAN communication (between ABS ECU and SCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1” and ABS ECU coupler “2”.
Between SCU coupler “1” and ABS ECU coupler “2”

G/L W/G W/R Gy/R
W/B L/W P/L L/W W/G G Y L R/B Br L/W B/W
L/B P/R R G/O W/Y L B W Y L/B B
Is resistance 0 Ω?
YES
→ Go to “Short circuit check”
NO
9-291
U0121
YES
NO
→ Go to step 3.
TIP
Disconnect the SCU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for MTT890D)” on page 9-4 and “PARTS CONNECT-
ED TO THE ABS ECU” on page 9-3.
blue/white–ground
blue/black–ground

SCU coupler “1”
ABS ECU coupler “2”
A B
1 1
L/B P/R L/B P/R

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-292
U0121

• Replace the ABS ECU, and complete the service.
9-293
U0125 (FI)
EAS20647
U0125 (FI)
EAS33127
TROUBLESHOOTING
Item
Signals cannot be transmitted between the ECU and the IMU.
Fail-safe system
Procedure
TIP
• P1600
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
9-294
U0125 (FI)

Between ECU coupler “1” and IMU coupler “2”
Between IMU coupler “2” and ignition fuse 1 holder
red/blue–red/blue
“3”
3
2
B/W L/W L/B R/L
1
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
→ Go to step 4.
TIP
Disconnect the ECU and IMU related connectors before checking.
blue/white–ground
red/blue–ground

ECU coupler “1”
IMU coupler “2”
black/white–any other coupler terminal
9-295
U0125 (FI)
A B
2 1
B/W L/W L/B R/L
2
B/W L/W L/B R/L
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Malfunction in IMU.
of the YDT.

YES
NO
→ Go to step 5.
9-296
U0125 (SCU)
EAS20648
U0125 (SCU)
EAS33128
TROUBLESHOOTING
Item
Signals cannot be transmitted between the SCU and the IMU.
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, IMU coupler “2” and ignition fuse 1 holder “3”.
Between SCU coupler “1” and IMU coupler “2”
red/blue–red/blue
“3”
3 2 1
G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
Is resistance 0 Ω?
YES
NO
9-297
U0125 (SCU)


YES
NO
→ Go to step 3.
TIP
blue/white–ground
red/blue–ground

SCU coupler “1”
IMU coupler “2” blue/black–any other coupler terminal
A B
1
2 2
G/R B R/B R/L Gy/L
B/W L/W L/B R/L G/L W/G W/R Gy/R B/W L/W L/B R/L
W/B L/W P/L
L/B P/R
YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Turn the main switch to “ON”, and then check the auxiliary system warning light.
9-298
U0125 (CLCU)
EAS20803
U0125 (CLCU)
EAS33562
TROUBLESHOOTING
Item
Signals cannot be transmitted between the CLCU and the IMU.
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO
YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
YES
NO
→ Go to step 3.
• Disconnect the CLCU coupler “1”, IMU coupler “2” and ignition fuse 1 holder “3”.
Between CLCU coupler “1” and IMU coupler “2”
red/blue–red/blue
“3”
9-299
U0125 (CLCU)
2 1
B/W L/W L/B R/L B L/R
L/W L/B
Is resistance 0 Ω?
YES
NO
YES
NO
→ Go to step 4.
blue/white–ground
red/blue–ground

IMU coupler “2” blue/black–any other coupler terminal
A B
2 1 2
B/W L/W L/B R/L B L/R B/W L/W L/B R/L
L/W L/B
YES
→ Go to step 4.
NO
9-300
U0125 (CLCU)

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO
YES
NO
→ Go to step 5.
YES
NO
→ Go to step 6.
• Replace the auxiliary light assembly, and complete the service.
9-301
U0155 or Err (FI)
EAS20649
U0155 or Err (FI)

EAS33129
TROUBLESHOOTING
Item
Multi-function meter: signals cannot be transmitted between the ECU and the multi-function meter.
Fail-safe system
Procedure
TIP
“Err” is displayed on the clock display of the multi-function meter, but the MIL does not come on.
1. Connection of meter assembly coupler and sub-wire harness (meter) coupler.
pins).

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness or sub-wire harness (meter).
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the meter assembly coupler “1”, sub-wire harness (meter) coupler “3” and ECU coupler
“2”.
9-302
U0155 or Err (FI)

Between meter assembly coupler “1” and sub-wire blue/black–blue/black
harness (meter) coupler “3” blue/white–blue/white
Between sub-wire harness (meter) coupler “3” and blue/black–blue/black
ECU coupler “2” blue/white–blue/white
1 2
R/G R/G R/W G/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/BSb/W L/B Y/L O/W Lg/L P/W P V L L Gy
G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
3
G/Y G/B W/R L/B L/W L/W L/B W/R G/B G/Y
B Br/YW/G W W/B W/B W W/G Br/Y B
Is resistance 0 Ω?
YES
NO
a. Replace the wire harness or sub-wire harness (meter).
of the YDT.

YES
NO
→ Go to step 4.
TIP
blue/white–ground
Between meter assembly coupler “1” and ground
blue/black–ground
blue/white–ground
Between ECU coupler “2” and ground
blue/black–ground

Meter assembly coupler “1”
ECU coupler “2”
9-303
U0155 or Err (FI)
A B
1 1
R/G R/G R/W G/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W R/G R/G R/W G/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W
G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G
2 2
L/B Y/L O/W Lg/L P/W P V L L Gy L/B Y/L O/W Lg/L P/W P V L L Gy
L/W B/Y Br/L G/L Gy/G Br/W B/L B/L L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
L/Y L/W Lg/B G/W G/W W/G W/Y L/Y L/W Lg/B G/W G/W W/G W/Y
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective meter assembly.
• Replace the meter assembly.
of the YDT.

YES
NO
→ Go to step 5.
9-304
U0155 or Err (SCU)
EAS20650
U0155 or Err (SCU)

EAS33130
TROUBLESHOOTING
Item
Multi-function meter: signals cannot be transmitted between the SCU and the multi-function meter.
Fail-safe system
Procedure
TIP
“Err” is displayed on the clock display of the multi-function meter, but the MIL does not come on.
1. Connection of meter assembly coupler and sub-wire harness (meter) coupler.
pins).

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness or sub-wire harness (meter).

YES
NO
→ Go to step 2.
• Disconnect the meter assembly coupler “1”, sub-wire harness (meter) coupler “3” and ECU coupler
“2”.
SCU coupler “2” blue/white–blue/white
1 2
G/R B R/B R/L Gy/L
G/L W/G W/R Gy/R
R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W W/B L/W P/L
G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G L/B P/R
3 G/Y G/B W/R L/B L/W L/W L/B W/R G/B G/Y
B Br/YW/G W W/B W/B W W/G Br/Y B
9-305
U0155 or Err (SCU)
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to step 3.
TIP
blue/white–ground
blue/black–ground
blue/white–ground
blue/black–ground

SCU coupler “2”
A B
1 1
R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W
G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G
2 2
L/B P/R L/B P/R
YES
→ Go to step 3.
NO
9-306
U0155 or Err (SCU)

YES
NO
→ Go to step 3.
3. Defective meter assembly.
• Replace the meter assembly.
9-307
U0401
EAS20651
U0401
EAS33131
TROUBLESHOOTING
Item
CAN communication: SCU is received abnormal data from ECU.
Fail-safe system
Procedure
TIP
If more than one DTC (SCU, ECU) is detected at the same time, perform troubleshooting first.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
Between SCU coupler “1” and ECU coupler “2”

G/L W/G W/R Gy/R
W/B L/W P/L L/B Y/L O/W Lg/L P/W P V L L Gy
L/B P/R L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
Is resistance 0 Ω?
YES
NO
9-308
U0401


YES
NO
→ Go to step 3.
TIP
Disconnect the SCU and ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for MTT890D)” on page 9-4 and “PARTS CONNECT-
ED TO THE ECU” on page 9-3.
blue/white–ground
blue/black–ground

SCU coupler “1”
ECU coupler “2”
A B
1 1
L/B P/R L/B P/R

YES
→ Go to step 3.
NO

YES
9-309
U0401
NO
→ Go to step 3.

