2015

SERVICE MANUAL

GPD150-A

2DP-F8197-E0
EAS20002

GPD150-A
SERVICE MANUAL
©2015 by PT Yamaha Indonesia Motor
Manufacturing
First edition, July 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
PT Yamaha Indonesia Motor Manufacturing
is expressly prohibited.
EAS20003

IMPORTANT
This manual was produced by the PT Yamaha Indonesia Motor Manufacturing primarily for use by
Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a me-
chanic in one manual. 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. Repair and maintenance work attempted by anyone without this knowledge is likely
to render the vehicle unsafe and unfit for use.
PT Yamaha Indonesia Motor Manufacturing is continually striving to improve all of its models. Modifi-
cations and significant 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
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.

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.

3
2

4
5
7
6
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

Silicone fluid
S
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
TROUBLESHOOTING 9
GENERAL INFORMATION

IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1

FEATURES...................................................................................................... 1-2
1
OUTLINE OF THE FI SYSTEM ................................................................. 1-2
FI SYSTEM................................................................................................ 1-3
OUTLINE OF THE ABS............................................................................. 1-4
ABS COMPONENT FUNCTIONS ............................................................. 1-8
ABS OPERATION ...................................................................................1-13
ABS WARNING LIGHT AND OPERATION............................................. 1-16
INSTRUMENT FUNCTIONS ...................................................................1-18

IMPORTANT INFORMATION .......................................................................1-22

PREPARATION FOR REMOVAL AND DISASSEMBLY.........................1-22
REPLACEMENT PARTS.........................................................................1-22
GASKETS, OIL SEALS AND O-RINGS ..................................................1-22
LOCK WASHERS/PLATES AND COTTER PINS ...................................1-22
BEARINGS AND OIL SEALS ..................................................................1-23
CIRCLIPS ................................................................................................ 1-23
RUBBER PARTS..................................................................................... 1-23

BASIC SERVICE INFORMATION................................................................. 1-24

QUICK FASTENERS...............................................................................1-24
ELECTRICAL SYSTEM...........................................................................1-25

SPECIAL TOOLS ..........................................................................................1-30

IDENTIFICATION

EAS20007

IDENTIFICATION
EAS30002

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.

EAS30004

ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
crankcase.

1-1
FEATURES

EAS20008

FEATURES
EAS30005

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.

9,10,11 12 13 14 2

15 16

8 7 6 5 4
1. Engine trouble warning light 14. ECU (Engine Control Unit)
2. ABS ECU 15. Fuel injector
3. Front wheel sensor 16. Ignition coil
4. VVA (variable valve actuator) solenoid
5. O2 sensor
6. Spark plug
7. Coolant temperature sensor
8. Crankshaft position sensor
9. Intake air temperature sensor
10. Intake air pressure sensor
11. Throttle position sensor
12. ISC (Idle Speed Control) unit
13. Battery

1-2
FEATURES

EAS30617

FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal
from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into
the intake manifold only during the time the passage remains open. Therefore, the longer the length of
time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied.
Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser
the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, coolant temperature sensor, crankshaft position sensor, intake air pressure
sensor, intake air temperature sensor, front wheel sensor and O2 sensor enable the ECU to determine
the injection duration. The injection timing is determined through the signals from the crankshaft posi-
tion sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in
accordance with the driving conditions.

5
C
1 A 4 6

3
2 7
B

16 8
12 6
13
9
15
14

11
10

1. Fuel pump 13. Intake air temperature sensor

2. Fuel injector 14. Throttle position sensor
3. Ignition coil 15. Intake air pressure sensor
4. ECU (Engine Control Unit) 16. Air filter case
5. Front wheel sensor
A. Fuel system
6. ISC (Idle Speed Control) unit
B. Air system
7. O2 sensor
C. Control system
8. Catalytic converter
9. Coolant temperature sensor
10. Crankshaft position sensor
11. Throttle body
12. Throttle body sensor assembly

1-3
FEATURES

EAS30683

OUTLINE OF THE ABS

1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the
front and rear brakes independently.
2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of
the vehicle.
3. The hydraulic unit assembly, which is the main component of the ABS, is centrally located on the
vehicle to increase mass centralization.

ABS layout

1
2

7 8,9,10

6
4
5 3

1. Hydraulic unit assembly

2. ABS warning light
3. Front wheel sensor rotor
4. Front wheel sensor
5. Rear wheel sensor rotor
6. Rear wheel sensor
7. ABS test coupler
8. ABS control unit fuse
9. ABS solenoid fuse
10. ABS motor fuse

1-4
FEATURES

ABS
The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with
a front brake lever for operating the front brake and a rear brake lever for operating the rear brake.
When wheel lock is detected during braking, hydraulic control is performed by the hydraulic system on
the front and rear brakes independently.

Useful terms
• Wheel speed:
The rotation speed of the front and rear wheels.
• Chassis speed:
The speed of the chassis.
When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis
travels forward by its inertia even though the wheel speed is reduced.
• Brake force:
The force applied by braking to reduce the wheel speed.
• Wheel lock:
A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle
continues to travel.
• Side force:
The force on the tires which supports the vehicle when cornering.
• Slip ratio:
When the brakes are applied, slipping occurs between the tires and the road surface. This causes a
difference between the wheel speed and the chassis speed.
Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula.
Slip ratio = (Chassis speed – Wheel speed)/Chassis speed × 100 (%)
0%: There is no slipping between the wheel and the road surface. The chassis speed is equal to the
wheel speed.
100%: The wheel speed is “0”, but the chassis is moving (i.e., wheel lock).

Brake force and vehicle stability

When the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire and
the road surface and brake force is generated. The limit of this brake force is determined by the friction
force between the tire and the road surface and is closely related to wheel slippage. Wheel slippage is
represented by the slip ratio.
Side force is also closely related to wheel slippage. See figure “A”. If the brakes are applied while keep-
ing the proper slip ratio, it is possible to obtain the maximum brake force without losing much side force.
ABS allows full use of the tires’ capabilities even on slippery road surfaces or less slippery road surfac-
es. See figure “B”.
A B
b e

f
a a
c

g
(%) d (%) d
a. Friction force between the tire and road e. Less slippery road surface
surface f. Controlling zone
b. Brake force g. Slippery road surface
c. Side force
d. Slip ratio

1-5
FEATURES

Wheel slip and hydraulic control

The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from
the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and
the rate of speed reduction based on the wheel speed values.
The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is
equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock.
When the wheel slip and the wheel speed reduction rate exceed the preset values, the ABS ECU de-
termines that the wheel has a tendency to lock.
If the slip is large and the wheel has a tendency to lock (point “A” in the following figure), the ABS ECU
reduces the hydraulic pressure in the brake caliper. Once the ABS ECU determines that the tendency
of the wheel to lock has diminished after the hydraulic pressure is reduced, it increases the hydraulic
pressure (point “B” in the following figure). The hydraulic pressure is initially increased quickly, and then
it is increased gradually.

b A

A
B
B A
B

A
c A
A

B B B

d e d e d e

a. Chassis speed d. Depressurizing phase

b. Wheel speed e. Pressurizing phase
c. Brake force

ABS operation and vehicle control

If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the
limit of control. To make the rider aware of this condition, the ABS has been designed to generate a
reaction-force pulsating action in the front brake lever and rear brake lever independently.
TIP
When the ABS is activated, a pulsating action may be felt at the front brake lever or rear brake lever,
but this does not indicate a malfunction.
The higher the side force on a tire, the less traction there is available for braking. This is true whether
the vehicle is equipped with ABS or not. Therefore, sudden braking while cornering is not recommend-
ed. Excessive side force, which ABS cannot prevent, could cause the tire to slip sideways.

1-6
FEATURES

EWA16510

WARNING
The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even in vehicles equipped with ABS, overturning of the vehicle cannot be prevented
if it is braked suddenly.
The ABS functions to prevent the tendency of the wheel to lock by controlling the hydraulic pressure.
However, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking,
the ABS may not be able to prevent the wheel from locking.
EWA13870

WARNING
The ABS controls only the tendency of the wheel to lock caused by applying the brakes. The
ABS cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine
braking, even if the ABS is operating.

(%)

a. Friction force between the tire and road c. Side force

surface d. Slip ratio
b. Brake force

Electronic ABS features

The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic
technology.
The ABS control is processed with good response under various vehicle travel conditions.
The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con-
dition and allows normal braking even if the ABS is not operating properly.
When this occurs, the ABS warning light on the meter assembly comes on.
The ABS stores the fault codes in the memory of the ABS ECU for easy problem identification and trou-
bleshooting.

1-7
FEATURES

ABS block diagram

1 2 3

4 4

6 5 6

7 7

8
9 9

10 13

11 14
12
1. Rear brake master cylinder 9. Buffer chamber
2. Hydraulic unit assembly 10. Rear brake caliper
3. Front brake master cylinder 11. Rear wheel sensor
4. Inlet solenoid valve 12. ABS warning light
5. ABS motor 13. Front brake caliper
6. Hydraulic pump 14. Front wheel sensor
7. Outlet solenoid valve
8. ABS ECU

EAS30684

ABS COMPONENT FUNCTIONS

Wheel sensors and wheel sensor rotors

Wheel sensors “1” detect the wheel speed and transmit the rotation signal to the ABS ECU.
Each wheel sensor is composed of a permanent magnet and a hall IC. The sensor rotors “2” rotate with
the wheels. The sensor rotors “2” have 40 slots and are installed close to the wheel sensors. As the
sensor rotor rotates, the hall element in the hall IC installed in the wheel sensor generates pulses. The
pulse frequency, which is proportional to the wheel speed, is converted into a wave in the hall IC so that
it can be output.
The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency.

1-8
FEATURES

1 2

7 3 7 4

8 8
5

3. At low speed 7. Voltage

4. At high speed 8. Time
5. Wheel sensor
6. Wheel sensor rotor

ABS warning light

The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs.
When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit
and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function
check is properly completed at a speed of 10 km/h [6 mi/h]).
TIP
After all checks and servicing are completed, the ABS warning light will go off when the vehicle is ridden
or pushed at a speed of 7 km/h (4 mi/h) or faster.
ECA22940

NOTICE
If the rear wheel is raced with the vehicle on a centerstand, the ABS warning light may flash or
come on. If this occurs, turn the main switch to “OFF”, then back to “ON”. The ABS operation
is normal if the ABS warning light goes off after the vehicle starts off. If the fault codes are not
deleted, the ABS warning light goes off after the vehicle is ridden at a speed of about 30 km/h
(19 mi/h).

1-9
FEATURES

Hydraulic unit assembly

The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid
valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The
hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according
to signals transmitted from the ABS ECU.

Hydraulic control valve

The hydraulic control valve is composed of a inlet solenoid valve and outlet solenoid valve.
The electromagnetic force generated in the inlet solenoid valve varies proportionally with the duty cycle
control voltage that is supplied to it. Since this voltage is continuously variable, the solenoid valve
moves smoothly and the hydraulic pressure is adjusted linearly.
1. When the brakes are operated normally, the inlet solenoid valve “1” is open and the outlet solenoid
valve “2” is closed. The brake line between the brake master cylinder and brake caliper is open.

3. Brake master cylinder

4. Brake caliper
2. When the ABS is activated, the inlet solenoid valve “1” closes and the outlet solenoid valve “2” opens
using the power supplied from the ABS ECU signals. This reduces the hydraulic pressure.

1-10
FEATURES

3. Brake caliper
4. ABS motor
3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve
“2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic
pressure difference between the brake fluid in the upper brake lines (brake master cylinder side) and
the brake fluid in the lower brake lines (brake caliper side).

Buffer chamber
The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating.

1. Buffer chamber (pressurizing phase) 3. Raised piston

2. Buffer chamber (depressurizing phase)

ABS ECU
The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design.
As shown in the following block diagram, the ABS ECU receives wheel sensor signals from the front
and rear wheels and also receives signals from other monitor circuits.

1-11
FEATURES

4 7

3
1 8 9
2
10 11
5 6 13
12
14 23
24

16 17
25

15
18 26
22 19
20 27
21

1. Battery 15. ABS ECU

2. AC magneto 16. ABS motor relay
3. Rectifier/regulator 17. Solenoid relay
4. Main fuse 18. Front brake outlet solenoid
5. ABS motor fuse 19. Front brake inlet solenoid
6. ABS solenoid fuse 20. Rear brake outlet solenoid
7. Main switch 21. Rear brake inlet solenoid
8. ABS control unit fuse 22. ABS motor
9. Signaling system fuse 23. Meter assembly
10. Rear brake light switch 24. ABS warning light
11. Front brake light switch 25. ECU (Engine Control Unit)
12. Tail/brake light 26. Front wheel sensor
13. ABS test coupler 27. Rear wheel sensor
14. Hydraulic unit assembly

The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the
hydraulic unit assembly.

ABS control operation

The ABS control operation performed in the ABS ECU is divided into the following two parts.
• Hydraulic control
• Self-diagnosis
When a malfunction is detected in the ABS, a fault code is stored in the memory of the ABS ECU for
easy problem identification and troubleshooting.
TIP
• Some types of malfunctions are not recorded in the memory of the ABS ECU (e.g., a blown ABS con-
trol unit fuse).

1-12
FEATURES

• The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned on. During this test, a “clicking” noise can be heard from front side, and if the
front brake lever or rear brake lever is even slightly operated, a vibration can be felt at the levers, but
these do not indicate a malfunction.

1
2

1. Software operation flow 6. Receive signals

2. Main switch “ON” 7. Control operation
3. Initialize 8. Depressurize/pressurize
4. Self-diagnosis (when static)
5. Self-diagnosis (when riding)

EAS30710

ABS OPERATION
The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de-
scribes the system for the front wheel only.

Normal braking (ABS not activated)

When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed
because a control signal has not been transmitted from the ABS ECU. Therefore, when the brake lever
is squeezed, the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent
to the brake caliper.
At this time, the inlet and outlet check valves of the hydraulic pump are closed. As a result of eliminating
the orifice, the brake master cylinder directly pressurizes the brake caliper during normal braking. When
the brake lever is released, the brake fluid in the brake caliper returns to the brake master cylinder.

1-13
FEATURES

7 6
5
8

9
10

11

12

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

Emergency braking (ABS activated)

1. Depressurizing phase
When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization”
signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the
spring and closes the brake line from the brake master cylinder. Because the outlet solenoid valve
is open, the brake fluid is sent to the buffer chamber. As a result, the hydraulic pressure in the brake
caliper is reduced.
The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy-
draulic pump linked to the ABS motor.

1-14
FEATURES

1. Brake master cylinder 8. Brake caliper

2. Brake light switch 9. Wheel sensor
3. ABS motor 10. ABS ECU
4. Hydraulic pump 11. ABS warning light
5. Buffer chamber 12. Brake fluid pressure
6. Outlet solenoid valve 13. Time
7. Inlet solenoid valve

2. Pressurizing phase
The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At
this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve
opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the
brake caliper.

1-15
FEATURES

1. Brake master cylinder 8. Brake caliper

2. Brake light switch 9. Wheel sensor
3. ABS motor 10. ABS ECU
4. Hydraulic pump 11. ABS warning light
5. Buffer chamber 12. Brake fluid pressure
6. Outlet solenoid valve 13. Time
7. Inlet solenoid valve

EAS30712

ABS WARNING LIGHT AND OPERATION

ABS warning light

• If the ABS warning light comes on while riding, stop the vehicle, and then turn the main switch to
“OFF”, then back to “ON”. The ABS operation is normal if the ABS warning light goes off after the ve-
hicle starts off.
• If the rear wheel is raced with the vehicle on a centerstand, the ABS warning light may flash or come
on. If this occurs, turn the main switch to “OFF”, then back to “ON”. The ABS operation is normal if the
ABS warning light goes off after the vehicle starts off.
• The ABS operation is normal if the ABS warning light flashes.
• Even if the ABS warning light remains on and does not go off, or if it comes on after riding, conven-
tional braking performance of the vehicle is maintained.

1-16
FEATURES

ABS function
EWA18300

WARNING
• When hydraulic control is performed by the ABS, the brake system alerts the rider that the
wheels have a tendency to lock by generating a reaction-force pulsating action in the front
brake lever or rear brake lever. When the ABS is activated, the grip between the road surface
and tires is close to the limit. The ABS cannot prevent wheel lock* on slippery surfaces, such
as ice, when it is caused by engine braking, even if the ABS is activated.
Use extreme care when operating the vehicle under these conditions.
• The ABS is not designed to shorten the braking distance or improve the cornering perfor-
mance.
• Depending on the road conditions, the braking distance may be longer compared to that of
vehicles not equipped with ABS. Therefore, ride at a safe speed and keep a safe distance be-
tween yourself and other vehicles.
• The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even vehicles equipped with ABS cannot be prevented from falling over if braked
suddenly.
• The ABS does not work when the main switch is turned to “OFF”. The conventional braking
function can be used.
* Wheel lock: A condition that occurs when the rotation of one or both of the wheels has
stopped, but the vehicle continues to travel.

1-17
FEATURES

EAS30682
Clock
INSTRUMENT FUNCTIONS
1
Multi-function meter unit
1 2 3 4

1. Clock
7 6 5
The clock uses a 12-hour time system.
1. Fuel meter
2. Clock [To set the clock]
3. Speedometer 1. Turn the key to “ON”.
4. Instantaneous fuel consumption meter 2. Push the “SELECT” button and “RESET” but-
5. “RESET” button ton together for at least two seconds.
6. Multi-function display 3. When the hour digits start flashing, push the
7. “SELECT” button “RESET” button to set the hours.
EWA12423
4. Push the “SELECT” button, and the minute
WARNING digits will start flashing.
Be sure to stop the vehicle before making 5. Push the “RESET” button to set the minutes.
any setting changes to the multi-function 6. Push the “SELECT” button and then release
meter unit. Changing settings while riding it to start the clock.
can distract the operator and increase the
Fuel meter
risk of an accident.
The multi-function meter unit is equipped with 1 2
the following:
• a speedometer
• a clock
• a fuel meter
• an instantaneous fuel consumption meter
• a multi-function display
TIP
Be sure to turn the key to “ON” before using the
“SELECT” and “RESET” buttons. 1. Fuel meter
2. Fuel level warning indicator “ ”
Speedometer The fuel meter indicates the amount of fuel in the
The speedometer shows the vehicle’s traveling fuel tank. The display segments of the fuel meter
speed. disappear towards “E” (Empty) as the fuel level
decreases. When the last segment and fuel level
warning indicator “ ” start flashing, refuel as
soon as possible.
TIP
This fuel meter is equipped with a self-diagnosis
system. If a problem is detected in the electrical
circuit, the following cycle is repeated until the
malfunction is corrected: fuel level segments

1-18
FEATURES

and fuel level warning indicator “ ” flash eight • an oil change tripmeter
times, then go off for approximately 3 seconds. • a V-belt replacement tripmeter
If this occurs, check the electrical circuit. • an oil change indicator
Refer to “SIGNALING SYSTEM” on page 8-19. • a V-belt replacement indicator
• a fault code display
Instantaneous fuel consumption meter Push the “SELECT” button to switch the display
between the odometer mode “ODO”, tripmeter
1 modes “TRIP 1” and “TRIP 2”, oil change tripme-
ter mode “OIL TRIP”, V-belt replacement tripme-
ter mode “V-BELT TRIP”, instantaneous fuel
consumption mode “F/ECO” (km/L or L/100 km)
and average fuel consumption mode “AVE
F/ECO” (km/L or L/100 km) in the following or-
der:

ODO → TRIP 1 → TRIP 2 → OIL TRIP → V-

BELT TRIP → F/ECO → AVE F/ECO → ODO
1. Instantaneous fuel consumption meter
This meter shows the instantaneous fuel con- If the fuel level warning indicator “ ” and last
sumption. segment of the fuel meter start flashing, the dis-
Depending on the display setting selected for play automatically changes to the fuel reserve
the instantaneous fuel consumption mode tripmeter mode “TRIP F” and starts counting the
“F/ECO”, the displayed segments increase or distance traveled from that point. In that case,
decrease. push the “SELECT” button to switch the display
• km/L: The number of segments displayed in- between the various tripmeter, odometer, oil
creases the more efficiently the vehicle is being change tripmeter, V-belt replacement tripmeter,
operated. instantaneous fuel consumption and average
• L/100 km: The number of segments displayed fuel consumption modes in the following order:
decreases the more efficiently the vehicle is
being operated. TRIP F → TRIP 1 → TRIP 2 → OIL TRIP → V-
BELT TRIP → F/ECO → AVE F/ECO → ODO
Multi-function display → TRIP F

To reset a tripmeter, select it by pushing the “SE-

LECT” button, and then push the “RESET” but-
ton for at least one second.
If you do not reset the fuel reserve tripmeter
manually, it resets itself automatically and the
display returns to the prior mode after refueling
and traveling 5 km (3 mi).
1 Instantaneous fuel consumption mode
1. Multi-function display
The multi-function display is equipped with the
following:
• an odometer
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
• a fuel reserve tripmeter (which shows the dis-
tance traveled since the last segment of the
fuel meter started flashing) 1
• an instantaneous fuel consumption display
1. Instantaneous fuel consumption display
• an average fuel consumption display

1-19
FEATURES

The instantaneous fuel consumption display can Oil change tripmeter mode
be set to either “km/L” or “L/100 km”.
• “km/L”: The distance that can be traveled on
1.0 L of fuel under the current riding conditions
is shown.
• “L/100 km”: The amount of fuel necessary to
travel 100 km under the current riding condi-
tions is shown.
To switch between the instantaneous fuel con-
sumption display settings, push the “SELECT”
1 2
button for one second.
TIP 1. Oil change indicator “OIL”
If traveling at speeds under 10 km/h (6 mi/h), “_ 2. Oil change tripmeter
_._” is displayed. The oil change tripmeter shows the distance
traveled since it was last reset (i.e., since the last
Average fuel consumption mode oil change).
The oil change indicator “OIL” will flash at the ini-
tial 1000 km (600 mi), then at 4000 km (2500 mi)
and every 4000 km thereafter to indicate that the
engine oil should be changed.
After changing the engine oil, reset the oil
change tripmeter and the oil change indicator.
To reset them both, select the oil change tripme-
ter, and then push the “RESET” button for one
second. Then, while “OIL” and the oil change
1 tripmeter are flashing, push the “RESET” button
1. Average fuel consumption display for three seconds. The oil change indicator will
be reset.
This display shows the average fuel consump- If the engine oil is changed before the oil change
tion since it was last reset. indicator comes on (i.e., before the periodic oil
The average fuel consumption display can be change interval has been reached), the oil
set to either “km/L” or “L/100 km”. change tripmeter must be reset for the next peri-
• “km/L”: The average distance that can be trav- odic oil change to be indicated at the correct
eled on 1.0 L of fuel is shown. time.
• “L/100 km”: The average amount of fuel neces-
sary to travel 100 km is shown. V-belt replacement tripmeter mode
To switch between the average fuel consump-
tion display settings, push the “SELECT” button
for one second.
To reset the average fuel consumption, push the
“RESET” button for at least one second.
TIP
After resetting the average fuel consumption, “_
_._” will be shown until the vehicle has traveled
0.1 km (0.06 mi).
1 2
1. V-belt replacement indicator “V-BELT”
2. V-belt replacement tripmeter
The V-belt replacement tripmeter shows the dis-
tance traveled since it was last reset (i.e., since
the last V-belt replacement).

1-20
FEATURES

The V-belt replacement indicator “V-BELT” will

flash at every 25000 km (15500 mi) thereafter to
indicate that the V-belt should be replaced.
After replacing the V-belt, reset the V-belt re-
placement tripmeter and the V-belt replacement
indicator. To reset them both, select the V-belt
replacement tripmeter, and then push the “RE-
SET” button for one second. Then, while “V-
BELT” and the V-belt replacement tripmeter are
flashing, push the “RESET” button for three sec-
onds. The V-belt replacement indicator will be
reset.
If the V-belt is replaced before the V-belt re-
placement indicator comes on (i.e., before the
periodic V-belt replacement interval has been
reached), the V-belt replacement tripmeter must
be reset for the next periodic V-belt replacement
to be indicated at the correct time.

Self-diagnosis device
1

2
1. Engine trouble warning light “ ”
2. Fault code display
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light will come on and
the display will indicate a fault code.
If the display indicates any fault codes, note the
code number, and then check the fuel injection
system. Refer to “FUEL INJECTION SYSTEM”
on page 8-25.
ECA20360

NOTICE
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
in order to avoid engine damage.

1-21
IMPORTANT INFORMATION

EAS20009

IMPORTANT INFORMATION
EAS30006

PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.

EAS30008

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-30.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.

1. Oil
2. Lip
3. Spring
4. Grease
EAS30009

LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS30007

REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.

1-22
IMPORTANT INFORMATION

EAS30010 EAS30012

BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in-
manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECA13300

NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.

EAS30011

CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.

1-23
BASIC SERVICE INFORMATION

EAS20010

BASIC SERVICE INFORMATION

EAS30013

QUICK FASTENERS

Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out. Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.

2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 2. Install:
the pin in with a screwdriver. Make sure that the • Quick fastener
pin is flush with the fastener’s head.
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.

1-24
BASIC SERVICE INFORMATION

ECA16760
EAS30014
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECA16600 tery lead connections could damage the
NOTICE electrical components.
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.

ECA16771

NOTICE
When connecting the battery leads to the
ECA16751 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
When disconnecting the battery leads from If the negative battery lead is connected first
the battery, be sure to disconnect the nega- and a tool or similar item contacts the vehi-
tive battery lead first, then the positive bat- cle while the positive battery lead is being
tery lead. If the positive battery lead is connected, a spark could be generated,
disconnected first and a tool or similar item which is extremely dangerous.
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.

ECA16610

NOTICE
Turn the main switch to “OFF” before dis-
TIP
connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to ponent.
rust on the battery terminal, remove the rust us-
ing hot water.

1-25
BASIC SERVICE INFORMATION

ECA16620

NOTICE Checking the electrical system

Handle electrical components with special TIP
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.

ECA16630 ECA14371

NOTICE NOTICE
Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end “a” of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.

ECA16640
TIP NOTICE
When resetting the ECU by turning the main
For waterproof couplers, never insert the
switch to “OFF”, be sure to wait approximately 5
tester probes directly into the coupler. When
seconds before turning the main switch back to
performing any checks using a waterproof
“ON”.
coupler, use the specified test harness or a
suitable commercially available test har-
ness.

1-26
BASIC SERVICE INFORMATION

2. Check:
Checking the connections • Lead
Check the leads, couplers, and connectors for • Coupler
stains, rust, moisture, etc. • Connector
1. Disconnect: Moisture → Dry with an air blower.
• Lead Rust/stains → Connect and disconnect sev-
• Coupler eral times.
• Connector
ECA16780

NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.

3. Check:
• All connections
Loose connection → Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling and assembling a coupler,
pull on the leads to make sure that they are in-
stalled securely.

ECA16790

NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.

1-27
BASIC SERVICE INFORMATION

• As a quick remedy, use a contact revitalizer

available at most part stores.

4. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.

6. Check:
• Resistance

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions
will be shown.

Coolant temperature sensor re-

sistance
2510–2770 Ω at 20 °C (2510–
5. Check: 2770 Ω at 68 °F)
• Continuity Coolant temperature sensor re-
(with the pocket tester) sistance
210–221 Ω at 100 °C (210–221 Ω
Pocket tester at 212 °F)
90890-03112
Analog pocket tester
YU-03112-C

TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).

1-28
BASIC SERVICE INFORMATION

1-29
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 numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.

Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-28, 1-28, 8-97,
90890-03112 8-98, 8-98, 8-99,
Analog pocket tester 8-102, 8-103,
YU-03112-C 8-103, 8-103,
8-104, 8-104,
8-105, 8-105,
8-106, 8-107,
8-108, 8-108
Tappet adjusting tool 3-7
90890-01311
Six piece tappet set
YM-A5970

YM-A5970

ø8 ø9 ø10

ø3 ø4
Yamaha diagnostic tool 3-7, 3-8, 4-65,
90890-03231 4-67, 7-14, 7-14,
8-28, 8-69, 8-90

Steering nut wrench 3-15, 3-16, 4-85

90890-01403
Exhaust flange nut wrench
YU-A9472

Thickness gauge 4-31

90890-03180
Feeler gauge set
YU-26900-9

T-handle 4-79, 4-80

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326

1-30
SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Fork seal driver weight 4-80, 4-81
90890-01367
Replacement hammer
YM-A9409-7

YM-A9409-7/YM-A5142-4

Fork seal driver attachment (ø30) 4-80, 4-81

90890-01400

Compression gauge 90890-03081

5-1
90890-03081
Engine compression tester
YU-33223

YU-33223

Extension 5-1
90890-04136

Camshaft wrench 5-13, 5-17

90890-04162
Camshaft wrench
YM-04162

Yamaha bond No. 1215 5-16, 5-64

90890-85505
(Three bond No.1215®)

Slide hammer bolt 5-19

90890-01085
Slide hammer bolt 8 mm
YU-01083-2

1-31
SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Weight 5-19
90890-01084
Weight
YU-01083-3

YU-01083-3

Valve spring compressor 5-23, 5-28

90890-04019
Valve spring compressor
YM-04019

Valve spring compressor attachment 5-23, 5-28

90890-04108
Valve spring compressor adapter 22 mm
YM-04108

Valve guide remover (ø5) 5-24

90890-04097
Valve guide remover (5.0 mm)
YM-04097

Valve guide installer (ø5) 5-24

90890-04098
Valve guide installer (5.0 mm)
YM-04098

Valve guide reamer (ø5) 5-24

90890-04099
Valve guide reamer (5.0 mm)
YM-04099

Piston pin puller set 5-30

90890-01304
Piston pin puller
YU-01304

YU-01304

1-32
SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Rotor holding tool 5-38, 5-43, 5-49,
90890-01235 5-49
Universal magneto and rotor holder
YU-01235

Rotor holding tool 5-38, 5-38, 5-42,

90890-04166 5-42
YM-04166

Socket wrench (39 mm) 5-38, 5-42

90890-01493

Sheave spring compressor 5-38, 5-41

90890-04134
Sheave spring compressor
YM-04134

Sheave fixed block 5-38, 5-41

90890-04135
Sheave fixed bracket
YM-04135

Oil seal guide (37 mm) 5-41

90890-04177

ø37
Flywheel puller 5-49
90890-01189
Flywheel puller
YM-01189

1-33
SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Digital circuit tester 5-52, 8-106,
90890-03174 8-109
Model 88 Multimeter with tachometer
YU-A1927

Crankcase separating tool 5-62

90890-01135
Crankcase separator
YU-01135-B

Crankshaft installer pot 5-63

90890-01274
Installing pot
YU-90058

YU-90058/YU-90059

Crankshaft installer bolt 5-63

90890-01275
Bolt
YU-90060

Adapter (M12) 5-63

90890-01278
Adapter #3
YU-90063

1-34
SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Spacer (crankshaft installer) 5-63
90890-04081
Pot spacer
YM-91044

YM-91044

Radiator cap tester 6-3, 6-3

90890-01325
Mityvac cooling system tester kit
YU-24460-A

YU-24460-A

Radiator cap tester adapter 6-3

90890-01352
Pressure tester adapter
YU-33984

YU-33984

Mechanical seal installer 6-9

90890-04145 ø30

ø10

Middle driven shaft bearing driver 6-9

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058

1-35
SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Pressure gauge 7-4
90890-03153
Pressure gauge
YU-03153

Fuel pressure adapter 6.3mm 7-4

90890-03227

Ignition checker 8-105

90890-06754
Oppama pet–4000 spark checker
YM-34487

1-36
SPECIAL TOOLS

1-37
SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................ 2-1

ENGINE SPECIFICATIONS ............................................................................ 2-2

CHASSIS SPECIFICATIONS .......................................................................... 2-7

ELECTRICAL SPECIFICATIONS ................................................................... 2-9

TIGHTENING TORQUES ..............................................................................2-11

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS .........................2-11
ENGINE TIGHTENING TORQUES .........................................................2-12
CHASSIS TIGHTENING TORQUES .......................................................2-15

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-19

ENGINE ...................................................................................................2-19

LUBRICATION SYSTEM CHART AND DIAGRAMS....................................2-21

ENGINE OIL LUBRICATION CHART .....................................................2-21
LUBRICATION DIAGRAMS ....................................................................2-23

COOLING SYSTEM DIAGRAMS ..................................................................2-27

CABLE ROUTING .........................................................................................2-29

GENERAL SPECIFICATIONS

EAS20013

GENERAL SPECIFICATIONS
Model
Model 2DP5

Dimensions
Overall length 1955 mm (77.0 in)
Overall width 740 mm (29.1 in)
Overall height 1115 mm (43.9 in)
Seat height 765 mm (30.1 in)
Wheelbase 1350 mm (53.1 in)
Ground clearance 135 mm (5.31 in)
Minimum turning radius 2000 mm (78.7 in)

Weight
Curb weight 127 kg (280 lb)
Maximum load 168 kg (370 lb)

2-1
ENGINE SPECIFICATIONS

EAS20014

ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, SOHC
Displacement 155 cm³
Cylinder arrangement Single cylinder
Bore × stroke 58.0 × 58.7 mm (2.28 × 2.31 in)
Compression ratio 10.5 : 1
Standard compression pressure (at sea level) 1800 kPa/860 r/min (18.0 kgf/cm²/860 r/min,
256.0 psi/860 r/min)
Minimum–Maximum 1566–2016 kPa/860 r/min (15.6–20.1
kgf/cm²/860 r/min, 221.8–285.8 psi/860 r/min)
Starting system Electric starter

Fuel
Recommended fuel Regular unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity 6.6 L (1.7 US gal, 1.5 Imp.gal)

Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA or MB
Engine oil quantity
Quantity (disassembled) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Periodic oil change 0.90 L (0.95 US qt, 0.79 Imp.qt)

Final transmission oil

Type Motor oil SAE 10W-30 Type SE or higher or
Gear oil SEA 85W SL-3
Quantity (disassembled) 0.16 L (0.17 US qt, 0.14 Imp.qt)
Quantity 0.15 L (0.16 US qt, 0.13 Imp.qt)

Oil filter
Oil filter type Centrifugal

Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance 0.150 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.25 mm (0.0098 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.18 mm (0.0071 in)
Rotor thickness 7.95–7.98 mm (0.3130–0.3142 in)

Coolant quantity
Radiator (including all routes) 0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)

2-2
ENGINE SPECIFICATIONS

Radiator cap valve opening pressure 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9
psi)

Thermostat
Valve opening temperature 74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature 90.0 °C (194.00 °F)
Valve lift (full open) 7.0 mm (0.28 in)

Radiator core
Width 158.6 mm (6.24 in)
Height 142.0 mm (5.59 in)
Depth 16.0 mm (0.63 in)

Water pump
Water pump type Single suction centrifugal pump

Spark plug(s)
Manufacturer/model NGK/CPR8EA-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)

Cylinder head
Warpage limit 0.05 mm (0.0020 in)

Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Lobe height (Intake) 32.211–32.311 mm (1.2681–1.2721 in)
Limit 32.111 mm (1.2642 in)
Lobe height (Intake high speed) 32.587–32.686 mm (1.2830–1.2869 in)
Limit (High speed) 32.487 mm (1.2790 in)
Lobe height (Exhaust) 29.420–29.520 mm (1.1583–1.1622 in)
Limit 29.320 mm (1.1543 in)
Camshaft runout limit 0.030 mm (0.0012 in)

Rocker arm/rocker arm shaft

Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in)
Limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in)
Limit 9.936 mm (0.3912 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm (0.0004–0.0013 in)
Limit 0.080 mm (0.0032 in)

Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve head diameter (intake) 19.40–19.60 mm (0.7638–0.7717 in)
Valve head diameter (exhaust) 16.90–17.10 mm (0.6654–0.6732 in)
Valve seat contact width (intake) 0.90–1.20 mm (0.0354–0.0472 in)
Limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) 0.90–1.20 mm (0.0354–0.0472 in)
Limit 1.6 mm (0.06 in)

2-3
ENGINE SPECIFICATIONS

Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)

Limit 4.920 mm (0.1937 in)
Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in)
Limit 4.925 mm (0.1939 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Limit 5.050 mm (0.1988 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Limit 5.050 mm (0.1988 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.110 mm (0.0043 in)
Valve stem runout 0.010 mm (0.0004 in)

Valve spring
Free length (intake) 33.79 mm (1.33 in)
Limit 32.10 mm (1.26 in)
Free length (exhaust) 33.80 mm (1.33 in)
Limit 32.06 mm (1.26 in)
Installed length (intake) 28.90 mm (1.14 in)
Installed length (exhaust) 28.90 mm (1.14 in)
Installed compression spring force (intake) 139.50–160.50 N (14.22–16.37 kgf, 31.36–
36.08 lbf)
Installed compression spring force (exhaust) 139.50–160.50 N (14.22–16.37 kgf, 31.36–
36.08 lbf)
Spring rate K1 (intake) 30.67 N/mm (3.13 kgf/mm, 175.13 lbf/in)
Spring rate K2 (intake) 49.28 N/mm (5.03 kgf/mm, 281.39 lbf/in)
Spring rate K1 (exhaust) 30.62 N/mm (3.12 kgf/mm, 174.84 lbf/in)
Spring rate K2 (exhaust) 39.71 N/mm (4.05 kgf/mm, 226.74 lbf/in)
Spring tilt (intake) 1.5 mm (0.06 in)
Spring tilt (exhaust) 1.5 mm (0.06 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise

Cylinder
Bore 58.000–58.010 mm (2.2835–2.2839 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Measuring point H 20.0–40.0 mm (0.79–1.57 in)
Warp limit 0.03 mm (0.0012 in)

Piston
Piston-to-cylinder clearance 0.015–0.048 mm (0.0006–0.0019 in)
Diameter 57.962–57.985 mm (2.2820–2.2829 in)
Measuring point (from piston skirt bottom) 6.0 mm (0.24 in)
Piston pin bore inside diameter 14.002–14.013 mm (0.5513–0.5517 in)
Limit 14.043 mm (0.5529 in)
Piston pin outside diameter 13.995–14.000 mm (0.5510–0.5512 in)
Limit 13.975 mm (0.5502 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.018 mm (0.0001–0.0007 in)

2-4
ENGINE SPECIFICATIONS

Piston ring
Top ring
Ring type Barrel
End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)
Limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in)
Limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Limit 0.115 mm (0.0045 in)
Oil ring
End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in)

Crankshaft
Crank assembly width 51.45–51.50 mm (2.026–2.028 in)
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.150–0.450 mm (0.0059–0.0177 in)
Big end radial clearance 0.004–0.014 mm (0.0002–0.0006 in)

Clutch
Clutch type Dry, centrifugal automatic

Automatic centrifugal clutch

Clutch shoe thickness 4.0 mm (0.16 in)
Limit 2.5 mm (0.10 in)
Clutch shoe spring free length 34.8 mm (1.37 in)
Clutch housing inside diameter 125.0 mm (4.92 in)
Limit 126.0 mm (4.96 in)
Compression spring free length 95.0 mm (3.74 in)
Limit 85.5 mm (3.37 in)
Weight outside diameter 20.0 mm (0.79 in)
Limit 19.5 mm (0.77 in)
Clutch-in revolution 2200–2600 r/min
Clutch-stall revolution 4700–5300 r/min

V-belt
V-belt width 25.5 mm (1.00 in)
Limit 23.0 mm (0.91 in)

Transmission
Transmission type V-belt automatic
Primary reduction ratio 1.000
Secondary reduction ratio 10.208 (56/16 × 35/12)
Final drive Gear
Gear ratio 2.248–0.708 : 1

Air filter
Air filter element Oil-coated paper element

2-5
ENGINE SPECIFICATIONS

Fuel injector
Model/quantity 5D78 00/1

Throttle body
Type/quantity AC28/1
ID mark 2DP1 00

Fuel injection sensor

Crankshaft position sensor resistance 228–342 Ω
Intake air pressure sensor output voltage 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at 1.01
kgf/cm², 3.88–4.12 V at 14.7 psi)
Intake air temperature sensor resistance 5700.0–6300.0 Ω at 0 °C (5700.0–6300.0 Ω at
32 °F)
Coolant temperature sensor resistance 2510–2770 Ω at 20 °C (2510–2770 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)

Idling condition
Fuel line pressure at idling 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Engine idling speed 1500–1700 r/min
CO% (Muffler tail pipe) 0.0–1.3 %
Water temperature 82.0–92.0 °C (179.60–197.60 °F)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)

2-6
CHASSIS SPECIFICATIONS

EAS20015

CHASSIS SPECIFICATIONS
Chassis
Frame type Underbone
Caster angle 26.00°
Trail 92 mm (3.6 in)

Front wheel
Wheel type Cast wheel
Rim size 13M/C × MT3.00
Rim material Aluminum
Wheel travel 100 mm (3.9 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)

Rear wheel
Wheel type Cast wheel
Rim size 13M/C × MT3.50
Rim material Aluminum
Wheel travel 90 mm (3.5 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)

Front tire
Type Tubeless
Size 110/70–13M/C 48P
Manufacturer/model IRC/SS-570F
Wear limit (front) 1.0 mm (0.04 in)

Rear tire
Type Tubeless
Size 130/70–13M/C 63P
Manufacturer/model IRC/SS-560R
Wear limit (rear) 1.0 mm (0.04 in)

Tire air pressure (measured on cold tires)

Front (1 person) 150 kPa (1.50 kgf/cm², 22 psi)
Rear (1 person) 250 kPa (2.50 kgf/cm², 36 psi)
Front (2 persons) 150 kPa (1.50 kgf/cm², 22 psi)
Rear (2 persons) 250 kPa (2.50 kgf/cm², 36 psi)

Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 230.0 × 4.0 mm (9.06 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 4.4 mm (0.17 in)
Limit 0.8 mm (0.03 in)
Brake pad lining thickness (outer) 4.4 mm (0.17 in)
Limit 0.8 mm (0.03 in)

2-7
CHASSIS SPECIFICATIONS

Master cylinder inside diameter 11.00 mm (0.43 in)

Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4)

Rear brake
Type Single disc brake
Operation Left hand operation
Rear disc brake
Disc outside diameter × thickness 230.0 × 4.5 mm (9.06 × 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 5.3 mm (0.21 in)
Limit 0.8 mm (0.03 in)
Brake pad lining thickness (outer) 5.3 mm (0.21 in)
Limit 0.8 mm (0.03 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid YAMAHA GENUINE BRAKE FLUID (DOT 4)

Steering
Steering bearing type Angular bearing
Center to lock angle (left) 47.5°
Center to lock angle (right) 47.5°

Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 100.0 mm (3.94 in)
Fork spring free length 245.3 mm (9.66 in)
Limit 240.0 mm (9.45 in)
Spring rate K1 5.00 N/mm (0.51 kgf/mm, 28.55 lbf/in)
Spring rate K2 7.50 N/mm (0.76 kgf/mm, 42.83 lbf/in)
Spring stroke K1 0.0–68.5 mm (0.00–2.70 in)
Spring stroke K2 68.5–100.0 mm (2.70–3.94 in)
Inner tube outer diameter 30.0 mm (1.18 in)
Recommended oil Fork oil 10W or equivalent
Quantity 86.0 cm³ (2.91 US oz, 3.03 Imp.oz)
Level 78.0 mm (3.07 in)

Rear suspension
Type Unit swing
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 86.0 mm (3.39 in)
Spring installed length 221.6 mm (8.72 in)
Spring rate K1 16.40 N/mm (1.67 kgf/mm, 93.64 lbf/in)
Spring rate K2 33.50 N/mm (3.42 kgf/mm, 191.29 lbf/in)
Spring stroke K1 0.0–54.0 mm (0.00–2.13 in)
Spring stroke K2 54.0–86.0 mm (2.13–3.39 in)

2-8
ELECTRICAL SPECIFICATIONS

EAS20016

ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V

Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0°/1600 r/min

Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ

Spark plug cap

Material Resin
Resistance 3.75–6.25 kΩ

AC magneto
Standard output 14.0 V, 150 W at 5000 r/min
Stator coil resistance 0.500–0.740 Ω

Rectifier/regulator
Regulated voltage (DC) 13.7–14.7 V
Rectifier capacity (DC) 15.0 A

Battery
Model YTZ7V
Voltage, capacity 12 V, 6.0 Ah
Manufacturer PT.YUASA
Ten hour rate charging current 0.60 A

Bulb voltage, wattage × quantity

Headlight LED
Auxiliary light 12 V, 5.0 W × 2
Tail/brake light 12 V, 10.0 W × 1/LED
Front turn signal light 12 V, 10.0 W × 2
Rear turn signal light 12 V, 10.0 W × 2
Meter lighting LED

Indicator light
Turn signal indicator light LED
High beam indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
ABS warning light LED

Starter motor
Power output 0.36 kW
Armature coil resistance 0.0279–0.0341 Ω
Brush overall length 7.0 mm (0.28 in)

2-9
ELECTRICAL SPECIFICATIONS

Limit 3.50 mm (0.14 in)

Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz)
Commutator diameter 17.6 mm (0.69 in)
Limit 16.6 mm (0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in)

Starter relay
Amperage 50.0 A
Coil resistance 54.00–66.00 Ω

Horn
Horn type Plane
Quantity 1
Maximum amperage 3.0 A
Coil resistance 1.06–1.11 Ω

Turn signal relay

Relay type Condenser
Built-in, self-canceling device No

Fuel sender unit

Sender unit resistance (full) 10.0–14.0 Ω
Sender unit resistance (empty) 267.0–273.0 Ω

Fuses
Main fuse 1 15.0 A
Main fuse 2 7.5 A
Taillight fuse 7.5 A
Signaling system fuse 7.5 A
ABS motor fuse 30.0 A
ABS control unit fuse 7.5 A
ABS solenoid fuse 15.0 A
Spare fuse 30.0 A
Spare fuse 15.0 A
Spare fuse 7.5 A

2-10
TIGHTENING TORQUES

EAS20017

TIGHTENING TORQUES
EAS30015

GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.

A. Distance between flats

B. Outside thread diameter

General tightening torques

A (nut) B (bolt)
Nm m·kgf ft·lbf
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94

2-11
TIGHTENING TORQUES

EAS30016

ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Muffler nut M8 2 15 Nm (1.5 m·kgf, 11 ft·lbf)
Muffler bolt M10 3 53 Nm (5.3 m·kgf, 38 ft·lbf)
Muffler protector bolt M6 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT

O2 sensor M12 1 25 Nm (2.5 m·kgf, 18 ft·lbf)

Camshaft stopper plate bolt (M5×16) M5 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf)

Camshaft stopper plate bolt (M6×14) M6 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Cylinder head bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head nut M8 4 24 Nm (2.4 m·kgf, 17 ft·lbf) M

VVA (variable valve actuator) sole-

M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
noid bolt
Fuel hose holder M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil check bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head stud bolt (exhaust
M8 2 15 Nm (1.5 m·kgf, 11 ft·lbf)
pipe)
Camshaft sprocket bolt M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head blind plug M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf) LT

Cylinder head cover breather plate

M5 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) LT
bolt
Valve clearance adjusting screw
M5 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
locknut
Yamaha
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) bond No.
1215
Timing chain guide bolt (intake side) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain guide stopper bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT

Coolant temperature sensor M10 1 15 Nm (1.5 m·kgf, 11 ft·lbf)

Coolant drain bolt (cylinder side) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump assembly bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump housing bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator fan case bolt M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Thermostat assembly bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Radiator fan bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt (radiator side) M12 1 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
Radiator cover bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump assembly screw M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Oil pump housing cover screw M3 1 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
Oil strainer cover M35 1 32 Nm (3.2 m·kgf, 23 ft·lbf)

2-12
TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Fuel injector bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Intake manifold bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Intake manifold clamp screw M5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
ISC (Idle Speed Control) unit holder
M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
screw
Air filter case joint clamp screw M5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter case bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Air filter case cover screw M5 6 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf)
Air filter case duct cover screw M5 2 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf)
AC magneto rotor nut M12 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Yamaha
Crankcase cover bolt 1 M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) bond No.
1215
Crankcase cover bolt 2 M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stator coil assembly bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT

Starter motor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Starter motor sub-wire harness bolt M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Starter motor cover bolt M4 2 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Brush holder screw M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Crankcase bolt M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft position sensor holder
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
bolt
Transmission case cover bolt M8 6 19 Nm (1.9 m·kgf, 14 ft·lbf)
Final transmission oil drain bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Yamaha
Starter clutch cover bolt 1 M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) bond No.
1215
Starter clutch cover bolt 2 M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
V-belt case bolt M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt M12 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Crankcase stud bolt M8 4 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
V-belt case air filter element cover
M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
bolt
Primary fixed sheave nut M12 1 49 Nm (4.9 m·kgf, 35 ft·lbf)
Clutch housing nut M12 1 45 Nm (4.5 m·kgf, 33 ft·lbf)
Secondary sheave nut M28 1 55 Nm (5.5 m·kgf, 40 ft·lbf)

2-13
TIGHTENING TORQUES

Cylinder head tightening sequence:

3 4

1 2

6 5

2-14
TIGHTENING TORQUES

EAS30017

CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Engine bracket nut M10 1 52 Nm (5.2 m·kgf, 38 ft·lbf)
Engine mounting nut (front right
M10 1 68 Nm (6.8 m·kgf, 49 ft·lbf)
side)
Engine mounting bolt (front left side) M10 1 68 Nm (6.8 m·kgf, 49 ft·lbf)
Engine mounting nut (rear side) M10 1 68 Nm (6.8 m·kgf, 49 ft·lbf)
Engine ground lead bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Headlight unit screw M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Lower handlebar cover screw M5 1 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Front lower cowling screw M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Meter assembly screw M5 4 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Front upper cowling assembly screw M5 3 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Meter assembly panel screw M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Leg shield bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Key shutter screw M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Front upper panel screw M5 6 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Front side cowling screw M5 8 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Front side cover screw M5 6 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Front cowling assembly screw (M5 ×
M5 4 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
15)
Front cowling assembly screw (M5 ×
M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
11)
Meter assembly panel bolt M6 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Footrest board and rear side cover
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
bolt
Footrest board assembly bolt M6 4 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Footrest board screw M5 6 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Grab bar bolt M8 4 17 Nm (1.7 m·kgf, 12 ft·lbf)
Upper handlebar cover assembly
M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
screw
Turn signal light screw M5 6 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Handlebar switch screw (right) M5 2 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
Fuel tank cover screw M5 4 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Center side cover screw M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Tail/brake light outer cover screw M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Rear side cover assembly screw M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Seat lock bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat nut M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat hinge nut M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat lock cable guide bolt M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Center cover bolt M5 1 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)

2-15
TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Battery cover screw M5 2 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
Storage box bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Seat hinge bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear fender bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake master cylinder holder
M6 2 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
bolt
Brake master cylinder reservoir cap
M4 4 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
screw
Front brake hose union bolt (master
M10 1 29 Nm (2.9 m·kgf, 21 ft·lbf)
cylinder side)
Rear brake hose union bolt (master
M10 1 29 Nm (2.9 m·kgf, 21 ft·lbf)
cylinder side)
Throttle cable holder bolt (handlebar
M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
switch side)
Throttle cable adjusting locknut M7 1 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Rearview mirror locknut M10 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Rearview mirror adaptor M10 2 22 Nm (2.2 m·kgf, 16 ft·lbf)
Handlebar switch screw (left) M5 2 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
Rear brake master cylinder holder
M6 2 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
bolt
Rear brake lever pivot bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf) S

Rear brake lever pivot nut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)

Front brake lever pivot bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf) S

Front brake lever pivot nut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)

Grip end bolt (left) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Grip end bolt (right) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Brake light switch screw M4 2 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf)
Handlebar bracket nut M10 1 63 Nm (6.3 m·kgf, 46 ft·lbf)
Upper handlebar holder bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Main switch bolt M8 2 19 Nm (1.9 m·kgf, 14 ft·lbf)
Lower ring nut M25 1 See TIP.
Upper ring nut M25 1 See TIP.
Horn bracket bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Horn bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Lower bracket pinch bolt M10 4 53 Nm (5.3 m·kgf, 38 ft·lbf)
Front fork damper rod bolt M10 2 23 Nm (2.3 m·kgf, 17 ft·lbf) LT

Ignition coil bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Ignition coil bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle cable guide bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fender bolt M6 4 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Front wheel sensor bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake caliper bolt M10 2 35 Nm (3.5 m·kgf, 25 ft·lbf)

2-16
TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Front brake hose union bolt (brake
M10 1 29 Nm (2.9 m·kgf, 21 ft·lbf)
caliper side)
Brake caliper bleed screw M8 2 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake hose guide bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front wheel axle nut M10 1 40 Nm (4.0 m·kgf, 29 ft·lbf)
Front brake hose holder bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake disc bolt M8 3 23 Nm (2.3 m·kgf, 17 ft·lbf) LT

Front wheel sensor rotor bolt M5 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT

Rear wheel sensor rotor bolt M5 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT

Rear brake hose bracket bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Rear brake hose holder bolt (front
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
side)
Rear brake hose holder bolt (rear
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
side)
Rear brake disc bolt M8 3 23 Nm (2.3 m·kgf, 17 ft·lbf) LT

Rear brake caliper bolt M10 2 35 Nm (3.5 m·kgf, 25 ft·lbf)

Rear wheel sensor bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear wheel axle nut M16 1 125 Nm (12.5 m·kgf, 90 ft·lbf)
Rear brake hose union bolt (brake
M10 1 29 Nm (2.9 m·kgf, 21 ft·lbf)
caliper side)
Front brake hose guide bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Hydraulic unit assembly bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake hose union bolt (hydrau-
M10 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
lic unit assembly side)
Rear brake hose union bolt (hydrau-
M10 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
lic unit assembly side)
Rectifier/regulator nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front cowling assembly bracket M8 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Rear shock absorber assembly nut M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Rear shock absorber assembly bolt M8 2 21 Nm (2.1 m·kgf, 15 ft·lbf)
Swingarm mounting bolt M10 2 57 Nm (5.7 m·kgf, 41 ft·lbf)
Bearing retaining plate bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel pump bracket bolt M5 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Throttle cable holder bolt (throttle
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
body side)
Coolant reservoir bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Sidestand switch bolt M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) LT

Centerstand spring hook bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

Sidestand nut M8 1 24 Nm (2.4 m·kgf, 17 ft·lbf)
Passenger footrest assembly bolt M8 4 28 Nm (2.8 m·kgf, 20 ft·lbf)

2-17
TIGHTENING TORQUES

TIP
Steering column ring nut
1. Tighten the lower ring nut 38 Nm (3.8 m·kgf, 27 ft·lbf) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 16 Nm (1.6 m·kgf, 12 ft·lbf) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 Nm (7.5 m·kgf, 54 ft·lbf)
with a torque wrench and the steering nut wrench.

