Service Manual: X-MAX 300 Evolis 300

2017
SERVICE MANUAL
X-MAX 300
EVOLIS 300
CZD300-A
CZD300-AH
B74-F8197-E0
EAS20003
IMPORTANT
This manual was produced by the PT Yamaha Indonesia Motor Manufacturing Ltd. 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. Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic
instructions that must be observed during servicing. Repair and maintenance work attempted by any-
one without this knowledge is likely to render the vehicle unsafe and unfit for use.
PT Yamaha Indonesia Motor Manufacturing Ltd. is continually striving to improve all of its models. Mod-
ifications 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
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION

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

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

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
EAS20002
CZD300-A/CZD300-AH
SERVICE MANUAL
©2017 by PT Yamaha Indonesia Motor
Manufacturing Ltd.
First edition, January 2017
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
PT Yamaha Indonesia Motor Manufacturing Ltd.
is expressly prohibited.
EAS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
3
7
4
5
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
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
MULTI-FUNCTION DISPLAY.................................................................... 1-2
SPECIAL TOOLS ............................................................................................ 1-8

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
EAS30003
MODEL LABEL
The model label “1” is affixed to the inside of the
storage box.
1-1
FEATURES
EAS20008
• information display
FEATURES TIP
EAS30618 For the UK: To switch the displays between kilo-
MULTI-FUNCTION DISPLAY meters and miles, turn the main switch to “ON”
while pushing the “INFO” switch, and then con-
2
tinue to push the “INFO” switch for eight sec-
1 3 onds.
4 Clock
6
1. Fuel meter
1
2. Information display
3. Coolant temperature meter
4. Clock
5. Tripmeter display
6. Icy road warning indicator “ ”
1. Clock
EWA12423
WARNING The clock uses a 24-hour time system.

Be sure to stop the vehicle before making
any setting changes to the multi-function [To set the clock]
meter unit. Changing settings while riding 1. Turn the main switch to “OFF”.
can distract the operator and increase the 2. Push and hold the “TRIP” switch.
risk of an accident. 3. Turn the main switch to “ON” while pushing
the “TRIP” switch, and then continue to push
The “TRIP/INFO” switch is located on the right the “TRIP” switch for eight seconds. The hour
side of the handlebar. This switch allows you to digits will start flashing.
control or change the settings of the multi-func- 4. Use the “TRIP” switch to set the hours.
tion meter unit. To use the “TRIP” switch, move 5. Push the “TRIP” switch for three seconds,
the “TRIP/INFO” switch in direction “a”. To use and then release it. The minute digits will start
the “INFO” switch, move the “TRIP/INFO” switch flashing.
in direction “b”. 6. Use the “TRIP” switch to set the minutes.
7. Push the “TRIP” switch for three seconds,
and then release it to start the clock.
Fuel meter
a b
1
1. “TRIP/INFO” switch
The multi-function display is equipped with the
following:
• clock
1. Fuel meter
• fuel meter
• coolant temperature meter
• tripmeter display
1-2
FEATURES
The fuel meter indicates the amount of fuel in the Tripmeter display
fuel tank. The segments of the fuel meter disap-
pear from “F” (full) towards “E” (empty) as the
fuel level decreases. When the last segment of
the fuel meter starts flashing, refuel as soon as
possible.
TIP
• If a problem is detected in the fuel meter, the all
segments will flash repeatedly. If this occurs, 1
check the electrical circuit. Refer to “SIGNAL-
ING SYSTEM” on page 8-19.
• When approximately 2.4 L (0.63 US gal, 0.53 1. Tripmeter display
Imp.gal) of fuel remains in the fuel tank, the last The tripmeter display is equipped with the fol-
segment of the fuel meter will start flashing. lowing:
The display will automatically change to the • odometer
fuel reserve tripmeter “F Trip” and start count- • tripmeter
ing the distance traveled from that point. • time tripmeter
• fuel reserve tripmeter
Coolant temperature meter • oil change tripmeter
• V-belt replacement tripmeter
Push the “TRIP” switch to change the display
between the odometer “Odo”, tripmeter “Trip”,
1
time tripmeter “Trip Time”, oil change tripmeter
“Oil Trip”, and V-belt replacement tripmeter “V-
Belt Trip” in the following order:
Odo → Trip → Trip Time → Oil Trip → V-Belt

Trip → Odo
TIP
1. Coolant temperature meter When approximately 2.4 L (0.63 US gal, 0.53
The coolant temperature meter indicates the Imp.gal) of fuel remains in the fuel tank, the last
temperature of the coolant. segment of the fuel meter will start flashing. The
If the top segment flashes, stop the vehicle, then display will automatically change to the fuel re-
stop the engine, and let the engine cool. serve tripmeter “F Trip” and start counting the
ECA10022 distance traveled from that point.
NOTICE
Do not continue to operate the engine if it is Odometer “Odo” and tripmeter “Trip”
overheating. The odometer shows the total distance traveled
by the vehicle.
TIP
The tripmeter shows the distance traveled since
• If a problem is detected in the coolant tempera- it was last reset.
ture meter, all segments will flash repeatedly. If To reset the tripmeter, select it by pushing the
this occurs, check the electrical circuit. Refer to “TRIP” switch, and then push the “TRIP” switch
“COOLING SYSTEM” on page 8-27. for three seconds.
• The coolant temperature varies with changes
TIP
in the weather and engine load.
• The odometer will lock at 999999.
• The tripmeter will reset and continue counting
after 9999.9 is reached.
1-3
FEATURES
Time tripmeter “Time” Oil change tripmeter “Oil Trip”
1
1 2
1. Time tripmeter 1. Oil change indicator “Oil”

2. Oil change tripmeter
The time tripmeter displays the time that has
elapsed while the main switch was in the “ON” The oil change tripmeter shows the distance
position since it was last reset. traveled since the oil was last changed.
The maximum time that can be shown is 99:59. The oil change indicator “OIL” flashes at the ini-
TIP tial 1000 km (600 mi), then at 4000 km (2400 mi)
To reset the time tripmeter, select it by pushing and every 5000 km (3000 mi) thereafter to indi-
the “TRIP” switch, and then push the “TRIP” cate that the engine oil should be changed.
switch for three seconds. After changing the engine oil, reset the oil
change indicator and the oil change tripmeter.
To reset them both, select the oil change tripme-
Fuel reserve tripmeter “F Trip” ter, and then push the “TRIP” switch for three
seconds.
While the oil change tripmeter is flashing, push
the “TRIP” switch for 15 to 20 seconds. Release
the “TRIP” switch, and the oil trip value will reset
to zero.
TIP
If the engine oil is changed before the oil change
1 indicator comes on (i.e., before the periodic oil
change interval has been reached), the oil
change tripmeter must be reset for the oil
1. Fuel reserve tripmeter
change indicator to come on at the correct time.
When approximately 2.4 L (0.63 US gal, 0.53
Imp.gal) of fuel remains in the fuel tank, the last V-belt replacement tripmeter “V-Belt Trip”
segment of the fuel meter will start flashing. The
display will automatically change to the fuel re-
serve tripmeter “F Trip” and start counting the
distance traveled from that point. In this case,
push the “TRIP” switch to switch the display in
the following order:
F Trip → Oil Trip → V-Belt Trip → Odo → Trip → 1

Trip Time → F Trip 2
To reset the fuel reserve tripmeter, select it by
pushing the “TRIP” switch, and then push the
1. V-belt replacement indicator “V-Belt”
“TRIP” switch for three seconds.
2. V-belt replacement tripmeter
The fuel reserve tripmeter will reset automatical-
ly and disappear after refueling and traveling 5 The V-belt replacement tripmeter shows the dis-
km (3 mi). tance traveled since the V-belt was last re-
placed.
1-4
FEATURES
The V-belt replacement indicator “V-Belt” will display “Consumption_ _._ km/L” or “Consump-
flash every 20000 km (12000 mi) to indicate that tion_ _._ L/100 km” and average speed display
the V-belt should be replaced. “Average” in the following order:
After replacing the V-belt, reset the V-belt re-
placement indicator and the V-belt replacement Air-temp → Battery → TCS ON or TCSOFF →
tripmeter. To reset them both, select the V-belt Consumption/Average_ _._ km/L → Consump-
replacement tripmeter, and then push the “TRIP” tion/Average_ _._ L/100 km → Consumption_
switch for three seconds. _._ km/L → Consumption_ _._ L/100 km → Av-
While the V-belt replacement tripmeter is flash- erage → Air-temp
ing, push the “TRIP” switch for 15 to 20 seconds.
Release the “TRIP” switch, and the V-belt trip For the UK:
value will reset to zero. Push the “TRIP” switch to change the display
TIP between the air temperature display “Air-temp”,
If the V-belt is replaced before the V-belt re- battery voltage display “Battery”, traction control
placement indicator comes on (i.e., before the system display “TCS ON” or “TCSOFF”, aver-
periodic V-belt replacement interval has been age fuel consumption display “Consumption/Av-
reached), the V-belt replacement tripmeter must erage_ _._ km/L”, “Consumption/Average_ _._
be reset for the V-belt replacement indicator to L/100 km” or “Consumption/Average_ _
come on at the correct time. _._MPG”, instantaneous fuel consumption dis-
play “Consumption_ _._ km/L”, “Consumption_
_._ L/100 km” or “Consumption_ _ _._MPG” and
Information display average speed display “Average” in the follow-
ing order:
1 Air-temp → Battery → TCS ON or TCSOFF →

Consumption/Average_ _._ km/L → Consump-
tion/Average_ _._ L/100 km → Consumption/
Average_ _ _._ MPG → Consumption_ _._ km/
L → Consumption_ _._ L/100 km → Consump-
tion_ _ _._ MPG → Average → Air-temp
TIP
• When kilometers are selected for the display
1. Information display
units, “Consumption/Average_ _ _._MPG” and
The information display is equipped with the fol- “Consumption_ _ _._MPG” are not displayed.
lowing: • When miles are selected for the display units,
• air temperature display “Consumption/Average_ _._ km/L”, “Con-
• battery voltage display sumption/Average_ _._ L/100 km”, “Consump-
• traction control system display tion_ _._ km/L”, and “Consumption_ _._ L/100
• average fuel consumption display km” are not displayed.
• instantaneous fuel consumption display
• average speed display
• warning message function
Navigating the information display

Push the “INFO” switch to change the display
between the air temperature display “Air-temp”,
battery voltage display “Battery”, traction control
system display “TCS ON” or “TCSOFF”, aver-
age fuel consumption display “Consumption/Av-
erage_ _._ km/L” or “Consumption/Average_
_._ L/100 km”, instantaneous fuel consumption
1-5
FEATURES
Air temperature display Traction control system mode display
1 1
1. Air temperature display 1. Traction control system mode display

2. Icy road warning indicator “ ”
This display shows the current status of the trac-
This display shows the air temperature from –10 tion control system.
°C to 50 °C in 1 °C increments. • “TCS ON”: the system is on
The icy road warning indicator “ ” will flash • “TCSOFF”: the system is off
when the temperature is below 4 °C. TIP
The temperature displayed may vary from the If only “TCS” is displayed, there is a communica-
actual ambient temperature. tion error within the vehicle. Check the electrical
TIP circuit. Refer to “SIGNALING SYSTEM” on page
The accuracy of the temperature reading may 8-19.
be affected by engine heat when riding slowly
(under 20 km/h [12 mi/h]) or when stopped at Average fuel consumption display
traffic signals, etc.
Battery voltage display 1
1. Average fuel consumption display

This function calculates the average fuel con-
sumption since it was last reset.
1. Battery voltage display
The average fuel consumption can be displayed
This display shows the current charge state of as either “Consumption/Average_ _._ km/L”,
the battery. “Consumption/Average_ _._ L/100 km” or “Con-
TIP sumption/Average_ _ _._ MPG” (for the UK).
• If the engine turns over slowly when using the • “Consumption/Average_ _._ km/L”: The aver-
start switch, check the battery. Refer to age distance that can be traveled on 1.0 L of
“CHECKING AND CHARGING THE BAT- fuel is shown.
TERY” on page 8-128. • “Consumption/Average_ _._ L/100 km”: The
• If “---” appears in the battery voltage display, average amount of fuel necessary to travel 100
check the battery. Refer to “CHECKING AND km is shown.
CHARGING THE BATTERY” on page 8-128. • “Consumption/Average_ _ _._ MPG” (for the
UK): The average distance that can be trav-
eled on 1.0 Imp.gal of fuel is shown.
To reset the average fuel consumption, push the
“INFO” switch for at least three seconds.
1-6
FEATURES
TIP The average speed “Average_ _ _kmh” or “Av-

After resetting the average fuel consumption, “_ erage_ _ _MPH” (for the UK) is displayed.
_._” will be shown until the vehicle has traveled The average speed is the total distance divided
1 km (0.6 mi). by the total time (with the main switch in the “ON”
position) since the display was last reset to zero.
This display shows the average speed since it
Instantaneous fuel consumption display was last reset.
To reset the average speed display, select it by
pushing the “INFO” switch, and then push the
1 “INFO” switch for three seconds.
Warning message function

This function displays a warning message corre-
sponding to the current warning.
“L FUEL”: Appears when the last segment of the
fuel meter starts flashing. If “L FUEL” is dis-
played, refuel as soon as possible.
1. Instantaneous fuel consumption display “H TEMP”: Appears when the top segment of the
This function calculates the fuel consumption coolant temperature meter starts flashing. If “H
under current riding conditions. TEMP” is displayed, stop the vehicle, then stop
The instantaneous fuel consumption can be dis- the engine, and let the engine cool.
played as either “Consumption_ _._km/L”, “Con- “ICE”: Appears when the icy road warning indi-
sumption_ _._L/100 km” or “Consumption_ _ cator “ ” starts flashing. If “ICE” is displayed, be
_._MPG” (for the UK). careful of icy roads.
• “Consumption_ _._km/L”: The distance that “OIL SERV”: Appears when the oil change indi-
can be traveled on 1.0 L of fuel under the cur- cator “OIL” starts flashing. If “OIL SERV” is dis-
rent riding conditions is shown. played, change the engine oil, and then reset the
• “Consumption_ _._L/100 km”: The amount of oil change indicator and oil change tripmeter.
fuel necessary to travel 100 km under the cur- “V-BELT SERV”: Appears when the V-belt re-
rent riding conditions is shown. placement indicator “V-Belt” starts flashing. If “V-
• “Consumption_ _ _._MPG” (for the UK): The BELT SERV” is displayed, replace the V-belt,
distance that can be traveled on 1.0 Imp.gal of and then reset the V-belt replacement indicator
fuel under the current riding conditions is and V-belt replacement tripmeter.
shown.
When there are two or more warnings, the warn-
TIP
ing messages are displayed in the following or-
If traveling at speeds under 10 km/h (6 mi/h), “_ der:
_._” is displayed.
L FUEL → H TEMP → ICE → OIL SERV →
Average speed display VBELT SERV → L FUEL
1. Average speed display
1-7
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
Yamaha diagnostic tool USB 3-4, 3-7, 3-8,
90890-03256 4-68, 4-69, 7-17,
7-17, 7-18, 7-18,
8-34, 8-88,
8-110, 8-128
Yamaha diagnostic tool (A/I) 3-4, 3-7, 3-8,

90890-03254 4-68, 4-69, 7-17,
7-17, 7-18, 7-18,
8-34, 8-88,
8-110, 8-128
Steering nut wrench 3-16, 4-89

90890-01403
Exhaust flange nut wrench
YU-A9472
Thickness gauge 4-32, 4-36

90890-03180
Feeler gauge set
YU-26900-9
T-handle 4-82, 4-84

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver weight 4-85, 4-85, 4-85

90890-01184
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø33) 4-85, 4-85

90890-01368
Replacement 33 mm
YM-A9409-4
1-8
SPECIAL TOOLS
Reference
pages
Compression gauge 90890-03081 5-5
90890-03081
Engine compression tester
YU-33223
YU-33223
Camshaft sprocket stopper 5-17, 5-20

90890-04182
Camshaft sprocket stopper
YM-04182
Yamaha bond No. 1215 5-20, 5-51, 5-63

90890-85505
(Three bond No.1215®)
Valve spring compressor 5-27, 5-31

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-27, 5-31

90890-06320
Valve guide remover (ø5) 5-28

90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø5) 5-28

90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5) 5-28

90890-04099
Valve guide reamer (5.0 mm)
YM-04099
1-9
SPECIAL TOOLS
Reference
pages
Piston pin puller set 5-33
90890-01304
Piston pin puller
YU-01304
YU-01304
Rotor holding tool 5-40, 5-45

90890-01235
Universal magneto and rotor holder
YU-01235
Rotor holding tool 5-40, 5-40, 5-44,

90890-04166 5-45, 5-49, 5-49,
Rotor holding tool 5-50, 5-51
YM-04166
Locknut wrench 5-40, 5-44

90890-01348
Locknut wrench
YM-01348
Sheave spring compressor 5-40, 5-43

90890-04134
Sheave spring compressor
YM-04134
1-10
SPECIAL TOOLS
Reference
pages
Sheave fixed block 5-40, 5-43
90890-04135
Sheave fixed bracket
YM-04135
Oil seal guide (40mm) 5-43

90890-01590
Sliding sheave guide 40mm
YM-01590
ø40
Flywheel puller 5-49
90890-01404
Flywheel puller
YM-01404
Rotor puller bolt M14 X L80 5-49

90890-04183 M14×P1.5
Rotor puller bolt M14 X L80
YM-04183
L80
Digital circuit tester (CD732) 5-54, 8-128,

90890-03243 8-129, 8-130,
Model 88 Multimeter with tachometer 8-131, 8-131,
YU-A1927 8-132, 8-133,
8-133, 8-133,
8-134, 8-134,
8-135, 8-135,
8-136, 8-137,
8-137, 8-138
Crankshaft metal installation base set 5-67, 5-72
90890-04181
Crankshaft metal installation base set
YM-04181
1-11
SPECIAL TOOLS
Reference
pages
Radiator cap tester 6-4, 6-5
90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 31mm 6-4, 6-5

90890-05375
Radiator cap tester adapter 31mm
YM-05375
Mechanical seal installer 6-10

90890-04145 ø30
ø10
Middle driven shaft bearing driver 6-10

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

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

90890-03186
Fuel pressure adapter
YM-03186
OBD/ GST Leadwire kit 8-34

90890-03249
Ignition checker 8-132

90890-06754
Oppama pet–4000 spark checker
YM-34487
1-12
SPECIAL TOOLS
1-13
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-7
ELECTRICAL SPECIFICATIONS ...................................................................2-9
TIGHTENING TORQUES .............................................................................. 2-11

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

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model B741 (CZD300-A_EUR/GLP/HRV/MTQ/TUR/
ZAF)
B742 (CZD300-A_EUR)
B743 (CZD300-AH)
B749 (CZD300-A_EUR)
Dimensions
Overall length 2185 mm (86.0 in)
Overall width 775 mm (30.5 in)
Overall height 1415/1465 mm (55.7/57.7 in)
Wheelbase 1540 mm (60.6 in)
Ground clearance 135 mm (5.31 in)
Minimum turning radius 2.6 m (8.53 ft)
Weight
Curb weight 179 kg (395 lb)
Loading
Maximum load 161 kg (355 lb)
Riding capacity 2 person
Storage compartment_1 location Left leg shield
Storage compartment_1 maximum load 1.0 kg (2 lb)
Storage compartment_2 location Right leg shield
Storage compartment_3 location Under seat
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train SOHC
Displacement 292 cm³
Number of cylinders Single cylinder
Bore × stroke 70.0 × 75.9 mm (2.76 × 2.99 in)
Compression ratio 10.9 : 1
Compression pressure 783–1008 kPa/860 r/min (7.8–10.1 kgf/cm²/860
r/min, 111.4–143.4 psi/860 r/min)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity 13 L (3.4 US gal, 2.9 Imp.gal)
Fuel reserve amount 2.4 L (0.63 US gal, 0.53 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA or MB
Lubrication system Wet sump
Engine oil quantity
Oil change 1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter removal 1.60 L (1.69 US qt, 1.41 Imp.qt)
Quantity (disassembled) 1.70 L (1.80 US qt, 1.50 Imp.qt)
Final transmission oil

Type Motor oil SAE 10W-30 type SE or higher or Gear
oil SAE 85W GL-3
Quantity (disassembled) 0.23 L (0.24 US qt, 0.20 Imp.qt)
Quantity 0.20 L (0.21 US qt, 0.18 Imp.qt)
Oil filter
Oil filter type Paper
Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0.100–0.150 mm (0.0039–0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.10–0.15 mm (0.0039–0.0059 in)
Limit 0.22 mm (0.0087 in)
Relief valve operating pressure 390.0 kPa (3.90 kgf/cm², 56.6 psi)
Cooling system
Coolant quantity
Radiator (including all routes) 1.10 L (1.16 US qt, 0.97 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.18 L (0.19 US qt, 0.16 Imp.qt)
2-2
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)
Water pump
Water pump type Single suction centrifugal pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug(s)
Manufacturer/model NGK/LMAR8A-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
Camshaft lobe dimensions
Lobe height (Intake) 40.017–40.117 mm (1.5755–1.5794 in)
Limit 39.917 mm (1.5715 in)
Lobe height (Exhaust) 39.954–40.054 mm (1.5730–1.5769 in)
Limit 39.854 mm (1.5691 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter 11.985–12.000 mm (0.4719–0.4724 in)
Limit 12.015 mm (0.4730 in)
Rocker arm shaft outside diameter 11.966–11.976 mm (0.4711–0.4715 in)
Limit 11.935 mm (0.4699 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 0.06–0.12 mm (0.0024–0.0047 in)
Exhaust 0.20–0.26 mm (0.0079–0.0102 in)
Valve dimensions
Valve seat contact width (intake) 0.90–1.20 mm (0.0354–0.0472 in)
Limit 1.7 mm (0.07 in)
Valve seat contact width (exhaust) 0.90–1.20 mm (0.0354–0.0472 in)
Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)
Limit 4.945 mm (0.1947 in)
Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in)
Limit 4.930 mm (0.1941 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 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)
2-3
Valve-stem-to-valve-guide clearance
(exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 35.87 mm (1.41 in)
Limit 34.07 mm (1.34 in)
Free length (exhaust) 35.87 mm (1.41 in)
Limit 34.07 mm (1.34 in)
Cylinder
Bore 70.000–70.025 mm (2.7559–2.7569 in)
Wear limit 70.075 mm (2.7589 in)
Piston
Diameter 69.962–69.985 mm (2.7544–2.7553 in)
Measuring point (from piston skirt bottom) 8.0 mm (0.31 in)
Piston-to-cylinder clearance 0.031–0.047 mm (0.0012–0.0019 in)
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.995–16.000 mm (0.6297–0.6299 in)
Limit 15.975 mm (0.6289 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.018 mm (0.0001–0.0007 in)
Piston ring
Top ring
Ring type Barrel
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
End gap limit 1.15 mm (0.0453 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)
Connecting rod
Oil clearance 0.033–0.057 mm (0.0013–0.0022 in)
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Crankshaft journal diameter 39.976–40.000 mm (1.5739–1.5748 in)
Crankshaft journal bearing inside diameter 40.015–40.056 mm (1.5754–1.5770 in)
Journal oil clearance 0.031–0.064 mm (0.0012–0.0025 in)
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
2-4
Code 4 Green
Code 5 Yellow
Code 6 Pink
Balancer shaft runout limit 0.030 mm (0.0012 in)
Clutch
Clutch type Dry, centrifugal, shoe
Automatic centrifugal clutch