YES
NO
→ Go to step 4.
9-310
U0432
EAS20804
U0432
EAS33563
TROUBLESHOOTING
Item
CAN communication: SCU is received abnormal data from IMU.
Fail-safe system
Procedure
TIP
If more than one DTC is detected at the same time, perform troubleshooting listed below first.
• C0520
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
• Disconnect the IMU coupler “1” and SCU coupler “2”.
Between SCU coupler “2” and IMU coupler “1”
1 2
G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
Is resistance 0 Ω?
YES
NO
9-311
U0432


YES
NO
→ Go to step 3.
TIP
blue/white–ground
Between IMU coupler “1” and ground
blue/black–ground

IMU coupler “1”
SCU coupler “2”
A B
2
1 1
G/R B R/B R/L Gy/L
B/W L/W L/B R/L B/W L/W L/B R/L G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.

YES
9-312
U0432
NO
→ Go to step 4.
• Replace the IMU, and completer the service.
9-313
51_IMMOBILIZER
EAS20680
51_IMMOBILIZER
EAS33309
TROUBLESHOOTING
Item
Code cannot be transmitted between the key and the immobilizer unit.
Cause
• Radio wave interference caused by objects around the keys and antennas.
• Immobilizer unit malfunction.
• Key malfunction.
Procedure
TIP
When a system malfunction occurs, the immobilizer system indicator light will flash. The DTC can be
identified by the flashing pattern. Refer to “HOW TO CHECK DTC” on page 9-20.
1. Keep magnets, metal objects, and other immobilizer system keys away from the keys and antennas.
Is DTC displayed?
YES
→ Go to step 2.
NO
2. Turn the main switch to “ON” with another key.
Is DTC displayed?
YES
→ Go to step 3.
NO
→ If the DTC is displayed due to a defective key, replace the key with a new one.
3. Replace the main switch/immobilizer unit, ECU and all key, and complete the service.
9-314
52_IMMOBILIZER
EAS20679
52_IMMOBILIZER
EAS33308
TROUBLESHOOTING
Item
Codes between the key and immobilizer unit do not match.
Cause
• Signal received from other transponder (failed to recognize code after ten consecutive attempts).
• Signal received from unregistered standard key.
• Immobilizer unit malfunction
• Key malfunction
Procedure
TIP
1. Place the immobilizer unit at least 50 mm away from the transponder of other vehicles.
Is DTC displayed?
YES
→ Go to step 2.
NO
2. Register the standard key.
Is DTC displayed?
YES
→ Go to step 3.
NO
3. Turn the main switch to “ON” with another key.
Is DTC displayed?
YES
→ Go to step 4.
NO
→ If the DTC is displayed due to a defective key, replace the key with a new one.
9-315
53_IMMOBILIZER
EAS20681
53_IMMOBILIZER
EAS33310
TROUBLESHOOTING
Item
Codes cannot be transmitted between the ECU and the immobilizer unit.
Cause
• Disconnected lead/cable.
• Open or short circuit in wire harness between immobilizer unit and ECU.
• ECU malfunction.
Procedure
TIP
1. Connection of immobilizer unit coupler and ECU coupler.
pins).

YES
→ Go to step 2.
NO
→ Connect the coupler securely or replace the wire harness.
Is DTC displayed?
YES
→ Go to step 3.
NO
• Disconnect the immobilizer unit coupler “1”, ECU coupler “2” and backup fuse 1 holder “3”.
Between immobilizer unit coupler “1” and ECU cou-
yellow/blue–yellow/blue
pler “2”
Between immobilizer unit coupler “1” and backup
Between immobilizer unit coupler “1” and ground black–ground
1 3 2
B R/G
Y/L Lg R L/B Y/L O/W Lg/L P/W P V L L Gy
9-316
53_IMMOBILIZER
Is resistance 0 Ω?
YES
NO
→ Replace the wire harness.
TIP
yellow/blue–ground
Between immobilizer unit coupler “1” and ground
red/green–ground

yellow/blue–any other coupler terminal
Immobilizer unit coupler “1” red/green–any other coupler terminal
ECU coupler “2” yellow/blue–any other coupler terminal
A B
2
1
B R/G L/B Y/L O/W Lg/L P/W P V L L Gy
Y/L Lg R 1 L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
B R/G L/Y L/W Lg/B G/W G/W W/G W/Y
Y/L Lg R
YES
→ Go to step 4.
NO
Is DTC displayed?
YES
→ Go to step 5.
NO
9-317
54_IMMOBILIZER
EAS20682
54_IMMOBILIZER
EAS33311
TROUBLESHOOTING
Item
Codes transmitted between the ECU and the immobilizer unit do not match.
Cause
• ECU failure. (The ECU or immobilizer unit was replaced with a used unit from another vehicle.)
Procedure
TIP
1. Connection of Immobilizer unit coupler and ECU coupler.
pins).

YES
→ Go to step 2.
NO
Is DTC displayed?
YES
→ Go to step 3.
NO
3. Register the code re-registering key and standard keys.
Is DTC displayed?
YES
→ Go to step 4.
NO
9-318
55_IMMOBILIZER
EAS20683
55_IMMOBILIZER
EAS33312
TROUBLESHOOTING
Item
Key code registration malfunction.
Cause
• Same standard key was attempted to be registered two consecutive times.
Procedure
TIP
1. Register another standard key, and complete the service.
9-319
56_IMMOBILIZER
EAS20684
56_IMMOBILIZER
EAS33313
TROUBLESHOOTING
Item
Unidentified code is received.
Cause
• Open or short circuit in wire harness between immobilizer unit and ECU.
Procedure
TIP
1. Connection of immobilizer unit coupler and ECU coupler.
pins).

YES
→ Go to step 2.
NO
Is DTC displayed?
YES
→ Go to step 3.
NO
• Disconnect the immobilizer unit coupler “1”, ECU coupler “2” and backup fuse 1 holder “3”.
Between immobilizer unit coupler “1” and ECU cou-
yellow/blue–yellow/blue
pler “2”
Between immobilizer unit coupler “1” and backup
Between immobilizer unit coupler “1” and ground black–ground
1 3 2
B R/G
Y/L Lg R L/B Y/L O/W Lg/L P/W P V L L Gy
9-320
56_IMMOBILIZER
Is resistance 0 Ω?
YES
NO
TIP
yellow/blue–ground
Between immobilizer unit coupler “1” and ground
red/green–ground

yellow/blue–any other coupler terminal
Immobilizer unit coupler “1” red/green–any other coupler terminal
ECU coupler “2” yellow/blue–any other coupler terminal
A B
2
1
B R/G L/B Y/L O/W Lg/L P/W P V L L Gy
Y/L Lg R 1 L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
B R/G L/Y L/W Lg/B G/W G/W W/G W/Y
Y/L Lg R
YES
→ Go to step 4.
NO
Is DTC displayed?
YES
→ Go to step 5.
NO
9-321
11_ABS
EAS20685
11_ABS
EAS33314
TROUBLESHOOTING
Item
Front wheel sensor (intermittent pulses or no pulses)
Procedure
TIP
If the rear wheel continues to turn for more than 20 seconds after the front wheel has stopped, this will
be recorded.
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.
Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-28.
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.
Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
4-30.
Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Replace the wheel sensor.
9-322
12_ABS
EAS20686
12_ABS
EAS33315
TROUBLESHOOTING
Item
Rear wheel sensor (intermittent pulses or no pulses)
Procedure
1. Foreign material adhered around the rear wheel sensor
Is check result OK?