2-18
LUBRICATION POINTS AND LUBRICANT TYPES

EAS20018

LUBRICATION POINTS AND LUBRICANT TYPES

EAS30018

ENGINE
Lubrication point Lubricant
Bearings E

O-rings LS

O-rings (cam shaft) M

Oil seals LS

Rocker arm stopper pin M

Cylinder head nut contact face and stud bolt thread M

Camshaft lobes M

Decompression cam M

Rocker arm shafts M

Valve stems and valve guide (intake and exhaust) M

Valve stem seals E

Valve stem ends (intake and exhaust) M

Rocker arm valve inner surface M

Camshaft sprocket M

Connecting rod big end face E

Piston pin outer surface E

Piston, piston ring, and cylinder inner surface E

Crank pin E

Cam chain sprocket inner surface M

Oil pump drive gear inner surface M

Oil pump shaft E

O-ring (fuel injector) E

Starter wheel and bearing E

Starter clutch idle gear inner surface M

Drive axle and bearings LS

Crankshaft threads and conical spring washer outer mating surface LS

Yamaha bond
Timing chain tensioner bolts
No.1215®
Yamaha bond
Crankcase mating surfaces
No.1215®
Yamaha bond
Crankcase bolt
No.1215®

2-19
LUBRICATION POINTS AND LUBRICANT TYPES

2-20
LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20019

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS30020

ENGINE OIL LUBRICATION CHART

2-21
LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil strainer
2. Oil pump assembly
3. Crankshaft
4. Oil nozzle
5. Camshaft

2-22
LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS30021

LUBRICATION DIAGRAMS

2 1

2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil strainer
2. Oil pump assembly
3. Camshaft

2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS

2-25
LUBRICATION SYSTEM CHART AND DIAGRAMS

1. Oil strainer
2. Oil pump assembly
3. Crankshaft
4. Rocker arm/Valve stem end

2-26
COOLING SYSTEM DIAGRAMS

EAS20020

COOLING SYSTEM DIAGRAMS

1 2 3
4
6

8
5

5
1 2 3 4

2-27
COOLING SYSTEM DIAGRAMS

1. Radiator cap
2. Coolant reservoir hose
3. Radiator
4. Radiator inlet hose
5. Radiator outlet hose
6. Thermostat assembly
7. Water pump inlet hose
8. Water pump assembly

2-28
CABLE ROUTING

EAS20021

CABLE ROUTING
Handlebar (front view)

1 A B
2

1 2

6 5 3
4

2-29
CABLE ROUTING

1. Front brake hose (front brake master cylinder to

hydraulic unit)
2. Rear brake hose (rear brake master cylinder to
hydraulic unit)
3. Rear brake light switch lead
4. Throttle cable (decelerator cable)
5. Throttle cable (accelerator cable)
6. Front brake light switch lead
7. Lower handlebar cover
A. 40–44 mm (1.57–1.73 in)
B. 5–9 mm (0.20–0.35 in)
C. Route the throttle cables through the hole in the
lower handlebar cover.

2-30
CABLE ROUTING

Handlebar (left side view)

4
3

7 8

7 7
1
1

1
3 5
3
6
4 6 4

2
1
A

5 4
3

10

5 9

8
6
6

B
11
6

2-31
CABLE ROUTING

1. Rear brake hose (rear brake master cylinder to

hydraulic unit)
2. Rear brake light switch lead
3. Throttle cable (decelerator cable)
4. Throttle cable (accelerator cable)
5. Handlebar switch coupler (left handlebar switch)
6. Wire harness
7. Front brake hose (front brake master cylinder to
hydraulic unit)
8. Handlebar switch coupler (right handlebar switch)
9. Front brake light switch lead
10. Handlebar switch connector (left handlebar switch)
11. Bracket
A. Route the throttle cable (accelerator cable) to the
front of the throttle cable (decelerator cable).
B. Insert the projection on the wire harness holder
into the hole in the bracket.

2-32
CABLE ROUTING

Front frame (front and left side view)

19

10
9
18

2
3 3 A 16
18
1
4 4 19
20
17
5

6 21 B
15
7 5

8
14 23

10
9 22

10
13
11
11
12

19 18

14 15

10
C
11 24
19 18 12

2-33
CABLE ROUTING

1. Main switch lead

2. Rectifier/regulator
3. Meter assembly lead
4. Turn signal relay
5. Turn signal relay lead
6. Headlight lead
7. Auxiliary light lead
8. Front turn signal light lead (front left turn signal
light)
9. Front wheel sensor lead
10. Front brake hose (hydraulic unit to front brake
caliper)
11. Wire harness
12. Rear brake hose (hydraulic unit to rear brake
caliper)
13. Hydraulic unit assembly lead
14. Hydraulic unit assembly
15. Front turn signal light lead (front right turn signal
light)
16. Meter assembly
17. Front wheel sensor coupler
18. Rear brake hose (rear brake master cylinder to
hydraulic unit)
19. Front brake hose (front brake master cylinder to
hydraulic unit)
20. Throttle cable (decelerator cable)
21. Throttle cable (accelerator cable)
22. Seat lock cable
23. Rectifier/regulator lead
24. Front turn signal light
A. After connecting the meter assembly coupler,
install the coupler cover completely until it contacts
the meter assembly.
B. Route the throttle cable (accelerator cable) to the
outside of the throttle cable (decelerator cable).
C. Route the front turn signal light lead as shown in
the illustration.

2-34
CABLE ROUTING

Front fork (rear and right side view)

1 2
C
1

3
3
6
F 6

7
G
7

B B

3
C
A
7
6
6

4
D
2
C 1 E
7 6

I H
6

6 7

7
B
F G

2-35
CABLE ROUTING

1. Horn lead
2. Front brake hose holder
3. Horn
4. Front wheel sensor
5. Front brake caliper
6. Front brake hose (hydraulic unit to front brake
caliper)
7. Front wheel sensor lead
A. Route the front brake hose (hydraulic unit to front
brake caliper) through the guide.
B. Position the holder within the range shown in the
illustration.
C. Route the horn lead through the holder.
D. Connect the horn lead (pink) to the horn terminal.
E. Connect the horn lead (brown) to the horn
terminal.
F. Inward
G. Outward
H. Forward
I. Rearward

2-36
CABLE ROUTING

Frame (left side view)

10
11 10

16 C
9
C 17 18
16
11 21 10

12 20
14
19
16 14 E

13
11
15
D
E

9 15

1 2 A

2
1
3 4
B

9
8
7 3
4
6

8 6 H
6 F

2-37
CABLE ROUTING

1. Throttle cable (decelerator cable)

2. Throttle cable (accelerator cable)
3. Seat lock cable
4. Tail/brake light assembly lead
5. Sidestand switch
6. Frame ground lead
7. Fuel pump lead
8. Sidestand switch lead
9. Wire harness
10. AC magneto lead
11. Starter motor lead
12. Starter motor sub-wire harness
13. Engine ground lead
14. Ignition coil lead
15. Positive battery lead
16. Negative battery lead
17. Yamaha diagnostic tool lead
18. ABS test coupler lead
19. ECU lead
20. Fuse box 1
21. Fuse box 2
A. White tape
B. Route the throttle cable (accelerator cable) and
throttle cable (decelerator cable) through the guide.
Be sure to route the throttle cable (accelerator
cable) above the throttle cable (decelerator cable).
C. Fasten the wire harness and negative battery lead
with the plastic band.
D. Make sure that the engine ground lead terminal
contacts the stopper on the crankcase.
E. To starter relay
F. Install the frame ground terminal as shown in the
illustration.
G. 90°
H. Install the frame ground lead terminal so that the
crimped section of the terminal that secures the
lead is facing upward.

2-38
CABLE ROUTING

Frame (right side view)

21

22

23

1
2 6
8
15

14
11 12 13

4 5 6 9 10
3 7 8
2
1

20
19
18 17 A 16 15
13 B
C
1
12
20 24
9

2-39
CABLE ROUTING

1. Coolant temperature sensor lead

2. Throttle body sensor assembly lead
3. Starter motor lead
4. ISC (Idle Speed Control) unit lead
5. AC magneto lead
6. Fuel injector lead
7. O2 sensor lead
8. VVA (variable valve actuator) solenoid lead
9. Ignition coil
10. Rear brake hose (hydraulic unit to rear brake
caliper)
11. Rear wheel sensor lead
12. Fuel tank overflow tray
13. Rear wheel sensor coupler
14. Wire harness
15. Fuel hose
16. VVA (variable valve actuator) solenoid
17. Spark plug lead
18. Water pump inlet hose
19. Thermostat assembly
20. Radiator inlet hose
21. Sidestand switch lead
22. Fuel pump lead
23. Fuel pump
24. Ignition coil lead
A. Route the spark plug lead between the VVA
(variable valve actuator) solenoid and the water
pump inlet hose. Make sure that the spark plug
lead does not contact the VVA (variable valve
actuator) solenoid or water pump inlet hose.
B. Insert the projection on the rear wheel sensor
coupler into the hole in the fuel tank overflow tray.
C. Fasten the coolant temperature sensor lead to the
radiator inlet hose with the plastic band. Point the
end of the plastic band outward.

2-40
CABLE ROUTING

Frame (top view)

3
E 4 6
9 5 9
3

2
7

8 B
4
1

5
6

9 12
C

13

9
D

11

10

2-41
CABLE ROUTING

1. ECU lead
2. Positive battery lead
3. Fuse box 1
4. Fuse box 2
5. Fuel tank overflow tray
6. Negative battery lead
7. ABS test coupler lead
8. Yamaha diagnostic tool lead
9. Storage box
10. Tail/brake light assembly lead
11. Seat lock cable
12. ABS test coupler
13. Yamaha diagnostic tool coupler
A. Route the seat lock cable through the hole in the
frame.
B. Install fuse box 2 completely onto the tab on the
storage box.
C. Install the protective cap onto the ABS test
coupler.
D. Route the negative battery lead through the hole in
the storage box.
E. Install fuse box 1 completely onto the tab on the
storage box.

2-42
CABLE ROUTING

Hydraulic unit (top and right side view)

6 2

5
4

6
1

5
2

7
C

2-43
CABLE ROUTING

1. Hydraulic unit assembly

2. Main switch lead
3. Rear brake hose (hydraulic unit to rear brake
caliper)
4. Rear brake hose (rear brake master cylinder to
hydraulic unit)
5. Front brake hose (front brake master cylinder to
hydraulic unit)
6. Front brake hose (hydraulic unit to front brake
caliper)
7. Hydraulic unit assembly lead
A. Route the main switch lead through the guide.
B. 30°
C. The holder may be facing in any direction.

2-44
CABLE ROUTING

Rear brake (right side view)

8
3
6 C 6 3
5 6 C
10
9 3
6
7
5

7
2
A
5
4
3
1

3 B
D

6 E

7 6

2-45
CABLE ROUTING

1. Rear brake caliper

2. Rear wheel sensor
3. Rear wheel sensor lead
4. Radiator
5. Coolant reservoir hose
6. Rear brake hose (hydraulic unit to rear brake
caliper)
7. Swingarm
8. Rear brake hose bracket
9. Rear brake hose holder
10. AC magneto lead
A. Connect the coolant reservoir hose to the radiator,
and then fasten the hose by inserting the projection
on the holder into the hole in the rear brake hose
bracket and rear brake hose holder.
B. Position the holder within the range shown in the
illustration.
C. Route the rear brake hose (hydraulic unit to rear
brake caliper) through the guide.
D. Upward
E. Downward

2-46
CABLE ROUTING

Fuel tank (right side view)

C
9
1

9
3
1 2
3

7
4
A

6 A

2-47
CABLE ROUTING

1. Rear brake hose (hydraulic unit to rear brake

caliper)
2. Rear wheel sensor lead
3. Fuel hose
4. Fuel tank overflow hose
5. Center lower cover
6. Coolant reservoir hose
7. Coolant reservoir breather hose
8. Fuel hose holder
9. O2 sensor lead
A. Install the hose completely onto the hose fitting.
B. Position the hose clamp 3–7 mm (0.12–0.28 in)
from the end of the hose. Point the ends of the
hose clamp upward.
C. Fasten the grommet on the fuel hose with the
holder.
D. Insert the end of the fuel tank overflow hose into
the center lower cover. Make sure that the end of
the hose protector on the fuel tank overflow hose
contacts the edge of the hole in the center lower
cover.

2-48
CABLE ROUTING

Fuel tank (top and bottom view)

3 B

2 B 1 A
C 4

2-49
CABLE ROUTING

1. Coolant reservoir cap

2. Coolant reservoir breather hose
3. Coolant reservoir hose
4. Fuel hose
A. Install the coolant reservoir cap as shown in the
illustration.
B. Align the white paint mark on the hose with the
projection on the coolant reservoir.
C. Fasten the grommet on the fuel hose with the
holder.

2-50
CABLE ROUTING

Radiator (top and right side view)

1 D
C
1
E

2 B
2

G F

A 3

4
D

G F

D 6 5 A E
O

6 A H D
E
I
5 N M D
7 B
E N M

3 E
J A

K
4
L
A

2-51
CABLE ROUTING

1. Water pump
2. Water pump inlet hose
3. Thermostat assembly
4. Radiator outlet hose
5. Radiator
6. Coolant reservoir hose
7. Radiator inlet hose
A. Install the hose completely onto the hose fitting.
B. Face the white paint mark on the hose to the left.
C. 3–5 mm (0.12–0.20 in)
D. Upward
E. Downward
F. Forward
G. Rearward
H. Point the ends of the hose clamp to the left. Make
sure not to install the hose clamp on the raised
portion of the hose fitting.
I. To coolant reservoir
J. Face the yellow paint mark on the hose to the right.
K. Align the yellow paint mark on the hose with the
center of the thermostat assembly.
L. Face the white paint mark on the hose upward.
M. Outward
N. Inward
O. Make sure that the hose clamp does not contact
the radiator fan cover.

2-52
CABLE ROUTING

Air filter case (top and left side view)

1
C C B
A B
2

D 3 E

1 3

2-53
CABLE ROUTING

1. Cylinder head breather hose

2. V-belt case breather hose
3. Air filter case
A. Face the white paint mark on the hose upward.
B. Point the ends of the hose clamp upward.
C. Install the hose completely onto the hose fitting.
D. 1–5 mm (0.04–0.20 in)
E. 5–6 mm (0.20–0.24 in)
F. Face the yellow paint mark on the hose outward.
G. Point the ends of the hose clamp outward.

2-54
CABLE ROUTING

2-55
PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE ............................................................................ 3-1

INTRODUCTION ....................................................................................... 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ................................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ....................... 3-1
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE FUEL FILTER ................................................................ 3-4
CHECKING THE SPARK PLUG ............................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-5
CHECKING THE ENGINE IDLING SPEED .............................................. 3-7
CHECKING THE EXHAUST SYSTEM...................................................... 3-7
ADJUSTING THE EXHAUST GAS VOLUME ........................................... 3-8
REPLACING THE AIR FILTER ELEMENT AND
CLEANING THE CHECK HOSE .............................................................. 3-8
CHECKING THE BREATHER HOSES ..................................................... 3-8
CLEANING THE V-BELT CASE AIR FILTER ELEMENT AND
3
CLEANING THE CHECK HOSE .............................................................. 3-9
CHECKING AND CHARGING THE BATTERY .......................................3-10
CHECKING THE BRAKE OPERATION ..................................................3-10
CHECKING THE FRONT BRAKE PADS ................................................3-10
CHECKING THE REAR BRAKE PADS ..................................................3-10
CHECKING THE BRAKE FLUID LEVEL.................................................3-10
CHECKING THE FRONT BRAKE HOSES ............................................. 3-11
CHECKING THE REAR BRAKE HOSES................................................3-11
BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-12
CHECKING THE WHEELS .....................................................................3-13
CHECKING THE TIRES .......................................................................... 3-13
CHECKING THE WHEEL BEARINGS ....................................................3-14
CHECKING AND ADJUSTING THE STEERING HEAD .........................3-14
LUBRICATING THE STEERING HEAD ..................................................3-16
CHECKING THE CHASSIS FASTENERS ..............................................3-16
LUBRICATING THE LEVERS ................................................................. 3-16
CHECKING THE SIDESTAND ................................................................3-16
LUBRICATING THE SIDESTAND...........................................................3-16
CHECKING THE CENTERSTAND .........................................................3-16
LUBRICATING THE CENTERSTAND ....................................................3-16
CHECKING THE SIDESTAND SWITCH.................................................3-16
CHECKING THE FRONT FORK .............................................................3-16
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES ................3-17
CHECKING THE ENGINE OIL LEVEL....................................................3-17
CHANGING THE ENGINE OIL ...............................................................3-17
CHECKING THE COOLANT LEVEL .......................................................3-19
CHECKING THE COOLING SYSTEM ....................................................3-19
CHANGING THE COOLANT...................................................................3-19
CHANGING THE FINAL TRANSMISSION OIL.......................................3-22
REPLACING THE V-BELT ......................................................................3-22
LUBRICATING THE SECONDARY SHEAVE .........................................3-22
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-23
CHECKING AND LUBRICATING THE CABLES ....................................3-23
CHECKING THE THROTTLE GRIP OPERATION .................................3-23
CHECKING THE SWITCHES, LIGHTS AND SIGNALS .........................3-24
ADJUSTING THE HEADLIGHT BEAM ...................................................3-24
PERIODIC MAINTENANCE

EAS20022

PERIODIC MAINTENANCE
EAS30022

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS30614

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 20000 km (12000 mi), repeat the maintenance intervals starting from 4000 km (2400 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.

ODOMETER READING (whichever comes first)

CHECK OR MAINTENANCE ANNUAL
NO. ITEM JOB 1000 km 4000 km 8000 km 12000 km 16000 km CHECK
(600 mi) (2400 mi) (4800 mi) (7200 mi) (9600 mi)

• Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √

2 * Fuel filter • Check condition. Every 12000 km (7500 mi)

• Replace if necessary.
• Check condition.
• Clean and regap. √ √ √ √
3 Spark plug
• Replace. Every 8000 km (5000 mi)
• Check valve clearance.
4 * Valves • Adjust if necessary. √ √
5 * Fuel injection
• Check engine idle speed. √ √ √ √ √
• Check for leakage.
• Tighten if necessary.
6 * Exhaust system
• Replace gasket(s) if neces- √ √ √ √ √
sary.

EAS30615

GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance is
performed instead.
• From 20000 km (12000 mi), repeat the maintenance intervals starting from 4000 km (2400 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.

ODOMETER READING (whichever comes first)

CHECK OR MAINTENANCE ANNUAL
NO. ITEM JOB 1000 km 4000 km 8000 km 12000 km 16000 km CHECK
(600 mi) (2400 mi) (4800 mi) (7200 mi) (9600 mi)

1 Air filter element • Replace. Every 12000 km (7500 mi)

Air filter check
2
hose
• Clean. √ √ √ √ √

3-1
PERIODIC MAINTENANCE

ODOMETER READING (whichever comes first)

CHECK OR MAINTENANCE ANNUAL
NO. ITEM 1000 km 4000 km 8000 km 12000 km 16000 km
JOB CHECK
(600 mi) (2400 mi) (4800 mi) (7200 mi) (9600 mi)

V-belt case air fil- • Clean.

3 *
ter element • Replace if necessary. √ √ √ √
• Check voltage.
4 * Battery
• Charge if necessary. √ √ √ √ √ √
• Check operation, fluid level
and vehicle for fluid leakage. √ √ √ √ √ √
5 * Front brake
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level
and vehicle for fluid leakage. √ √ √ √ √ √
6 * Rear brake
• Replace brake pads. Whenever worn to the limit
• Check for cracks or damage.
• Check for correct routing and √ √ √ √ √
7 * Brake hoses clamping.
• Replace. Every 4 years
8 * Brake fluid • Replace. Every 2 years
• Check runout and for dam-
9 * Wheels
age. √ √ √ √
• Check tread depth and for
damage.
10 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearings for loose-
11 * Wheel bearings ness or damage. √ √ √ √
• Check bearing play and steer-
ing for roughness. √ √ √ √ √
12 * Steering bearings
• Lubricate with lithium-soap-
based grease. Every 24000 km (14000 mi)

• Make sure that all nuts, bolts and

13 * Chassis fasteners screws are properly tightened. √ √ √ √ √
Front brake lever • Lubricate with silicone
14 pivot shaft grease. √ √ √ √ √
Rear brake lever • Lubricate with silicone
15 pivot shaft grease. √ √ √ √ √
• Check operation.
Sidestand, center-
16 stand • Lubricate with lithium-soap- √ √ √ √ √
based grease.
17 * Sidestand switch • Check operation. √ √ √ √ √ √
• Check operation and for oil
18 * Front fork
leakage. √ √ √ √

19 * Shock absorber
• Check operation and shock
assemblies absorbers for oil leakage. √ √ √ √
The first 500 km (312 mi) ~ 1000 km (625 mi), next every 3000 km
• Change.
(1875 mi) ~ 4000 km (2500 mi) or when the oil change indicator flashes.
20 Engine oil
• Check oil level and vehicle for
√ √ √ √ √ √
oil leakage.
21 * Engine oil strainer • Clean. The first 500 km (312 mi) ~ 1000 km (625 mi), next every 10000 km (6250 mi)
• Check coolant level and vehi-
cle for coolant leakage. √ √ √ √ √
22 * Cooling system
• Change coolant. Every 12000 km (7500 mi)

Final transmis- • Check vehicle for oil leakage. √ √ √ √ √

23
sion oil • Change. √ Every 12000 km (7500 mi)
• Check for damage and wear. √ √ √
24 * V-belt When the V-belt replacement indicator flashes [every 25000 km (15500
• Replace.
mi)]

25 * V-belt secondary • Lubricate. Every 12000 km (7500 mi)

sheave

26 * Front and rear • Check operation. √ √ √ √ √ √

brake switches

3-2
PERIODIC MAINTENANCE

ODOMETER READING (whichever comes first)

CHECK OR MAINTENANCE ANNUAL
NO. ITEM 1000 km 4000 km 8000 km 12000 km 16000 km
JOB CHECK
(600 mi) (2400 mi) (4800 mi) (7200 mi) (9600 mi)

Moving parts and

27
cables
• Lubricate. √ √ √ √ √
• Check operation.
• Check throttle grip free play,
28 * Throttle grip and adjust if necessary. √ √ √ √ √
• Lubricate cable and grip
housing.
Lights, signals • Check operation.
29 *
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.
• V-belt case air filter
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• V-belt
• The V-belt should be checked at the initial 8000 km (5000 mi) and every 4000 km (2500 mi) there-
after. Replace the V-belt if any damage or excessive wear is found. The V-belt needs to be replaced
every 25000 km (15500 mi) even if there is not wear or damage.
• 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.
• Fuel system service
• Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal en-
gine parts, such as the valves and piston rings, as well as to the exhaust system.
• Replace the fuel filler cover every two years or if cracked or damaged.
• Check the fuel filter for clogging or damage every 12000 km (7500 mi).
• Battery service
• Check the condition and service the battery every 3 months.
• Recharge the battery immediately if the voltage is less than 12.4 V.
• If the battery tends to discharge, replace it immediately.

3-3
PERIODIC MAINTENANCE

EAS30619

CHECKING THE FUEL LINE

1. Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-4.
• Footrest board assembly (right) 1
Refer to “GENERAL CHASSIS (5)” on page
4-12.
2. Check:
• Fuel hose “1”
3. Install:
Cracks/damage → Replace.
• Fuel filter
Loose connections → Connect properly.
Refer to “FUEL TANK” on page 7-1.
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on page
4-12.
• Fuel tank cover
1 Refer to “GENERAL CHASSIS (3)” on page
4-7.
• Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-4.
3. Install: EAS30620

• Footrest board assembly (right) CHECKING THE SPARK PLUG

Refer to “GENERAL CHASSIS (5)” on page 1. Remove:
4-12. • Front side cover (right)
• Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page
Refer to “GENERAL CHASSIS (2)” on page 4-4.
4-4. • Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on page
EAS31178
4-12.
CHECKING THE FUEL FILTER
2. Remove:
1. Remove:
• Spark plug cap
• Front side covers
• Spark plug
Refer to “GENERAL CHASSIS (2)” on page ECA13330

4-4. NOTICE
• Fuel tank cover Before removing the spark plug, blow away
Refer to “GENERAL CHASSIS (3)” on page any dirt accumulated in the spark plug well
4-7. with compressed air to prevent it from falling
• Center lower cover into the cylinder.
Refer to “GENERAL CHASSIS (5)” on page
4-12. 3. Check:
• Fuel filter • Spark plug type
Refer to “FUEL TANK” on page 7-1. Incorrect → Change.
2. Check:
Manufacturer/model
• Fuel filter “1”
NGK/CPR8EA-9
Damage/contaminants → Replace.
TIP 4. Check:
Replace the fuel filter every 12000 km (7500 mi) • Electrode “1”
of operation. Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.

3-4
PERIODIC MAINTENANCE

b
a 2

5. Clean: 8. Install:
• Spark plug • Footrest board assembly (right)
(with a spark plug cleaner or wire brush) Refer to “GENERAL CHASSIS (5)” on page
6. Measure: 4-12.
• Spark plug gap “a” • Front side cover (right)
(with a wire thickness gauge) Refer to “GENERAL CHASSIS (2)” on page
Out of specification → Regap. 4-4.

Spark plug gap EAS30622

0.8–0.9 mm (0.031–0.035 in) ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
• Battery
Refer to “GENERAL CHASSIS (1)” on page
7. Install:
4-1.
• Spark plug “1”
• Front side covers
• Spark plug cap
Refer to “GENERAL CHASSIS (2)” on page
Spark plug 4-4.
13 Nm (1.3 m·kgf, 9.4 ft·lbf) • Fuel tank cover
T.
R.

Refer to “GENERAL CHASSIS (3)” on page

TIP 4-7.
• Before installing the spark plug, clean the • Center lower cover
spark plug and gasket surface. Refer to “GENERAL CHASSIS (5)” on page
• When tightening the spark plug, make sure 4-12.
that the inside “a” of the spark plug wrench “2” • Fuel tank
does not the contact the portion “b” of the spark Refer to “FUEL TANK” on page 7-1.
plug. • Cylinder head cover
• To route the spark plug lead, refer to “CON- Refer to “CYLINDER HEAD” on page 5-9.
NECTING THE LEADS” on page 5-8. • Radiator cover
Refer to “RADIATOR” on page 6-1.
2. Move:
• Radiator “1”
TIP
Move the rear of the radiator outward.

3-5
PERIODIC MAINTENANCE

a b

3. Move: c. Measure the valve clearance with a thickness

• Water pump assembly “1” gauge “1”.
TIP Out of specification → Adjust.
Move the water pump assembly in the direction
shown in the illustration.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Adjust:
• Valve clearance
4. Measure:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve clearance a. Loosen the locknut “1”.
Out of specification → Adjust. b. Insert a thickness gauge “2” between the end
of the adjusting screw and the valve tip.
Valve clearance (cold)
Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 in)
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.

c. Turn the adjusting screw “3” in direction “a” or

“b” with the tappet adjusting tool “4” until the
specified valve clearance is obtained.

Direction “a”
Valve clearance is increased.
Direction “b”
b. When the piston is at the Top Dead Center Valve clearance is decreased.
(TDC) on the compression stroke, align the
mark “a” on the camshaft sprocket with the
match mark “b” on the camshaft stopper
plate.

3-6
PERIODIC MAINTENANCE

“02” → Clean the ISC (idle speed control) unit

Tappet adjusting tool and throttle body.
90890-01311 Refer to “CLEANING THE ISC (IDLE SPEED
Six piece tappet set CONTROL) UNIT AND THROTTLE BODY”
YM-A5970
on page 7-12.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the Yamaha diagnostic tool.
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
3 9-5.

Yamaha diagnostic tool

90890-03231
a
b 4
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Hold the adjusting screw to prevent it from EAS30625

moving and tighten the locknut to specifica- CHECKING THE EXHAUST SYSTEM
tion. 1. Check:
• Muffler “1”
Valve clearance adjusting screw Cracks/damage → Replace.
locknut • Gasket “2”
T.
R.

7 Nm (0.7 m·kgf, 5.1 ft·lbf) Exhaust gas leaks → Replace.

2. Check:
e. Measure the valve clearance again.
Tightening torque
f. If the valve clearance is still out of specifica-
• Muffler nuts “3”
tion, repeat all of the valve clearance adjust-
• Muffler bolts “4”
ment steps until the specified clearance is
obtained. Muffler nut
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
R.

6. Install: Muffler bolt

• All removed parts 53 Nm (5.3 m·kgf, 38 ft·lbf)
TIP
For installation, reverse the removal procedure.

EAS31017

CHECKING THE ENGINE IDLING SPEED

TIP
Prior to checking the engine idling speed, the air
filter element should be clean, and the engine
should have adequate compression. 4

1. Start the engine and let it warm up for several

minutes. 1
2. Check: 2
• Engine idling speed 4
Out of specification → Go to next step.

Engine idling speed 3

1500–1700 r/min

3. Check:
4
• ISC (idle speed control) learning value
“00” or “01” → Check the intake system.

3-7
PERIODIC MAINTENANCE

EAS30799

ADJUSTING THE EXHAUST GAS VOLUME 2

TIP
• Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume.
• To adjust the exhaust gas volume, use the CO
adjustment mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
1. Connect the Yamaha diagnostic tool to the
connector. For information about connecting 2. Check:
the Yamaha diagnostic tool, refer to • Air filter element
“YAMAHA DIAGNOSTIC TOOL” on page Damage → Replace.
8-28. TIP
• Replace the air filter element every 12000 km
Yamaha diagnostic tool
(7500 mi) of operation.
90890-03231
• The air filter needs more frequent service if you
EAS31130
are riding in unusually wet or dusty areas.
REPLACING THE AIR FILTER ELEMENT 3. Install:
AND CLEANING THE CHECK HOSE • Air filter element
TIP • Air filter case cover
Check the air filter check hose “1” that is located
on the rear side of the air filter case. If dust or Air filter case cover screw
water or both collects in the hose, clean the hose 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf)
T.
R.

and replace the air filter element. ECA20480

NOTICE
Never operate the engine without the air filter
1 element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
tuning, leading to poor engine performance
and possible overheating.
TIP
1. Remove: When installing the air filter element into the air
• Air filter case cover “1” filter case, make sure that the sealing surfaces
• Air filter element “2” are aligned to prevent any air leaks.

1 EAS31179

CHECKING THE BREATHER HOSES

1. Remove:
• Battery
Refer to “GENERAL CHASSIS (1)” on page
4-1.
• Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-4.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on page
4-7.

3-8
PERIODIC MAINTENANCE

• Storage box EAS31704

CLEANING THE V-BELT CASE AIR FILTER

Refer to “GENERAL CHASSIS (4)” on page
ELEMENT AND CLEANING THE CHECK
4-9.
HOSE
2. Check:
• Cylinder head breather hose “1” TIP
• Transmission case breather hose “2” Check the V-belt case air filter check hose “1”
Cracks/damage → Replace. that is located on the rear side of the V-belt case.
Loose connections → Connect properly. If dust or water or both collects in the hose, clean
ECA21600 the hose and replace the V-belt case air filter el-
NOTICE ement.
Make sure the cylinder head breather hose
and transmission case breather hose are
routed correctly.

1. Remove:
• V-belt case air filter element cover “1”
• V-belt case air filter element “2”

2 1

3. Install:
• Storage box
Refer to “GENERAL CHASSIS (4)” on page
4-9.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on page
4-7. 2
• Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-4.
• Battery 2. Clean:
Refer to “GENERAL CHASSIS (1)” on page • V-belt case air filter element
4-1. (with solvent)
EWA17971

WARNING
Never use low flash point solvents, such as
gasoline, to clean the V-belt case air filter el-
ement. Such solvents may cause a fire or an
explosion.

3-9
PERIODIC MAINTENANCE

TIP TIP
• The air filter needs more frequent service if you Drive on the road, operate the front and rear
are riding in unusually wet or dusty areas. brakes separately and check to see if the brakes
• After cleaning, gently squeeze the V-belt case are operating properly.
air filter element to remove the excess solvent.
EAS30633
ECA21590

NOTICE CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the
Do not twist the V-belt case air filter element
brake pads.
when squeezing it.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicator grooves “a” almost disap-
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-36.

a
a
3. Check:
• V-belt case air filter element
Damage → Replace.
4. Apply the recommended oil to the entire sur-
face of the V-belt case air filter element and
squeeze out the excess oil. The V-belt case EAS30634

air filter element should be wet but not drip- CHECKING THE REAR BRAKE PADS
ping. The following procedure applies to all of the
brake pads.
Recommended oil 1. Operate the brake.
Engine oil 2. Check:
• Rear brake pad
5. Install: Wear indicators “a” almost touch the brake
• V-belt case air filter element
disc → Replace the brake pads as a set.
• V-belt case air filter element cover Refer to “REAR BRAKE” on page 4-49.
V-belt case air filter element cov-
er bolt
T.
R.

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

EAS30816

CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-99.
EAS30801
a
CHECKING THE BRAKE OPERATION
1. Check: EAS30632

• Brake operation CHECKING THE BRAKE FLUID LEVEL

Brake not working properly → Check the 1. Stand the vehicle on a level surface.
brake system. TIP
Refer to “FRONT BRAKE” on page 4-36 and • Place the vehicle on the centerstand.
“REAR BRAKE” on page 4-49. • Make sure the vehicle is upright.

3-10
PERIODIC MAINTENANCE

• In order to ensure a correct reading of the ECA13540

brake fluid level, make sure the top of the brake NOTICE
fluid reservoir is horizontal. Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
2. Check: any spilt brake fluid immediately.
• Brake fluid level
Below the minimum level mark “a” → Add the EAS30635
specified brake fluid to the proper level. CHECKING THE FRONT BRAKE HOSES
1. Check:
Specified brake fluid • Brake hoses “1”
YAMAHA GENUINE BRAKE
Cracks/damage → Replace.
FLUID (DOT 4)

A 1
a

1
2. Check:
• Brake hose holder
B • Brake hose guide
Loose → Tighten the holder and guide bolt.
3. Hold the vehicle upright and apply the front
brake several times.
a 4. Check:
• Brake hoses
Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-36 and
“ABS (ANTI-LOCK BRAKE SYSTEM)” on
A. Front brake page 4-61.
B. Rear brake
EAS30636
EWA13540
CHECKING THE REAR BRAKE HOSES
WARNING
1. Check:
• Use only the designated brake fluid. Other • Brake hoses “1”
brake fluids may cause the rubber seals to Cracks/damage/wear → Replace.
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that 1
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 1
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock. 2. Check:
• Brake hose holder
Loose → Tighten the holder bolt.

3-11
PERIODIC MAINTENANCE

3. Hold the vehicle upright and apply the rear

A
brake several times. 2
4. Check:
• Brake hoses
Brake fluid leakage → Replace the brake 1
hose.
Refer to “REAR BRAKE” on page 4-49 and
“ABS (ANTI-LOCK BRAKE SYSTEM)” on
page 4-61.
EAS30893

BLEEDING THE HYDRAULIC BRAKE B

SYSTEM
EWA14000

WARNING
Always bleed the brake system when the 1
brake related parts are removed.
ECA22780
2
NOTICE
• Bleed the brake system in the following or-
der.
• 1st step: Front brake caliper A. Front brake caliper
• 2nd step: Rear brake caliper B. Rear brake caliper
EWA16530
d. Place the other end of the hose into a con-
WARNING tainer.
Bleed the ABS whenever: e. Slowly apply the brake several times.
• the system is disassembled. f. Fully squeeze the brake lever and hold it in
• a brake hose is loosened, disconnected or position.
replaced. g. Loosen the bleed screw.
• the brake fluid level is very low. TIP
• brake operation is faulty.
Loosening the bleed screw will release the pres-
TIP sure and cause the brake lever to contact the
• Be careful not to spill any brake fluid or allow throttle grip or handlebar grip.
the brake master cylinder reservoir to overflow. h. Tighten the bleed screw and then release the
• When bleeding the ABS, make sure that there brake lever.
is always enough brake fluid before applying i. Repeat steps (e) to (h) until all of the air bub-
the brake. Ignoring this precaution could allow bles have disappeared from the brake fluid in
air to enter the ABS, considerably lengthening the plastic hose.
the bleeding procedure. j. Check the operation of the hydraulic unit.
• If bleeding is difficult, it may be necessary to let Refer to “HYDRAULIC UNIT OPERATION
the brake fluid settle for a few hours. TESTS” on page 4-65.
• Repeat the bleeding procedure when the tiny ECA18060

bubbles in the hose have disappeared. NOTICE

1. Bleed: Make sure that the main switch is turned to

• ABS “OFF” before checking the operation of the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
hydraulic unit.
a. Fill the brake master cylinder reservoir to the k. After operating the ABS, repeat steps (e) to
proper level with the specified brake fluid. (i), and then fill the brake master cylinder res-
b. Install the brake master cylinder diaphragm. ervoir to the proper level with the specified
c. Connect a clear plastic hose “1” tightly to the brake fluid.
bleed screw “2”. l. Tighten the bleed screw to specification.

3-12
PERIODIC MAINTENANCE

EWA13181

Brake caliper bleed screw WARNING

6 Nm (0.6 m·kgf, 4.3 ft·lbf) • The tire pressure should only be checked
T.
R.

and regulated when the tire temperature

m. Fill the brake master cylinder reservoir to the equals the ambient air temperature.
proper level with the specified brake fluid. • The tire pressure and the suspension must
Refer to “CHECKING THE BRAKE FLUID be adjusted according to the total weight
LEVEL” on page 3-10. (including cargo, rider, passenger and ac-
EWA13110

WARNING cessories) and the anticipated riding

speed.
After bleeding the hydraulic brake system,
• Operation of an overloaded vehicle could
check the brake operation.
cause tire damage, an accident or an injury.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NEVER OVERLOAD THE VEHICLE.
EAS30638

CHECKING THE WHEELS Tire air pressure (measured on

The following procedure applies to all of the cold tires)
wheels. Front (1 person)
1. Check: 150 kPa (1.50 kgf/cm², 22 psi)
• Wheel Rear (1 person)
Damage/out-of-round → Replace. 250 kPa (2.50 kgf/cm², 36 psi)
EWA13260 Front (2 persons)
WARNING 150 kPa (1.50 kgf/cm², 22 psi)
Never attempt to make any repairs to the Rear (2 persons)
wheel. 250 kPa (2.50 kgf/cm², 36 psi)
Maximum load
TIP 150 kg (311 lb)
After a tire or wheel has been changed or re- * Total weight of rider, passenger, cargo
placed, always balance the wheel. and accessories
2. Measure: EWA13190

• Radial wheel runout WARNING

• Lateral wheel runout It is dangerous to ride with a worn-out tire.
Refer to “CHECKING THE FRONT WHEEL” When the tire tread reaches the wear limit, re-
on page 4-27 and “CHECKING THE REAR place the tire immediately.
WHEEL” on page 4-34.
2. Check:
EAS30640 • Tire surfaces
CHECKING THE TIRES Damage/wear → Replace the tire.
The following procedure applies to all of the
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.

1. Tire tread depth

2. Side wall
3. Wear indicator

3-13
PERIODIC MAINTENANCE

Wear limit (front) Front tire

1.0 mm (0.04 in) Size
Wear limit (rear) 110/70–13M/C 48P
1.0 mm (0.04 in) Manufacturer/model
IRC/SS-570F
EWA14080

WARNING
• Do not use a tubeless tire on a wheel de- Rear tire
signed only for tube tires to avoid tire fail- Size
ure and personal injury from sudden 130/70–13M/C 63P
deflation. Manufacturer/model
IRC/SS-560R
• When using a tube tire, be sure to install the
correct tube. EWA13210

• Always replace a new tube tire and a new WARNING

tube as a set. New tires have a relatively low grip on the
• To avoid pinching the tube, make sure the road surface until they have been slightly
wheel rim band and tube are centered in the worn. Therefore, approximately 100 km
wheel groove. should be traveled at normal speed before
• Patching a punctured tube is not recom- any high-speed riding is done.
mended. If it is absolutely necessary to do
so, use great care and replace the tube as TIP
soon as possible with a good quality re- For tires with a direction of rotation mark “1”:
placement. • Install the tire with the mark pointing in the di-
rection of wheel rotation.
A B • Align the mark “2” with the valve installation
point.

2
1

A. Tire
B. Wheel

Tube wheel Tube tire only EAS30641

Tubeless wheel Tube or tubeless tire CHECKING THE WHEEL BEARINGS

The following procedure applies to all of the
EWA14090

WARNING
wheel bearings.
1. Check:
After extensive tests, the tires listed below • Wheel bearings
have been approved by Yamaha Motor Co., Refer to “CHECKING THE FRONT WHEEL”
Ltd. for this model. The front and rear tires on page 4-27.
should always be by the same manufacturer
and of the same design. No guarantee con- EAS30645

cerning handling characteristics can be giv- CHECKING AND ADJUSTING THE

en if a tire combination other than one STEERING HEAD
approved by Yamaha is used on this vehicle. 1. Stand the vehicle on a level surface.
EWA13120

WARNING
Securely support the vehicle so that there is
no danger of it falling over.

3-14
PERIODIC MAINTENANCE

TIP
Place the vehicle on a suitable stand so that the
front wheel elevated.
2. Check:
• Steering head
Grasp the handlebar and gently rock the han-
dlebar. 6
Binding/looseness → Adjust the steering
head. 5
3. Remove: c. Loosen the lower ring nut 1/4 of a turn, and
• Front side covers then tighten it to specification with a steering
Refer to “GENERAL CHASSIS (2)” on page nut wrench.
4-4. EWA13140

• Center lower cover WARNING

Refer to “GENERAL CHASSIS (5)” on page Do not overtighten the lower ring nut.
4-12.
• Front upper cowling assembly Lower ring nut (final tightening
Refer to “GENERAL CHASSIS (6)” on page torque)
T.
R.
4-16. 16 Nm (1.6 m·kgf, 12 ft·lbf)
• Handlebar
Refer to “HANDLEBAR” on page 4-69. d. Check the steering head for looseness or
4. Adjust: binding by turning the front fork all the way in
• Steering head both directions. If any binding is felt, remove
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the lower bracket and check the upper and
a. Remove the upper ring nut “1”, lock washer lower bearings.
“2”, center ring nut “3” and rubber washer “4”. Refer to “STEERING HEAD” on page 4-83.
e. Install the rubber washer.
f. Install the center ring nut.
g. Finger tighten the center ring nut, then align
the slots of both ring nuts. If necessary, hold
1 the lower ring nut and tighten the center ring
3 nut until their slots are aligned.
h. Install the lock washer “2”.
4 TIP
2 Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
b. Loosen the lower ring nut “5” and then tighten
it to specification with a steering nut wrench
“6”.
TIP 2
Set the torque wrench at a right angle to the a
steering nut wrench.

Steering nut wrench b

90890-01403
Exhaust flange nut wrench
YU-A9472
i. Hold the lower and center ring nuts with a
steering nut wrench and tighten the upper
Lower ring nut (initial tightening ring nut with a another steering nut wrench.
torque)
T.
R.

38 Nm (3.8 m·kgf, 27 ft·lbf)

3-15
PERIODIC MAINTENANCE

EAS30651

Steering nut wrench LUBRICATING THE SIDESTAND

90890-01403 Lubricate the pivoting point, metal-to-metal mov-
Exhaust flange nut wrench ing parts, and spring contact point of the side-
YU-A9472 stand.

Recommended lubricant
Upper ring nut Lithium-soap-based grease
75 Nm (7.5 m·kgf, 54 ft·lbf)
T.
R.

EAS30856

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE CENTERSTAND

5. Install: 1. Check:
• Handlebar • Centerstand operation
Refer to “HANDLEBAR” on page 4-69. Check that the centerstand moves smoothly.
• Front upper cowling assembly Rough movement → Repair or replace.
Refer to “GENERAL CHASSIS (6)” on page EAS30857

4-16. LUBRICATING THE CENTERSTAND

• Center lower cover Lubricate the pivoting point, metal-to-metal mov-
Refer to “GENERAL CHASSIS (5)” on page ing parts, and spring contact points of the center-
4-12. stand.
• Front side covers
Refer to “GENERAL CHASSIS (2)” on page Recommended lubricant
4-4. Lithium-soap-based grease

EAS30646 EAS30652
LUBRICATING THE STEERING HEAD CHECKING THE SIDESTAND SWITCH
1. Lubricate: Refer to “CHECKING THE SWITCHES” on
• Upper bearing page 8-95.
• Lower bearing
EAS30653
• Lower bearing dust seal
CHECKING THE FRONT FORK
Recommended lubricant 1. Stand the vehicle on a level surface.
EWA13120
Lithium-soap-based grease
WARNING
EAS31186
Securely support the vehicle so that there is
CHECKING THE CHASSIS FASTENERS no danger of it falling over.
Make sure that all nuts, bolts, and screws are 2. Check:
properly tightened. • Inner tube
Refer to “CHASSIS TIGHTENING TORQUES” Damage/scratches → Replace.
on page 2-15. • Oil seal
EAS30648 Oil leakage → Replace.
LUBRICATING THE LEVERS 3. Hold the vehicle upright and apply the front
Lubricate the pivoting point and metal-to-metal brake.
moving parts of the levers. 4. Check:
• Front fork operation
Recommended lubricant Push down hard on the handlebar several
Silicone grease times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
EAS30650

CHECKING THE SIDESTAND

1. Check: Refer to “FRONT FORK” on page 4-76.
• Sidestand operation
Check that the sidestand moves smoothly.
Rough movement → Repair or replace.

3-16
PERIODIC MAINTENANCE

TIP
• Before checking the engine oil level, wait a few
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
the oil level.

EAS30808

1 1
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES b
The following procedure applies to both of the
rear shock absorber assemblies. a
1. Stand the vehicle on a level surface.
EWA13120

WARNING Recommended brand

Securely support the vehicle so that there is YAMALUBE
no danger of it falling over. Type
SAE 10W-40
2. Check: Recommended engine oil grade
• Rear shock absorber assembly API service SG type or higher,
Oil leaks → Replace the rear shock absorber JASO standard MA or MB
assembly.
Refer to “CHECKING THE REAR SHOCK
ABSORBER ASSEMBLY” on page 4-90.
3. Check:
• Rear shock absorber assembly operation
Push down seat on the vehicle several times
and check if the rear shock absorber assem-
bly rebounds smoothly.
Rough movement → Replace.
–20 –10 0 10
Refer to “REAR SHOCK ABSORBER AS-
SEMBLIES AND SWINGARM” on page
ECA13370
4-88. NOTICE
EAS30656 Do not allow foreign materials to enter the
CHECKING THE ENGINE OIL LEVEL crankcase.
1. Stand the vehicle on a level surface.
5. Start the engine, warm it up for several min-
TIP
utes, and then turn it off.
• Place the vehicle on the centerstand. 6. Check the engine oil level again.
• Make sure the vehicle is upright.
TIP
2. Start the engine, warm it up for several min- Before checking the engine oil level, wait a few
utes, and then turn it off. minutes until the oil has settled.
3. Remove:
• Dipstick “1” EAS30657

4. Check: CHANGING THE ENGINE OIL

• Engine oil level 1. Start the engine, warm it up for several min-
The engine oil level should be between the utes, and then turn it off.
minimum level mark “a” and maximum level 2. Place a container under the engine oil drain
mark “b”. bolt.
Below the minimum level mark → Add the 3. Remove:
recommended engine oil to the proper level. • Dipstick “1”

3-17
PERIODIC MAINTENANCE

• Engine oil drain bolt “2”

(along with the gasket “3”) Oil strainer cover
32 Nm (3.2 m·kgf, 23 ft·lbf)

T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Engine oil drain bolt
(along with the gasket New )
1 Engine oil drain bolt
20 Nm (2.0 m·kgf, 14 ft·lbf)

T.
R.
7. Fill:
• Crankcase
(with the specified amount of the recom-
mended engine oil)

Engine oil quantity

3 2 Quantity (disassembled)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Periodic oil change
0.90 L (0.95 US qt, 0.79 Imp.qt)

4. Drain: 8. Install:
• Engine oil • Dipstick
(completely from the crankcase) 9. Start the engine, warm it up for several min-
5. If the oil strainer is also to be cleaned, per- utes, and then turn it off.
form the following procedure. 10.Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Engine
a. Remove the oil strainer cover “1”, spring “2”, (for engine oil leaks)
and oil strainer “3”. 11.Check:
b. Install a new O-ring “4”. • Engine oil level
TIP Refer to “CHECKING THE ENGINE OIL
Lubricate the O-ring with lithium-soap-based LEVEL” on page 3-17.
grease. 12.Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-4.
• Footrest board assembly (right)
3 Refer to “GENERAL CHASSIS (5)” on page
4-12.
2 13.Check:
• Engine oil pressure
4 New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Slightly loosen the oil check bolt “1”.

c. Clean the engine oil strainer with solvent, and

then check it for damage and replace it if nec-
essary.
d. Install the oil strainer, spring, and oil strainer
1
cover.

3-18
PERIODIC MAINTENANCE

b. Start the engine and keep it idling until engine 3. Start the engine, warm it up for several min-
oil starts to seep from the oil check bolt. If no utes, and then turn it off.
engine oil comes out after one minute, turn 4. Check:
the engine off so that it will not seize. • Coolant level
c. Check the engine oil passages and the oil TIP
pump for damage or leakage. Refer to “OIL Before checking the coolant level, wait a few
PUMP” on page 5-54. minutes until the coolant has settled.
d. Start the engine after solving the problem(s)
and check the engine oil pressure again. EAS30812

e. Tighten the oil check bolt to specification. CHECKING THE COOLING SYSTEM
1. Remove:
Engine oil check bolt • Radiator cover
7 Nm (0.7 m·kgf, 5.1 ft·lbf) Refer to “RADIATOR” on page 6-1.
T.
R.

2. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Radiator “1”
14.Reset: • Coolant reservoir hose “2”
• Oil change indicator • Radiator inlet hose “3”
Refer to “INSTRUMENT FUNCTIONS” on • Radiator outlet hose “4”
page 1-18. • Thermostat assembly “5”
EAS30811 • Water pump inlet hose “6”
CHECKING THE COOLANT LEVEL Cracks/tears → Replace.
1. Stand the vehicle on a level surface. Refer to “RADIATOR” on page 6-1 and
TIP “THERMOSTAT” on page 6-5.
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright. 3 2
2. Check: 5
• Coolant level
The coolant level should be between the min- 1
imum level mark “a” and maximum level mark
“b”.
Below the minimum level mark → Add the 4 6
recommended coolant to the proper level.
3. Install:
• Radiator cover
b Refer to “RADIATOR” on page 6-1.
a EAS30813

CHANGING THE COOLANT

1. Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-4.
ECA13470 • Bottom cover
NOTICE • Footrest board assembly (right)
• Adding water instead of coolant lowers the Refer to “GENERAL CHASSIS (5)” on page
antifreeze content of the coolant. If water is 4-12.
used instead of coolant check, and if nec- 2. Disconnect:
essary, correct the antifreeze concentra- • Coolant reservoir hose “1”
tion of the coolant. • Coolant reservoir breather hose “2”
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.

3-19
PERIODIC MAINTENANCE

EWA13030

WARNING
A hot radiator is under pressure. Therefore,
2 do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
1
cap and slowly turn the radiator cap counter-
3. Remove: clockwise toward the detent to allow any re-
• Coolant reservoir cap “1” sidual pressure to escape. When the hissing
• Coolant reservoir “2” sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
7. Remove:
• Coolant drain bolt (radiator side) “1”
1 (along with the O-ring)
• Coolant drain bolt (cylinder side) “2”
(along with the copper washer)

4. Drain:
• Coolant
(from the coolant reservoir)
5. Remove:
• Radiator cover “1”

6. Remove:
• Radiator cap “1” 2

1 8. Drain:
• Coolant
(from the engine and radiator)
9. Install:
• Coolant drain bolt (cylinder side)
(along with the copper washer New )
• Coolant drain bolt (radiator side)
(along with the O-ring New )

3-20
PERIODIC MAINTENANCE

Coolant drain bolt (cylinder side) Coolant reservoir bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf) 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.

T.
R.

R.
Coolant drain bolt (radiator side)
1.0 Nm (0.10 m·kgf, 0.72 ft·lbf) 13.Fill:
• Coolant reservoir
10.Connect: (with the recommended coolant to the maxi-
• Coolant reservoir breather hose mum level mark “a”)
• Coolant reservoir hose
11.Fill:
• Cooling system a
(with the specified amount of the recom-
mended coolant)

Recommended antifreeze
YAMAHA GENUINE COOLANT
Mixing ratio
1:1 (antifreeze: water)
Radiator (including all routes)
0.46 L (0.49 US qt, 0.40 Imp.qt) 14.Install:
Coolant reservoir (up to the • Coolant reservoir cap “1”
maximum level mark) TIP
0.25 L (0.26 US qt, 0.22 Imp.qt) Point the tab “a” on the coolant reservoir cap for-
ward.
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
EWA13040

WARNING
1 a
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc- FWD
tor.
• If coolant splashes on your clothes, quickly
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting 15.Start the engine, warm it up for several min-
and get immediate medical attention. utes, and then turn it off.
ECA13481 16.Check:
NOTICE • Coolant level
• Adding water instead of coolant lowers the Refer to “CHECKING THE COOLANT LEV-
antifreeze content of the coolant. If water is EL” on page 3-19.
used instead of coolant, check, and if nec- TIP
essary, correct the antifreeze concentra- Before checking the coolant level, wait a few
tion of the coolant. minutes until the coolant has settled.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may 17.Install:
be used. • Radiator cover
• If coolant comes into contact with painted Radiator cover bolt
surfaces, immediately wash them with wa- 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.

ter.
• Do not mix different types of antifreeze. 18.Install:
12.Install: • Footrest board assembly (right)
• Radiator cap Refer to “GENERAL CHASSIS (5)” on page
• Coolant reservoir 4-12.