Clutch shoe thickness 3.0 mm (0.12 in)
Clutch housing inside diameter 150.0 mm (5.91 in)
Limit 150.5 mm (5.93 in)
Clutch weight spring free length 30.0 mm (1.18 in)
Spring quantity 5 pcs
Clutch-in revolution 2000–2400 r/min
Clutch-stall revolution 4500–5100 r/min
V-belt
V-belt width 27.7 mm (1.09 in)
Limit 26.7 mm (1.05 in)
Drivetrain
Primary reduction ratio 1.000
Transmission type V-belt automatic
Transmission ratio 2.386–0.746 : 1
Weight outside diameter 23.0 mm (0.91 in)
Limit 22.5 mm (0.89 in)
Compression spring free length 111.0 mm (4.37 in)
Limit 99.9 mm (3.93 in)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 7.590 (48/18 × 37/13)
Final drive Gear
Air filter
Air filter element Oil-coated paper element/Dry element
V-belt filter element Dry element
Fuel pump
Pump type Electrical
Maximum consumption amperage 1.7 A
Type × quantity AC35 × 1
Fuel injector
Resistance 12.2 Ω
Throttle body
ID mark B741 00
Idling condition
Engine idling speed 1500–1700 r/min
O2 feedback control Active
2-5
Exhaust gas sampling point Muffler tail pipe

CO% 0.0–1.0 %
Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-6
CHASSIS SPECIFICATIONS
EAS20015
Chassis
Frame type Backbone
Caster angle 26.5 °
Trail 95 mm (3.7 in)
Front wheel
Wheel type Cast wheel
Rim size J15M/C × MT3.5
Rim material Aluminum
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 J14M/C × MT4.0
Rim material Aluminum
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 120/70–15 M/C 56P
Manufacturer/model DUNLOP/SCOOTSMART
Rear tire
Type Tubeless
Size 140/70–14 M/C 62P
Manufacturer/model DUNLOP/SCOOTSMART
Tire air pressure (measured on cold tires)

1 person
Front 200 kPa (2.00 kgf/cm², 29 psi)
Rear 225 kPa (2.25 kgf/cm², 33 psi)
2 persons
Front 200 kPa (2.00 kgf/cm², 29 psi)
Rear 225 kPa (2.25 kgf/cm², 33 psi)
Front brake
Type Hydraulic single disc brake
Disc outside diameter × thickness 267.0 × 4.5 mm (10.51 × 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 5.3 mm (0.21 in)
Master cylinder inside diameter 12.70 mm (0.50 in)
Caliper cylinder inside diameter (right) 26.99 mm, 26.99 mm (1.06 in, 1.06 in)
Specified brake fluid DOT 4
Rear brake
Type Hydraulic single disc brake
2-7
Disc outside diameter × thickness 245.0 × 5.0 mm (9.65 × 0.20 in)

Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 6.7 mm (0.26 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Fork spring free length 348.3 mm (13.71 in)
Limit 341.3 mm (13.44 in)
Recommended oil Yamaha Suspension Oil G10
Quantity (left) 235.0 cm³ (7.95 US oz, 8.29 Imp.oz)
Quantity (right) 235.0 cm³ (7.95 US oz, 8.29 Imp.oz)
Level (left) 155 mm (6.1 in)
Level (right) 155 mm (6.1 in)
Rear suspension
Type Unit swing
Spring Coil spring
Shock absorber Hydraulic damper
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Cam position
Adjustment value (Soft) 1
Adjustment value (STD) 3
Adjustment value (Hard) 5
2-8
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 °/1600 r/min
Engine control unit

Model/manufacturer B740/PT. YAMAHA MOTOR ELECTRONICS
INDONESIA
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

Resistance 3.75–6.25 kΩ
Lean angle sensor output voltage

Operating angle 50 °
Output voltage up to operating angle 0.4–1.4 V
Output voltage over operating angle 3.7–4.4 V
Charging system
Charging system AC magneto
Standard output 14.0 V, 12.5 A at 5000 r/min
Standard output 14.0 V, 175 W at 5000 r/min
Stator coil resistance 0.360–0.540 Ω
Rectifier/regulator
Regulator type Single-phase
Regulated voltage (DC) 14.0–15.0 V
Rectifier capacity (DC) 20.0 A
Battery
Model GTZ8V
Voltage, capacity 12 V, 7.0 Ah (10 HR)
Bulb wattage
Headlight LED
Tail/brake light LED
Front turn signal light 10.0 W
Rear turn signal light 10.0 W
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED
High beam indicator light LED
Turn signal indicator light LED
2-9
Engine trouble warning light LED

ABS warning light LED
Smart key system indicator light LED
Traction control system indicator light LED
Starter motor
Power output 0.40 kW
Armature coil resistance 0.063–0.077 Ω
Brush overall length 7.0 mm (0.28 in)
Limit 3.00 mm (0.12 in)
Brush spring force 6.08–9.12 N (620–930 gf, 21.89–32.83 oz)
Commutator diameter 24.5 mm (0.96 in)
Limit 23.5 mm (0.93 in)
Mica undercut (depth) 1.50 mm (0.06 in)
Fuel sender unit

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

Crankshaft position sensor resistance 228–342 Ω
Intake air temperature sensor resistance 5700–6300 Ω at 0 °C (5700–6300 Ω at 32 °F)
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)
Fuse(s)
Main fuse 20.0 A
Main fuse 2 7.5 A
Signaling system fuse 10.0 A
Signaling system fuse 2 7.5 A
Radiator fan motor fuse 7.5 A
Turn signal light and hazard fuse 7.5 A
ABS control unit fuse 7.5 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
Terminal fuse 2.0 A
Answer back fuse 2.0 A
Backup fuse 7.5 A
2-10
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Exhaust pipe nut M8 2 15 N·m (1.5 kgf·m, 11 lb·ft)
Clamp bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Muffler bolt M10 3 53 N·m (5.3 kgf·m, 39 lb·ft)
Muffler protector bolt M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Muffler cap bolt M6 1 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Coolant drain bolt (water pump side) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Coolant drain bolt (radiator side) M10 1 1.6 N·m (0.16 kgf·m, 1.2 lb·ft)
Engine oil drain bolt M12 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Final transmission oil drain bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Oil filter element cover bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Clutch housing nut M14 1 75 N·m (7.5 kgf·m, 55 lb·ft)
Cylinder head cover bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Spark plug M10 1 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Generator rotor bolt M10 1 75 N·m (7.5 kgf·m, 55 lb·ft) M
Generator cover bolt M6 11 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Primary fixed sheave bolt M12 1 See TIP. M
Secondary sheave nut M30 1 85 N·m (8.5 kgf·m, 63 lb·ft)
TIP
115 N·m (11.5 kgf·m, 85 lb·ft): Tightening torque when reusing the primary fixed sheave bolt and wash-
er
120 N·m (12 kgf·m, 89 lb·ft): Tightening torque when installing a new primary fixed sheave bolt and
washer
2-11
TIGHTENING TORQUES
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Upper handlebar holder bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft)
Front brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)
Brake caliper bleed screw M7 2 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front wheel axle nut M14 1 52 N·m (5.2 kgf·m, 38 lb·ft) LS
Rear brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)

Rear wheel axle nut M16 1 125 N·m (12.5 kgf·m, 92 lb·ft) LS
Upper bracket pinch bolt M8 2 23 N·m (2.3 kgf·m, 17 lb·ft)

Lower bracket pinch bolt M10 2 30 N·m (3.0 kgf·m, 22 lb·ft)
Steering stem nut M22 1 91 N·m (9.1 kgf·m, 67 lb·ft)
Lower ring nut M22 1 See TIP.
TIP
1. Tighten the lower ring nut 48 N·m (4.8 kgf·m, 35 lb·ft) with a torque wrench and the steering nut
wrench, and then loosen the nut completely.
2. Tighten the lower ring nut 14 N·m (1.4 kgf·m, 10 lb·ft) with a torque wrench and the steering nut
wrench.
2-12
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
1 2
C
B A 6
5 3
2-13
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. Handlebar switch lead (left handlebar switch)
4. Throttle cable (decelerator cable)
5. Throttle cable (accelerator cable)
6. Handlebar switch lead (right handlebar switch)
7. Lower handlebar cover
A. Face the paint mark on the front brake hose (front
brake master cylinder to hydraulic unit) to the front.
B. Position the front brake hose (front brake master
cylinder to hydraulic unit) so that its projection
contacts the front brake master cylinder.
C. Position the rear brake hose (rear brake master
cylinder to hydraulic unit) so that its projection
contacts the rear brake master cylinder.
D. Route the throttle cables through the hole in the
lower handlebar cover.
2-14
CABLE ROUTING
Handlebar (left side view)
6 5
5 6
6 1
5
1
4 4
3 2 3 1
2
4 1 5
2 6
2
3 5
4
4
3
3 4
2-15
CABLE ROUTING

hydraulic unit)
hydraulic unit)
2-16
CABLE ROUTING
Steering (left side view)

9 2 13
2
12
11
15
13
A 12
2
16 B 11 8
17
18 B 14
19
10
11
12
3
23 1
8
2
3
4
5
6
4 7 20
19 23 E
D 3
C
22
21
4
14
15
24
8
2-17
CABLE ROUTING
1. Front brake hose (hydraulic unit to front brake

caliper)
2. Front wheel sensor lead
3. Wire harness
4. Starter motor lead
7. Sidestand switch lead
8. Fuel tank cap lid lock cable
9. Main switch coupler
10. Handlebar switch coupler (right handlebar switch)
13. Main switch lead
14. Seat lock cable
15. ECU (Engine Control Unit)
16. Radiator fan motor relay
17. Rollover valve
18. Starting circuit cut-off relay
19. Rectifier/regulator
20. Main switch
21. Rear brake hose (hydraulic unit to rear brake
caliper)
22. Front storage compartment lock cable
23. Rectifier/regulator coupler
24. Horn
A. Position the tapes on the right handlebar switch
lead and left handlebar switch lead to the rear of
the guide on the frame.
B. Position the fan motor relay and starting circuit cut-
off relay in any order.
C. Insert the projection on the wire harness holder
(tape) into the hole in the frame.
D. Point the end of the plastic band outward.
E. Install the coupler cover completely until it contacts
the rectifier/regulator.
2-18
CABLE ROUTING
Frame (left side view)
5 D
3
2 3 3
2 12
1 E
4 1 4
2
4 1
A
4 5
1 2 3
3 B
8
9 C
5
11 10
10 10 F
5 4 3
5
8
2-19
CABLE ROUTING

3. Seat lock cable
5. Wire harness
6. Smart key unit
7. Rear wheel sensor lead
8. Ignition coil
9. Frame ground
10. Sidestand switch
11. Sidestand switch lead
12. AC magneto lead
A. Route the wire harness through the guide on the
frame.
B. Route the seat lock cable to the inside of the
frame.
C. Make sure that the frame ground terminal contact
the frame.
D. Fasten the wire harness with the plastic band.
Route the plastic band through the upper hole of
the stay on the flame.
E. Point the end of plastic band downward. Make sure
that the end does not contact the fuel tank.
F. Connect the wire harness to the ignition coil as
shown in the illustration.
2-20
CABLE ROUTING
Frame (top view)
14
14
G
13
12
11
A
2
3
10
9 4
14
6
7
B
H 7
6
5
6
7
F
5
E D 8 C
5
2-21
CABLE ROUTING
1. Fuel tank cap lid lock cable

2. ISC (Idle Speed Control) unit coupler
3. Coolant temperature sensor coupler
4. Throttle body sensor assembly coupler
5. Seat lock cable
6. AC magneto lead
8. Engine ground lead
9. Crankshaft position sensor coupler
10. Stator coil coupler
11. O2 sensor coupler
12. Fuel injector coupler
13. Spark plug lead
14. Wire harness
A. Route the wire harness under the fuel hose.
B. Route the wire harness under the engine ground
lead and over the AC magneto lead.
C. Make sure that the engine ground lead terminal
contacts the stopper on the crankcase.
D. Route the wire harness and rear wheel sensor
lead through the guide.
E. Route the seat lock cable through the guide.
F. Route the rear wheel sensor lead to the rear of
wire harness.
G. When routing the spark plug lead, make sure that
the distance between the lead and the frame is 5
mm (0.20 in) or more.
H. Route the AC magneto lead over the starter motor
lead.
I. Route the AC magneto lead between the starter
motor and the right crankcase.
J. Insert the projection on the wire harness holder
into the hole in the frame.
2-22
CABLE ROUTING
Radiator (front and left view)
1 A
B
G
C
F
E D
5
6
A I
2
4
2
7 H
J 2
2-23
CABLE ROUTING
1. Radiator rear cover

2. Coolant reservoir hose
3. Radiator outlet hose
4. Radiator inlet hose
5. Radiator filler hose
6. Radiator fan motor lead
7. Coolant reservoir breather hose
A. Fasten the coolant reservoir hose with the holder
on the radiator rear cover.
B. Align the holder with the paint mark on the coolant
reservoir hose.
C. Route the coolant reservoir hose to the rear of the
projection on the radiator rear cover.
D. Install the coolant reservoir hose with its paint
mark facing forward.
E. Point the ends of the hose clamp forward.
F. Face the paint mark on the radiator filler hose
forward.
G. Fasten the coolant reservoir breather hose with the
clamp on the radiator rear cover.
H. Install the coolant reservoir hose with its paint
mark facing upward.
I. Fasten the radiator fan motor lead with the holder
on the radiator rear cover.
J. Align the paint mark on the coolant reservoir hose
with the projection on the coolant reservoir.
2-24
CABLE ROUTING
Radiator (right side view)
2
9
3 4
2
4
I
9
2 4
5
A
B 2 2
4 C
D
1
E
6
F
H H
K
G
8 7 J
8
8
7
2-25
CABLE ROUTING
1. Thermostat
2. Cooling system air bleed hose
3. Canister purge hose
4. Fuel tank breather hose (rollover valve to canister)
5. Coolant reservoir hose
6. Radiator filler hose
9. Fuel tank overflow tray
A. Install the cooling system air bleed hose with its
paint mark facing upward. Point the end of clamp
upward.
B. Install the radiator inlet hose with its paint mark
facing upward. Point the end of clamp upward.
C. Install the coolant reservoir hose with its paint
mark facing to the right.
D. Install the cooling system air bleed hose with its
paint mark facing to the right. Point the end of
clamp to the right.
E. Install the radiator filler hose with its paint mark
facing forward. Point the end of clamp forward.
F. Install the radiator filler hose with its paint mark
facing to the right. Point the end of clamp to the
right.
G. Make sure that the end of the hoses contact the
projections on the radiator.
H. Point the end of clamp to the right.
I. Install the radiator inlet hose with its paint mark to
the right.
J. Install the radiator outlet hose with its paint mark
facing upward. Point the end of clamp upward.
K. Install the radiator outlet hose with its paint mark to
the right.
2-26
CABLE ROUTING
Tail/brake light (left side view)
B
3 4
2
A
1
3 2
C D
2
2-27
CABLE ROUTING
1. Wire harness
2. Tail/brake light lead (right tail/brake light)
3. Tail/brake light lead (left tail/brake light)
4. License plate light lead
5. Frame
A. Route the wire harness through the hole in the rear
lower cowling assembly. Align the tape on the wire
harness with the hole.
B. Route the tail/brake light leads and license plate
light lead through the hole in the rear lower cowling
assembly. Align the tapes on the leads with the
hole.
C. Route the license plate light lead to the hole on the
frame.
D. Route the tail/brake light lead (left tail/brake light)
to the rear of the turn signal light lead and the front
of the rear lower cowling assembly.
E. Route the tail/brake light lead (right tail/brake light)
and license plate light lead through the guide.
F. Route the tail/brake light lead (left tail/brake light),
tail/brake light lead (right tail/brake light) and
license plate light lead between the frame.
2-28
CABLE ROUTING
Air filter case (top view)
1 3 I
2 J
E
F H
I
1
G
1
2
D
A 3
C
C
2-29
CABLE ROUTING
1. Cylinder head breather hose

2. Air filter case joint
3. Transmission case breather hose
4. Air filter case
A. Install the cylinder head breather hose with its
paint mark facing upward and completely onto the
hose fitting.
B. Fasten the hose with the clamp with its end facing
upward.
C. 1–5 mm (0.04–0.20 in)
D. Point the ends of hose clamp to the rearward.
E. Fasten the hose with the clamp with its end facing
downward.
F. Install the cylinder head breather hose with its
paint mark facing to the right and completely onto
the hose fitting.
G. 1–3 mm (0.04–0.12 in)
H. Route the cylinder head breather hose through the
guide on the air filter case joint.
I. Install the cylinder head breather hose with its
paint mark facing rightward and completely onto
the hose fitting.
J. 5–6 mm (0.20–0.24 in)
2-30
CABLE ROUTING
Hydraulic unit (top and left/right side view)
2 3
1
5
2 3
2 6
1 6
2-31
CABLE ROUTING

caliper)
caliper)
hydraulic unit)
hydraulic unit)
5. Hydraulic unit assembly
6. Front wheel sensor lead
2-32
CABLE ROUTING
Battery (front side view)
2 3
6
7
10 B 3
9
A
2-33
CABLE ROUTING
1. ABS test coupler

2. Negative battery lead
3. Positive battery lead
4. Battery
5. Yamaha diagnostic tool coupler
6. Starter relay
7. Fuse box 2
8. Fuse box 1
9. Battery band
10. ABS test coupler lead
A. Route the positive battery leads through the
battery band.
B. Route the ABS test coupler lead through the
battery band.
2-34
CABLE ROUTING
Battery (rear view)
2 3 3
2 1
3 2
2
3
2
2-35
CABLE ROUTING
1. Headlight lead
2. Wire harness
3. Starter relay lead
4. Meter assembly coupler
A. Route the wire harness through the guide.
2-36
CABLE ROUTING
Front fork (right side view)
1
B
2
2 1 1 A
2
1
1
C
2
2-37
CABLE ROUTING

caliper)
2. Front wheel sensor
A. Fasten the front brake hose (hydraulic unit to front
brake caliper) and front wheel sensor with the
clamp in the area shown in the illustration.
B. Rearward
C. Forward
2-38
CABLE ROUTING
Fuel tank (right side view)
10 6 10 H
7 4
7
10
6
1 E
C
F 4
6 10 5
G
6 7
B
1 2
3 A B
6
7
I 2
2-39
CABLE ROUTING

2. Fuel hose
3. Canister
4. Fuel tank breather hose (fuel tank to rollover valve)
5. Rollover valve
7. Fuel tank breather hose (rollover valve to canister)
8. Fuel tank
9. Canister breather hose
10. Fuel tank overflow tray
A. Face the paint mark on the canister purge hose to
the right.
B. Face the paint mark on the fuel tank breather hose
(rollover valve to canister) to the right.
C. Face the paint mark on the fuel tank breather hose
(fuel tank to rollover valve) to the right.
D. Face the paint mark on the canister breather hose
to the right.
E. Rearward
F. Forward
G. Fasten the canister purge hose and cooling
system air bleed hose with the holder. Align the
holder with the paint mark on the canister purge
hose.
H. Install the fuel tank breather hose (fuel tank to
rollover valve) completely onto the hose fitting.
I. Position the grommet on the fuel hose to the fuel
pump bracket.
2-40
CABLE ROUTING
Fuel tank (top view)
1 A
E
2
4
D C
B
2-41
CABLE ROUTING
1. Fuel tank overflow hose

2. Fuel tank
3. Canister
A. Face the paint mark on the fuel tank overflow hose
upward.
B. Fasten the canister purge hose with the holder.
Align the holder with the paint mark on the canister
purge hose.
C. Forward
D. Rearward
E. Face the paint mark on the canister purge hose
forward. Point the end of hose clamp forward.
F. Install the canister purge hose up to the bend in
the hose fitting on the throttle body.
2-42
CABLE ROUTING
Rear brake (right side view)
A 1 B 1 C
1 A
1
1
D
2 E
2-43
CABLE ROUTING
1. Rear wheel sensor lead

caliper)
A. Route the rear wheel sensor lead through the
guide on the V-belt case air filter element cover.
Position the rearside edge of the tape on the lead
in the area shown in the illustration.
B. Position the grommet on the rear wheel sensor
lead to the holder on the V-belt case air filter
element cover.
C. Route the rear wheel sensor lead to the upward of
the V-belt case air filter element cover rib.
D. Route the rear wheel sensor lead through the
guide on the V-belt case air filter element cover.
Position the inside edge of the tape on the lead in
the area shown in the illustration.
E. Position the rear brake hose (hydraulic unit to rear
brake caliper) so that the projection on the rear
brake caliper contacts the hose.
2-44
CABLE ROUTING
2-45
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL ........................................................................................................ 3-4
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUG ............................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-8
ADJUSTING THE EXHAUST GAS VOLUME ...........................................3-8
CHECKING THE CANISTER .................................................................... 3-8
REPLACING THE AIR FILTER ELEMENT AND CLEANING THE
CHECK HOSE .......................................................................................... 3-9
3
CLEANING THE V-BELT CASE AIR FILTER ELEMENT .......................3-10
CHECKING THE BRAKE OPERATION .................................................. 3-11
CHECKING THE FRONT BRAKE PADS ................................................ 3-11
CHECKING THE REAR BRAKE PADS .................................................. 3-11
CHECKING THE BRAKE FLUID LEVEL................................................. 3-11
CHECKING THE FRONT BRAKE HOSES ............................................. 3-12
CHECKING THE REAR BRAKE HOSES................................................ 3-12
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)......................... 3-12
CHECKING THE WHEELS ..................................................................... 3-13
CHECKING THE TIRES..........................................................................3-14
CHECKING THE WHEEL BEARINGS ....................................................3-15
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-15
LUBRICATING THE STEERING HEAD.................................................. 3-16
CHECKING THE CHASSIS FASTENERS .............................................. 3-16
LUBRICATING THE LEVERS .................................................................3-17
CHECKING THE SIDESTAND................................................................3-17
LUBRICATING THE SIDESTAND........................................................... 3-17
CHECKING THE CENTERSTAND ......................................................... 3-17
LUBRICATING THE CENTERSTAND ....................................................3-17
CHECKING THE SIDESTAND SWITCH................................................. 3-17
CHECKING THE FRONT FORK ............................................................. 3-17
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-17
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES .............. 3-17
CHECKING THE ENGINE OIL LEVEL....................................................3-18
CHANGING THE ENGINE OIL ...............................................................3-19
CHANGING THE FINAL TRANSMISSION OIL....................................... 3-20
CHECKING THE COOLANT LEVEL.......................................................3-20
CHECKING THE COOLING SYSTEM ....................................................3-21
CHANGING THE COOLANT................................................................... 3-21
REPLACING THE V-BELT ...................................................................... 3-24
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-24
CHECKING AND LUBRICATING THE CABLES .................................... 3-24
CHECKING THE THROTTLE GRIP OPERATION .................................3-24
CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......................... 3-25
ADJUSTING THE HEADLIGHT BEAM ...................................................3-25
PERIODIC MAINTENANCE
EAS20022
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• The annual checks must be performed every year, except if a kilometerbased maintenance, or
for the UK, a mileage-based maintenance, is performed instead.
• From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
CHECK OR MAINTENANCE
JOB ODOMETER READINGS
ANNUAL
NO. ITEM X 1000 km 1 10 20 30 40 CHECK
X 1000 mi 0.6 6 12 18 24
• Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition.
• Adjust gap and clean. √ √
2 * Spark plug
• Replace. √ √
3 * Valve clearance • Check and adjust. Every 20000 km (12000 mi)
4 * Fuel injection • Check engine idle speed. √ √ √ √ √ √
• Check for leakage.
5 * Exhaust system • Tighten if necessary. √ √ √ √ √
• Replace gasket if necessary.
Evaporative emis- • Check control system for
6 * sion control sys- damage. √ √
tem • Replace if necessary.
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• The annual checks must be performed every year, except if a kilometerbased maintenance, or
for the UK, a mileage-based maintenance, is performed instead.
• From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READINGS
JOB
ANNUAL
NO. ITEM
X 1000 km 1 10 20 30 40 CHECK
X 1000 mi 0.6 6 12 18 24
• Perform dynamic inspection
Diagnostic sys-
1 * tem check using Yamaha diagnostic tool. √ √ √ √ √ √
• Check the fault codes.
2 * Air filter element • Replace. √ √
3-1
ODOMETER READINGS
JOB
ANNUAL
NO. ITEM
X 1000 km 1 10 20 30 40 CHECK
X 1000 mi 0.6 6 12 18 24
Pre air filter ele-
3 * • Clean. √ √
ment
Sub air filter ele-
4 * • Replace. √ √
ment
Air filter case
5 check hose • Clean. √ √ √ √ √
6 * V-belt case air fil- • Clean. √ √ √ √ √

ter element • Replace if necessary.
• Check operation, fluid level,
7 * Front brake and for fluid leakage. √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check operation, fluid level,
and for fluid leakage.
8 * Rear brake • Replace brake pads if neces- √ √ √ √ √ √
sary.
• Check for cracks or damage. √ √ √ √ √
9 * Brake hoses
• Replace. Every 4 years
10 * Brake fluid • Change. Every 2 years
• Check runout and for dam-
11 * Wheels age. √ √ √ √
• Check tread depth and for
damage.
12 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
13 * Wheel bearings • Check bearing for looseness √ √ √ √

or damage.
• Check bearing assemblies for
√ √ √
looseness.
14 * Steering bearings
• Moderately repack with lithi-
um-soap-based grease. √ √
• Make sure that all nuts, bolts

15 * Chassis fasteners and screws are properly tight- √ √ √ √ √
ened.
Front and rear • Lubricate with silicone
16 brake lever pivot √ √ √ √ √
shaft grease.
Sidestand, center- • Check operation.