YES
→ Go to step 2.
NO
2. Incorrect installation of the rear wheel
Refer to “CHECKING THE REAR WHEEL” on page 4-36.
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR” on page
4-37.
Is check result OK?

YES
→ Go to step 4.
NO
4. Defective rear wheel sensor or incorrect installation of the sensor
4-37.
Is check result OK?

YES
NO
9-323
13, 26_ABS
EAS20687
13, 26_ABS
EAS33316
TROUBLESHOOTING
Item
Front wheel sensor (abnormal pulse period)
Procedure
TIP
• If the front brake ABS operates continuously for 20 seconds or more, DTC No. 26 will be recorded. If
the front brake ABS operates continuously for 36 seconds or more, DTC No. 13 will be recorded.
• Vehicle possibly ridden on uneven roads.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
4-30.
Is check result OK?

YES
→ Go to step 4.
NO
4-30.
Is check result OK?

YES
NO
9-324
14, 27_ABS
EAS20688
14, 27_ABS
EAS33317
TROUBLESHOOTING
Item
Rear wheel sensor (abnormal pulse period)
Procedure
TIP
• If the rear brake ABS operates continuously for 20 seconds or more, DTC No. 27 will be recorded. If
the rear brake ABS operates continuously for 36 seconds or more, DTC No. 14 will be recorded.
• Vehicle possibly ridden on uneven roads.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
4-37.
Is check result OK?

YES
→ Go to step 4.
NO
4-37.
Is check result OK?

YES
NO
9-325
15_ABS
EAS20662
15_ABS
EAS33040
TROUBLESHOOTING
Item
Front wheel sensor (open or short circuit)
Procedure
1. Defective coupler between the front wheel sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the ABS ECU coupler “1” and front wheel sensor coupler “2”.
Between ABS ECU coupler “1” and front wheel sen- brown–brown
sor coupler “2” yellow–yellow
1
2
Br Y
Is resistance 0 Ω?
YES
NO
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-3.
yellow–ground
Between ABS ECU coupler “1” and ground
brown–ground
9-326
15_ABS

A B
1 1
L/W W/G G Y L R/B Br L/W B/W L/W W/G G Y L R/B Br L/W B/W
R G/O W/Y L B W Y L/B B R G/O W/Y L B W Y L/B B
YES
→ Go to step 3.
NO
3. Defective front wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions 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 4-26 and “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-66.
9-327
16_ABS
EAS20663
16_ABS
EAS33285
TROUBLESHOOTING
Item
Rear wheel sensor (open or short circuit)
Procedure
1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the ABS ECU coupler “1” and rear wheel sensor coupler “2”.
Between ABS ECU coupler “1” and rear wheel sen- white–white
sor coupler “2” black–black
1
2
B W
Is resistance 0 Ω?
YES
NO
TIP
white–ground
black–ground
9-328
16_ABS

A B
1 1
YES
→ Go to step 3.
NO
3. Defective rear wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions 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 4-33 and “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-66.
9-329
21_ABS
EAS20690
21_ABS
EAS33320
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective solenoid drive circuit)
Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-66.
9-330
31_ABS
EAS20691
31_ABS
EAS33321
TROUBLESHOOTING
Hydraulic unit assembly (defective ABS solenoid power circuit)
Procedure
1. Blown ABS solenoid fuse
• Check the ABS solenoid fuse.
Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
2. Defective coupler between the battery and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS solenoid fuse holder “1” and ABS ECU coupler “2”.
Between ABS solenoid fuse holder “1” and ABS
ECU coupler “2”
1 2
Is resistance 0 Ω?
YES
NO
9-331
31_ABS
TIP
Between ABS ECU coupler “2” and ground blue/white–ground

ABS ECU coupler “2” blue/white–any other coupler terminal
A B
2 2
YES
→ Go to step 4.
NO
9-332
33_ABS
EAS20692
33_ABS
EAS33322
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal ABS motor power supply)
Procedure
1. Blown ABS motor fuse
• Check the ABS motor fuse.
Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS motor fuse holder “1” and ABS ECU coupler “2”.
Between ABS motor fuse holder “1” and ABS ECU
red–red
coupler “2”
1 2
Is resistance 0 Ω?
YES
NO
9-333
33_ABS
TIP
Between ABS ECU coupler “2” and ground red–ground

ABS ECU coupler “2” red–any other coupler terminal
A B
2 2
YES
→ Go to step 4.
NO
9-334
34_ABS
EAS20693
34_ABS
EAS33323
TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS motor power supply circuit)
Procedure
9-335
41_ABS
EAS20694
41_ABS
EAS33331
TROUBLESHOOTING
Item
Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization)
Procedure
1. Incorrect installation of the front wheel sensor
4-30.
Is check result OK?

YES
→ Go to step 2.
NO
→ Repair or replace the defective part.
2. Incorrect rotation of the front wheel
• Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” on page 4-28 and “CHECKING THE FRONT BRAKE
Is check result OK?

YES
→ Go to step 3.
NO
3. Front brake dragging
• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever
is operated and that the pressure decreases when the lever is released.
Refer to “CHECKING THE FRONT BRAKE DISCS” on page 4-47.
Is check result OK?

YES
→ Go to step 4.
NO
9-336
42_ABS
EAS20695
42_ABS
EAS33324
TROUBLESHOOTING
Item
Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization)
Procedure
1. Incorrect installation of the rear wheel sensor
4-37.
Is check result OK?

YES
→ Go to step 2.
NO
2. 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 4-36 and “CHECKING THE REAR BRAKE
DISC” on page 4-60.
Is check result OK?

YES
→ Go to step 3.
NO
3. 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 4-60.
Is check result OK?

YES
→ Go to step 4.
NO
9-337
43, 45_ABS
EAS20696
43, 45_ABS
EAS33330
TROUBLESHOOTING
Item
Front wheel sensor (missing pulses)
Procedure
TIP
After the DTC 45 is recorded, DTC 43 will be recorded if a certain speed and time are exceeded.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
4-30.
Is check result OK?

YES
→ Go to step 4.
NO
4-30.
Is check result OK?

YES
NO
9-338
44, 46_ABS
EAS20697
44, 46_ABS
EAS33325
TROUBLESHOOTING
Item
Rear wheel sensor (missing pulses)
Procedure
TIP
After the DTC 46 is recorded, DTC 44 will be recorded if a certain speed and time are exceeded.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
4-37.
Is check result OK?

YES
→ Go to step 4.
NO
4-37.
Is check result OK?

YES
NO
9-339
51_ABS
EAS20698
51_ABS
EAS33326
TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is high)
Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
2. Disconnected battery terminal
• Check the connection.
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace or reconnect the terminal.
3. Defective charging system
Is check result OK?

YES
NO
→ Confirm the cause of the problem and repair it, and check again.
9-340
53_ABS
EAS20699
53_ABS
EAS33327
TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is low)
Procedure
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS ECU fuse holder “1” and ABS ECU coupler “2”.
Between ABS ECU fuse holder “1” and ABS ECU
coupler “2”
2
Is resistance 0 Ω?
YES
NO
TIP
Between ABS ECU coupler “2” and ground red/black–ground
9-341
53_ABS

ABS ECU coupler “2” red/black–any other coupler terminal
A B
2 2
YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
9-342
55_ABS
EAS20700
55_ABS
EAS33328
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS ECU)
Procedure
9-343
56_ABS
EAS20701
56_ABS
EAS33329
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal internal circuit)
Procedure
9-344
57_ABS
EAS20666
57_ABS
EAS33292
TROUBLESHOOTING
Item
Vehicle CAN communication line or power source of vehicle system
Procedure
• Disconnect the ECU coupler “1” and ABS ECU coupler “2”.
Between ECU coupler “1” and ABS ECU coupler “2”
2
1
Is resistance 0 Ω?
YES
NO
TIP
ECU” on page 9-3.
blue/white–ground
blue/black–ground

ECU coupler “1”
9-345
57_ABS
A B
2 1
L/W W/G G Y L R/B Br L/W B/W L/B Y/L O/W Lg/L P/W P V L L Gy
R G/O W/Y L B W Y L/B B L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
2
YES
→ Go to step 2.
NO
TIP
Is check result OK?