3-21
PERIODIC MAINTENANCE

• Front side cover (right)

Refer to “GENERAL CHASSIS (2)” on page Final transmission oil
4-4. Type
Motor oil SAE 10W-30 type SE or
EAS31187 higher or Gear oil SAE 85W GL-3
CHANGING THE FINAL TRANSMISSION OIL Quantity
1. Stand the vehicle on a level surface. 0.15 L (0.16 US qt, 0.13 Imp.qt)
TIP
• Place the vehicle on the centerstand. 7. Install:
• Make sure the vehicle is upright. • Final transmission oil filler cap
(along with the O-ring New )
2. Start the engine, warm it up for several min-
TIP
utes, and then turn it off.
3. Place a container under the final transmis- Lubricate the O-ring with lithium-soap-based
sion. grease.
4. Remove: 8. Start the engine, warm it up for several min-
• Final transmission oil filler cap “1” utes, and then turn it off.
(along with the O-ring “2”) 9. Check:
• Final transmission oil drain bolt “3” • Final transmission oil leakage
(along with the copper washer “4”)
Completely drain the final transmission oil. EAS31188

REPLACING THE V-BELT

1 1. Remove:
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7.
• V-belt case
2 Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
2. Check:
• V-belt
Damage/wear → Replace.
Grease/oil → Clean the primary and second-
ary pulleys.
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-34.
TIP
Replace the V-belt every 25000 km (15500 mi)
4 3 of operation.
3. Install:
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
5. Install: SION” on page 5-34.
• Final transmission oil drain bolt • Air filter case
(along with the copper washer New ) Refer to “AIR FILTER CASE” on page 7-7.
EAS31705
Final transmission oil drain bolt LUBRICATING THE SECONDARY SHEAVE
20 Nm (2.0 m·kgf, 14 ft·lbf) 1. Remove:
T.
R.

• Air filter case

6. Fill:
Refer to “AIR FILTER CASE” on page 7-7.
• Final transmission oil
• Secondary sheave assembly
(with the specified amount of the recom-
Refer to “V-BELT AUTOMATIC TRANSMIS-
mended final transmission oil)
SION” on page 5-34.

3-22
PERIODIC MAINTENANCE

2. Disassemble: Faulty → Refer to “CHECKING THE

• Secondary sheave assembly SWITCHES” on page 8-95.
Refer to “V-BELT AUTOMATIC TRANSMIS-
EAS30660
SION” on page 5-34. CHECKING AND LUBRICATING THE
3. Lubricate: CABLES
• Spring seat“1” The following procedure applies to all of the in-
• O-rings “2” ner and outer cables.
• Oil seals “3” EWA13270

• Secondary sliding sheave“4” WARNING

• Secondary fixed sheave“5” Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
Recommended lubricant place damaged outer cable and inner cables
Shell dolium grease R®
as soon as possible.
1. Check:
1 • Outer cable
Damage → Replace.
2. Check:
• Cable operation
5 Rough movement → Lubricate.

Recommended lubricant
Engine oil or a suitable cable lu-
bricant
4
3 TIP
Hold the cable end upright and pour a few drops
3 of lubricant into the cable sheath or use a suit-
2 able lubricating device.

EAS30861

CHECKING THE THROTTLE GRIP

OPERATION
1. Check:
• Throttle cables
4. Assemble: Damage/deterioration → Replace.
• Secondary sheave assembly • Throttle cable installation
Refer to “V-BELT AUTOMATIC TRANSMIS- Incorrect → Reinstall the throttle cables.
SION” on page 5-34. Refer to “HANDLEBAR” on page 4-69.
5. Install: 2. Check:
• Secondary sheave assembly • Throttle grip movement
Refer to “V-BELT AUTOMATIC TRANSMIS- Rough movement → Lubricate or replace the
SION” on page 5-34. defective part(s).
• Air filter case
Recommended lubricant
Refer to “AIR FILTER CASE” on page 7-7. Suitable cable lubricant
EAS30658

CHECKING THE BRAKE LIGHT SWITCHES TIP

1. Check: With the engine stopped, turn the throttle grip
• Front brake light switch operation slowly and release it. Make sure that the throttle
• Rear brake light switch operation grip turns smoothly and returns properly when
When operating the brake levers, confirm released.
that the brake light comes on. Repeat this check with the handlebar turned all
the way to the left and right.

3-23
PERIODIC MAINTENANCE

3. Check: EWA17990

• Throttle grip free play “a” WARNING

Out of specification → Adjust. After adjusting the throttle grip free play,
start the engine and turn the handlebars to
Throttle grip free play the right and to the left to ensure that this
3.0–5.0 mm (0.12–0.20 in) does not cause the engine idling speed to
change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30663

CHECKING THE SWITCHES, LIGHTS AND

SIGNALS
1. Check that all switches operate and that all
lights come on.
a Refer to “INSTRUMENT AND CONTROL
FUNCTIONS” in Owner’s manual.
Faulty → Refer to “CHECKING THE
4. Adjust: SWITCHES” on page 8-95 and “CHECKING
• Throttle grip free play THE BULBS AND BULB SOCKETS” on
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ page 8-98.
a. Slide back the rubber cover “1”.
EAS30664
b. Loosen the locknut “2”. ADJUSTING THE HEADLIGHT BEAM
c. Turn the adjusting nut “3” in direction “a” or “b” 1. Adjust:
until the specified throttle grip free play is ob- • Headlight beam (vertically)
tained. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
Direction “a” “b”.
Throttle grip free play is increased.
Direction “b” Direction “a”
Throttle grip free play is decreased. Headlight beam is raised.
Direction “b”
Headlight beam is lowered.

a 1
a b
1
b 3
2

d. Tighten the locknut.

Throttle cable adjusting locknut

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T.
R.

e. Slide the rubber cover its original position.

TIP
Make sure that the adjusting nut is covered com-
pletely by the rubber cover.

3-24
PERIODIC MAINTENANCE

3-25
CHASSIS

GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE BATTERY COVER ....................................................... 4-2
INSTALLING THE BATTERY COVER ...................................................... 4-2
REMOVING THE ECU (engine control unit) ............................................. 4-2
INSTALLING THE ECU (engine control unit) ............................................ 4-2

GENERAL CHASSIS (2) ................................................................................. 4-4

REMOVING THE TAIL/BRAKE LIGHT OUTER COVER .......................... 4-5
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER......................... 4-5
REMOVING THE FRONT SIDE COVER .................................................. 4-5
INSTALLING THE FRONT SIDE COVER ................................................. 4-5

GENERAL CHASSIS (3) ................................................................................. 4-7

REMOVING THE FUEL TANK COVER .................................................... 4-8
INSTALLING THE FUEL TANK COVER ................................................... 4-8

GENERAL CHASSIS (4) ................................................................................. 4-9

REMOVING THE REAR SIDE COVER ASSEMBLY ..............................4-11
INSTALLING THE REAR SIDE COVER ASSEMBLY .............................4-11 4
GENERAL CHASSIS (5) ...............................................................................4-12
INSTALLING THE SIDESTAND ..............................................................4-14
INSTALLING THE CENTER LOWER COVER........................................4-14
INSTALLING THE FOOTREST BOARD ASSEMBLY.............................4-14
INSTALLING THE BOTTOM COVER .....................................................4-14

GENERAL CHASSIS (6) ...............................................................................4-16

REMOVING THE FRONT UPPER COWLING ASSEMBLY ...................4-17
INSTALLING THE FRONT UPPER COWLING ASSEMBLY ..................4-17
DISASSEMBLING THE FRONT UPPER COWLING ASSEMBLY..........4-17
ASSEMBLING THE FRONT UPPER COWLING ASSEMBLY................4-17

GENERAL CHASSIS (7) ...............................................................................4-19

REMOVING THE FRONT COWLING ASSEMBLY .................................4-21
INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-21
REMOVING THE FRONT SIDE COWLING ............................................4-21
INSTALLING THE FRONT SIDE COWLING ..........................................4-22
INSTALLING THE FRONT TURN SIGNAL LIGHT .................................4-22

GENERAL CHASSIS (8) ...............................................................................4-23

INSTALLING THE KEY SHUTTER .........................................................4-24
FRONT WHEEL.............................................................................................4-25
REMOVING THE FRONT WHEEL..........................................................4-27
DISASSEMBLING THE FRONT WHEEL ................................................4-27
CHECKING THE FRONT WHEEL ..........................................................4-27
MAINTENANCE OF THE FRONT WHEEL SENSOR AND
SENSOR ROTOR ..................................................................................4-28
ASSEMBLING THE FRONT WHEEL ...................................................... 4-28
ADJUSTING THE FRONT WHEEL STATIC BALANCE .........................4-29
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)..................4-30

REAR WHEEL ...............................................................................................4-33

REMOVING THE REAR WHEEL (DISC) ................................................4-34
CHECKING THE REAR WHEEL.............................................................4-34
MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR .................4-34
ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-34
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-34

FRONT BRAKE .............................................................................................4-36

INTRODUCTION ..................................................................................... 4-42
CHECKING THE FRONT BRAKE DISC .................................................4-42
REPLACING THE FRONT BRAKE PADS ..............................................4-43
REMOVING THE FRONT BRAKE CALIPER ..........................................4-44
DISASSEMBLING THE FRONT BRAKE CALIPER ................................ 4-44
CHECKING THE FRONT BRAKE CALIPER ..........................................4-45
ASSEMBLING THE FRONT BRAKE CALIPER ......................................4-45
INSTALLING THE FRONT BRAKE CALIPER ........................................4-45
REMOVING THE FRONT BRAKE MASTER CYLINDER ....................... 4-46
CHECKING THE FRONT BRAKE MASTER CYLINDER........................4-47
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................4-47
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-47

REAR BRAKE ...............................................................................................4-49

INTRODUCTION ..................................................................................... 4-55
CHECKING THE REAR BRAKE DISC....................................................4-55
REPLACING THE REAR BRAKE PADS.................................................4-55
REMOVING THE REAR BRAKE CALIPER ............................................4-56
DISASSEMBLING THE REAR BRAKE CALIPER .................................. 4-57
CHECKING THE REAR BRAKE CALIPER ............................................. 4-57
ASSEMBLING THE REAR BRAKE CALIPER ........................................4-58
INSTALLING THE REAR BRAKE CALIPER ........................................... 4-58
REMOVING THE REAR BRAKE MASTER CYLINDER .........................4-59
CHECKING THE REAR BRAKE MASTER CYLINDER ..........................4-59
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-59
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................4-59

ABS (ANTI-LOCK BRAKE SYSTEM)...........................................................4-61

REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-63
CHECKING THE HYDRAULIC UNIT ASSEMBLY .................................. 4-63
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ................................ 4-63
HYDRAULIC UNIT OPERATION TESTS................................................4-65
CHECKING THE ABS WARNING LIGHT ...............................................4-68
HANDLEBAR ................................................................................................ 4-69
REMOVING THE UPPER HANDLEBAR COVER ASSEMBLY ..............4-72
DISASSEMBLING THE UPPER HANDLEBAR COVER
ASSEMBLY ............................................................................................4-72
REMOVING THE HANDLEBAR ..............................................................4-72
CHECKING THE HANDLEBAR ..............................................................4-72
INSTALLING THE HANDLEBAR ............................................................4-72
ASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ..........4-75
INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY .............4-75

FRONT FORK................................................................................................ 4-76

REMOVING THE FRONT FORK LEGS ..................................................4-78
DISASSEMBLING THE FRONT FORK LEGS ........................................4-78
CHECKING THE FRONT FORK LEGS ..................................................4-79
ASSEMBLING THE FRONT FORK LEGS ..............................................4-79
INSTALLING THE FRONT FORK LEGS ................................................4-82

STEERING HEAD..........................................................................................4-83
REMOVING THE LOWER BRACKET.....................................................4-85
CHECKING THE STEERING HEAD .......................................................4-85
INSTALLING THE STEERING HEAD .....................................................4-85

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM...................4-88

REMOVING THE SWINGARM................................................................4-90
MAINTENANCE OF THE REAR WHEEL SENSOR ...............................4-90
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-90
CHECKING THE SWINGARM ................................................................4-90
INSTALLING THE SWINGARM ..............................................................4-90
GENERAL CHASSIS (1)

EAS20026

GENERAL CHASSIS (1)

Removing the battery and ECU

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
1

Order Job/Parts to remove Q’ty Remarks

Seat Open.
1 Battery cover 1
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery 1
5 ECU coupler 1 Disconnect.
6 ECU (Engine Control Unit) 1
7 Band 1

4-1
GENERAL CHASSIS (1)

EAS31677

REMOVING THE BATTERY COVER

1. Remove: 1
• Battery cover “1”
a
b

b. Install the battery cover screws, and then

tighten the screws to specification.

Battery cover screw

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)

T.
a. Open the seat.

R.
b. Remove the battery cover screws. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Slide the battery cover rearward to remove
EAS31679
the projections “a” on the battery cover from REMOVING THE ECU (engine control unit)
the holes “b” in the storage box. 1. Disconnect:
• ECU coupler “1”
1 TIP
While pushing the portion “a” of the ECU cou-
a pler, move the lock lever “b” in the direction of
b the arrow shown to disconnect the coupler.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31678

INSTALLING THE BATTERY COVER b

1. Install:
• Battery cover “1” a

EAS31680

INSTALLING THE ECU (engine control unit)

1. Connect:
• ECU coupler “1”
TIP
Connect the ECU coupler, and then push the
lock lever “a” of the coupler in the direction of the
arrow shown.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the battery cover
into the holes “b” in the storage box, and then
slide the cover forward.

4-2
GENERAL CHASSIS (1)

4-3
GENERAL CHASSIS (2)

EAS20155

GENERAL CHASSIS (2)

Removing the grab bar and front side covers

1
17 Nm (1.7 m•kgf, 12 ft•Ibf)

T.R
.
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
2
3
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)
T.R
.

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Grab bar 1
2 Tail/brake light outer cover 1
3 Tail/brake light inner cover 1
4 Front side cover (left) 1
5 Front side cover (right) 1

4-4
GENERAL CHASSIS (2)

EAS31681

REMOVING THE TAIL/BRAKE LIGHT OUTER

COVER
a
1. Remove:
• Tail/brake light outer cover “1”
b

b. Install the tail/brake light outer cover screws,

and then tighten the screws to specification.

Tail/brake light outer cover screw

1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)

T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the tail/brake light outer cover ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
screws.
EAS31683
b. Slide the tail/brake light outer cover rearward REMOVING THE FRONT SIDE COVER
to remove the projection “a” on the cover from The following procedure applies to both of the
the hole “b” in the tail/brake light. front side cover.
1. Remove:
• Front side cover “1”
a

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31682

INSTALLING THE TAIL/BRAKE LIGHT ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

OUTER COVER a. Remove the front side cover screws.
1. Install: b. Pull the front side cover outward to remove
• Tail/brake light outer cover “1” the projections “a” from the grommets “b”.

b b

a
1

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Slide the tail/brake light outer cover forward,
EAS31684
fit the projection “a” on the cover into the hole INSTALLING THE FRONT SIDE COVER
“b” in the tail/brake light. The following procedure applies to both of the
front side cover.
1. Install:
• Front side cover “1”

4-5
GENERAL CHASSIS (2)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the front side cowl-
ing into the grommets “b”.

b b

a
1

b. Install the front side cover screws, and then

tighten the screw to specification.

Front side cover screw

1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
T.
R.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-6
GENERAL CHASSIS (3)

EAS20156

GENERAL CHASSIS (3)

Removing the fuel tank cover and seat assembly

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

4
3

1 6

2
5
7
(3)
(4)

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-4.
1 Fuel tank cap 1
2 Fuel tank cover 1
3 Center cover 1
4 Seat assembly 1
5 Owner’s tool kit 1
6 Seat 1
7 Seat hinge 1

4-7
GENERAL CHASSIS (3)

EAS31685

REMOVING THE FUEL TANK COVER

1. Remove:
• Fuel tank cover “1”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slide the fuel tank cover forward and fit the
projections “a” on the cover into the holes “b”
in the leg shield.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Fit the projections “c” on the fuel tank cover
a. Remove the fuel tank cover screws.
into the holes “d” in the storage box.
b. Pull the fuel tank cover upward to remove the
c. Install the fuel tank cover screws, and then
projections “a” on the cover from the holes “b”
tighten the screws to specification.
in the storage box.
c. Slide the fuel tank cover rearward to remove Fuel tank cover screw
the projections “c” on the cover from the holes 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
T.
R.

“d” in the leg shield.

c a

d b
c a

1 1

a a c c

b d

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31686

INSTALLING THE FUEL TANK COVER

1. Install:
• Fuel tank cover “1”

4-8
GENERAL CHASSIS (4)

EAS20157

GENERAL CHASSIS (4)

Removing the rear side covers and storage box
7

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
6
4

5 1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
(3)

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

(3) 2 1

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

3
T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Battery Refer to “GENERAL CHASSIS (1)” on page

4-1.

Front side cover Refer to “GENERAL CHASSIS (2)” on page

4-4.

Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page

4-7.
1 Rear side cover assembly (left) 1
2 Center side cover (left) 1
3 Rear side cover (left) 1
4 Rear side cover assembly (right) 1
5 Center side cover (right) 1
6 Rear side cover (right) 1
7 Brake light coupler 1 Disconnect.
8 Taillight/rear turn signal coupler 1 Disconnect.

4-9
GENERAL CHASSIS (4)

Removing the rear side covers and storage box

13
12
11
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
14

10
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
(3)

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

(3)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

9 Tail/brake light assembly 1
10 Starter relay 1
11 Fuse box 1 1
12 Fuse box 2 1
13 Storage box 1
14 Flap 1

4-10
GENERAL CHASSIS (4)

EAS31687

REMOVING THE REAR SIDE COVER 1

ASSEMBLY
The following procedure applies to both of the a
rear side cover assembly.
1. Remove:
• Rear side cover assembly “1” b

b. Install the quick fasteners, screw, and bolt,

and then tighten the screw and bolts to spec-
ification.

Rear side cover assembly screw

1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)

T.
R.
Footrest board and rear side cov-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ er bolt
a. Remove the quick fasteners, screw and bolt. 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
b. Remove the projections “a” on the rear side
cover assembly from the holes “b” in the stor- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
age box.

1
a

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31688

INSTALLING THE REAR SIDE COVER

ASSEMBLY
The following procedure applies to both of the
rear side cover assembly.
1. Install:
• Rear side cover assembly “1”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the rear side cover
assembly into the holes “b” in the storage
box.

4-11
GENERAL CHASSIS (5)

EAS20158

GENERAL CHASSIS (5)

Removing the bottom cover, center lower cover and footrest board
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
3 3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)

T.R
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)

T.R
.
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
5
24 Nm (2.4 m•kgf, 17 ft•Ibf)

T.R
.

LS
4

LS

1 7

2
Order Job/Parts to remove Q’ty Remarks
Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-4.
Refer to “GENERAL CHASSIS (3)” on page
Seat assembly 4-7.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-9.
1 Bottom cover 1
2 Footrest board mat (left) 2
3 Footrest board mat (right) 2
4 Footrest board assembly (left) 1
5 Footrest board assembly (right) 1
6 Center lower cover 1
7 Front lower cover (left) 1
8 Footrest board (left) 1

4-12
GENERAL CHASSIS (5)

Removing the bottom cover, center lower cover and footrest board
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)

T.R
.
10
11

3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf)

T.R
.
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
24 Nm (2.4 m•kgf, 17 ft•Ibf)

T.R
.
LS
9
14

12

13
LS

Order Job/Parts to remove Q’ty Remarks

9 Front lower cover (right) 1
10 Coolant reservoir cap cover 1
11 Footrest board (right) 1
12 Outer spring 1
13 Inner spring 1
14 Sidestand 1

4-13
GENERAL CHASSIS (5)

EAS31732 EAS31690

INSTALLING THE SIDESTAND INSTALLING THE FOOTREST BOARD

1. Install: ASSEMBLY
• Sidestand “1” 1. Install:
• Inner spring “2” • Footrest board assembly “1”
• Outer spring “3”

Sidestand nut
24 Nm (2.4 m·kgf, 17 ft·lbf)
T.
R.

TIP
Make sure that the hooked end “a” of the outer
spring is positions to the outside.

a 2 3
Footrest board assembly bolt
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)

T.
R.
TIP
Make sure that the projection “a” on the frame
fits into the hole “b” in the footrest board assem-
1 bly.
EAS31689

INSTALLING THE CENTER LOWER COVER a

1. Install:
• Center lower cover “1”
b

EAS31691

INSTALLING THE BOTTOM COVER

1. Install:
• Bottom cover “1”
TIP
• Fit the end of the fuel tank overflow hose “2”
into the hole “a” in the center lower cover.
• Fit the hole “b” in the center lower cover over
the hook “c” on the frame.

c
b
1
a 2
TIP
Make sure that the projections “a” on the center
lower cover fit into the holes “b” in the bottom
cover.

4-14
GENERAL CHASSIS (5)

a b

4-15
GENERAL CHASSIS (6)

EAS20159

GENERAL CHASSIS (6)

Removing the meter assembly
3.8 Nm (0.38 m•kgf, 2.8 ft•Ibf) 1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R

T.R
.

.
8
2 5
0.4 Nm (0.04 m•kgf, 0.29 ft•Ibf)
T.R
.

1
9
7
(4) (4)
3 6

(3) 4

(4)
(6)

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Windshield 1
2 Front upper cowling assembly 1
3 Front upper cowling 1
4 Front upper panel 1
5 Meter panel assembly 1
6 Meter assembly coupler 1 Disconnect.
7 Meter assembly 1
8 Meter assembly inner panel 1
9 Meter assembly panel 1

4-16
GENERAL CHASSIS (6)

EAS31692

REMOVING THE FRONT UPPER COWLING c

ASSEMBLY 1
1. Remove: d
• Front upper cowling assembly “1”

a
a
b b

b. Install the front upper cowling assembly

screw, and then tighten the screw to specifi-
cation.

Front upper cowling assembly

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
screw

T.
a. Remove the front upper cowling assembly

R.
1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
screw.
b. Remove the projections “a” on the front upper
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
cowling assembly from the holes “b” in the leg
EAS31694
shield and remove the projections “c” from DISASSEMBLING THE FRONT UPPER
the holes “d” in the headlight unit. COWLING ASSEMBLY
a 1. Disassemble:
1 • Front upper cowling “1”
b • Front upper panel “2”
TIP
Remove the projections “a” on the front upper
cowling from the holes “b” in the front upper pan-
c el, slide the panel in the direction shown in the il-
c lustration, and remove the projections “c” on the
d d
panel from the holes “d” in the cowling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31693
b
INSTALLING THE FRONT UPPER COWLING 2
ASSEMBLY
1. Install: c
a
• Front upper cowling assembly “1” 1

a
d
EAS31695

ASSEMBLING THE FRONT UPPER

COWLING ASSEMBLY
1. Assemble:
• Front upper panel “1”
• Front upper cowling “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the front upper cowl- Front upper panel screw
ing assembly into the holes “b” in the head- 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
T.
R.

light unit and fit the projections “c” into the

holes “d” in the leg shield.

4-17
GENERAL CHASSIS (6)

TIP
Slide the front upper panel in the direction
shown in the illustration, fit the projections “a” on
the panel into the holes “b” in the front upper
cowling, and fit the projections “c” on the cowling
into the holes “d” in the panel.

d
1
a
c
2

c
b

4-18
GENERAL CHASSIS (7)

EAS20193

GENERAL CHASSIS (7)

Removing the front cowling assembly
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
(5) 1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
(3)

(8)

(5)
3
(3)

2 1

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-4.
Refer to “GENERAL CHASSIS (3)” on page
Seat assembly 4-7.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-9.
Refer to “GENERAL CHASSIS (5)” on page
Center lower cover 4-12.
Refer to “GENERAL CHASSIS (6)” on page
Meter panel assembly 4-16.
1 Headlight unit coupler 1 Disconnect.
2 Auxiliary light coupler 1 Disconnect.
3 Front turn signal light coupler (left) 1 Disconnect.

4-19
GENERAL CHASSIS (7)

Removing the front cowling assembly

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
(5) 1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.
4
(3)
11 5
(8)
7
(5)
10 (3)
8

6
9

13 1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

12

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

4 Front turn signal light coupler (right) 1 Disconnect.
5 Front cowling assembly 1
6 Front turn signal light (left) 1
7 Front turn signal light (right) 1
8 Front side cowling (left) 1
9 Front side panel (left) 1
10 Front side cowling (right) 1
11 Front side panel (right) 1
12 Front lower cowling 1
13 Headlight unit 1

4-20
GENERAL CHASSIS (7)

EAS31278

REMOVING THE FRONT COWLING b

ASSEMBLY b a
1. Remove: 1
• Front cowling assembly “1”

b. Install the front cowling assembly screws,

and then tighten the screws to specification.

Front cowling assembly screw

(M5 × 15)

T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
a. Remove the front cowling assembly screws. Front cowling assembly screw
b. Pull the front cowling assembly forward to re- (M5 × 11)
move the projections “a” on the leg shield 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
from the holes “b” in the front cowling assem-
bly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31696
b
b a REMOVING THE FRONT SIDE COWLING
The following procedure applies to both of the
1 front side cowling.
1. Remove:
• Front side cowling “1”
a

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31279

INSTALLING THE FRONT COWLING

ASSEMBLY
1. Install:
• Front cowling assembly “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the front side cowling screws.
b. Remove the projections “a” on the front side
cowling from the holes “b” in the front lower
cowling.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the leg shield into
the holes “b” in the front cowling assembly. b
a
a

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

4-21
GENERAL CHASSIS (7)

EAS31697

INSTALLING THE FRONT SIDE COWLING

The following procedure applies to both of the
front side cowling.
1. Install: 2 3
• Front side cowling “1”

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the front side cowl-
ing into the holes “b” in the front lower cowl-
ing.

b
a
a
b. Install the front side cowling screws, and then
tighten the screws to specification.

Front side cowling screw

1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
T.
R.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31698

INSTALLING THE FRONT TURN SIGNAL

LIGHT
The following procedure applies to both of the
front turn signal light.
1. Install:
• Turn signal light “1”

Turn signal light screw

1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)
T.
R.

TIP
Tighten the turn signal light screw in the proper
tightening sequence as shown.

4-22
GENERAL CHASSIS (8)

EAS20194

GENERAL CHASSIS (8)

Removing the leg shield

3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)

T.R
.
1

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-4.
Refer to “GENERAL CHASSIS (3)” on page
Seat assembly 4-7.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-9.
Refer to “GENERAL CHASSIS (5)” on page
Center lower cover 4-12.
Refer to “GENERAL CHASSIS (6)” on page
Meter panel assembly 4-16.
Refer to “GENERAL CHASSIS (7)” on page
Front cowling assembly 4-19.
1 Key shutter 1
2 Leg shield 1

4-23
GENERAL CHASSIS (8)

EAS31700

INSTALLING THE KEY SHUTTER

1. Install:
• Key shutter “1”

Key shutter screw

3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
T.
R.

TIP
While holding the key shutter so that it contacts
the leg shield “2”, tighten the key shutter screw
“3” to specification.

4-24
FRONT WHEEL

EAS20028

FRONT WHEEL
Removing the front wheel and brake disc

40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
.

3 8
7
1

4 6 10
LS LT

New
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

New LT

New LT
8 Nm (0.8 m•kgf, 5.8 ft•Ibf) 23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Front brake hose guide 1
2 Front wheel sensor lead holder 1
3 Front brake caliper 1
4 Front wheel sensor 1
5 Front wheel axle nut 1
6 Front wheel axle 1
7 Collar 2
8 Front wheel 1
9 Front wheel sensor rotor 1
10 Front brake disc 1

4-25
FRONT WHEEL

Disassembling the front wheel

New 1
New 2

LS

3
New 2
New 1

LS

Order Job/Parts to remove Q’ty Remarks

1 Oil seal 2
2 Wheel bearing 2
3 Spacer 1

4-26
FRONT WHEEL

EAS30145

REMOVING THE FRONT WHEEL

ECA20981

NOTICE
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or 2
front wheel sensor rotor; otherwise, the
sensor or rotor may be damaged, resulting 1
in improper performance of the ABS sys-
tem.
• Do not drop the front wheel sensor rotor or c. Remove the wheel bearings “3” with a gener-
subject it to shocks. al bearing puller.
• If any solvent gets on the front wheel sen-
sor rotor, wipe it off immediately.
1. Stand the vehicle on a level surface.
EWA13120

WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Front brake caliper
ECA21830
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTICE
EAS30147
Do not apply the brake lever when removing CHECKING THE FRONT WHEEL
the brake caliper. 1. Check:
3. Elevate: • Wheel axle
• Front wheel Roll the wheel axle on a flat surface.
Bends → Replace.
TIP EWA13460

Place the vehicle on a suitable stand so that the WARNING

front wheel is elevated. Do not attempt to straighten a bent wheel ax-
le.
EAS30146

DISASSEMBLING THE FRONT WHEEL

1. Remove:
• Oil seals
• Wheel bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface. 2. Check:
• Tire
• Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-13 and “CHECKING THE WHEELS” on
page 3-13.
3. Measure:
• Radial wheel runout “1”

4-27
FRONT WHEEL

• Lateral wheel runout “2” 1. Check:

Over the specified limits → Replace. • Front wheel sensor “1”
Cracks/bends/distortion → Replace.
Radial wheel runout limit Iron powder/dust → Clean.
1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)

2
1

2. Check:
• Front wheel sensor rotor “1”
Cracks/damage/scratches → Replace the
4. Check: front wheel sensor rotor.
• Wheel bearings Iron powder/dust/solvent → Clean.
Front wheel turns roughly or is loose → Re- TIP
place the wheel bearings. When cleaning the wheel sensor rotor, be care-
• Oil seals ful not to damage the surface of the sensor rotor.
Damage/wear → Replace.

EAS30151
EAS30155
ASSEMBLING THE FRONT WHEEL
MAINTENANCE OF THE FRONT WHEEL 1. Lubricate:
SENSOR AND SENSOR ROTOR • Oil seal lips
ECA21070

NOTICE
Recommended lubricant
• Handle the ABS components with care Lithium-soap-based grease
since they have been accurately adjusted.
Keep them away from dirt and do not sub- 2. Install:
ject them to shocks. • Wheel bearings New
• The front wheel sensor cannot be disas-
sembled. Do not attempt to disassemble it. • Oil seals New
If faulty, replace with a new one. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearing (right side).
• Keep any type of magnets (including mag- ECA18110

netic pick-up tools, magnetic screwdrivers, NOTICE

etc.) away from the front wheel sensor or Do not contact the wheel bearing inner race
front wheel sensor rotor. “1” or balls “2”. Contact should be made
• Do not drop or shock the wheel sensor or only with the outer race “3”.
the wheel sensor rotor.

4-28
FRONT WHEEL

TIP b. When the front wheel stops, put an “X1” mark

Use a socket “4” that matches the diameter of at the bottom of the wheel.
the wheel bearing outer race.

c. Turn the front wheel 90° so that the “X1” mark

is positioned as shown.
b. Install the spacer.
d. Release the front wheel.
c. Install the new wheel bearing (left side).
e. When the wheel stops, put an “X2” mark at
TIP
the bottom of the wheel.
Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
“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”.

f. Repeat steps (c) through (e) several times

until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30152 3. Adjust:
ADJUSTING THE FRONT WHEEL STATIC • Front wheel static balance
BALANCE TIP
TIP • Install the balancing weights on the rim of the
• After replacing the tire, wheel or both, the front brake disc side of the wheel.
wheel static balance should be adjusted. • Install up to four balancing weights on the rim.
• Adjust the front wheel static balance with the
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
brake disc installed. a. Install a balancing weight “1” onto the rim ex-
1. Remove: actly opposite the heavy spot “X”.
• Balancing weight(s) TIP
2. Find: Start with the lightest weight.
• Front wheel’s heavy spot
TIP
Place the front wheel on a suitable balancing
stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.

4-29
FRONT WHEEL

Front wheel sensor rotor bolt

8 Nm (0.8 m·kgf, 5.8 ft·lbf)

T.
R.
LOCTITE®
Front brake disc bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
LOCTITE®
ECA21011

NOTICE
• Do not drop the wheel sensor rotor or sub-
b. Turn the front wheel 90° so that the heavy ject it to shocks.
spot is positioned as shown. • If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones.
TIP
• Install the brake disc with its chamfered side
“a” facing inward.
• Install the front wheel sensor rotor with the
stamped mark “b” facing away from the wheel.
• Tighten the bolts in stages.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel 1
is balanced. 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at a
each position shown.

b. If the front wheel does not remain stationary

at all of the positions, rebalance it. 2. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Front brake disc
EAS30154 Refer to “CHECKING THE FRONT BRAKE
INSTALLING THE FRONT WHEEL (FRONT DISC” on page 4-42.
BRAKE DISC) 3. Lubricate:
1. Install: • Wheel axle
• Front brake disc “1”
• Front wheel sensor rotor “2” Recommended lubricant
Lithium-soap-based grease

4-30
FRONT WHEEL

4. Install: Out of specification → Check the wheel bear-

• Front wheel ing for looseness, and the front wheel sensor
• Collars and sensor rotor installation conditions (war-
• Front wheel axle page caused by overtorque, wrong installa-
TIP tion direction, rotor decentering, LOCTITE®
Install the front wheel with the mark “a” on the on the mounting surface of the rotor, defor-
front tire pointing in the direction of wheel rota- mation caused by an impact during service
tion. and caught foreign materials). If there is any
defective part, repair or replace the defective
part.

a Distance “a” (between the front

wheel sensor rotor and front
wheel sensor)
0.92–1.66 mm (0.036–0.065 in)

TIP
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
5. Tighten: places in one rotation of the front wheel. Do not
• Front wheel axle nut turn the front wheel while the thickness gauge is
installed. This may damage the front wheel sen-
Front wheel axle nut sor rotor and the front wheel sensor.
40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.

ECA14140 Thickness gauge

NOTICE 90890-03180
Feeler gauge set
Before tightening the wheel axle nut, push
YU-26900-9
down hard on the handlebar(s) several times
and check if the front fork rebounds smooth-
ly. a
6. Install: 2
• Front wheel sensor
2
Front wheel sensor bolt 1
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.

1
ECA21020

NOTICE
Make sure there are no foreign materials in
8. Install:
the front wheel sensor rotor and front wheel
• Front brake caliper
sensor. Foreign materials cause damage to
• Front wheel sensor lead holder “1”
the front wheel sensor rotor and front wheel
• Front brake hose guide “2”
sensor.
TIP Front brake caliper bolt
35 Nm (3.5 m·kgf, 25 ft·lbf)
T.

• When installing the front wheel sensor, check

R.

Front brake hose guide bolt

the wheel sensor lead for twists. 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
• To route the front wheel sensor lead, refer to
“CABLE ROUTING” on page 2-29. EWA13500

WARNING
7. Measure:
• Distance “a” Make sure the brake hose is routed properly.
(between the front wheel sensor rotor “1” and
front wheel sensor “2”)

4-31
FRONT WHEEL

TIP
While holding the front brake hose guide and
front wheel sensor lead holder so that the por-
tions “a” of the guide and holder contact the front
fork outer tube, tighten the bolts to specification.

4-32
REAR WHEEL

EAS20029

REAR WHEEL
Removing the rear wheel and brake disc

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.
23 Nm (2.3 m•kgf, 17 ft•Ibf)

T.R
.
LT
LT

LT
New

1 3

LT
2
LT
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R

New
.

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-4.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-7.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-9.
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Radiator cover Refer to “RADIATOR” on page 6-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-7.
Refer to “REAR SHOCK ABSORBER AS-
Swingarm assembly SEMBLIES AND SWINGARM” on page
4-88.
1 Rear wheel 1
2 Rear wheel sensor rotor 1
3 Rear brake disc 1

4-33
REAR WHEEL

EAS30156
• Keep any type of magnets (including mag-
REMOVING THE REAR WHEEL (DISC)
ECA22870
netic pick-up tools, magnetic screwdrivers,
NOTICE etc.) away from the rear wheel sensor rotor.
• Keep any type of magnets (including mag- • Do not drop or shock the wheel sensor ro-
netic pick-up tools, magnetic screwdrivers, tor.
etc.) away from the rear wheel sensor rotor; 1. Check:
otherwise, the rotor may be damaged, re- • Rear wheel sensor rotor
sulting in improper performance of the ABS Refer to “MAINTENANCE OF THE FRONT
system. WHEEL SENSOR AND SENSOR ROTOR”
• Do not drop the rear wheel sensor rotor or on page 4-28.
subject it to shocks.
EAS30164
• If any solvent gets on the rear wheel sensor ADJUSTING THE REAR WHEEL STATIC
rotor, wipe it off immediately. BALANCE
1. Stand the vehicle on a level surface. TIP
EWA13120
• After replacing the tire, wheel or both, the rear
WARNING
wheel static balance should be adjusted.
Securely support the vehicle so that there is • Adjust the rear wheel static balance with the
no danger of it falling over. brake disc installed.
TIP 1. Adjust:
Place the vehicle on the centerstand so that the • Rear wheel static balance
rear wheel is elevated. Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-29.
EAS30159

CHECKING THE REAR WHEEL EAS30165

1. Check: INSTALLING THE REAR WHEEL (REAR

• Tire BRAKE DISC)
• Rear wheel 1. Install:
Damage/wear → Replace. • Rear brake disc “1”
Refer to “CHECKING THE TIRES” on page • Rear wheel sensor rotor “2”
3-13 and “CHECKING THE WHEELS” on Rear wheel sensor rotor bolt
page 3-13. 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
T.

2. Measure:
R.

LOCTITE®
• Radial wheel runout Rear brake disc bolt
• Lateral wheel runout 23 Nm (2.3 m·kgf, 17 ft·lbf)
Refer to “CHECKING THE FRONT WHEEL” LOCTITE®
on page 4-27.
ECA21011

Radial wheel runout limit NOTICE

1.0 mm (0.04 in) • Do not drop the wheel sensor rotor or sub-
Lateral wheel runout limit ject it to shocks.
1.0 mm (0.04 in) • If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
EAS31630
• Replace the brake disc bolts and wheel
MAINTENANCE OF THE REAR WHEEL
sensor rotor bolts with new ones.
SENSOR ROTOR
ECA22890
TIP
NOTICE
• Install the brake disc with its chamfered side
• Handle the ABS components with care “a” facing inward.
since they have been accurately adjusted. • Install the front wheel sensor rotor with the
Keep them away from dirt and do not sub- stamped mark “b” facing away from the wheel.
ject them to shocks. • Tighten the bolts in stages.

4-34
REAR WHEEL

1 1

b
2

2. Check:
• Rear brake disc
Refer to “CHECKING THE REAR BRAKE
DISC” on page 4-55.

4-35
FRONT BRAKE

EAS20030

FRONT BRAKE
Removing the front brake pads

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.

2
4

1
7
3

5
35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Front wheel sensor lead holder 1
2 Front brake caliper 1
3 Brake pad clip 2
4 Brake pad pin 1
5 Brake pad (inner) 1
6 Brake pad (outer) 1
7 Brake pad spring 1
8 Brake caliper bleed screw 1

4-36
FRONT BRAKE

Removing the front brake master cylinder

11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.

3
29 Nm (2.9 m•kgf, 21 ft•Ibf)

T.R
.
8
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
9 New
T.R
.

6
S

5 4
6

6 Nm (0.6 m•kgf, 4.3 ft•Ibf) 1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-69.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 er 1

3 Brake master cylinder reservoir diaphragm 1

4 Front brake light switch connector 2 Disconnect.
5 Front brake light switch 1
6 Front brake lever pivot bolt/nut 1/1
7 Front brake lever 1
Front brake hose union bolt (master cylinder
8 side) 1

9 Brake hose gasket 2

4-37
FRONT BRAKE

Removing the front brake master cylinder

11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

11

T.R
.
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)
T.R
.

29 Nm (2.9 m•kgf, 21 ft•Ibf)

T.R
12

.
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
New
T.R
.

10

6 Nm (0.6 m•kgf, 4.3 ft•Ibf) 1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

Front brake hose (front brake master cylinder to
10 hydraulic unit) 1 Disconnect.

11 Front brake master cylinder holder 1

12 Front brake master cylinder assembly 1

4-38
FRONT BRAKE

Disassembling the front brake master cylinder

BF
S

BF
2

1 New

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder kit 1
2 Brake master cylinder body 1

4-39
FRONT BRAKE

Removing the front brake caliper

1 3

2 New
4
5
29 Nm (2.9 m•kgf, 21 ft•Ibf)
T.R
.

35 Nm (3.5 m•kgf, 25 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Front brake hose union bolt (brake caliper side) 1
2 Brake hose gasket 2
Front brake hose (hydraulic unit to front brake
3 caliper) 1 Disconnect.

4 Front wheel sensor lead holder 1

5 Front brake caliper 1

4-40
FRONT BRAKE

Disassembling the front brake caliper

6
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.
S

7
11 New 8
New 9
10

2 5

BF
S 3

4
1

Order Job/Parts to remove Q’ty Remarks

1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad (inner) 1
4 Brake pad (outer) 1
5 Brake pad spring 1
6 Front brake caliper bracket 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Brake caliper bleed screw 1
11 Brake caliper body 1

4-41
FRONT BRAKE

EAS30168
e. Measure the runout 1.5 mm (0.06 in) below
INTRODUCTION
EWA14101
the edge of the brake disc.
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
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

• Never use solvents on internal brake com- 4. Measure:

ponents. • Brake disc thickness
• Use only clean or new brake fluid for clean- Measure the brake disc thickness at a few dif-
ing brake components. ferent locations.
• Brake fluid may damage painted surfaces Out of specification → Replace.
and plastic parts. Therefore, always clean
Brake disc thickness limit
up any spilt brake fluid immediately.
3.5 mm (0.14 in)
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.

EAS30169

CHECKING THE FRONT BRAKE DISC

1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-25.
2. Check: 5. Adjust:
• Brake disc • Brake disc runout
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Damage/galling → Replace. a. Remove the brake disc.
3. Measure: b. Rotate the brake disc by one bolt hole.
• Brake disc runout c. Install the brake disc.
Out of specification → Correct the brake disc
runout or replace the brake disc. Front brake disc bolt
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.

Brake disc runout limit (as mea-

R.

LOCTITE®
sured on wheel)
0.15 mm (0.0059 in) ECA19150

NOTICE
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Replace the brake disc bolts with new ones.
a. Place the vehicle on a suitable stand so that
the front wheel is elevated. TIP
b. Before measuring the front brake disc runout, • Install the brake disc “1” with its chamfered
turn the handlebar to the left or right to ensure side “a” facing inward.
that the front wheel is stationary. • Tighten the brake disc bolts in stages.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.

4-42
FRONT BRAKE

B
1
1
a

A. Inner
d. Measure the brake disc runout.
B. Outer
e. If out of specification, repeat the adjustment
steps until the brake disc runout is within 2. Install:
specification. • Brake pad spring “1”
f. If the brake disc runout cannot be brought • Brake pads
within specification, replace the brake disc. TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always install new brake pads, and new brake
6. Install: pad spring, as a set.
• Front wheel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “FRONT WHEEL” on page 4-25. a. Connect a clear plastic hose “1” tightly to the
EAS30170 bleed screw “2”. Put the other end of the hose
REPLACING THE FRONT BRAKE PADS into an open container.
TIP b. Loosen the bleed screw and push the brake
When replacing the brake pads, it is not neces- caliper piston into the brake caliper with your
sary to disconnect the brake hose or disassem- finger.
ble the brake caliper.
1
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set. 2

Brake pad lining thickness (in-

ner)
4.4 mm (0.17 in)
Limit
0.8 mm (0.03 in) c. Tighten the bleed screw.
Brake pad lining thickness (out-
er) Brake caliper bleed screw
4.4 mm (0.17 in) 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
R.

Limit
0.8 mm (0.03 in) d. Install new brake pad spring and new brake
pads.
TIP
A
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
a piston.

4-43
FRONT BRAKE

5. Check:
a • Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1
EAS31328

REMOVING THE FRONT BRAKE CALIPER

TIP
Before removing the brake caliper, drain the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
brake fluid from the entire brake system.
3. Install:
• Brake pad pin 1. Remove:
• Brake pad clips • Brake hose union bolt “1”
• Front brake caliper • Brake hose gaskets “2”
• Front wheel sensor lead holder “1” • Front brake hose “3”
• Front brake caliper bolts TIP
Put the end of the brake hose into a container
Front brake caliper bolt and pump out the brake fluid carefully.
35 Nm (3.5 m·kgf, 25 ft·lbf)
T.
R.

TIP
3
While holding the front wheel sensor lead holder
so that the portion “a” of the holder contacts the
front fork outer tube, tighten the bolt to specifica-
tion. 1

EAS30172

DISASSEMBLING THE FRONT BRAKE

a CALIPER
1. Remove:
1 • Brake caliper piston “1”
• Brake caliper piston dust seal “2”
• Brake caliper piston seal “3”
4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID 3
LEVEL” on page 3-10. 2
1
a

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint
opening “a” to force out the piston from the
brake caliper “1”.

4-44
FRONT BRAKE

EWA13550

WARNING
• Cover the brake caliper piston with a rag. 2 3
Be careful not to get injured when the pis- 1
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.

2. Check:
• Brake caliper bracket
Cracks/damage → Replace.
EAS30174

ASSEMBLING THE FRONT BRAKE CALIPER

1 EWA13621

WARNING
b. Remove the brake caliper piston dust seal • Before installation, all internal brake com-
and brake caliper piston seal. ponents should be cleaned and lubricated
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ with clean or new brake fluid.
EAS30173
• Never use solvents on internal brake com-
CHECKING THE FRONT BRAKE CALIPER ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
Recommended brake component replacement
schedule seals to swell and distort.
• Whenever a brake caliper is disassembled,
Brake pads If necessary replace the brake caliper piston dust seals
Piston seal Every two years and brake caliper piston seals.
Piston dust seal Every two years
Brake hose Every four years Specified brake fluid
YAMAHA GENUINE BRAKE
Every two years and FLUID (DOT 4)
Brake fluid whenever the brake is
disassembled
EAS30934

1. Check: INSTALLING THE FRONT BRAKE CALIPER

• Brake caliper piston “1” 1. Install:
Rust/scratches/wear → Replace the brake • Front brake caliper “1”
caliper piston. (temporarily)
• Brake caliper cylinder “2” • Brake hose gaskets “2” New
Scratches/wear → Replace the brake caliper • Front brake hose “3”
assembly. • Brake hose union bolt “4”
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper Front brake hose union bolt
assembly. (brake caliper side)
T.
R.

• Brake fluid delivery passages 29 Nm (2.9 m·kgf, 21 ft·lbf)

(brake caliper body) EWA13531

Obstruction → Blow out with compressed air. WARNING

EWA17070

WARNING Proper brake hose routing is essential to in-

sure safe vehicle operation.
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.

4-45
FRONT BRAKE

ECA19080
• When refilling, be careful that water does
NOTICE not enter the brake master cylinder reser-
When installing the brake hose onto the voir. Water will significantly lower the boil-
brake caliper “1”, make sure the brake pipe ing point of the brake fluid and could cause
“a” passes between the projections “b” on vapor lock.
the brake caliper. ECA13540

NOTICE
3 Brake fluid may damage painted surfaces
1 and plastic parts. Therefore, always clean up
b any spilt brake fluid immediately.
a 5. Bleed:
• Brake system
4 Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
New 2
6. Check:
• Brake fluid level
2. Remove: Below the minimum level mark “a” → Add the
• Front brake caliper specified brake fluid to the proper level.
3. Install: Refer to “BLEEDING THE HYDRAULIC
• Brake pad spring BRAKE SYSTEM” on page 3-12.
• Brake pads
• Brake pad pin a
• Brake pad clips
• Front brake caliper
• Front wheel sensor lead holder
• Front brake caliper bolts

Front brake caliper bolt

35 Nm (3.5 m·kgf, 25 ft·lbf)
T.
R.

Refer to “REPLACING THE FRONT BRAKE

PADS” on page 4-43. 7. Check:
4. Fill: • Brake lever operation
• Brake master cylinder reservoir Soft or spongy feeling → Bleed the brake sys-
(with the specified amount of the specified tem.
brake fluid) Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
Specified brake fluid
EAS30179
YAMAHA GENUINE BRAKE
REMOVING THE FRONT BRAKE MASTER
FLUID (DOT 4)
CYLINDER
EWA13540 TIP
WARNING Before removing the front brake master cylinder,
• Use only the designated brake fluid. Other drain the brake fluid from the entire brake sys-
brake fluids may cause the rubber seals to tem.
deteriorate, causing leakage and poor
brake performance. 1. Remove:
• Refill with the same type of brake fluid that • Brake hose union bolt “1”
is already in the system. Mixing brake fluids • Brake hose gaskets “2”
may result in a harmful chemical reaction, • Front brake hose “3”
leading to poor brake performance. TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.

4-46
FRONT BRAKE

Specified brake fluid

YAMAHA GENUINE BRAKE
FLUID (DOT 4)
2
EAS30182

INSTALLING THE FRONT BRAKE MASTER

3 CYLINDER
1 1. Install:
• Brake master cylinder
• Brake master cylinder holder “1”
EAS30725

CHECKING THE FRONT BRAKE MASTER Front brake master cylinder hold-
CYLINDER er bolt

T.
R.
1. Check: 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
• Brake master cylinder
Damage/scratches/wear → Replace. TIP
• Brake fluid delivery passages • Install the brake master cylinder holder with the
(brake master cylinder body) “UP” mark “a” facing up.
Obstruction → Blow out with compressed air. • Align the edge “b” of the brake master cylinder
2. Check: holder with the edge “c” of the stay on the han-
• Brake master cylinder kit dlebar as shown in the illustration.
Damage/scratches/wear → Replace. • First, tighten the upper bolt, then the lower bolt.
3. Check:
• Brake master cylinder reservoir “1”
b
• Brake master cylinder reservoir cap “2”
• Brake master cylinder reservoir diaphragm c
1
holder “3”
• Brake master cylinder reservoir diaphragm
“4”
Damage/wear → Replace.
a
2
1
2. Install:
3 • Brake hose gaskets “1” New
• Front brake hose “2”
• Brake hose union bolt “3”
4
Front brake hose union bolt
(master cylinder side)
T.
R.

29 Nm (2.9 m·kgf, 21 ft·lbf)

4. Check:
• Front brake hose EWA13531

Cracks/damage/wear → Replace. WARNING

EAS30181
Proper brake hose routing is essential to in-
ASSEMBLING THE FRONT BRAKE MASTER sure safe vehicle operation.
CYLINDER
EWA13520 TIP
WARNING • Make sure that the distance “a” between the
• Before installation, all internal brake com- brake hose and the handlebar “4” is 40–44 mm
ponents should be cleaned and lubricated (1.57–1.73 in) as shown in the illustration.
with clean or new brake fluid.
• Never use solvents on internal brake com-
ponents.

4-47
FRONT BRAKE

• Turn the handlebar to the left and right to make

sure the brake hose does not touch other parts a
(e.g., wire harness, cables, leads). Correct if
necessary.

New 1
3
4 6. Check:
• Brake lever operation
2 a Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
3. Fill:
BRAKE SYSTEM” on page 3-12.
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

Specified brake fluid

YAMAHA GENUINE BRAKE
FLUID (DOT 4)
EWA13540

WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
5. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-10.

4-48
REAR BRAKE

EAS20031

REAR BRAKE
Removing the rear brake pads

35 Nm (3.5 m•kgf, 25 ft•Ibf)

T.R
.
4

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Rear brake caliper 1
2 Brake pad clip 2
3 Brake pad pin 1
4 Brake pad (inner) 1
5 Brake pad (outer) 1
6 Brake pad spring 1
7 Brake caliper bleed screw 1

4-49
REAR BRAKE

Removing the rear brake master cylinder

11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.

T.R
.
1
2
3

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.
6
29 Nm (2.9 m•kgf, 21 ft•Ibf)
T.R

8
.

9 New

5 7

6
4
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
T.R

1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

.
T.R
.

Order Job/Parts to remove Q’ty Remarks

Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-69.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 er 1

3 Brake master cylinder reservoir diaphragm 1

4 Rear brake light switch connector 2 Disconnect.
5 Rear brake light switch 1
6 Rear brake lever pivot bolt/nut 1/1
7 Rear brake lever 1
Rear brake hose union bolt (master cylinder
8 side) 1

9 Brake hose gasket 2

4-50
REAR BRAKE

Removing the rear brake master cylinder

11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.

T.R
.
11

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.
29 Nm (2.9 m•kgf, 21 ft•Ibf)
T.R
.

New

S
12

10

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R

1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

.
T.R
.

Order Job/Parts to remove Q’ty Remarks

Rear brake hose (rear brake master cylinder to
10 hydraulic unit) 1 Disconnect.

11 Rear brake master cylinder holder 1

12 Rear brake master cylinder assembly 1

4-51
REAR BRAKE

Disassembling the rear brake master cylinder

BF
S

2
BF

1 New

Order Job/Parts to remove Q’ty Remarks

1 Brake master cylinder kit 1
2 Brake master cylinder body 1

4-52
REAR BRAKE

Removing the rear brake caliper

4 35 Nm (3.5 m•kgf, 25 ft•Ibf)

T.R
.
29 Nm (2.9 m•kgf, 21 ft•Ibf)
T.R
.

2 New

1
3

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Rear brake hose union bolt (brake caliper side) 1
2 Brake hose gasket 2
Rear brake hose (hydraulic unit to rear brake
3 caliper) 1 Disconnect.

4 Rear brake caliper 1

4-53
REAR BRAKE

Disassembling the rear brake caliper

6
S

7
S 4
8 New BF
9 New
5
11

10

6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R

2
.

Order Job/Parts to remove Q’ty Remarks

1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad (inner) 1
4 Brake pad (outer) 1
5 Brake pad spring 1
6 Brake caliper bracket 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Brake caliper bleed screw 1
11 Brake caliper body 1

4-54
REAR BRAKE

EAS30183

INTRODUCTION Brake disc thickness limit

EWA14101
4.0 mm (0.16 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc runout
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISC” on page 4-42.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 23 Nm (2.3 m·kgf, 17 ft·lbf)

T.
R.
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
sembly. 6. Install:
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-33.
• Use only clean or new brake fluid for clean- EAS30185

ing brake components. REPLACING THE REAR BRAKE PADS

• Brake fluid may damage painted surfaces TIP
and plastic parts. Therefore, always clean When replacing the brake pads, it is not neces-
up any spilt brake fluid immediately. sary to disconnect the brake hose or disassem-
• Avoid brake fluid coming into contact with ble the brake caliper.
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING 1. Measure:
THE EYES: • Brake pad wear limit “a”
• Flush with water for 15 minutes and get im- Out of specification → Replace the brake
mediate medical attention. pads as a set.

Brake pad lining thickness (in-

EAS30184

CHECKING THE REAR BRAKE DISC ner)

5.3 mm (0.21 in)
1. Remove:
Limit
• Rear wheel
0.8 mm (0.03 in)
Refer to “REAR WHEEL” on page 4-33. Brake pad lining thickness (out-
2. Check: er)
• Brake disc 5.3 mm (0.21 in)
Damage/galling → Replace. Limit
3. Measure: 0.8 mm (0.03 in)
• Brake disc runout
Out of specification → Correct the brake disc A
runout or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-42. a
Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in)

4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification → Replace.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-42.