17 • Lubricate with lithium-soap- √ √ √ √ √
stand based grease.
18 * Sidestand switch • Check operation and replace √ √ √ √ √ √

if necessary.
• Check operation and for oil
19 * Front fork leakage. √ √ √ √
• Check operation and for oil
Shock absorber
20 * assemblies leakage. √ √ √ √
• Change (warm engine before
21 Engine oil draining). At the initial interval and when the oil change indicator flash- √
• Check oil level and vehicle for es or comes on.
oil leakage.
Engine oil filter el-
22 ement • Replace. √ √ √
• Check vehicle for oil leakage. √ √ √ √ √

23 * Final transmis-
sion oil • Change. √ √ √
3-2
ODOMETER READINGS
JOB
ANNUAL
NO. ITEM
X 1000 km 1 10 20 30 40 CHECK
X 1000 mi 0.6 6 12 18 24
• Check coolant level and vehi-

√ √ √ √ √
24 * Cooling system cle for coolant leakage.
• Change. Every 3 years
25 * V-belt • Replace. When the V-belt replacement indicator flashes

[every 20000 km (12000 mi)]
Front and rear
26 * • Check operation. √ √ √ √ √ √
brake switches
Moving parts and
27 * cables • Lubricate. √ √ √ √ √
• Check operation and free

play.
Throttle grip • Adjust the throttle cable free
28 * housing and ca- √ √ √ √ √
ble play if necessary.
• Lubricate the throttle grip
housing and cable.
29 * Lights, signals • Check operation. √ √ √ √ √ √

and switches • Adjust headlight beam.
TIP
• Engine air filter and V-belt air filter
• This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not
be cleaned with compressed air to avoid damaging it.
• The engine air filter element and sub air filter element need to be replaced and the V-belt air filter
element needs to be serviced more frequently when riding in unusually wet or dusty areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
EAS32024
5. Install:
CHECKING THE VEHICLE USING THE
• Battery cover assembly
YAMAHA DIAGNOSTIC TOOL
Refer to “GENERAL CHASSIS (1)” on page
Use the Yamaha diagnostic tool and check the
4-1.
vehicle according to the following procedure.
1. Remove: EAS30619
• Battery cover assembly CHECKING THE FUEL LINE

Refer to “GENERAL CHASSIS (1)” on page 1. Remove:
4-1. • Battery cover assembly
2. Remove the protective cap, and then connect Refer to “GENERAL CHASSIS (1)” on page
the Yamaha diagnostic tool to the coupler. 4-1.
• Front cowling assemblies
Yamaha diagnostic tool USB Refer to “GENERAL CHASSIS (2)” on page
90890-03256 4-4.
Yamaha diagnostic tool (A/I) • Lower side covers
90890-03254 Refer to “GENERAL CHASSIS (4)” on page
4-10.
• Bottom cover assembly
2 Refer to “GENERAL CHASSIS (5)” on page
4-13.
1 2. Check:
• Fuel hose “1”
Cracks/damage → Replace.
Loose connections → Connect properly.

2. ABS test coupler
3. Check:
• Fault codes (fuel injection system and ABS)
TIP
Use the “Diagnosis of malfunction” function of
1
the Yamaha diagnostic tool to check the fault
codes. For information about using the Yamaha 3. Install:
diagnostic tool, refer to the operation manual • Bottom cover assembly
that is included with the tool. Refer to “GENERAL CHASSIS (5)” on page
4-13.
Fault code number is displayed → Check and • Lower side covers
repair the probable cause of the malfunction. Refer to “GENERAL CHASSIS (4)” on page
Refer to “TROUBLESHOOTING DETAILS” 4-10.
on page 8-34 and “[B-2] DIAGNOSIS USING • Front cowling assemblies
THE FAULT CODES” on page 8-88. Refer to “GENERAL CHASSIS (2)” on page
4. Perform: 4-4.
• Dynamic inspection • Battery cover assembly
TIP Refer to “GENERAL CHASSIS (1)” on page
Use the “Dynamic inspection” function of the 4-1.
Yamaha diagnostic tool version 3.0 and after to EAS30620
perform the dynamic inspection. For information CHECKING THE SPARK PLUG
about using the Yamaha diagnostic tool, refer to 1. Remove:
the operation manual that is included with the • Storage box
tool. Refer to “GENERAL CHASSIS (4)” on page
4-10.
3-4
2. Remove: 7. Install:
• Spark plug cap • Spark plug “1”
• Spark plug • Spark plug cap
ECA13330
NOTICE Spark plug

Before removing the spark plug, blow away 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling TIP
into the cylinder. • Before installing the spark plug, clean the
spark plug and gasket surface.
3. Check:
• When tightening the spark plug, make sure
• Spark plug type
that the inside “a” of the spark plug wrench “2”
Incorrect → Change.
does not the contact the portion “b” of the spark
Manufacturer/model plug.
NGK/LMAR8A-9
b
4. Check: a 2
• Electrode “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug. 1
Normal color is medium-to-light tan.
8. Install:
• Storage box
4-10.
EAS30622
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
5. Clean: valves.
• Spark plug TIP
(with a spark plug cleaner or wire brush) • Valve clearance adjustment should be made
6. Measure: on a cold engine, at room temperature.
• Spark plug gap “a” • When the valve clearance is to be measured or
(with a wire thickness gauge) adjusted, the piston must be at top dead center
Out of specification → Regap. (TDC) on the compression stroke.
Spark plug gap 1. Remove:
0.8–0.9 mm (0.031–0.035 in) • Battery cover assembly
4-1.
4-4.
• Lower side covers
4-10.
• Bottom cover assembly
4-13.
3-5
• Muffler assembly c
Refer to “ENGINE REMOVAL” on page 5-7. d
• Cylinder head cover
Refer to “CYLINDER HEAD” on page 5-13.
2. Remove:
• Crankshaft end cover “1”
• Timing mark accessing bolt “2”
2
c. Measure the valve clearance with a thick-
ness gauge “1”.
Out of specification → Adjust.
1
1
3. Measure:
• Valve clearance
Valve clearance (cold)

Intake
0.06–0.12 mm (0.0024–0.0047 in)
4. Adjust:
Exhaust
0.20–0.26 mm (0.0079–0.0102 in) • Valve clearance
a. Remove the collars “1”.
a. Turn the crankshaft clockwise.
b. Position the mark “a” on the generator ro-
tor on both sides of the slots “b” in the gen- 1
erator rotor cover.
b. Slide the rocker arms “2” toward the timing

chain, and then remove the valve pads
“3”.
a
TIP 3
2
When the piston is at TDC on the compression
stroke, align the “I” mark “c” on the camshaft
sprocket with the match mark “d” on the cylinder
head.
3
TIP
• Before removing the valve pads, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
3-6
• Make a note of the position of each valve pad Valve pad number = 163
so that they can be reinstalled in their original Rounded value = 165
place. New valve pad number = 165
g. Install the new valve pad.
c. Calculate the difference between the
specified valve clearance and the mea- TIP
sured valve clearance. • Lubricate the valve pad with molybdenum di-
Example: sulfide oil.
Specified valve clearance = 0.06–0.12 • Install the valve pad in the correct place.
mm (0.0024–0.0047 in) h. Measure the valve clearance again.
Measured valve clearance = 0.17 mm i. If the valve clearance is still out of specifi-
(0.0067 in) cation, repeat all of the valve clearance
0.17 mm (0.0067 in)–0.09 mm (0.0035 in) adjustment steps until the specified clear-
= 0.08 mm (0.0031 in) ance is obtained.
d. Check the thickness of the current valve 5. Install:
pad. • All removed parts
TIP TIP
The thickness of each valve pad is marked in For installation, reverse the removal procedure.
hundredths of millimeters on the side that touch-
es the valve cotter. EAS31017
Example: CHECKING THE ENGINE IDLING SPEED

If the valve pad is marked “158”, the pad TIP
thickness is 1.58 mm (0.0622 in). Prior to checking the engine idling speed, the air
e. Calculate the sum of the values obtained filter element should be clean, and the engine
in steps (b) and (c) to determine the re- should have adequate compression.
quired valve pad thickness and the valve 1. Start the engine and let it warm up for several
pad number. minutes.
Example: 2. Check:
1.58 mm (0.0622 in) + 0.05 mm (0.0020 • Engine idling speed
in) = 1.63 mm (0.0641 in) Out of specification → Go to next step.
The valve pad number is 163.
f. Round off the valve pad number according Engine idling speed
to the following table, and then select the 1500–1700 r/min
suitable valve pad.
Last digit Rounded value 3. Check:
• ISC (idle speed control) learning value
1 0
“00” or “01” → Check the intake system.
3, 4 5 “02” → Clean the ISC (idle speed control) unit
6, 7 8 and throttle body.
9 10 Refer to “CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY”
TIP on page 7-15.
Refer to the following table for the available a. Connect the Yamaha diagnostic tool.
valve pads. Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNC-
Valve pad range No. 150–350 TION AND DIAGNOSTIC CODE TABLE”
1.50–3.50 mm on page 9-1.
Valve pad thickness
(0.0590–0.1378 in)
81 thicknesses in 0.025 Yamaha diagnostic tool USB
Available valve pads mm (0.0010 in) incre- 90890-03256
ments Yamaha diagnostic tool (A/I)
90890-03254
Example:
3-7
EAS30625
“YAMAHA DIAGNOSTIC TOOL” on page
CHECKING THE EXHAUST SYSTEM
8-34.
1. Check:
• Exhaust pipe “1” Yamaha diagnostic tool USB
• Muffler assembly “2” 90890-03256
Cracks/damage → Replace. Yamaha diagnostic tool (A/I)
• Gaskets “3”, “4” 90890-03254
Exhaust gas leaks → Replace.
2. Check: EAS31922
Tightening torque CHECKING THE CANISTER

• Exhaust pipe nuts “5” 1. Remove:
• Clamp bolt “6” • Battery
• Muffler assembly bolts “7” Refer to “GENERAL CHASSIS (1)” on page
4-1.
Exhaust pipe nut • Front cowling assemblies
15 N·m (1.5 kgf·m, 11 lb·ft) Refer to “GENERAL CHASSIS (2)” on page
T.
R.
Clamp bolt 4-4.

20 N·m (2.0 kgf·m, 15 lb·ft) • Meter assembly
Muffler assembly bolt Refer to “GENERAL CHASSIS (3)” on page
53 N·m (5.3 kgf·m, 39 lb·ft) 4-7.
4-10.
• Footrest board assembly
4-13.
• Leg shield assembly
4-16.
2. Check:
• Fuel tank breather hose (rollover valve to
canister) “1”
2 • Canister purge hose “2”
• Canister breather hose “3”
7 3
• Canister “4”
1 Damage → Replace.
4
6
5 4 2
3
EAS30799
ADJUSTING THE EXHAUST GAS VOLUME 1

TIP
• Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume. 3. Install:
• To adjust the exhaust gas volume, use the CO • Leg shield assembly
adjustment mode of the Yamaha diagnostic Refer to “GENERAL CHASSIS (6)” on page
tool. For more information, refer to the opera- 4-16.
tion manual of the Yamaha diagnostic tool. • Footrest board assembly
1. Connect the Yamaha diagnostic tool to the Refer to “GENERAL CHASSIS (5)” on page
connector. For information about connecting 4-13.
the Yamaha diagnostic tool, refer to
3-8

4-10.
• Meter assembly
4-7.
4-4.
• Battery
Refer to “GENERAL CHASSIS (1)” on page 3. Install:
4-1. • Pre air filter element
Refer to “INSTALLING THE AIR FILTER
EAS31130
REPLACING THE AIR FILTER ELEMENT CASE” on page 7-12.

AND CLEANING THE CHECK HOSE 4. Remove:
• Sub air filter element “1”
TIP
• Air filter element “2”
Check the air filter check hose “1” that is located Refer to “AIR FILTER CASE” on page 7-11.
on the rear side of the air filter case. If dust or
water or both collects in the hose, clean the hose 1
and replace the air filter element.
1. Remove: 2
• Air filter case cover
• Pre air filter element “1”
Refer to “AIR FILTER CASE” on page 7-11.
5. Check:
• Sub air filter element
• Air filter element
Damage → Replace.
TIP
1 • Replace the air filter element every 20000 km
(12000 mi) of operation.
2. Clean:
• The air filter needs more frequent service if you
• Pre air filter element
are riding in unusually wet or dusty areas.
Blow the compressed air to the outer surface
of the pre air filter element. 6. Install:
• Sub air filter element
• Air filter element
3-9
Air filter case cover screw

1.2 N·m (0.12 kgf·m, 0.88 lb·ft) 1
T.
R.
ECA20480
NOTICE
Never operate the engine without the air filter
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 3. Remove:
and possible overheating. • V-belt case air filter element “1”
TIP
When installing the air filter element into the air
filter case, make sure that the sealing surfaces
are aligned to prevent any air leaks.
EAS31181
CLEANING THE V-BELT CASE AIR FILTER

ELEMENT
1
1. Remove:
• Air filter case cover 4. Clean:
Refer to “AIR FILTER CASE” on page 7-11. • V-belt case air filter element
• Air filter cover bolts “1” Blow the compressed air to the outer surface
• V-belt case air filter element cover “2” of the V-belt case air filter element.
TIP
Lift up the air filter case slightly, remove the rear
wheel sensor lead “3” from the holders “a” on the
V-belt case air filter element cover, and then re-
move the V-belt case air filter element cover.
5. Check:
• V-belt case air filter element
2 Damage → Replace.
ECA13441
1 NOTICE
Since the V-belt case air filter element is a
dry type, do not let grease or water contact it.
a a 6. Install:
• V-belt case air filter element
• V-belt case air duct
• V-belt case air filter element cover
• Air filter case bolts
3
2. Remove:
• V-belt case air duct “1”
3-10
1. Operate the brake.

V-belt case air duct bolt 2. Check:
7 N·m (0.7 kgf·m, 5.2 lb·ft) • Rear brake pad
T.
R.
V-belt case air filter element cov- Wear indicators “a” almost touch the brake
er bolt
disc → Replace the brake pads and brake
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Air filter case bolt pad shims as a set.
10 N·m (1.0 kgf·m, 7.4 lb·ft) Refer to “REAR BRAKE” on page 4-51.
TIP
To route the rear wheel sensor lead, refer to
“CABLE ROUTING” on page 2-13.
7. Install:
Refer to “AIR FILTER CASE” on page 7-11.
a
EAS30801
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 4-38 and • Place the vehicle on the centerstand.
“REAR BRAKE” on page 4-51. • Make sure the vehicle is upright.
TIP • In order to ensure a correct reading of the
Drive on the road, operate the front and rear brake fluid level, make sure the top of the brake
brakes separately and check to see if the brakes fluid reservoir is horizontal.
are operating properly. 2. Check:
• Brake fluid level
EAS30633
Below the minimum level mark “a” → Add the
CHECKING THE FRONT BRAKE PADS specified brake fluid to the proper level.
brake pads. Specified brake fluid
1. Operate the brake. DOT 4
2. Check:
• Front brake pad A
Wear indicator grooves “a” almost disap-
a
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-38.
a
a
EAS30634
CHECKING THE REAR BRAKE PADS

brake pads.
3-11
3. Hold the vehicle upright and apply the front

B
brake several times.
4. Check:
a • Brake hoses
Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-38 and
“ABS (ANTI-LOCK BRAKE SYSTEM)” on
page 4-63.
EAS30636
A. Front brake CHECKING THE REAR BRAKE HOSES

B. Rear brake 1. Check:
EWA13540
• Brake hoses “1”
WARNING Cracks/damage → Replace.
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor 1
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids 1
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- 2. Check:
ing point of the brake fluid and could cause • Rear brake hose holder
vapor lock. Loose → Tighten the holder bolt.
3. Hold the vehicle upright and apply the rear
ECA13540
brake several times.
NOTICE
4. Check:
Brake fluid may damage painted surfaces • Brake hoses
and plastic parts. Therefore, always clean up Brake fluid leakage → Replace the brake
any spilt brake fluid immediately. hose.
Refer to “REAR BRAKE” on page 4-51 and
EAS30635
CHECKING THE FRONT BRAKE HOSES “ABS (ANTI-LOCK BRAKE SYSTEM)” on

1. Check: page 4-63.
• Brake hoses “1” EAS30893
Cracks/damage → Replace. BLEEDING THE HYDRAULIC BRAKE

SYSTEM (ABS)
1 EWA14000
WARNING
Always bleed the brake system when the
1 brake related parts are removed.
ECA22780
NOTICE
• Bleed the brake system in the following or-
der.
• 1st step: Front brake caliper
2. Check: • 2nd step: Rear brake caliper
• Front brake hose/lead guide EWA16530
• Front brake hose holder WARNING

Loose → Tighten the holder and guide bolt. Bleed the ABS whenever:
3-12
• 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
• When bleeding the ABS, make sure that there the brake lever.
is always enough brake fluid before applying i. Repeat steps (e) to (h) until all of the air
the brake. Ignoring this precaution could allow bubbles have disappeared from the brake
air to enter the ABS, considerably lengthening fluid in 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 OPERA-
the brake fluid settle for a few hours. TION TESTS” on page 4-67.
• Repeat the bleeding procedure when the tiny k. After operating the ABS, repeat steps (e)
bubbles in the hose have disappeared. to (i), and then fill the brake master cylin-
1. Bleed: der reservoir to the proper level with the
• ABS specified brake fluid.
a. Fill the brake master cylinder reservoir to l. Tighten the bleed screw to specification.
the proper level with the specified brake Brake caliper bleed screw
fluid. 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
b. Install the brake master cylinder dia-

phragm. m. Fill the brake master cylinder reservoir to
c. Connect a clear plastic hose “1” tightly to the proper level with the specified brake
the bleed screw “2”. fluid.
A Refer to “CHECKING THE BRAKE FLUID
2 LEVEL” on page 3-11.
EWA13110
1
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
EAS30638
CHECKING THE WHEELS

wheels.
B 1. Check:
• Wheel
Damage/out-of-round → Replace.
EWA13260
WARNING
2 Never attempt to make any repairs to the
wheel.
1
TIP
After a tire or wheel has been replaced, always
A. Front brake caliper balance the wheel.
B. Rear brake caliper
2. Measure:
d. Place the other end of the hose into a con- • Radial wheel runout
tainer.
e. Slowly apply the brake several times.
3-13
• Lateral wheel runout EWA13190
Refer to “CHECKING THE FRONT WHEEL” WARNING

on page 4-29 and “CHECKING THE REAR It is dangerous to ride with a worn-out tire.
WHEEL” on page 4-35. When the tire tread reaches the wear limit, re-
place the tire immediately.
EAS30640
CHECKING THE TIRES 2. Check:

The following procedure applies to all of the • Tire surfaces
tires. Damage/wear → Replace the tire.
1. Check:
• Tire pressure
Out of specification → Regulate.
1. Tire tread depth

2. Side wall
3. Wear indicator
EWA13181
WARNING
Wear limit (front)
• The tire pressure should only be checked 1.6 mm (0.06 in) (EUR/MBK
and regulated when the tire temperature brand)
equals the ambient air temperature. 1.5 mm (0.06 in) (OCE)
• The tire pressure and the suspension must Wear limit (rear)
be adjusted according to the total weight 1.6 mm (0.06 in) (EUR/MBK
(including cargo, rider, passenger and ac- brand)
cessories) and the anticipated riding 1.5 mm (0.06 in) (OCE)
speed.
EWA14080
• Operation of an overloaded vehicle could
WARNING
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE. • Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire fail-
ure and personal injury from sudden
Tire air pressure (measured on
deflation.
cold tires)
1 person • When using a tube tire, be sure to install the
Front correct tube.
200 kPa (2.00 kgf/cm², 29 psi) • Always replace a new tube tire and a new
Rear tube as a set.
225 kPa (2.25 kgf/cm², 33 psi) • To avoid pinching the tube, make sure the
2 persons wheel rim band and tube are centered in the
Front wheel groove.
200 kPa (2.00 kgf/cm², 29 psi) • Patching a punctured tube is not recom-
Rear mended. If it is absolutely necessary to do
225 kPa (2.25 kgf/cm², 33 psi) so, use great care and replace the tube as
Maximum load soon as possible with a good quality re-
161 kg (355 lb)
placement.
* Total weight of rider, passenger, cargo
and accessories
3-14
A B
2
1
TUBELESS
FOR TUBELESS
A. Tire
B. Wheel
EAS30641
Tube wheel Tube tire only CHECKING THE WHEEL BEARINGS
Tubeless wheel Tube or tubeless tire The following procedure applies to all of the
EWA14090
wheel bearings.
WARNING 1. Check:
• Wheel bearings
After extensive tests, the tires listed below
Refer to “CHECKING THE FRONT WHEEL”
have been approved by Yamaha Motor Co.,
on page 4-29.
Ltd. for this model. The front and rear tires
should always be by the same manufacturer EAS30645
and of the same design. No guarantee con- CHECKING AND ADJUSTING THE
cerning handling characteristics can be giv- STEERING HEAD
en if a tire combination other than one 1. Stand the vehicle on a level surface.
EWA13120
approved by Yamaha is used on this vehicle.
WARNING
Securely support the vehicle so that there is
Front tire
Size no danger of it falling over.
120/70–15 M/C 56P TIP
Manufacturer/model
Place the vehicle on a suitable stand so that the
DUNLOP/SCOOTSMART
front wheel elevated.
2. Check:
Rear tire
• Steering head
Size
140/70–14 M/C 62P Grasp the handlebar and gently rock the han-
Manufacturer/model dlebar.
DUNLOP/SCOOTSMART Binding/looseness → Adjust the steering
head.
EWA13210
3. Remove:
WARNING • Battery
New tires have a relatively low grip on the Refer to “GENERAL CHASSIS (1)” on page
road surface until they have been slightly 4-1.
worn. Therefore, approximately 100 km • Front cowling assemblies
should be traveled at normal speed before Refer to “GENERAL CHASSIS (2)” on page
any high-speed riding is done. 4-4.
• Meter panel assembly
TIP
For tires with a direction of rotation mark “1”: 4-7.
• Install the tire with the mark pointing in the di- • Handlebar
rection of wheel rotation. Refer to “HANDLEBAR” on page 4-71.
• Align the mark “2” with the valve installation 4. Adjust:
point. • Steering head
a. Remove the lock washer “1”, upper ring
nut “2” and rubber washer “3”.
3-15
Refer to “STEERING HEAD” on page