YES
→ Go to step 4.
NO
• Disconnect the ABS ECU fuse “1”, ABS solenoid fuse “2” and ABS ECU coupler “3”.
Between ABS ECU fuse holder “1” and ABS ECU
coupler “3”
Between ABS solenoid fuse holder “2” and ABS
ECU coupler “3”
9-346
57_ABS
2 3
Is resistance 0 Ω?
YES
NO
TIP
red/black–ground
blue/white–ground

red/black–any other coupler terminal
A B
3 3
YES
→ Go to step 5.
NO
YES
NO
9-347
57_ABS
9-348
62_ABS
EAS20702
62_ABS
EAS33333
TROUBLESHOOTING
Item
Power supply voltage failure in pressure sensor
Procedure
9-349
68_ABS
EAS20705
68_ABS
EAS33336
TROUBLESHOOTING
Item
Defective hydraulic unit assembly (defective front pressure sensor)
Procedure
1. Defective front brake line
• Check the front brake line.
Is check result OK?

YES
→ Go to step 2.
NO
→ If there is bending or blocking, replace the front brake line.
9-350
89_ABS
EAS20669
89_ABS
EAS33299
TROUBLESHOOTING
Item
CAN communication (between meter assembly and hydraulic unit assembly)
Procedure
1. Defective coupler between the meter assembly, sub-wire harness (meter) and the hydraulic unit as-
sembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
→ Connect the coupler securely or replace the wire harness or sub-wire harness (meter).
• Disconnect the meter assembly coupler “1”, sub-wire harness (meter) coupler “3” and ABS ECU
coupler “2”.
ABS ECU coupler “2” blue/white–blue/white
1
R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/BSb/W 3
G/L W/Y W/L Br B G/O Br/WBr/B G Br/R B/R Br/Y B/G
G/Y G/B W/R L/B L/W
B Br/YW/G W W/B
2 L/W L/B W/R G/B G/Y

W/B W W/G Br/Y B
Is resistance 0 Ω?
YES
NO
9-351
89_ABS
TIP
blue/white–ground
blue/black–ground
blue/white–ground
blue/black–ground

A B
1 2
1
R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W
G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G G/L W/Y W/L Br B G/O Br/W Br/B G Br/R B/R Br/Y B/G R G/O W/Y L B W Y L/B B

YES
→ Go to step 3.
NO
→ Replace the wire harness or sub-wire harness (meter).
3. Defective meter assembly
• Replace the meter assembly, and check again.
9-352
90_ABS
EAS20670
90_ABS
EAS33300
TROUBLESHOOTING
Item
CAN communication (between ECU and hydraulic unit assembly)
Procedure
1. Defective coupler between the ECU and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the ECU coupler “1” and ABS ECU coupler “2”.
Between ECU coupler “1” and ABS ECU coupler “2”
2
R G/O W/Y L B W Y L/B B 1
Is resistance 0 Ω?
YES
NO
TIP
ECU” on page 9-3.
blue/white–ground
blue/black–ground
9-353
90_ABS

ECU coupler “1”
A B
2 1
L/W W/G G Y L R/B Br L/W B/W L/B Y/L O/W Lg/L P/W P V L L Gy
R G/O W/Y L B W Y L/B B L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
2
YES
→ Go to step 3.
NO
3. Defective ECU
• Replace the ECU, and check again.
9-354
91_ABS
EAS20671
91_ABS
EAS33301
TROUBLESHOOTING
Item
CAN communication (between IMU and hydraulic unit assembly)
Procedure
1. Defective coupler between the IMU and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the IMU coupler “1” and ABS ECU coupler “2”.
Between IMU coupler “1” and ABS ECU coupler “2”
1 2
B/W L/W L/B R/L
Is resistance 0 Ω?
YES
NO
TIP
blue/white–ground
Between IMU coupler “1” and ground
blue/black–ground
9-355
91_ABS