4-55
REAR BRAKE

a
a
a

A. Inner ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
B. Outer 3. Install:
• Brake pad pin
2. Install: • Brake pad clips
• Brake pad spring • Rear brake caliper
• Brake pads • Rear brake caliper bolts
TIP
Always install new brake pads and brake pad Rear brake caliper bolt
spring as a set. 35 Nm (3.5 m·kgf, 25 ft·lbf)
T.
R.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Check:
a. Connect a clear plastic hose “1” tightly to the • Brake fluid level
bleed screw “2”. Put the other end of the hose Below the minimum level mark “a” → Add the
into an open container. specified brake fluid to the proper level.
b. Loosen the bleed screw and push the brake Refer to “CHECKING THE BRAKE FLUID
caliper piston into the brake caliper with your LEVEL” on page 3-10.
finger.

2
1

5. Check:
c. Tighten the bleed screw. • Brake lever operation
Brake caliper bleed screw Soft or spongy feeling → Bleed the brake sys-
6 Nm (0.6 m·kgf, 4.3 ft·lbf) tem.
T.

Refer to “BLEEDING THE HYDRAULIC

R.

d. Install new brake pad spring and new brake BRAKE SYSTEM” on page 3-12.
pads. EAS30186

TIP REMOVING THE REAR BRAKE CALIPER

The longer tangs “a” of the brake pad spring TIP
must point in the direction of the brake caliper Before removing the brake caliper, drain the
position. brake fluid from the entire brake system.
1. Remove:
• Rear brake hose union bolt “1”
• Brake hose gaskets “2”
• Rear brake hose “3”

4-56
REAR BRAKE

TIP b. Remove the brake caliper piston dust seal

Put the end of the brake hose into a container and brake caliper piston seal.
and pump out the brake fluid carefully. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30188

CHECKING THE REAR BRAKE CALIPER

Recommended brake component replacement
2 schedule
Brake pads If necessary
3
Piston seal Every two years
1
Piston dust seal Every two years
Brake hose Every four years
Every two years and
Brake fluid whenever the brake is
EAS30187
disassembled
DISASSEMBLING THE REAR BRAKE
CALIPER 1. Check:
1. Remove: • Brake caliper piston “1”
• Brake caliper piston “1” Rust/scratches/wear → Replace the brake
• Brake caliper piston dust seal “2” caliper piston.
• Brake caliper piston seal “3” • Brake caliper cylinder “2”
Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body “3”
1 Cracks/damage → Replace the brake caliper
2 3
assembly.
• Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
EWA17070

WARNING
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Whenever a brake caliper is disassembled,
a. Blow compressed air into the brake hose joint replace the brake caliper piston dust seal
opening “a” to force out the piston from the and brake caliper piston seal.
brake caliper.
EWA13550

WARNING 3
• Cover the brake caliper piston with a rag. 1 2
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.

2. Check:
• Brake caliper bracket
Cracks/damage → Replace.
a

4-57
REAR BRAKE

EAS30189
3. Install:
ASSEMBLING THE REAR BRAKE CALIPER
EWA17080
• Brake pad spring
WARNING • Brake pads
• Before installation, all internal brake com- • Brake pad pin
ponents should be cleaned and lubricated • Brake pad clips
with clean or new brake fluid. • Rear brake caliper
• Never use solvents on internal brake com- Rear brake caliper bolt
ponents as they will cause the brake caliper 35 Nm (3.5 m·kgf, 25 ft·lbf)

T.
R.
piston dust seal and brake caliper piston
seal to swell and distort. Refer to “REPLACING THE REAR BRAKE
• Whenever a brake caliper is disassembled, PADS” on page 4-55.
replace the brake caliper piston dust seal 4. Fill:
and brake caliper piston seal. • Brake master cylinder reservoir
(with the specified amount of the specified
Specified brake fluid brake fluid)
YAMAHA GENUINE BRAKE
FLUID (DOT 4) Specified brake fluid
YAMAHA GENUINE BRAKE
EAS30190 FLUID (DOT 4)
INSTALLING THE REAR BRAKE CALIPER
EWA13540
1. Install:
WARNING
• Rear brake caliper “1”
(temporarily) • Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
• Brake hose gaskets “2” New
deteriorate, causing leakage and poor
• Rear brake hose “3”
brake performance.
• Brake hose union bolt “4”
• Refill with the same type of brake fluid that
Rear brake hose union bolt is already in the system. Mixing brake fluids
(brake caliper side) may result in a harmful chemical reaction,
T.
R.

29 Nm (2.9 m·kgf, 21 ft·lbf) leading to poor brake performance.

• When refilling, be careful that water does
EWA13531
not enter the brake master cylinder reser-
WARNING voir. Water will significantly lower the boil-
Proper brake hose routing is essential to in- ing point of the brake fluid and could cause
sure safe vehicle operation. vapor lock.
ECA19080 ECA13540

NOTICE NOTICE
When installing the brake hose onto the Brake fluid may damage painted surfaces
brake caliper “1”, make sure the brake pipe and plastic parts. Therefore, always clean up
“a” passes between the projections “b” on any spilt brake fluid immediately.
the brake caliper.
5. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
1 BRAKE SYSTEM” on page 3-12.
b 6. Check:
• Brake fluid level
2 New
a Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
4 LEVEL” on page 3-10.
3
2. Remove:
• Rear brake caliper

4-58
REAR BRAKE

2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir “1”
a
• Brake master cylinder reservoir cap
• Brake master cylinder reservoir diaphragm
holder “2”
• Brake master cylinder reservoir diaphragm
“3”
7. Check: Damage/wear → Replace.
• Brake lever operation 4. Check:
Soft or spongy feeling → Bleed the brake sys- • Brake hose
tem. Cracks/damage/wear → Replace.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12. 2
1
EAS30193

REMOVING THE REAR BRAKE MASTER

CYLINDER 3
TIP
Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.
1. Remove: EAS30195

• Brake hose union bolt “1” ASSEMBLING THE REAR BRAKE MASTER
• Brake hose gaskets “2” CYLINDER
EWA13520
• Brake hose “3”
WARNING
TIP
• Before installation, all internal brake com-
To collect any remaining brake fluid, place a ponents should be cleaned and lubricated
container under the master cylinder and the end with clean or new brake fluid.
of the brake hose. • Never use solvents on internal brake com-
ponents.
1 2
Specified brake fluid
YAMAHA GENUINE BRAKE
FLUID (DOT 4)

EAS30196

INSTALLING THE REAR BRAKE MASTER

CYLINDER
3
1. Install:
• Brake master cylinder
EAS30194

CHECKING THE REAR BRAKE MASTER • Brake master cylinder holder “1”
CYLINDER
Rear brake master cylinder hold-
1. Check: er bolt
T.

• Brake master cylinder

R.

11 Nm (1.1 m·kgf, 8.0 ft·lbf)

Damage/scratches/wear → Replace.
• Brake fluid delivery passages TIP
(brake master cylinder body)
• Install the brake master cylinder holder with the
Obstruction → Blow out with compressed air.
“UP” mark “a” facing up.

4-59
REAR BRAKE

• Align the edge “b” of the brake master cylinder

holder with the edge “c” of the stay on the han- Specified brake fluid
dlebar as shown in the illustration. YAMAHA GENUINE BRAKE
• First, tighten the upper bolt, then the lower bolt. FLUID (DOT 4)
EWA13540

1 WARNING
b
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
c deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
a may result in a harmful chemical reaction,
leading to poor brake performance.
2. Install: • When refilling, be careful that water does
not enter the brake master cylinder reser-
• Brake hose gaskets “1” New
voir. Water will significantly lower the boil-
• Rear brake hose “2”
ing point of the brake fluid and could cause
• Brake hose union bolt “3”
vapor lock.
Rear brake hose union bolt (mas- ECA13540

ter cylinder side) NOTICE

T.
R.

29 Nm (2.9 m·kgf, 21 ft·lbf) Brake fluid may damage painted surfaces

EWA13531
and plastic parts. Therefore, always clean up
WARNING any spilt brake fluid immediately.
Proper brake hose routing is essential to in- 4. Bleed:
sure safe vehicle operation. • Brake system
Refer to “BLEEDING THE HYDRAULIC
TIP BRAKE SYSTEM” on page 3-12.
• Make sure that the distance “a” between the 5. Check:
brake hose and the handlebar “4” is 5.0–9.0 • Brake fluid level
mm (0.20–0.35 in) as shown in the illustration. Below the minimum level mark “a” → Add the
• Turn the handlebar to the left and right to make specified brake fluid to the proper level.
sure the brake hose does not touch other parts Refer to “CHECKING THE BRAKE FLUID
(e.g., wire harness, cables, leads). Correct if LEVEL” on page 3-10.
necessary.

1 New
a
4
3 a

2 6. Check:
3. Fill: • Brake lever operation
• Brake master cylinder reservoir Soft or spongy feeling → Bleed the brake sys-
(with the specified amount of the specified tem.
brake fluid) Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.

4-60
ABS (ANTI-LOCK BRAKE SYSTEM)

EAS20032

ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly
29 Nm (2.9 m•kgf, 21 ft•Ibf)
T.R
.

29 Nm (2.9 m•kgf, 21 ft•Ibf)

T.R
.
2
5

3
4 New
3
2 New 4

4 New
4 New

New 4

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
Refer to “GENERAL CHASSIS (2)” on page
Front side cover (right) 4-4.
Refer to “GENERAL CHASSIS (6)” on page
Front upper cowling assembly 4-16.
1 ABS ECU coupler 1 Disconnect.
Front brake hose union bolt (hydraulic unit as-
2 sembly side) 2

Rear brake hose union bolt (hydraulic unit as-

3 sembly side) 2

4 Brake hose gasket 8

Front brake hose (hydraulic unit to front brake
5 caliper) 1 Disconnect.

4-61
ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly

29 Nm (2.9 m•kgf, 21 ft•Ibf)
T.R
.

29 Nm (2.9 m•kgf, 21 ft•Ibf)

T.R
.
New

New

7 8
New
6 New

New
9

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Front brake hose (front brake master cylinder to
6 hydraulic unit) 1 Disconnect.

Rear brake hose (rear brake master cylinder to

7 hydraulic unit) 1 Disconnect.

Rear brake hose (hydraulic unit to rear brake

8 caliper) 1 Disconnect.

9 Hydraulic unit assembly 1

4-62
ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30197

REMOVING THE HYDRAULIC UNIT TIP

ASSEMBLY Do not operate the brake levers while removing
ECA21091 the brake hoses.
NOTICE ECA14530

Unless necessary, avoid removing and in- NOTICE

stalling the brake hoses of the hydraulic unit When removing the brake hoses, cover the
assembly. area around the hydraulic unit to catch any
EWA13930 spilt brake fluid. Do not allow the brake fluid
WARNING to contact other parts.
Refill with the same type of brake fluid that is 3. Remove:
already in the system. Mixing fluids may re- • Hydraulic unit assembly “1”
sult in a harmful chemical reaction, leading
TIP
to poor braking performance.
ECA18241
• To avoid brake fluid leakage and to prevent for-
NOTICE eign materials from entering the hydraulic unit
assembly, insert a rubber plug “a” or a bolt
• Handle the ABS components with care (M10 × 1.25) into each brake hose union bolt
since they have been accurately adjusted. hole.
Keep them away from dirt and do not sub- • When using a bolt, do not tighten the bolt until
ject them to shocks. the bolt head touches the hydraulic unit. Other-
• Do not turn the main switch to “ON” when wise, the brake hose union bolt seating surface
removing the hydraulic unit assembly. could be deformed.
• Do not clean with compressed air.
• Do not reuse the brake fluid.
1
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. a
• Do not allow any brake fluid to contact the
couplers. Brake fluid may damage the cou-
plers and cause bad contacts.
• 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. EAS30198

CHECKING THE HYDRAULIC UNIT

1. Disconnect: ASSEMBLY
• ABS ECU coupler “1” 1. Check:
TIP • Hydraulic unit assembly
While pushing the portion “a” of the ABS ECU Cracks/damage → Replace the hydraulic unit
coupler, move the lock lever “b” in the direction assembly and the brake hoses that are con-
of the arrow shown to disconnect the coupler. nected to the assembly as a set.
EAS30200

b 1
INSTALLING THE HYDRAULIC UNIT
ASSEMBLY
1. Install:
a • Hydraulic unit assembly

Hydraulic unit assembly bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.

2. Remove:
• Brake hoses

4-63
ABS (ANTI-LOCK BRAKE SYSTEM)

ECA21110
TIP
NOTICE
• Connect the ABS ECU coupler, and then push
Do not remove the rubber plugs or bolts
the lock lever “a” of the coupler in the direction
(M10 × 1.25) installed in the brake hose union
of the arrow shown.
bolt holes before installing the hydraulic unit
• Make sure that the ABS ECU coupler is con-
assembly.
nected in the correct position as shown in illus-
TIP tration “A”.
Do not allow any foreign materials to enter the
hydraulic unit assembly or the brake hoses 1
when installing the hydraulic unit assembly. a

2. Remove:
• Rubber plugs or bolts (M10 × 1.25)
3. Install:
• Rear brake hose (hydraulic unit to rear brake
caliper) “1”
• Rear brake hose (rear brake master cylinder
to hydraulic unit) “2”
• Front brake hose (front brake master cylinder
to hydraulic unit) “3” A B
• Front brake hose (hydraulic unit to front brake
caliper) “4”

Front brake hose union bolt (hy-

draulic unit assembly side)
T.
R.

29 Nm (2.9 m·kgf, 21 ft·lbf)

Rear brake hose union bolt (hy-
draulic unit assembly side)
29 Nm (2.9 m·kgf, 21 ft·lbf)
A. The ABS ECU coupler is connected correctly.
ECA21121 B. The ABS ECU coupler is not connected.
NOTICE
5. Fill:
If the brake hose union bolt does not turn
• Brake master cylinder reservoir
easily, replace the hydraulic unit assembly,
• Brake fluid reservoir
brake hoses, and related parts as a set.
(with the specified amount of the specified
TIP brake fluid)
Position the pipe sections of the brake hoses at
Specified brake fluid
a 30° angle from the line “a” as shown in the il-
YAMAHA GENUINE BRAKE
lustration, and then tighten the brake hose union FLUID (DOT 4)
bolts to specification.
EWA13090

WARNING
• Use only the designated brake fluid. Other
4 brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
1 • Refill with the same type of brake fluid that
3
2 is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
a leading to poor brake performance.
4. Connect:
• ABS ECU coupler “1”

4-64
ABS (ANTI-LOCK BRAKE SYSTEM)

• When refilling, be careful that water does • Before performing the brake line routing confir-
not enter the brake fluid reservoir. Water mation, make sure that no malfunctions have
will significantly lower the boiling point of been detected in the ABS ECU and that the
the brake fluid and could cause vapor lock. wheels are not rotating.
ECA13540
1. Place the vehicle on a center stand.
NOTICE
2. Turn the main switch to “OFF”.
Brake fluid may damage painted surfaces 3. Open the seat.
and plastic parts. Therefore, always clean up 4. Remove:
any spilt brake fluid immediately. • Battery cover
6. Bleed: Refer to “GENERAL CHASSIS (1)” on page
• Brake system 4-1.
Refer to “BLEEDING THE HYDRAULIC 5. Check:
BRAKE SYSTEM” on page 3-12. • Battery voltage
7. Check the operation of the hydraulic unit ac- Lower than 12.8 V → Charge or replace the
cording to the brake levers response. (Refer battery.
to “HYDRAULIC UNIT OPERATION TESTS”
Battery voltage
on page 4-65.)
ECA14550
Higher than 12.8 V
NOTICE
Always check the operation of the hydraulic TIP
unit according to the brake lever response. If the battery voltage is lower than 12.8 V, charge
the battery, and then perform brake line routing
8. Delete the fault codes. (Refer to “[B-3] DE- confirmation.
LETING THE FAULT CODES” on page
8-90.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-68.)
EAS30201

HYDRAULIC UNIT OPERATION TESTS

The reaction-force pulsating action generated in
the brake levers when the ABS is activated can
be tested when the vehicle is stopped.
The hydraulic unit operation can be tested using
the following two methods.
6. Removing the protective cap “1”, and then
• Brake line routing confirmation: this test
connect the Yamaha diagnostic tool to the
checks the function of the ABS after the sys-
Yamaha diagnostic tool coupler (4P).
tem was disassembled, adjusted, or serviced.
• ABS reaction-force confirmation: this test gen- Yamaha diagnostic tool
erates the same reaction-force pulsating action 90890-03231
that is generated in the front brake lever and
rear brake lever when the ABS is front activat-
ed. 1

Brake line routing confirmation

EWA13120

WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
• For the brake line routing confirmation, use the
diagnosis mode of the Yamaha diagnostic tool.

4-65
ABS (ANTI-LOCK BRAKE SYSTEM)

7. Start the Yamaha diagnostic tool and display

the diagnosis mode screen.
8. Select code No. 2, “Brake line routing confir-
mation”.
9. Click “Action” “1”, and then operate the front
brake lever “2” and rear brake lever “3” simul-
taneously.
TIP
1 2
• The hydraulic unit operates 1 second after the
front brake lever and rear brake lever are oper-
ated simultaneously and continues for approx- TIP
imately 5 seconds. “ON” and “OFF” on the tool screen indicate
• The operation of the hydraulic unit can be con- when the brakes are being applied and released
firmed using the indicator. respectively.
On: The hydraulic unit is operating. ECA22080

Flashing: The conditions for operating the hy- NOTICE

draulic unit have not been met. • Check that the pulse is felt in the front
Off: The front brake lever and rear brake lever brake lever, rear brake lever, and again in
are not being operated. the front brake lever, in this order.
• If the pulse is felt in the rear brake lever be-
fore it is felt in the front 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 front
1
brake lever or rear brake lever, check that
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
sembly.
11.If the operation of the hydraulic unit is normal,
delete all of the fault codes.

ABS reaction-force confirmation

EWA13120

WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2 3
TIP
• For the ABS reaction-force confirmation, use
10.Check:
the diagnosis mode of the Yamaha diagnostic
• Hydraulic unit operation
tool. For more information, refer to the opera-
Click “Action”, a single pulse will be generat-
tion manual of the Yamaha diagnostic tool.
ed in the front brake lever “1”, rear brake lever
• Before performing the ABS reaction-force con-
“2”, and again in the front brake lever “1”, in
firmation, make sure that no malfunctions have
this order.
been detected in the ABS ECU and that the
wheels are not rotating.

4-66
ABS (ANTI-LOCK BRAKE SYSTEM)

1. Place the vehicle on a center stand. 7. Start the Yamaha diagnostic tool and display
2. Turn the main switch to “OFF”. the diagnosis mode screen.
3. Open the seat. 8. Select code No. 1, “ABS reaction-force con-
4. Remove: firmation”.
• Battery cover 9. Click “Action” “1”, and then operate the front
Refer to “GENERAL CHASSIS (1)” on page brake lever “2” and rear brake lever “3” simul-
4-1. taneously.
5. Check: TIP
• Battery voltage • The hydraulic unit operates 1 second after the
Lower than 12.8 V → Charge or replace the front brake lever and rear brake lever are oper-
battery. ated simultaneously and continues for approx-
imately 5 seconds.
Battery voltage
Higher than 12.8 V • The operation of the hydraulic unit can be con-
firmed using the indicator.
TIP On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
If the battery voltage is lower than 12.8 V, charge
draulic unit have not been met.
the battery, and then perform ABS reaction-
Off: The front brake lever and rear brake lever
force confirmation.
are not being operated.

6. Removing the protective cap “1”, and then

connect the Yamaha diagnostic tool to the
Yamaha diagnostic tool coupler (4P).

Yamaha diagnostic tool

90890-03231

1
2 3

10.A reaction-force pulsating action is generated

in the front brake lever “1” and continues for a
few seconds.
TIP
• The reaction-force pulsating action consists of
quick pulses.
• Be sure to continue operating the front brake
lever and rear brake lever even after the pul-
sating action has stopped.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.

4-67
ABS (ANTI-LOCK BRAKE SYSTEM)

• If the pulse is hardly felt in either the front

brake lever or rear brake lever, check that
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
sembly.
13.Turn the main switch to “OFF”.
14.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
1 stall the protective cap.
15.Turn the main switch to “ON”.
11.After the pulsating action has stopped in the 16.Check for brake fluid leakage around the hy-
front brake lever, it is generated in the rear draulic unit.
brake lever “1” and continues for a few sec- Brake fluid leakage → Replace the hydraulic
onds. unit, brake hoses, and related parts as a set.
TIP 17.If the operation of the hydraulic unit is normal,
• The reaction-force pulsating action consists of delete all of the fault codes.
quick pulses.
EAS30202
• Be sure to continue operating the front brake CHECKING THE ABS WARNING LIGHT
lever and rear brake lever even after the pul- After all checks and servicing are completed, en-
sating action has stopped. sure that the ABS warning light goes off by walk-
• “ON” and “OFF” on the tool screen indicate ing the vehicle at a speed of faster than 10 km/h
when the brakes are being applied and re- (6 mph) or performing a trial run.
leased respectively.

1
12.After the pulsating action has stopped in the
rear brake lever, it is generated in the front
brake lever and continues for a few seconds.
TIP
• The reaction-force pulsating action consists of
quick pulses.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
ECA22080

NOTICE
• Check that the pulse is felt in the front
brake lever, rear brake lever, and again in
the front brake lever, in this order.
• If the pulse is felt in the rear brake lever be-
fore it is felt in the front brake lever, check
that the brake hoses and brake pipes are
connected correctly to the hydraulic unit
assembly.

4-68
HANDLEBAR

EAS20033

HANDLEBAR
Removing the rearview mirror and handlebar cover

2
1

3
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.

4
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Rearview mirror 2
2 Upper handlebar cover assembly 1
3 Upper handlebar panel 1
4 Upper handlebar cover 1

4-69
HANDLEBAR

Removing the handlebar

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

T.R
.
1 S 6 21 Nm (2.1 m•kgf, 15 ft•Ibf)

T.R
.
LS
LS 8

LS 5
9
LS 11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

T.R
.
7 6
4 3
2

S
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)
T.R
.

11
10
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)

T.R
.

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Grip end (right) 1
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder 1
5 Handlebar switch coupler (right) 1 Disconnect.
6 Handlebar switch (right) 1
7 Throttle cable 2 Disconnect.
8 Throttle grip 1
9 Handlebar weight (right) 1
10 Grip end (left) 1
11 Handlebar grip 1

4-70
HANDLEBAR

Removing the handlebar

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

T.R
.
S 21 Nm (2.1 m•kgf, 15 ft•Ibf)

T.R
.
LS
LS

LS

LS 20 11 Nm (1.1 m•kgf, 8.0 ft•Ibf)

T.R
.
13 15 17

16
22 S
2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)
T.R
.

21

19 22
12 18
14
17
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

2.3 Nm (0.23 m•kgf, 1.7 ft•Ibf)

T.R
.

1.8 Nm (0.18 m•kgf, 1.3 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

12 Rear brake light switch connector 2 Disconnect.
13 Rear brake master cylinder holder 1
14 Rear brake master cylinder 1
15 Handlebar switch connector 1 Disconnect.
16 Handlebar switch coupler (left) 1 Disconnect.
17 Handlebar switch (left) 1
18 Handlebar weight (left) 1
19 Lower handlebar cover 1
20 Upper handlebar holder 2
21 Handlebar 1
22 Lower handlebar holder 2

4-71
HANDLEBAR

EAS31622

REMOVING THE UPPER HANDLEBAR TIP

COVER ASSEMBLY While holding the grip end, loosen the grip end
1. Remove: bolt.
• Upper handlebar cover assembly “1” 3. Remove:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Handlebar grip “1”
a. Remove the quick fastener and upper han-
dlebar cover assembly screws. TIP
b. Unhook the projections “a” on the upper han- Blow compressed air between the handlebar
dlebar cover assembly from the slots “b” in and the handlebar grip, and gradually push the
the lower handlebar cover. grip off the handlebar.
a a

b
a
b

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS30204

EAS31701
CHECKING THE HANDLEBAR
DISASSEMBLING THE UPPER HANDLEBAR 1. Check:
COVER ASSEMBLY • Handlebar
1. Disassemble: Bends/cracks/damage → Replace.
EWA13690
• Upper handlebar panel “1”
WARNING
• Upper handlebar cover “2”
TIP
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
Unhook the projections “a” on the upper handle-
bar panel from the slots “b” in the upper handle- EAS30205
bar cover. INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface.
a EWA13120

WARNING
1
Securely support the vehicle so that there is
b no danger of it falling over.
a
2 2. Install:
• Lower handlebar holders “1”
• Handlebar “2”
• Upper handlebar holders “3”
b
Upper handlebar holder bolt
EAS30203

REMOVING THE HANDLEBAR 21 Nm (2.1 m·kgf, 15 ft·lbf)

T.
R.

1. Stand the vehicle on a level surface. ECA18300

EWA13120
NOTICE
WARNING
First, tighten the bolts on the front side of the
Securely support the vehicle so that there is
handlebar holder, and then on the rear side.
no danger of it falling over.
2. Remove: TIP
• Grip end • Make sure that the projection “a” of the handle-
bar contacts the lower handlebar holder.

4-72
HANDLEBAR

• The upper handlebar holders should be in-

stalled with the punch mark “b” facing forward. Rear brake master cylinder hold-
er bolt

T.
R.
3 11 Nm (1.1 m·kgf, 8.0 ft·lbf)
b
b
TIP
• Install the brake master cylinder holder with the
“UP” mark “a” facing up.
a 2
• Align the edge “b” of the brake master cylinder
holder with the edge “c” of the stay on the han-
dlebar as shown in the illustration.
1 • First, tighten the upper bolt, then the lower bolt.

3. Install: 1
• Handlebar weight (left) “1” b
TIP
Fit the projections “a” on the handlebar weight c
into the holes “b” in the handlebar.

1
a
b
a 6. Install:
• Handlebar grip “1”
• Grip end (left) “2”
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b
a. Apply a thin coat of a rubber adhesive to the
a left end of the handlebar.
4. Install: b. Slide the handlebar grip over the left end of
• Handlebar switch (left) “1” the handlebar.
TIP
Handlebar switch screw (left) Make sure that the distance “a” between the end
2.3 Nm (0.23 m·kgf, 1.7 ft·lbf) of the left handlebar switch and the end of the
T.
R.

handlebar grip is 0 mm (0 in).

TIP
Align the projection “a” on the left handlebar
a
switch with the hole “b” in the handlebar. 1

b a
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700

5. Install: WARNING
• Rear brake master cylinder Do not touch the handlebar grip until the rub-
• Rear brake master cylinder holder “1” ber adhesive has fully dried.
d. Install the left grip end.

4-73
HANDLEBAR

Grip end bolt (left) Handlebar switch screw (right)

7 Nm (0.7 m·kgf, 5.1 ft·lbf) 2.3 Nm (0.23 m·kgf, 1.7 ft·lbf)
T.

T.
R.

R.
Throttle cable holder bolt (han-
TIP dlebar switch side)
• Align the projection “a” on the grip end with the 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Grip end bolt (right)
slot “b” in the handlebar weight.
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
• There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “c” between the handlebar grip and
TIP
the grip end.
• Lubricate the end of the throttle cables and the
inside of the throttle grip with a thin coat of lith-
ium-soap-based grease.
• Align the projection “a” on the right handlebar
b
2 switch with the hole “b” in the handlebar.
1 • Align the projection “c” on the grip end with the
slot “d” in the handlebar weight.
• There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “e” between the throttle grip and the
a grip end.

3 LS
c 1 LS

1
2
2 1 b
a
2

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3
7. Install:
• Handlebar weight (right) “1”
TIP
Fit the projections “a” on the handlebar weight
into the holes “b” in the handlebar.
d
1 4
c
b
a
e

1
b

a
8. Install: 3 4
• Handlebar switch (right) “1”
• Throttle cables “2”
• Throttle grip “3” 9. Install:
• Grip end (right) “4” • Front brake master cylinder
• Front brake master cylinder holder “1”

4-74
HANDLEBAR

EAS31623

Front brake master cylinder hold- INSTALLING THE UPPER HANDLEBAR

er bolt COVER ASSEMBLY
T.
R.

11 Nm (1.1 m·kgf, 8.0 ft·lbf) 1. Install:

• Upper handlebar cover assembly “1”
TIP ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the upper handlebar
• Install the brake master cylinder holder with the
cover into the slots “b” in the lower handlebar
“UP” mark “a” facing up.
cover.
• Align the edge “b” of the brake master cylinder
holder with the edge “c” of the stay on the han- a a
dlebar as shown in the illustration.
• First, tighten the upper bolt, then the lower bolt. 1

b b
a
c b
1
b

TIP
a There should be 2.0–4.0 mm (0.08–0.16 in) of
clearance “c” between the upper handlebar cov-
10.Adjust: er assembly and the right handlebar switch “2”
• Throttle grip free play and between the cover assembly and the left
Refer to “CHECKING THE THROTTLE GRIP handlebar switch “3”.
OPERATION” on page 3-23.

Throttle grip free play 1

3.0–5.0 mm (0.12–0.20 in)
3 2
EAS31702

ASSEMBLING THE UPPER HANDLEBAR

COVER ASSEMBLY c
1. Assemble: c
• Upper handlebar cover “1”
• Upper handlebar panel “2”
b. Install the upper handlebar cover assembly
TIP
screws and quick fasteners, and then tighten
Fit the projections “a” on the upper handlebar the screws to specification.
panel into the slots “b” in the upper handlebar
cover. Upper handlebar cover assembly
screw
T.
R.

a 1.8 Nm (0.18 m·kgf, 1.3 ft·lbf)

1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

a b
2

4-75
FRONT FORK

EAS20034

FRONT FORK
Removing the front fork legs

53 Nm (5.3 m•kgf, 38 ft•Ibf)

T.R
.

2
2

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.

1 8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-25.
1 Front fender 1
2 Lower bracket pinch bolt 2
3 Front fork leg 1

4-76
FRONT FORK

Disassembling the front fork legs

9
12
New 14
LS 1 New
10
15 2
LS
3 New

11

13

LT 8 New
5 New

7
6 New
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front fork legs.
1 Front fork cap clip 1
2 Front fork cap 1
3 O-ring 1
4 Fork spring 1
5 Dust seal 1
6 Oil seal clip 1
7 Front fork damper rod bolt 1
8 Copper washer 1
9 Oil flow stopper 1
10 Damper rod 1
11 Rebound spring 1
12 Damper rod ring 1
13 Inner tube 1
14 Oil seal 1
15 Outer tube 1

4-77
FRONT FORK

EAS30206

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs. 1
1. Stand the vehicle on a level surface.
EWA13120
2
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the 2. Drain:
front wheels are elevated. • Fork oil
TIP
2. Loosen:
• Lower bracket pinch bolts “1” Stroke the outer tube several times while drain-
EWA18000 ing the fork oil.
WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg.

1
1

3. Remove:
• Dust seal “1”
• Oil seal clip “2”
EAS30207 (with a flathead screwdriver)
DISASSEMBLING THE FRONT FORK LEGS ECA14180

The following procedure applies to both of the NOTICE

front fork legs. Do not scratch the inner tube.
ECA19110

NOTICE
1
• The front fork leg has a very sophisticated
internal construction, which are particular-
ly sensitive to foreign material. 2
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
1. Remove:
• Front fork cap clip “1”
• Front fork cap “2” 4. Remove:
TIP • Front fork damper rod bolt “1”
Push the front fork cap in the direction of the ar- • Copper washer
row shown in the illustration to remove the front TIP
fork cap clip. While holding the damper rod with the hexagon
bit socket (14 mm) “2” and T-handle “3”, loosen
the front fork damper rod bolt.

4-78
FRONT FORK

EAS30209

T-handle ASSEMBLING THE FRONT FORK LEGS

90890-01326 The following procedure applies to both of the
T-handle 3/8" drive 60 cm long front fork legs.
YM-01326 EWA13660

WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
1 2 3 dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
–Front fork cap clip
–Oil seal
EAS30208
–Oil seal clip
CHECKING THE FRONT FORK LEGS –Dust seal
The following procedure applies to both of the –Copper washer
front fork legs. –O-ring
1. Check: • Before assembling the front fork leg, make
• Inner tube sure all of the components are clean.
• Outer tube 1. Install:
Bends/damage/scratches → Replace. • Damper rod ring “1”
EWA13650

WARNING • Damper rod “2”

• Rebound spring “3”
Do not attempt to straighten a bent inner
(in the inner tube “4”)
tube as this may dangerously weaken it.
• Oil flow stopper “5”
2. Measure: ECA22740

• Fork spring free length “a” NOTICE

Out of specification → Replace. Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
Fork spring free length tom of the inner tube. Be careful not to dam-
245.3 mm (9.66 in) age the inner tube.
Limit
240.0 mm (9.45 in) TIP
Fit the damper rod ring into the damper rod
groove so that the side of the ring with the pro-
jections is facing in the direction shown in the il-
lustration.
a

2
1

3. Check:
• Damper rod
Damage/wear → Replace.
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage → Replace.

4-79
FRONT FORK

3. Lubricate:
• Inner tube’s outer surface

Recommended oil
Fork oil 10W or equivalent

4. Install:
• Inner tube
5 4 3 1 2 (in the outer tube)
5. Install:

2. Install: • Copper washer New

• Front fork damper rod bolt “1”
• Oil seal “1” New
(with the fork seal driver attachment “2” and Front fork damper rod bolt
fork seal driver weight “3”) 23 Nm (2.3 m·kgf, 17 ft·lbf)

T.
R.
ECA14220
LOCTITE®
NOTICE
Make sure the numbered side of the oil seal TIP
faces up. While holding the damper rod assembly with the
TIP hexagon bit socket (14 mm) “2” and T-handle
“3”, tighten the front fork damper rod bolt.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of T-handle
the front fork leg with a plastic bag to protect 90890-01326
T-handle 3/8" drive 60 cm long
the oil seal during installation.
YM-01326

Fork seal driver weight

90890-01367
Replacement hammer
YM-A9409-7 1 2 3
Fork seal driver attachment (ø30)
90890-01400

6. Install:
• Oil seal clip “1” New
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.

2
1 New

1 New

4-80
FRONT FORK

7. Install:
• Dust seal “1” New
(with the fork seal driver attachment “2” and
fork seal driver weight “3”) 1
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø30)
90890-01400 10.Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
TIP
3 Be sure to bleed the front fork leg of any residual
air.
2 11.Measure:
• Front fork leg oil level “a”
1 New (from the top of the inner tube, with the inner
tube fully compressed and without the fork
spring)
8. Fill: Out of specification → Correct.
• Front fork leg
(with the specified amount of the recom- Level
mended fork oil) 78.0 mm (3.07 in)

Recommended oil TIP

Fork oil 10W or equivalent • While filling the front fork leg, keep it upright.
Quantity
• After filling, slowly pump the front fork leg up
86.0 cm³ (2.91 US oz, 3.03
Imp.oz) and down to distribute the fork oil.

ECA14230

NOTICE
• Be sure to use the recommended fork oil.
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.
9. After filling the front fork leg, slowly stroke the
inner tube “1” up and down (at least ten 12.Install:
times) to distribute the fork oil. • Fork spring “1”
TIP
• O-ring New
Be sure to stroke the inner tube slowly because • Front fork cap
the fork oil may spurt out.
• Front fork cap clip New
TIP
Install the fork spring with its smaller pitch down-
ward.

4-81
FRONT FORK

1 1
1

EAS30210

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Remove:
• Front side cover
• Refer to “GENERAL CHASSIS (2)” on page
4-4.
2. Install:
• Front fork leg “1”
Temporarily tighten the lower bracket pinch
bolts.
TIP
Make sure the inner tube end is flush with the top
of the lower bracket.

3. Tighten:
• Lower bracket pinch bolts “1”

Lower bracket pinch bolt

53 Nm (5.3 m·kgf, 38 ft·lbf)
T.
R.

TIP
Tighten the lower bracket pinch bolts to specifi-
cation twice. Tighten the upper and lower bolts
alternately, starting with the upper bolts.

4-82
STEERING HEAD

EAS20035

STEERING HEAD
Removing the lower bracket
63 Nm (6.3 m•kgf, 46 ft•Ibf) 1

T.R
.
LS

LS
75 Nm (7.5 m•kgf, 54 ft•Ibf)

T.R
.
1st 38 Nm (3.8 m•kgf, 27 ft•Ibf)
*2nd 16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.
LS

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

3 2
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

* Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.

Order Job/Parts to remove Q’ty Remarks

Front side covers Refer to “GENERAL CHASSIS (2)” on page

4-4.

Center lower cover Refer to “GENERAL CHASSIS (5)” on page

4-12.

Front upper cowling assembly Refer to “GENERAL CHASSIS (6)” on page

4-16.
Front wheel Refer to “FRONT WHEEL” on page 4-25.
Handlebar Refer to “HANDLEBAR” on page 4-69.
Front fork legs Refer to “FRONT FORK” on page 4-76.
1 Handlebar bracket 1
2 Horn connector 2 Disconnect.
3 Horn 1
4 Horn bracket 1
5 Front brake hose holder 1

4-83
STEERING HEAD

Removing the lower bracket

63 Nm (6.3 m•kgf, 46 ft•Ibf)

T.R
.
LS
19
16
6
LS 17
75 Nm (7.5 m•kgf, 54 ft•Ibf) 7

T.R
.
18
1st 38 Nm (3.8 m•kgf, 27 ft•Ibf)
*2nd 16 Nm (1.6 m•kgf, 12 ft•Ibf) 8

T.R
.
9
10
LS
11
12 13
14
15
7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 20
T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

* Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.

Order Job/Parts to remove Q’ty Remarks

6 Ring nut cover 1
7 Upper ring nut 1
8 Lock washer 1
9 Center ring nut 1
10 Rubber washer 1
11 Lower ring nut 1
12 Lower bracket 1
13 Bearing cover 1
14 Upper bearing inner race 1
15 Upper bearing 1
16 Lower bearing 1
17 Lower bearing inner race 1
18 Dust seal 1
19 Lower bearing outer race 1
20 Upper bearing outer race 1

4-84
STEERING HEAD

EAS30213
3. Replace:
REMOVING THE LOWER BRACKET
• Bearings
1. Stand the vehicle on a level surface.
EWA13120
• Bearing races
WARNING ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
Securely support the vehicle so that there is head pipe “1” with a long rod “2” and hammer.
no danger of it falling over. b. Remove the bearing race “3” from the lower
2. Remove: bracket with a floor chisel “4” and hammer.
• Ring nut cover c. Install a new dust seal and new bearing rac-
• Upper ring nut “1” es.
ECA14270
• Lock washer
NOTICE
• Center ring nut
• Rubber washer If the bearing race is not installed properly,
• Lower ring nut the steering head pipe could be damaged.
• Lower bracket TIP
EWA13730

WARNING • Always replace the bearings and bearing races

Securely support the lower bracket so that as a set.
there is no danger of it falling. • Whenever the steering head is disassembled,
replace the dust seal.
TIP
Remove the upper ring nut and lower ring nut
with the steering nut wrench “2”.

Steering nut wrench

90890-01403
Exhaust flange nut wrench
YU-A9472

1
EAS30214

CHECKING THE STEERING HEAD

1. Wash: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Bearings 4. Check:
• Bearing races • Lower bracket
(along with the steering stem)
Recommended cleaning solvent Bends/cracks/damage → Replace.
Kerosene
EAS30216

2. Check: INSTALLING THE STEERING HEAD

• Bearings 1. Install:
• Bearing races • Upper bearing “1”
Damage/pitting → Replace the bearings and • Lower bearing
bearing races as a set. • Lower bearing dust seal

4-85
STEERING HEAD

TIP 4. Install:
• Apply lithium-soap-based grease to each part. • Horn bracket “1”
• Be sure to install the upper bearing so that the • Horn “2”
marks “a” on the bearing are facing upward.
Horn bracket bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)

T.
R.
a Horn bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP
1 • While holding the horn bracket so that the
bracket contacts the portion “a” of the lower
bracket “3”, tighten the bolt to specification.
• While holding the horn so that the horn con-
tacts the portion “b” of the horn bracket, tighten
2. Install: the bolt to specification.
• Lower ring nut “1”
• Rubber washer “2”
a
• Center ring nut “3”
• Lock washer “4” 3
• Upper ring nut “5”
Refer to “CHECKING AND ADJUSTING 1
THE STEERING HEAD” on page 3-14.

5
4 3
2
1 1
3. Install:
• Front brake hose holder “1” b
2
Front brake hose holder bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf) 5. Install:
T.
R.

• Handlebar bracket “1”

TIP
Handlebar bracket nut
While holding the front brake hose holder so that
63 Nm (6.3 m·kgf, 46 ft·lbf)
T.

the holder contacts the projection “a” on the low-

R.

er bracket, tighten the bolt to specification.

TIP
Align the slots “a” in the lower bracket with the
pin “b” on the handlebar bracket.
a

4-86
STEERING HEAD

b
a

4-87
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

EAS20189

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

Removing the rear shock absorber assemblies and swingarm

3
2

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
LS

LS New

57 Nm (5.7 m•kgf, 41 ft•Ibf)

T.R
.
LS
New

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

21 Nm (2.1 m•kgf, 15 ft•Ibf) 125 Nm (12.5 m•kgf, 90 ft•lbf)

T.R
.
T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
T.R
.

35 Nm (3.5 m•kgf, 25 ft•Ibf)

T.R
.

21 Nm (2.1 m•kgf, 15 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-4.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-7.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-9.
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Radiator cover Refer to “RADIATOR” on page 6-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-7.
1 Rear wheel axle nut 1
2 Rear brake hose holder (rear side) 1
3 Rear wheel sensor 1

4-88
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

Removing the rear shock absorber assemblies and swingarm

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
13
LS

LS New
10 57 Nm (5.7 m•kgf, 41 ft•Ibf)

T.R
.
LS
New 6
12 7
11
5 8
9
10

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

5
21 Nm (2.1 m•kgf, 15 ft•Ibf) 125 Nm (12.5 m•kgf, 90 ft•lbf)
T.R
.
T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
.
T.R
.

35 Nm (3.5 m•kgf, 25 ft•Ibf)

T.R
.

21 Nm (2.1 m•kgf, 15 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

4 Rear brake caliper 1
5 Rear shock absorber assembly 2
6 Swingarm assembly 1
7 Rear brake hose guide 1
8 Spacer 1
9 Bearing retaining plate 1
10 Oil seal 2
11 Bearing 1
12 Swingarm 1
13 Collar 1

4-89
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

EAS31228
1. Check:
REMOVING THE SWINGARM
ECA22880
• Rear wheel sensor
NOTICE Refer to “MAINTENANCE OF THE FRONT
Keep any type of magnets (including mag- WHEEL SENSOR AND SENSOR ROTOR”
netic pick-up tools, magnetic screwdrivers, on page 4-28.
etc.) away from the rear wheel sensor; other- 2. Check:
wise, the sensor may be damaged, resulting • Rear wheel sensor rotor
in improper performance of the ABS system. Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR”
1. Stand the vehicle on a level surface. on page 4-28.
EWA13120

WARNING EAS31229

Securely support the vehicle so that there is CHECKING THE REAR SHOCK ABSORBER
no danger of it falling over. ASSEMBLY
1. Check:
TIP • Rear shock absorber rod
Place the vehicle on the centerstand so that the Bends/damage → Replace the rear shock
rear wheel is elevated. absorber assembly.
• Rear shock absorber assembly
2. Remove:
Oil leaks → Replace the rear shock absorber
• Rear wheel axle nut “1”
assembly.
• Rear brake hose holder (rear side) “2”
• Spring
• Rear wheel sensor “3”
Damage/wear → Replace the rear shock ab-
• Rear brake caliper “4”
ECA21830
sorber assembly.
NOTICE • Bushings
Damage/wear → Replace the rear shock ab-
Do not apply the brake lever when removing
sorber assembly.
the brake caliper.
• Bolts
Bends/damage/wear → Replace.
2
EAS31230

CHECKING THE SWINGARM

4 1. Check:
• Swingarm
Bends/cracks/damage → Replace.
3
2. Check:
1 • Spacer
• Collar
• Oil seal
EAS31734
• Bearing
MAINTENANCE OF THE REAR WHEEL
Damage/wear → Replace.
SENSOR
ECA22900
EAS31231
NOTICE INSTALLING THE SWINGARM
• Handle the ABS components with care 1. Lubricate:
since they have been accurately adjusted. • Oil seal lips
Keep them away from dirt and do not sub-
ject them to shocks. Recommended lubricant
• The rear wheel sensor cannot be disassem- Lithium-soap-based grease
bled. Do not attempt to disassemble it. If
2. Assemble:
faulty, replace with a new one.
• Bearing “1”
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers, • Oil seals “2” New
etc.) away from the rear wheel sensor. • Bearing retaining plate “3”
• Do not drop or shock the wheel sensor. • Rear brake hose guide “4”

4-90
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

• Spacer “5” • Swingarm mounting bolt (lower side) “4”

(to the swingarm “6”) (temporarily tighten)
4. Tighten:
Bearing retaining plate bolt • Rear wheel axle nut “2”
7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Swingarm mounting bolt (upper side) “3”
T.
R.

• Swingarm mounting bolt (lower side) “4”

TIP
• Install the oil seal until it is flush with the sur- Rear wheel axle nut
face “a” of the swingarm. 125 Nm (12.5 m·kgf, 90 ft·lbf)

T.
R.
• Install the oil seal until it is flush with the sur- Swingarm mounting bolt
face “b” of the bearing retaining plate. 57 Nm (5.7 m·kgf, 41 ft·lbf)
• Install the bearing retaining plate with the
punch mark “c” facing outward. TIP
• While holding the rear brake hose guide so that Tighten the rear wheel axle nut “2”, then the
the portion “d” of the guide contacts the bearing swingarm mounting bolts “3”, “4”.
retaining plate.
1

3
6

2 4
3
1
2 New 5. Install:
New 2
5 • Rear shock absorber assemblies
LS
Rear shock absorber assembly
2 New nut
T.
R.

LS 16 Nm (1.6 m·kgf, 12 ft·lbf)

Rear shock absorber assembly
2 New bolt
21 Nm (2.1 m·kgf, 15 ft·lbf)
b
a TIP
Tighten the rear shock absorber assembly nuts
and bolts temporarily, and then tighten them to
specification.
3
6. Measure:
TIP
Measure the distance “a” only if the wheel bear-
c ings, wheel sensor rotor, or both were replaced.
• Distance “a”
4 (between the wheel sensor rotor “1” and
d swingarm “2” (edge of the wheel sensor in-
stallation hole “b”))
3. Install:
Out of specification → Reinstall the bearing
• Swingarm assembly “1”
or replace the wheel sensor rotor.
• Rear wheel axle nut “2”
(temporarily tighten)
• Swingarm mounting bolt (upper side) “3”
(temporarily tighten)

4-91
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

Distance “a” (between the wheel

sensor rotor and swingarm (edge
of the wheel sensor installation
hole))
18.92–19.60 mm (0.74–0.77 in)

b
1

2
a
7. Install:
• Rear wheel sensor

Rear wheel sensor bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.

ECA22910

NOTICE
Make sure there are no foreign materials in
the rear wheel sensor. Foreign materials
cause damage to the rear wheel sensor.
TIP
To route the rear wheel sensor lead, refer to
“CABLE ROUTING” on page 2-29.
8. Install:
• Rear brake hose holder (rear side) “1”

Rear brake hose holder bolt (rear

side)
T.
R.

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP
Fit the projection “a” on the rear brake hose hold-
er into the hole “b” in the swingarm.

a
b

4-92
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

4-93
ENGINE

ENGINE INSPECTION .................................................................................... 5-1

MEASURING THE COMPRESSION PRESSURE .................................... 5-1

ENGINE REMOVAL ........................................................................................ 5-3

INSTALLING THE ENGINE....................................................................... 5-7
CONNECTING THE LEADS ..................................................................... 5-8
INSTALLING THE MUFFLER ................................................................... 5-8

CYLINDER HEAD............................................................................................ 5-9

REMOVING THE CYLINDER HEAD.......................................................5-13
CHECKING THE CYLINDER HEAD .......................................................5-13
CHECKING THE CAMSHAFT SPROCKET ............................................5-14
CHECKING THE TIMING CHAIN TENSIONER......................................5-14
CHECKING THE DECOMPRESSION SYSTEM.....................................5-15
CHECKING THE VVA SOLENOID..........................................................5-15
INSTALLING THE CYLINDER HEAD .....................................................5-15

CAMSHAFT ...................................................................................................5-18
REMOVING THE CAMSHAFT ................................................................5-19
CHECKING THE CAMSHAFT................................................................. 5-19
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........5-20
INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................5-20

VALVES AND VALVE SPRINGS..................................................................5-22

5
REMOVING THE VALVES ......................................................................5-23
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-23
CHECKING THE VALVE SEATS ............................................................5-25
CHECKING THE VALVE SPRINGS........................................................ 5-26
INSTALLING THE VALVES ....................................................................5-27

CYLINDER AND PISTON..............................................................................5-29

REMOVING THE PISTON ......................................................................5-30
CHECKING THE CYLINDER AND PISTON ........................................... 5-30
CHECKING THE PISTON RINGS...........................................................5-31
CHECKING THE PISTON PIN ................................................................5-32
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) .................5-32
INSTALLING THE PISTON AND CYLINDER .........................................5-32
V-BELT AUTOMATIC TRANSMISSION .......................................................5-34
REMOVING THE PRIMARY SHEAVE ....................................................5-38
REMOVING THE SECONDARY SHEAVE ............................................. 5-38
DISASSEMBLING THE SECONDARY SHEAVE....................................5-38
CHECKING THE CLUTCH HOUSING ....................................................5-39
CHECKING THE CLUTCH SHOES ........................................................ 5-39
CHECKING THE V-BELT ........................................................................5-39
CHECKING THE PRIMARY SHEAVE ....................................................5-39
CHECKING THE PRIMARY SHEAVE WEIGHTS...................................5-40
CHECKING THE PRIMARY SHEAVE SLIDERS ....................................5-40
CHECKING THE SECONDARY SHEAVE ..............................................5-40
ASSEMBLING THE PRIMARY SHEAVE ................................................5-40
ASSEMBLING THE SECONDARY SHEAVE..........................................5-40
INSTALLING THE PRIMARY SHEAVE, V-BELT AND
SECONDARY SHEAVE .........................................................................5-41

STARTER CLUTCH ......................................................................................5-44

CHECKING THE STARTER WHEEL ...................................................... 5-46
CHECKING THE STARTER CLUTCH ....................................................5-46
CHECKING THE TIMING CHAIN............................................................5-46
CHECKING THE TIMING CHAIN GUIDE (INTAKE SIDE) ..................... 5-46
INSTALLING THE STARTER CLUTCH ..................................................5-46

AC MAGNETO...............................................................................................5-47
REMOVING THE AC MAGNETO............................................................5-49
INSTALLING THE AC MAGNETO ..........................................................5-49

ELECTRIC STARTER ...................................................................................5-50

CHECKING THE STARTER MOTOR .....................................................5-52
ASSEMBLING THE STARTER MOTOR .................................................5-53
INSTALLING THE STARTER MOTOR ...................................................5-53

OIL PUMP......................................................................................................5-54
CHECKING THE OIL STRAINER ...........................................................5-56
CHECKING THE OIL PUMP ...................................................................5-56
ASSEMBLING THE OIL PUMP ...............................................................5-56

TRANSMISSION............................................................................................5-57
CHECKING THE TRANSMISSION .........................................................5-59
INSTALLING THE TRANSMISSION .......................................................5-59
CRANKSHAFT ..............................................................................................5-60
DISASSEMBLING THE CRANKCASE....................................................5-62
REMOVING THE CRANKSHAFT ASSEMBLY .......................................5-62
CHECKING THE CRANKSHAFT ASSEMBLY........................................5-62
CHECKING THE CRANKCASE ..............................................................5-63
CHECKING THE BEARING ....................................................................5-63
CHECKING THE OIL PUMP DRIVE GEAR ............................................5-63
INSTALLING THE CRANKSHAFT ..........................................................5-63
ASSEMBLING THE CRANKCASE..........................................................5-64
INSTALLING THE CENTERSTAND .......................................................5-64
ENGINE INSPECTION

EAS20041
7. Measure:
ENGINE INSPECTION • Compression pressure
EAS30249
Out of specification → Refer to steps (c) and
MEASURING THE COMPRESSION (d).
PRESSURE
Standard compression pressure
TIP (at sea level)
Insufficient compression pressure will result in a 1800 kPa/860 r/min (18.0
loss of performance. kgf/cm²/860 r/min, 256.0 psi/860
r/min)
1. Measure:
Minimum–Maximum
• Valve clearance 1570–2020 kPa/860 r/min (15.7–
Out of specification → Adjust. 20.2 kgf/cm²/860 r/min, 223.3–
Refer to “ADJUSTING THE VALVE CLEAR- 287.3 psi/860 r/min)
ANCE” on page 3-5.
2. Start the engine, warm it up for several min- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
utes, and then turn it off. a. Turn the main switch to “ON”.
3. Remove: b. With the throttle wide open, crank the engine
• Front side cover (right) until the reading on the compression gauge
Refer to “GENERAL CHASSIS (2)” on page stabilizes.
EWA12960
4-4.
WARNING
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on page To prevent sparking, ground the spark plug
4-12. lead before cranking the engine.
4. Disconnect: c. If the compression pressure is above the
• Spark plug cap maximum specification, check the cylinder
5. Remove: head, valve surfaces and piston crown for
• Spark plug carbon deposits.
ECA20470
Carbon deposits → Eliminate.
NOTICE
d. If the compression pressure is below the min-
Before removing the spark plug, use com- imum specification, pour a teaspoonful of en-
pressed air to blow away any dirt accumulat- gine oil into the spark plug bore and measure
ed in the spark plug well to prevent it from again.
falling into the cylinder. Refer to the following table.
6. Install: Compression pressure (with oil applied into the
• Compression gauge “1” cylinder)
• Extension “2” Reading Diagnosis
Piston ring(s) wear or
Compression gauge Higher than without oil
damage → Repair.
90890-03081
Engine compression tester Piston, valves, cylinder
YU-33223 head gasket or piston
Same as without oil
ring(s) possibly defec-
Extension
tive → Repair.
90890-04136
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

1 8. Install:
• Spark plug “1”

Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.

5-1
ENGINE INSPECTION

TIP
When tightening the spark plug, make sure that
the inside “a” of the spark plug wrench “2” does
not contact the portion “b” of the spark plug.

b
a 2

9. Connect:
• Spark plug cap
TIP
To route the spark plug lead, refer to “CON-
NECTING THE LEADS” on page 5-8.
10.Install:
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on page
4-12.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-4.

5-2
ENGINE REMOVAL

EAS20042

ENGINE REMOVAL
Removing the muffler

8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.

53 Nm (5.3 m•kgf, 38 ft•Ibf)

T.R
.

LT New 3
2

1 53 Nm (5.3 m•kgf, 38 ft•Ibf)

T.R
.