4-87.
2
e. Install the rubber washer.
f. Install the upper ring nut.
3
g. Finger tighten the upper ring nut, then
1 align the slots of both ring nuts. If neces-
sary, hold the lower ring nut and tighten
the upper ring nut until their slots are
aligned.
h. Install the lock washer “1”.
b. Loosen the lower ring nut “4” and then TIP
tighten it to specification with a steering Make sure the lock washer tabs “a” sit correctly
nut wrench “5”. in the ring nut slots “b”.
TIP
Set the torque wrench at a right angle to the 1
steering nut wrench.
a
Steering nut wrench
90890-01403
Exhaust flange nut wrench b
YU-A9472
Lower ring nut (initial tightening

torque) 5. Install:
T.
R.
48 N·m (4.8 kgf·m, 35 lb·ft) • Handlebar

Refer to “HANDLEBAR” on page 4-71.
• Meter panel assembly
4-7.
5 Refer to “GENERAL CHASSIS (2)” on page
4-4.
• Battery
4 4-1.
c. Loosen the lower ring nut, and then tighten EAS30646
LUBRICATING THE STEERING HEAD

it to specification with a steering nut
1. Lubricate:
wrench.
EWA13140 • Bearing cover
WARNING • Upper bearing
Do not overtighten the lower ring nut. • Lower bearing
• Dust seal
Lower ring nut (final tightening Recommended lubricant
torque) Lithium-soap-based grease
T.
R.
14 N·m (1.4 kgf·m, 10 lb·ft)

EAS31186
d. Check the steering head for looseness or CHECKING THE CHASSIS FASTENERS
binding by turning the front fork all the way Make sure that all nuts, bolts, and screws are
in both directions. If any binding is felt, re- properly tightened.
move the lower bracket and check the up-
per and lower bearings.
3-16
EAS30648
3. Hold the vehicle upright and apply the front
LUBRICATING THE LEVERS
brake.
Lubricate the pivoting point and metal-to-metal
4. Check:
moving parts of the levers.
• Front fork operation
Recommended lubricant Push down hard on the handlebar several
Silicone grease times and check if the front fork rebounds
smoothly.
EAS30650 Rough movement → Repair.
CHECKING THE SIDESTAND Refer to “FRONT FORK” on page 4-78.
1. Check:
• Sidestand operation
Check that the sidestand moves smoothly.
Rough movement → Repair or replace.
EAS30651
LUBRICATING THE SIDESTAND

Lubricate the pivoting point, metal-to-metal mov-
ing parts, and spring contact point of the side-
stand.
Recommended lubricant EAS30808
Lithium-soap-based grease CHECKING THE REAR SHOCK ABSORBER

ASSEMBLIES
EAS30856 The following procedure applies to both of the
CHECKING THE CENTERSTAND rear shock absorber assemblies.
1. Check: 1. Stand the vehicle on a level surface.
• Centerstand operation EWA13120
Check that the centerstand moves smoothly. WARNING

Rough movement → Repair or replace. Securely support the vehicle so that there is
EAS30857
no danger of it falling over.
LUBRICATING THE CENTERSTAND 2. Check:
Lubricate the pivoting point, metal-to-metal mov- • Rear shock absorber assembly
ing parts, and spring contact points of the center- Oil leaks → Replace the rear shock absorber
stand. assembly.
Refer to “CHECKING THE REAR SHOCK
Recommended lubricant
Lithium-soap-based grease ABSORBER ASSEMBLY” on page 4-92.
3. Check:
EAS30652
• Rear shock absorber assembly operation
CHECKING THE SIDESTAND SWITCH Push down seat on the vehicle several times
Refer to “CHECKING THE SWITCHES” on and check if the rear shock absorber assem-
page 8-127. bly rebounds smoothly.
Rough movement → Replace.
EAS30653
CHECKING THE FRONT FORK Refer to “REAR SHOCK ABSORBER AS-

1. Stand the vehicle on a level surface. SEMBLIES AND SWINGARM” on page
EWA13120 4-91.
WARNING
EAS30655
Securely support the vehicle so that there is ADJUSTING THE REAR SHOCK ABSORBER
no danger of it falling over. ASSEMBLIES
2. Check: The following procedure applies to both of the
• Inner tube rear shock absorber assemblies.
EWA17520
Damage/scratches → Replace. WARNING
• Oil seal
• Securely support the vehicle so that there
Oil leakage → Replace.
is no danger of it falling over.
3-17
• Always adjust both rear shock absorber as- EAS30656
CHECKING THE ENGINE OIL LEVEL

semblies evenly. Uneven adjustment can
1. Stand the vehicle on a level surface.
result in poor handling and loss of stability.
TIP
• Place the vehicle on the centerstand.
Spring preload
ECA13590 • Make sure the vehicle is upright.
NOTICE 2. Start the engine, warm it up for several min-
Never go beyond the maximum or minimum utes, and then turn it off.
adjustment positions. 3. Check:
1. Adjust: • Engine oil level
• Spring preload The engine oil level should be between the
minimum level mark “a” and maximum level
TIP
mark “b”.
Adjust the spring preload with the special Below the minimum level mark → Add the
wrench and extension bar included in the own- recommended engine oil to the proper level.
er’s tool kit.
TIP
a. Turn the adjusting ring “1” in direction “a” Before checking the engine oil level, wait a few
or “b”. minutes until the oil has settled.
b. Align the desired position on the adjusting
ring with the position indicator “2”. b
Direction “a”
Spring preload is increased (suspen-
sion is harder). a
Direction “b”
Spring preload is decreased (suspen-
sion is softer).
Adjusting positions
Adjustment value (Soft) Recommended brand
1 YAMALUBE
Adjustment value (STD) SAE viscosity grades
3 10W-40
Adjustment value (Hard) Recommended engine oil grade
5 API service SG type or higher,
JASO standard MA or MB
TIP
ECA13370
The adjustment value is the adjusting ring posi-
NOTICE
tion number.
Do not allow foreign materials to enter the
crankcase.
4. Start the engine, warm it up for several min-
1 a b
utes, and then turn it off.
5. Check the engine oil level again.
TIP
1
2
3
4
Before checking the engine oil level, wait a few
5
minutes until the oil has settled.
2
3-18
EAS30657
c. Install the oil filter element and oil filter el-
CHANGING THE ENGINE OIL
ement cover.
utes, and then turn it off. Oil filter element cover bolt
2. Place a container under the engine oil drain 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
bolt.
3. Remove: 6. Install:
• Engine oil filler cap “1” • Engine oil drain bolt
(along with the O-ring “2”) (along with the gasket New )
• Engine oil drain bolt “3”
(along with the gasket “4”) Engine oil drain bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
1 7. Fill:
• Crankcase
(with the specified amount of the recom-
mended engine oil)
2 Engine oil quantity

Oil change
1.50 L (1.59 US qt, 1.32 Imp.qt)
With oil filter removal
1.60 L (1.69 US qt, 1.41 Imp.qt)
Quantity (disassembled)
1.70 L (1.80 US qt, 1.50 Imp.qt)
8. Install:
• Engine oil filler cap
4 3
(along with the O-ring New )
10.Check:
4. Drain: • Engine
• Engine oil (for engine oil leaks)
(completely from the crankcase) 11.Check:
5. If the oil strainer is also to be cleaned, per- • Engine oil level
form the following procedure. Refer to “CHECKING THE ENGINE OIL
a. Remove the oil filter element cover “1” and LEVEL” on page 3-18.
oil filter element “2”. 12.Remove:
b. Install a new O-ring “3” New . • Storage box
TIP
4-10.
Lubricate the O-ring with lithium-soap-based 13.Check:
grease. • Engine oil pressure
a. Slightly loosen the oil check bolt “1”.
1 2
LS
3 New
1
3-19
b. Start the engine and keep it idling until en- 5. Install:

gine oil starts to seep from the oil check • Final transmission oil drain bolt
bolt. If no engine oil comes out after one (along with the copper washer New )
minute, turn the engine off so that it will not
seize. Final transmission oil drain bolt
c. Check the engine oil passages and the oil 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
pump for damage or leakage. Refer to
“OIL PUMP” on page 5-56. 6. Fill:
d. Start the engine after solving the prob- • Final transmission oil
lem(s) and check the engine oil pressure (with the specified amount of the recom-
again. mended final transmission oil)
e. Tighten the oil check bolt to specification.
Final transmission oil
Engine oil check bolt Type
7 N·m (0.7 kgf·m, 5.2 lb·ft) Motor oil SAE 10W-30 type SE
T.
or higher or Gear oil SAE 85W

R.
EAS31187
GL-3
CHANGING THE FINAL TRANSMISSION OIL Quantity (disassembled)
1. Stand the vehicle on a level surface. 0.23 L (0.24 US qt, 0.20 Imp.qt)
Quantity
TIP 0.20 L (0.21 US qt, 0.18 Imp.qt)
• Make sure the vehicle is upright. 7. Install:
2. Start the engine, warm it up for several min- • Final transmission oil filler cap
utes, and then turn it off. (along with the O-ring New )
3. Place a container under the final transmis- TIP
sion. Lubricate the O-ring with lithium-soap-based
4. Remove: grease.
• Final transmission oil filler cap “1”
(along with the O-ring “2”) 8. Start the engine, warm it up for several min-
• Final transmission oil drain bolt “3” utes, and then turn it off.
(along with the copper washer “4”) 9. Check:
Completely drain the final transmission oil. • Final transmission oil leakage
EAS30811
CHECKING THE COOLANT LEVEL

1 1. Stand the vehicle on a level surface.
TIP
• Make sure the vehicle is upright.
2 2. Check:
• Coolant level
The coolant level should be between the min-
imum level mark “a” and maximum level mark
“b”.
Below the minimum level mark → Add the
recommended coolant to the proper level.
4 3
3-20
• Thermostat assembly “8”

• Water pump inlet hose “9”
• Water pump outlet pipe “10”
Cracks/tears → Replace.
Refer to “RADIATOR” on page 6-2, “THER-
b MOSTAT” on page 6-6 and “WATER PUMP”
a on page 6-8.
ECA13470
2 9
NOTICE 4
• Adding water instead of coolant lowers the 5 8
10
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis- 1
tilled water is not available, soft water may
be used.
3. Start the engine, warm it up for several min- 6
4. Check:
• Coolant level
TIP
Before checking the coolant level, wait a few 7
minutes until the coolant has settled.
3. Install:
EAS30812
• Exhaust pipe
CHECKING THE COOLING SYSTEM
Refer to “ENGINE REMOVAL” on page 5-7.
1. Remove:
• Radiator cover
4-13.
4-1.
4-10.
4-4.
4-4.
4-10.
• Radiator cover
4-1.
4-13.
• Exhaust pipe EAS30813
Refer to “ENGINE REMOVAL” on page 5-7. CHANGING THE COOLANT

2. Check: 1. Remove:
• Radiator “1” • Battery cover assembly
• Cooling system air bleed hose “2” Refer to “GENERAL CHASSIS (1)” on page
• Coolant reservoir hose “3” 4-1.
• Radiator filler pipe “4” • Front cowling assemblies
• Radiator filler hose “5” Refer to “GENERAL CHASSIS (2)” on page
• Radiator outlet hose “6” 4-4.
• Radiator inlet hose “7”
3-21
• Lower side covers 5. Remove:

Refer to “GENERAL CHASSIS (4)” on page • Coolant drain bolt (radiator side) “1”
4-10. (along with the O-ring)
• Radiator cover • Coolant drain bolt (water pump side) “2”
Refer to “GENERAL CHASSIS (5)” on page (along with the copper washer)
4-13.
2. Disconnect:
• Coolant reservoir breather hose “1”
• Coolant reservoir hose “2”
1
2
3. Drain:
• Coolant
(from the coolant reservoir)
4. Remove:
• Radiator cap “1”
EWA13030
2
WARNING
6. Drain:
A hot radiator is under pressure. Therefore, • Coolant
do not remove the radiator cap when the en- (from the engine and radiator)
gine is hot. Scalding hot fluid and steam may 7. Install:
be blown out, which could cause serious in- • Coolant drain bolt (water pump side)
jury. When the engine has cooled, open the
radiator cap as follows: (along with the copper washer New )
Place a thick rag or a towel over the radiator • Coolant drain bolt (radiator side)
cap and slowly turn the radiator cap counter- (along with the O-ring New )
clockwise toward the detent to allow any re-
Coolant drain bolt (water pump
sidual pressure to escape. When the hissing
side)
T.
sound has stopped, press down on the radi-

R.
10 N·m (1.0 kgf·m, 7.4 lb·ft)

ator cap and turn it counterclockwise to re- Coolant drain bolt (radiator side)
move. 1.6 N·m (0.16 kgf·m, 1.2 lb·ft)
TIP
8. Fill:
When removing the radiator cap, hold the radia- • Cooling system
tor filler pipe “2”. (with the specified amount of the recom-
mended coolant)
1
Mixing ratio 1:1 (antifreeze: wa-
ter)
Radiator (including all routes)
1.10 L (1.16 US qt, 0.97 Imp.qt)
Coolant reservoir (up to the
2 maximum level mark)
0.18 L (0.19 US qt, 0.16 Imp.qt)
Handling notes for coolant
3-22
Coolant is potentially harmful and should be

handled with special care.
EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
• If coolant splashes on your clothes, quickly a
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting 13.Install:
and get immediate medical attention. • Coolant reservoir cap “1”
ECA13481
TIP
NOTICE Point the tab “a” on the coolant reservoir cap
• Adding water instead of coolant lowers the rearward.
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
1
tion of the coolant. a
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with wa- D
FW
ter.
• Do not mix different types of antifreeze.
14.Start the engine, warm it up for several min-
9. Install: utes, and then turn it off.
• Radiator cap “1” 15.Check:
TIP • Coolant level
Make sure that the projection “a” on the radiator Refer to “CHECKING THE COOLANT LEV-
cap contacts the projection “b” on the radiator fill- EL” on page 3-20.
er pipe. TIP
Before checking the coolant level, wait a few
a 1 minutes until the coolant has settled.
16.Install:
• Radiator cover
b Refer to “GENERAL CHASSIS (5)” on page
4-13.
4-10.
10.Connect: Refer to “GENERAL CHASSIS (2)” on page
• Coolant reservoir hose 4-4.
Coolant reservoir breather hose • Battery cover assembly
11.Remove: Refer to “GENERAL CHASSIS (1)” on page
• Coolant reservoir cap 4-1.
12.Fill:
• Coolant reservoir
(with the recommended coolant to the maxi-
mum level mark “a”)
3-23
EAS31188
1. Check:
REPLACING THE V-BELT
• Outer cable
1. Remove:
Damage → Replace.
• Storage box
2. Check:
• Cable operation
4-10.
Rough movement → Lubricate.
• Air filter case
Refer to “AIR FILTER CASE” on page 7-11. Recommended lubricant
• V-belt case Engine oil or a suitable cable lu-
Refer to “V-BELT AUTOMATIC TRANSMIS- bricant
SION” on page 5-37.
2. Check: TIP
• V-belt Hold the cable end upright and pour a few drops
Damage/wear → Replace. of lubricant into the cable sheath or use a suit-
Grease/oil → Clean the primary and second- able lubricating device.
ary pulleys.
Refer to “V-BELT AUTOMATIC TRANSMIS- EAS30861
SION” on page 5-37. CHECKING THE THROTTLE GRIP

TIP OPERATION
Replace the V-belt every 20000 km (12000 mi) 1. Check:
of operation. • Throttle cables
Damage/deterioration → Replace.
3. Install: • Throttle cable installation
• V-belt case Incorrect → Reinstall the throttle cables.
Refer to “V-BELT AUTOMATIC TRANSMIS- Refer to “HANDLEBAR” on page 4-71.
SION” on page 5-37. 2. Check:
• Air filter case • Throttle grip movement
Refer to “AIR FILTER CASE” on page 7-11. Rough movement → Lubricate or replace the
• Storage box defective part(s).
4-10. Recommended lubricant
Suitable cable lubricant
EAS30658
CHECKING THE BRAKE LIGHT SWITCHES

TIP
1. Check:
• Front brake light switch operation With the engine stopped, turn the throttle grip
• Rear brake light switch operation slowly and release it. Make sure that the throttle
When operating the brake levers, confirm grip turns smoothly and returns properly when
that the brake light comes on. released.
Faulty → Refer to “CHECKING THE Repeat this check with the handlebar turned all
SWITCHES” on page 8-127. the way to the left and right.
EAS30660
3. Check:
CHECKING AND LUBRICATING THE • Throttle grip free play “a”
CABLES Out of specification → Adjust.
The following procedure applies to all of the in-
ner and outer cables. Throttle grip free play
EWA13270 3.0–5.0 mm (0.12–0.20 in)
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
3-24
Faulty → Refer to “CHECKING THE

SWITCHES” on page 8-127 and “CHECK-
ING THE BULBS AND BULB SOCKETS” in
“BASIC INFORMATION” (separate volume).
EAS30664
ADJUSTING THE HEADLIGHT BEAM

a 1. Adjust:
• Headlight beam (vertically)
a. Turn the adjusting bolt “1”.
4. Adjust:
• Throttle grip free play
a. Slide back the rubber cover “1”.
b. Loosen the locknut “2”.
c. Turn the adjusting nut “3” until the speci-
fied throttle grip free play is obtained. 1
3 1
2
d. Tighten the locknut.
Throttle cable adjusting locknut

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
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.
EWA17990
WARNING
After adjusting the throttle grip free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
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.
Refer to “Instrument and control functions” in
OWNER’S MANUAL.
3-25
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

INSTALLING THE BATTERY BAND.........................................................4-2
REMOVING THE BATTERY COVER ASSEMBLY ...................................4-2
INSTALLING THE BATTERY COVER ASSEMBLY..................................4-2
DISASSEMBLING THE BATTERY COVER ASSEMBLY .........................4-3
ASSEMBLING THE BATTERY COVER ASSEMBLY ............................... 4-3
ADJUSTING THE WINDSHIELD HEIGHT................................................ 4-3
GENERAL CHASSIS (2) ................................................................................. 4-4

REMOVING THE FRONT COWLING ASSEMBLIES ............................... 4-5
INSTALLING THE FRONT COWLING ASSEMBLIES .............................. 4-5
DISASSEMBLING THE FRONT COWLING ASSEMBLIES......................4-5
ASSEMBLING THE FRONT COWLING ASSEMBLIES............................ 4-5
GENERAL CHASSIS (3) ................................................................................. 4-7

REMOVING THE METER ASSEMBLY PANEL MOLDING ......................4-9
INSTALLING THE METER ASSEMBLY PANEL MOLDING..................... 4-9
GENERAL CHASSIS (4) ............................................................................... 4-10

REMOVING THE UPPER SIDE COVERS.............................................. 4-11
4
INSTALLING THE UPPER SIDE COVERS ............................................4-11
REMOVING THE LOWER CENTER COVER .........................................4-11
INSTALLING THE LOWER CENTER COVER........................................ 4-11
REMOVING THE LOWER SIDE COVERS ............................................. 4-12
INSTALLING THE LOWER SIDE COVERS............................................4-12
GENERAL CHASSIS (5) ............................................................................... 4-13

DISASSEMBLING THE FOOTREST BOARD ASSEMBLIES................. 4-15
ASSEMBLING THE FOOTREST BOARD ASSEMBLIES.......................4-15
INSTALLING THE RADIATOR COVER .................................................. 4-15
GENERAL CHASSIS (6) ............................................................................... 4-16

REMOVING THE FUEL TANK CAP LID COVER ................................... 4-19
INSTALLING THE FUEL TANK CAP LID COVER..................................4-19
REMOVING THE UPPER CENTER COVER..........................................4-19
INSTALLING THE UPPER CENTER COVER ........................................ 4-19
GENERAL CHASSIS (7) ............................................................................... 4-21

INSTALLING THE SEAT DAMPER......................................................... 4-22
GENERAL CHASSIS (8) ............................................................................... 4-23

REMOVING THE REAR CENTER COVER ............................................4-25
INSTALLING THE REAR CENTER COVER...........................................4-25
REMOVING THE REAR UPPER COWLINGS........................................ 4-25
INSTALLING THE REAR UPPER COWLINGS ...................................... 4-26
FRONT WHEEL............................................................................................. 4-27
REMOVING THE FRONT WHEEL.......................................................... 4-29
DISASSEMBLING THE FRONT WHEEL................................................ 4-29
CHECKING THE FRONT WHEEL .......................................................... 4-29
MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR
ROTOR................................................................................................... 4-30
ASSEMBLING THE FRONT WHEEL......................................................4-30
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-31
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC).................. 4-31
REAR WHEEL ...............................................................................................4-34

REMOVING THE REAR WHEEL (DISC) ................................................ 4-35
CHECKING THE REAR WHEEL............................................................. 4-35
MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR
ROTOR................................................................................................... 4-35
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-35
INSTALLING THE REAR WHEEL SENSOR ..........................................4-35
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-36
FRONT BRAKE ............................................................................................. 4-38

INTRODUCTION .....................................................................................4-44
CHECKING THE FRONT BRAKE DISC ................................................. 4-44
REPLACING THE FRONT BRAKE PADS .............................................. 4-45
REMOVING THE FRONT BRAKE CALIPER..........................................4-46
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-46
CHECKING THE FRONT BRAKE CALIPER ..........................................4-47
ASSEMBLING THE FRONT BRAKE CALIPER ...................................... 4-47
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-47
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-48
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-49
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-49
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-49
REAR BRAKE ...............................................................................................4-51

INTRODUCTION .....................................................................................4-57
CHECKING THE REAR BRAKE DISC....................................................4-57
REPLACING THE REAR BRAKE PADS................................................. 4-57
REMOVING THE REAR BRAKE CALIPER ............................................4-58
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-59
CHECKING THE REAR BRAKE CALIPER............................................. 4-59
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-59
INSTALLING THE REAR BRAKE CALIPER...........................................4-60
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-61
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-61
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-61
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-61
ABS (ANTI-LOCK BRAKE SYSTEM)........................................................... 4-63
REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-65
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-65
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-65
HYDRAULIC UNIT OPERATION TESTS................................................ 4-67
CHECKING THE ABS WARNING LIGHT ............................................... 4-70
HANDLEBAR ................................................................................................4-71
ADJUSTING THE HANDLEBAR POSITION...........................................4-74
REMOVING THE UPPER HANDLEBAR COVER................................... 4-74
REMOVING THE HANDLEBAR..............................................................4-74
CHECKING THE HANDLEBAR ..............................................................4-75
INSTALLING THE HANDLEBAR ............................................................ 4-75
INSTALLING THE UPPER HANDLEBAR COVER .................................4-77
FRONT FORK................................................................................................4-78
REMOVING THE FRONT FORK LEGS.................................................. 4-82
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-82
CHECKING THE FRONT FORK LEGS .................................................. 4-83
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-83
INSTALLING THE FRONT FORK LEGS ................................................ 4-86
STEERING HEAD.......................................................................................... 4-87

REMOVING THE LOWER BRACKET.....................................................4-89
CHECKING THE STEERING HEAD .......................................................4-89
INSTALLING THE STEERING HEAD .....................................................4-89
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM................... 4-91

REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ............... 4-92
REMOVING THE SWINGARM................................................................4-92
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-92
CHECKING THE SWINGARM ................................................................4-92
INSTALLING THE SWINGARM ..............................................................4-92
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the battery cover assembly and windshield
0.5 N•m (0.05 kgf•m, 0.37 lb•ft)
T.R
.
5
4
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
6
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
7
9 10
11
8
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
1
2
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
Order Job/Parts to remove Q’ty Remarks

1 Battery cover assembly 1
2 Battery front cover 1
3 Battery rear cover 1
4 Windshield cover 2
5 Windshield 1
6 Windshield bracket 2
7 Negative battery lead 1 Disconnect.
8 Positive battery lead 1 Disconnect.
9 ABS test coupler 1
10 Battery 1
11 Battery band 1
4-1
GENERAL CHASSIS (1)
EAS32305 EAS32307
INSTALLING THE BATTERY BAND INSTALLING THE BATTERY COVER

1. Install: ASSEMBLY
• Battery band “1” 1. Install:
TIP • Battery cover assembly “1”
Install the battery band with the arrow mark “a”
pointing up.
1
a a. Fit the projections “a” on the battery cover

assembly into the grommets.
b. Fit the projections “b” on the battery cover
EAS32306 assembly into the holes “c” in the front up-
REMOVING THE BATTERY COVER per cowlings.
ASSEMBLY
1. Remove: b
• Battery cover assembly “1” 1 c
1 a
c
c
b a b
c. Install the battery cover assembly screws,

and then tighten the screws to specifica-
tion.
a. Remove the battery cover assembly
screws. Battery cover assembly screw
b. Remove the projections “a” on the battery 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
cover assembly from the holes “b” in the

front upper cowlings.
c. Pull the battery cover assembly forward to
remove the projections “c” on the battery
cover assembly from the grommets.
1 a
b
c
b
b
a c a
4-2
GENERAL CHASSIS (1)
EAS32308
DISASSEMBLING THE BATTERY COVER

ASSEMBLY 1
1. Remove the battery cover screws and quick
fastener.
2. Remove the projections “a” on the battery
front cover “1” from the holes “b” in the battery
rear cover “2”. 1
b b 2
3. Install:
b • Windshield
• Windshield covers
a a
Windshield screw
1 0.5 N·m (0.05 kgf·m, 0.37 lb·ft)
T.
R.
a
EAS32309
ASSEMBLING THE BATTERY COVER

ASSEMBLY
1. Fit the projections “a” on the battery front cov-
er “1” into the holes “b” in the battery rear cov-
er “2”.
b b 2
b
a a
1
a
2. Install the battery cover screws and quick fas-

tener, and then tighten the screws to specifi-
cation.
Battery cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
EAS31397
ADJUSTING THE WINDSHIELD HEIGHT

1. Remove:
• Windshield covers
• Windshield
2. Adjust:
• Windshield height position
TIP
Remove the bolts, and then install the bolts “1”
in the desired position.
4-3
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the front cowlings
4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
T.R
.
.
5 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
10
2
6 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1
11 12
7
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
4
8
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 3

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 9

T.R
.