IMU coupler “1”
A B
1 1
B/W L/W L/B R/L B/W L/W L/B R/L

YES
→ Go to step 3.
NO
3. Defective IMU
• Replace the IMU, and check again.
9-356
EAS20091
56. Ignition coil #1 111.License plate light
WIRING DIAGRAM 57. Ignition coil #2 112.Brake light relay
MTT890 2021 58. Ignition coil #3 113.Radiator fan motor
1. AC magneto 59. Spark plug A. Wire harness
2. Rectifier/regulator 60. Injector #1 B. Sub-wire harness (meter)
3. Main switch 61. Injector #2 C. Sub-wire harness (oil pressure
4. Main fuse 62. Injector #3 switch)
5. Radiator fan motor relay 63. Grip warmer (left) (option) D. Sub-wire harness (headlight
6. Fuel injection system fuse 64. Grip warmer (right) (option) control unit)
7. Electronic throttle valve fuse 65. Throttle position sensor
8. Backup fuse 2 66. Throttle servo motor
9. Ignition fuse 2 67. ABS ECU
10. Signaling system fuse 68. Front wheel sensor
11. Auxiliary DC jack fuse “TERMI- 69. Rear wheel sensor
NAL 2” 70. Intake air temperature sensor
12. Ignition fuse 1 71. IMU (Inertial Measurement
13. Headlight fuse Unit)
14. ABS ECU fuse 72. Purge cut valve solenoid
15. Accessory fuse 73. Shift sensor (option)
16. Auxiliary DC jack 1 fuse “TER- 74. YDT coupler
MINAL 1” 75. Meter assembly
17. Brake light fuse 76. Immobilizer system indicator
18. Cruise control fuse light
19. ABS solenoid fuse 77. Neutral indicator light
20. ABS motor fuse 78. Oil pressure and coolant tem-
21. Backup fuse 1 perature warning light
22. Seat heater fuse 79. Auxiliary system warning light
23. Radiator fan motor fuse 80. Multi-function meter
24. Auxiliary DC jack 81. Stability control indicator light
25. Auxiliary DC jack 1 (option) 82. Fuel level warning light
26. Accessory (option) 83. Malfunction indicator light
27. Battery 84. Turn signal indicator light (left)
28. Frame ground 85. Turn signal indicator light (right)
29. Starter motor 86. Cruise control system indicator
30. Starter relay light
31. Seat heater relay 87. Cruise control setting indicator
32. Seat heater (option) light
33. Immobilizer unit 88. Meter light
34. Clutch switch 89. ABS warning light
35. Front brake light switch 90. High beam indicator light
36. Rear brake light switch 91. Auxiliary light
37. Handlebar switch (right) 92. Handlebar switch (left)
38. Menu switch 93. Cruise control power switch
39. Stop/run/start switch 94. Cruise control setting switch
40. Accelerator position sensor 95. Dimmer/pass switch
41. Relay unit 96. Horn switch
42. Starting circuit cut-off relay 97. Horn
43. Fuel pump relay 98. Mode switch
44. Neutral switch 99. Select switch
45. Sidestand switch 100.Hazard switch
46. Fuel sender 101.Turn signal switch
47. Fuel pump 102.Oil pressure switch
48. Joint coupler 103.Rear turn signal light (right)
49. Gear position sensor 104.Rear turn signal light (left)
50. Intake air pressure sensor 1 105.Front turn signal light (right)
51. Intake air pressure sensor 2 106.Front turn signal light (left)
52. O2 sensor 107.Headlight control unit
53. Crankshaft position sensor 108.Headlight (high beam)
54. Coolant temperature sensor 109.Headlight (low beam)
55. ECU (Engine Control Unit) 110.Tail/brake light
MTT890D 2021 58. Ignition coil #3 113.Radiator fan motor
1. AC magneto 59. Spark plug 114.Front fork solenoid (left)
2. Rectifier/regulator 60. Injector #1 115.Front fork solenoid (right)
3. Main switch 61. Injector #2 116.Rear shock absorber assem-
4. Main fuse 62. Injector #3 bly solenoid
5. Radiator fan motor relay 63. Grip warmer (left) 117.Angular position sensor
6. Fuel injection system fuse 64. Grip warmer (right) 118.SCU (Suspension Control
7. Electronic throttle valve fuse 65. Throttle position sensor Unit)
8. Backup fuse 2 66. Throttle servo motor 119.SCU fuse
9. Ignition fuse 2 67. ABS ECU 120.CLCU (cornering light control
10. Signaling system fuse 68. Front wheel sensor unit)
11. Auxiliary DC jack fuse “TERMI- 69. Rear wheel sensor A. Wire harness
NAL 2” 70. Intake air temperature sensor B. Sub-wire harness (meter)
12. Ignition fuse 1 71. IMU (Inertial Measurement C. Sub-wire harness (oil pressure
13. Headlight fuse Unit) switch)
14. ABS ECU fuse 72. Purge cut valve solenoid D. Sub-wire harness (headlight
15. Accessory fuse 73. Shift sensor control unit)
16. Auxiliary DC jack 1 fuse “TER- 74. YDT coupler E. Sub-wire harness (neutral
MINAL 1” 75. Meter assembly switch)
17. Brake light fuse 76. Immobilizer system indicator F. Sub-wire harness (front fork so-
18. Cruise control fuse light lenoid (left))
19. ABS solenoid fuse 77. Neutral indicator light G. Sub-wire harness (front fork so-
20. ABS motor fuse 78. Oil pressure and coolant tem- lenoid (right))
21. Backup fuse 1 perature warning light
22. Seat heater fuse 79. Auxiliary system warning light
23. Radiator fan motor fuse 80. Multi-function meter
24. Auxiliary DC jack 81. Stability control indicator light
25. Auxiliary DC jack 1 (option) 82. Fuel level warning light
26. Accessory (option) 83. Malfunction indicator light
27. Battery 84. Turn signal indicator light (left)
28. Frame ground 85. Turn signal indicator light (right)
29. Starter motor 86. Cruise control system indicator
30. Starter relay light
31. Seat heater relay 87. Cruise control setting indicator
32. Seat heater (option) light
33. Immobilizer unit 88. Meter light
34. Clutch switch 89. ABS warning light
35. Front brake light switch 90. High beam indicator light
36. Rear brake light switch 91. Auxiliary light
37. Handlebar switch (right) 92. Handlebar switch (left)
38. Menu switch 93. Cruise control power switch
39. Stop/run/start switch 94. Cruise control setting switch
40. Accelerator position sensor 95. Dimmer/pass switch
41. Relay unit 96. Horn switch
42. Starting circuit cut-off relay 97. Horn
43. Fuel pump relay 98. Mode switch
44. Neutral switch 99. Select switch
45. Sidestand switch 100.Hazard switch
46. Fuel sender 101.Turn signal switch
47. Fuel pump 102.Oil pressure switch
48. Joint coupler 103.Rear turn signal light (right)
49. Gear position sensor 104.Rear turn signal light (left)
50. Intake air pressure sensor 1 105.Front turn signal light (right)
51. Intake air pressure sensor 2 106.Front turn signal light (left)
52. O2 sensor 107.Headlight control unit
53. Crankshaft position sensor 108.Headlight (high beam)
54. Coolant temperature sensor 109.Headlight (low beam)
55. ECU (Engine Control Unit) 110.Tail/brake light
56. Ignition coil #1 111.License plate light
57. Ignition coil #2 112.Brake light relay
EAS30613
COLOR CODE Y/R Yellow/Red

Y/W Yellow/White
B Black
Br Brown
Ch Chocolate
Dgy Dark gray
G Green
Gy Gray
L Blue
Lg Light green
O Orange
P Pink
R Red
Sb Sky blue
V Violet
W White
Y Yellow
B/G Black/Green
B/L Black/Blue
B/R Black/Red
B/W Black/White
B/Y Black/Yellow
Br/B Brown/Black
Br/L Brown/Blue
Br/R Brown/Red
Br/W Brown/White
Br/Y Brown/Yellow
G/B Green/Black
G/L Green/Blue
G/O Green/Orange
G/R Green/Red
G/W Green/White
G/Y Green/Yellow
Gy/G Gray/Green
Gy/L Gray/Blue
Gy/R Gray/Red
L/B Blue/Black
L/R Blue/Red
L/W Blue/White
L/Y Blue/Yellow
Lg/B Light green/Black
Lg/L Light green/Blue
Lg/R Light green/Red
O/G Orange/Green
O/W Orange/White
P/B Pink/Black
P/L Pink/Blue
P/R Pink/Red
P/W Pink/White
R/B Red/Black
R/G Red/Green
R/L Red/Blue
R/W Red/White
R/Y Red/Yellow
Sb/W Sky blue/White
W/B White/Black
W/G White/Green
W/L White/Blue
W/R White/Red
W/Y White/Yellow
Y/B Yellow/Black
Y/L Yellow/Blue
Y/G Yellow/Green
MTT890 2021 MTT890 2021 MTT890 2021 MTT890 2021 MTT890 2021
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
1 W W W W W W 33 R/G B B R/G
A
R/W Lg Y/L Y/L Lg R R R/L R/L R/L R/L R/L R/W R R/W R/W R/W
R/W
WWW R/G R/G R/L B W/Y W/Y B R/W R/G R/G
Lg R/G R B Y/L W/L Br/L Br/R G B B B B G Br/R Br W/L
R/W L/W
W W
B W R
2 B R (B) (B)
(B)
30 A B
(Dgy)
R 4
R R
R/W
Y/L R/W
O
56
R/W O R/W
R L/W L/W L/B W/R G/B G/Y G/Y G/B W/R L/B L/W
R R
R/L
L/W
59 (B) W/B W W/G Br/Y B B Br/YW/G W W/B
R RR B
(B) (B)
Y/R P/B O/G Gy/R O W/R G L Br/Y R/W O
R/W
57
3 R W Br/R Br/R
27 29 R R/W Y Br/Y 41 W WR Sb/W Br
Lg/R L/B G/B R/B B Y W Y/R Gy/R Gy/R Gy/R R/W A B
OFF
ON R,W R
59 (B)
B Y Br/Y
Br/L Br/L
31 32 B/G B Br W R L/W R 42 43 (B) (B)
Br/L B B B R W L/W R L/B L Sb B Sb/W L

L
L
R/W
O/G
58 Sb/W Lg B/W G/O G/L
Y G/W B/R B/G Br/Y
G/L G/OB/W Lg Sb/W
Br/Y B/G B/R G/W Y
Y Y B/R B B/G O/G R/W
LL
Br/R
28 R/W B/R R
L/W
B Sb L
L/B
R L/W L/W 59 (B)
R/L
BBB L/Y R/B R/L A B
B/Y
R/G
(Gy) 60 B
R/B R/B R/L