LT

8 Nm (0.8 m•kgf, 5.8 ft•Ibf) 15 Nm (1.5 m•kgf, 11 ft•Ibf)

T.R
.
T.R
.

53 Nm (5.3 m•kgf, 38 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Muffler protector 1
2 Muffler 1
3 Exhaust gasket 1

5-3
ENGINE REMOVAL

Disconnecting the leads

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-4.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-7.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-9.
Refer to “GENERAL CHASSIS (5)” on page
Center lower cover 4-12.
Air filter case Refer to “AIR FILTER CASE” on page 7-7.
Refer to “V-BELT AUTOMATIC TRANSMIS-
V-belt case air duct SION” on page 5-34.
Fuel injector Refer to “FUEL INJECTOR” on page 7-5.
Throttle body Refer to “THROTTLE BODY” on page 7-10.
Rear brake caliper Refer to “REAR BRAKE” on page 4-49.

5-4
ENGINE REMOVAL

Disconnecting the leads

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
8

7
2

6 5

Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Refer to “REAR SHOCK ABSORBER AS-
Rear wheel sensor SEMBLIES AND SWINGARM” on page
4-88.
1 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 AC magneto lead coupler 1 Disconnect.

4 O2 sensor coupler 1 Disconnect.

5 Spark plug cap 1 Disconnect.

6 Coolant temperature sensor coupler 1 Disconnect.
7 Starter motor sub-wire harness coupler 1 Disconnect.
8 Engine ground lead 1 Disconnect.

5-5
ENGINE REMOVAL

Removing the engine

21 Nm (2.1 m•kgf, 15 ft•Ibf)

T.R
.
16 Nm (1.6 m•kgf, 12 ft•Ibf)

T.R
.
68 Nm (6.8 m•kgf, 49 ft•Ibf)
T.R
.

1
21 Nm (2.1 m•kgf, 15 ft•Ibf)

T.R
.
1
2

4
6 68 Nm (6.8 m•kgf, 49 ft•Ibf)
T.R
.

6 10 3
4
2 11
8 5

7
9
52 Nm (5.2 m•kgf, 38 ft•Ibf) 8 11
T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Rear shock absorber assembly 2
2 Engine bracket nut/bolt 1/1
3 Engine 1
4 Engine mounting nut/bolt (rear side) 1/1
5 Engine mounting nut/bolt (front left side) 1/1
6 Engine mounting nut/bolt (front right side) 1/1
7 Engine bracket 1
8 Damper 2
9 Spacer 1
10 Stopper 1
11 Collar 2

5-6
ENGINE REMOVAL

EAS30251

INSTALLING THE ENGINE

1. Install:
• Collars “1”
• Stopper “2” 1 1 6
(to the engine “3”) 8 8 7 7
2. Install: 2
• Spacer “4” 9
• Dampers “5” 9
(to the engine bracket “6”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the damper into the left side of the en- 5. Tighten:
gine bracket and press the damper until it is • Engine mounting nut (rear side)
flush with the edge “a” of the bracket.
Engine mounting nut (rear side)
b. Install the damper into the right side of the en- 68 Nm (6.8 m·kgf, 49 ft·lbf)

T.
gine bracket and press the damper until the

R.
edge “b” of the damper contacts the spacer. 6. Install:
• Engine bracket bolt/nut “10”
a 6 4 b
TIP
Do not fully tighten the nut.
A B
7. Install:
• Rear shock absorber assemblies “11”

5 4 b 5 Rear shock absorber assembly

nut
T.
R.

16 Nm (1.6 m·kgf, 12 ft·lbf)

Rear shock absorber assembly
A. Left side bolt
B. Right side 21 Nm (2.1 m·kgf, 15 ft·lbf)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
3. Install:
• Engine bracket “6” Tighten the rear shock absorber assembly nuts
• Engine mounting bolt/nut (front right side) “7” and bolts temporarily, and then tighten them to
• Engine mounting bolt/nut (front left side) “8” specification.
• Engine mounting bolt/nut (rear side) “9” 8. Tighten:
TIP • Engine bracket nut
Do not fully tighten the nuts and bolts.
Engine bracket nut
4. Tighten: 52 Nm (5.2 m·kgf, 38 ft·lbf)
T.
R.

• Engine mounting nut (front right side)

• Engine mounting bolt (front left side) TIP
Before tightening the engine bracket nut, place
Engine mounting nut (front right
the vehicle on the centerstand so that the rear
side)
T.

wheel is elevated.
R.

68 Nm (6.8 m·kgf, 49 ft·lbf)

Engine mounting bolt (front left 9. Check:
side) • Stopper installation
68 Nm (6.8 m·kgf, 49 ft·lbf) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Raise the centerstand so that the rear wheel
TIP is on the ground.
Tighten the engine mounting nut, and then tight- b. Make sure that the stopper “2” is not touching
en the engine mounting bolt. the engine “3”.

5-7
ENGINE REMOVAL

2. Connect:
• Spark plug cap “1”
TIP
3 2
Route the spark plug lead between the VVA
(variable valve actuator) solenoid “2” and the
water pump inlet hose “3”. Make sure that the
spark plug lead does not contact the VVA (vari-
able valve actuator) solenoid or water pump inlet
hose.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

1
3
11
10
EAS31588

2 INSTALLING THE MUFFLER

1. Install:
1 • Exhaust gaskets “1” New
9
7 (to the cylinder head)
7
TIP
9 1
10 8 8 Install the exhaust gasket with its projections “a”
5 facing toward the cylinder head.
6 3
4
5

EAS31717

CONNECTING THE LEADS a

1. Connect:
• Engine ground lead “1”

Engine ground lead bolt a 1 New

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.

TIP
Make sure that the engine ground lead terminal
“a” contacts the stopper “b” on the crankcase.

a
b
1

5-8
CYLINDER HEAD

EAS20044

CYLINDER HEAD
Removing the cylinder head

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New

New
New
New New *
(4)
LS LT

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

(4) New
M
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
(4) New
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) (4)

T.R
.

24 Nm (2.4 m•kgf, 17 ft•Ibf)

New
T.R
.

13 Nm (1.3 m•kgf, 9.4 ft•Ibf)

T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

30 Nm (3.0 m•kgf, 22 ft•Ibf)

New
T.R
.

15 Nm (1.5 m•kgf, 11 ft•Ibf) 25 Nm (2.5 m•kgf, 18 ft•Ibf)

T.R

T.R
.

* Apply Yamaha bond No.1215 (90890-85505).

Order Job/Parts to remove Q’ty Remarks

Battery Refer to “GENERAL CHASSIS (1)” on page

4-1.

Front side covers Refer to “GENERAL CHASSIS (2)” on page

4-4.

Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page

4-7.

Storage box Refer to “GENERAL CHASSIS (4)” on page

4-9.

Center lower cover Refer to “GENERAL CHASSIS (5)” on page

4-12.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Radiator Refer to “RADIATOR” on page 6-1.
Thermostat assembly Refer to “THERMOSTAT” on page 6-5.
Water pump Refer to “WATER PUMP” on page 6-7.
Fuel tank Refer to “FUEL TANK” on page 7-1.

5-9
CYLINDER HEAD

Removing the cylinder head

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New
New
New
New New *
(4)
LS LT

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
(4) New
M
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
(4) New
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) (4)

T.R
.

24 Nm (2.4 m•kgf, 17 ft•Ibf)

New
T.R
.

M
1 2

13 Nm (1.3 m•kgf, 9.4 ft•Ibf)

T.R
.

3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 5
T.R
.

30 Nm (3.0 m•kgf, 22 ft•Ibf)

New
T.R
.

4
15 Nm (1.5 m•kgf, 11 ft•Ibf) 25 Nm (2.5 m•kgf, 18 ft•Ibf)
T.R

T.R
.

* Apply Yamaha bond No.1215 (90890-85505).

Order Job/Parts to remove Q’ty Remarks

Air filter case Refer to “AIR FILTER CASE” on page 7-7.
Fuel injector Refer to “FUEL INJECTOR” on page 7-5.
Intake manifold Refer to “THROTTLE BODY” on page 7-10.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1

3 O2 sensor coupler 1 Disconnect.

TIP
4 O2 sensor 1 Remove the O2 sensor only when neces-
sary.

5 Coolant temperature sensor coupler 1 Disconnect.

5-10
CYLINDER HEAD

Removing the cylinder head

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 12

T.R
.
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New
8
9 New
14 New
7 10 New New
*
(4)
LS LT

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
11 13 (4) New
M 15
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
(4) New
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) (4)

T.R
.

24 Nm (2.4 m•kgf, 17 ft•Ibf)

New
T.R
.

13 Nm (1.3 m•kgf, 9.4 ft•Ibf)

T.R
.

15
6
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

30 Nm (3.0 m•kgf, 22 ft•Ibf)

New
T.R
.

15 Nm (1.5 m•kgf, 11 ft•Ibf) 25 Nm (2.5 m•kgf, 18 ft•Ibf)

T.R

T.R
.

* Apply Yamaha bond No.1215 (90890-85505).

Order Job/Parts to remove Q’ty Remarks

6 Coolant temperature sensor 1
7 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
8 VVA (variable valve actuator) solenoid 1
9 VVA (variable valve actuator) solenoid gasket 1
10 VVA (variable valve actuator) solenoid rod 1
11 Fuel hose holder 1
12 Cylinder head breather hose 1
13 Cylinder head cover 1
14 Cylinder head cover gasket 1
15 Dowel pin 2

5-11
CYLINDER HEAD

Removing the cylinder head

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New
19
New
New 16 20
17 New New 21 *
18

(4)
LS LT

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
28
(4) New 27
M
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
(4) 26 New
T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) (4)

T.R
.

24 Nm (2.4 m•kgf, 17 ft•Ibf)

New
T.R
.

27
M

22
13 Nm (1.3 m•kgf, 9.4 ft•Ibf)
25 24
T.R
.

23
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

30 Nm (3.0 m•kgf, 22 ft•Ibf)

New
T.R
.

15 Nm (1.5 m•kgf, 11 ft•Ibf) 25 Nm (2.5 m•kgf, 18 ft•Ibf)

T.R

T.R
.

* Apply Yamaha bond No.1215 (90890-85505).

Order Job/Parts to remove Q’ty Remarks

16 Cylinder head cover breather plate 1
17 Cylinder head cover breather plate gasket 1
18 Oil seal 1
19 Timing chain tensioner plug 1
20 Timing chain tensioner 1
21 Timing chain tensioner gasket 1
22 Camshaft sprocket bolt 1
23 Camshaft sprocket 1
24 Decompression cam 1
25 Cylinder head 1
26 Cylinder head gasket 1
27 Dowel pin 2
28 Engine oil check bolt 1

5-12
CYLINDER HEAD

EAS30276
3. Remove:
REMOVING THE CYLINDER HEAD
• Cylinder head
1. Align:
• “I” mark “a” on the AC magneto rotor TIP
(with the match mark “b” on the right crank- • Loosen the bolts and nuts in the proper se-
case) quence as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Loosen each bolt and nuts 1/2 of a turn at a
a. Turn the crankshaft clockwise. time. After all of the bolts and nuts are fully
loosened, remove them.

×
4 3 4

b ×
2
6 5
a
b. When the piston is at TDC on the compres- 1 2
sion stroke, align the “I” mark “c” on the cam-
EAS30277
shaft sprocket with the match mark “d” on the CHECKING THE CYLINDER HEAD
camshaft stopper plate. 1. Eliminate:
• Combustion chamber carbon deposits
c (with a rounded scraper)
d
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
• Valve seats

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Loosen:
• Camshaft sprocket bolt “1”
TIP
Use the camshaft wrench “2” and loosen the
camshaft sprocket bolt.

Camshaft wrench
2. Check:
90890-04162
• Cylinder head
Camshaft wrench
YM-04162 Damage/scratches → Replace.
• Cylinder head water jacket
Mineral deposits/rust → Eliminate.
3. Measure:
1 • Cylinder head warpage
2 Out of specification → Resurface the cylinder
head.

Warpage limit
0.05 mm (0.0020 in)

5-13
CYLINDER HEAD

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.

a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
1 2
EAS30279

CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
Cracks/damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the timing chain tensioner plug.
b. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful-
b. Measure the warpage. ly clockwise with a thin screwdriver “1”.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place 400–600 grit wet sandpaper on the sur-
face plate and resurface the cylinder head
using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31232
c. While holding the timing chain tensioner rod
CHECKING THE CAMSHAFT SPROCKET in place with your hand, turn the screwdriver
1. Check: counterclockwise, remove the screwdriver,
• Camshaft sprocket and slowly release the timing chain tensioner
More than 1/4 tooth wear “a” → Replace the rod.
camshaft sprocket, timing chain and crank-
shaft as a set.

d. Make sure that the timing chain tensioner rod

comes out of the timing chain tensioner hous-
ing smoothly. If there is rough movement, re-
place the timing chain tensioner.

5-14
CYLINDER HEAD

e. Install the timing chain tensioner plug. • Tighten the cylinder head nuts and bolts in the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ proper tightening sequence as shown and
EAS30280
torque them in two stages.
CHECKING THE DECOMPRESSION SYSTEM
1. Check:
×
• Decompression system 3 4 4
TIP
1 1 ×
• Check that the decompression lever moves
2
smoothly.
• Check that the operating range “a” of the de- 2 1 2 2
compression lever is the same as the range
shown in the illustration. 6 5

a 2. Install:
• Decompression cam “1”
• Camshaft sprocket “2”
• Timing chain
• Camshaft sprocket bolt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. Align the “I” mark “a” on the AC magneto rotor
with the match mark “b” on the right crank-
case.
a. 20.88°
EAS31624

CHECKING THE VVA SOLENOID

1. Check:
• VVA (variable valve actuator) solenoid “1”
Cracks/damage → Replace. b

1
a
c. Install the decompression cam.
d. Install the timing chain onto the camshaft
sprocket, then the camshaft sprocket onto
the camshaft, and then finger tighten the
camshaft sprocket bolt.
ECA20600

NOTICE
EAS30282

INSTALLING THE CYLINDER HEAD Do not turn the crankshaft when installing
1. Tighten: the camshaft sprocket to avoid damage or
• Cylinder head nuts “1” improper valve timing.
• Cylinder head bolts “2”
TIP
Cylinder head nut • Fit the pin on the decompression cam into the
24 Nm (2.4 m·kgf, 17 ft·lbf) slot “c” in the decompression lever on the cam-
T.
R.

Cylinder head bolt shaft sprocket.

10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Align the “I” mark “d” on the camshaft sprocket
with the match mark “e” on the camshaft stop-
TIP per plate.
• Lubricate the cylinder head nuts and washers
with molybdenum disulfide grease.

5-15
CYLINDER HEAD

Timing chain tensioner bolt

2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
e

T.
R.
1
d a
a

e. While holding the camshaft, temporarily tight- 2

en the camshaft sprocket bolt.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install: d. Turn the timing chain tensioner rod counter-
• Timing chain tensioner gasket New clockwise with a thin screwdriver “1”, make
• Timing chain tensioner sure it releases, and then install the timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ chain tensioner plug.
a. Remove the timing chain tensioner plug.
b. While lightly pressing the timing chain ten- 1
sioner rod by hand, turn the tensioner rod ful-
ly clockwise with a thin screwdriver “1”.
TIP
Make sure that the tensioner rod has been fully
turned clockwise.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Turn:
• Crankshaft
(several turns clockwise)
5. Check:
1 • “I” mark “a”
Make sure the “I” mark “a” on the AC magne-
c. Install the gasket and the timing chain ten- to rotor is aligned with the match mark “b” on
sioner “2” onto the cylinder. the right crankcase.
EWA17620 • “I” mark “c”
WARNING Make sure the “I” mark “c” on the camshaft
Always use a new gasket. sprocket is aligned with the match mark “d”
on the camshaft stopper plate.
TIP Out of alignment → Correct.
• Install the timing chain tensioner gasket so that Refer to the installation steps above.
the tabs “a” on the gasket are protruding in the
directions shown in the illustration.
• Apply Yamaha bond No. 1215 to the threads of
the timing chain tensioner bolts.

Yamaha bond No. 1215 b

90890-85505
(Three bond No.1215®)
a

5-16
CYLINDER HEAD

TIP
Install the oil seal so that it is facing in the direc-
c d tion shown in the illustration. Press the oil seal
into the cylinder head cover using a suitable di-
ameter socket “3”.

3 2

6. Tighten: 1
• Camshaft sprocket bolt “1”

Camshaft sprocket bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.

9. Install:
Camshaft wrench • VVA (variable valve actuator) solenoid “1”
90890-04162
Camshaft wrench VVA (variable valve actuator) so-
YM-04162 lenoid bolt
T.
R.

10 Nm (1.0 m·kgf, 7.2 ft·lbf)

ECA20610

NOTICE
TIP
Be sure to tighten the camshaft sprocket bolt
While holding the VVA (variable valve actuator)
to the specified torque to avoid the possibil-
solenoid so that it is contacting the cylinder head
ity of the bolt coming loose and damaging
cover “2”, tighten the bolts to specification.
the engine.
TIP
Tighten the camshaft sprocket bolt with the cam-
shaft wrench “2”. 1
2

1
2

7. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
8. Install:
• Oil seal “1”
(into the cylinder head cover “2”)

5-17
CAMSHAFT

EAS20043

CAMSHAFT
Removing the rocker arms and camshaft
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

2
New M
11 14
14

12 10
13 4 New
9
M

3
M

M E
8
6 7
E

E 5
2 M

7 E
M
2 M 5
M
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
1 Camshaft stopper plate 1
2 Locknut 4
3 Camshaft assembly 1
4 Bearing 1
5 Rocker arm shaft 2
6 Exhaust rocker arm 1
7 Adjusting screw (exhaust side) 2
8 Plate 1
9 Spring 1
10 Intake rocker arm 1 1
11 Intake rocker arm stopper pin 1
12 Spring 1
13 Intake rocker arm 2 1
14 Adjusting screw (intake side) 2

5-18
CAMSHAFT

EAS30256
2. Measure:
REMOVING THE CAMSHAFT
• Camshaft lobe dimensions “a” and “b”
1. Loosen:
Out of specification → Replace the camshaft.
• Adjusting screws (intake/exhaust)
2. Remove: Camshaft lobe dimensions
• Camshaft assembly “1” Lobe height (Intake)
32.211–32.311 mm (1.2681–
Slide hammer bolt 1.2721 in)
90890-01085 Limit
Slide hammer bolt 8 mm 32.111 mm (1.2642 in)
YU-01083-2 Lobe height (Intake high speed)
Weight 32.587–32.686 mm (1.2830–
90890-01084 1.2869 in)
Weight Limit (High speed)
YU-01083-3 32.487 mm (1.2790 in)
Lobe height (Exhaust)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 29.420–29.430 mm (1.1583–
a. Align the holes “a” in intake rocker arm 1 “2” 1.1587 in)
and intake rocker arm 2 “3”, and then push Limit
the intake rocker arm stopper pin “4” in the di- 29.320 mm (1.1543 in)
rection of the arrow shown in the illustration.

4
a

b. While pushing intake rocker arm 1 “2” and in-

take rocker arm 2 “3” in the direction of the ar-
row shown in the illustration, remove the
camshaft assembly using a slide hammer
bolt “5” and weight “6”.

3
1
5 3. Measure:
• Camshaft runout
6 Out of specification → Replace the camshaft.

Camshaft runout limit

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 0.030 mm (0.0012 in)
EAS30257

CHECKING THE CAMSHAFT

1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
place the camshaft.

5-19
CAMSHAFT

4. Check: 4. Measure:
• Camshaft oil passage • Rocker arm shaft outside diameter “a”
Obstruction → Blow out with compressed air. Out of specification → Replace.
EAS30259
Rocker arm shaft outside diame-
CHECKING THE ROCKER ARMS AND ter
ROCKER ARM SHAFTS 9.966–9.976 mm (0.3924–0.3928
The following procedure applies to all of the in)
rocker arms and rocker arm shafts. Limit
1. Check: 9.936 mm (0.3912 in)
• Rocker arm
• Rocker arm roller “1”
Damage/wear → Replace.

1 1 5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
2. Check: TIP
• Rocker arm shaft Calculate the clearance by subtracting the rock-
Blue discoloration/excessive wear/pit- er arm shaft outside diameter from the rocker
ting/scratches → Replace or check the lubri- arm inside diameter.
cation system.
3. Measure: Out of specification → Replace the defective
• Rocker arm inside diameter “a” part(s).
Out of specification → Replace.
Rocker-arm-to-rocker-arm-shaft
Rocker arm inside diameter clearance
9.985–10.000 mm (0.3931– 0.009–0.034 mm (0.0004–0.0013
0.3937 in) in)
Limit Limit
10.015 mm (0.3943 in) 0.080 mm (0.0032 in)

EAS30270

INSTALLING THE CAMSHAFT AND ROCKER

ARMS
1. Lubricate:
• Camshaft assembly

5-20
CAMSHAFT

b. While pushing intake rocker arm 1 “2” and in-

Recommended lubricant take rocker arm 2 “3” in the direction of the ar-
Camshaft row shown in the illustration, install the
Molybdenum disulfide oil camshaft assembly.
Camshaft bearing
Engine oil TIP
Install the camshaft with the punch mark “a” fac-
2. Lubricate: ing upward.
• Rocker arms
• Rocker arm shafts
• Spring 2
• Intake rocker arm stopper pin
3
Recommended lubricant
Rocker arm shaft
Intake rocker arm stopper pin
Molybdenum disulfide oil
Spring a
Rocker arm roller
Engine oil ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
3. Install:
• Camshaft stopper plate
• Spring “1”
TIP Camshaft stopper plate bolt
Install the spring so that the ends “a” of the (M5×16)
T.
R.

spring are positioned at the locations shown in 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
the illustration. Camshaft stopper plate bolt
(M6×14)
a 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf)

TIP
Before installing the camshaft stopper plate,
make sure that the slots “a” in the rocker arm
shafts “2” are parallel with the edge “b” of the cyl-
inder head and that the camshaft stopper plate
bolt holes in the cylinder head and rocker arm
shafts are aligned.
4. Install: b
• Camshaft assembly “1” 2 a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Align the holes “a” in intake rocker arm 1 “2”
and intake rocker arm 2 “3”, and then push a
the intake rocker arm stopper pin “4” in the di-
rection of the arrow shown in the illustration.

4
a

5-21
VALVES AND VALVE SPRINGS

EAS20045

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

1 2 3 8 New
6 New

8 New
4
7
E

7
M
M
6 New

1
E

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
Camshaft/Rocker arms Refer to “CAMSHAFT” on page 5-18.
1 Valve cotter 8
2 Valve spring retainer 4
3 Valve spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Valve spring seat 4
8 Valve guide 4

5-22
VALVES AND VALVE SPRINGS

EAS30283

REMOVING THE VALVES 2

The following procedure applies to all of the
valves and related components.
TIP
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check: 1
• Valve sealing
Leakage at the valve seat → Check the valve 3. Remove:
face, valve seat, and valve seat width. • Valve spring retainer “1”
Refer to “CHECKING THE VALVE SEATS” • Valve spring “2”
on page 5-25. • Valve “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve stem seal “4”
a. Pour a clean solvent “a” into the intake and • Valve spring seat “5”
exhaust ports. TIP
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
1
5
2

3
4

EAS30284

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE VALVES AND VALVE

2. Remove: GUIDES
• Valve cotters “1” The following procedure applies to all of the
valves and valve guides.
TIP
1. Measure:
Remove the valve cotters by compressing the • Valve-stem-to-valve-guide clearance
valve spring with the valve spring compressor Out of specification → Replace the valve
and the valve spring compressor attachment “2”. guide.
Valve-stem-to-valve-guide clearance =
Valve spring compressor Valve guide inside diameter “a” -
90890-04019 Valve stem diameter “b”
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108

5-23
VALVES AND VALVE SPRINGS

b. Install the new valve guide with the valve

Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover
ance (intake) “1”.
0.010–0.037 mm (0.0004–0.0015
in) Valve guide position
Limit 9.9–10.3 mm (0.39–0.41 in)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.110 mm (0.0043 in)

a. Valve guide position

c. After installing the valve guide, bore the valve
guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.

TIP
2. Replace: After replacing the valve guide, reface the valve
seat.
• Valve guide New
TIP
Valve guide remover (ø5)
To ease valve guide removal and installation, 90890-04097
and to maintain the correct fit, heat the cylinder Valve guide remover (5.0 mm)
head to 100 °C (212 °F) in an oven. YM-04097
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Valve guide installer (ø5)
a. Remove the valve guide with the valve guide 90890-04098
remover “1”. Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)

5-24
VALVES AND VALVE SPRINGS

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. Measure:
• Valve stem runout
Out of specification → Replace the valve.
TIP
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• When installing a new valve, always replace
a. Apply Blue layout fluid “b” onto the valve face.
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.

Valve stem runout

0.010 mm (0.0004 in)

b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
EAS30285
Where the valve seat and valve face contacted
CHECKING THE VALVE SEATS one another, the blue layout fluid will have been
The following procedure applies to all of the removed.
valves and valve seats.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1. Eliminate:
4. Lap:
• Carbon deposits
• Valve face
(from the valve face and valve seat)
• Valve seat
2. Check:
• Valve seat TIP
Pitting/wear → Replace the cylinder head. After replacing the cylinder head or replacing the
3. Measure: valve and valve guide, the valve seat and valve
• Valve seat width “a” face should be lapped.
Out of specification → Replace the cylinder ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
head. a. Apply a coarse lapping compound “a” to the
valve face.
Valve seat contact width (intake) ECA13790

0.90–1.20 mm (0.0354–0.0472 in) NOTICE

Limit Do not let the lapping compound enter the
1.6 mm (0.06 in)
gap between the valve stem and the valve
Valve seat contact width (ex-
guide.
haust)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.6 mm (0.06 in)

5-25
VALVES AND VALVE SPRINGS

j. Measure the valve seat width again. If the

valve seat width is out of specification, reface
and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30286

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the
valve springs.
1. Measure:
• Valve spring free length “a”
b. Apply molybdenum disulfide oil onto the Out of specification → Replace the valve
valve stem. spring.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve Free length (intake)
seat are evenly polished, and then clean off 33.79 mm (1.33 in)
all of the lapping compound. Limit
32.10 mm (1.26 in)
TIP Free length (exhaust)
For the best lapping results, lightly tap the valve 33.80 mm (1.33 in)
seat while rotating the valve back and forth be- Limit
tween your hands. 32.06 mm (1.26 in)

e. Apply a fine lapping compound to the valve 2. Measure:

face and repeat the above steps. • Compressed valve spring force “a”
f. After every lapping procedure, be sure to Out of specification → Replace the valve
clean off all of the lapping compound from the spring.
valve face and valve seat.
g. Apply blue layout fluid “b” onto the valve face. Installed compression spring
force (intake)
139.50–160.50 N (14.22–16.37
kgf, 31.36–36.08 lbf)
Installed compression spring
force (exhaust)
139.50–160.50 N (14.22–16.37
kgf, 31.36–36.08 lbf)
Installed length (intake)
28.90 mm (1.14 in)
Installed length (exhaust)
28.90 mm (1.14 in)
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.

5-26
VALVES AND VALVE SPRINGS

• Valve stem seal “2”

(with the recommended lubricant)

Recommended lubricant
Engine oil

E
b. Installed length
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring.
5. Install:
Spring tilt (intake) • Valve spring seat “1”
1.5 mm (0.06 in)
Spring tilt (exhaust) • Valve stem seal “2” New
1.5 mm (0.06 in) • Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.

5
EAS30288
1
INSTALLING THE VALVES 4
The following procedure applies to all of the
valves and related components. 3
• Valve stem end
(with an oil stone) 2 New

4. Lubricate:
• Valve stem “1”
b. Smaller pitch
Recommended lubricant
Molybdenum disulfide oil 6. Install:
• Valve cotters “1”

5-27
VALVES AND VALVE SPRINGS

TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.

Valve spring compressor

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108

7. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800

NOTICE
Hitting the valve tip with excessive force
could damage the valve.

5-28
CYLINDER AND PISTON

EAS20046

CYLINDER AND PISTON

Removing the cylinder and piston

3 New
4
2

E
1 5 New
7
New
10
9
11 6
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 5 New
T.R
.

8 E

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
11 Coolant drain bolt (cylinder side) 1

5-29
CYLINDER AND PISTON

EAS30289

REMOVING THE PISTON TIP

1. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
ECA13810

NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar- EAS30291

ea. If both areas are deburred and the piston CHECKING THE CYLINDER AND PISTON
pin is still difficult to remove, remove it with the 1. Check:
piston pin puller set “4”. • Piston wall
• Cylinder wall
Vertical scratches → Rebore or replace the
Piston pin puller set cylinder, and replace the piston and piston
90890-01304
rings as a set.
Piston pin puller
2. Measure:
YU-01304
• Piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
TIP
2 1 Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.

Bore
3
58.000–58.010 mm (2.2835–
2.2839 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)

“C” = maximum of D1 - D2
“T” = maximum of D1 or D2 - maximum of D5 or
D6
“R” = maximum of D1, D3 or D5 - minimum of D2,
2. Remove: D4 or D6
• Top ring
• 2nd ring
• Oil ring

5-30
CYLINDER AND PISTON

EAS30292

CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston Piston ring
rings as a set. Top ring
c. Measure piston skirt diameter D “a” with the Ring side clearance
micrometer. 0.030–0.065 mm (0.0012–
0.0026 in)
Limit
0.115 mm (0.0045 in)
2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–
0.0022 in)
Limit
0.115 mm (0.0045 in)

b. 6.0 mm (0.24 in) from the bottom edge of the

piston

Piston
Diameter
57.962–57.985 mm (2.2820–
2.2829 in)

d. If out of specification, replace the piston and

piston rings as a set. 2. Install:
e. Calculate the piston-to-cylinder clearance • Piston ring
with the following formula. (into the cylinder)
Piston-to-cylinder clearance = TIP
Cylinder bore “C” -
Piston skirt diameter “D”
Use the piston crown to level the position ring
near the bottom of the cylinder where the cylin-
der wear is lowest.
Piston-to-cylinder clearance
0.015–0.048 mm (0.0006–0.0019 3. Measure:
in) • Piston ring end gap
Out of specification → Replace the piston
f. If out of specification, rebore or replace the ring.
cylinder, and replace the piston and piston TIP
rings as a set. The oil ring expander spacer end gap cannot be
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ measured. If the oil ring rail gap is excessive, re-
place all three piston rings.

5-31
CYLINDER AND PISTON

Piston ring
Top ring
End gap (installed)
0.10–0.25 mm (0.0039–0.0098
in)
Limit
0.50 mm (0.0197 in)
2nd ring
End gap (installed)
0.35–0.50 mm (0.0138–0.0197
in) 3. Measure:
Limit • Piston pin bore diameter “b”
0.85 mm (0.0335 in) Out of specification → Replace the piston.
Oil ring
End gap (installed) Piston pin bore inside diameter
0.20–0.70 mm (0.0079–0.0276 14.002–14.013 mm (0.5513–
in) 0.5517 in)
Limit
14.043 mm (0.5529 in)

a. Bottom of cylinder
b. Upper of cylinder
4. Calculate:
EAS30293
• Piston-pin-to-piston-pin-bore clearance
CHECKING THE PISTON PIN
Out of specification → Replace the piston pin
1. Check:
and piston as a set.
• Piston pin
Blue discoloration/grooves → Replace the Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” -
piston pin, and then check the lubrication sys- Piston pin outside diameter “a”
tem.
2. Measure:
• Piston pin outside diameter “a” Piston-pin-to-piston-pin-bore
Out of specification → Replace the piston pin. clearance
0.002–0.018 mm (0.0001–0.0007
Piston pin outside diameter in)
13.995–14.000 mm (0.5510–
0.5512 in) EAS30290

Limit CHECKING THE TIMING CHAIN GUIDE

13.975 mm (0.5502 in) (EXHAUST SIDE)
1. Check:
• Timing chain guide (exhaust side)
Damage/wear → Replace.
EAS30294

INSTALLING THE PISTON AND CYLINDER

1. Install:
• Lower oil ring rail “1”
• Oil ring expander “2”

5-32
CYLINDER AND PISTON

• Upper oil ring rail “3” 3. Lubricate:

• 2nd ring “4” • Piston
• Top ring “5” • Piston rings
TIP • Cylinder
Be sure to install the piston rings so that the (with the recommended lubricant)
manufacturer marks face up.
Recommended lubricant
Engine oil
5
4. Offset:
• Piston ring end gaps
4 c
3

2
b a
1
135˚
45˚ 45˚
2. Install:
• Piston “1” e d
• Piston pin “2” 45˚ 45˚
A
• Piston pin clips “3” New
a. Top ring
TIP
b. 2nd ring
• Apply engine oil to the piston pin.
c. Upper oil ring rail
• Make sure the punch mark “a” on the piston
d. Oil ring expander
points towards the exhaust side of the cylinder.
e. Lower oil ring rail
• Before installing the piston pin clips, cover the
A. Exhaust side
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase. 5. Install:
• When installing a piston pin clip, make sure • Dowel pins
that the clip ends “b” are positioned away from • Cylinder gasket New
the cutout “c” in the piston as shown in the illus- • Cylinder “1”
tration.
TIP
• While holding the piston “2” with one hand, in-
New 3 stall the cylinder with the other hand.
2 • Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.

1 2
1

3 New 2
1
b

5-33
V-BELT AUTOMATIC TRANSMISSION

EAS20050

V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt case

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New
(10)
5

New 1
New
3
2
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

New

(6)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-4.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-7.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-9.
Air filter case Refer to “AIR FILTER CASE” on page 7-7.
1 V-belt case air filter element cover 1
2 V-belt case air filter element 1
3 V-belt case air filter element support 1
4 V-belt case air duct 1
5 V-belt case 1

5-34
V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt case

9
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
New
(10)

7 8
New
New 6

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

New

(6)

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

TIP
When removing the V-belt case gasket, cut
the center portion of the gasket. Before in-
6 V-belt case gasket 1 stalling a new V-belt case gasket, remove
the V-belt.
Refer to “Removing the V-belt, primary
sheave and secondary sheave”.

7 Dowel pin 1
8 V-belt case check hose 1
9 Bearing 1

5-35
V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt, primary sheave and secondary sheave

45 Nm (4.5 m•kgf, 33 ft•Ibf)

T.R
.
13

12

10
9 11
10
LS 8

10 5

7 6

LS
3
4 1

2
49 Nm (4.9 m•kgf, 35 ft•Ibf)
T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Primary fixed sheave nut 1
2 Conical spring washer 1
3 Washer 1
4 Primary fixed sheave 1
5 V-belt 1
6 Collar 1
7 Primary sliding sheave 1
8 Primary sheave weight 6
9 Cam 1
10 Slider 3
11 Clutch housing nut 1
12 Clutch housing 1
13 Secondary sheave assembly 1

5-36
V-BELT AUTOMATIC TRANSMISSION

Disassembling the secondary sheave

* 55 Nm (5.5 m•kgf, 40 ft•Ibf)

T.R
.
4

3
2
10
11 New 13
12
5 1
6

9 New 7

9 New
* 8 New

* Apply Shell dolium grease R®.

Order Job/Parts to remove Q’ty Remarks

1 Secondary sheave nut 1
2 Clutch carrier assembly 1
3 Compression spring 1
4 Spring seat 1
5 Guide pin 3
6 Collar 3
7 Secondary sliding sheave 1
8 O-ring 2
9 Oil seal 2
10 Bearing 1
11 Circlip 1
12 Bearing 1
13 Secondary fixed sheave 1

5-37
V-BELT AUTOMATIC TRANSMISSION

EAS30310 ECA21820

REMOVING THE PRIMARY SHEAVE NOTICE

1. Remove: Do not remove the secondary sheave nut at
• Primary fixed sheave nut “1” this stage.
• Conical spring washer
• Washer TIP
• Primary fixed sheave “2” While holding the secondary sheave with the ro-
TIP tor holding tool “2”, loosen the secondary
While holding the primary fixed sheave with the sheave nut one full turn with the socket wrench
rotor holding tool “3”, loosen the primary fixed “3”.
sheave nut.
Rotor holding tool
Rotor holding tool 90890-04166
90890-01235 YM-04166
Universal magneto and rotor Socket wrench (39 mm)
holder 90890-01493
YU-01235

3
1

3 2

2
EAS30312

EAS30311
DISASSEMBLING THE SECONDARY
REMOVING THE SECONDARY SHEAVE SHEAVE
1. Remove: 1. Remove:
• Clutch housing nut “1” • Secondary sheave nut “1”
• Clutch housing “2” TIP
TIP Install the sheave spring compressor “2” and
While holding the clutch housing with the rotor sheave fixed block “3” onto the secondary
holding tool “3”, loosen the clutch housing nut. sheave as shown. Then, compress the spring,
and remove the secondary sheave nut.
Rotor holding tool
90890-04166 Sheave spring compressor
YM-04166 90890-04134
Sheave spring compressor
YM-04134
Sheave fixed block
90890-04135
Sheave fixed bracket
YM-04135

3
2
1
2. Loosen:
• Secondary sheave nut “1”

5-38
V-BELT AUTOMATIC TRANSMISSION

2 Clutch shoe thickness

4.0 mm (0.16 in)
1 Limit
2.5 mm (0.10 in)

a a

3 a
a
EAS30313

CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing
Damage/wear → Replace. a a
2. Measure:
EAS30315
• Clutch housing inside diameter “a”
CHECKING THE V-BELT
Out of specification → Replace the clutch
1. Check:
housing.
• V-belt “1”
Clutch housing inside diameter Cracks/damage/wear → Replace.
125.0 mm (4.92 in) Grease/oil → Clean the primary and second-
Limit ary sheave.
126.0 mm (4.96 in) 2. Measure:
• V-belt width “a”
Out of specification → Replace.

V-belt width
25.5 mm (1.00 in)
a Limit
23.0 mm (0.91 in)

EAS30314

CHECKING THE CLUTCH SHOES

The following procedure applies to all of the
clutch shoes.
1. Check:
• Clutch shoe
Damage/wear → Replace the clutch shoes
EAS30316
and springs as a set.
CHECKING THE PRIMARY SHEAVE
Glazed areas → Sand with coarse sandpa-
1. Check:
per.
• Primary sliding sheave
TIP • Primary fixed sheave
After sanding the glazed areas, clean the clutch • Collar
with a cloth. Cracks/damage/wear → Replace the primary
2. Measure: sliding sheave, primary fixed sheave, and
• Clutch shoe thickness “a” collar as a set.
Out of specification → Replace the clutch
shoes and springs as a set.

5-39
V-BELT AUTOMATIC TRANSMISSION

EAS30317

CHECKING THE PRIMARY SHEAVE

WEIGHTS 1
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
• Primary sheave weight
Cracks/damage/wear → Replace. a
2. Measure:
• Primary sheave weight outside diameter “a”
Out of specification → Replace.
4. Check:
Weight outside diameter • Spring free length
20.0 mm (0.79 in) Out of specification → Replace the spring.
Limit
19.5 mm (0.77 in) Compression spring free length
95.0 mm (3.74 in)
Limit
85.5 mm (3.37 in)

EAS31233

CHECKING THE PRIMARY SHEAVE

SLIDERS
EAS30320
1. Check:
ASSEMBLING THE PRIMARY SHEAVE
• Primary sheave slider
1. Clean:
Cracks/damage/wear → Replace.
• Primary fixed sheave
EAS30319 • Primary sliding sheave
CHECKING THE SECONDARY SHEAVE • Primary sheave weights
1. Check: • Cam
• Secondary fixed sheave
EAS30321
• Secondary sliding sheave
ASSEMBLING THE SECONDARY SHEAVE
Cracks/damage/wear → Replace the sec-
1. Lubricate:
ondary fixed and sliding sheaves as a set.
• Secondary sliding sheave inner surface
2. Check:
• Oil seals “1”
• Torque cam groove “a”
(with the recommended lubricant)
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set. Recommended lubricant
3. Check: Shell dolium grease R®
• Guide pin “1”
Damage/wear → Replace the secondary TIP
fixed and sliding sheaves as a set. Do not apply grease to the inner surface “a” of
the secondary fixed sheave “2”. If any grease
gets on the inner surface of the secondary fixed
sheave, be sure to wipe it off thoroughly.

5-40
V-BELT AUTOMATIC TRANSMISSION

• Compression spring
2 * • Clutch carrier assembly
1 • Secondary sheave nut “1”
TIP
• Install the sheave spring compressor “2” and
* sheave fixed block “3” onto the secondary
sheave as shown. Then, compress the spring,
a 1
and install the secondary sheave nut.
• Install the secondary sheave nut “1” with its ta-
pered side facing the clutch carrier.
2. Install:
• Oil seals New Sheave spring compressor
• Secondary sliding sheave “1” 90890-04134
TIP Sheave spring compressor
Install the secondary sliding sheave onto the YM-04134
secondary fixed sheave “2” with the oil seal Sheave fixed block
90890-04135
guide “3”.
Sheave fixed bracket
YM-04135
Oil seal guide (37 mm)
90890-04177
2

1
1

2
3
EAS31234

INSTALLING THE PRIMARY SHEAVE, V-

3. Install: BELT AND SECONDARY SHEAVE
• Guide pins “1” 1. Install:
4. Lubricate: • Secondary sheave assembly
• Guide pin grooves “a” TIP
• O-rings “2” New Before installing the secondary sheave assem-
(with the recommended lubricant) bly, check that there is no grease on the splines
“a” of the primary drive gear. If there is any
Recommended lubricant grease on the splines, be sure to wipe it off thor-
Shell dolium grease R®
oughly.

1
New 2
a

5. Install: 2. Tighten:
• Spring seat • Secondary sheave nut “1”

5-41
V-BELT AUTOMATIC TRANSMISSION

TIP
Secondary sheave nut
55 Nm (5.5 m·kgf, 40 ft·lbf) When installing the primary sliding sheave as-
T.

sembly, hold the cam to prevent the primary

R.

TIP
sheave weights from falling out of the primary
sliding sheave.
While holding the secondary sheave with the ro-
tor holding tool “2”, tighten the secondary
sheave nut with the socket wrench “3”.

Rotor holding tool 1

90890-04166
YM-04166
Socket wrench (39 mm)
90890-01493

2 5. Install:
• V-belt “1”
ECA21720

NOTICE

1 Do not allow grease to come in contact with

the V-belt.
TIP
3
• Install the V-belt with the printed arrow mark on
3. Install: the V-belt facing in the direction shown in the il-
• Clutch housing “1” lustration.
• Clutch housing nut “2” • Install the V-belt onto the primary sheave side.

Clutch housing nut

45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.

TIP
While holding the clutch housing with the rotor
holding tool “3”, tighten the clutch housing nut.
1

Rotor holding tool

90890-04166
YM-04166 6. Install:
• Primary fixed sheave “1”
• Washer
3 • Conical spring washer “2”
• Primary fixed sheave nut
ECA21730

NOTICE
Do not allow grease to contact the primary
sheave assembly.
1 TIP
2 • Apply lithium-soap-based grease to the prima-
4. Install: ry fixed sheave nut side of the conical spring
• Primary sliding sheave assembly “1” washer and to the threaded portion of the
crankshaft.

5-42
V-BELT AUTOMATIC TRANSMISSION

• Install the conical spring washer with the mark

“a” facing outward.
• Install the V-belt in the primary sheave (when
the pulley is at its widest position) and in the
secondary sheave (when the pulley is at its
narrowest position), and make sure the V-belt
is tight.

2
7. Tighten:
• Primary fixed sheave nut “1”

Primary fixed sheave nut

49 Nm (4.9 m·kgf, 35 ft·lbf)
T.
R.

TIP
While holding the primary fixed sheave with the
rotor holding tool “2”, tighten the primary fixed
sheave nut.

Rotor holding tool

90890-01235
Universal magneto and rotor
holder
YU-01235

5-43
STARTER CLUTCH

EAS20049

STARTER CLUTCH
Removing the starter clutch

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
M

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

LT

T.R
3 LT

.
5
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
4

T.R
.
3
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

New
LS (3)
New

E 6
8
9 2 New
7 New
1
*
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) LS
T.R
.

*Apply Yamaha bond No. 1215 (90890-85505).

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.

Secondary sheave assembly Refer to “V-BELT AUTOMATIC TRANSMIS-

SION” on page 5-34.
1 Starter clutch cover 1
2 Oil seal 1
3 Dowel pin 2
4 Starter clutch idle gear 1
5 Starter clutch idle gear shaft 1
6 Collar 1
7 Starter clutch 1
8 Collar 1
9 Starter wheel 1

5-44
STARTER CLUTCH

Removing the starter clutch

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
14

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

LT

T.R
LT

.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
12 T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

New
LS (3)
New 10 11
13
E

New

New

*
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) LS
T.R
.

*Apply Yamaha bond No. 1215 (90890-85505).

Order Job/Parts to remove Q’ty Remarks

10 Circlip 1
11 Bearing 1
12 Timing chain guide stopper 1
13 Timing chain 1
14 Timing chain guide (intake side) 1

5-45
STARTER CLUTCH

EAS31236 EAS31237

CHECKING THE STARTER WHEEL CHECKING THE TIMING CHAIN

1. Check: 1. Check:
• Bearing • Timing chain
Damage/wear → Replace. Damage/stiffness → Replace the timing
2. Check: chain and camshaft sprocket as a set.
• Starter clutch idle gear
• Starter wheel “1”
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• Starter wheel’s contacting surfaces
Damage/pitting/wear → Replace the starter
wheel.

1
EAS31238

CHECKING THE TIMING CHAIN GUIDE

(INTAKE SIDE)
1. Check:
• Timing chain guide (intake side)
Damage/wear → Replace.
EAS30309

INSTALLING THE STARTER CLUTCH

EAS30306 1. Install:
CHECKING THE STARTER CLUTCH
1. Check: • Oil seal “1” New
• Starter clutch operation (to the starter clutch cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter wheel “1” onto the starter Installed depth “a”
1.0–1.5 mm (0.04–0.06 in)
clutch “2” and hold the starter clutch.
b. When turning the starter wheel counterclock-
TIP
wise “A”, the starter clutch and the starter
wheel should engage, otherwise the starter Lubricate the oil seal with lithium-soap-based
clutch is faulty and must be replaced. grease.
c. When turning the starter wheel clockwise “B”,
it should turn freely, otherwise the starter
clutch is faulty and must be replaced.
1

B 1 New
a
A

2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5-46
AC MAGNETO

EAS20190

AC MAGNETO
Removing the stator coil assembly

1
1

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
LT

LT 2
LT

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 80 Nm (8.0 m•kgf, 58 ft•Ibf)

T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side cover (right) 4-4.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-7.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-9.
Refer to “GENERAL CHASSIS (5)” on page
Footrest board assembly (right)/Bottom cover 4-12.
Radiator fan Refer to “RADIATOR” on page 6-1.
Crankshaft position sensor coupler/Stator coil
1 assembly coupler 1/1 Disconnect.

2 AC magneto rotor nut 1

5-47
AC MAGNETO

Removing the stator coil assembly

6
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
5

LT
3
4
7

LT
LT

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 80 Nm (8.0 m•kgf, 58 ft•Ibf)

T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

3 AC magneto rotor 1
4 Woodruff key 1
5 Crankshaft position sensor holder 1
6 Crankshaft position sensor 1
7 Stator coil assembly 1

5-48
AC MAGNETO

EAS31239

REMOVING THE AC MAGNETO

1. Remove:
• AC magneto rotor nut “1”
• Washer
TIP
While holding the AC magneto rotor “2” with the
rotor holding tool “3”, loosen the AC magneto ro- 1
tor nut.
2
Rotor holding tool EAS31240

90890-01235 INSTALLING THE AC MAGNETO

Universal magneto and rotor 1. Install:
holder • Woodruff key
YU-01235 • AC magneto rotor
• Washer
• AC magneto rotor nut
TIP
3
• Clean the tapered portion of the crankshaft and
the AC magneto rotor hub.
• When installing the AC magneto rotor, make
sure the woodruff key is properly seated in the
1
keyway of the crankshaft.
2 2. Tighten:
• AC magneto rotor nut “1”
2. Remove:
• AC magneto rotor “1” AC magneto rotor nut
(with the flywheel puller “2”) 80 Nm (8.0 m·kgf, 58 ft·lbf)
T.
R.

• Woodruff key
ECA21740 TIP
NOTICE While holding the AC magneto rotor “2” with the
To protect the end of the crankshaft, place an rotor holding tool “3”, tighten the AC magneto ro-
appropriate sized socket between the fly- tor nut.
wheel puller center bolt and the crankshaft.
TIP Rotor holding tool
90890-01235
Make sure the flywheel puller is centered over
Universal magneto and rotor
the AC magneto rotor. holder
YU-01235
Flywheel puller
90890-01189
Flywheel puller
YM-01189 3

1
2

5-49
ELECTRIC STARTER

EAS20052

ELECTRIC STARTER
Removing the starter motor

3.5 Nm (0.35 m•kgf, 2.5 ft•Ibf)

T.R
.
LS

New

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (4)” on page
Flap 4-9.
1 Starter motor lead 1 Disconnect.
2 Starter motor 1
3 Starter motor sub-wire harness 1

5-50
ELECTRIC STARTER

Disassembling the starter motor

1 4

1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
3

New 2

5 New

2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Starter motor front cover 1
2 Gasket 1
3 Armature assembly 1
4 Brush holder set 1
5 Starter motor rear cover 1

5-51
ELECTRIC STARTER

EAS30325
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances
1. Check: with the digital circuit tester.
• Commutator
Dirt → Clean with 600 grit sandpaper. Digital circuit tester
2. Measure: 90890-03174
• Commutator diameter “a” Model 88 Multimeter with ta-
Out of specification → Replace the starter chometer
motor. YU-A1927

Commutator diameter
17.6 mm (0.69 in) Armature coil resistance
Limit 0.0279–0.0341 Ω
16.6 mm (0.65 in) Insulation resistance “2”
No continuity (Above 1 MΩ at 20
°C (68 °F))

a
1

3. Measure:
• Mica undercut “a”
b. If any resistance is out of specification, re-
Out of specification → Scrape the mica to the
place the starter motor.
proper measurement with a hacksaw blade
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
that has been grounded to fit the commutator.
5. Measure:
Mica undercut (depth) • Brush length “a”
1.35 mm (0.05 in) Out of specification → Replace the brushes
as a set.
TIP
The mica of the commutator must be undercut to Brush overall length
ensure proper operation of the commutator. 7.0 mm (0.28 in)
Limit
3.50 mm (0.14 in)

4. Measure: a
• Armature assembly resistances (commutator
and insulation) “1” 6. Measure:
Out of specification → Replace the starter • Brush spring force
motor. Out of specification → Replace the brush
springs as a set.

5-52
ELECTRIC STARTER

Brush spring force Starter motor sub-wire harness

3.92–5.88 N (400–600 gf, 14.11– bolt

T.
R.
21.17 oz) 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)

TIP
Install the starter motor sub-wire harness to the
starter motor so that the harness is parallel to the
starter motor axis “a”.

2
7. Check:
• Gear teeth a
Damage/wear → Replace the gear.
8. Check:
• Bearing
• Oil seal
Damage/wear → Replace the defective
part(s).
EAS30326

ASSEMBLING THE STARTER MOTOR

1. Assemble:
• Starter motor front cover “1”
• Starter motor rear cover “2”

Starter motor cover bolt

2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
T.
R.

TIP
Align the match mark “a” on the starter motor
rear cover with the match mark “b” on the starter
motor front cover.

2
b

EAS30327

INSTALLING THE STARTER MOTOR

1. Install:
• Starter motor sub-wire harness “1”
(to the starter motor “2”)

5-53
OIL PUMP

EAS20054

OIL PUMP
Removing the oil pump

5 New
6
7 New
LS

6 4

*
*

3 8

4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf) (4)

T.R

2
.

LS

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

New
32 Nm (3.2 m•kgf, 23 ft•Ibf)
T.R
.

* Apply Yamaha bond No. 1215 (90890-85505).

Order Job/Parts to remove Q’ty Remarks

Stator coil assembly Refer to “AC MAGNETO” on page 5-47.
1 Oil strainer cover 1
2 Spring 1
3 Oil strainer 1
4 Crankcase cover (right) 1
5 Gasket 1
6 Dowel pin 2
7 Oil seal 1
8 Oil pump assembly 1

5-54
OIL PUMP

Disassembling the oil pump

1.0 Nm (0.10 m•kgf, 0.72 ft•Ibf)

T.R
.

7
5
3
6

Order Job/Parts to remove Q’ty Remarks

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump driven gear 1
4 Oil pump rotor assembly 1
5 Oil pump inner rotor 1
6 Oil pump outer rotor 1
7 Oil pump housing 1

5-55
OIL PUMP

EAS30340

CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS30337

CHECKING THE OIL PUMP

1. Check:
• Oil pump drive gear
• Oil pump driven gear EAS30342

• Oil pump housing ASSEMBLING THE OIL PUMP

• Oil pump housing cover 1. Lubricate:
Cracks/damage/wear → Replace the oil • Inner rotor
pump. • Outer rotor
2. Measure: • Oil pump shaft
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance Recommended lubricant
“b” Engine oil
Out of specification → Replace the oil pump.
2. Install:
• Oil pump housing “1”
• Oil pump outer rotor “2”
• Oil pump inner rotor “3”
• Oil pump driven gear “4”
• Pin “5”
• Oil pump housing cover

Oil pump housing cover screw

1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
T.
R.

1. Inner rotor TIP

2. Outer rotor When installing the inner rotor, align the pin in
3. Oil pump housing the oil pump driven gear with the groove “a” in
the inner rotor.
Inner-rotor-to-outer-rotor-tip
clearance
4
0.150 mm (0.0059 in) 3
5
Limit
0.23 mm (0.0091 in) 2
Outer-rotor-to-oil-pump-housing
clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit 1
0.25 mm (0.0098 in) a

3. Check: 3. Check:
• Oil pump operation • Oil pump operation
Rough movement → Repeat steps (1) and Refer to “CHECKING THE OIL PUMP” on
(2) or replace the oil pump. page 5-56.

5-56
TRANSMISSION

EAS20062

TRANSMISSION
Removing the transmission

20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.

LS
New

2
New

1
New 5
E
LS E

4 New
E
E

E New

3
LS
New
LS (6)
19 Nm (1.9 m•kgf, 14 ft•Ibf)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Radiator cover Refer to “RADIATOR” on page 6-1.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-34.
Refer to “REAR SHOCK ABSORBER AS-
Swingarm SEMBLIES AND SWINGARM” on page
4-88.
Rear wheel Refer to “REAR WHEEL” on page 4-33.
1 Final transmission oil filler cap 1
2 Final transmission oil drain bolt 1
3 Transmission case cover 1
4 Transmission case cover gasket 1
5 Dowel pin 2

5-57
TRANSMISSION

Removing the transmission

20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.