Battery cover assembly 4-1.
1 Footrest board mat (left) 1
2 Footrest board mat (right) 1
3 Front cowling assembly (left) 1
4 Front turn signal light coupler (left) 1 Disconnect.
5 Front cowling assembly (right) 1
6 Front turn signal light coupler (right) 1 Disconnect.
7 Front upper cowling (left) 1
8 Front turn signal light (left) 1
9 Front lower cowling (left) 1
10 Front upper cowling (right) 1
11 Front turn signal light (right) 1
12 Front lower cowling (right) 1
4-4
GENERAL CHASSIS (2)
EAS32310
REMOVING THE FRONT COWLING

ASSEMBLIES b a 1
The following procedure applies to both of the
front cowling assemblies.
1. Remove:
• Front cowling assembly “1”
b
a
b. Install the front cowling assembly bolt,

screws, and quick fasteners, and then
tighten the bolt and screws to specifica-
tion.
1 Front cowling assembly bolt
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
a. Remove the front cowling assembly bolt, Front cowling assembly screw
screws, and quick fasteners. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
b. Pull the front cowling assembly outward to
remove the projections “a” on the front EAS32312
cowling assembly from the holes “b” in the DISASSEMBLING THE FRONT COWLING
leg shield assembly and headlight unit ASSEMBLIES
cover. The following procedure applies to both of the
1. Remove the front cowling screws and clamp.
b a 1 2. Remove the projections “a” on the front upper
cowling “1” from the holes “b” in the front low-
er cowling “2”.
a
b
a
b
EAS32311
2
INSTALLING THE FRONT COWLING
ASSEMBLIES a
1
The following procedure applies to both of the b b
1. Install: EAS32313
• Front cowling assembly “1” ASSEMBLING THE FRONT COWLING

ASSEMBLIES
a. Fit the projections “a” on the front cowling

assembly into the holes “b” in the leg
shield assembly and headlight unit cover.
4-5
GENERAL CHASSIS (2)
1. Fit the projections “a” on the front upper cowl-

ing “1” into the holes “b” in the front lower
cowling “2”.
b
2
a
1
b b
2. Install the front cowling screws and clamp,

and then tighten the screws to specification.
Front cowling screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
3. Route the front turn signal light lead through

the guides “a” on the front upper cowling and
front lower cowling.
4. Fit the front turn signal light coupler into the
slot “b” in the front upper cowling.
4-6
GENERAL CHASSIS (3)
EAS20156
GENERAL CHASSIS (3)

Removing the headlight unit and meter assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
5
8 N•m (0.8 kgf•m, 5.9 lb•ft)

10
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
8 9
6
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1 4
2
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Battery 4-1.
Front cowling assemblies 4-4.
1 Headlight assembly 1
2 Headlight unit coupler 1 Disconnect.
3 Headlight unit cover 1
4 Headlight unit 1
5 Meter assembly panel molding 1
6 Starter relay 1
7 Fuse box 1 1
8 Fuse box 2 1
9 Yamaha diagnostic tool coupler 1
10 Battery box 1
4-7
GENERAL CHASSIS (3)
Removing the headlight unit and meter assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
13
8 N•m (0.8 kgf•m, 5.9 lb•ft)

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

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

T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

11 Windshield plate 2
12 Meter assembly coupler 1 Disconnect.
13 Meter panel assembly 1
14 Meter assembly panel 1
15 Meter assembly 1
4-8
GENERAL CHASSIS (3)
EAS32314
REMOVING THE METER ASSEMBLY PANEL

MOLDING
1. Remove:
• Meter assembly panel molding “1”
TIP
Remove the projections “a” on the meter assem-
bly panel molding from the holes “b” in the meter
assembly panel.
b a
1
EAS32315
INSTALLING THE METER ASSEMBLY

PANEL MOLDING
1. Install:
• Meter assembly panel molding “1”
TIP
Fit the projections “a” on the meter assembly
panel molding into the holes “b” in the meter as-
sembly panel.
b a
4-9
GENERAL CHASSIS (4)
EAS20157
GENERAL CHASSIS (4)

Removing the storage box and side covers
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
3
2 1
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 4

T.R
.
7
6
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
9 8
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

5
T.R
.

1 Storage box 1
2 Storage box light connector 2 Disconnect.
3 Storage box light 1
4 Flap 1
5 Upper side cover (left) 1
6 Upper side cover (right) 1
7 Lower center cover 1
8 Lower side cover (left) 1
9 Lower side cover (right) 1
4-10
GENERAL CHASSIS (4)
EAS32316
REMOVING THE UPPER SIDE COVERS b

upper side covers. a
1. Remove:
• Upper side cover “1”
1 1
b. Install the quick fasteners.

EAS32318
REMOVING THE LOWER CENTER COVER

1. Remove:
• Lower center cover “1”
a. Remove the quick fasteners.
b. Pull the upper side cover outward to re- 1
move the projections “a” from the holes “b”
in the lower side covers.
b
1 a. Remove the lower center cover screws.

b. Pull the lower center cover outward to re-
move the projections “a” on the cover from
the holes “b” in the lower side cover.
EAS32317
INSTALLING THE UPPER SIDE COVERS 1

upper side covers.
1. Install:
• Upper side cover “1” a
1
b
EAS32319
INSTALLING THE LOWER CENTER COVER

1. Install:
• Lower center cover “1”
1
a. Fit the projections “a” on the upper side
cover into the holes “b” in the lower side
covers.
4-11
GENERAL CHASSIS (4)
a. Fit the projections “a” on the lower center 1. Install:

cover into the holes “b” in the lower side • Lower side cover “1”
cover.
1
a
b
a. Fit the projections “a” on the lower side
b. Install the lower center cover screws, and cover into the grommets “b”.
then tighten the screws to specification.
b
Lower center cover screw 1
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
EAS32320
REMOVING THE LOWER SIDE COVERS

lower side covers.
1. Remove: a
• Lower side cover “1”
b. Install the lower side cover bolt and
screws, and then tighten the bolt to speci-
fication.
Lower side cover bolt

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
1
R.
Lower side cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
a. Remove the lower side cover bolt and

screws.
b. Pull the lower side cover outward to re-
move the projections “a” on the cover from
the grommets “b”.
b
1
EAS32321
INSTALLING THE LOWER SIDE COVERS

lower side covers.
4-12
GENERAL CHASSIS (5)
EAS20158
GENERAL CHASSIS (5)

Removing the footrest boards and bottom cover
2 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
4 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 1
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
5
7
6 3
8
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
T.R
.

Lower side covers 4-10.
1 Footrest board mat (left) 1
2 Footrest board mat (right) 1
3 Footrest board assembly (left) 1
4 Footrest board assembly (right) 1
5 Radiator cover 1
6 Bottom cover assembly 1
7 Footrest board molding (left) 1
8 Footrest board (left) 1
4-13
GENERAL CHASSIS (5)
Removing the footrest boards and bottom cover

3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
11 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
10
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
9
12
13
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
T.R
.
T.R
.

9 Coolant reservoir cap cover 1
10 Footrest board molding (right) 1
11 Footrest board (right) 1
12 Bottom cover 1 1
13 Bottom cover 2 1
4-14
GENERAL CHASSIS (5)
EAS32326
DISASSEMBLING THE FOOTREST BOARD

ASSEMBLIES
footrest board assemblies.
1. Remove the footrest board screws and
clamps.
2. Remove the projections “a” on the footrest
board molding “1” from the holes “b” in the 1
footrest board “2”.
b TIP
2 Fit the hole “a” in the radiator cover the hook “b”
on the frame.
a
1
1 b
EAS32327
a
ASSEMBLING THE FOOTREST BOARD
ASSEMBLIES
footrest board assemblies.
1. Fit the projections “a” on the footrest board
molding “1” into the holes “b” in the footrest
board “2”.
b
2
2. Install the footrest board screws and clamps,

and then tighten the screws to specification.
Footrest board screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
EAS32348
INSTALLING THE RADIATOR COVER

1. Install:
• Radiator cover “1”
Radiator cover bolt

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
4-15
GENERAL CHASSIS (6)
EAS20159
GENERAL CHASSIS (6)

Removing the leg shield assembly
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
1
2
4
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.

Battery 4-1.
Meter assembly 4-7.
Footrest board assemblies 4-13.
1 Fuel tank cap lid assembly 1
2 Fuel tank cap lid lock cable 1 Disconnect.
3 Fuel tank cap lid cover 1
4 Fuel tank cap lid 1
4-16
GENERAL CHASSIS (6)
Removing the leg shield assembly
10
7
9
11
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
6
8
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.

5 Front storage box (left) 1 Open.
6 Front storage box (right) 1 Open.
7 Upper center cover 1
8 Auxiliary DC jack coupler 1 Disconnect.
9 Buzzer coupler 1 Disconnect.
10 Front storage compartment lock cable assembly 1
11 Leg shield assembly 1
4-17
GENERAL CHASSIS (6)
Disassembling the leg shield assembly
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.
5
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
3
4
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
2.8 N•m (0.28 kgf•m, 2.1 lb•ft) 1

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1 Front storage box (left) 1
2 Auxiliary DC jack 1
3 Front storage box (right) 1
4 Buzzer 1
5 Leg shield 1
4-18
GENERAL CHASSIS (6)
EAS32349
REMOVING THE FUEL TANK CAP LID

a 1
COVER
1. Remove:
• Fuel tank cap lid cover “1”
1
b
b. Install the fuel tank cap lid cover screw,

and then tighten the screw to specification.
Fuel tank cap lid cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
a. Remove the screw.
b. Remove the projections “a” on the fuel EAS32329
tank cap lid cover from the holes “b” in the REMOVING THE UPPER CENTER COVER
fuel tank cap lid. 1. Remove:
• Upper center cover “1”
a 1
1
EAS32350
INSTALLING THE FUEL TANK CAP LID a. Remove the quick fasteners.
COVER b. Pull the upper center cover outward to re-
1. Install: move the projections “a” on the cover from
• Fuel tank cap lid cover “1” the holes “b” in the leg shield.
a
b
1
a. Fit the projections “a” on the fuel tank cap EAS32330
lid cover into the holes “b” in the fuel tank INSTALLING THE UPPER CENTER COVER
cap lid. 1. Install:
• Upper center cover “1”
4-19
GENERAL CHASSIS (6)
a. Fit the projections “a” on the upper center

cover into the holes “b” in the leg shield.
a
b
1
b. Install the quick fasteners.
4-20
GENERAL CHASSIS (7)
EAS20193
GENERAL CHASSIS (7)

Removing the seat and seat hinge
1
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
4
6
25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
5
New
3

Lower side cover 4-10.
Footrest board assemblies 4-13.
1 Seat 1
2 Seat damper pivot 1
3 Seat hinge pin 1
4 Seat hinge 1
5 Seat hinge molding 2
6 Seat damper 1
7 Seat damper bracket 1
4-21
GENERAL CHASSIS (7)
EAS32331
INSTALLING THE SEAT DAMPER

1. Install:
• Seat damper “1”
TIP
Install the seat damper so that the rod “a” is
pointing downward as shown in the illustration.
4-22
GENERAL CHASSIS (8)
EAS20194
GENERAL CHASSIS (8)

Removing the rear upper cowlings and rear lower cowling assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft) 1
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
4 10
5
6
7
3
8 9
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
T.R
T.R
.
.

1 Rear center cover 1
2 Grab bar (left) 1
3 Rear upper cowling (left) 1
4 Grab bar (right) 1
5 Rear upper cowling (right) 1
6 Tail/brake light coupler (left tail/brake light) 1 Disconnect.
7 Tail/brake light connector (left tail/brake light) 1 Disconnect.
8 Tail/brake light coupler (right tail/brake light) 1 Disconnect.
9 Tail/brake light connector (right tail/brake light) 1 Disconnect.
10 Rear lower cowling assembly 1
4-23
GENERAL CHASSIS (8)
Disassembling the rear lower cowling assembly
1.8 N•m (0.18 kgf•m, 1.3 lb •ft)

T.
R.
4 1
3
2
1.8 N•m (0.18 kgf•m, 1.3 lb •ft)
T.
R.
1.8 N•m (0.18 kgf•m, 1.3 lb •ft)

T.
R.

1 Tail/brake light cover 1
2 Rear lower cowling (left) 1
3 Tail/brake light (left) 1
4 Rear lower cowling (right) 1
5 Tail/brake light (right) 1
4-24
GENERAL CHASSIS (8)
EAS32351
b. Fit the projections “c” on the rear center
REMOVING THE REAR CENTER COVER
cover into the holes “d” in the tail/brake
1. Remove:
light cover.
• Rear center cover “1”
c. Fit the holes “e” in the rear center cover to
the projection “f” on the tail/brake light cov-
1 er.
1
c
d
a
e b
a. Remove the rear center cover screws.

f
b. Remove the holes “a” in the rear center
cover from the projections “b” on the tail/
d. Tighten the rear center cover screws to
brake light cover.
specification.
c. Pull the rear center cover rearward to re-
move the projections “c” on the rear center Rear center cover screw
cover from the holes “d” in the rear upper 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
cowlings.
d. Pull the rear center cover upward to re- EAS32354
move the projections “e” on the rear center REMOVING THE REAR UPPER COWLINGS
cover from the holes “f” in the tail/brake The following procedure applies to both of the
light cover. rear upper cowlings.
1. Remove:
1 • Rear upper cowling “1”
e
f
c
a d
1
EAS32352
INSTALLING THE REAR CENTER COVER

1. Install: a. Remove the rear upper cowling screw and
• Rear center cover “1” bolt.
b. Pull the rear upper cowling rearward to re-
1 move the projection “a” on the rear upper
cowling from the hole “b” in the rear lower
cowling.
a
a. Fit the projections “a” on the rear center b
cover into the holes “b” in the rear upper
cowling.
4-25
GENERAL CHASSIS (8)
EAS32353
INSTALLING THE REAR UPPER COWLINGS

rear upper cowlings.
1. Install:
• Rear upper cowling “1”
a. Fit the projection “a” on the rear upper

cowling into the hole “b” in the rear lower
cowling.
a
b
b. Tighten the rear upper cowling bolt and

screw to specification.
Rear upper cowling bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Rear upper cowling screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
4-26
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake disc
7 N•m (0.7 kgf•m, 5.2 lb•ft) 52 N•m (5.2 kgf•m, 38 lb•ft)
T.R
T.R
.
.
LS
1 6
2
9
5 LS
3
8
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
LT
LT
.
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
(3)
(5)
6 LT
8 N•m (0.8 kgf•m, 5.9 lb•ft) New 23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
T.R
.

1 Front brake hose/lead guide 1
2 Front brake caliper 1
3 Front wheel sensor 1
4 Front wheel axle nut 1
5 Front wheel axle 1
6 Collar 2
7 Front wheel 1
8 Front wheel sensor rotor 1
9 Front brake disc 1
4-27
FRONT WHEEL
Disassembling the front wheel
2 New
1 New
LS
1 New
3
4 New
LS

1 Oil seal 2
2 Wheel bearing (left) 1
3 Spacer 1
4 Wheel bearing (right) 1
4-28
FRONT WHEEL
EAS30145
REMOVING THE FRONT WHEEL

ECA20981
NOTICE 2
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor; otherwise, the
1
sensor or rotor may be damaged, resulting
in improper performance of the ABS sys-
tem.
c. Remove the wheel bearings “3” with a
• Do not drop the front wheel sensor rotor or
subject it to shocks. general bearing puller.
• If any solvent gets on the front wheel sen-
sor rotor, wipe it off immediately.
EWA13120
WARNING
2. Remove:
• Front brake caliper
ECA21830
EAS30147
NOTICE CHECKING THE FRONT WHEEL
Do not apply the brake lever when removing 1. Check:
the brake caliper. • Wheel axle
Roll the wheel axle on a flat surface.
3. Elevate:
Bends → Replace.
• Front wheel EWA13460
TIP WARNING
Place the vehicle on a suitable stand so that the Do not attempt to straighten a bent wheel ax-
front wheel is elevated. 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” 2. Check:
between the screwdriver and the wheel surface. • Tire
• Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-14 and “CHECKING THE WHEELS” on
page 3-13.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
4-29
FRONT WHEEL
Radial wheel runout limit

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
front wheel sensor rotor.
Iron powder/dust/solvent → Clean.
4. Check: TIP
• Wheel bearings When cleaning the wheel sensor rotor, be care-
Front wheel turns roughly or is loose → Re- ful not to damage the surface of the sensor rotor.
place the wheel bearings.
• Oil seals 1
EAS30151
ASSEMBLING THE FRONT WHEEL

1. Lubricate:
EAS30155
• Oil seal lips
MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR Recommended lubricant
ECA21070
Lithium-soap-based grease
NOTICE
• Handle the ABS components with care 2. Install:
since they have been accurately adjusted. • Wheel bearings New
Keep them away from dirt and do not sub-
• Oil seals New
ject them to shocks.
a. Install the new wheel bearing (right side).
• The front wheel sensor cannot be disas- ECA18110
sembled. Do not attempt to disassemble it. NOTICE

If faulty, replace with a new one. Do not contact the wheel bearing inner race
• Keep any type of magnets (including mag- “1” or balls “2”. Contact should be made
netic pick-up tools, magnetic screwdrivers, only with the outer race “3”.
etc.) away from the front wheel sensor or
front wheel sensor rotor. TIP
• Do not drop or shock the wheel sensor or Use a socket “4” that matches the diameter of
the wheel sensor rotor. the wheel bearing outer race.
1. Check:
• Front wheel sensor “1”
Cracks/bends/distortion → Replace.
Iron powder/dust → Clean.
4-30
FRONT WHEEL
Front brake disc bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
LOCTITE®
Front wheel sensor rotor bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
LOCTITE®
ECA21011
NOTICE
• Do not drop the wheel sensor rotor or sub-
b. Install the spacer. ject it to shocks.
c. Install the new wheel bearing (left side). • If any solvent gets on the wheel sensor ro-
TIP tor, wipe it off immediately.
Place a suitable washer “1” between the socket • Replace the brake disc bolts and wheel
“2” and the bearing so that both the inner race sensor rotor bolts with new ones.
“3” and outer race “4” are pressed at the same TIP
time, and then press the bearing until the inner
• Install the brake disc with its chamfered side
race makes contact with the spacer “5”.
“a” facing inward.
• Install the front wheel sensor rotor with the
stamped mark “b” facing away from the wheel.
• Tighten the bolts in stages.
1 a
EAS30152
ADJUSTING THE FRONT WHEEL STATIC

BALANCE
TIP
• After replacing the tire, wheel or both, the front b
wheel static balance should be adjusted. 2
• Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
• Balancing weight(s)
2. Find:
• Front wheel’s heavy spot
3. Adjust:
• Front wheel static balance 2. Check:
4. Check: • Front brake disc
• Front wheel static balance Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-44.
EAS30154
INSTALLING THE FRONT WHEEL (FRONT 3. Lubricate:

BRAKE DISC) • Front wheel axle
1. Install: • Front wheel axle nut
• Front brake disc “1”
• Front wheel sensor rotor “2” Lithium-soap-based grease
4-31
FRONT WHEEL
4. Install: 7. Measure:
• Front wheel • Distance “a”
• Collars (between the front wheel sensor rotor “1” and
• Front wheel axle front wheel sensor “2”)
• Front wheel axle nut Out of specification → Check the wheel bear-
TIP ing for looseness, and the front wheel sensor
Install the front wheel with the mark “a” on the and sensor rotor installation conditions
front tire pointing in the direction of wheel rota- (warpage caused by overtorque, wrong in-
tion. stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
vice and caught foreign materials). If there is
a any defective part, repair or replace the de-
fective part.
Distance “a” (between the front

wheel sensor rotor and front
wheel sensor)
0.83–1.55 mm (0.033–0.061 in)
5. Tighten: TIP
• Front wheel axle nut Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
Front wheel axle nut places in one rotation of the front wheel. Do not
52 N·m (5.2 kgf·m, 38 lb·ft) turn the front wheel while the thickness gauge is
T.
R.
ECA14140
installed. This may damage the front wheel sen-
NOTICE sor rotor and the front wheel sensor.
Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times Thickness gauge
and check if the front fork rebounds smooth- 90890-03180
ly. Feeler gauge set
YU-26900-9
6. Install:
• Front wheel sensor
a
Front wheel sensor bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft) 2
T.
R.
ECA21020
2
NOTICE 1
Make sure there are no foreign materials in
the front wheel sensor rotor and front wheel 1
sensor. Foreign materials cause damage to
the front wheel sensor rotor and front wheel
8. Install:
sensor.
TIP • Front brake hose/lead guide
• When installing the front wheel sensor, check
the wheel sensor lead for twists. Front brake caliper bolt
35 N·m (3.5 kgf·m, 26 lb·ft)
T.
• To route the front wheel sensor lead, refer to

R.
Front brake hose/lead guide bolt

“CABLE ROUTING” on page 2-13. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
4-32
FRONT WHEEL
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-33
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel and brake disc
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
5 4
3
1
10 N•m (1.0 kgf•m, 7.4 lb•ft) (3)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
2
New LT
(3)
LT New
23 N•m (2.3 kgf•m, 17 lb•ft)

T.
R.

Muffler Refer to “ENGINE REMOVAL” on page 5-7.
Refer to “REAR SHOCK ABSORBER AS-
Swingarm assembly SEMBLIES AND SWINGARM” on page
4-91.
1 Rear wheel 1
2 Rear brake disc 1
3 Rear wheel sensor rotor 1
4 Rear wheel sensor bracket 1
5 Rear wheel sensor 1
4-34
REAR WHEEL
EAS30156
• The rear wheel sensor cannot be disassem-
REMOVING THE REAR WHEEL (DISC)
ECA21030
bled. Do not attempt to disassemble it. If
NOTICE faulty, replace with a new one.
• Keep any type of magnets (including mag- • Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers, netic pick-up tools, magnetic screwdrivers,
etc.) away from the rear wheel sensor or etc.) away from the rear wheel sensor or
rear wheel sensor rotor; otherwise, the sen- rear wheel sensor rotor.
sor or rotor may be damaged, resulting in • Do not drop or shock the wheel sensor or
improper performance of the ABS system. the wheel sensor rotor.
• Do not drop the rear wheel sensor rotor or 1. Check:
subject it to shocks. • Rear wheel sensor
• If any solvent gets on the rear wheel sensor Refer to “MAINTENANCE OF THE FRONT
rotor, wipe it off immediately. WHEEL SENSOR AND SENSOR ROTOR”
1. Stand the vehicle on a level surface. on page 4-30.
EWA13120 2. Check:
WARNING • Rear wheel sensor rotor
Securely support the vehicle so that there is Refer to “MAINTENANCE OF THE FRONT
no danger of it falling over. WHEEL SENSOR AND SENSOR ROTOR”
on page 4-30.
TIP
EAS30164
Place the vehicle on the centerstand so that the ADJUSTING THE REAR WHEEL STATIC
rear wheel is elevated. BALANCE
TIP
EAS30159
CHECKING THE REAR WHEEL • After replacing the tire, wheel or both, the rear
1. Check: wheel static balance should be adjusted.
• Tire • Adjust the rear wheel static balance with the
• Rear wheel brake disc installed.
Damage/wear → Replace. 1. Adjust:
Refer to “CHECKING THE TIRES” on page • Rear wheel static balance
3-14 and “CHECKING THE WHEELS” on Refer to “ADJUSTING THE FRONT WHEEL
page 3-13. STATIC BALANCE” on page 4-31.
2. Measure:
• Radial wheel runout EAS32332
• Lateral wheel runout INSTALLING THE REAR WHEEL SENSOR