L/W R B/L B/L
R W/G W W/B R/W R/W L/W L/B L G/W B/L 49 G/W G/W G/B G/B R/L
R/W
R Y/B B/Y G/W Y/W G/Y Y/B
37 Sb
R/L B G/W B (B)
L L
61 G/L G/L
L/W 5 R
R/W 38 R R/L
39 W/R Y/G Br W/R
L/B G/W R/L
(B)
W/R
W/B
G/B R/L
L/W
R/W
R
R/W 34 35 Y/B G/W G/W Y/B 36 Br G
G Br G/Y Y/B B/W W/G W/B OFF
40 W/B Y/R Y/R W/B 45 B Y/R
Y/B (Gy)
A C
L/W
R G/Y
G/Y
R/W
R OFF
ON
B/Y Y/B
L/Y L/W
Y/B B/Y
Y/W L/Y
OFF
ON
Y/W G/Y G/Y Y/W OFF Y B Lg/B Lg/L R B R/W
RUN
START L/W R/L Y/G W/G
W/G Y/B Y/B Y
L/B B B B
46 47 Y
Br
L/B L/B R/L
C
L/W (B)
(B)
(B)
ON
B Y
(B) (B)
(B)
(B) (B) L L/Y B W L/W 62
(B)
B/W B Br W/B W/R 44 (B)
B B
L/Y L/Y L L/Y B/Y B/Y B/Y B B/Y W L/W L/W W W L/W
50
L L/B R/L
R/Y Y/B
Br Y/W L/Y
G/Y Y/B
Lg/B Lg/L W/B W/G B/W R/W L/W Y/B Y/R Y B 48 48 48 B/L P/W L B/L
P/W P/W (Gy)
Y/B R/Y
B B B B
6 7 R/W B W (Dl)
R/Y Y Y R/Y
R R/L
R/G 48 L/B L/B L/B L/W L/WL/W
L
8 9
B/L P L 51 B/L
P P L/B Y/L O/W Lg/L P/W P V L L Gy
R
R/L YY Y
Y Y Y 48 L/B L/B
48 L/W
L/W L/WL/W L/W B B B L/B L/B L/B L/B
B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R (Dl) L/W B/Y Br/L G/L Gy/G Br/W B/L B/L
A D
R/W L/B L/W L/W R B B P/B P/B
R RRR L/R L/Y L/W Lg/B G/W G/W W/G W/Y
R B/L W L Gy/G Gy/G
Br/R L/R
R
R 10 11 L/R
L/R
L/R (B)
Br/Y L/R
R P/B B B
52
R/L
R
R/L R/L
B 48 Gy/G B/L W L
Br/L 12 13 B
(B)
(B)
55 Br/Y
Br/Y Br B
Br/L Br/L R/Y