LS
13 New

14
New

12
14
8 6
New
7 E
LS 14 E

New
14
E
E
14
10
E 11 New
9
LS
New 13
LS
14 (6)
19 Nm (1.9 m•kgf, 14 ft•Ibf)
T.R
.

Order Job/Parts to remove Q’ty Remarks

6 Main axle assembly 1
7 Primary driven gear 1
8 Main axle 1
9 Drive axle 1
10 1st wheel gear 1
11 Circlip 1
12 Primary drive gear 1
13 Oil seal 2
14 Bearing 6

5-58
TRANSMISSION

EAS30433

CHECKING THE TRANSMISSION

1. Check:
• Transmission gears 2
1
Blue discoloration/pitting/wear → Replace New
the defective gear(s).
• Transmission gear dogs 1 New
Cracks/damage/rounded edges → Replace
the defective gear(s).
2
2. Check:
• Transmission gear engagement
3. Install:
(each pinion gear to its respective wheel
• Primary driven gear “1”
gear)
(to the main axle “2”)
Incorrect → Reassemble the transmission
axle assemblies. Primary driven gear installed
3. Check: depth “a”
• Transmission gear movement 0.5–0.9 mm (0.020–0.035 in)
Rough movement → Replace the defective
part(s). a
EAS30438

INSTALLING THE TRANSMISSION

1. Install: 2
• Oil seal “1” New
(to the transmission case cover “2”)
• Oil seal “3” New 1
(to the right crankcase “4”)

Installed depth “a” 4. Install:

21.7–21.8 mm (0.85–0.86 in) • Transmission case cover “1”
Installed depth “b”
0.25–0.75 mm (0.01–0.03 in) Transmission case cover bolt
19 Nm (1.9 m·kgf, 14 ft·lbf)
T.
R.

New 1 2 TIP
Tighten the transmission case cover bolts in the
a proper tightening sequence as shown.

1 5
3 New 4

b 4 6

2. Install:
3 1
• Circlip “1” New
(to the drive axle “2”) 2 7
TIP 8
Install the circlip with its chamfered side facing
as shown.

5-59
CRANKSHAFT

EAS20061

CRANKSHAFT
Removing the crankshaft

1
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) E
T.R
.

LS
New

(8)

LS

LS 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

New
2
New LS

4 5
3 20 Nm (2.0 m•kgf, 14 ft•Ibf)
LS
T.R
.

Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL” on page 5-3.
Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
Refer to “CYLINDER AND PISTON” on page
Piston 5-29.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-34.
Starter clutch Refer to “STARTER CLUTCH” on page 5-44.
1 Dipstick 1
2 Engine oil drain bolt 1
3 Outer spring 1
4 Inner spring 1
5 Centerstand shaft 1

5-60
CRANKSHAFT

Removing the crankshaft

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) E

T.R
.

LS
New

(8)
9

8
10

LS

LS 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
6 New
7 New LS

LS
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.

Order Job/Parts to remove Q’ty Remarks

6 Centerstand 1
7 Crankcase (left) 1
8 Dowel pin 2
9 Crankshaft assembly 1
10 Crankcase (right) 1

5-61
CRANKSHAFT

EAS31241 ECA20630

DISASSEMBLING THE CRANKCASE NOTICE

1. Remove: • To protect the end of the crankshaft, place
• Crankcase bolts an appropriate sized socket between the
TIP crankcase separating tool bolt and the
Loosen each bolt 1/4 of a turn at a time, in stag- crankshaft.
es and in a crisscross pattern. After all of the • Do not tap on the crankshaft.
bolts are fully loosened, remove them.
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B

2
2. Remove:
• Crankcase (left) “1”
1
ECA13900

NOTICE 3
Tap on one side of the crankcase with a soft-
EAS31242
face hammer. Tap only on reinforced por- CHECKING THE CRANKSHAFT ASSEMBLY
tions of the crankcase, not on the crankcase 1. Measure:
mating surfaces. Work slowly and carefully • Crankshaft runout
and make sure the crankcase halves sepa- Out of specification → Replace the crank-
rate evenly. shaft assembly.
TIP
Turn the crankshaft slowly.

Runout limit
0.030 mm (0.0012 in)

EAS30414

REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:
• Crankshaft assembly “1”
TIP
• Remove the crankshaft assembly with the
crankcase separating tool “2” and M6 bolts “3”. 2. Measure:
• Make sure that the crankcase separating tool • Big end side clearance
is centered over the crankshaft assembly. Out of specification → Replace the crank-
shaft assembly.

Big end side clearance

0.150–0.450 mm (0.0059–0.0177
in)

5-62
CRANKSHAFT

EAS31244

CHECKING THE BEARING

1. Check:
• Bearing
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement → Replace.
EAS31245

CHECKING THE OIL PUMP DRIVE GEAR

1. Check:
3. Measure: • Oil pump drive gear
• Crankshaft width Damage/wear → Replace.
Out of specification → Replace the crank- EAS30791
shaft assembly. INSTALLING THE CRANKSHAFT
1. Install:
Crank assembly width • Crankshaft assembly “1”
51.45–51.50 mm (2.026–2.028 in)
TIP
• Install the crankshaft assembly with the crank-
shaft installer pot “2”, crankshaft installer bolt
“3”, adapter “4”, and crankshaft installer spacer
“5”.
• Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of
the crankshaft installer bolt with the other. Turn
the crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.

4. Check: Crankshaft installer pot

• Crankshaft sprocket “1” 90890-01274
Damage/wear → Replace the crankshaft as- Installing pot
sembly. YU-90058
• Bearing “2” Crankshaft installer bolt
Cracks/damage/wear → Replace the crank- 90890-01275
shaft assembly. Bolt
YU-90060
2 Adapter (M12)
90890-01278
Adapter #3
1 YU-90063
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044

EAS31243
5
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a 1 4
mild solvent. 2
2. Thoroughly clean all the gasket surfaces and
3
crankcase mating surfaces.
3. Check:
• Crankcase
Cracks/damage → Replace.

5-63
CRANKSHAFT

EAS31246

ASSEMBLING THE CRANKCASE

1. Thoroughly clean all the gasket mating sur-
1
faces and crankcase mating surfaces.
2. Apply: a 2 3
• Sealant
(onto the crankcase mating surfaces)

Yamaha bond No. 1215 b

90890-85505
(Three bond No.1215®)

TIP
Do not allow any sealant to come into contact
with the oil gallery.

3. Install:
• Crankcase (right)
(onto the crankcase (left))
• Crankcase bolts

Crankcase bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.

TIP
• Thoroughly wipe off any sealant that protrudes
from between the left crankcase and the right
crankcase.
• Tighten the crankcase bolts in stages and in a
crisscross pattern.

EAS31247

INSTALLING THE CENTERSTAND

1. Install:
• Centerstand “1”
• Inner spring “2”
• Outer spring “3”
TIP
• Make sure that the hooked end “a” of the inner
spring is positioned to the outside.
• Make sure that the hooked end “b” of the outer
spring is positioned to the outside.

5-64
CRANKSHAFT

5-65
COOLING SYSTEM

RADIATOR ...................................................................................................... 6-1

CHECKING THE RADIATOR .................................................................... 6-3
INSTALLING THE RADIATOR .................................................................. 6-3

THERMOSTAT ................................................................................................ 6-5

CHECKING THE THERMOSTAT ASSEMBLY ......................................... 6-6
INSTALLING THE THERMOSTAT ASSEMBLY ....................................... 6-6

WATER PUMP................................................................................................. 6-7

DISASSEMBLING THE WATER PUMP.................................................... 6-9
CHECKING THE WATER PUMP .............................................................. 6-9
ASSEMBLING THE WATER PUMP.......................................................... 6-9
INSTALLING THE WATER PUMP ............................................................ 6-9

6
RADIATOR

EAS20063

RADIATOR
Removing the radiator

7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
T.R

.
.

(3)

(5)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

(4)

LS New
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

1.0 Nm (0.10 m•kgf, 0.72 ft•Ibf)

T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.

Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page

4-4.

Footrest board assembly (right)/Bottom cover Refer to “GENERAL CHASSIS (5)” on page
4-12.
1 Radiator cover 1
2 Coolant reservoir breather hose 1
3 Coolant reservoir hose 1
4 Rear brake hose bracket 1
5 Rear brake hose holder (front side) 1

6-1
RADIATOR

Removing the radiator

7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
T.R

.
.

11

(3) 12
9

7
(5)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

(4)
8 6

10

LS New
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.

1.0 Nm (0.10 m•kgf, 0.72 ft•Ibf)

T.R
.

10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
T.R
.

Order Job/Parts to remove Q’ty Remarks

6 Coolant reservoir 1
7 Radiator inlet hose 1
8 Radiator outlet hose 1
9 Radiator cap 1
10 Radiator 1
11 Radiator fan case 1
12 Radiator fan 1

6-2
RADIATOR

EAS30439

CHECKING THE RADIATOR 1

1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor. 2
Damage → Repair or replace.
TIP
3
Straighten any flattened fins with a thin, flathead
screwdriver. b. Apply the specified pressure for ten seconds
and make sure there is no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Radiator fan
Damage → Replace.
EAS30440

INSTALLING THE RADIATOR

1. Fill:
• Cooling system
(with the specified amount of the recom-
2. Check: mended coolant)
• Radiator hoses Refer to “CHANGING THE COOLANT” on
• Coolant reservoir hose page 3-19.
Cracks/damage → Replace. 2. Check:
3. Measure: • Cooling system
• Radiator cap valve opening pressure Leaks → Repair or replace any faulty part.
Below the specified pressure → Replace the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Attach the radiator cap tester “1” to the radia-
radiator cap.
tor.
Radiator cap valve opening pres-
sure Radiator cap tester
78.6–137.4 kPa (0.78–1.37 90890-01325
kgf/cm², 11.5–19.9 psi) Mityvac cooling system tester kit
YU-24460-A
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester “1” and radiator
cap tester adapter “2” to the radiator cap “3”.

Radiator cap tester

90890-01325
Mityvac cooling system tester kit
YU-24460-A 1
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
b. Apply 196 kPa (1.96 kg/cm², 27.87 psi) of
pressure.
c. Measure the pressure to check its maintain-
ing applied pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

6-3
RADIATOR

3. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
4. Install:
• Rear brake hose holder (front side) “1”

Rear brake hose holder bolt

(front side)
T.
R.

7 Nm (0.7 m·kgf, 5.1 ft·lbf)

TIP
Make sure that the projection “a” on the radiator
fan case “2” fits into the hole “b” in the rear brake
hose holder.

a
2
b

6-4
THERMOSTAT

EAS20065

THERMOSTAT
Removing the thermostat assembly

LS

New
1
4

2 3

9 Nm (0.9 m•kgf, 6.5 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.

Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page

4-4.

Footrest board assembly (right)/Bottom cover Refer to “GENERAL CHASSIS (5)” on page
4-12.
1 Radiator inlet hose 1 Disconnect.
2 Radiator outlet hose 1 Disconnect.
3 Water pump inlet hose 1 Disconnect.
4 Thermostat assembly 1

6-5
T H E R M O S T A T

EAS31248

CHECKING THE THERMOSTAT ASSEMBLY

B
1. Check:
• Thermostat “1”
Does not open at 74–78°C (165–172°F) → 0.5 mm
(0.02 in) 7 mm
Replace.
(0.28 in)

A
74 – 78˚C 90˚C
(165 – 172˚F) (194˚F)
1
A. Fully closed
B. Fully open

TIP
If the accuracy of the thermostat is in doubt, re-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
place it. A faulty thermostat could cause serious
a. Suspend the thermostat “1” in a container “2” overheating or overcooling.
filled with water.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Slowly heat the water.
EAS30445
c. Place a thermometer “3” in the water. INSTALLING THE THERMOSTAT
d. While stirring the water “4”, observe the ther- ASSEMBLY
mostat and thermometer’s indicated temper- 1. Fill:
ature. • Cooling system
(with the specified amount of the recom-
mended coolant)
3
Refer to “CHANGING THE COOLANT” on
page 3-19.
2. Check:
4 • Cooling system
1 Leaks → Repair or replace any faulty part.
2 Refer to “INSTALLING THE RADIATOR” on
page 6-3.
3. Measure:
e. Check the thermostat element position “5”. • Radiator cap opening pressure
Same level for the thermostat element upper Below the specified pressure → Replace the
end and the hole lower line “a” at 90 °C(194 radiator cap.
°F) Refer to “CHECKING THE RADIATOR” on
page 6-3.

6-6
WATER PUMP

EAS20066

WATER PUMP
Removing the water pump

3 2

LS

New

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.

Front side cover (left) Refer to “GENERAL CHASSIS (2)” on page

4-4.

Footrest board assembly (left)/Bottom cover Refer to “GENERAL CHASSIS (4)” on page
4-9.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1
3 Dowel pin 2

6-7
WATER PUMP

Disassembling the water pump

7
3 New
6

5 New

4 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
2 New

New
LS

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Water pump housing cover 1
2 Water pump housing gasket 1
3 Circlip 1
4 Impeller shaft 1
5 Water pump seal 1
6 Bearing 1
7 Water pump housing 1

6-8
WATER PUMP

EAS30446

DISASSEMBLING THE WATER PUMP A

1. Remove:
• Water pump seal “1” 4
TIP
3
Remove the water pump seal from the inside of
the water pump housing “2”. 2 1 New

1
2 A. Push down
3. Mechanical seal installer
4. Middle driven shaft bearing driver

1
a

EAS30447

CHECKING THE WATER PUMP 2

1. Check:
• Water pump housing cover
• Water pump housing
• Impeller shaft
Cracks/damage/wear → Replace.
a. Installed depth of water pump seal
EAS30448

ASSEMBLING THE WATER PUMP 2. Lubricate:

1. Install: • Water pump seal
• Water pump seal “1” New Recommended lubricant
(into the water pump housing “2”) Lithium-soap-based grease
TIP
Install the water pump seal with the special tools 3. Install:
to the specified depth as shown in the illustra- • Impeller shaft “1”
tion. • Circlip New
TIP
Installed depth of water pump After installation, check that the impeller shaft ro-
seal tates smoothly.
0–0.5 mm (0–0.02 in)

Mechanical seal installer

90890-04145
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058 1

EAS30449

INSTALLING THE WATER PUMP

1. Install:
• O-rings “1” New
• Water pump assembly “2”

6-9
WATER PUMP

Water pump assembly bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.

TIP
• Align the projection “a” on the impeller shaft
with the slit “b” on the camshaft sprocket bolt.
• Lubricate the O-ring with a thin coat of lithium-
soap-based grease.

a b
2

New 1
LS

2. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.

6-10
WATER PUMP

6-11
FUEL SYSTEM

FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK .................................................................. 7-2
REMOVING THE FUEL PUMP ................................................................. 7-2
REMOVING THE FUEL FILTER ............................................................... 7-2
CHECKING THE FUEL PUMP BODY....................................................... 7-2
CHECKING THE FUEL FILTER ................................................................ 7-2
INSTALLING THE FUEL FILTER .............................................................. 7-2
INSTALLING THE FUEL PUMP ................................................................ 7-3
INSTALLING THE FUEL TANK................................................................. 7-3
CHECKING THE FUEL PRESSURE ........................................................ 7-3

FUEL INJECTOR............................................................................................. 7-5

REMOVING THE FUEL HOSE ................................................................. 7-6
CHECKING THE FUEL INJECTOR .......................................................... 7-6
INSTALLING THE FUEL INJECTOR ........................................................ 7-6
INSTALLING THE FUEL HOSE ................................................................ 7-6

AIR FILTER CASE .......................................................................................... 7-7

INSTALLING THE AIR FILTER CASE ...................................................... 7-9

THROTTLE BODY.........................................................................................7-10
REMOVING THE THROTTLE BODY...................................................... 7-12
CHECKING THE THROTTLE BODY ...................................................... 7-12
CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND
THROTTLE BODY .................................................................................7-12
REPLACING THE THROTTLE BODY ....................................................7-14
INSTALLING THE THROTTLE BODY ....................................................7-14

7
FUEL TANK

EAS20067

FUEL TANK
Removing the fuel tank

1
2

5
4
6

7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
3

(4) 7

10 New

8
11
(4)
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Front side covers Refer to “GENERAL CHASSIS (2)” on page

4-4.

Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page

4-7.

Center lower cover Refer to “GENERAL CHASSIS (5)” on page

4-12.
1 Fuel tank cap 1
2 Fuel tank overflow tray 1
3 Fuel tank overflow hose 1
4 Fuel sender coupler 1 Disconnect.
5 Fuel pump coupler 1 Disconnect.
6 Fuel hose 1 Disconnect.
7 Fuel tank 1
8 Fuel pump bracket 1
9 Fuel pump 1
10 Fuel pump gasket 1
11 Fuel filter 1

7-1
FUEL TANK

EAS30450 EAS31376

REMOVING THE FUEL TANK REMOVING THE FUEL FILTER

1. Extract the fuel in the fuel tank through the 1. Remove:
fuel tank cap with a pump. • Fuel filter “1”
2. Disconnect: TIP
• Fuel sender coupler Remove the projections “a” on the fuel pump
• Fuel pump coupler from the holes “b” in the fuel filter and slide the
• Fuel hose fuel filter in the direction of the arrow shown to
EWA18020

WARNING remove it.

Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in 1
the fuel lines could cause fuel to spurt out
when removing the hose.
ECA20020
b
NOTICE a
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
EAS30454

TIP CHECKING THE FUEL PUMP BODY

• To remove the fuel hose from the fuel pump, 1. Check:
slide the fuel hose connector cover “1” on the • Fuel pump body
end of the hose in the direction of the arrow Obstruction → Clean.
shown, and then remove the hose. Cracks/damage → Replace fuel pump as-
• Before removing the hose, place a few rags in sembly.
the area under where it will be removed. EAS31249

CHECKING THE FUEL FILTER

1. Check:
• Fuel filter
Damage → Replace.
Contaminants → Clean with solvent.
1 EAS31377

INSTALLING THE FUEL FILTER

1. Install:
• Fuel filter “1”
TIP
3. Remove: Fit the projections “a” on the fuel pump into the
• Fuel tank holes “b” in the fuel filter and slide the fuel filter
EAS30451 in the direction of the arrow shown to install it.
REMOVING THE FUEL PUMP
1. Remove:
1
• Fuel pump
ECA14721

NOTICE
• Do not drop the fuel pump or give it a b
strong shock. a
• Do not touch the base section of the fuel
sender.

7-2
FUEL TANK

EAS30456
b. Install the fuel tank overflow tray and fuel tank
INSTALLING THE FUEL PUMP
cover “3”. To install the fuel tank cover, refer
1. Install:
to “GENERAL CHASSIS (3)” on page 4-7.
• Fuel pump gasket “1” New c. Tighten the fuel tank bolts to specification.
• Fuel pump
• Fuel pump bracket Fuel tank bolt
7 Nm (0.7 m·kgf, 5.1 ft·lbf)

T.
R.
Fuel pump bracket bolt
4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
T.
R.

3
TIP
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump. 2
• Always use a new fuel pump gasket.
• The gasket lip “a” shall face toward the fuel
pump.
• Align the projections “b” (two locations) on the 2 1
fuel pump gasket with the slots “c” in the fuel
pump. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Align the projection “d” on the fuel pump with 2. Install:
the slot in the fuel pump bracket. • Fuel hose
• Tighten the fuel pump bolts in the proper tight- ECA17500

ening sequence as shown. NOTICE

When installing the fuel hose, make sure that
a it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
c will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel
pump until a distinct “click” is heard.
1 New • To install the fuel hose, slide the fuel hose con-
b
nector cover “1” on each end of the hose in the
direction of the arrow shown.
1
d

4
3
1

2
EAS30457

INSTALLING THE FUEL TANK

EAS30703
1. Install: CHECKING THE FUEL PRESSURE
• Fuel tank “1” 1. Remove:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Temporarily install the fuel tank. • Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
TIP
4-4.
Make sure that the flanges of the fuel tank bolts
“2” do not contact the fuel tank.

7-3
FUEL TANK

• Footrest board assembly (right) Refer to “INSTALLING THE FUEL TANK” on

Refer to “GENERAL CHASSIS (5)” on page page 7-3.
4-12. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check: 3. Install:
• Pressure regulator operation • Footrest board assembly (right)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Refer to “GENERAL CHASSIS (5)” on page
a. Disconnect the fuel hose from the fuel pump.
EWA18020
4-12.
WARNING • Front side cover (right)
Cover the fuel hose connection with a cloth Refer to “GENERAL CHASSIS (2)” on page
when disconnecting it. Residual pressure in 4-4.
the fuel lines could cause fuel to spurt out
when removing the hose.
ECA20020

NOTICE
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
TIP
Before removing the hose, place a few rags in
the area under where it will be removed.
b. Connect the pressure gauge “1” and fuel
pressure adapter “2” to the fuel hose “3”.

Pressure gauge
90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 6.3mm
90890-03227

1 2

c. Start the engine.

d. Measure the fuel pressure.

Fuel line pressure at idling

300–390 kPa (3.0–3.9 kgf/cm²,
43.5–57.2 psi)

Faulty → Replace the fuel pump.

e. Connect the fuel hose.

7-4
FUEL INJECTOR

EAS20191

FUEL INJECTOR
Removing the fuel injector

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
3

1
2
4

New
E

Order Job/Parts to remove Q’ty Remarks

Battery Refer to “GENERAL CHASSIS (1)” on page

4-1.

Front side covers Refer to “GENERAL CHASSIS (2)” on page

4-4.

Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page

4-7.

Storage box Refer to “GENERAL CHASSIS (4)” on page

4-9.

Center lower cover Refer to “GENERAL CHASSIS (5)” on page

4-12.
1 Fuel hose 1
2 Fuel injector coupler 1 Disconnect.
3 Fuel injector 1
4 Fuel injector adaptor 1

7-5
FUEL INJECTOR

EAS31250

REMOVING THE FUEL HOSE Fuel injector bolt

1. Disconnect: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

T.
R.
• Fuel hose
EWA17610
TIP
WARNING
• Lubricate the O-ring with engine oil.
Cover fuel hose connections with a cloth
• Align the projection “a” on the fuel injector
when disconnecting them. Residual pres-
adapter with the hole “b” in the intake manifold.
sure in the fuel lines could cause fuel to
• Align the projection “c” on the fuel injector with
spurt out when removing the hoses.
the hole “d” in the fuel injector adapter.
ECA20020

NOTICE
Although the fuel has been removed from 3
the fuel tank, be careful when removing the New 2
fuel hose, since there may be fuel remaining c
a
in it.
b 1
TIP
• To remove the fuel hose from the fuel injector, d
slide the fuel hose connector cover “1”on the
end of the hose in the direction of the arrow
shown, and then remove the hose. EAS31253

• Before removing the hose, place a few rags in INSTALLING THE FUEL HOSE
the area under where it will be removed. 1. Install:
• Fuel hose
ECA17500

NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
1
the correct position, otherwise the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel in-
EAS31251 jector until a distinct “click” is heard.
CHECKING THE FUEL INJECTOR • To install the fuel hose onto the fuel injector,
1. Check: slide the fuel hose connector cover “1” on the
• Injector end of the hose in the direction of the arrow
Obstruction → Replace and check the fuel shown.
pump/fuel supply system.
Deposit → Replace.
Damage → Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJEC- 1
TOR” on page 7-6.
EAS31617

INSTALLING THE FUEL INJECTOR

1. Install:
• Fuel injector adaptor “1”
• O-ring “2” New
(to the fuel injector)
• Fuel injector “3”

7-6
AIR FILTER CASE

EAS20068

AIR FILTER CASE

Removing the air filter case

1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

T.R
.
New
4
New

(6)
3

3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)
T.R

T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

Battery Refer to “GENERAL CHASSIS (1)” on page

4-1.

Front side covers Refer to “GENERAL CHASSIS (2)” on page

4-4.

Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page

4-7.

Storage box Refer to “GENERAL CHASSIS (4)” on page

4-9.
1 Air filter case cover 1
2 Air filter case duct cover 1
3 Air filter case duct 1
4 Air filter element 1
5 Transmission case breather hose 1

7-7
AIR FILTER CASE

Removing the air filter case

8
1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)
9

T.R
.
New

New

10
7

(6)
11

3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)
T.R

T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

6 Cylinder head breather hose 1 Disconnect.
7 Air filter case joint clamp screw 1 Loosen.
8 Air filter case 1
9 Air filter check hose 1
10 Air filter case joint 1
11 Hose 1

7-8
AIR FILTER CASE

EAS31618

INSTALLING THE AIR FILTER CASE

1. Install: 2
• Hose “1” 1
(to the air filter case joint “2”)
• Clamp “3”
TIP
• Apply Three bond 1521 “4” onto the mating
surfaces of the hose and air filter case joint. b
a
• Align the slot “a” on the air filter case joint with
the projection “b” in the hose. 4. Install:
• Air filter case duct “1”
TIP
1 2
Fit the projection “a” on the air filter case duct be-
tween the projections “b” on the air filter case
3 a cover “2”.
b
2

4
2. Install: b
• Air filter case joint “1”
(to the air filter case “2”)
TIP 1
• Apply Three Bond 1521 “3” onto the mating a
surfaces of the air filter case joint and air filter
case.
• Fit the projection “a” on the air filter case joint
between the projections “b” on the air filter
case.

b 2
a
1

3. Install:
• Air filter case joint clamp “1”
(to the air filter case joint “2”)

Air filter case joint clamp screw

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
T.
R.

TIP
Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.

7-9
THROTTLE BODY

EAS20070

THROTTLE BODY
Removing the throttle body

5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.

3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)

T.R
.
1
New

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

New

LS
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Battery Refer to “GENERAL CHASSIS (1)” on page

4-1.

Front side covers Refer to “GENERAL CHASSIS (2)” on page

4-4.

Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page

4-7.

Storage box Refer to “GENERAL CHASSIS (4)” on page

4-9.

Center lower cover Refer to “GENERAL CHASSIS (5)” on page

4-12.
Air filter case joint Refer to “AIR FILTER CASE” on page 7-7.
Fuel injector Refer to “FUEL INJECTOR” on page 7-5.
1 ISC (Idle Speed Control) unit coupler 1 Disconnect.
2 Throttle body sensor assembly coupler 1 Disconnect.

7-10
THROTTLE BODY

Removing the throttle body

5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.

8 3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)

T.R
.
9

New 6
10
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.

5
New 7
4

LS
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

3 Throttle cable 2 Disconnect.
4 Throttle cable holder 1
5 Intake manifold clamp screw 1 Loosen.
6 Throttle body 1
7 Intake manifold 1
8 ISC (Idle Speed Control) unit holder 1
9 ISC (Idle Speed Control) unit 1
10 Spring 1

7-11
THROTTLE BODY

EAS30979
2. Remove:
REMOVING THE THROTTLE BODY
• Screw “1”
1. Remove:
• ISC (Idle Speed Control) unit holder “2”
• Throttle body
ECA20500
• ISC (Idle Speed Control) unit “3”
ECA21780
NOTICE
NOTICE
Do not remove the throttle body sensor as-
Because the force of the spring may push
sembly from the throttle body.
out the ISC unit unexpectedly, be sure to
EAS30479
hold the ISC unit when removing the compo-
CHECKING THE THROTTLE BODY nents.
TIP
Before checking the throttle body, check the fol-
lowing items: 2 3
• Valve clearance
• Spark plug
• Air filter element
• Intake manifold 1
• Fuel hose
• Exhaust system
• Cylinder head breather hose
EWA18030
3. Remove:
WARNING • Spring “1”
• O-ring “2”
If the throttle body is subjected to strong
shocks or dropped during, replace it.
1. Check:
• Throttle body 1
Cracks/damage → Replace the throttle body. 2
2. Check:
• Butterfly valve
Damage/scratches/wear → Replace the
throttle body.
ECA21770

NOTICE
4. Check:
Do not adjust the stop screw “1”. • ISC (Idle Speed Control) unit
Plunger “1” does not rotate smoothly/plunger
rotates together with the motor shaft “2” →
Replace.

1
1

EAS31254 2
CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY
1. Remove the throttle body from the vehicle. 5. Check:
TIP • Spring
Before removing the throttle body, disconnect Damage/bent → Replace.
the throttle cables and couplers. 6. Clean:
• Area “a” of the ISC unit

7-12
THROTTLE BODY

• Areas “b” and “c” of the throttle body • Do not allow the removed deposits or for-
Clogs or foreign materials cannot be re- eign materials to adhere to the sealing sur-
moved → Replace. faces of the O-ring.
• Do not scratch or deform the ISC valve or
air passage; otherwise, poor starting per-
a formance, an unstable engine idling speed,
or uncontrollable engine speed could re-
sult.
• Do not clean any areas other than the areas
“a”, “b”, and “c”. If the cleaning agent en-
ters the ISC unit or throttle body, thorough-
ly wipe it off.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Adjust the ISC unit plunger to the specified
distance “a” from the motor assembly body.
b
Distance “a”
0.0–3.0 mm (0.0–0.12 in)

8. Install:
• Spring
• O-ring “1” New
• ISC (Idle Speed Control) unit “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ECA21800

a. Use a rag soaked in the recommended clean- NOTICE

ing agent to wipe off any deposits and foreign • Do not use the ISC unit if it was dropped.
materials. • Do not allow water to enter the ISC unit and
do not allow foreign materials to adhere to
Recommended cleaning agent the assembly.
Yamaha oil & brake cleaner
• Do not touch the terminals of the coupler
ECA21790 directly.
NOTICE • Because the force of the spring may push
• Be sure to use the recommended cleaning out the ISC unit unexpectedly, be sure to
agent. hold the motor assembly when installing
• Do not spray the cleaning agent directly the components.
onto the ISC unit or throttle body and do TIP
not immerse them in the cleaning agent.
• Install the new O-ring until it contacts the raised
• To prevent scratching the components, do
portion of the ISC unit body.
not use a brush, metal file, or other abra-
• When installing the ISC unit, be sure to align
sive tool.
the oval portion “a” of the ISC unit with the oval
• Do not clean with compressed air.
hole “b” in the throttle body.

7-13
THROTTLE BODY

Yamaha diagnostic tool

90890-03231
2 1 New
12.Place the vehicle on the centerstand so that
the rear wheel is elevated.
13.Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed. Within specifi-
cation → Service is finished.
Out of specification → Replace the throttle
body.
Refer to “REPLACING THE THROTTLE
BODY” on page 7-14.

Engine idling speed

1500–1700 r/min

EAS31160

b a REPLACING THE THROTTLE BODY

9. Install: 1. Remove the throttle body from the vehicle.
• ISC (Idle Speed Control) unit holder “1” 2. Install a new throttle body to the vehicle.
• Screw 3. Reset:
• ISC learning valves
ISC (Idle Speed Control) unit Use the diagnostic code number “67”.
holder screw Refer to “SELF-DIAGNOSTIC FUNCTION
T.
R.

5 Nm (0.5 m·kgf, 3.6 ft·lbf) AND DIAGNOSTIC CODE TABLE” on page

9-5.
TIP • ISC valve position
Align the slot “a” in the ISC unit holder with the Use the diagnostic code number “54”
projection “b” on the ISC unit “2”. Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-5.
b
a 2 Yamaha diagnostic tool
90890-03231
1 4. Place the vehicle on the centerstand so that
the rear wheel is elevated.
5. Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
10.Install the throttle body to the vehicle. sure the engine idling speed.
11.Reset:
• ISC learning valves Engine idling speed
1500–1700 r/min
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
EAS30980
AND DIAGNOSTIC CODE TABLE” on page INSTALLING THE THROTTLE BODY
9-5. 1. Install:
• ISC valve position • Throttle body
Use the diagnostic code number “54”.
Refer to “SELF-DIAGNOSTIC FUNCTION Intake manifold clamp screw
AND DIAGNOSTIC CODE TABLE” on page 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
T.
R.

9-5.

7-14
THROTTLE BODY

TIP
• Align the projection “a” on the throttle body with
the slot “b” in the intake manifold.
• Align the projection “c” on the intake manifold
“1” with slot “d” in the intake manifold clamp “2”.

a
b

c
1

7-15
ELECTRICAL SYSTEM

IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
TROUBLESHOOTING .............................................................................. 8-3

ELECTRIC STARTING SYSTEM .................................................................... 8-5

CIRCUIT DIAGRAM .................................................................................. 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-7
TROUBLESHOOTING .............................................................................. 8-8

CHARGING SYSTEM....................................................................................8-11
CIRCUIT DIAGRAM ................................................................................8-11
TROUBLESHOOTING ............................................................................ 8-13

LIGHTING SYSTEM ......................................................................................8-15

CIRCUIT DIAGRAM ................................................................................8-15
TROUBLESHOOTING ............................................................................ 8-17

SIGNALING SYSTEM ...................................................................................8-19

CIRCUIT DIAGRAM ................................................................................8-19
TROUBLESHOOTING ............................................................................ 8-21

FUEL INJECTION SYSTEM.......................................................................... 8-25

CIRCUIT DIAGRAM ................................................................................8-25
ECU SELF-DIAGNOSTIC FUNCTION ....................................................8-27
TROUBLESHOOTING METHOD ............................................................8-27
YAMAHA DIAGNOSTIC TOOL ...............................................................8-28
TROUBLESHOOTING DETAILS ............................................................8-31

FUEL PUMP SYSTEM...................................................................................8-57

CIRCUIT DIAGRAM ................................................................................8-57
TROUBLESHOOTING ............................................................................ 8-59

8
ABS (ANTI-LOCK BRAKE SYSTEM)...........................................................8-61
CIRCUIT DIAGRAM ................................................................................8-61
ABS COUPLER LOCATION CHART ...................................................... 8-63
MAINTENANCE OF THE ABS ECU .......................................................8-65
ABS TROUBLESHOOTING OUTLINE....................................................8-65
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................8-66
BASIC PROCESS FOR TROUBLESHOOTING .....................................8-67
[A] CHECKING THE ABS WARNING LIGHT ..........................................8-68
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON.............8-68
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................8-68
[A-3] THE ABS WARNING LIGHT COMES ON ......................................8-68
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE
(The select unit screen does not appear.) ..............................................8-69
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE
(Cannot connect due to a tool error.)...................................................... 8-69
[B-1] MALFUNCTION ARE CURRENTLY DETECTED ..........................8-69
[B-2] DIAGNOSIS USING THE FAULT CODES .....................................8-69
[B-3] DELETING THE FAULT CODES....................................................8-90
[C-1] FINAL CHECK ................................................................................8-91

ELECTRICAL COMPONENTS......................................................................8-93
CHECKING THE SWITCHES ................................................................. 8-95
CHECKING THE BULBS AND BULB SOCKETS ...................................8-98
CHECKING THE FUSES ........................................................................8-99
REPLACING THE ECU (engine control unit) ..........................................8-99
CHECKING AND CHARGING THE BATTERY .......................................8-99
CHECKING THE RELAYS ....................................................................8-102
CHECKING THE TURN SIGNAL RELAY .............................................8-103
CHECKING THE DIODE .......................................................................8-103
CHECKING THE SPARK PLUG CAP ...................................................8-104
CHECKING THE IGNITION COIL .........................................................8-104
CHECKING THE IGNITION SPARK GAP.............................................8-105
CHECKING THE CRANKSHAFT POSITION SENSOR........................8-105
CHECKING THE STARTER MOTOR OPERATION .............................8-106
CHECKING THE STATOR COIL ..........................................................8-106
CHECKING THE RECTIFIER/REGULATOR ........................................8-106
CHECKING THE FUEL SENDER .........................................................8-107
CHECKING THE FUEL METER/FUEL LEVEL WARNING
INDICATOR ..........................................................................................8-107
CHECKING THE COOLANT TEMPERATURE SENSOR..................... 8-108
CHECKING THE FUEL INJECTOR ...................................................... 8-108
CHECKING THE VVA SOLENOID........................................................8-109
EAS30490
EAS20072
A

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
B/W,B R R B R/L
CIRCUIT DIAGRAM

W W W W Y L/W
30
W W 13 W/R O O
2 9 R
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B G/R G/R
B/W
IGNITION SYSTEM

12 15 L/W G/R B/L 22

B
R (B) B/L B/L
16
B
L/W L/W G R/L
23 24 P/W P/W
10 B B 32
B A Br/W Br/W B Gy/R
L/W B B Gy/R Gy/R B
ON 25
OFF B B/L Y L P/W Br/W B/L B/L (B) (B)
L/W 19 20 26 Y Y
(B)
R/B 3 L/W L L
R B
Br
R/B 4 L/Y P P G G
B L/B G/Y G/Y
R R 17 P G/Y Sb Gy
L/W B G L/B R/L 29
27 Gy Gy 33 G Ch
R/L 5 Sb Sb Ch Ch
R/B 11 14 L/Y (Gy) (B) (B)
L/Y L/Y (Gy)
6 R/L R
B L/Y
Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
Br/W (L) (L)
G R/L R/B B R/B
B 21
Y/L Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W

8-1
L
Br Br B/W
Br Br
Br Br
42 Br/W
41 Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
R/B G Br Dg Ch Y Br Y G Ch Y L Ch Dg
59 (Gy) 56 47
Ch Dg
R/L
57 48 49 50 51 R
B
55 B
54 Br/W

Ch Dg
60 58
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 W B G L
Br G Y B L 34
L L W
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
B Y W B Br Y
B Y/B (Br) (G) L B Y Y W
35
Br Y G
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
IGNITION SYSTEM
IGNITION SYSTEM

1. Crankshaft position sensor

3. Main fuse 1
10.Main switch
12.Battery
18.Sidestand switch
29.ECU (Engine Control Unit)
30.Ignition coil
31.Spark plug
52.Engine ground
53.Frame ground

8-2
IGNITION SYSTEM

EAS30492

TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Footrest board assemblies
6. Front cowling assembly

1. Check the fuse. NG →

(Main 1)
Replace the fuse.
Refer to “CHECKING THE FUS-
ES” on page 8-99.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-99.

OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-4.

OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 8-105.

NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 8-104.

OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-104.

OK ↓
7. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the stator coil assembly.
SHAFT POSITION SENSOR” on
page 8-105.

OK ↓

8-3
IGNITION SYSTEM

8. Check the main switch. NG →

Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-95.

OK ↓
9. Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
SWITCHES” on page 8-95.

OK ↓
10.Check the entire ignition system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-1.

OK ↓
Replace the ECU. Refer to “REPLAC-
ING THE ECU (engine control unit)”
on page 8-99.

8-4
EAS30493
EAS20073
A

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
B/W,B R R B R/L
CIRCUIT DIAGRAM

W W W W Y L/W
30
W W 13 W/R O O
2 9 R
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B G/R G/R
B/W 12 G/R B/L 22
15 L/W
B
R (B) B/L B/L
16
B
L/W L/W G R/L
23 24 P/W P/W
10 B B 32
B A Br/W Br/W B Gy/R
L/W B B Gy/R Gy/R B
ON 25
OFF B B/L Y L P/W Br/W B/L B/L (B) (B)
L/W 19 20 26 Y Y
(B)
R/B 3 L/W L L
R B
Br
R/B 4 L/Y P P G G
B L/B G/Y G/Y
R R 17 P G/Y Sb Gy
L/W B G L/B R/L 29
27 Gy Gy 33 G Ch
R/L 5 Sb Sb Ch Ch
R/B 11 14 L/Y (Gy) (B) (B)
L/Y L/Y (Gy)
6 R/L R
B L/Y
Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
ELECTRIC STARTING SYSTEM

Br/W (L) (L)

G R/L R/B B R/B
B 21
Y/L Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W

8-5
L
Br Br B/W
Br Br
Br Br
42 Br/W
41 Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
R/B G Br Dg Ch Y Br Y G Ch Y L Ch Dg
59 (Gy) 56 47
Ch Dg
R/L
57 48 49 50 51 R
B
55 B
54 Br/W

Ch Dg
60 58
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 W B G L
Br G Y B L 34
L L W
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
B Y W B Br Y
B Y/B (Br) (G) L B Y Y W
35
Br Y G
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
ELECTRIC STARTING SYSTEM
ELECTRIC STARTING SYSTEM

3. Main fuse 1
7. Signaling system fuse
10.Main switch
12.Battery
13.Starter relay
14.Starter motor
15.Handlebar switch (right)
16.Start switch
17.Diode
18.Sidestand switch
39.Rear brake light switch
40.Front brake light switch
53.Frame ground
A. Wire harness
B. Starter motor sub-wire harness

8-6
ELECTRIC STARTING SYSTEM

EAS30494

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to “ON” and the start switch “ ” is pushed, the starter motor can only oper-
ate if at least one of the following conditions is met:
• The front brake lever is pulled to the handlebar (the front brake light switch is closed) and the side-
stand is up (the sidestand switch is closed).
• The rear brake lever is pulled to the handlebar (the rear brake light switch is closed) and the sidestand
is up (the sidestand switch is closed).

11

10

1 7
2
5 6 8
3

4 9

1. Battery
2. Main fuse 1
3. Main switch
4. Signaling system fuse
5. Rear brake light switch
6. Front brake light switch
7. Start switch
8. Diode
9. Sidestand switch
10. Starter relay
11. Starter motor

8-7
ELECTRIC STARTING SYSTEM

EAS30495

TROUBLESHOOTING
The starter motor fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Footrest board assemblies
6. Front cowling assembly

1. Check the fuses. NG →

(Main 1 and signaling system)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-99.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-99.

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.
8-106.

NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-52.

OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 8-102.

OK ↓
6. Check the diode. NG →
Refer to “CHECKING THE DIODE” Replace the diode.
on page 8-103.

OK ↓
7. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-95.

OK ↓

8-8
ELECTRIC STARTING SYSTEM

8. Check the sidestand switch. NG →

Refer to “CHECKING THE Replace the sidestand switch.
SWITCHES” on page 8-95.

OK ↓
9. Check the start switch. NG →
The start switch is faulty. Replace the right
Refer to “CHECKING THE
handlebar switch.
SWITCHES” on page 8-95.

OK ↓
10.Check the brake light switches. NG →
(Front and rear)
Replace the brake light switch(es).
Refer to “CHECKING THE
SWITCHES” on page 8-95.

OK ↓
11.Check the entire starting system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-5.

OK ↓
The starting system circuit is OK.

8-9
ELECTRIC STARTING SYSTEM

8-10
EAS30496
EAS20074
A

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
B/W,B R R B R/L
CIRCUIT DIAGRAM

W W W W Y L/W
30
W W 13 W/R O O
2 9 R
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B G/R G/R
B/W 12 G/R B/L 22
15 L/W
B
R (B) B/L B/L
16
CHARGING SYSTEM

B
L/W L/W G R/L
23 24 P/W P/W
10 B B 32
B A Br/W Br/W B Gy/R
L/W B B Gy/R Gy/R B
ON 25
OFF B B/L Y L P/W Br/W B/L B/L (B) (B)
L/W 19 20 26 Y Y
(B)
R/B 3 L/W L L
R B
Br
R/B 4 L/Y P P G G
B L/B G/Y G/Y
R R 17 P G/Y Sb Gy
L/W B G L/B R/L 29
27 Gy Gy 33 G Ch
R/L 5 Sb Sb Ch Ch
R/B 11 14 L/Y (Gy) (B) (B)
L/Y L/Y (Gy)
6 R/L R
B L/Y
Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
Br/W (L) (L)
G R/L R/B B R/B
B 21
Y/L Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W
L
Br Br B/W

8-11
Br Br
Br Br
42 Br/W
41 Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
R/B G Br Dg Ch Y Br Y G Ch Y L Ch Dg
59 (Gy) 56 47
Ch Dg
R/L
57 48 49 50 51 R
B
55 B
54 Br/W

Ch Dg
60 58
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 W B G L
Br G Y B L 34
L L W
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
B Y W B Br Y
B Y/B (Br) (G) L B Y Y W
35
Br Y G
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
CHARGING SYSTEM
CHARGING SYSTEM

2. AC magneto
3. Main fuse 1
9. Rectifier/regulator
12.Battery
53.Frame ground

8-12
CHARGING SYSTEM

EAS30497

TROUBLESHOOTING
The battery is not being charged.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Footrest board assemblies
4. Front upper cowling assembly

1. Check the fuse. NG →

(Main 1)
Replace the fuse.
Refer to “CHECKING THE FUS-
ES” on page 8-99.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-99.

OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator coil assembly.
COIL” on page 8-106.

OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
8-106.

OK ↓
5. Check the entire charging system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-11.

OK ↓
The charging system circuit is OK.

8-13
CHARGING SYSTEM

8-14
EAS30498
EAS20075
A

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
B/W,B R R B R/L
CIRCUIT DIAGRAM

W W W W Y L/W
30
W W 13 W/R O O
2 9 R
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B G/R G/R
B/W 12 G/R B/L 22
15 L/W
B
LIGHTING SYSTEM

R (B) B/L B/L

16
B
L/W L/W G R/L
23 24 P/W P/W
10 B B 32
B A Br/W Br/W B Gy/R
L/W B B Gy/R Gy/R B
ON 25
OFF B B/L Y L P/W Br/W B/L B/L (B) (B)
L/W 19 20 26 Y Y
(B)
R/B 3 L/W L L
R B
Br
R/B 4 L/Y P P G G
B L/B G/Y G/Y
R R 17 P G/Y Sb Gy
L/W B G L/B R/L 29
27 Gy Gy 33 G Ch
R/L 5 Sb Sb Ch Ch
R/B 11 14 L/Y (Gy) (B) (B)
L/Y L/Y (Gy)
6 R/L R
B L/Y
Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
Br/W (L) (L)
G R/L R/B B R/B
B 21
Y/L Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W
L
Br Br B/W

8-15
Br Br
Br Br
42 Br/W
41 Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
R/B G Br Dg Ch Y Br Y G Ch Y L Ch Dg
59 (Gy) 56 47
Ch Dg
R/L
57 48 49 50 51 R
B
55 B
54 Br/W

Ch Dg
60 58
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 W B G L
Br G Y B L 34
L L W
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
B Y W B Br Y
B Y/B (Br) (G) L B Y Y W
35
Br Y G
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
LIGHTING SYSTEM
LIGHTING SYSTEM

3. Main fuse 1
6. Taillight fuse
10.Main switch
12.Battery
29.ECU (Engine Control Unit)
43.Handlebar switch (left)
44.Dimmer switch
47.Tail/brake light assembly
49.Taillight
52.Engine ground
53.Frame ground
56.Headlight unit
57.Auxiliary light
58.Headlight
59.Meter assembly
60.Multi-function meter
64.Meter light
67.High beam indicator light

8-16
LIGHTING SYSTEM

EAS30499

TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary lights or meter
light.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Footrest board assembly
4. Front cowling assembly
5. Leg shield
6. Upper handlebar cover assembly

1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
8-98.

OK ↓
2. Check the fuses. NG →
(Main 1 and taillight)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-99.

OK ↓
3. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-99.

OK ↓
4. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-95.

OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
Refer to “CHECKING THE
left handlebar switch.
SWITCHES” on page 8-95.

OK ↓
6. Check the entire lighting system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-15.

OK ↓
Replace the ECU, meter assembly,
tail/brake light assembly or headlight
unit. Refer to “REPLACING THE ECU
(engine control unit)” on page 8-99.

8-17
LIGHTING SYSTEM

8-18
EAS30500
EAS20076
A

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
B/W,B R R B R/L
CIRCUIT DIAGRAM

W W W W Y L/W
30
W W 13 W/R O O
2 9 R
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B G/R G/R
B/W 12 G/R B/L 22
15 L/W
B
R (B) B/L B/L
16
B
SIGNALING SYSTEM

L/W L/W G R/L

23 24 P/W P/W
10 B B 32
B A Br/W Br/W B Gy/R
L/W B B Gy/R Gy/R B
ON 25
OFF B B/L Y L P/W Br/W B/L B/L (B) (B)
L/W 19 20 26 Y Y
(B)
R/B 3 L/W L L
R B
Br
R/B 4 L/Y P P G G
B L/B G/Y G/Y
R R 17 P G/Y Sb Gy
L/W B G L/B R/L 29
27 Gy Gy 33 G Ch
R/L 5 Sb Sb Ch Ch
R/B 11 14 L/Y (Gy) (B) (B)
L/Y L/Y (Gy)
6 R/L R
B L/Y
Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
Br/W (L) (L)
G R/L R/B B R/B
B 21
Y/L Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W
L
Br Br B/W

8-19
Br Br
Br Br
42 Br/W
41 Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
R/B G Br Dg Ch Y Br Y G Ch Y L Ch Dg
59 (Gy) 56 47
Ch Dg
R/L
57 48 49 50 51 R
B
55 B
54 Br/W

Ch Dg
60 58
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 W B G L
Br G Y B L 34
L L W
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
B Y W B Br Y
B Y/B (Br) (G) L B Y Y W
35
Br Y G
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
SIGNALING SYSTEM
SIGNALING SYSTEM

3. Main fuse 1
6. Taillight fuse
7. Signaling system fuse
8. ABS control unit fuse
10.Main switch
12.Battery
19.Fuel sender
21.Yamaha diagnostic tool coupler
22.Coolant temperature sensor
29.ECU (Engine Control Unit)
34.Front wheel sensor
38.ABS ECU
39.Rear brake light switch
40.Front brake light switch
41.Turn signal relay
42.Horn
43.Handlebar switch (left)
45.Horn switch
46.Turn signal switch
47.Tail/brake light assembly
48.Brake light
50.Rear turn signal light (left)
51.Rear turn signal light (right)
52.Engine ground
53.Frame ground
54.Front turn signal light (right)
55.Front turn signal light (left)
59.Meter assembly
60.Multi-function meter
61.Coolant temperature warning light
65.Turn signal indicator light (right)
66.Turn signal indicator light (left)

8-20
SIGNALING SYSTEM

EAS30501

TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light, warning lights or indicator lights.
• The horn fails to sound.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The instantaneous fuel consumption meter fails to operation.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Center lower cover
6. Upper handlebar cover assembly

1. Check the fuses. NG →

(Main 1, taillight, signaling system,
and ABS control unit) Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-99.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-99.

OK ↓
3. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-95.

OK ↓
4. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.

Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
The horn switch is faulty. Replace the left
Refer to “CHECKING THE
handlebar switch.
SWITCHES” on page 8-95.

OK ↓

8-21
SIGNALING SYSTEM

2. Check the entire signaling system NG →

wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OK ↓
Replace the horn.

The brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
SWITCHES” on page 8-95.

OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
SWITCHES” on page 8-95.

OK ↓
3. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OK ↓
Replace the tail/brake light assembly.

The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulbs NG →
and sockets.
Replace the turn signal light bulb, socket or
Refer to “CHECKING THE BULBS
both.
AND BULB SOCKETS” on page
8-98.

OK ↓
2. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
Refer to “CHECKING THE
the left handlebar switch.
SWITCHES” on page 8-95.

OK ↓
3. Check the turn signal relay. NG →
Refer to “CHECKING THE TURN Replace the turn signal relay.
SIGNAL RELAY” on page 8-103.

OK ↓

8-22
SIGNALING SYSTEM

4. Check the entire signaling system NG →

wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OK ↓
Replace the meter assembly.

The 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 8-108.

OK ↓
2. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OK ↓
Replace the meter assembly or ECU.
Refer to “REPLACING THE ECU (en-
gine control unit)” on page 8-99.

The fuel meter, fuel level warning light, or both fails to come on.
1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
SENDER” on page 8-107.

OK ↓
2. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.

OK ↓
Replace the meter assembly.

The speedometer, V-belt replacement indicator, engine oil change indicator, instantaneous fuel con-
sumption meter fails to operate.
1. Check the front wheel sensor. NG →
Refer to “MAINTENANCE OF THE
Replace the front wheel sensor.
FRONT WHEEL SENSOR AND
SENSOR ROTOR” on page 4-28.

OK ↓

8-23
SIGNALING SYSTEM

2. Check the entire wiring. NG → Properly connect or replace the wiring har-
Refer to TIP. ness.

OK ↓
Replace the ECU, ABS ECU, or meter
assembly. Refer to “REPLACING THE
ECU (engine control unit)” on page
8-99.

TIP
Replace the wire harness if there is an open or short circuit.
• Between front wheel sensor coupler and ABS ECU coupler.
(Green–Green)
(Blue–Blue)
• Between ABS ECU coupler and ECU coupler.
(White–White)
• Between ECU coupler and meter assembly coupler.
(Yellow/Blue–Yellow/Blue)

8-24
EAS30504
EAS20078
A

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
B/W,B R R B R/L
CIRCUIT DIAGRAM

W W W W Y L/W
30
W W 13 W/R O O
2 9 R
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B G/R G/R
B/W 12 G/R B/L 22
15 L/W
B
R (B) B/L B/L
16
B
L/W L/W G R/L
23 24 P/W P/W
10 B B 32
B A Br/W Br/W B Gy/R
L/W B B Gy/R Gy/R B
ON 25
OFF B B/L Y L P/W Br/W B/L B/L (B) (B)
L/W 19 20 26 Y Y
(B)
R/B 3 L/W L L
R B
Br
R/B 4 L/Y P P G G
B L/B G/Y G/Y
R R 17 P G/Y Sb Gy
L/W B G L/B R/L 29
27 Gy Gy 33 G Ch
FUEL INJECTION SYSTEM

R/L 5 Sb Sb Ch Ch
R/B 11 14 L/Y (Gy) (B) (B)
L/Y L/Y (Gy)
6 R/L R
B L/Y
Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
Br/W (L) (L)
G R/L R/B B R/B
B 21
Y/L Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W
L
Br Br B/W

8-25
Br Br
Br Br
42 Br/W
41 Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
R/B G Br Dg Ch Y Br Y G Ch Y L Ch Dg
59 (Gy) 56 47
Ch Dg
R/L
57 48 49 50 51 R
B
55 B
54 Br/W

Ch Dg
60 58
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 W B G L
Br G Y B L 34
L L W
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
B Y W B Br Y
B Y/B (Br) (G) L B Y Y W
35
Br Y G
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM

1. Crankshaft position sensor

3. Main fuse 1
5. Main fuse 2
6. Taillight fuse
8. ABS control unit fuse
10.Main switch
12.Battery
18.Sidestand switch
20.Fuel pump
21.Yamaha diagnostic tool coupler
22.Coolant temperature sensor
23.Throttle body sensor assembly
24.Intake air pressure sensor
25.Intake air temperature sensor
26.Throttle position sensor
27.ISC (Idle Speed Control) unit
28.Fuel injector
29.ECU (Engine Control Unit)
30.Ignition coil
31.Spark plug
32.O2 sensor
33.VVA (variable valve actuator) solenoid
34.Front wheel sensor
38.ABS ECU
43.Handlebar switch (left)
44.Dimmer switch
52.Engine ground
53.Frame ground
56.Headlight unit
58.Headlight
59.Meter assembly
60.Multi-function meter
63.Engine trouble warning light
67.High beam indicator light

8-26
FUEL INJECTION SYSTEM

EAS30505

ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code
number is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes while the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the meter display. This
number remains stored in the memory of the ECU until it is deleted.

Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation
Warning provided when
Flashing* Operation stopped Cannot be operated
unable to start engine
Operated with substitute
Can or cannot be operat-
characteristics in accor-
Remains on Malfunction detected ed depending on the fault
dance with the descrip-
code
tion of the malfunction

* The warning light flashes when any one of the following conditions is present and the start switch is
pushed:
Fuel injector
12: Crankshaft position sensor 39:
(short circuit)
Blue/Yellow ECU lead ECU internal malfunction
19: 50:
(broken or disconnected) (memory check error)

Checking the engine trouble warning light

The engine trouble warning light comes on for around 2 seconds after the main switch has been set to
“ON” and it comes on while the start switch is being pushed. If the warning light does not come on under
these conditions, the warning light (LED) may be defective.

ECU detects an abnormal signal from a sensor

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS30506

TROUBLESHOOTING METHOD

The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code number displayed on the computer.
b. Identify the faulty system with the fault code number.

8-27
FUEL INJECTION SYSTEM

c. Identify the probable cause of the malfunction.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of the malfunction.
Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOTING Check and repair.
DETAILS” on page 8-31.
Monitor the operation of the sensors and actuators in
the diagnostic mode. Refer to “TROUBLESHOOT-
ING DETAILS” on page 8-31 and “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE”
on page 9-5.

3. Perform the reinstatement action for the fuel injection system.

Refer to “Confirmation of service completion” in the appropriate table in “TROUBLESHOOTING DE-
TAILS” on page 8-31.
4. Set the main switch to “OFF”, then to “ON” again, and then check that no fault code number is dis-
played.
TIP
If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode. Refer to “Sensor operation table (Diagnostic
code No. 62)”.
TIP
Turning the main switch to “OFF” will not erase the malfunction history.

The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “TROU-
BLESHOOTING DETAILS” on page 8-31.
01: Throttle position sensor signal (throttle angle)
30: Ignition coil
36: Fuel injector

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.
EAS30951

YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.

Yamaha diagnostic tool

90890-03231

Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth-
ods.
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying mal-
functions and for maintenance to display on the computer. The displayed information includes the sen-
sor output data and information recorded in the ECU.

8-28
FUEL INJECTION SYSTEM

Functions of the Yamaha diagnostic tool

Fault diagnosis mode: Fault codes recorded on the ECU are read, and the contents are dis-
played.
The freeze frame data (FFD) is the operation data when a malfunction
was detected. This data can be used to identify when the malfunction
occurred and check the engine conditions and running conditions when
it occurred.
Function diagnostic mode: Check the operation of the output value of each sensor and actuator.
Inspection mode: Determine whether each sensor or actuator is functioning properly.
CO adjustment mode: Adjust the concentration of CO admissions during idling.
Monitoring mode: Displays a graph of sensor output values for actual operating condi-
tions.
Logging mode: Records and saves the sensor output value in actual driving conditions.
View log: Displays the logging data.
ECU rewrite: If necessary, the ECU is rewritten using ECU rewrite data provided by
Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle’s
original state.

However, the Diagnostic Tool cannot be used to freely change the basic vehicle functions, such as ad-
justing the ignition timing.
Connecting the Yamaha diagnostic tool
Disconnect the Yamaha diagnostic tool coupler “1”, and then connect the Yamaha diagnostic tool “2”
to the coupler.
1
2

TIP
When the Yamaha diagnostic tool is connected to the vehicle, “Er-1” or “Er-4” will be displayed on the
multi-function meter.
Operation of the Yamaha diagnostic tool (Malfunction mode)
Malfunction results are displayed in the top part of the window area.

8-29
FUEL INJECTION SYSTEM

3 4 5 6 7 8 9 10 11 12

1. Recovered
The item list of the malfunction detected in the past (already recovered) are displayed.
2. Detected
The item list of the malfunction currently occurred are displayed.
3. Code
The following icons and the fault code numbers for the detected malfunctions are displayed.

A B

A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed.
5. Item
The item names of the detected malfunction are displayed.

8-30
FUEL INJECTION SYSTEM

6. Condition
The current conditions are displayed. (Detected/Recovered)
7. Symptom
The symptoms of the detected malfunction are displayed.
8. Diagnosis code
The diagnosis codes related to the detected malfunction are displayed.
9. FFD (only for models that can display freeze frame data)
The mark “ ” is displayed when the freeze frame data is available.
10.ECU conduction time (hour: minute: second)
The total ECU conduction time (total hours the vehicle’s main switch was ON) when the malfunction
was detected is displayed.
11.Number of main switch operation after detection
The number of times the main switch was turned on between the malfunction detection and code
reading is displayed.
12.Number of occurrences
The number of malfunction occurrences between the malfunction detection and code reading is dis-
played.
EAS30508

TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the computer. Check and ser-
vice the items or components that are the probable cause of the malfunction following the order given.
Fault code No.:
Fault code number displayed on the computer when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5.

Fault code No. 12

Fault code No. 12

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of crankshaft posi- Improperly connected → Con- Crank the engine.
tion sensor coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).

8-31
FUEL INJECTION SYSTEM

Fault code No. 12

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
2 Connection of ECU coupler. Improperly connected → Con- Crank the engine.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played → Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 3.
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Crank the engine.
the wire harness. Fault code number is not dis-
Between crankshaft position played → Service is finished.
sensor coupler and ECU cou- Fault code number is displayed
pler. → Go to item 4.
White/Red–White/Red
Black/Blue–Black/Blue
4 Installed condition of crankshaft Improperly installed sensor → Crank the engine.
position sensor. Reinstall or replace the sensor. Fault code number is not dis-
Check for looseness or pinch- Refer to “AC MAGNETO” on played → Service is finished.
ing. page 5-47. Fault code number is displayed
Check the gap between the → Go to item 5.
crankshaft position sensor and
the stator coil assembly.
5 Defective crankshaft position Check the crankshaft position Crank the engine.
sensor. sensor. Fault code number is not dis-
Refer to “CHECKING THE played → Service is finished.
CRANKSHAFT POSITION Fault code number is displayed
SENSOR” on page 8-105. → Go to item 6.
Replace if defective.
6 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 13

ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.

Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Operate the throttle while pushing the start switch “ ”. (If the display val-
Procedure
ue changes, the performance is OK.)

8-32
FUEL INJECTION SYSTEM

Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of throttle body sen- Improperly connected → Con- Turn the main switch to “ON”.
sor assembly coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Turn the main switch to “ON”.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played → Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 3.
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between throttle body sensor played → Service is finished.
assembly coupler and ECU cou- Fault code number is displayed
pler. → Go to item 4.
Black/Blue–Black/Blue
Pink/White–Pink/White
Blue–Blue
4 Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”.
body sensor assembly. ing. Fault code number is not dis-
Check for looseness or pinch- Improperly installed sensor → played → Service is finished.
ing. Replace the throttle body. Fault code number is displayed
Refer to “THROTTLE BODY” on → Go to item 5.
page 7-10.

8-33
FUEL INJECTION SYSTEM

Fault code No. 13

Item Intake air pressure sensor: open or short circuit detected.
5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”.
sensor. (Code No. 03) Fault code number is not dis-
When engine is stopped: played → Service is finished.
Atmospheric pressure at the Fault code number is displayed
current altitude and weather → Go to item 6.
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea lev-
el: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. → Re-
place the throttle body if defec-
tive.
Refer to “THROTTLE BODY” on
page 7-10.
6 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 14

ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
TIP
If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number
“13” first.

Fault code No. 14

Intake air pressure sensor: system malfunction (clogged hole or de-

Item
tached).
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Operate the throttle while pushing the start switch “ ”. (If the display val-
Procedure
ue changes, the performance is OK.)
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-34
FUEL INJECTION SYSTEM

Fault code No. 14

Intake air pressure sensor: system malfunction (clogged hole or de-
Item
tached).
1 Installed condition of throttle po- Check the mounting section for Start the engine and let it idle for
sition sensor assembly. loose or pinched mounting. approximately 5 seconds.
Improperly installed sensor → Fault code number is not dis-
Replace the throttle body. played → Service is finished.
Refer to “THROTTLE BODY” on Fault code number is displayed
page 7-10. → Go to item 2.
2 Defective intake air pressure Execute the diagnostic mode.
sensor. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea lev-
el: Approx. 80 kPa (600.0
mmHg, 23.6 inHg)
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. → Re-
place the throttle body if defec-
tive.
Refer to “THROTTLE BODY” on
page 7-10.

Fault code No. 15

ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.

Fault code No. 15

Item Throttle position sensor: open or short circuit detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 01
Throttle position sensor signal
Tool display • 13–21 (fully closed position)
• 92–102 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-35
FUEL INJECTION SYSTEM

Fault code No. 15

Item Throttle position sensor: open or short circuit detected.
1 Connection of throttle body sen- Improperly connected → Con- Turn the main switch to “ON”.
sor assembly coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Turn the main switch to “ON”.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played → Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 3.
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between throttle body sensor played → Service is finished.
assembly coupler and ECU cou- Fault code number is displayed
pler. → Go to item 4.
Black/Blue–Black/Blue
Yellow–Yellow
Blue–Blue
4 Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”.
body sensor assembly. ing. Fault code number is not dis-
Check for looseness or pinch- Improperly installed sensor → played → Service is finished.
ing. Replace the throttle body. Fault code number is displayed
Refer to “THROTTLE BODY” on → Go to item 5.
page 7-10.
5 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ON”.
sor. signal. Fault code number is not dis-
Execute the diagnostic mode. played → Service is finished.
(Code No. 01) Fault code number is displayed
When the throttle valves are ful- → Go to item 6.
ly closed:
A value of 13–21 is indicated.
When throttle valves are fully
open:
A value of 92–102 is indicated.
An indicated value is out of the
specified range → Replace the
throttle body if defective.
Refer to “THROTTLE BODY” on
page 7-10.
6 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 16

ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.

8-36
FUEL INJECTION SYSTEM

Fault code No. 16

Item Throttle position sensor: stuck throttle position sensor is detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 01
Throttle position sensor signal
Tool display • 13–21 (fully closed position)
• 92–102 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”
body sensor assembly. ing. and then open and close the
Improperly installed sensor → throttle valves.
Replace the throttle body. Fault code number is not dis-
Refer to “THROTTLE BODY” on played → Service is finished.
page 7-10. Fault code number is displayed
→ Go to item 2.
2 Defective throttle position sen- Execute the diagnostic mode. Turn the main switch to “ON”
sor. (Code No. 01) and then open and close the
When the throttle valves are ful- throttle valves.
ly closed: Fault code number is not dis-
A value of 13–21 is indicated. played → Service is finished.
When throttle valves are fully Fault code number is displayed
open: → Go to item 3.
A value of 92–102 is indicated.
An indicated value is out of the
specified range → Replace the
throttle body.
Refer to “THROTTLE BODY” on
page 7-10.
3 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 19

Fault code No. 19

Sidestand switch: a break or disconnection of the Blue/Yellow lead

Item
of the ECU is detected.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. 20
Blue/Yellow lead of the ECU
Tool display • “ON” (stand retracted)
• “OFF” (stand extended)
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-37
FUEL INJECTION SYSTEM

Fault code No. 19

Sidestand switch: a break or disconnection of the Blue/Yellow lead

Item
of the ECU is detected.
1 Connection of sidestand switch Improperly connected → Con- Turn the main switch to “ON”
coupler. nect the coupler securely or re- and then extend and retract the
Check the locking condition of place the wire harness. sidestand.
the coupler. Fault code number is not dis-
Disconnect the coupler and played → Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition → Go to item 2.
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Turn the main switch to “ON”
Check the locking condition of nect the coupler securely or re- and then extend and retract the
the coupler. place the wire harness. sidestand.
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played → Service is finished.
terminals and locking condition Fault code number is displayed
of the pins). → Go to item 3.
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”
the wire harness. and then extend and retract the
Between ECU coupler and side- sidestand.
stand switch coupler. Fault code number is not dis-
Blue/Yellow–Blue/Yellow played → Service is finished.
Fault code number is displayed
→ Go to item 4.
4 Defective sidestand switch. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 20) and then extend and retract the
Sidestand retracted: “ON” sidestand.
Sidestand extended: “OFF” Fault code number is not dis-
Replace if defective. played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 21

TIP
Perform this procedure when the engine is cold.

Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 06
When engine is cold: Displays temperature closer to air temperature.
Tool display
When engine is hot: Displays current coolant temperature.
Compare the actually measured coolant temperature with the computer
Procedure
display value.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-38
FUEL INJECTION SYSTEM

Fault code No. 21

Item Coolant temperature sensor: open or short circuit detected.
1 Connection of coolant tempera- Improperly connected → Con- Turn the main switch to “ON”.
ture sensor coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Turn the main switch to “ON”.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played → Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 3.
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between coolant temperature played → Service is finished.
sensor coupler and ECU cou- Fault code number is displayed
pler. → Go to item 4.
Green/Red–Green/Red
Black/Blue–Black/Blue
4 Installed condition of coolant Improperly installed sensor → Turn the main switch to “ON”.
temperature sensor. Reinstall or replace the sensor. Fault code number is not dis-
Check for looseness or pinch- Refer to “CYLINDER HEAD” on played → Service is finished.
ing. page 5-9. Fault code number is displayed
→ Go to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to “ON”.
sensor. (Code No. 06) Fault code number is not dis-
When engine is cold: played → Service is finished.
Displayed temperature is close Fault code number is displayed
to the ambient temperature. → Go to item 6.
The displayed temperature is
not close to the ambient temper-
ature → Check the coolant tem-
perature sensor.
Replace if defective.
Refer to “CHECKING THE
COOLANT TEMPERATURE
SENSOR” on page 8-108.
6 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 22

ECA20500

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
TIP
Perform this procedure when the engine is cold.

8-39
FUEL INJECTION SYSTEM

Fault code No. 22

Item Intake air temperature sensor: open or short circuit detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 05
Tool display Displays the intake air temperature.
When engine is cold: Displays temperature closer to air temperature
Procedure
When engine is hot: Air temperature + approx. 20 °C (68 °F)
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of throttle body sen- Improperly connected → Con- Turn the main switch to “ON”.
sor assembly coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of ECU coupler. Improperly connected → Con- Turn the main switch to “ON”.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played → Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 3.
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between throttle body sensor played → Service is finished.
assembly coupler and ECU cou- Fault code number is displayed
pler. → Go to item 4.
Black/Blue–Black/Blue
Brown/White–Brown/White
4 Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”.
body sensor assembly. ing. Fault code number is not dis-
Improperly installed sensor → played → Service is finished.
Replace the throttle body. Fault code number is displayed
Refer to “THROTTLE BODY” on → Go to item 5.
page 7-10.
5 Defective intake air tempera- Execute the diagnostic mode. Turn the main switch to “ON”.
ture sensor. (Code No. 05) Fault code number is not dis-
When engine is cold: played → Service is finished.
Displayed temperature is close Fault code number is displayed
to the ambient temperature. → Go to item 6.
The displayed temperature is
not close to the ambient temper-
ature. → Replace the throttle
body if defective.
Refer to “THROTTLE BODY” on
page 7-10.
6 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

8-40
FUEL INJECTION SYSTEM

Fault code No. 24

Fault code No. 24

Item O2 sensor: no normal signals are received from the O2 sensor.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Installed condition of O2 sensor. Improperly installed sensor → Start the engine, warm it up,
Replace the sensor. and then race it, or execute the
Refer to “ENGINE REMOVAL” diagnostic mode. (Code No. 62)
on page 5-3. Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 2.
2 Connection of O2 sensor cou- Improperly connected → Con- Start the engine, warm it up,
pler. nect the coupler securely or re- and then race it, or execute the
Check the locking condition of place the wire harness. diagnostic mode. (Code No. 62)
the coupler. Fault code number is not dis-
Disconnect the coupler and played → Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition → Go to item 3.
of the pins).
3 Connection of ECU coupler. Improperly connected → Con- Start the engine, warm it up,
Check the locking condition of nect the coupler securely or re- and then race it, or execute the
the coupler. place the wire harness. diagnostic mode. (Code No. 62)
Disconnect the coupler and Fault code number is not dis-
check the pins (bent or broken played → Service is finished.
terminals and locking condition Fault code number is displayed
of the pins). → Go to item 4.
4 Wire harness continuity. Open or short circuit → Replace Start the engine, warm it up,
the wire harness. and then race it, or execute the
Between O2 sensor coupler and diagnostic mode. (Code No. 62)
ECU coupler. Fault code number is not dis-
Gray/Red–Gray/Red played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5 Check fuel pressure. Refer to “CHECKING THE Start the engine, warm it up,
FUEL PRESSURE” on page and then race it, or execute the
7-3. diagnostic mode. (Code No. 62)
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 6.
6 Defective O2 sensor. Check the O2 sensor. Start the engine, warm it up,
Replace if defective. and then race it, or execute the
Refer to “ENGINE REMOVAL” diagnostic mode. (Code No. 62)
on page 5-3. Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 7.

8-41
FUEL INJECTION SYSTEM

Fault code No. 24

Item O2 sensor: no normal signals are received from the O2 sensor.

7 Malfunction in ECU. Replace the ECU.

Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 37

TIP
• If fault code numbers “37” and “46” are both indicated, take the actions specified for fault code number
“46” first.
• If fault code numbers “37” and “42” are both indicated, take the actions specified for fault code number
“42” first.
• If fault code numbers “37” and “61” are both indicated, take the actions specified for fault code number
“61” first.

Fault code No. 37

Component other than ISC (idle speed control) unit is defec-

A
tive (ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating sound is
B
not heard).
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 54
Fully closes the ISC valve, and then opens the valve. This operation
Actuation takes approximately 3 seconds. The “CHECK” indicator and “ ” on the
Yamaha diagnostic tool screen comes on during the operation.
Procedure The ISC unit vibrates when the ISC valve operates.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
A-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard →
(Code No. 54) Go to item A-2.
Fully closes the ISC (idle speed ISC operating sound is not
control) valve, and then fully heard → Go to item B-2 for the
opens the valve. This operation defective ISC (idle speed con-
takes approximately 3 seconds. trol) unit.
A-2 Incorrect front wheel sensor sig- Check the front wheel sensor. Start the engine and let it idle for
nal. Execute the diagnostic mode. approximately 10 seconds.
(Code No. 07) Fault code number is not dis-
Rotate the front wheel by hand played → Service is finished.
and check that the indicated val- Fault code number is displayed
ue increases. → Go to item A-3.
Value does not increase → Go
to fault code No. 42.
A-3 Throttle valve does not fully Check the throttle grip free play. Start the engine and let it idle for
close due to malfunction in Refer to “CHECKING THE approximately 10 seconds.
throttle cables. THROTTLE GRIP OPERA- Fault code number is not dis-
TION” on page 3-23. played → Service is finished.
Fault code number is displayed
→ Go to item A-4.

8-42
FUEL INJECTION SYSTEM

Fault code No. 37

Component other than ISC (idle speed control) unit is defec-
A
tive (ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating sound is
B
not heard).
A-4 Air leak from the throttle body. Check the throttle body. Start the engine and let it idle for
Refer to “CHECKING THE approximately 10 seconds.
THROTTLE BODY” on page Fault code number is not dis-
7-12. played → Service is finished.
Fault code number is displayed
→ Go to item A-5.
A-5 Air leak from the ISC (idle speed Improperly installed ISC (idle Start the engine and let it idle for
control) unit. speed control) unit → Reinstall approximately 10 seconds.
the ISC (idle speed control) unit. Fault code number is not dis-
Check the intake air passages played → Service is finished.
for air leaks. Fault code number is displayed
→ Go to item A-6.
A-6 The air volume for the throttle Clean the throttle body and ISC Start the engine and let it idle for
body and ISC (idle speed con- (idle speed control) unit. approximately 10 seconds.
trol) unit is excessive. Refer to “CLEANING THE ISC Fault code number is not dis-
(IDLE SPEED CONTROL) UNIT played → Service is finished.
AND THROTTLE BODY” on Fault code number is displayed
page 7-12. → Go to item A-7.
A-7 ISC (idle speed control) unit is Replace the ISC (idle speed Start the engine and let it idle for
not moving correctly. control) unit. approximately 10 seconds.
Refer to “CLEANING THE ISC Fault code number is not dis-
(IDLE SPEED CONTROL) UNIT played → Service is finished.
AND THROTTLE BODY” on Fault code number is displayed
page 7-12. → Go to item A-8.
A-8 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 37

Component other than ISC (idle speed control) unit is defec-

A
tive (ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating sound is
B
not heard).
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 54
Fully closes the ISC valve, and then opens the valve. This operation
Actuation takes approximately 3 seconds. The “CHECK” indicator and “ ” on the
Yamaha diagnostic tool screen comes on during the operation.
Procedure The ISC unit vibrates when the ISC valve operates.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion

8-43
FUEL INJECTION SYSTEM

Fault code No. 37

Component other than ISC (idle speed control) unit is defec-
A
tive (ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating sound is
B
not heard).
B-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard →
(Code No. 54) Go to item A-2 for the compo-
Fully closes the ISC (idle speed nent other than ISC (idle speed
control) valve, and then fully control) unit is defective.
opens the valve. This operation ISC operating sound is not
takes approximately 3 seconds. heard → Go to item B-2.
B-2 Connection of ISC (idle speed Improperly connected → Con- Execute the diagnostic mode.
control) unit coupler. nect the coupler securely or re- (Code No. 54)
Check the locking condition of place the wire harness. ISC operating sound is heard →
the coupler. Go to item B-9 and delete the
Disconnect the coupler and fault code.
check the pins (bent or broken ISC operating sound is not
terminals and locking condition heard → Go to item B-3.
of the pins).
B-3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 54)
the coupler. place the wire harness. ISC operating sound is heard →
Disconnect the coupler and Go to item B-9 and delete the
check the pins (bent or broken fault code.
terminals and locking condition ISC operating sound is not
of the pins). heard → Go to item B-4.
B-4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 54)
Between ISC (idle speed con- ISC operating sound is heard →
trol) unit coupler and ECU cou- Go to item B-9 and delete the
pler. fault code.
Pink–Pink ISC operating sound is not
Green/Yellow–Green/Yellow heard → Go to item B-5.
Gray–Gray
Sky blue–Sky blue
B-5 Installed condition of ISC (idle Check for looseness or pinch- Execute the diagnostic mode.
speed control) unit. ing. (Code No. 54)
Improperly installed ISC (idle ISC operating sound is heard →
speed control) unit → Reinstall Go to item B-9 and delete the
the ISC (idle speed control) unit. fault code.
Check the intake air passages ISC operating sound is not
for air leaks. heard → Go to item B-6.
B-6 Battery malfunction Check the battery voltage. Execute the diagnostic mode.
Refer to “CHECKING AND (Code No. 54)
CHARGING THE BATTERY” on ISC operating sound is heard →
page 8-99. Go to item B-9 and delete the
fault code.
ISC operating sound is not
heard → Go to item B-7.
B-7 ISC (idle speed control) unit is Replace the ISC (idle speed Execute the diagnostic mode.
not moving correctly. control) unit. (Code No. 54)
Refer to “CLEANING THE ISC ISC operating sound is heard →
(IDLE SPEED CONTROL) UNIT Go to item B-9 and delete the
AND THROTTLE BODY” on fault code.
page 7-12. ISC operating sound is not
heard → Go to item B-8.

8-44
FUEL INJECTION SYSTEM

Fault code No. 37

Component other than ISC (idle speed control) unit is defec-

A
tive (ISC operating sound is heard).
Item
Defective ISC (idle speed control) unit (ISC operating sound is
B
not heard).
B-8 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
Refer to “REPLACING THE (Code No. 54)
ECU (engine control unit)” on Return the ISC (idle speed con-
page 8-99. trol) valve to the initial opening
position.
B-9 Delete the fault code. Start the engine and let it idle for
approximately 10 seconds.
Check that the fault code num-
ber is not displayed.

Fault code No. 39

Fault code No. 39

Item Fuel injector: open or short circuit detected.

Unable to start engine.
Fail-safe system
Unable to drive vehicle.
Diagnostic code No. 36
Actuates fuel injector five times at one-second intervals.
Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen
36 comes on each time the fuel injector is actuated.
Disconnect the fuel pump coupler. Check that fuel injector is actuated
Procedure
five times by listening for the operating sound.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of fuel injector cou- Improperly connected → Con- Execute the diagnostic mode.
pler. nect the coupler securely or re- (Code No. 36)
Check the locking condition of place the wire harness. Operating sound → Go to item
the coupler. 6.
Disconnect the coupler and No operating sound → Go to
check the pins (bent or broken item 2.
terminals and locking condition
of the pins).
2 Defective fuel injector. Measure the fuel injector resis- Execute the diagnostic mode.
tance. (Code No. 36)
Replace if out of specification. Operating sound → Go to item
Refer to “CHECKING THE 6.
FUEL INJECTOR” on page No operating sound → Go to
8-108. item 3.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 36)
the coupler. place the wire harness. Operating sound → Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound → Go to
terminals and locking condition item 4.
of the pins).

8-45
FUEL INJECTION SYSTEM

Fault code No. 39

Item Fuel injector: open or short circuit detected.

4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 36)
Between fuel injector coupler Operating sound → Go to item
and ECU coupler. 6.
Orange/Black–Orange/Black No operating sound → Go to
Between fuel injector coupler item 5.
and main switch connector.
Red/Blue–Brown
5 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.
6 Delete the fault code. Start the engine and let it idle for
approximately 5 seconds.
Check that the fault code num-
ber is not displayed.

Fault code No. 42

Fault code No. 42

Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 07
Front wheel sensor pulse
Tool display
0–999
Check that the number increases when the front wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of front wheel sen- Improperly connected → Con- Execute the diagnostic mode.
sor coupler. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate the front wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue increases.
check the pins (bent or broken Value increases → Go to item 7
terminals and locking condition and delete the fault code.
of the pins). Value does not increase → Go
to item 2.
2 Connection of ABS ECU cou- Improperly connected → Con- Execute the diagnostic mode.
pler. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate the front wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue increases.
check the pins (bent or broken Value increases → Go to item 7
terminals and locking condition and delete the fault code.
of the pins). Value does not increase → Go
to item 3.

8-46
FUEL INJECTION SYSTEM

Fault code No. 42

Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 07)
the coupler. place the wire harness. Rotate the front wheel by hand
Disconnect the coupler and and check that the indicated val-
check the pins (bent or broken ue increases.
terminals and locking condition Value increases → Go to item 7
of the pins). and delete the fault code.
Value does not increase → Go
to item 4.
4 Front wheel sensor lead conti- Open or short circuit or detec- Execute the diagnostic mode.
nuity or detective front wheel tive front wheel sensor → Re- (Code No. 07)
sensor. place the front wheel sensor. Rotate the front wheel by hand
Between front wheel sensor and check that the indicated val-
coupler and ECU coupler. ue increases.
Green –Green Value increases → Go to item 7
Blue–Blue and delete the fault code.
Between ABS ECU coupler and Value does not increase → Go
ECU coupler. to item 5.
White–White
5 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
Refer to “REPLACING THE (Code No. 07)
ECU (engine control unit)” on Rotate the front wheel by hand
page 8-99. and check that the indicated val-
ue increases.
Value increases → Go to item 7
and delete the fault code.
Value does not increase → Go
to item 6.
6 Malfunction in ABS ECU. Replace the hydraulic unit as- Go to item 7 and delete the fault
sembly. code.
Refer to “ABS (ANTI-LOCK
BRAKE SYSTEM)” on page
4-61.
7 Turn the main switch to “ON”
and then rotate the front wheel
by hand.
Check that the fault code num-
ber is not displayed.

Fault code No. 44

Fault code No. 44

EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 60
EEPROM fault code display
• 00 (no history): No malfunctions detected (If the self-diagnosis fault
Tool display
code 44 is indicated, the ECU is defective.)
• 01: Data error for ISC (idle speed control) learning value.
Procedure —

8-47
FUEL INJECTION SYSTEM

Fault code No. 44

EEPROM fault code number: an error is detected while reading or
Item
writing on EEPROM.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Locate the malfunction Execute the diagnostic mode.
(Code No. 60)
00: Go to item 3.
01: Go to item 2.
2 “11” is indicated in diagnostic Turn the main switch to “OFF”. Turn the main switch to “ON”.
mode (code No. 60). EEPROM Fault code number is not dis-
data error for ISC (idle speed played → Service is finished.
control) learning values. Fault code number is displayed
→ Repeat item 1. If the same
number is indicated, go to item
3.
3 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 46

Fault code No. 46

Item Charging voltage is abnormal.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle for
Refer to “CHARGING SYSTEM” approximately 5 seconds.
on page 8-11. Fault code number is not dis-
Defective rectifier/regulator or played → Service is finished.
AC magneto → Replace. Fault code number is displayed
Defective connection in the → Repeat the maintenance job.
charging system circuit → Prop-
erly connect or replace the wire
harness.

Fault code No. 50

Fault code No. 50

Faulty ECU memory. (When this malfunction is detected in the ECU,

Item
the fault code number might not appear on the tool display.)
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —

8-48
FUEL INJECTION SYSTEM

Fault code No. 50

Faulty ECU memory. (When this malfunction is detected in the ECU,
Item
the fault code number might not appear on the tool display.)
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ON”.
Refer to “REPLACING THE Check that the fault code num-
ECU (engine control unit)” on ber is not displayed.
page 8-99.

Fault code No. 61

Fault code No. 61

Item ISC (idle speed control) unit: open or short circuit detected.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. –
Action –
Procedure –
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of ISC unit coupler. Improperly connected → Con- Set the main switch to “ON”.
Check the locking condition of nect the coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played → Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken → Go to item 2.
terminals and locking condition
of the pins).
2 Connection of wire harness Improperly connected → Con- Set the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 3.
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Set the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between ISC unit coupler and played → Service is finished.
ECU coupler. Fault code number is displayed
Pink–Pink → Go to item 4.
Green/Yellow–Green/Yellow
Gray–Gray
Sky blue–Sky blue
4 Faulty ISC unit operation. Execute the diagnostic mode. Set the main switch to “ON”.
(Code No. D54) Fault code number is not dis-
ISC unit operation sound is not played → Service is finished.
heard. → Replace the ISC unit. Fault code number is displayed
Refer to “CLEANING THE ISC → Go to item 5.
(IDLE SPEED CONTROL)
UNIT AND THROTTLE BODY”
on page 7-12.

8-49
FUEL INJECTION SYSTEM

Fault code No. 61

Item ISC (idle speed control) unit: open or short circuit detected.
5 Malfunction in ECU Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. 84

Fault code No. 84

VVA (variable valve actuator) solenoid: open or short circuit detect-

Item
ed.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 45
Actuates the VVA (variable valve actuator) solenoid five times at three-
second intervals. The “CHECK” indicator and “ ” on the Yamaha diag-
Action
nostic tool screen come on each time the VVA (variable valve actuator)
solenoid is actuated.
Remove the VVA (variable valve actuator) solenoid from the cylinder
head, and then connect the VVA (variable valve actuator) solenoid cou-
pler.
Procedure
Refer to “CYLINDER HEAD” on page 5-9.
Visually check that the VVA (variable valve actuator) solenoid is actuated
five times.
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of VVA (variable Improperly connected → Con- Set the main switch to “ON”.
valve actuator) solenoid coupler. nect the coupler securely or re- Start the engine and accelerate
Check the locking condition of place the wire harness. to 6000 r/min.
the coupler. Disconnect the cou- Fault code number is not dis-
pler and check the pins (bent or played → Service is finished.
broken terminals and locking Fault code number is displayed
condition of the pins). → Go to item 2.
2 Connection of wire harness Improperly connected → Con- Set the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Start the engine and accelerate
Check the locking condition of place the wire harness. to 6000 r/min.
the coupler. Fault code number is not dis-
Disconnect the coupler and played → Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition → Go to item 3.
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Set the main switch to “ON”.
the wire harness. Start the engine and accelerate
Between VVA (variable valve to 6000 r/min.
actuator) solenoid coupler and Fault code number is not dis-
ECU coupler. played → Service is finished.
Green–Green Fault code number is displayed
Chocolate-Chocolate → Go to item 4.
Between engine ground and
ECU coupler.
Black/Yellow–Black/Yellow

8-50
FUEL INJECTION SYSTEM

Fault code No. 84

VVA (variable valve actuator) solenoid: open or short circuit detect-
Item
ed.
4 Defective VVA (variable valve Measure the VVA (variable Set the main switch to “ON”.
actuator) solenoid. valve actuator) solenoid resis- Start the engine and accelerate
tance. to 6000 r/min.
Replace it out of specification. Fault code number is not dis-
Refer to “CHECKING THE VVA played → Service is finished.
SOLENOID” on page 8-109. Fault code number is displayed
→ Go to item 5.
5 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. Er-1 (fault code display)

Fault code No. Er-1 (fault code display)

ECU (engine control unit) internal malfunction (output signal error):

Item signals cannot be transmitted between the ECU and the multi-func-
tion meter.
Able to start engine (unable when ECU is malfunctioning)
Fail-safe system
Able to drive vehicle (unable when ECU is malfunctioning)
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ON”.
coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of wire harness Improperly connected → Con- Turn the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 3.
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between ECU coupler and played → Service is finished.
Yamaha diagnostic tool coupler. Fault code number is displayed
Yellow/Blue–Yellow/Blue → Go to item 4.
Between Yamaha diagnostic
tool coupler and meter assem-
bly coupler.
Yellow/Blue–Yellow/Blue

8-51
FUEL INJECTION SYSTEM

Fault code No. Er-1 (fault code display)

ECU (engine control unit) internal malfunction (output signal error):
Item signals cannot be transmitted between the ECU and the multi-func-
tion meter.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. Er-2

Fault code No. Er-2
ECU (engine control unit) internal malfunction (output signal error):
Item
no signals are received from the ECU within the specified duration.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ON”.
coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of wire harness Improperly connected → Con- Turn the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 3.
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between ECU coupler and played → Service is finished.
Yamaha diagnostic tool coupler. Fault code number is displayed
Yellow/Blue–Yellow/Blue → Go to item 4.
Between Yamaha diagnostic
tool coupler and meter assem-
bly coupler.
Yellow/Blue–Yellow/Blue

8-52
FUEL INJECTION SYSTEM

Fault code No. Er-2

ECU (engine control unit) internal malfunction (output signal error):

Item
no signals are received from the ECU within the specified duration.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. Er-3

Fault code No. Er-3

ECU (engine control unit) internal malfunction (output signal error):

Item
data from the ECU cannot be received correctly.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ON”.
coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of wire harness Improperly connected → Con- Turn the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 3.
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between ECU coupler and played → Service is finished.
Yamaha diagnostic tool coupler. Fault code number is displayed
Yellow/Blue–Yellow/Blue → Go to item 4.
Between Yamaha diagnostic
tool coupler and meter assem-
bly coupler.
Yellow/Blue–Yellow/Blue

8-53
FUEL INJECTION SYSTEM

Fault code No. Er-3

ECU (engine control unit) internal malfunction (output signal error):

Item
data from the ECU cannot be received correctly.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

Fault code No. Er-4 (fault code display)

Fault code No. Er-4 (fault code display)

ECU (engine control unit) internal malfunction (input signal error):

Item
non-registered data has been received from the meter.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ON”.
coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins).
2 Connection of wire harness Improperly connected → Con- Turn the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played → Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and → Go to item 3.
check the pins (bent or broken
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”.
the wire harness. Fault code number is not dis-
Between ECU coupler and played → Service is finished.
Yamaha diagnostic tool coupler. Fault code number is displayed
Yellow/Blue–Yellow/Blue → Go to item 4.
Between Yamaha diagnostic
tool coupler and meter assem-
bly coupler.
Yellow/Blue–Yellow/Blue

8-54
FUEL INJECTION SYSTEM

Fault code No. Er-4 (fault code display)

ECU (engine control unit) internal malfunction (input signal error):

Item
non-registered data has been received from the meter.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”.
Fault code number is not dis-
played → Service is finished.
Fault code number is displayed
→ Go to item 5.
5 Malfunction in ECU. Replace the ECU.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-99.

8-55
FUEL INJECTION SYSTEM

8-56
EAS30513
EAS20081
A

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
B/W,B R R B R/L
CIRCUIT DIAGRAM

W W W W Y L/W
30
W W 13 W/R O O
2 9 R
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B G/R G/R
B/W 12 G/R B/L 22
15 L/W
B
R (B) B/L B/L
16
B
L/W L/W G R/L
23 24 P/W P/W
B B
FUEL PUMP SYSTEM

10 B
32
A L/W B Br/W Br/W B Gy/R
ON B 25 Gy/R Gy/R B
OFF B B/L Y L P/W Br/W B/L B/L (B) (B)
L/W 19 20 26 Y Y
(B)
R/B 3 L/W L L
R B
Br
R/B 4 L/Y P P G G
B L/B G/Y G/Y
R R 17 P G/Y Sb Gy
L/W B G L/B R/L 29
27 Gy Gy 33 G Ch
R/L 5 Sb Sb Ch Ch
R/B 11 14 L/Y (Gy) (B) (B)
L/Y L/Y (Gy)
6 R/L R
B L/Y
Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
Br/W (L) (L)
G R/L R/B B R/B
B 21
Y/L Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W
L
Br Br B/W

8-57
Br Br
Br Br
42 Br/W
41 Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
R/B G Br Dg Ch Y Br Y G Ch Y L Ch Dg
59 (Gy) 56 47
Ch Dg
R/L
57 48 49 50 51 R
B
55 B
54 Br/W

Ch Dg
60 58
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 W B G L
Br G Y B L 34
L L W
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
B Y W B Br Y
B Y/B (Br) (G) L B Y Y W
35
Br Y G
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM

3. Main fuse 1
5. Main fuse 2
10.Main switch
12.Battery
20.Fuel pump
29.ECU (Engine Control Unit)
52.Engine ground
53.Frame ground

8-58
FUEL PUMP SYSTEM

EAS30514

TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Footrest board assemblies
4. Fuel tank

1. Check the fuses. NG →

(Main 1 and main 2)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-99.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-99.

OK ↓
3. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-95.

OK ↓
4. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-3.

OK ↓
5. Check the entire fuel pump system NG →
wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-57.

OK ↓
Replace the ECU. Refer to “REPLAC-
ING THE ECU (engine control unit)”
on page 8-99.

8-59
FUEL PUMP SYSTEM

8-60
EAS30843
EAS20085
A

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
B/W,B R R B R/L
CIRCUIT DIAGRAM

W W W W Y L/W
30
W W 13 W/R O O
2 9 R
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B G/R G/R
B/W 12 G/R B/L 22
15 L/W
B
R (B) B/L B/L
16
B
L/W L/W G R/L
23 24 P/W P/W
10 B B 32
B A Br/W Br/W B Gy/R
L/W B B Gy/R Gy/R B
ON 25
OFF B B/L Y L P/W Br/W B/L B/L (B) (B)
L/W 19 20 26 Y Y
(B)
R/B 3 L/W L L
R B
Br
R/B 4 L/Y P P G G
B L/B G/Y G/Y
R R 17 P G/Y Sb Gy
L/W B G L/B R/L 29
27 Gy Gy 33 G Ch
R/L 5 Sb Sb Ch Ch
R/B 11 14 L/Y (Gy) (B) (B)
L/Y L/Y (Gy)
6 R/L R
B L/Y
Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
Br/W (L) (L)
G R/L R/B B R/B
B 21
Y/L Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
ABS (ANTI-LOCK BRAKE SYSTEM)

B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W
L
Br Br B/W

8-61
Br Br
Br Br
42 Br/W
41 Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
R/B G Br Dg Ch Y Br Y G Ch Y L Ch Dg
59 (Gy) 56 47
Ch Dg
R/L
57 48 49 50 51 R
B
55 B
54 Br/W

Ch Dg
60 58
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 W B G L
Br G Y B L 34
L L W
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
B Y W B Br Y
B Y/B (Br) (G) L B Y Y W
35
Br Y G
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
ABS (ANTI-LOCK BRAKE SYSTEM)
ABS (ANTI-LOCK BRAKE SYSTEM)

3. Main fuse 1
4. ABS solenoid fuse
6. Taillight fuse
7. Signaling system fuse
8. ABS control unit fuse
10.Main switch
11.ABS motor fuse
12.Battery
21.Yamaha diagnostic tool coupler
29.ECU (Engine Control Unit)
34.Front wheel sensor
35.Rear wheel sensor
36.Joint connector
37.ABS test coupler
38.ABS ECU
39.Rear brake light switch
40.Front brake light switch
47.Tail/brake light assembly
48.Brake light
52.Engine ground
53.Frame ground
59.Meter assembly
60.Multi-function meter
62.ABS warning light

8-62
ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30844

ABS COUPLER LOCATION CHART

R G L Br Y W W/L B/W

R/L Y Br/W L/R L/B B/W B

(B)

G L W B

Br Y W B

3
L/R L/B
R/B B
4

Ch Dg Y/B Y/B B W/L

Br R/B G Y/L B Y

(Gy)

8-63
ABS (ANTI-LOCK BRAKE SYSTEM)

1. ABS ECU coupler

2. Rear wheel sensor coupler
3. ABS test coupler
4. Meter assembly coupler
5. Front wheel sensor coupler

8-64
ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30845

MAINTENANCE OF THE ABS ECU

Checking the ABS ECU

1. Check:
• Terminals “1” of the 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

EAS30528

ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU (electronic control unit) has a self-diagnosis function. When failures occur in the system,
the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the
Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG-
NOSIS USING THE FAULT CODES” on page 8-69. For troubleshooting items other than the following
items, follow the normal service method.
EWA16710

WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-91.

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 “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 8-66.

8-65
ABS (ANTI-LOCK BRAKE SYSTEM)

Self-diagnosis and servicing

The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page 8-90.
By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause correctly
if another malfunction occurs.
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 front side, and if
the front brake lever or rear brake lever are even slightly applied, a vibration can be felt at the levers,
but these do not indicate a malfunction.
Self-diagnosis using 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 detect-
ed, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the
ABS ECU has entered the self-diagnosis mode.

Special precautions for handling and servicing a vehicle equipped with ABS
ECA18490

NOTICE
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction
occurs.)
EAS30529

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

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.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.

8-66
ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30530

BASIC PROCESS FOR TROUBLESHOOTING

[A] Turn the main switch to “ ON ”, Fails to • The ABS warning light (LED)
come on [A-1] Does only the ABS
and check the ABS warning Yes is defective.
warning light fail to Return to [A].
light. • The wire harness is grounded
come on?
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.
No
• The main switch is defective.
[A-2] Do all indicator lights Yes • The battery voltage is low. Return to [A].
fail to come on? • The taillight fuse is blown.
• The meter assembly circuit is
defective.

[A-3] The ABS warning light comes Cannot communicate • The connection with the Yamaha
on. diagnostic tool is defective. Return to [A].
Connect the Yamaha • The ABS control unit fuse is blown.
diagnostic tool, and then • The ABS ECU coupler is
execute functional diagnosis. disconnected.
Can the tool communicate with
the ABS ECU?
• The wire harness is defective.
• The hydraulic unit assembly
Can communicate is defective.
• The ABS solenoid fuse is blown.
Refer to “ Troubleshooting details
of fault code No. 31 ”.

[B-1] Check for ABS fault Yes [B-2] Diagnose by the fault [B-3] Delete the fault codes.
Return to [A].
codes in the screen for the code.
Yamaha diagnostic tool.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect.
• The brake hoses and brake
[C-1] Perform the final checks. No pipes are not connected
Were all of the final checks correctly. Return to [A].
completed normally? The ABS warning light does
not go off when the light is
Yes checked.
(Check that the ABS warning • The malfunction is not
light goes off during the ABS
corrected.
warning light check.)
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The meter assembly circuit
is defective.
• The ABS warning light circuit
in the hydraulic unit assembly
is defective.

Finished.

8-67
ABS (ANTI-LOCK BRAKE SYSTEM)

EWA16710

WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-91.

EAS30531

[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]
EAS30532

[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the White/Blue terminal of the ABS ECU coupler and
White/Blue 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.
EAS30964

[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-95.
• If there is no continuity, replace the main switch.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-99.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Taillight fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-99.
• If the taillight fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 8-61.
• If the meter assembly circuit is open, replace the wire harness.
EAS31162

[A-3] THE ABS WARNING LIGHT COMES ON

Connect the Yamaha diagnostic tool to the ABS test coupler and execute functional diagnosis. (For in-
formation about how to execute functional diagnosis, refer to the operation manual that is included with
the tool.)
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.)

8-68
ABS (ANTI-LOCK BRAKE SYSTEM)

EAS31163

[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE (The select unit screen does not appear.)
1. ABS control unit fuse
• Check the ABS control unit fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-99.
• If the ABS control unit fuse is blown, replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-63.
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 terminal of the main switch coupler and Brown/White terminal
of the ABS ECU coupler.
Check for continuity between Black/White terminal of the ABS ECU coupler and the ground, and be-
tween the Black terminal of the ABS ECU coupler and ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the ABS test coupler.
Check for continuity between Blue/Red terminal of the ABS ECU coupler and Blue/Red terminal of
the ABS test coupler. (CANH)
Check for continuity between Blue/Black terminal of the ABS ECU coupler and Blue/Black terminal
of the ABS test coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS31164

[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE (Cannot connect due to a tool error.)
1. Yamaha diagnostic tool
Check that the Yamaha diagnostic tool is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the ABS test coupler.
Check for continuity between Blue/Red terminal of the ABS ECU coupler and Blue/Red terminal of
the ABS test coupler. (CANH)
Check for continuity between Blue/Black terminal of the ABS ECU coupler and Blue/Black terminal
of the ABS test coupler. (CANL)
EAS31165

[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed
on the computer screen.
• A fault code is displayed. [B-2]
• A fault code is not displayed. [C-1]
EAS31166

[B-2] DIAGNOSIS USING THE FAULT CODES

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.

Yamaha diagnostic tool

90890-03231

Connecting the Yamaha diagnostic tool

Removing the battery cover. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.

8-69
ABS (ANTI-LOCK BRAKE SYSTEM)

Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.

Operation of the Yamaha diagnostic tool (Fault diagnosis mode)

Malfunction results are displayed in the top part of the window area.
3 4 5 6 7 8

2 Hydraulic unit assembly Detected Power is not supplied to the ABS motor.

1 Rear wheel sensor Recovered Rear wheel sensor circuit is open or short-circuited.

1. Recovered
The item list of the malfunction detected in the past (already recovered) are displayed.
2. Detected
The item list of the malfunction currently occurred are displayed.
3. Code
The following icons and the fault code numbers for the detected malfunctions are displayed.

8-70
ABS (ANTI-LOCK BRAKE SYSTEM)

A B

A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed.
(e.g., FI, ABS)
5. Item
The item names of the detected malfunction are displayed.
6. Condition
The current conditions are displayed. (Detected/Recovered)
7. Symptom
The symptoms of the detected malfunction are displayed.
8. Diagnosis code
The diagnosis codes related to the detected malfunction are displayed.

Fault code table

TIP
Record all of the fault codes displayed and inspect the check points.

Fault code No. Item Symptom Check point

11* Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
25* 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
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor

8-71
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. Item Symptom Check point

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
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
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
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
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
• Defective front wheel sen-
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
• Open or short circuit in the
wire harness between the
rear wheel sensor and the
hydraulic unit assembly
• Defective rear wheel sen-
sor or hydraulic unit as-
sembly
17* 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
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor

8-72
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. Item Symptom Check point

18* 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
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor
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.
24 Brake light switch or brake Brake light signal is not re- • Defective signaling system
light ceived properly while the ve- (brake light or brake light
hicle is traveling. (Brake light switch)
circuit, or front or rear brake • Defective coupler between
light switch circuit) the signaling system (brake
light or brake light switch)
and the hydraulic unit as-
sembly
• Open or short circuit in the
wire harness between the
signaling system (brake
light or brake light switch)
and the hydraulic unit as-
sembly
• Defective hydraulic unit as-
sembly
31 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS solenoid fuse
normal ABS solenoid power solenoid circuit in the hy- • Defective coupler between
supply) draulic unit assembly. the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS solenoid the solenoid power supply sembly
power supply circuit) circuit in the hydraulic unit
assembly.
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
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
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.

8-73
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. Item Symptom Check point

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
47 tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault
incorrect depressurization) mittently while the vehicle code No. 42)
is traveling. (for fault code • Incorrect rotation of the
No. 42) 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
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
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
44 Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
pulses) not received properly. (Miss- around the rear wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) rear wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective rear wheel sen-
sor or incorrect installation
of the sensor
51 • Vehicle system power sup- • Power voltage supplied to • Defective battery
52 ply (voltage of ABS ECU the ABS ECU in the hy- • Disconnected battery ter-
power supply is high) (for draulic unit assembly is too minal
fault code No. 51) high. (for fault code No. 51) • Defective charging system
• Vehicle system power sup- • Power voltage supplied to
ply (voltage of wheel sen- the wheel sensor is too
sor power supply is high) high. (for fault code No. 52)
(for fault code No. 52)

8-74
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. Item Symptom Check point

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
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
54 Hydraulic unit assembly (de- Abnormality is detected in • Defective battery
fective ABS solenoid and the solenoid or motor power • Defective coupler between
ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau-
cuits) unit assembly. lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
• Defective hydraulic unit as-
sembly
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 is detected in • Defective hydraulic unit as-
normal internal power sup- the power supply circuit in sembly
ply) the hydraulic unit assembly.
63 Front wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the front ness between the front
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
• Defective front wheel sen-
sor
• Defective hydraulic unit as-
sembly
64 Rear wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the rear ness between the rear
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
• Defective rear wheel sen-
sor
• Defective hydraulic unit as-
sembly

* The fault code number varies according to the vehicle conditions.

Fault code No. 11, 25

TIP
With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code
No. 11) or for longer than about 2 seconds (fault code No. 25).

8-75
ABS (ANTI-LOCK BRAKE SYSTEM)

11
Fault code No.
25

Item Front wheel sensor (intermittent pulses or no pulses)

Front wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-27.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.

Fault code No. 12

Fault code No. 12

Item Rear wheel sensor (intermittent pulses or no pulses)

Rear wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-34.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR ROTOR” on page 4-34.
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR ROTOR” on page 4-34.

Fault code No. 13, 26

TIP
• If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record-
ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re-
corded.

8-76
ABS (ANTI-LOCK BRAKE SYSTEM)

• Vehicle possibly ridden on uneven roads.

13
Fault code No.
26

Item Front wheel sensor (abnormal pulse period)

Front wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-27.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage. Re-
lation of the rotor place the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.

Fault code No. 14, 27

TIP
• If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record-
ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re-
corded.
• Vehicle possibly ridden on uneven roads.

14
Fault code No.
27

Item Rear wheel sensor (abnormal pulse period)

Rear wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-34.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR ROTOR” on page 4-34.

8-77
ABS (ANTI-LOCK BRAKE SYSTEM)

14
Fault code No.
27

Item Rear wheel sensor (abnormal pulse period)

Rear wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR ROTOR” on page 4-34.

Fault code No. 15

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 15

Item Front wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the front wheel sensor.

Order Item/components and probable cause Check or maintenance job

1 Defective coupler between the front wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.

8-78
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 15

Item Front wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the front wheel sensor.

Order Item/components and probable cause Check or maintenance job

2 Open or short circuit in the wire harness • Check for continuity between the Green terminal “1”
between the front wheel sensor and the and the Green terminal “4” and between the Blue ter-
hydraulic unit assembly minal “2” and the Blue terminal “5”.
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the Green
terminal “1” and the Blue terminal “2” and between the
Green terminal “4” and the Blue terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the
Black/White terminal “3” and the Green terminal “4”
and between the Black/White terminal “3” and the Blue
terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.

1 2 3
4 5
R G L Br Y W W/L B/W
G L W B
R/L Y Br/W L/R L/B B/W B

6
7

6. ABS ECU
7. Front wheel sensor
3 Defective front wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly 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 4-25 and “ABS (AN-
TI-LOCK BRAKE SYSTEM)” on page 4-61.

Fault code No. 16

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 16

Item Rear wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the rear wheel sensor.

Order Item/components and probable cause Check or maintenance job

1 Defective coupler between the rear wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.

8-79
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 16

Item Rear wheel sensor (open or short circuit)

Symptom Open or short circuit is detected in the rear wheel sensor.

Order Item/components and probable cause Check or maintenance job

2 Open or short circuit in the wire harness • Check for continuity between the Brown terminal “1”
between the rear wheel sensor and the and the Brown terminal “4” and between the Yellow
hydraulic unit assembly terminal “2” and the Yellow terminal “5”.
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the Brown
terminal “1” and the Yellow terminal “2” and between
the Brown terminal “4” and the Yellow terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the
Black/White terminal “3” and the Brown terminal “4”
and between the Black/White terminal “3” and the Yel-
low terminal “5”.
• If there is short circuit, the wire harness is defective.
Replace the wire harness.

1 2 3
4 5
R G L Br Y W W/L B/W
Br Y W B
R/L Y Br/W L/R L/B B/W B

6
7

6. ABS ECU
7. Rear wheel sensor
3 Defective rear wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly 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 4-61.

Fault code No. 17, 45

TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 45 will be recorded first and fault code No. 17 will be recorded if the condition continues.

8-80
ABS (ANTI-LOCK BRAKE SYSTEM)

17
Fault code No.
45

Item Front wheel sensor (missing pulses)

Front wheel sensor signal is not received properly. (Missing pulses

Symptom
are detected in the signal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-27.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.

Fault code No. 18, 46

TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 46 will be recorded first and fault code No. 18 will be recorded if the condition continues.

18
Fault code No.
46

Item Rear wheel sensor (missing pulses)

Rear wheel sensor signal is not received properly. (Missing pulses are
Symptom
detected in the signal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-34.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR ROTOR” on page 4-34.
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR ROTOR” on page 4-34.

8-81
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 21

Fault code No. 21

Item Hydraulic unit assembly (defective solenoid drive circuit)

Solenoid drive circuit in the hydraulic unit assembly is open or short-
Symptom
circuited.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 24

Fault code No. 24

Item Brake light switch or brake light

Brake light signal is not received properly while the vehicle is travel-
Symptom
ing (Brake light circuit, or front or rear brake light switch circuit).