Refer to “CHECKING THE FRONT WHEEL” 1. Install:
on page 4-29. • Rear wheel sensor
(to rear wheel sensor bracket)
Radial wheel runout limit • Rear wheel sensor bracket “1”
1.0 mm (0.04 in)
Lateral wheel runout limit Rear wheel sensor bolt
1.0 mm (0.04 in) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Rear wheel sensor bracket bolt

EAS30167
10 N·m (1.0 kgf·m, 7.4 lb·ft)
MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR TIP
ECA21060
Face the projection “a” on the rear wheel sensor
NOTICE
bracket outward.
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
4-35
REAR WHEEL
2 b
a
EAS30165 2. Check:
INSTALLING THE REAR WHEEL (REAR • Rear brake disc
BRAKE DISC) Refer to “CHECKING THE REAR BRAKE
1. Install: DISC” on page 4-57.
• Rear wheel sensor rotor “1” 3. Install:
• Rear brake disc “2” • Swingarm assembly
Rear brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft) SEMBLIES AND SWINGARM” on page
T.
4-91.
R.
LOCTITE®
Rear wheel sensor rotor bolt 4. Measure:
8 N·m (0.8 kgf·m, 5.9 lb·ft) • Distance “a”
LOCTITE® (between the rear wheel sensor rotor “1” and
rear wheel sensor “2”)
ECA21011
Out of specification → Check the wheel bear-
NOTICE
ing for looseness, and the rear wheel sensor
• Do not drop the wheel sensor rotor or sub- and sensor rotor installation conditions
ject it to shocks. (warpage caused by overtorque, wrong in-
• If any solvent gets on the wheel sensor ro- stallation direction, rotor decentering, LOC-
tor, wipe it off immediately. TITE® on the mounting surface of the rotor,
• Replace the brake disc bolts and wheel deformation caused by an impact during ser-
sensor rotor bolts with new ones. vice and caught foreign materials). If there is
TIP any defective part, repair or replace the de-
fective part.
• Install the rear wheel sensor rotor with the
stamped mark “a” facing away from the wheel. Distance “a” (between the rear
• Install the brake disc with its chamfered side wheel sensor rotor and rear
“b” facing inward. wheel sensor)
1.03–1.97 mm (0.04–0.08 in)
a
TIP
1 Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
places in one rotation of the rear wheel. Do not
turn the rear wheel while the thickness gauge is
installed. This may damage the rear wheel sen-
sor rotor and the rear wheel sensor.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
4-36
REAR WHEEL
a
2
1
1
4-37
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
2
8
6 N•m (0.6 kgf•m, 4.4 lb•ft)

7
T.R
.
4 35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
5
6

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 Loosen.
4-38
FRONT BRAKE
Removing the front brake master cylinder
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
1
2
3
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
6
S
7 New
5 4
6 8
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
New
6 N•m (0.6 kgf•m, 4.4 lb•ft) 1.1 N•m (0.11 kgf•m, 0.81 lb•ft)
T.R
T.R
.
.

Upper handlebar cover Refer to “HANDLEBAR” on page 4-71.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-12.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
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 1
side)
4-39
FRONT BRAKE
Removing the front brake master cylinder
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
11
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
12
.
9 New
10
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
New 9
6 N•m (0.6 kgf•m, 4.4 lb•ft) 1.1 N•m (0.11 kgf•m, 0.81 lb•ft)
T.R
T.R
.
.

9 Brake hose gasket 2
Front brake hose (front brake master cylinder to
10 1 Disconnect.
hydraulic unit)
11 Front brake master cylinder holder 1
12 Front brake master cylinder assembly 1
4-40
FRONT BRAKE
Disassembling the front brake master cylinder
S
BF
1 New

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
4-41
FRONT BRAKE
Removing the front brake caliper
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
1 3
5
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
New 2
29 N•m (2.9 kgf•m, 21 lb•ft)

T.R
.

Drain.
1 Front brake hose union bolt (brake caliper side) 1
Front brake hose (hydraulic unit to front brake
3 1 Disconnect.
caliper)
4-42
FRONT BRAKE
Disassembling the front brake caliper
6 N•m (0.6 kgf•m, 4.4 lb•ft) 7

T.R
.
New 8
New 9
BF
10 11
S
7
S
8 New
1
9 New
BF 3
5
S
2 4

1 Brake pad clip 2
2 Brake pad pin 1
6 Front brake caliper bracket 1
7 Brake caliper piston 2
8 Brake caliper piston dust seal 2
9 Brake caliper piston seal 2
10 Brake caliper bleed screw 1
11 Brake caliper body 1
4-43
FRONT BRAKE
EAS30168
e. Measure the runout 1.5 mm (0.06 in) be-
INTRODUCTION
EWA14101
low 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. 4. Measure:
• Never use solvents on internal brake com- • Brake disc thickness
ponents. Measure the brake disc thickness at a few dif-
• Use only clean or new brake fluid for clean- ferent locations.
ing brake components. Out of specification → Replace.
• Brake fluid may damage painted surfaces Brake disc thickness limit
and plastic parts. Therefore, always clean 4.0 mm (0.16 in)
up any spilt brake fluid immediately.
• 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 5. Adjust:
Refer to “FRONT WHEEL” on page 4-27. • Brake disc runout
2. Check: a. Remove the brake disc.
• Brake disc b. Rotate the brake disc by one bolt hole.
Damage/galling → Replace. c. Install the brake disc.
3. Measure:
• Brake disc runout Front brake disc bolt
Out of specification → Correct the brake disc 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
runout or replace the brake disc. LOCTITE®
Brake disc runout limit (as mea- ECA19150
sured on wheel) NOTICE

0.15 mm (0.0059 in) Replace the brake disc bolts with new ones.
a. Place the vehicle on a suitable stand so TIP

that the front wheel is elevated. • Install the brake disc “1” with its chamfered
b. Before measuring the front brake disc side “a” facing inward.
runout, turn the handlebar to the left or • Tighten the brake disc bolts in stages.
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
4-44
FRONT BRAKE
A
1 a
d. Measure the brake disc runout. B

e. If out of specification, repeat the adjust-
ment steps until the brake disc runout is
within specification. a
f. If the brake disc runout cannot be brought
within specification, replace the brake
disc.
6. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-27.
A. Inner
EAS30170 B. Outer
REPLACING THE FRONT BRAKE PADS
2. Install:
TIP
• Brake pad spring
When replacing the brake pads, it is not neces- • Brake pads
sary to disconnect the brake hose or disassem-
TIP
ble the brake caliper.
Always install new brake pads, and new brake
1. Measure: pad spring, as a set.
• Brake pad wear limit “a”
Out of specification → Replace the brake a. Connect a clear plastic hose “1” tightly to
pads as a set. the bleed screw “2”. Put the other end of
the hose into an open container.
Brake pad lining thickness b. Loosen the bleed screw and push the
5.3 mm (0.21 in) brake caliper piston into the brake caliper
Limit with your finger.
0.8 mm (0.03 in)
c. Tighten the bleed screw.
Brake caliper bleed screw

6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
d. Install new brake pad spring “3” and new

brake pads.
4-45
FRONT BRAKE
EAS31328
TIP REMOVING THE FRONT 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
piston.
brake fluid from the entire brake system.
a 1. Remove:
• Front brake hose union bolt “1”
• Brake hose gaskets “2”
• Front brake hose “3”
3
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
3
3. Install:
• Brake pad pin
• Brake pad clips 1
• Front brake hose/lead guide
• Front brake caliper bolts
• Front brake hose/lead guide bolt 2
Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft) EAS30172
T.
DISASSEMBLING THE FRONT BRAKE

R.

7 N·m (0.7 kgf·m, 5.2 lb·ft) CALIPER
1. Remove:
4. Check: • Brake caliper pistons “1”
• Brake fluid level • Brake caliper piston dust seals “2”
Below the minimum level mark “a” → Add the • Brake caliper piston seals “3”
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-11. 3
2
a 1
3
2
1
a. Blow compressed air into the brake hose
joint opening “a” to force out the pistons
from the brake caliper “1”.
EWA13550
5. Check:
WARNING
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys- • Cover the brake caliper piston with a rag.
tem. Be careful not to get injured when the pis-
Refer to “BLEEDING THE HYDRAULIC ton is expelled from the brake caliper.
BRAKE SYSTEM (ABS)” on page 3-12. • Never try to pry out the brake caliper pis-
ton.
4-46
FRONT BRAKE
a 2. Check:
• Brake caliper bracket
EAS30174
ASSEMBLING THE FRONT BRAKE CALIPER

EWA13621
WARNING
1 • Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
b. Remove the brake caliper piston dust • Never use solvents on internal brake com-
seals and brake caliper piston seals. ponents as they will cause the brake caliper
EAS30173
piston dust seals and brake caliper piston
CHECKING THE FRONT BRAKE CALIPER seals to swell and distort.
• Whenever a brake caliper is disassembled,
Recommended brake component replacement
schedule replace the brake caliper piston dust seals
and brake caliper piston seals.
Brake pads If necessary
Piston seals Every two years Specified brake fluid
Piston dust seals Every two years DOT 4
Brake hose Every four years
EAS30934
Every two years and INSTALLING THE FRONT BRAKE CALIPER
Brake fluid whenever the brake is 1. Install:
disassembled
• Front brake caliper “1”
1. Check: (temporarily)
• Brake caliper pistons “1” • Front brake hose/lead guide “2”
Rust/scratches/wear → Replace the brake • Brake hose gaskets “3” New
caliper piston. • Front brake hose “4”
• Brake caliper cylinders “2” • Front brake hose union bolt “5”
Scratches/wear → Replace the brake caliper
assembly. Front brake hose union bolt
• Brake caliper body “3” (brake caliper side)
T.
R.
Cracks/damage → Replace the brake caliper 29 N·m (2.9 kgf·m, 21 lb·ft)

assembly. EWA13531
• Brake fluid delivery passages WARNING

(brake caliper body) Proper brake hose routing is essential to in-
Obstruction → Blow out with compressed air. sure safe vehicle operation.
EWA17070
WARNING ECA19080
NOTICE
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal When installing the brake hose onto the
and brake caliper piston seal. brake caliper “1”, make sure the brake pipe
“a” passes between the projections “b” on
the brake caliper.
3
2
1
4-47
FRONT BRAKE
ECA13540
2 NOTICE
4
Brake fluid may damage painted surfaces
1 and plastic parts. Therefore, always clean up
a b any spilt brake fluid immediately.
5
5. Bleed:
• Brake system
New 3 Refer to “BLEEDING THE HYDRAULIC
6. Check:
2. Remove: • Brake fluid level
• Front brake caliper Below the minimum level mark “a” → Add the
3. Install: specified brake fluid to the proper level.
• Brake pad spring Refer to “BLEEDING THE HYDRAULIC
• Brake pads BRAKE SYSTEM (ABS)” on page 3-12.
• Brake pad pin
• Brake pad clips
• Front brake caliper a
• Front brake hose/lead guide
• Front brake caliper bolts
• Front brake hose/lead guide bolt
Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)
7. Check:
Refer to “REPLACING THE FRONT BRAKE • Brake lever operation
PADS” on page 4-45. Soft or spongy feeling → Bleed the brake sys-
4. Fill: tem.
• Brake master cylinder reservoir Refer to “BLEEDING THE HYDRAULIC
(with the specified amount of the specified BRAKE SYSTEM (ABS)” on page 3-12.
brake fluid) EAS30179
REMOVING THE FRONT BRAKE MASTER

Specified brake fluid
CYLINDER
DOT 4
TIP
EWA13540
Before removing the front brake master cylinder,
WARNING drain the brake fluid from the entire brake sys-
• Use only the designated brake fluid. Other tem.
deteriorate, causing leakage and poor 1. Remove:
brake performance. • Front brake hose union bolt “1”
• Refill with the same type of brake fluid that • Brake hose gaskets “2”
is already in the system. Mixing brake fluids • Front brake hose “3”
may result in a harmful chemical reaction, TIP
leading to poor brake performance. To collect any remaining brake fluid, place a
• When refilling, be careful that water does container under the master cylinder and the end
not enter the brake master cylinder reser- of the brake hose.
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
4-48
FRONT BRAKE
3 Specified brake fluid

DOT 4
2
EAS30182
INSTALLING THE FRONT BRAKE MASTER

1 CYLINDER
1. Install:
• Front brake master cylinder assembly
• Front brake master cylinder holder “1”
EAS30725 Front brake master cylinder hold-

CHECKING THE FRONT BRAKE MASTER er bolt
T.
R.
CYLINDER 11 N·m (1.1 kgf·m, 8.1 lb·ft)
1. Check:
• Brake master cylinder TIP
Damage/scratches/wear → Replace. • Install the brake master cylinder holder with the
• Brake fluid delivery passages “UP” mark “a” facing up.
(brake master cylinder body) • Align the end of the front brake master cylinder
Obstruction → Blow out with compressed air. holder with the punch mark “b” on the handle-
2. Check: bar.
• Brake master cylinder kit • First, tighten the upper bolt, then the lower bolt.
Damage/scratches/wear → Replace.
3. Check: 1
• Brake master cylinder reservoir “1”
• Brake master cylinder reservoir cap “2”
• Brake master cylinder reservoir diaphragm b
holder “3”
• Brake master cylinder reservoir diaphragm
“4”
a
2 2. Install:
4
• Brake hose gaskets “1” New
• Front brake hose “2”
1 3 • Front brake hose union bolt “3”
Front brake hose union bolt

(master cylinder side)
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft)

4. Check: EWA13531
• Front brake hose WARNING

Cracks/damage/wear → Replace. Proper brake hose routing is essential to in-
EAS30181
sure safe vehicle operation.
ASSEMBLING THE FRONT BRAKE MASTER ECA14160
CYLINDER NOTICE
EWA13520
When installing the brake hose onto the
WARNING
brake master cylinder, make sure the brake
• Before installation, all internal brake com- pipe touches the projection “a” as shown.
with clean or new brake fluid. TIP
• Never use solvents on internal brake com- • Install the brake pipe so that paint mark “b” on
ponents. the pipe faces to the front of the vehicle.
4-49
FRONT BRAKE
• Turn the handlebar to the left and right to make

sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if a
necessary.
New 1
2
3
a 6. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
b tem.
Refer to “BLEEDING THE HYDRAULIC
3. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

DOT 4
EWA13540
WARNING
deteriorate, causing leakage and poor
brake performance.
is already in the system. Mixing brake fluids
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
vapor lock.
ECA13540
NOTICE
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
5. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
LEVEL” on page 3-11.
4-50
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
9
3
35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
.
6
4
5

1 Rear brake caliper 1
2 Brake pad clip 2
3 Brake pad pin 1
6 Brake pad shim (inner) 1
7 Brake pad shim (outer) 1
9 Brake caliper bleed screw 1 Loosen.
4-51
REAR BRAKE
Removing the rear brake master cylinder
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
1
2
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
6
S
7
4
5
6
New
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
29 N•m (2.9 kgf•m, 21 lb•ft)

T.R
.
1.1 N•m (0.11 kgf•m, 0.81 lb•ft)

T.R
.

Upper handlebar cover Refer to “HANDLEBAR” on page 4-71.
Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
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
4-52
REAR BRAKE
Removing the rear brake master cylinder
11 N•m (1.1 kgf•m, 8.1 lb•ft)

11
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
12 6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
S
10
9 New
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
29 N•m (2.9 kgf•m, 21 lb•ft)

8
T.R
.
1.1 N•m (0.11 kgf•m, 0.81 lb•ft)

T.R
.

Rear brake hose union bolt (master cylinder
8 1
side)
Rear brake hose (rear brake master cylinder to
10 1 Disconnect.
hydraulic unit)
11 Rear brake master cylinder holder 1
12 Rear brake master cylinder assembly 1
4-53
REAR BRAKE
Disassembling the rear brake master cylinder
S
BF
1 New

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
4-54
REAR BRAKE
Removing the rear brake caliper
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
1
3
2 New
35 N•m (3.5 kgf•m, 26 lb•ft) 4

T.R
.

Drain.
1 Rear brake hose union bolt (brake caliper side) 1
Rear brake hose (hydraulic unit to rear brake
3 1 Disconnect.
caliper)
4-55
REAR BRAKE
Disassembling the rear brake caliper

S
31 N•m (3.1 kgf•m, 23 lb•ft) S

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
13
14
8
10
11 New
1
12 New
S 7 2
BF
9
S
23 N•m (2.3 kgf•m, 17 lb •ft)

T.
R.
5
3
4
6

1 Brake pad clip 2
2 Brake pad pin 1
5 Brake pad shim (inner) 1
6 Brake pad shim (outer) 1
8 Brake caliper bracket 1
9 Collar 1
10 Brake caliper piston 1
11 Brake caliper piston dust seal 1
12 Brake caliper piston seal 1
13 Brake caliper bleed screw 1
14 Brake caliper body 1
4-56
REAR BRAKE
EAS30183
INTRODUCTION Brake disc thickness limit

EWA14101
4.5 mm (0.18 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 4-44.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
sembly. 6. Install:
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-34.
• 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

EAS30184
CHECKING THE REAR BRAKE DISC 6.7 mm (0.26 in)

Limit
1. Remove:
0.8 mm (0.03 in)
• Rear wheel
Refer to “REAR WHEEL” on page 4-34.
2. Check: A
• Brake disc
Damage/galling → Replace.
3. Measure: a
• Brake disc runout
Out of specification → Correct the brake disc
runout or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-44.
B
Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in) a
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 A. Inner
DISC” on page 4-44. B. Outer
4-57
REAR BRAKE
2. Install:
• Brake pad spring Rear brake caliper bolt
• Brake pad shims 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
• Brake pads
4. Check:
TIP • Brake fluid level
Always install new brake pads, brake pad shims Below the minimum level mark “a” → Add the
and brake pad spring as a set. specified brake fluid to the proper level.
a. Connect a clear plastic hose “1” tightly to Refer to “CHECKING THE BRAKE FLUID
the bleed screw “2”. Put the other end of LEVEL” on page 3-11.
the hose into an open container.
b. Loosen the bleed screw and push the
brake caliper piston into the brake caliper
with your finger. a
5. Check:
2 • Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
c. Tighten the bleed screw. Refer to “BLEEDING THE HYDRAULIC
Brake caliper bleed screw
EAS30186
6 N·m (0.6 kgf·m, 4.4 lb·ft) REMOVING THE REAR BRAKE CALIPER
T.
R.
d. Install the brake pad shims onto each TIP

brake pads. Before removing the brake caliper, drain the
e. Install new brake pad spring and new brake fluid from the entire brake system.
brake pads. 1. Remove:
TIP • Rear brake hose union bolt “1”
The longer tangs “a” of the brake pad spring • Brake hose gaskets “2”
must point in the direction of the brake caliper • Rear brake hose “3”
position. TIP
Put the end of the brake hose into a container
a and pump out the brake fluid carefully.
3
3. Install: 2
• Brake pad pin
• Brake pad clips
• Rear brake caliper
• Rear brake caliper bolts
4-58
REAR BRAKE
EAS30187
1. Check:
DISASSEMBLING THE REAR BRAKE
• Brake caliper piston “1”
CALIPER
Rust/scratches/wear → Replace the brake
1. Remove:
caliper piston.
• Brake caliper piston “1”
• Brake caliper cylinder “2”
• Brake caliper piston dust seal “2”
Scratches/wear → Replace the brake caliper
• Brake caliper piston seal “3”
assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
1 • Brake fluid delivery passages
2 3 (brake caliper body)
Obstruction → Blow out with compressed air.
EWA17070
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
a. Blow compressed air into the brake hose and brake caliper piston seal.
joint opening “a” to force out the piston
from the brake caliper.
EWA13550
WARNING 3
• Cover the brake caliper piston with a rag. 1
Be careful not to get injured when the pis- 2
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
a
2. Check:
• Brake caliper bracket
EAS30189
ASSEMBLING THE REAR BRAKE CALIPER

EWA17080
WARNING
• Before installation, all internal brake com-
b. Remove the brake caliper piston dust seal ponents should be cleaned and lubricated
and brake caliper piston seal. with clean or new brake fluid.
• Never use solvents on internal brake com-
EAS30188 ponents as they will cause the brake caliper
CHECKING THE REAR BRAKE CALIPER piston dust seal and brake caliper piston
Recommended brake component replacement seal to swell and distort.
schedule • Whenever a brake caliper is disassembled,
Brake pads If necessary replace the brake caliper piston dust seal
and brake caliper piston seal.
Piston seal Every two years
Piston dust seal Every two years
Brake hose Every four years DOT 4
Every two years and
Brake fluid whenever the brake is
disassembled
4-59
REAR BRAKE
EAS30190
INSTALLING THE REAR BRAKE CALIPER Specified brake fluid

1. Install: DOT 4
• Rear brake caliper “1”
(temporarily) EWA13540
WARNING
• Brake hose gaskets “2” New
• Rear brake hose “3” • Use only the designated brake fluid. Other
• Rear brake hose union bolt “4” brake fluids may cause the rubber seals to
Rear brake hose union bolt brake performance.
(brake caliper side) • Refill with the same type of brake fluid that
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft) is already in the system. Mixing brake fluids
EWA13531
WARNING
Proper brake hose routing is essential to in- not enter the brake master cylinder reser-
sure safe vehicle operation. voir. Water will significantly lower the boil-
ECA19080
NOTICE vapor lock.
When installing the brake hose onto the ECA13540
brake caliper “1”, make sure the brake pipe NOTICE

“a” passes between the projections “b” on Brake fluid may damage painted surfaces
the brake caliper. and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
5. Bleed:
1 b • Brake system
3 6. Check:
a • Brake fluid level
2 New Below the minimum level mark “a” → Add the
4
2. Remove: LEVEL” on page 3-11.
3. Install:
• Brake pad spring
• Brake pad shims
a
• Brake pads
• Brake pad pin
• Brake pad clips
Rear brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
7. Check:
R.
Refer to “REPLACING THE REAR BRAKE • Brake lever operation

PADS” on page 4-57. Soft or spongy feeling → Bleed the brake sys-
4. Fill: tem.
brake fluid)
4-60
REAR BRAKE
EAS30193
REMOVING THE REAR BRAKE MASTER 2

CYLINDER 1
TIP
Before removing the rear brake master cylinder, 3
drain the brake fluid from the entire brake sys-
tem. 4
1. Remove:
• Rear brake hose union bolt “1”
• Brake hose gaskets “2”
• Brake hose “3” EAS30195
ASSEMBLING THE REAR BRAKE MASTER

TIP
CYLINDER
To collect any remaining brake fluid, place a EWA13520
container under the master cylinder and the end WARNING

of the brake hose. • Before installation, all internal brake com-
with clean or new brake fluid.
3 • Never use solvents on internal brake com-
ponents.