B
B Gy Gy
Br/Y Br/Y Br/Y 63 B Br Br/Y B
Br/L R/Y
R/B
B/L B/L B/L B/L
B/L B/L B/L B/L
L/B L/B
L/B L/B
L/W L/W
L/W L/W
Gy B 53 Gy B/L B/L
Br/Y
(B) (B)
14 B L/R
Gy B/L
G/W
B/L
G/W
Br/Y W L B B
B
B
Br/L
91 B/R
L/R (B) 54
Br/Y
L/R G/W B/L 64 L W Br/Y B
15 16 L/R
(Gy) (Gy)
Br/Y (B)
B B/R L/R B W B/L L B
(B) Sb/W Lg
Y/B Y/B Y/B (B)
B Br/Y A A
L L
Br/Y Sb/W Lg B/L
B B
A Y/B B/L Br/W Br/W W W 65
Br/Y B L/R G/W Y/W Y/B L/R L/R
Y/B
Y/B 48 B/L B/L
Br/Y L/R
17 18 Sb/W Lg 70 B
24 Br/Y
B
Br/Y
B A B
Y/B
92 SET
95 L
75 Br/W B/L 48
R/W Y/W
94 FREE Lg/R Lg/R
R L/W
93 RES HI
96 ON
98 FREE
99 UP
100 OFF L/R (B) Y/R Y/R 66 B B B B
19 20 L/R
L/R
Lg/B
Lg/B
W/R G/B Y/W O/W G/L Br/L LO
PASS
OFF PUSH (N)
DOWN
ON
101 R
N R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W
76 R/L B/W
Y/B
B
B Br/Y 25 Br/Y
B
R
R/G
W/G B W/Y W/L L Y Y/B PUSH
FREE L/R B
B
B/W
W/G
Br/L L
78 G/Y
Y/R Lg/R
(Gy) R R/G
112
(Gy) (L) (B)
(Gy) 77 71 (B)
21 O/W Br/L Y B G/Y B G/B W/R Br/L W/L W/Y
Br/L G/L O/W Y/W G/B W/R G/L B L/R 97 Br/L R/L A R/W
L/W L/B
G/L
R Y Y
B
L/R Y/B Y L/R W/L W/Y B G/Y
(L) (B) W/B A W/B 79 B/W L/W L/B R/L O/W L/W W/G G Y L R/B Br L/W B/W
22 23 Lg/B Y B
(Gy)
W A
W/G A
W
W/G (B)
Br/L
Lg/L
Lg/B
R L/W
Br/Y
B A B 72 (B)
B Br/Y 26 B R/G G/W A G/W 80
R/W Y/R Y/R
G G R
(Gy) R/G R/G R/G A R/G
R/G R/G A R/G L L/W
R/W Y/R
L/W A L/W R/B
B G/L A G/L L/B A L/B
(B)
B
B
B
W/R
G/B
A
A
W/R
G/B
W/G
W/Y
W/G
W/Y
Y
Br
Y
Br
W
B 68
B
B
G/Y A G/Y
81 B/L V L R W B B B/L
L/W
L/B
67
W
B
B
B
W/Y
W/L
A
A
W/Y
W/L 73 W
R
V
L
V W B
B
B/W
L/W
L/R Y
B R/Y Y/B Y B R/Y
Br/L A Br 82 (B) (B)
L/W
L G/L
Br Y
113 B B B B B B/W L
C C C C C C
B R/Y Y/B Y B R/Y G/L 83 B/W A B/W B/W B/W B B
L/B
G/O
B B B B B B/W 110 Br/B Y
L
L/W L
48
L/R Br/B Br/W
Br/W
Br/R A Br/R 84 85 L/W L/W B
W
B 69
G/R 107 Br/R G
G A G L/B
R/G 74 R/G L/B
B/W
B
BB
111 Ch
106 Ch
105 G/L
90
B
B B/W
W B
B Ch
104 Ch
103 B 86 87 (R)
B
B
B
L/R B B G/R
L Y Y L/R 108 109 B Ch B Ch G/L Y A Y
B W
B B B
B (Gy) B Ch Br/R B B Ch G B
B
B
B
B
R/Y B Y/B Y B R/Y B
A
Br/B B
B
A
Br/W B
(B) 102
B/R A
B/G A
B/R
B/G
88
(B) Br/Y A Br/Y G/O A G/O B
B (B) B B B B/W
B/W
89 B
B
B
B B/W
B B
MTT890 2021 MTT890 2021 MTT890 2021 MTT890 2021 MTT890 2021
1 33 A
2 (B) (B)
(B)
30 A B
(Dgy)
4
56
59 (B)
(B) (B)
57
3 27 29 41 A B
OFF
ON
59 (B)
31 32 42 43 (B) (B)
58
28 59 (B)
A B
(Gy) 60 B
49
37 (B) 61
5 38 39 (B)
34 35 36 OFF
40 45 (Gy)
A C
OFF
ON
OFF
ON
OFF
RUN
START 46 47 C
(B)
(B)
(B)
ON
(B) (B)
(B)
(B) (B) 62
(B)
44 (B)
50
48 48 48 (Gy)
6 7 (Dl)
48
8 9 51
48 48 (Dl) A D
10 11 (B)
52
48
12 13
(B)
(B)
55
63
53 (B) (B)
14
91 (B) 54 64
15 16 (Gy) (Gy)
(B)
(B)
(B)
A A
A 65
48
17 18 70
24 A 92 SET
95 75 48
94 FREE
93 RES HI
96 ON
98 FREE
99 UP
100 OFF (B) 66
19 20 LO
PASS
OFF PUSH (N)
DOWN
ON
101 R
N 76
25 PUSH
FREE L 78
(Gy)
112
(Gy) (L) (B)
(Gy) 77 71 (B)
21
97 A
(L) (B) A 79
22 23 (Gy)
A
A (B)
A 72 (B)
26 A 80
(Gy) A
A
A
A A
(B)
A
A 68
A
81 67
A
A 73
A 82 (B) (B)
113 C C C C C C
83 A
110
48 A 84 85 69
107 A
74
111 106 105 90
104 103 B 86 87 (R)
108 109 A
(Gy)
A A (B) 102
A
A
88
(B) A A
(B)
89
MTT890D 2021 MTT890D 2021 MTT890D 2021 MTT890D 2021 MTT890D 2021
A
1 W W W W W W 33 R/G B B R/G
R/W Lg Y/L Y/L Lg R R R/L R/L R/L R/L R/L R/W R R/W R/W R/W
R/W
WWW R/G R/G R/L B W/Y W/Y B R/W R/G R/G
Lg R/G R B Y/L W/L Br/L Br/R G B B B B G Br/R Br W/L
R/W L/W
W W
B W R
2 B R (B) (B)
(B)
30 A B
(Dgy)
R 4
R R
R/W
Y/L R/W
O
56
R/W O R/W
R L/W L/W L/B W/R G/B G/Y G/Y G/B W/R L/B L/W
R R
R/L
L/W
59 (B) W/B W W/G Br/Y B B Br/YW/G W W/B
R RR B
(B) (B)
Y/R P/B O/G Gy/R O W/R G L Br/Y R/W O
R/W
57
3 R W Br/R Br/R
27 29 R R/W Y Br/Y 41 W WR Sb/W Br
Lg/R L/B G/B R/B B Y W Y/R Gy/R Gy/R Gy/R R/W A B
OFF
ON R,W R
59 (B)
B Y Br/Y
Br/L Br/L
31 32 B/G B Br W R L/W R 42 43 (B) (B)
Br/L B B B R W L/W R L/B L Sb B Sb/W L
L
L
R/W
O/G
58 Y G/W B/R B/G Br/Y Br/Y B/G B/R G/W Y
Y Y B/R B B/G O/G R/W
LL
Br/R
28 R/W B/R R
L/W
B Sb L
L/B
R L/W L/W 59 (B)
D R/L
BBB Sb L/Y R/B R/L
A B
B/Y B
R/G
(Gy) 60
R/B R/B R/L
L/W R B/L B/L
R W/G W W/B R/W R/W L/W L/B L G/W B/L 49 G/W G/W G/B G/B R/L
R/W
R Y/B B/Y G/W Y/W G/Y Y/B
37 Sb
R/L B G/W B (B)
L L
61 G/L G/L
L/W 5 R
R/W 38 R R/L
39 W/R Y/G Br W/R
L/B G/W R/L
(B)
W/R
W/B
G/B R/L
L/W
R/W
R
R/W 34 35 Y/B G/W G/W Y/B 36 Br G
G Br G/Y Y/B B/W W/G W/B OFF
40 W/B Y/R Y/R W/B 45 B Y/R
Y/B (Gy)
A C
L/W
R G/Y
G/Y
R/W
R OFF
ON
B/Y Y/B
L/Y L/W
Y/B B/Y
Y/W L/Y
OFF
ON
Y/W G/Y G/Y Y/W OFF Y B Lg/B Lg/L R B R/W
RUN
START L/W R/L Y/G W/G
W/G Y/B Y/B Y
L/B B B B
46 47 Y
Br
L/B L/B R/L
C
L/W (B)
(B)
(B)
ON
B Y
(B) (B)
(B)
(B) (B) L L/Y B W L/W 62
(B)
B/W B Br W/B W/R 44 (B)
B B
L/Y L/Y L L/Y B/Y B/Y B/Y B B/Y W L/W L/W W W L/W
50
L L/B R/L
Y/B R/Y R/Y Y/B
Br Y/W L/Y
G/Y Y/B
Lg/B Lg/L W/B W/G B/W R/W L/W Y/B Y/R Y B 48 48 48 B/L P/W L B/L
P/W P/W (Gy) B B B B
6 7 R/W B W (Dl)
R/Y Y Y R/Y
R R/L
R/G 48 L/B L/B L/B L/B L/B L/W L/W L/W L/WL/W
L
8 9
B/L P L 51 B/L
P P
R
R/L YY Y
Y Y Y 48 L/B L/B L/B
48 L/W L/W
L/W L/WL/W L/W B B B L/B L/B L/B L/B
B/L B/L B/L B/L B/L B/L B/L B/L L/R L/R L/R L/R (Dl)
L/B
L/W
Y/L
B/Y
O/W Lg/L P/W P
Br/L G/L Gy/G Br/W
V L L
B/L B/L
Gy
A D
R/W L/B L/B L/W L/W L/W R B B P/B P/B D
R RRR L/R L/Y L/W Lg/B G/W G/W W/G W/Y
R B/L W L Gy/G Gy/G
Br/R L/R
R
R 10 11 L/R
L/R
L/R (B)
Br/Y L/R
R P/B B B
52 Sb Sb
R/L
R
R/L R/L R/L R/L
R/L B 48 Gy/G B/L W L
Br/L 12 13 B
(B)
(B)
55 Br/Y
Br/Y Br B
Br/L Br/L R/Y