Order Item/components and probable cause Check or maintenance job

1 Defective signaling system (brake light or Check the brake light switches.
brake light switch) Refer to “CHECKING THE SWITCHES” on page 8-95.
2 Defective coupler between the signaling • Check the coupler for any pins that may be pulled out.
system (brake light or brake light switch) • Check the locking condition of the coupler.
and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
3 Open or short circuit in the wire harness • Between front brake light switch connector and rear
between the signaling system (brake light brake light switch connector.
or brake light switch) and the hydraulic (Green/Yellow–Green/Yellow)
unit assembly • Between ABS ECU coupler and rear brake light switch
connector.
(Yellow–Yellow)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 31

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 31

Item Hydraulic unit assembly (abnormal ABS solenoid power supply)

Power is not supplied to the solenoid circuit in the hydraulic unit as-
Symptom
sembly.

Order Item/components and probable cause Check or maintenance job

1 Blown ABS solenoid fuse Check the ABS solenoid fuse. If the ABS solenoid fuse
is blown, replace the fuse and check the wire harness.
Refer to “CHECKING THE FUSES” on page 8-99.

8-82
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 31

Item Hydraulic unit assembly (abnormal ABS solenoid power supply)

Power is not supplied to the solenoid circuit in the hydraulic unit as-
Symptom
sembly.
Order Item/components and probable cause Check or maintenance job
2 Defective coupler between the battery • Check the locking condition of the coupler.
and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS solenoid fuse.
assembly (Red–Red)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 32

Fault code No. 32

Hydraulic unit assembly (short circuit in ABS solenoid power supply

Item
circuit)

Short circuit is detected in the solenoid power supply circuit in the hy-
Symptom
draulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 33

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 33

Item Hydraulic unit assembly (abnormal ABS motor power supply)

Power is not supplied to the motor circuit in the hydraulic unit assem-
Symptom
bly.

Order Item/components and probable cause Check or maintenance job

1 Blown ABS motor fuse Check the ABS motor fuse. If the ABS motor fuse is
blown, replace the fuse and check the wire harness.
Refer to “CHECKING THE FUSES” on page 8-99.
2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.

8-83
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 33

Item Hydraulic unit assembly (abnormal ABS motor power supply)

Power is not supplied to the motor circuit in the hydraulic unit assem-
Symptom
bly.
Order Item/components and probable cause Check or maintenance job
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS motor fuse.
assembly (Red/Blue–Red/Blue)
• Between ABS ECU coupler and ground.
(Black–Black)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 34

Fault code No. 34

Hydraulic unit assembly (short circuit in ABS motor power supply cir-
Item
cuit)

Short circuit is detected in the motor power supply circuit in the hy-
Symptom
draulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 41

Fault code No. 41

Front wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)

• Pulses from the front wheel sensor are received intermittently while
the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.
Order Item/components and probable cause Check or maintenance job
1 Incorrect installation of the front wheel Check the components for looseness, distortion, and
sensor bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-27.
2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel
and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” on page
4-27 and “CHECKING THE FRONT BRAKE DISC” on
page 4-42.

8-84
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 41

Front wheel ABS (intermittent wheel speed pulses or incorrect de-
Item
pressurization)

• Pulses from the front wheel sensor are received intermittently while
the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

Order Item/components and probable cause Check or maintenance job

3 Front brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake lever is operated
and that the pressure decreases when the lever is re-
leased.
Refer to “CHECKING THE FRONT BRAKE DISC” on
page 4-42.
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 42, 47

42
Fault code No.
47

Rear wheel ABS (intermittent wheel speed pulses or incorrect depres-

Item
surization)
• Pulses from the rear wheel sensor are received intermittently while
the vehicle is traveling. (for fault code No. 42)
Symptom • Rear wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

Order Item/components and probable cause Check or maintenance job

1 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
sensor (for fault code No. 42) bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-34.
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
4-34.
3 Rear brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake lever is operated
and that the pressure decreases when the lever is re-
leased.
Refer to “CHECKING THE REAR BRAKE DISC” on
page 4-55.
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

8-85
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 43

Fault code No. 43

Item Front wheel sensor (missing pulses)

Front wheel sensor signal is not received properly. (Missing pulses
Symptom
are detected in the signal while the vehicle is traveling.)

Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-27.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage. Re-
lation of the rotor place the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-28.

Fault code No. 44

Fault code No. 44

Item Rear wheel sensor (missing pulses)

Rear wheel sensor signal is not received properly. (Missing pulses are
Symptom
detected in the signal while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job
1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-34.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage. Re-
lation of the rotor place the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR ROTOR” on page 4-34.
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Refer to “MAINTENANCE OF THE REAR WHEEL
SENSOR ROTOR” on page 4-34.

8-86
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 51, 52

51
Fault code No.
52

• Vehicle system power supply (voltage of ABS ECU power supply is

high) (for fault code No. 51)
Item
• Vehicle system power supply (voltage of wheel sensor power supply
is high) (for fault code No. 52)

• Power voltage supplied to the ABS ECU in the hydraulic unit assem-
bly is too high. (for fault code No. 51)
Symptom
• Power voltage supplied to the wheel sensor is too high. (for fault
code No. 52)

Order Item/components and probable cause Check or maintenance job

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-99.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
Refer to “CIRCUIT DIAGRAM” on page 8-11.

Fault code No. 53

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Fault code No. 53

Vehicle system power supply (voltage of ABS ECU power supply is

Item
low)

Power voltage supplied to the ABS ECU in the hydraulic unit assem-
Symptom
bly is too low.

Order Item/components and probable cause Check or maintenance job

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-99.
2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS control unit fuse.
assembly (Brown/White–Brown/White)
4 Defective charging system Check the charging system.
Refer to “CIRCUIT DIAGRAM” on page 8-11.

Fault code No. 54

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

8-87
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 54

Hydraulic unit assembly (defective ABS solenoid and ABS motor
Item
power supply circuits)

Abnormality is detected in the solenoid or motor power supply circuit

Symptom
in the hydraulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-99.
2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS motor fuse.
assembly (Red/Blue–Red/Blue)
• Between ABS ECU coupler and ABS solenoid fuse.
(Red–Red)
4 Defective charging system Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-11.
5 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 55

Fault code No. 55

Item Hydraulic unit assembly (defective ABS ECU)

Symptom Abnormal data is detected in the hydraulic unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

Fault code No. 56

Fault code No. 56

Item Hydraulic unit assembly (abnormal internal power supply)

Abnormality is detected in the power supply circuit in the hydraulic
Symptom
unit assembly.

Order Item/components and probable cause Check or maintenance job

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

8-88
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 63

Fault code No. 63

Item Front wheel sensor power supply (voltage of power supply is low)
Power voltage supplied from the ABS ECU to the front wheel sensor is
Symptom
too low.

Order Item/components and probable cause Check or maintenance job

1 Short circuit in the wire harness between • Check that there is no short circuit between the Green
the front wheel sensor and the hydraulic terminal “1” and the Blue terminal “2”.
unit assembly • Check that there is no short circuit between the
Black/White terminal “3” and the Green terminal “1”.
• If there is a short circuit, the wire harness is defective.
Replace the wire harness.

3
1 2
R G L Br Y W W/L B/W
G L W B
R/L Y Br/W L/R L/B B/W B

4
5

4. ABS ECU
5. Front wheel sensor
2 Defective front wheel sensor • Check that there is no short circuit between the Black
terminal “1” and the White terminal “2”.
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.

2 1
R G L Br Y W W/L B/W
G L W B
R/L Y Br/W L/R L/B B/W B

3
4

3. ABS ECU
4. Front wheel sensor
3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

8-89
ABS (ANTI-LOCK BRAKE SYSTEM)

Fault code No. 64

Fault code No. 64

Item Rear wheel sensor power supply (voltage of power supply is low)
Power voltage supplied from the ABS ECU to the rear wheel sensor is
Symptom
too low.

Order Item/components and probable cause Check or maintenance job

1 Short circuit in the wire harness between • Check that there is no short circuit between the Yellow
the rear wheel sensor and the hydraulic terminal “1” and the Brown terminal “2”.
unit assembly • Check that there is no short circuit between the
Black/White terminal “3” and the Yellow terminal “1”.
• If there is a short circuit, the wire harness is defective.
Replace the wire harness.

3
2 1
R G L Br Y W W/L B/W
Br Y W B
R/L Y Br/W L/R L/B B/W B

4
5

4. ABS ECU
5. Rear wheel sensor
2 Defective rear wheel sensor • Check that there is no short circuit between the Black
terminal “1” and the White terminal “2”.
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.

2 1
R G L Br Y W W/L B/W
Br Y W B
R/L Y Br/W L/R L/B B/W B

3
4

3. ABS ECU
4. Rear wheel sensor
3 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-61.

EAS31167

[B-3] DELETING THE FAULT CODES

To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault
codes, refer to the operation manual of the Yamaha diagnostic tool.
Check that all the displayed fault codes are deleted.

Yamaha diagnostic tool

90890-03231

8-90
ABS (ANTI-LOCK BRAKE SYSTEM)

Connecting the Yamaha diagnostic tool

Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.

EAS31168

[C-1] FINAL CHECK

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 rear brake master cylinder
reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-10.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)” on page 4-30 and “INSTALL-
ING THE REAR WHEEL (REAR BRAKE DISC)” on page 4-34.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-65.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 8-90.
5. Checking the ABS warning light.
Check that the ABS warning light goes off.
If the ABS warning light does not come on or if it does not go off, refer to “CHECKING THE ABS
WARNING LIGHT” on page 4-68.
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 White/Blue terminal of the ABS ECU coupler and White/Blue terminal
of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.

8-91
ABS (ANTI-LOCK BRAKE SYSTEM)

8-92
ELECTRICAL COMPONENTS

EAS20089

ELECTRICAL COMPONENTS

3 4
2 5
6
7

8
1
9

32 10

11

31
27,28,29,30

12

13

14
26

25
15

17
24

16
18
22
23 21 19
20

8-93
ELECTRICAL COMPONENTS

1. Starter relay
2. Battery
3. ECU (Engine Control Unit)
4. Fuse box 1
5. Front brake light switch
6. Rear brake light switch
7. Fuse box 2
8. Main switch
9. Turn signal relay
10. Rectifier/regulator
11. ABS ECU
12. Horn
13. Diode
14. Ignition coil
15. Front wheel sensor
16. Fuel sender
17. Fuel pump
18. Sidestand switch
19. Spark plug
20. O2 sensor
21. Coolant temperature sensor
22. VVA (variable valve actuator) solenoid
23. AC magneto
24. Crankshaft position sensor
25. Rear wheel sensor
26. Starter motor
27. Throttle body sensor assembly
28. Intake air pressure sensor
29. Intake air temperature sensor
30. Throttle position sensor
31. ISC (Idle Speed Control) unit
32. Fuel injector

8-94
ELECTRICAL COMPONENTS

EAS30549

CHECKING THE SWITCHES

1 2
R Br
ON
OFF

3
8
Y L/B

7
P B

6
Ch Br/W Dg
Dg B
Br/W Ch
L/B P

4
L/W B
5 L/W
B
B
B
B

8-95
ELECTRICAL COMPONENTS

1. Rear brake light switch

2. Main switch
3. Front brake light switch
4. Start switch
5. Sidestand switch
6. Turn signal switch
7. Horn switch
8. Dimmer switch

8-96
ELECTRICAL COMPONENTS

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14371

NOTICE
Never insert the tester probes into the coupler terminal slots. Always insert the probes from the
opposite end “a” of the coupler, taking care not to loosen or damage the leads.

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.

The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red and brown when the switch is turned to “ON”.

R Br
ON
a
OFF

8-97
ELECTRICAL COMPONENTS

EAS30550

CHECKING THE BULBS AND BULB Pocket tester

SOCKETS 90890-03112
TIP Analog pocket tester
Do not check any of the lights that use LEDs. YU-03112-C

Check each bulb and bulb socket for damage or TIP

wear, proper connections, and also for continuity Before checking for continuity, set the pocket
between the terminals. tester to “0” and to the “Ω × 1” range.
Damage/wear → Repair or replace the bulb,
bulb socket or both. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Improperly connected → Properly connect. a. Connect the positive tester probe to terminal
No continuity → Repair or replace the bulb, bulb “1” and the negative tester probe to terminal
socket or both. “2”, and check the continuity.
b. Connect the positive tester probe to terminal
Types of bulbs “1” and the negative tester probe to terminal
The bulbs used on this vehicle are shown in the “3”, and check the continuity.
illustration. c. If either of the readings indicate no continuity,
• Bulbs “a” are used for turn signal and taillights replace the bulb.
and can be removed from the socket by push- ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ing and turning the bulb counterclockwise.
• Bulbs “b” are used for auxiliary lights and can
be removed from their respective sockets by
carefully pulling them out.

Checking the condition of the bulb sockets

The following procedure applies to all of the bulb
sockets.
1. Check:
Checking the condition of the bulbs • Bulb socket (for continuity)
The following procedure applies to all of the (with the pocket tester)
bulbs. No continuity → Replace.
1. Remove:
• Bulb Pocket tester
ECA22810 90890-03112
NOTICE Analog pocket tester
YU-03112-C
Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
TIP
wise it may be pulled out of the terminal in
the coupler. Check each bulb socket for continuity in the
same manner as described in the bulb section;
2. Check: however, note the following.
• Bulb (for continuity)
(with the pocket tester) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
No continuity → Replace.
b. Connect the pocket tester probes to the re-
spective leads of the bulb socket.

8-98
ELECTRICAL COMPONENTS

c. Check the bulb socket for continuity. If any of Amperage

the readings indicate no continuity, replace Fuses Q’ty
rating
the bulb socket.
ABS control unit 7.5 A 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Spare 30 A 1
EAS30551

CHECKING THE FUSES Spare 15 A 1

The following procedure applies to all of the fus- Spare 7.5 A 1
es. EWA13310
ECA20520

NOTICE WARNING
To avoid a short circuit, always turn the main Never use a fuse with an amperage rating
switch to “OFF” when checking or replacing other than that specified. Improvising or us-
a fuse. ing a fuse with the wrong amperage rating
may cause extensive damage to the electri-
1. Remove: cal system, cause the lighting and ignition
• Battery cover systems to malfunction and could possibly
Refer to “GENERAL CHASSIS (1)” on page cause a fire.
4-1.
2. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuse 4. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Battery cover
a. Connect the pocket tester to the fuse and Refer to “GENERAL CHASSIS (1)” on page
check the continuity. 4-1.
TIP
EAS31006
Set the pocket tester selector to “Ω × 1”. REPLACING THE ECU (engine control unit)
1. Turn the main switch to “OFF”.
Pocket tester 2. Replace the ECU (engine control unit).
90890-03112 3. Clean the throttle body.
Analog pocket tester Refer to “CLEANING THE ISC (IDLE SPEED
YU-03112-C CONTROL) UNIT AND THROTTLE BODY”
on page 7-12.
b. If the pocket tester indicates “∞”, replace the 4. Check:
fuse. • Engine idling speed
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Start the engine, warm it up, and then mea-
3. Replace: sure the engine idling speed.
• Blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Engine idling speed
a. Turn the main switch to “OFF”. 1500–1700 r/min
b. Install a new fuse of the correct amperage
rating. EAS30552

c. Set on the switches to verify if the electrical CHECKING AND CHARGING THE BATTERY
EWA13290
circuit is operational. WARNING
d. If the fuse immediately blows again, check
Batteries generate explosive hydrogen gas
the electrical circuit.
and contain electrolyte which is made of poi-
Amperage sonous and highly caustic sulfuric acid.
Fuses Q’ty
rating Therefore, always follow these preventive
ABS motor 30 A 1 measures:
Main 1 15 A 1 • Wear protective eye gear when handling or
working near batteries.
ABS solenoid 15 A 1
• Charge batteries in a well-ventilated area.
Main 2 7.5 A 1 • Keep batteries away from fire, sparks or
Taillight 7.5 A 1 open flames (e.g., welding equipment,
Signaling system 7.5 A 1 lighted cigarettes).

8-99
ELECTRICAL COMPONENTS

• DO NOT SMOKE when charging or han- ECA13640

dling batteries. NOTICE

• KEEP BATTERIES AND ELECTROLYTE First, disconnect the negative battery lead
OUT OF REACH OF CHILDREN. “1”, and then positive battery lead “2”.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury. 2
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL 1
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or 3. Remove:
vegetable oil. Get immediate medical atten- • Battery
tion. 4. Check:
ECA20530 • Battery charge
NOTICE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• This is a VRLA (Valve Regulated Lead Acid) a. Connect a pocket tester to the battery termi-
battery. Never remove the sealing caps be- nals.
cause the balance between cells will not be • Positive tester probe →
maintained and battery performance will positive battery terminal
deteriorate. • Negative tester probe →
negative battery terminal
• Charging time, charging amperage and
charging voltage for a VRLA (Valve Regu- TIP
lated Lead Acid) battery are different from
• The charge state of an VRLA (Valve Regulated
those of conventional batteries. The VRLA
Lead Acid) battery can be checked by measur-
(Valve Regulated Lead Acid) battery should
ing its open-circuit voltage (i.e., the voltage
be charged according to the appropriate
when the positive battery terminal is discon-
charging method. If the battery is over-
nected).
charged, the electrolyte level will drop con-
• No charging is necessary when the open-cir-
siderably. Therefore, take special care
cuit voltage equals or exceeds 12.8 V.
when charging the battery.
b. Check the charge of the battery, as shown in
TIP the charts and the following example.
Since VRLA (Valve Regulated Lead Acid) bat- Example
teries are sealed, it is not possible to check the Open-circuit voltage = 12.0 V
charge state of the battery by measuring the Charging time = 6.5 hours
specific gravity of the electrolyte. Therefore, the Charge of the battery = 20–30%
charge of the battery has to be checked by mea-
suring the voltage at the battery terminals.
1. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
2. Disconnect:
• Battery leads
(from the battery terminals)

A. Open-circuit voltage (V)

B. Charging time (hours)

8-100
ELECTRICAL COMPONENTS

C. Relationship between the open-circuit voltage • If the battery becomes hot to the touch at
and the charging time at 20 °C (68 °F) any time during the charging process, dis-
D. These values vary with the temperature, the connect the battery charger and let the bat-
condition of the battery plates, and the tery cool before reconnecting it. Hot
electrolyte level. batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.

A. Open-circuit voltage (V)

B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
(refer to the appropriate charging method)
EWA13300
A. Open-circuit voltage (V)
WARNING B. Time (minutes)
C. Charging
Do not quick charge a battery.
D. Ambient temperature 20 °C (68 °F)
ECA13671
E. Check the open-circuit voltage.
NOTICE
• Do not use a high-rate battery charger ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
since it forces a high-amperage current Charging method using a variable-current
into the battery quickly and can cause bat- (voltage) charger
tery overheating and battery plate damage. a. Measure the open-circuit voltage prior to
• If it is impossible to regulate the charging charging.
current on the battery charger, be careful TIP
not to overcharge the battery. Voltage should be measured 30 minutes after
• When charging a battery, be sure to remove the engine is stopped.
it from the vehicle. (If charging has to be
done with the battery mounted on the vehi- b. Connect a charger and ammeter to the bat-
cle, disconnect the negative battery lead tery and start charging.
from the battery terminal.) TIP
• To reduce the chance of sparks, do not Set the charging voltage to 16–17 V. If the set-
plug in the battery charger until the battery ting is lower, charging will be insufficient. If too
charger leads are connected to the battery. high, the battery will be over-charged.
• Before removing the battery charger lead
clips from the battery terminals, be sure to c. Make sure that the current is higher than the
turn off the battery charger. standard charging current written on the bat-
• Make sure the battery charger lead clips are tery.
in full contact with the battery terminal and TIP
that they are not shorted. A corroded bat- If the current is lower than the standard charging
tery charger lead clip may generate heat in current written on the battery, set the charging
the contact area and a weak clip spring may voltage adjust dial at 20–24 V and monitor the
cause sparks. amperage for 3–5 minutes to check the battery.

8-101
ELECTRICAL COMPONENTS

• Standard charging current is reached 12.8 V or more --- Charging is complete.

Battery is good. 12.7 V or less --- Recharging is required.
• Standard charging current is not reached Under 12.0 V --- Replace the battery.
Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Adjust the voltage so that the current is at the 6. Install:
standard charging level. • Battery
e. Set the time according to the charging time 7. Connect:
suitable for the open-circuit voltage. • Battery leads
f. If charging requires more than 5 hours, it is (to the battery terminals)
advisable to check the charging current after ECA13630

a lapse of 5 hours. If there is any change in NOTICE

the amperage, readjust the voltage to obtain First, connect the positive battery lead “1”,
the standard charging current. and then the negative battery lead “2”.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes. 1
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2
Charging method using a constant volt-
age charger
a. Measure the open-circuit voltage prior to 8. Check:
charging. • Battery terminals
Dirt → Clean with a wire brush.
TIP
Loose connection → Connect properly.
Voltage should be measured 30 minutes after 9. Lubricate:
the engine is stopped. • Battery terminals
b. Connect a charger and ammeter to the bat-
tery and start charging. Recommended lubricant
Dielectric grease
c. Make sure that the current is higher than the
standard charging current written on the bat- 10.Install:
tery. • Battery cover
TIP Refer to “GENERAL CHASSIS (1)” on page
If the current is lower than the standard charging 4-1.
current written on the battery, this type of battery
EAS30553
charger cannot charge the VRLA (Valve Regu- CHECKING THE RELAYS
lated Lead Acid) battery. A variable voltage Check each switch for continuity with the pocket
charger is recommended. tester. If the continuity reading is incorrect, re-
d. Charge the battery until the battery’s charg- place the relay.
ing voltage is 15 V.
Pocket tester
TIP
90890-03112
Set the charging time at 20 hours (maximum). Analog pocket tester
e. Measure the battery open-circuit voltage after YU-03112-C
leaving the battery unused for more than 30
1. Disconnect the relay from the wire harness.
minutes.
2. Connect the pocket tester (Ω × 1) and battery
(12 V) to the relay terminals as shown.
Check the relay operation.
Out of specification → Replace.

8-102
E L E C T R IC A L C O M P O N E N T S

Starter relay b. Turn the main switch to “ON”.

c. Measure the turn signal relay input voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 3
2. Check:
• Turn signal relay output voltage
R B Out of specification → Replace.
Y L/W

Turn signal relay output voltage

2 1 DC 12V

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
1. Positive battery terminal
turn signal relay terminal as shown.
2. Negative battery terminal
3. Positive tester probe Pocket tester
4. Negative tester probe 90890-03112
Analog pocket tester
Result YU-03112-C
Continuity
(between “3” and “4”) • Positive tester probe
Brown/White “1”
EAS30554
• Negative tester probe
CHECKING THE TURN SIGNAL RELAY Ground
1. Check:
• Turn signal relay input voltage
Out of specification → The wiring circuit from 1
the main switch to the turn signal relay cou-
pler is faulty and replace the wire harness. Br/W
Turn signal relay input voltage Br
DC 12V

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal relay terminal as shown. b. Turn the main switch to “ON”.
c. Measure the turn signal relay output voltage.
Pocket tester
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-03112
Analog pocket tester EAS30555

YU-03112-C CHECKING THE DIODE

1. Check:
• Positive tester probe
• Diode
Brown “1” Out of specification → Replace.
• Negative tester probe
Ground Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

1 TIP
Br/W The pocket tester and the analog pocket tester
readings are shown in the following table.
Br

8-103
ELECTRICAL COMPONENTS

Continuity
Positive tester probe →
Blue/Yellow “1”
Negative tester probe →
Blue/White “2”
No continuity
Positive tester probe →
Blue/White “2”
Negative tester probe →
Blue/Yellow “1”
c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30558
1
CHECKING THE IGNITION COIL
L/Y
1. Check:
• Primary coil resistance
L/W Out of specification → Replace.

Primary coil resistance

2 2.16–2.64 Ω

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the diode from the wire harness. a. Disconnect the ignition coil connectors from
b. Connect the pocket tester (Ω × 1) to the diode the ignition coil terminals.
terminals. b. Connect the pocket tester (Ω × 1) to the igni-
c. Check the diode for continuity. tion coil as shown.
d. Check the diode for no continuity.
Pocket tester
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 90890-03112
EAS30557 Analog pocket tester
CHECKING THE SPARK PLUG CAP YU-03112-C
1. Check:
• Spark plug cap resistance • Positive tester probe →
Out of specification → Replace. Red/Blue “1”
• Negative tester probe →
Resistance Orange “2”
3.75–6.25 kΩ

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug lead.
b. Connect the pocket tester (Ω × 1k) to the 2
spark plug cap as shown.

Pocket tester
90890-03112
Analog pocket tester 1
YU-03112-C
c. Measure the primary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Secondary coil resistance
Out of specification → Replace.

Secondary coil resistance

8.64–12.96 kΩ

8-104
ELECTRICAL COMPONENTS

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

• Positive tester probe →

Red/Blue “1”
• Negative tester probe → 2. Ignition coil
High tension cord “2”
c. Turn the main switch to “ON”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the “ ” of the
1 start switch and gradually increase the spark
gap until a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30560

CHECKING THE CRANKSHAFT POSITION

SENSOR
2 1. Disconnect:
• Crankshaft position sensor coupler
b. Measure the secondary coil resistance. (from the wire harness)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check:
EAS30556 • Crankshaft position sensor resistance
CHECKING THE IGNITION SPARK GAP Out of specification → Replace the crank-
1. Check: shaft position sensor/stator assembly.
• Ignition spark gap
Out of specification → Perform the ignition Crankshaft position sensor resis-
system troubleshooting, starting with step 5. tance
Refer to “TROUBLESHOOTING” on page 228–342 Ω
8-3.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
Minimum ignition spark gap
6.0 mm (0.24 in) crankshaft position sensor coupler as shown.

Pocket tester
TIP 90890-03112
If the ignition spark gap is within specification, Analog pocket tester
the ignition system circuit is operating normally. YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the spark • Positive tester probe →
plug. White/Red “1”
• Negative tester probe →
b. Connect the ignition checker “1” as shown. White/Blue “2”
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487

8-105
ELECTRICAL COMPONENTS

2. Check:
• Stator coil resistance
2 Out of specification → Replace the stator coil.
W/L Stator coil resistance
0.500–0.740 Ω
W/R
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Connect the digital circuit tester to the stator
coil coupler as shown.

b. Measure the crankshaft position sensor re- Digital circuit tester

sistance. 90890-03174
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Model 88 Multimeter with ta-
EAS30562
chometer
CHECKING THE STARTER MOTOR YU-A1927
OPERATION
1. Check: • Positive tester probe →
White “1”
• Starter motor operation • Negative tester probe →
Does not operate → Perform the electric White “2”
starting system troubleshooting, starting with
step 4.
Refer to “TROUBLESHOOTING” on page
8-8. 1
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a. Connect the positive battery terminal “1” and W
starter motor lead “2” with a jumper lead “3”. W
EWA13810

WARNING 2
• A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may b. Measure the stator coil resistance.
burn.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• This check is likely to produce sparks,
EAS30680
therefore, make sure no flammable gas or CHECKING THE RECTIFIER/REGULATOR
fluid is in the vicinity. 1. Check:
• Charging voltage
Out of specification → Replace the rectifi-
er/regulator.

Charging voltage
14 V at 5000 r/min

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a. Connect the engine tachometer to the spark
plug lead.
b. Connect the pocket tester (DC 20 V) to the
b. Check the starter motor operation. battery terminals as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30566
Pocket tester
CHECKING THE STATOR COIL 90890-03112
1. Disconnect: Analog pocket tester
• Stator coil coupler YU-03112-C
(from the wire harness)

8-106
ELECTRICAL COMPONENTS

• Positive tester probe →

positive battery terminal “1”
• Negative tester probe → 2
negative battery terminal “2”

R/L B
L/B G
1
1

b. Move the fuel sender float to minimum “3”

and maximum “4” level position.
2
4
c. Start the engine and let it run at approximate-
ly 5000 r/min.
d. Measure the charging voltage. 3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30573

CHECKING THE FUEL SENDER

1. Remove:
• Fuel pump c. Measure the fuel sender resistance.
(from the fuel tank) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
EAS31557
• Fuel sender resistance CHECKING THE FUEL METER/FUEL LEVEL
Out of specification → Replace the fuel pump WARNING INDICATOR
assembly. This model is equipped with a self-diagnosis de-
vice for the fuel level detection circuit.
Fuel sender
Sender unit resistance (full) 1. Check:
10.0–14.0 Ω • Fuel meter “1”
Sender unit resistance (empty) • Fuel level warning indicator “2”
267.0–273.0 Ω (Turn the main switch to “ON”.)
Warning light comes on for a few seconds,
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ then goes off → Warning light is OK.
a. Connect the pocket tester (Ω × 10/× 100) to Warning light does not come on → Replace
the fuel sender terminals as shown. the meter assembly.
Warning light flashes eight times, then goes
Pocket tester
off for 3 seconds in a repeated cycle (mal-
90890-03112
Analog pocket tester function detected in fuel sender) → Replace
YU-03112-C the fuel pump assembly.
1 2
• Positive tester probe →
Green “1”
• Negative tester probe →
Black “2”

8-107
ELECTRICAL COMPONENTS

EAS30578

CHECKING THE COOLANT TEMPERATURE

SENSOR
1. Remove:
• Coolant temperature sensor
Refer to “CYLINDER HEAD” on page 5-9.
EWA14130

WARNING
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature sen-
sor to strong shocks. If the coolant temper-
ature sensor is dropped, replace it.
2. Check:
• Coolant temperature sensor resistance
Out of specification → Replace.

Coolant temperature sensor re-

sistance
2510–2770 Ω at 20 °C (2510–
2770 Ω at 68 °F)
Coolant temperature sensor re-
sistance d. Heat the coolant or let it cool down to the
210–221 Ω at 100 °C (210–221 Ω specified temperatures.
at 212 °F) e. Measure the coolant temperature sensor re-
sistance.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Connect the pocket tester (Ω × 100/× 1 kΩ) to
3. Install:
the coolant temperature sensor terminals as
• Coolant temperature sensor
shown.
Coolant temperature sensor
Pocket tester
15 Nm (1.5 m·kgf, 11 ft·lbf)
T.

90890-03112
R.

Analog pocket tester

EAS30681
YU-03112-C CHECKING THE FUEL INJECTOR
1. Check:
b. Immerse the coolant temperature sensor “1”
• Fuel injector resistance
in a container filled with coolant “2”.
Out of specification → Replace the fuel injec-
TIP tor.
Make sure that the coolant temperature sensor
terminals do not get wet. Resistance
12.0 Ω at 20 °C (12.0 Ω at 68 °F)
c. Place a thermometer “3” in the coolant.
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a. Disconnect the fuel injector coupler from fuel
injector.
b. Connect the pocket tester (Ω × 10) to the fuel
injector terminals as shown.

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

8-108
ELECTRICAL COMPONENTS

• Positive tester probe

Injector terminal “1”
• Negative tester probe
Injector terminal “2”

2 1

c. Measure the fuel injector resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31612

CHECKING THE VVA SOLENOID

1. Check:
• VVA solenoid resistance
Out of specification → Replace.

Resistance
1.8–2.2 Ω at 20 °C (12.0 Ω at 68
°F)

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a. Disconnect the VVA solenoid coupler from
the VVA solenoid.
b. Connect the digital circuit tester to the VVA
solenoid terminal as shown.

Digital circuit tester

90890-03174
Model 88 Multimeter with ta-
chometer
YU-A1927

• Positive tester probe

Solenoid terminal “1”
• Negative tester probe
Solenoid terminal “2”

1 2

c. Measure the VVA solenoid resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

8-109
TROUBLESHOOTING

TROUBLESHOOTING..................................................................................... 9-1
GENERAL INFORMATION ....................................................................... 9-1
STARTING FAILURE/HARD STARTING .................................................. 9-1
INCORRECT ENGINE IDLING SPEED .................................................... 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................... 9-2
FAULTY CLUTCH ..................................................................................... 9-2
OVERHEATING ........................................................................................ 9-2
OVERCOOLING ........................................................................................ 9-3
POOR BRAKING PERFORMANCE .......................................................... 9-3
FAULTY FRONT FORK LEGS .................................................................. 9-3
UNSTABLE HANDLING ............................................................................ 9-3
FAULTY LIGHTING OR SIGNALING SYSTEM ........................................ 9-3

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE............ 9-5

SELF-DIAGNOSTIC FUNCTION TABLE .................................................. 9-5
COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC
TOOL ........................................................................................................ 9-5
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ............................. 9-6
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ........................ 9-7

EVENT CODE TABLE..................................................................................... 9-9

9
TROUBLESHOOTING

EAS20090
Electrical system
TROUBLESHOOTING 1. Battery
EAS30599
• Discharged battery
GENERAL INFORMATION • Faulty battery
TIP 2. Fuse(s)
• Blown, damaged or incorrect fuse
The following guide for troubleshooting does not
• Improperly installed fuse
cover all the possible causes of trouble. It should
3. Spark plug
be helpful, however, as a guide to basic trouble-
• Incorrect spark plug gap
shooting. Refer to the relative procedure in this
• Incorrect spark plug heat range
manual for checks, adjustments, and replace-
• Fouled spark plug
ment of parts.
• Worn or damaged electrode
EAS31258
• Worn or damaged insulator
STARTING FAILURE/HARD STARTING • Faulty spark plug cap
4. Ignition coil
Engine • Cracked or broken ignition coil body
1. Cylinder and cylinder head • Broken or shorted primary or secondary coils
• Loose spark plug • Faulty spark plug lead
• Loose cylinder head or cylinder 5. Ignition system
• Damaged cylinder head gasket • Faulty ECU
• Damaged cylinder gasket • Faulty crankshaft position sensor
• Worn or damaged cylinder • Broken AC magneto rotor woodruff key
• Incorrect valve clearance 6. Switches and wiring
• Improperly sealed valve • Faulty main switch
• Incorrect valve-to-valve-seat contact • Broken or shorted wiring
• Incorrect valve timing • Faulty front, rear or both brake light switches
• Faulty valve spring • Faulty start switch
• Seized valve • Faulty sidestand switch
2. Piston and piston ring(s) • Improperly grounded circuit
• Improperly installed piston ring • Loose connections
• Damaged, worn or fatigued piston ring 7. Starting system
• Seized piston ring • Faulty starter motor
• Seized or damaged piston • Faulty starter relay
3. Air filter • Faulty starter clutch
• Improperly installed air filter EAS30601
• Clogged air filter element INCORRECT ENGINE IDLING SPEED
4. Crankcase and crankshaft
• Improperly assembled crankcase Engine
• Seized crankshaft 1. Cylinder and cylinder head
• Incorrect valve clearance
Fuel system • Damaged valve train components
1. Fuel tank 2. Air filter
• Empty fuel tank • Clogged air filter element
• Clogged fuel tank cap breather hole
• Deteriorated or contaminated fuel Fuel system
• Clogged or damaged fuel hose 1. Throttle body
2. Fuel pump • Damaged or loose throttle body joint
• Faulty fuel pump • Faulty ISC (idle speed control) unit
• Clogged fuel pump filter • Improper throttle grip free play
3. Throttle body
• Deteriorated or contaminated fuel Electrical system
• Sucked-in air 1. Battery
• Discharged battery

9-1
TROUBLESHOOTING

• Faulty battery Poor starting performance

2. Spark plug 1. V-belt
• Incorrect spark plug gap • Slipping V-belt
• Incorrect spark plug heat range • Oil or grease on the V-belt
• Fouled spark plug 2. Primary sliding sheave
• Worn or damaged electrode • Faulty operation
• Worn or damaged insulator 3. Clutch shoe(s)
• Faulty spark plug cap • Bent, damaged or worn clutch shoe
3. Ignition coil
• Broken or shorted primary or secondary coil Poor speed performance
• Faulty spark plug lead 1. V-belt
4. Ignition system • Slipping V-belt
• Faulty ECU • Oil or grease on the V-belt
• Faulty crankshaft position sensor 2. Primary sheave weight(s)
• Faulty operation
EAS30602

POOR MEDIUM-AND-HIGH-SPEED • Worn primary sheave weight

PERFORMANCE 3. Primary fixed sheave
Refer to “STARTING FAILURE/HARD START- • Worn primary fixed sheave
ING” on page 9-1. 4. Primary sliding sheave
• Worn primary sliding sheave
Engine 5. Secondary fixed sheave
1. Air filter • Worn secondary fixed sheave
• Clogged air filter element 6. Secondary sliding sheave
• Worn secondary sliding sheave
Fuel system EAS30607

1. Throttle body OVERHEATING

• Faulty throttle body
2. Fuel pump Engine
• Faulty fuel pump 1. Clogged coolant passages
2. Cylinder head and piston
EAS30849

FAULTY CLUTCH • Heavy carbon buildup

3. Engine oil
Engine operates but vehicle will not move • Incorrect oil level
1. V-belt • Incorrect oil viscosity
• Bent, damaged or worn V-belt • Inferior oil quality
• Slipping V-belt
2. Primary sheave cam and primary sheave Cooling system
slider(s) 1. Coolant
• Damaged or worn primary sheave cam • Low coolant level
• Damaged or worn primary sheave slider 2. Radiator
3. Clutch spring • Damaged or leaking radiator
• Damaged clutch spring • Faulty radiator cap
4. Transmission gear(s) • Bent or damaged radiator fin
• Damaged transmission gear 3. Water pump
• Damaged or faulty water pump
Clutch slips 4. Thermostat
1. Clutch shoe spring(s) • Thermostat stays closed
• Damaged, loose or worn clutch shoe spring 5. Hose(s) and pipe(s)
2. Clutch shoe(s) • Damaged hose
• Damaged or worn clutch shoe • Improperly connected hose
3. Primary sliding sheave • Damaged pipe
• Seized primary sliding sheave • Improperly connected pipe

9-2
TROUBLESHOOTING

Fuel system • Incorrect oil viscosity

1. Throttle body • Incorrect oil level
• Damaged or loose throttle body joint
EAS30611
2. Air filter UNSTABLE HANDLING
• Clogged air filter element 1. Handlebar
• Bent or improperly installed handlebar
Chassis 2. Steering head components
1. Brake(s) • Improperly installed lower bracket
• Dragging brake (improperly tightened ring nut)
• Damaged ball bearing or bearing race
Electrical system
3. Front fork leg(s)
1. Spark plug
• Uneven oil levels (both front fork legs)
• Incorrect spark plug gap
• Unevenly tensioned fork spring (both front
• Incorrect spark plug heat range
fork legs)
2. Ignition system
• Broken fork spring
• Faulty ECU
• Bent or damaged inner tube
EAS30608 • Bent or damaged outer tube
OVERCOOLING 4. Swingarm
• Worn bearing or bushing
Cooling system • Bent or damaged swingarm
1. Thermostat 5. Rear shock absorber assembly(-ies)
• Thermostat stays open • Faulty rear shock absorber spring
EAS30609
• Leaking oil
POOR BRAKING PERFORMANCE 6. Tire(s)
• Worn brake pad • Uneven tire pressures (front and rear)
• Worn brake disc • Incorrect tire pressure
• Air in hydraulic brake system • Uneven tire wear
• Leaking brake fluid 7. Wheel(s)
• Faulty brake caliper kit • Incorrect wheel balance
• Faulty brake caliper seal • Deformed cast wheel
• Loose union bolt • Damaged wheel bearing
• Damaged brake hose • Bent or loose wheel axle
• Oil or grease on the brake disc • Excessive wheel runout
• Oil or grease on the brake pad 8. Frame
• Incorrect brake fluid level • Bent frame
• Damaged steering head pipe
EAS30610

FAULTY FRONT FORK LEGS • Improperly installed bearing race

EAS30612

Leaking oil FAULTY LIGHTING OR SIGNALING SYSTEM

• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube Headlight does not come on
• Improperly installed oil seal • Faulty headlight unit
• Damaged oil seal lip • Too many electrical accessories
• Incorrect oil level (high) • Hard charging
• Loose damper rod bolt • Incorrect connection
• Damaged damper rod bolt copper washer • Improperly grounded circuit
• Cracked or damaged front fork cap O-ring • Poor contacts (main switch)

Malfunction Tail/brake light does not come on

• Bent or damaged inner tube • Wrong tail/brake light LED
• Bent or damaged outer tube • Too many electrical accessories
• Damaged fork spring • Incorrect connection
• Bent or damaged damper rod

9-3
TROUBLESHOOTING

Turn signal does not come on

• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal light bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
• Blown, damaged or incorrect fuse

Turn signal blinks slowly

• Faulty turn signal relay
• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal light bulb

Turn signal remains lit

• Faulty turn signal relay
• Burnt-out turn signal light bulb

Turn signal blinks quickly

• Incorrect turn signal light bulb
• Faulty turn signal relay
• Burnt-out turn signal light bulb

Horn does not sound

• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Blown, damaged or incorrect fuse
• Faulty wire harness

9-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS20116

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS31118

SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-27.

Fault code No. Item

Crankshaft position sensor: no normal signals are received from the crankshaft position
12
sensor.
13 Intake air pressure sensor: open or short circuit detected.
14 Intake air pressure sensor: system malfunction (clogged hole or detached).
15 Throttle position sensor: open or short circuit detected.
16 Throttle position sensor: stuck throttle position sensor is detected.
Sidestand switch: a break or disconnection of the Blue/Yellow lead of the ECU is detect-
19
ed.
21 Coolant temperature sensor: open or short circuit detected.
22 Intake air temperature sensor: open or short circuit detected.
24 O2 sensor: no normal signals are received from the O2 sensor.
Component other than ISC (idle speed control) unit is defective (ISC operating sound is
37 heard).
Defective ISC (idle speed control) unit (ISC operating sound is not heard).
39 Fuel injector: open or short circuit detected.
42 Front wheel sensor: no normal signals are received from the front wheel sensor.
44 EEPROM fault code number: an error is detected while reading or writing on EEPROM.
46 Charging voltage is abnormal.
Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code num-
50
ber might not appear on the tool display.)
61 ISC (idle speed control) unit: open or short circuit detected.
84 VVA (variable valve actuator) solenoid: open or short circuit detected.

EAS31259

COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-27.

Fault code No. Item

Er-1 (fault code ECU (engine control unit) internal malfunction (output signal error): signals cannot be
display) transmitted between the ECU and the multi-function meter.
Waiting for con-
ECU (engine control unit) internal malfunction (output signal error): Signals cannot be
nection (Yamaha
transmitted between the ECU and Yamaha diagnostic tool.
diagnostic tool)
ECU (engine control unit) internal malfunction (output signal error): no signals are re-
Er-2
ceived from the ECU within the specified duration.
ECU (engine control unit) internal malfunction (output signal error): data from the ECU
Er-3
cannot be received correctly.
Er-4 (fault code ECU (engine control unit) internal malfunction (input signal error): non-registered data
display) has been received from the meter.

9-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code No. Item

Er-4 (Yamaha di- ECU (engine control unit) internal malfunction (input signal error): no normal signals are
agnostic tool) received from the Yamaha diagnostic tool.
EAS31120

DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor sig-
nal
• Fully closed position 13–21 Check with throttle valve fully
closed.
• Fully open position 92–102 Check with throttle valve fully
open.
03 Intake air pressure Displays the intake air pres- Operate the throttle while
sure. pulling the brake lever and
pushing the start switch “ ”.
(If the display value changes,
the performance is OK.)
05 Intake air temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured air temperature with
air temperature the computer display value.
When engine is hot: Air tem-
perature + approx. 20 °C (68
°F)
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
air temperature. with the computer display
When engine is hot: Displays value.
current coolant temperature.
07 Front wheel speed pulse Front wheel speed pulse Check that the number in-
0–999 creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
09 Fuel system voltage Approximately 12.0 Compare the actually mea-
(battery voltage) sured battery voltage with
the computer display value.
(If the actually measured bat-
tery voltage is low, recharge
the battery.)
20 Sidestand switch Extend and retract the side-
stand.
• Stand retracted ON
• Stand extended OFF
60 EEPROM fault code display —
• No history 00
• No malfunctions detected
(If the self-diagnosis fault
code 44 is indicated, the
ECU is defective.)
01(Data error for ISC (idle
History exists speed control) learning val-
ue)

9-6
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
61 Malfunction history code dis- —
play
• No history 00
• History exists Fault codes 12–84
• (If more than one code
number is detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code era-
sure
• No history 00 —
• History exists • Displays the total number To erase the history, click
of malfunctions, including “Action” on the Yamaha diag-
the current malfunction, nostic tool screen.
that have occurred since
the history was last erased.
(For example, if there have
been three malfunctions,
“03” is displayed.)
67 ISC (idle speed control) 00 To erase the ISC (idle speed
learning condition display ISC (idle speed control) control) learning data, click
ISC (idle speed control) learning data has been “Action” on the Yamaha diag-
learning data erasure erased. nostic tool screen 3 times in
01 5 seconds.
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 [-] —
EAS31121

DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates ignition coil five Check that a spark is gener-
times at one-second inter- ated five times.
vals. • Connect an ignition check-
The “CHECK” indicator and er.
“ ” on the Yamaha diag-
nostic tool screen come on
each time the ignition coil is
actuated.

9-7
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Actuation Procedure
code No.
36 Fuel injector Actuates fuel injector five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that fuel injector is ac-
The “CHECK” indicator and tuated five times by listening
“ ” on the Yamaha diag- for the operating sound.
nostic tool screen come on
each time the fuel injector is
actuated.
45 VVA (variable valve actuator) Actuates the VVA (variable Remove the VVA (variable
solenoid valve actuator) solenoid five valve actuator) solenoid from
times at three-second inter- the cylinder head, and then
vals. connect the VVA (variable
The “CHECK” indicator and valve actuator) solenoid cou-
“ ” on the Yamaha diag- pler.
nostic tool screen come on Refer to “CYLINDER HEAD”
each time the VVA (variable on page 5-9.
valve actuator) solenoid is Visually check that the VVA
actuated. (variable valve actuator) so-
lenoid is actuated five times.
52 Headlight relay Actuates the headlight relay Check that the headlight re-
five times at five-second in- lay is actuated five times by
tervals. listening for the operating
The “CHECK” indicator and sound.
“ ” on the Yamaha diag-
nostic tool screen come on
each time the relay is actuat-
ed.
54 ISC valve Fully closes the ISC valve, Check that the ISC (idle
and then opens the valve. speed control) unit operates
This operation takes approxi- by listening for the operating
mately 3 seconds. sound while the ISC unit op-
The “CHECK” indicator and erates for 3 seconds.
“ ” on the Yamaha diag-
nostic tool screen come on
during the operation.

9-8
EVENT CODE TABLE

EAS20164

EVENT CODE TABLE

No. Item Symptom Possible cause Remarks
192 Intake air pressure sen- Brief abnormality de- Same as for fault code Perform the checks and
sor tected in intake air pres- number 13 maintenance jobs for
sure sensor fault code number 13.
193 Throttle position sensor Brief abnormality de- Same as for fault code Perform the checks and
tected in throttle posi- number 15 maintenance jobs for
tion sensor fault code number 15.
196 Coolant temperature Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in coolant tem- number 21 maintenance jobs for
perature sensor fault code number 21.
197 Intake air temperature Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in intake air tem- number 22 maintenance jobs for
perature sensor fault code number 22.
218 Crankshaft position Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in crankshaft po- number 12 maintenance jobs for
sition sensor fault code number 12.
240 O2 sensor Correction value re- • Open or short circuit • If a fault code is indi-
(Correction value re- mains at upper limit in the wire harness cated, perform the
mains at upper limit) during O2 feedback between the sensor checks and mainte-
and the ECU nance jobs for the
Gray/Red–Gray/Red fault code first.
• Low fuel pressure * Event code number
• Clogged fuel injector 240 may be indicated
• Sensor malfunction even if the system is
• Defective ECU normal.
• Defective fuel injec-
tion system
241 O2 sensor Correction value re- • Open or short circuit • If a fault code is indi-
(Correction value re- mains at lower limit dur- in the wire harness cated, perform the
mains at lower limit) ing O2 feedback between the sensor checks and mainte-
and the ECU nance jobs for the
Gray/Red–Gray/Red fault code first.
• Low fuel pressure * Event code number
• Clogged fuel injector 241 may be indicated
• Sensor malfunction even if the system is
• Defective ECU normal.
• Defective fuel injec-
tion system
242 ISC (idle speed control) Correction value re- Low engine idling • Execute the diagnos-
(Correction value re- mains at upper limit speed tic mode (diagnostic
mains at upper limit) while the engine is • Clogged throttle body code number 67) and
idling • Improperly adjusted check the ISC mainte-
throttle cable nance requirements.
• Defective fuel injec- • If a fault code is indi-
tion system cated, perform the
• Dirty or worn spark checks and mainte-
plug nance jobs for the
• Defective battery fault code first.
• Defective ECU * Event code number
242 may be indicated
even if the system is
normal.

9-9
EVENT CODE TABLE

No. Item Symptom Possible cause Remarks

243 ISC (idle speed control) Correction value re- High engine idling • If a fault code is indi-
(Correction value re- mains at lower limit speed cated, perform the
mains at lower limit) while the engine is • Improperly adjusted checks and mainte-
idling throttle cable nance jobs for the
• Defective fuel injec- fault code first.
tion system * Event code number
• Dirty or worn spark 243 may be indicated
plug even if the system is
• Defective battery normal.
• Defective ECU
244 Difficult/unable to start Engine starting diffi- • Empty fuel tank • If a fault code is indi-
engine cult/unable condition • Defective fuel injec- cated, perform the
detected tion system checks and mainte-
• Dirty or worn spark nance jobs for the
plug fault code first.
• Defective battery * Event code number
• Defective ECU 244 may be indicated
even if the system is
normal.
245 Engine stall Engine stall detected • Empty fuel tank • If a fault code is indi-
• Improperly adjusted cated, perform the
throttle cable checks and mainte-
• Defective fuel injec- nance jobs for the
tion system fault code first.
• Dirty or worn spark * Event code number
plug 245 may be indicated
• Defective battery even if the system is
• Defective ECU normal.
247 Event code used for de- This is not a system
velopment malfunction

9-10
EAS20091
57. Auxiliary light EAS30613

WIRING DIAGRAM 58. Headlight COLOR CODE

GPD150-A 2015 59. Meter assembly B Black
1. Crankshaft position sensor 60. Multi-function meter Br Brown
2. AC magneto 61. Coolant temperature warning Ch Chocolate
3. Main fuse 1 light Dg Dark green
4. ABS solenoid fuse 62. ABS warning light G Green
5. Main fuse 2 63. Engine trouble warning light Gy Gray
64. Meter light L Blue
6. Taillight fuse
65. Turn signal indicator light (right) O Orange
7. Signaling system fuse
P Pink
8. ABS control unit fuse 66. Turn signal indicator light (left)
R Red
9. Rectifier/regulator 67. High beam indicator light
Sb Sky blue
10. Main switch A. Wire harness
W White
11. ABS motor fuse B. Starter motor sub-wire harness Y Yellow
12. Battery B/L Black/Blue
13. Starter relay B/W Black/White
14. Starter motor B/Y Black/Yellow
15. Handlebar switch (right) Br/W Brown/White
16. Start switch G/R Green/Red
17. Diode G/Y Green/Yellow
18. Sidestand switch Gy/R Gray/Red
19. Fuel sender L/B Blue/Black
20. Fuel pump L/R Blue/Red
21. Yamaha diagnostic tool coupler L/W Blue/White
22. Coolant temperature sensor L/Y Blue/Yellow
23. Throttle body sensor assembly O/B Orange/Black
24. Intake air pressure sensor P/W Pink/White
25. Intake air temperature sensor R/B Red/Black
26. Throttle position sensor R/L Red/Blue
27. ISC (Idle Speed Control) unit R/W Red/White
W/L White/Blue
28. Fuel injector
W/R White/Red
29. ECU (Engine Control Unit)
Y/B Yellow/Black
30. Ignition coil
Y/L Yellow/Blue
31. Spark plug
32. O2 sensor
33. VVA (variable valve actuator)
solenoid
34. Front wheel sensor
35. Rear wheel sensor
36. Joint connector
37. ABS test coupler
38. ABS ECU
39. Rear brake light switch
40. Front brake light switch
41. Turn signal relay
42. Horn
43. Handlebar switch (left)
44. Dimmer switch
45. Horn switch
46. Turn signal switch
47. Tail/brake light assembly
48. Brake light
49. Taillight
50. Rear turn signal light (left)
51. Rear turn signal light (right)
52. Engine ground
53. Frame ground
54. Front turn signal light (right)
55. Front turn signal light (left)
56. Headlight unit
GPD150-A 2015
WIRING DIAGRAM

B B

A B

G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y B/L
B/L W/L 1 B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/R
W/L B/L
W/R W/R
(B)
B/W,B R
W W W W
R
Y L/W
B R/L
30
W W
2 9 R
13 W/R O O
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B
B/W 12 15 L/W G/R B/L 22 G/R G/R
B
R (B) B/L B/L
16
10 B B
B
L/W L/W G R/L
23 24 P/W P/W
32
B A
ON
OFF
L/W B B
B/L Y L P/W Br/W
25 Br/W Br/W Gy/R Gy/R B
(B)
B Gy/R

B B/L B/L (B)

L/W 19 20 26 Y Y
R/B 3 L/W
(B)
L L
R B

R/B 4 Br
L/Y
B L/B
P P G G
R R
L/W 17 B G L/B R/L P G/Y Sb Gy
27
G/Y G/Y
29 33
R/L 5 14
Gy
Sb Sb
Gy
Ch Ch
G Ch

R/B 11 L/Y (Gy) (B) (B)

L/Y
6 R/L R
B L/Y
L/Y (Gy)

Br B O/B R/L

7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L

8 L/B B B 18 L/B
Br Br R/W
Br/W (L) (L)
G R/L R/B B R/B
B
Y/L 21 Y/L

R/B R/B
Y/L Y/L Y/L
B
B
B B
B B Y/B
B
B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W
L
Br Br B/W
Br Br
Br Br
42 41 Br/W

Br
40 39
Br/W
P
43 L/B P Br/W

44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B

Y
B Ch Dg Y
Y
R G L Br Y W W/L B/W
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G Y/L B Y (B)
Ch Ch
Y/L
59 R/B G Br (Gy)
Dg Ch Y
56 Br Y G Ch
Ch Dg
47 Y L Ch Dg

R/L
57 48 49 50 51
B
55 B
54 R
Br/W

60 58 Ch Dg

(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 Br G Y B L
L L W
34 W B G L

B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B

Br
B Y/B
Y G
(Br) (G)
B Y L B Y Y W 35 W B Br Y

Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
GPD150-A 2015
WIRING DIAGRAM

A B

1
(B)
30
2 9 13
31
12 15 22
(B)
16
10 23 24 32
A
ON
OFF
25 (B) (B)
19 20 26
3 (B)

4
17 27 29 33
5 14
11 (Gy) (B) (B)

6 (Gy)

7 (B) 28
8 18
(L) (L)

21

42 41
40 39

43
44 45 46

(B)

59 (Gy) 56 47
57 48 49 50 51
55 54
60 58
(Br) (G)
61 62 63 64 65 66 67 34
38
(Br) (G) 35
(B)

36

37

53
52