DOT 4
1 2 EAS30196
INSTALLING THE REAR BRAKE MASTER

CYLINDER
EAS30194
1. Install:
CHECKING THE REAR BRAKE MASTER
• Rear brake master cylinder assembly
CYLINDER
• Rear brake master cylinder holder “1”
1. Check:
• Brake master cylinder Rear brake master cylinder hold-
Damage/scratches/wear → Replace. er bolt
T.
R.
• Brake fluid delivery passages 11 N·m (1.1 kgf·m, 8.1 lb·ft)

(brake master cylinder body)
Obstruction → Blow out with compressed air. TIP
2. Check: • Install the brake master cylinder holder with the
• Brake master cylinder kit “UP” mark “a” facing up.
Damage/scratches/wear → Replace. • Align the end of the rear brake master cylinder
3. Check: holder with the punch mark “b” on the handle-
• Brake master cylinder reservoir “1” bar.
• Brake master cylinder reservoir cap “2” • First, tighten the upper bolt, then the lower bolt.
holder “3”
“4” 1
Damage/wear → Replace. b
4. Check:
• Brake hose
Cracks/damage/wear → Replace.
4-61
REAR BRAKE
2. Install: • When refilling, be careful that water does

• Brake hose gaskets “1” New not enter the brake master cylinder reser-
• Rear brake hose “2” voir. Water will significantly lower the boil-
• Rear brake hose union bolt “3” ing point of the brake fluid and could cause
vapor lock.
Rear brake hose union bolt (mas- ECA13540
ter cylinder side) NOTICE

T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft)

ECA14160 and plastic parts. Therefore, always clean up
NOTICE any spilt brake fluid immediately.
When installing the brake hose onto the 4. Bleed:
brake master cylinder, make sure the brake • Brake system
pipe touches the projection “a” as shown. Refer to “BLEEDING THE HYDRAULIC
EWA13531 BRAKE SYSTEM (ABS)” on page 3-12.
WARNING 5. Check:
Proper brake hose routing is essential to in- • Brake fluid level
sure safe vehicle operation. Below the minimum level mark “a” → Add the
TIP Refer to “CHECKING THE BRAKE FLUID
Turn the handlebar to the left and right to make LEVEL” on page 3-11.
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
a
a
2
6. Check:
1 New • Brake lever operation
3 Soft or spongy feeling → Bleed the brake sys-
3. Fill: tem.
brake fluid)

DOT 4
EWA13540
WARNING
brake performance.
is already in the system. Mixing brake fluids
4-62
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS20032

Removing the hydraulic unit assembly
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
3
.
T.R
.
2
3
2
New 4
4 New
5
New 4
4 New
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Drain.
Battery 4-1.
Battery box 4-7.
1 ABS ECU coupler 1 Disconnect.
Front brake hose union bolt (hydraulic unit as-
2 2
sembly side)
Rear brake hose union bolt (hydraulic unit as-
3 2
sembly side)
Rear brake hose (rear brake master cylinder to
5 1 Disconnect.
hydraulic unit)
4-63
Removing the hydraulic unit assembly
T.R
.
29 N•m (2.9 kgf•m, 21 lb•ft)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
T.R
.
New
New
7
6
8
New
New
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Rear brake hose (hydraulic unit to rear brake
6 1 Disconnect.
caliper)
Front brake hose (hydraulic unit to front brake
7 1 Disconnect.
caliper)
Front brake hose (front brake master cylinder to
8 1 Disconnect.
hydraulic unit)
9 Hydraulic unit assembly 1
4-64
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
1 INSTALLING THE HYDRAULIC UNIT

ASSEMBLY
1. Install:
• Hydraulic unit assembly
b
Hydraulic unit assembly bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
2. Remove:
• Brake hoses
4-65
ECA21110
d. Position the rear brake hose (hydraulic
NOTICE unit to rear brake caliper) “3” so that its
Do not remove the rubber plugs or bolts projection “c” contacts the rear brake hose
(M10 × 1.25) installed in the brake hose union (rear brake master cylinder to hydraulic
bolt holes before installing the hydraulic unit unit) “4”, and then temporarily tighten the
assembly. union bolt for the rear brake hose (hydrau-
lic unit to rear brake caliper).
TIP
e. Position the rear brake hose (rear brake
Do not allow any foreign materials to enter the master cylinder to hydraulic unit) “4” so
hydraulic unit assembly or the brake hoses that its pipe “d” contacts the rear brake
when installing the hydraulic unit assembly. hose (hydraulic unit to rear brake caliper)
2. Remove: “3”.
• Rubber plugs or bolts (M10 × 1.25) f. Tighten the brake hose union bolts to
3. Install: specification.
• Front brake hose (front brake master cylinder
3 d c
to hydraulic unit) “1” 1
• Front brake hose (hydraulic unit to front brake
caliper) “2”
• Rear brake hose (hydraulic unit to rear brake 4
caliper) “3”
• Rear brake hose (rear brake master cylinder 2
to hydraulic unit) “4” b a
Front brake hose union bolt (hy-
draulic unit assembly side) 4. Connect:
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft) • ABS ECU coupler “1”

Rear brake hose union bolt (hy-
draulic unit assembly side) TIP
29 N·m (2.9 kgf·m, 21 lb·ft) • Connect the ABS ECU coupler, and then push
the lock lever “a” of the coupler in the direction
ECA21121
of the arrow shown.
NOTICE • Make sure that the ABS ECU coupler is con-
If the brake hose union bolt does not turn nected in the correct position as shown in illus-
easily, replace the hydraulic unit assembly, tration “A”.
brake hoses, and related parts as a set.
a. Temporarily install the brake hoses as 1
b. Position the front brake hose (front brake
master cylinder to hydraulic unit) “1” so
that its projection “a” contacts the front
brake hose (hydraulic unit to front brake
caliper) “2”, and then temporarily tighten
the union bolt for the front brake hose a
(front brake master cylinder to hydraulic
unit).
c. Position the front brake hose (hydraulic
unit to front brake caliper) “2” so that its
projection “b” contacts the front brake
hose (front brake master cylinder to hy-
draulic unit) “1”, and then temporarily tight-
en the union bolt for the front brake hose
(hydraulic unit to front brake caliper).
4-66
8. Delete the fault codes. (Refer to “[B-3] DE-

A B LETING THE FAULT CODES” on page
8-110.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-70.)
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.
A. The ABS ECU coupler is connected correctly. The hydraulic unit operation can be tested using
B. The ABS ECU coupler is not connected. the following two methods.
• Brake line routing confirmation: this test
5. Fill:
checks the function of the ABS after the sys-
• Brake master cylinder reservoir
tem was disassembled, adjusted, or serviced.
Specified brake fluid • ABS reaction-force confirmation: this test gen-
DOT 4 erates the same reaction-force pulsating action
that is generated in the front brake lever and
EWA13090
rear brake lever when the ABS is front activat-
WARNING ed.
brake fluids may cause the rubber seals to Brake line routing confirmation
deteriorate, causing leakage and poor EWA13120
brake performance. WARNING

• Refill with the same type of brake fluid that Securely support the vehicle so that there is
is already in the system. Mixing brake fluids no danger of it falling over.
TIP
• For the brake line routing confirmation, use the
diagnosis mode of the Yamaha diagnostic tool.
not enter the brake fluid reservoir. Water
• Before performing the brake line routing confir-
will significantly lower the boiling point of
mation, make sure that no malfunctions have
the brake fluid and could cause vapor lock.
been detected in the ABS ECU and that the
ECA13540
wheels are not rotating.
NOTICE
Brake fluid may damage painted surfaces 1. Place the vehicle on a centerstand.
and plastic parts. Therefore, always clean up 2. Turn the main switch to “OFF”.
any spilt brake fluid immediately. 3. Remove:
6. Bleed: Refer to “GENERAL CHASSIS (1)” on page
• Brake system 4-1.
Refer to “BLEEDING THE HYDRAULIC 4. Check:
BRAKE SYSTEM (ABS)” 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”
on page 4-67.) Battery voltage
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
confirmation.
4-67
1 2
5. Removing the protective cap “1”, and then 9. Check:

connect the Yamaha diagnostic tool to the • Hydraulic unit operation
ABS test coupler (4P). Click “Actuator Check”, a single pulse will be
generated in the front brake lever “1”, rear
Yamaha diagnostic tool USB brake lever “2”, and again in the front brake
90890-03256 lever “1”, in this order.
Yamaha diagnostic tool (A/I)
90890-03254
1 2
TIP
“ON” and “OFF” on the tool screen indicate
6. Start the Yamaha diagnostic tool and display when the brakes are being applied and released
the diagnosis mode screen. respectively.
7. Select code No. 2, “Brake line routing confir- ECA22080
mation”. NOTICE
8. Click “Actuator Check”, and then operate the • Check that the pulse is felt in the front
front brake lever “1” and rear brake lever “2” brake lever, rear brake lever, and again in
simultaneously. the front brake lever, in this order.
TIP • If the pulse is felt in the rear brake lever be-
• The hydraulic unit operates 1 second after the fore it is felt in the front brake lever, check
front brake lever and rear brake lever are oper- that the brake hoses and brake pipes are
ated simultaneously and continues for approx- connected correctly to the hydraulic unit
imately 5 seconds. assembly.
• The operation of the hydraulic unit can be con- • If the pulse is hardly felt in either the front
firmed using the indicator. brake lever or rear brake lever, check that
On: The hydraulic unit is operating. the brake hoses and brake pipes are con-
Flashing: The conditions for operating the hy- nected correctly to the hydraulic unit as-
draulic unit have not been met. sembly.
Off: The front brake lever and rear brake lever
are not being operated.
4-68
10.If the operation of the hydraulic unit is normal, 5. Removing the protective cap “1”, and then
delete all of the fault codes. connect the Yamaha diagnostic tool to the
ABS test coupler (4P).
ABS reaction-force confirmation
EWA13120 Yamaha diagnostic tool USB
WARNING 90890-03256
Securely support the vehicle so that there is Yamaha diagnostic tool (A/I)
no danger of it falling over. 90890-03254
TIP
• For the ABS reaction-force confirmation, use 1
the diagnosis mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
1. Place the vehicle on a centerstand. 6. Start the Yamaha diagnostic tool and display
2. Turn the main switch to “OFF”. the diagnosis mode screen.
3. Remove: 7. Select code No. 1, “ABS reaction-force con-
• Battery cover assembly firmation”.
Refer to “GENERAL CHASSIS (1)” on page 8. Click “Actuator Check”, and then operate the
4-1. front brake lever “1” and rear brake lever “2”
4. Check: simultaneously.
• Battery voltage
TIP
Lower than 12.8 V → Charge or replace the
battery. • The hydraulic unit operates 1 second after the
front brake lever and rear brake lever are oper-
Battery voltage ated simultaneously and continues for approx-
Higher than 12.8 V imately 5 seconds.
• The operation of the hydraulic unit can be con-
TIP firmed using the indicator.
If the battery voltage is lower than 12.8 V, charge On: The hydraulic unit is operating.
the battery, and then perform ABS reaction- Flashing: The conditions for operating the hy-
force confirmation. draulic unit have not been met.
Off: The front brake lever and rear brake lever
are not being operated.
1 2
4-69
9. A reaction-force pulsating action is generated 11.After the pulsating action has stopped in the
in the front brake lever “1” and continues for a rear brake lever, it is generated in the front
few seconds. brake lever and continues for a few seconds.
TIP TIP
• The reaction-force pulsating action consists of • The reaction-force pulsating action consists of
quick pulses. quick pulses.
• Be sure to continue operating the front brake • “ON” and “OFF” on the tool screen indicate
lever and rear brake lever even after the pul- when the brakes are being applied and re-
sating action has stopped. leased respectively.
• “ON” and “OFF” on the tool screen indicate ECA22080
when the brakes are being applied and re- NOTICE

leased respectively. • 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.
• 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-
1 nected correctly to the hydraulic unit as-
sembly.
12.Turn the main switch to “OFF”.
10.After the pulsating action has stopped in the 13.Remove the Yamaha diagnostic tool from the
front brake lever, it is generated in the rear ABS test coupler, and then install the protec-
brake lever “1” and continues for a few sec- tive cap.
onds. 14.Turn the main switch to “ON”.
TIP 15.Check for brake fluid leakage around the hy-
• The reaction-force pulsating action consists of draulic unit.
quick pulses. Brake fluid leakage → Replace the hydraulic
• Be sure to continue operating the front brake unit, brake hoses, and related parts as a set.
lever and rear brake lever even after the pul- 16.If the operation of the hydraulic unit is normal,
sating action has stopped. delete all of the fault codes.
• “ON” and “OFF” on the tool screen indicate EAS30202
when the brakes are being applied and re- CHECKING THE ABS WARNING LIGHT
leased respectively. After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 10 km/h
(6 mph) or performing a trial run.
4-70
HANDLEBAR
EAS20033
HANDLEBAR
Removing the rearview mirror and handlebar cover
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
2
22 N•m (2.2 kgf•m, 16 lb•ft) 1
T.R
.
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
3
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

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

1 Rearview mirror 2
2 Upper handlebar panel 1
3 Upper handlebar cover 1
4-71
HANDLEBAR
Removing the handlebar

7 N•m (0.7 kgf•m, 5.2 lb•ft) 21 N•m (2.1 kgf•m, 15 lb •ft)
T.R
T.
.
R.
1.8 N•m (0.18 kgf•m, 1.3 lb •ft)
T.
R.
LS
11
7
LS
LS
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
12 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9 11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
6
10 11
8 4
2
2.5 N•m (0.25 kgf•m, 1.8 lb •ft) 1
T.
R.
2.3 N•m (0.23 kgf•m, 1.7 lb •ft)

T.
R.
3 5
2.3 N•m (0.23 kgf•m, 1.7 lb •ft)
T.
R.

1 Grip end (left) 1
2 Handlebar grip 1
3 Rear brake light switch connector 2 Disconnect.
4 Rear brake master cylinder holder 1
5 Rear brake master cylinder 1
6 Handlebar switch (left) 1
7 Grip end (right) 1
8 Front brake light switch connector 2 Disconnect.
9 Front brake master cylinder holder 1
10 Front brake master cylinder 1
11 Handlebar switch (right) 1
12 Throttle cable 2 Disconnect.
4-72
HANDLEBAR
Removing the handlebar

7 N•m (0.7 kgf•m, 5.2 lb•ft) 21 N•m (2.1 kgf•m, 15 lb •ft)
T.R
T.
.
R.
1.8 N•m (0.18 kgf•m, 1.3 lb •ft)
T.
R.
LS
14
13 LS
14
LS
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
15
16
2.5 N•m (0.25 kgf•m, 1.8 lb •ft)

T.
R.
2.3 N•m (0.23 kgf•m, 1.7 lb •ft) 16

T.
R.
2.3 N•m (0.23 kgf•m, 1.7 lb •ft)

17
T.
R.

13 Throttle grip 1
14 Upper handlebar holder 2
15 Handlebar 1
16 Lower handlebar holder 2
17 Lower handlebar cover 1
4-73
HANDLEBAR
EAS31396 ECA18300
ADJUSTING THE HANDLEBAR POSITION NOTICE

1. Remove: First, tighten the bolts on the front side of the
• Upper handlebar cover handlebar holder, and then on the rear side.
Refer to “REMOVING THE UPPER HAN-
DLEBAR COVER” on page 4-74. TIP
2. Check: • The upper handlebar holders should be in-
• Handlebar position stalled with the punch mark “a” facing forward.
TIP • Align the punch mark “b” on the handlebar with
The handlebar position can be adjusted to one the inner edge of the upper surface of the right
of two positions to suit the rider’s preference. lower handlebar holder.
3. Adjust: a
• Handlebar position
a. Remove the upper handlebar holders “1”.
4. Install:
• Upper handlebar cover
Refer to “INSTALLING THE UPPER HAN-
b. Remove the handlebar. DLEBAR COVER” on page 4-77.
c. Fit the projections “a” on the lower handle- EAS32355
bar holders into the slots shown in the il- REMOVING THE UPPER HANDLEBAR
lustration for the desired position. COVER
TIP 1. Remove:
Make sure that the lower handlebar holders are • Upper handlebar cover “1”
installed in the same position. a. Remove the quick fasteners and upper
handlebar cover screws.
b. Remove the projections “a” on the upper
b handlebar cover from the holes “b” in the
lower handlebar cover.
1 a
a b
b. Standard position
c. Rear position
d. Install the handlebar.
e. Install the upper handlebar holders. EAS30203
REMOVING THE HANDLEBAR

Upper handlebar holder bolt 1. Stand the vehicle on a level surface.
EWA13120
21 N·m (2.1 kgf·m, 15 lb·ft)
T.
WARNING
R.

4-74
HANDLEBAR
2. Remove: • The upper handlebar holders should be in-

• Handlebar grip “1” stalled with the punch mark “d” facing forward.
TIP • Align the punch mark “e” on the handlebar with
Blow compressed air between the handlebar the inner edge of the upper surface of the right
and the handlebar grip, and gradually push the lower handlebar holder.
grip off the handlebar.
3
1
a
b d 2
3
c e
1
1
b. Standard position
EAS30204
c. Rear position
CHECKING THE HANDLEBAR 3. Install:
1. Check: • Handlebar switch (right) “1”
• Handlebar • Throttle cables “2”
Bends/cracks/damage → Replace. • Throttle grip “3”
EWA13690
WARNING • Grip end (right) “4”

Do not attempt to straighten a bent handle- Handlebar switch screw (right
bar as this may dangerously weaken it. handlebar switch)
T.
R.
2.3 N·m (0.23 kgf·m, 1.7 lb·ft)

EAS30205 Throttle cable holder bolt (han-
INSTALLING THE HANDLEBAR dlebar switch side)
1. Stand the vehicle on a level surface. 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
EWA13120
Grip end bolt (right)
WARNING 7 N·m (0.7 kgf·m, 5.2 lb·ft)
no danger of it falling over. TIP
2. Install: • Lubricate the end of the throttle cables and the
• Lower handlebar holders “1” inside of the throttle grip with a thin coat of lith-
• Handlebar “2” ium-soap-based grease.
• Upper handlebar holders “3” • Align the projection “a” on the right handlebar
switch with the hole “b” in the handlebar.
Upper handlebar holder bolt • First, tighten the front screw, then the rear
21 N·m (2.1 kgf·m, 15 lb·ft) screw.
T.
R.
ECA18300
• There should be 1.0–5.0 mm (0.04–0.20 in) of
NOTICE clearance “c” between the throttle grip and the
grip end.
First, tighten the bolts on the front side of the
handlebar holder, and then on the rear side.
TIP
• Fit the projection “a” on the lower handlebar
holders into the slots shown in the illustration
for the desired position, make sure that the
lower handlebar holders are installed in the
same position.
4-75
HANDLEBAR
6. Install:
LS 1
3 • Handlebar switch (left) “1”
2
Handlebar switch screw (left han-
a
dlebar switch)
T.
R.
2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
b LS
TIP
• Align the projection “a” on the left handlebar
1
switch with the hole “b” in the handlebar.
• First, tighten the front screw, then the rear
screw.
1 b
c
a
3 4
4. Install: 1
• Front brake master cylinder
• Front brake master cylinder holder “1” 7. Install:
• Rear brake master cylinder
Front brake master cylinder hold- • Rear brake master cylinder holder “1”
er bolt
T.
R.
11 N·m (1.1 kgf·m, 8.1 lb·ft) Rear brake master cylinder hold-
er bolt
T.
R.
TIP 11 N·m (1.1 kgf·m, 8.1 lb·ft)

• Install the brake master cylinder holder with the
“UP” mark “a” facing up. TIP
• Align the end of the front brake master cylinder • Install the brake master cylinder holder with the
holder with the punch mark “b” on the handle- “UP” mark “a” facing up.
bar. • Align the end of the front brake master cylinder
• First, tighten the upper bolt, then the lower bolt. holder with the punch mark “b” on the handle-
bar.
1 • First, tighten the front bolt, then the rear bolt.
b
1
b
5. Adjust: a
• Throttle grip free play
Refer to “CHECKING THE THROTTLE GRIP 8. Install:
OPERATION” on page 3-24. • Handlebar grip “1”
• Grip end (left) “2”
Throttle grip free play a. Apply a thin coat of a rubber adhesive to
3.0–5.0 mm (0.12–0.20 in) the left end of the handlebar.
4-76
HANDLEBAR
b. Slide the handlebar grip over the left end TIP

of the handlebar. There should be 0.5–4.0 mm (0.02–0.16 in) of
TIP clearance “c” between the upper handlebar cov-
Make sure that the distance “a” between the end er and handlebar switch.
of the left handlebar switch and the end of the
handlebar grip is 0 mm (0 in). 1 a
b
a
1
c. Wipe off any excess rubber adhesive with

a clean rag.
EWA13700
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried. 2
1
d. Install the left grip end. c c
Grip end bolt (left) b. Install the quick fasteners and upper han-
7 N·m (0.7 kgf·m, 5.2 lb·ft) dlebar cover screws, and then tighten the
T.
R.
screws to specification.
TIP
There should be 1.0–5.0 mm (0.04–0.20 in) of Upper handlebar cover screw
clearance “a” between the handlebar grip and 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
the grip end.
a
2
EAS32356
INSTALLING THE UPPER HANDLEBAR

COVER
1. Install:
• Upper handlebar cover “1”
• Upper handlebar panel “2”
a. Fit the projections “a” on the upper handle-
bar cover into the holes “b” in the lower
handlebar cover.
4-77
FRONT FORK
EAS20034
FRONT FORK
Removing the front fork legs
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

5
T.R
.
T.R
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

The following procedure applies to both of
the front fork legs.
Battery 4-1.
Meter panel assembly 4-7.
Front wheel Refer to “FRONT WHEEL” on page 4-27.
1 Front fender assembly 1
2 Front fender side cover (left) 1
3 Front fender side cover (right) 1
4 Front fender 1
5 Front fork cap 1
4-78
FRONT FORK
Removing the front fork legs

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
7
30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
8 6
T.R
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

6 Front fork cap bolt 1 Loosen.
7 Upper bracket pinch bolt 1 Loosen.
8 Lower bracket pinch bolt 1 Loosen.
9 Front fork leg 1
4-79
FRONT FORK
Disassembling the front fork legs
6 New 1
LS
7 New 2 New
LS
New
3
New
10 4
9 New
5
LT
LT
8 New
30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.

The following procedure applies to both of
the front fork legs.
1 Front fork cap bolt 1
2 O-ring 1
3 Spacer 1
4 Spring seat 1
5 Fork spring 1
6 Dust seal 1
7 Oil seal clip 1
8 Front fork damper rod bolt 1
9 Copper washer 1
10 Damper rod 1
4-80
FRONT FORK
Disassembling the front fork legs
LS New
New New
LS
17 New
11
18
19 New
13
New 20
12
LT
LT
16 New
15
30 N•m (3.0 kgf•m, 22 lb•ft) 14

T.R
.