B
B Gy Gy
Br/Y Br/Y Br/Y 63 B Br Br/Y B
Br/L R/Y
R/B
R/Y L/R B/L B/L B/L B/L
B/L B/L B/L B/L
L/B L/B
L/B L/B
L/W L/W
L/W L/W
Gy B 53 Gy B/L B/L
Br/Y
(B) (B)
A E
R/Y E
14 L/R B L/WL/B B L/R
Gy B/L
G/W
B/L
G/W
Br/Y W L B B
B
B
Br/L
R Br W B/R
Br/Y 120 91 L/R
L/R (B) 54 G/W B/L 64 L W Br/Y B
Gy/R Gy/L Gy/L Gy/R
15 16 B L/R R B
L/R
(Gy) (Gy)
(B) (B)
Br/Y (B)
L/W L/B W Br B B/R L/R B W B/L L B
B Br/Y
(B) (B)
Y/B Y/B Y/B
Sb/W Lg
A A
(B) A F
L L F
Br/Y Sb/W Lg B/L
B B
A Y/B B/L Br/W Br/W W W 65
Br/Y B L/R G/W Y/W Y/B L/R L/R
Y/B
Y/B 48 B/L B/L
Br/Y L/R
17 18 Sb/W Lg 70 B
24 Br/Y
B
Br/Y
B A B
Y/B
92 SET
95 L
75 Br/W B/L 48 G/L G/R G/R G/L
R/W Y/W
94 FREE Lg/R Lg/R
R L/W
93 RES HI
96 ON
98 FREE
99 UP
100 OFF L/R (B) Y/R Y/R 66 B B B B
19 20 L/R
L/R
Lg/B
Lg/B
W/R G/B Y/W O/W G/L Br/L LO
PASS
OFF PUSH (N)
DOWN
ON
101 R
N R/G R/G R/W B/W Lg L/W L/B G/W Y G/Y W/R G/B W W/G W/B Sb/W
76 R/L B/W
Y/B
B
A G
B Br/Y 25 Br/Y
B
R
R/G
W/G B W/Y W/L L Y Y/B PUSH
FREE L/R B
B
B/W
W/G
Br/L L
78 G/Y
Y/R Lg/R
(Gy) R R/G
112
(Gy) (L) (B)
(Gy) 77 71 (B)
21 119 O/W Br/L Y B G/Y B G/B W/R Br/L W/L W/Y
R/B Br/L G/L O/W Y/W G/B W/R G/L B L/R 97 Br/L R/L A R/W
L/W L/B
G/L
R Y Y
B
L/R Y/B Y L/R W/L W/Y B G/Y
(L) (B) W/B A W/B 79 B/W L/W L/B R/L O/W L/W W/G G Y L R/B Br L/W B/W
22 23 Lg/B Y B
(Gy)
W A
W/G A
W
W/G (B)
Br/L
Lg/L
Lg/B
R L/W
Br/Y
B A B 72 (B)
B Br/Y 26 B R/G G/W A G/W 80
R/W Y/R Y/R
G G R
(Gy) R/G R/G R/G A R/G
R/G R/G A R/G L L/W
R/W Y/R
L/W A L/W R/B
B G/L A G/L L/B A L/B
(B)
B
B
B
W/R
G/B
A
A
W/R
G/B
W/G
W/Y
W/G
W/Y
Y
Br
Y
Br
W
B 68
B
B
G/Y A G/Y
81 B/L V L R W B B B/L
L/W
L/B
67
W
B
B
B
W/Y
W/L
A
A
W/Y
W/L 73 W
R
V
L
V W B
B
B/W
L/W
L/R Y
B R/Y Y/B Y B R/Y
Br/L A Br 82 (B) (B)
G/L L/W
L Br Y
R/L
B
113 B B B B B B B/W L
C C C C C C
B R/Y Y/B Y B R/Y G/L 83 B/W A B/W B/W B/W B B
L/B
G/O
R/B B B B B B B/W 110 Br/B Y
L
Gy/R E Gy/R W
L/W L
48
L/R Br/B Br/W
Br/W
Br/R A Br/R 84 85 L/W L/W B
W
B 69
Gy/L E Gy/L B 114 B W Gy/R Gy/L
G/R 107 Br/R G
G A G L/B
R/G 74 R/G L/B
(B)
B/W
B
BBB
111 Ch
106 Ch
105 G/L
90
B
B B/W
W B
B Ch
104 Ch
103 B 86 87 (R)
G/R
G/L
F
F
G/R
G/L
W
B 115 B W G/R G/L B
B
B
B
L/R B B G/R
L Y Y L/R 108 109 B Ch B Ch G/L Y A Y
B W
(B) B B B
B (Gy) B Ch Br/R B B Ch G B
118
B
B
B
B
R/Y B Y/B Y B R/Y B
A
Br/B B
B
A
Br/W B
(B) 102
B/R A
B/G A
B/R
B/G
88
P/R P/R W (B) Br/Y A Br/Y G/O A G/O B
P/L P/L B 116 W B P/L P/R B (B) B B B
89 B/W
B/W
B
B
(Gy) B
B B/W
B B
W/R W/R P
W/G
W/B
W/G
W/B
W
B
117 P W B W/B W/G W/R
(B)
L/W
L/B
G/R B R/B R/L Gy/L

G/L W/G W/R Gy/R
W/B L/W P/L
L/B P/R
(B)
MTT890D 2021 MTT890D 2021 MTT890D 2021 MTT890D 2021 MTT890D 2021
A
1 33
2 (B) (B)
(B)
30 A B
(Dgy)
4
56
59 (B)
(B) (B)
57
3 27 29 41 A B
OFF
ON
59 (B)
31 32 42 43 (B) (B)
58
28 59 (B)
D
A B
B
(Gy) 60
49
37 (B) 61
5 38 39 (B)
34 35 36 OFF
40 45 (Gy)
A C
OFF
ON
OFF
ON
OFF
RUN
START 46 47 C
(B)
(B)
(B)
ON
(B) (B)
(B)
(B) (B) 62
(B)
44 (B)
50
48 48 48 (Gy)
6 7 (Dl)
48
8 9 51
48 48 (Dl) A D
D
10 11 (B)
52
48
12 13
(B)
(B)
55
63
53 (B) (B)
A E
E
14
120 91 (B) 54 64
15 16 (Gy) (Gy)
(B) (B)
(B)
(B) (B)
A A
(B) A F
F
A 65
48
17 18 70
24 A 92 SET
95 75 48
94 FREE
93 RES HI
96 ON
98 FREE
99 UP
100 OFF (B) 66
19 20 LO
PASS
OFF PUSH (N)
DOWN
ON
101 R
N 76 A G
25 PUSH
FREE L 78
(Gy)
112
(Gy) (L) (B)
(Gy) 77 71 (B)
21 119
97 A
(L) (B) A 79
22 23 (Gy)
A
A (B)
A 72 (B)
26 A 80
(Gy) A
A
A
A A
(B)
A
A 68
A
81 67
A
A 73
A 82 (B) (B)
113 C C C C C C
83 A
110
E 48 A 84 85 69
E 114 107 A
74
(B) 111 106 105 90
104 103 B 86 87 (R)
F
F 115 108 109 A
(B) (Gy)
118 A A (B) 102

A
A
88
(B) A A
116 (B)
89
(Gy)
117
(B)
(B)

Tracer 9gt - Taller

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Tracer 9gt - Taller

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2021

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could result

A NOTICE indicates special precautions that must be taken to avoid damage to

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

BASIC SERVICE INFORMATION.................................................................1-12

SPECIAL TOOLS .......................................................................................... 1-13

VEHICLE IDENTIFICATION NUMBER

1. Vehicle information displays 1. Vehicle information displays

TIP The six vehicle information displays can be indi-

1. Vehicle information displays

Odometer: Average fuel economy:

When the fuel tank reserve level has been

TRIP1 and TRIP2 show the distance traveled

• “--” will be displayed if the detected tempera- TIP

The coolant temperature is displayed from 40 °C

Displays the selected speed setting for the

Displays how much fuel has been consumed

MODE display (for MTT890D) MODE display (for MTT890)

This display shows the currently selected “D-

NOTICE To unpause the timer, push the dimmer/pass

• The headlight will flash when the dimmer/pass ECA26410

switch is pressed. NOTICE

a SCU error (for MTT890D).

Manual TCS Setting

LIF 1 The vehicle setting module allows you to adjust

This module allows you to customize the “TCS-

BC Setting Shift Indicator

The quick shift system indicators are divided into

pendently turned on or off. INTERVAL 1 1000 km

QS can be set to ON or OFF. INTERVAL 2 1000 km

“Unit” After confirming the minutes, you will be re-

This module allows you to switch the display be- km/h

This module allows you to set the clock.

BASIC SERVICE INFORMATION

Electrical parts handling

Yamaha diagnostic tool (A/I) 3-4, 3-11, 3-33,

Thickness gauge 3-6, 4-32, 4-39,

Valve lapper (ø14) 90890-04101

Vacuum gauge 3-9

Steering nut wrench 3-20, 4-114

Oil filter wrench 3-26

Oil pressure gauge joint 18 mm 3-27

Oil pressure gauge set 3-27

Fork spring compressor 4-90, 4-95

Rod holder 4-90, 4-95

Damper rod holder (ø27) 4-91, 4-92,

Fork seal driver 4-93, 4-93, 4-93,

Rod puller attachment (M10 long) 4-94, 4-95

Front fork hexagonal cap bolt wrench 42mm 4-102, 4-102,

Fork spring compression tool 29mm 4-102, 4-109

Damper rod holder 18.5mm 4-102, 4-109,