11 Damper rod ring 1
12 Rebound spring 1
13 Inner tube 1
14 Oil flow stopper 1
15 Oil flow stopper spring 1
16 Inner tube bushing 1
17 Oil seal 1
18 Washer 1
19 Outer tube bushing 1
20 Outer tube 1
4-81
FRONT FORK
EAS30206
REMOVING THE FRONT FORK LEGS

front fork legs.
EWA13120
WARNING
TIP
Place the vehicle on a suitable stand so that the 2. Remove:
front wheel is elevated. • Dust seal “1”
• Oil seal clip “2”
2. Loosen: (with a flathead screwdriver)
• Front fork cap bolt “1” ECA14180
• Upper bracket pinch bolt “2” NOTICE

• Lower bracket pinch bolt “3” Do not scratch the inner tube.
EWA13640
WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
2
3. Remove:
• Front fork damper rod bolt “1”
• Copper washer
TIP
While holding the damper rod with a hexagon bit
socket (14 mm) “2” and the T-handle “3”, loosen
the front fork damper rod bolt.
3
T-handle
90890-01326
YM-01326
EAS30207
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
1. Drain:
• Fork oil
TIP
Stroke the outer tube several times while drain-
ing the fork oil.
4. Remove:
• Inner tube
a. Hold the front fork leg horizontally.
4-82
FRONT FORK
b. Securely clamp the brake caliper bracket

in a vise with soft jaws.
c. Separate the inner tube from the outer
tube by pulling the inner tube forcefully but
carefully.
ECA14190
NOTICE
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bush-
ing must be replaced.
• Avoid bottoming the inner tube into the out-
3. Check:
er tube during the above procedure, as the
• Damper rod
oil flow stopper will be damaged.
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage → Replace.
ECA14200
NOTICE
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
EAS30208 • When disassembling and assembling the
CHECKING THE FRONT FORK LEGS front fork leg, do not allow any foreign ma-
The following procedure applies to both of the terial to enter the front fork.
front fork legs.
1. Check: EAS30209
• Inner tube ASSEMBLING THE FRONT FORK LEGS

• Outer tube The following procedure applies to both of the
Bends/damage/scratches → Replace. front fork legs.
EWA13650 EWA13660
WARNING WARNING
Do not attempt to straighten a bent inner • Make sure the oil levels in both front fork
tube as this may dangerously weaken it. legs are equal.
• Uneven oil levels can result in poor han-
2. Measure: dling and a loss of stability.
• Fork spring free length “a”
Out of specification → Replace. TIP
• When assembling the front fork leg, be sure to
Fork spring free length replace the following parts:
348.3 mm (13.71 in)
–Outer tube bushing
Limit
341.3 mm (13.44 in) –Inner tube bushing
–Oil seal
–Oil seal clip
–Dust seal
–O-ring
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• Inner tube bushing New
2. Install:
• Oil flow stopper spring “1”
4-83
FRONT FORK
• Oil flow stopper “2”

• Damper rod ring “3”
• Damper rod “4”
• Rebound spring 4
a. Install the oil flow stopper spring into the oil
flow stopper.
TIP
Make sure that the oil flow stopper spring is in-
stalled securely into the grooves “a” in the oil
flow stopper.
d. Install the oil flow stopper onto the inner
tube “5”.
a
1
2
5
2
b. Install the damper rod ring onto the damp-

er rod. 3. Lubricate:
TIP • Inner tube’s outer surface
Fit the damper rod ring into the damper rod
groove so that the side of the ring with the pro- Recommended oil
Yamaha fork oil 10WT
jections is facing in the direction shown in the il-
lustration.
4. Install:
• Inner tube
3 (in the outer tube)
5. Install:
4 • Copper washer New
• Front fork damper rod bolt
6. Tighten:
• Front fork damper rod bolt “1”
Front fork damper rod bolt

30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
c. Install the damper rod and rebound spring LOCTITE®

to the inner tube.
TIP TIP
Allow the damper rod to slide slowly down the in- While holding the damper rod assembly with a
ner tube until it protrudes from the bottom of the hexagon bit socket (14 mm) “2” and the T-han-
inner tube. Be careful not to damage the inner dle “3”, tighten the front fork damper rod bolt.
tube.
T-handle
90890-01326
YM-01326
4-84
FRONT FORK
Fork seal driver weight

90890-01184
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø33)
90890-01368
Replacement 33 mm
LT YM-A9409-4
7. Install:
• Outer tube bushing “1” New
• Washer “2”
(with the fork seal driver attachment “3” and
fork seal driver weight “4”)
Fork seal driver weight

90890-01184
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø33)
90890-01368
Replacement 33 mm 3
YM-A9409-4
4 New 1
3 9. Install:
2 • Oil seal clip “1” New
TIP
New 1
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
8. Install:
• Oil seal “1” New
(with the fork seal driver attachment “2” and
fork seal driver weight “3”)
ECA14220
NOTICE
New 1
Make sure the numbered side of the oil seal
faces up.
TIP
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease. 10.Install:
• Lubricate the outer surface of the inner tube • Dust seal “1” New
with fork oil. (with the fork seal driver weight “2”)
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect Fork seal driver weight
the oil seal during installation. 90890-01184
Replacement hammer
YM-A9409-7
4-85
FRONT FORK
• Front fork cap bolt

(along with the O-ring New )
TIP
2 • Before installing the front fork cap bolt, lubri-
cate its O-ring with grease.
• Install the spring with the smaller pitch facing
New 1 down.
• Temporarily tighten the front fork cap bolt.
• Tighten the front fork cap bolt specified torque,
when installing the front fork with upper brack-
11.Fill:
et.
• Front fork leg
EAS30210
mended fork oil) INSTALLING THE FRONT FORK LEGS
Recommended oil
Yamaha Suspension Oil G10 front fork legs.
Quantity (left) 1. Install:
235.0 cm³ (7.95 US oz, 8.29 • Front fork leg
Imp.oz) Temporarily tighten the lower bracket pinch
Quantity (right) bolt.
235.0 cm³ (7.95 US oz, 8.29 TIP
Imp.oz) Make sure the inner tube end is flush with the top
of the upper bracket.
12.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification → Correct.
Level (left)
155 mm (6.1 in)
Level (right)
155 mm (6.1 in)
2. Tighten:
TIP
• Lower bracket pinch bolt
• While filling the front fork leg, keep it upright. • Upper bracket pinch bolt
• After filling, slowly pump the front fork leg up • Front fork cap bolt
and down to distribute the fork oil.
Lower bracket pinch bolt
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
Upper bracket pinch bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
Front fork cap bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
13.Install:
• Fork spring
• Spring seat
• Spacer
4-86
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
91 N•m (9.1 kgf•m, 67 lb•ft) 3
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1st 48 N•m (4.8 kgf•m, 35 lb•ft)

T.R
*2nd 14 N•m (1.4 kgf•m, 10 lb•ft)

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

T.R
.
New
* Loosen the lower ring nut completely, and then tighten it to specification.

Battery 4-1.
Meter panel assembly 4-7.
Front wheel Refer to “FRONT WHEEL” on page 4-27.
Handlebar Refer to “HANDLEBAR” on page 4-71.
Front fork legs Refer to “FRONT FORK” on page 4-78.
1 Front brake hose guide 1
2 Front brake hose holder 1
3 Steering stem nut 1
4-87
STEERING HEAD
Removing the lower bracket

91 N•m (9.1 kgf•m, 67 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
4
5
1st 48 N•m (4.8 kgf•m, 35 lb•ft) 6
7
T.R
*2nd 14 N•m (1.4 kgf•m, 10 lb•ft)

.
8
LS
11
LS 12
13 LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
14 New
10
* Loosen the lower ring nut completely, and then tighten it to specification.

4 Upper bracket 1
5 Lock washer 1
6 Upper ring nut 1
7 Rubber washer 1
8 Lower ring nut 1
9 Lower bracket 1
10 Lower bracket cap 1
11 Bearing cover 1
12 Upper bearing 1
13 Lower bearing 1
14 Dust seal 1
4-88
STEERING HEAD
EAS30213
a. Remove the bearing races from the steer-
REMOVING THE LOWER BRACKET
ing head pipe “1” with a long rod “2” and
EWA13120
hammer.
WARNING b. Remove the bearing race “3” from the low-
Securely support the vehicle so that there is er bracket with a floor chisel “4” and ham-
no danger of it falling over. mer.
c. Install a new dust seal and new bearing
2. Remove: races.
• Upper ring nut ECA14270
• Rubber washer NOTICE

• Lower ring nut “1” If the bearing race is not installed properly,
• Lower bracket the steering head pipe could be damaged.
EWA13730
WARNING TIP
Securely support the lower bracket so that • Always replace the bearings and bearing races
there is no danger of it falling. as a set.
• Whenever the steering head is disassembled,
TIP replace the dust seal.
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
2
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 • Lower bracket cap “1”
Damage/pitting → Replace the bearings and (onto the lower bracket “2”)
bearing races as a set. TIP
3. Replace: Face the holes “a” in the lower bracket cap rear-
• Bearings ward.
• Bearing races
4-89
STEERING HEAD
a
1
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Upper ring nut “3”
• Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-15.
2
1 4
3. Install:
• Front brake hose holder “1”
Front brake hose holder bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
TIP
While holding the front brake hose holder so that
the portion “a” of the holder contacts the lower
bracket, tighten the bolt to specification.
4-90
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
EAS20189

Removing the rear shock absorber assemblies and swingarm
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2
1
6
11 New 12
30 N•m (3.0 kgf•m, 22 lb •ft)
T.
R.
LS
LS
10
New 9
3 New 8
5
3 4
30 N•m (3.0 kgf•m, 22 lb •ft)
T.
R.
LS
LS
23 N•m (2.3 kgf•m, 17 lb •ft)
125 N•m (12.5 kgf•m, 92 lb•ft)
T.
R.
T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
23 N•m (2.3 kgf•m, 17 lb •ft) 57 N•m (5.7 kgf•m, 42 lb•ft)

T.R
.
T.
R.

1 Rear brake hose holder 1
3 Rear shock absorber assembly 2
4 Rear wheel axle nut 1
5 Spacer 1
6 Swingarm assembly 1
7 Collar 1
8 Oil seal 1
9 Circlip 1
10 Bearing 1
11 Oil seal 1
12 Swingarm 1
4-91
EAS31227 EAS31230
REMOVING THE REAR SHOCK ABSORBER CHECKING THE SWINGARM

ASSEMBLIES 1. Check:
1. Stand the vehicle on a level surface. • Swingarm
EWA13120
Bends/cracks/damage → Replace.
WARNING 2. Check:
Securely support the vehicle so that there is • Circlip
no danger of it falling over. • Oil seals
• Bearing
TIP
Place the vehicle on the centerstand so that the
rear wheel is elevated. EAS31231
INSTALLING THE SWINGARM

EAS31228
1. Lubricate:
REMOVING THE SWINGARM • Oil seal lips
EWA13120 Recommended lubricant
WARNING Lithium-soap-based grease
no danger of it falling over. 2. Assemble:
• Bearing “1”
TIP • Oil seals “2” New
Place the vehicle on the centerstand so that the • Circlip “3” New
rear wheel is elevated.
TIP
2. Remove: • Install the bearing until it is flush with the sur-
• Rear brake hose holder face “a” of the swingarm.
• Rear brake caliper • Install the oil seal until it is flush with the sur-
ECA21830
face “b” of the swingarm.
NOTICE
• Install the oil seal until it is contact with the sur-
Do not apply the brake lever when removing face “c” of the circlip.
the brake caliper.
EAS31229
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
• Rear shock absorber rod a 3 New
1
Bends/damage → Replace the rear shock
absorber assembly.
• Rear shock absorber assembly
Oil leaks → Replace the rear shock absorber 2 New
assembly.
• Spring
Damage/wear → Replace the rear shock ab-
sorber assembly. LS
• Bushings New 2
LS
Damage/wear → Replace the rear shock ab-
sorber assembly. New 2
• Bolts
New 3
Bends/damage/wear → Replace.
c
b
3. Install:
• Swingarm assembly “1”
• Spacer
4-92
• Rear wheel axle nut “2”

(temporarily tighten) 1
• Swingarm mounting bolt (upper side) “3”
(temporarily tighten)
b
• Swingarm mounting bolt (lower side) “4”
(temporarily tighten)
a
4. Tighten:
• Rear wheel axle nut “2”
• Swingarm mounting bolt (upper side) “3”
• Swingarm mounting bolt (lower side) “4”
Rear wheel axle nut

125 N·m (12.5 kgf·m, 92 lb·ft)
T.
R.
Swingarm mounting bolt

57 N·m (5.7 kgf·m, 42 lb·ft)
TIP
Tighten the rear wheel axle nut “2”, then the
swingarm mounting bolts “3”, “4”.
1
3
2 4
5. Install:
• Rear shock absorber assemblies
Rear shock absorber assembly

bolt
T.
R.
30 N·m (3.0 kgf·m, 22 lb·ft)

bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
TIP
Tighten the rear shock absorber assembly bolts
temporarily, and then tighten them to specifica-
tion.
6. Install:
• Rear brake hose holder “1”
Rear brake hose holder bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
TIP
Fit the projection “a” on the rear brake hose hold-
er into the hole “b” in the swingarm.
4-93
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

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

MEASURING THE COMPRESSION PRESSURE....................................5-5
CHECKING THE BREATHER HOSES .....................................................5-6
ENGINE REMOVAL ........................................................................................5-7

INSTALLING THE ENGINE..................................................................... 5-11
CONNECTING THE LEADS ................................................................... 5-11
INSTALLING THE EXHAUST PIPE AND MUFFLER..............................5-12
CYLINDER HEAD.......................................................................................... 5-13

REMOVING THE CYLINDER HEAD.......................................................5-17
CHECKING THE CYLINDER HEAD .......................................................5-17
CHECKING THE CAMSHAFT SPROCKET............................................5-18
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-18
INSTALLING THE CYLINDER HEAD .....................................................5-18
CAMSHAFT ................................................................................................... 5-22

REMOVING THE CAMSHAFT ................................................................5-23
CHECKING THE CAMSHAFT ASSEMBLY ............................................5-23
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-23
5
INSTALLING THE CAMSHAFT...............................................................5-24
VALVES AND VALVE SPRINGS.................................................................. 5-26

REMOVING THE VALVES...................................................................... 5-27
CHECKING THE VALVES AND VALVE GUIDES ..................................5-27
CHECKING THE VALVE SEATS ............................................................ 5-29
CHECKING THE VALVE SPRINGS........................................................ 5-30
INSTALLING THE VALVES .................................................................... 5-30
CYLINDER AND PISTON.............................................................................. 5-32

REMOVING THE PISTON ...................................................................... 5-33
CHECKING THE CYLINDER AND PISTON ...........................................5-33
CHECKING THE PISTON RINGS........................................................... 5-34
CHECKING THE PISTON PIN ................................................................5-35
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................. 5-35
INSTALLING THE PISTON AND CYLINDER .........................................5-35
V-BELT AUTOMATIC TRANSMISSION .......................................................5-37
REMOVING THE PRIMARY FIXED SHEAVE ........................................ 5-40
REMOVING THE SECONDARY SHEAVE ............................................. 5-40
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-40
CHECKING THE CLUTCH HOUSING ....................................................5-41
CHECKING THE CLUTCH SHOES ........................................................ 5-41
CHECKING THE V-BELT........................................................................5-41
CHECKING THE PRIMARY SHEAVE ....................................................5-41
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-42
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-42
CHECKING THE SECONDARY SHEAVE .............................................. 5-42
ASSEMBLING THE SECONDARY SHEAVE..........................................5-42
ASSEMBLING THE PRIMARY FIXED SHEAVE .................................... 5-43
INSTALLING THE PRIMARY SHEAVE, V-BELT AND SECONDARY
SHEAVE .................................................................................................5-44
GENERATOR AND STARTER CLUTCH......................................................5-46

REMOVING THE GENERATOR ............................................................. 5-49
REMOVING THE STARTER CLUTCH ...................................................5-49
CHECKING THE STARTER CLUTCH ....................................................5-49
INSTALLING THE STARTER CLUTCH .................................................. 5-50
INSTALLING THE GENERATOR............................................................ 5-50
ELECTRIC STARTER ...................................................................................5-52

CHECKING THE STARTER MOTOR .....................................................5-54
ASSEMBLING THE STARTER MOTOR................................................. 5-55
INSTALLING THE STARTER MOTOR ...................................................5-55
OIL PUMP...................................................................................................... 5-56

CHECKING THE OIL STRAINER ........................................................... 5-59
CHECKING THE OIL PUMP ................................................................... 5-59
CHECKING THE OIL PUMP DRIVE CHAIN ...........................................5-59
ASSEMBLING THE OIL PUMP...............................................................5-59
INSTALLING THE OIL PUMP .................................................................5-60
CRANKCASE ................................................................................................5-61
DISASSEMBLING THE CRANKCASE....................................................5-63
CHECKING THE CRANKCASE ..............................................................5-63
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE............. 5-63
CHECKING THE RELIEF VALVE ........................................................... 5-63
CHECKING THE OIL STRAINER ........................................................... 5-63
ASSEMBLING THE CRANKCASE.......................................................... 5-63
CRANKSHAFT ..............................................................................................5-65
REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......................5-67
CHECKING THE CRANKSHAFT AND CONNECTING ROD ................. 5-67
CHECKING THE BALANCER SHAFT ASSEMBLY................................5-70
INSTALLING THE CONNECTING ROD ................................................. 5-70
INSTALLING THE CRANKSHAFT JOURNAL BEARINGS.....................5-71
INSTALLING THE CRANKSHAFT ASSEMBLY AND BALANCER
SHAFT ASSEMBLY ............................................................................... 5-72
TRANSMISSION............................................................................................ 5-73
CHECKING THE TRANSMISSION ......................................................... 5-75
INSTALLING THE TRANSMISSION .......................................................5-75
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20298

EAS32362
ENGINE OIL LUBRICATION CHART
13
8
12
9
5
3 4
2
10 11
1. Oil strainer
2. Oil pump (feed)
3. Oil filter element
4. Relief valve assembly
5. Main gallery
6. Crankshaft
7. To piston
8. Camshaft
9. Oil pump (scavenge)
10. Crankcase (left)
11. Crankcase (right)
12. Cylinder
13. Cylinder head
5-1
EAS32363
LUBRICATION DIAGRAMS

2. Engine oil check bolt
5-2
4 5 1
1. Oil strainer (feed)
2. Oil strainer (scavenge)
3. Crankshaft
5. Oil pump (feed)
5-3
3
4
6 5
1. Camshaft
2. Crankshaft
4. Oil pump (feed)
5. Relief valve assembly
5-4
ENGINE INSPECTION
EAS20041
ENGINE INSPECTION Compression pressure

783–1008 kPa/860 r/min (7.8–
EAS30249
10.1 kgf/cm²/860 r/min, 111.4–
MEASURING THE COMPRESSION 143.4 psi/860 r/min)
PRESSURE
TIP a. Turn the main switch to “ON”.
Insufficient compression pressure will result in a b. With the throttle wide open, crank the en-
loss of performance. gine until the reading on the compression
gauge stabilizes.
1. Measure: EWA12960
• Valve clearance WARNING

Out of specification → Adjust. To prevent sparking, ground the spark plug
Refer to “ADJUSTING THE VALVE CLEAR- lead before cranking the engine.
ANCE” on page 3-5.
2. Start the engine, warm it up for several min- c. If the compression pressure is above the
utes, and then turn it off. maximum specification, check the cylinder
3. Remove: head, valve surfaces and piston crown for
• Storage box carbon deposits.
Refer to “GENERAL CHASSIS (4)” on page Carbon deposits → Eliminate.
4-10. d. If the compression pressure is below the
4. Disconnect: minimum specification, pour a teaspoonful
• Spark plug cap of engine oil into the spark plug bore and
5. Remove: measure again.
• Spark plug Refer to the following table.
ECA20470 Compression pressure (with oil applied into the
NOTICE cylinder)
Before removing the spark plug, use com- Reading Diagnosis
pressed air to blow away any dirt accumulat- Piston ring(s) wear or
ed in the spark plug well to prevent it from Higher than without oil
damage → Repair.
falling into the cylinder. Piston, valves, cylinder
6. Install: head gasket or piston
Same as without oil
• Compression gauge “1” ring(s) possibly defec-
tive → Repair.
Compression gauge
8. Install:
90890-03081
Engine compression tester • Spark plug “1”
YU-33223
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
TIP
1 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
7. Measure:
• Compression pressure
Out of specification → Refer to steps (c) and 1
(d).
5-5
ENGINE INSPECTION
9. Connect:
• Spark plug cap
10.Install:
• Storage box
4-10.
EAS31742
CHECKING THE BREATHER HOSES

1. Remove:
• Storage box
4-10.
2. Check:
• Cylinder head breather hose “1”
• Transmission case breather hose “2”
Loose connections → Connect properly.
ECA21600
NOTICE
Make sure the cylinder head breather hose
and transmission case breather hose are
routed correctly.
3. Install:
• Storage box
4-10.
5-6
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler and exhaust pipe
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
8
LT
9
3 New 6
53 N•m (5.3 kgf•m, 39 lb•ft)
T.R
.
New 4
LT
1 5
LT
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft) 15 N•m (1.5 kgf•m, 11 lb•ft)

T.R
T.R
.

1 Clamp bolt 1 Loosen.
2 Muffler assembly 1
3 Clamp 1
4 Gasket 1
5 Exhaust pipe 1
6 Exhaust gasket 1
7 Muffler protector 1
8 Muffler cap 1
9 Muffler 1
5-7
ENGINE REMOVAL
Disconnecting the leads

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-19.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-21.
Bottom cover assembly 4-13.
Rear lower cowling assembly 4-23.
Rear brake caliper Refer to “REAR BRAKE” on page 4-51.
Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-7.
5-8
ENGINE REMOVAL
Disconnecting the leads

3 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
6
4
2

Thermostat assembly Refer to “THERMOSTAT” on page 6-6.
Fuel injector Refer to “FUEL INJECTOR” on page 7-8.
Air filter case joint Refer to “AIR FILTER CASE” on page 7-11.
Intake manifold Refer to “THROTTLE BODY” on page 7-13.
1 Crankshaft position sensor coupler 1 Disconnect.
2 Stator coil coupler 1 Disconnect.
3 Coolant temperature sensor coupler 1 Disconnect.
4 O2 sensor coupler 1 Disconnect.
5 Spark plug cap 1 Disconnect.

6 Engine ground lead 1 Disconnect.
7 Rear wheel sensor coupler 1 Disconnect.
5-9
ENGINE REMOVAL
Removing the engine

45 N•m (4.5 kgf•m, 33 lb•ft) 30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
.
T.R
.
3
1
1
2 23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
45 N•m (4.5 kgf•m, 33 lb•ft)
T.R
.
3 60 N•m (6.0 kgf•m, 44 lb•ft)
T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
6
5
7
2 LS
4 6

1 Rear shock absorber assembly 2
2 Engine mounting nut/bolt (front side) 2/2
3 Engine mounting nut/bolt (rear side) 2/2
4 Engine 1
5 Starter motor lead 1 Disconnect.
6 Engine bracket nut/bolt 1/1
7 Engine bracket 1
5-10
ENGINE REMOVAL
EAS30251
INSTALLING THE ENGINE Engine mounting bolt (rear side)

1. Lubricate: 45 N·m (4.5 kgf·m, 33 lb·ft)
T.
R.
• Engine bracket bolt “1” Engine mounting bolt (front side)
45 N·m (4.5 kgf·m, 33 lb·ft)
Lithium-soap-based grease 7. Install:
• Rear shock absorber assemblies “7”
TIP
Apply lithium-soap-based grease to the area “a” Rear shock absorber assembly
shown in the illustration. Do not apply lithium- bolt
T.
R.
soap-based grease to the threads on the end of 30 N·m (3.0 kgf·m, 22 lb·ft)
the bolt.
bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
a TIP
Tighten the rear shock absorber assembly bolts
temporarily, and then tighten them to specifica-
tion.
5 7
2. Install: 7
• Engine bracket “1”
(to the engine)
• Engine bracket bolt/nut “2”
6
TIP 5
Do not fully tighten the nut.
3
3. Tighten: 6
• Engine bracket nut 2
Engine bracket nut
60 N·m (6.0 kgf·m, 44 lb·ft) 5
T.
R.
4. Connect: 1
• Starter motor lead “3”
6
Starter motor lead screw 4
3.5 N·m (0.35 kgf·m, 2.6 lb·ft) 2
T.
R.
EAS31717
5. Install:
CONNECTING THE LEADS
• Engine “4”
1. Connect:
• Engine mounting bolt/nut (rear side) “5”
• Engine ground lead “1”
• Engine mounting bolt/nut (front side) “6”
TIP Engine ground lead bolt
Do not fully tighten the nut. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
6. Tighten: TIP
• Engine mounting bolt (rear side)
Make sure that the engine ground lead terminal
• Engine mounting bolt (front side)
“a” contacts the stopper “b” on the crankcase.
5-11
ENGINE REMOVAL
a b
EAS30252
INSTALLING THE EXHAUST PIPE AND

MUFFLER
1. Install:
• Exhaust gasket “1” New
(to the cylinder head)
TIP
Install the exhaust gasket with its projections “a”
facing toward the cylinder head.
1 New
a
5-12
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) *
T.R
.
New
(3) 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
New 13 N•m (1.3 kgf•m, 9.6 lb•ft) New
*
T.R
.
15 N•m (1.5 kgf•m, 11 lb•ft) LS
T.R
.
New
New
New
New
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
(4)
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)
T.R
.
1st 16 N•m (1.6 kgf•m, 12 lb•ft) New

**2nd 16 N•m (1.6 kgf•m, 12 lb•ft) M
T.R
.
Specified angle 180°

25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
* Apply Yamaha bond No.1215 (90890-85505).

** Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after
loosening the bolt, retighten it before loosening the next bolt).

Drain.
page 3-21.
5-13
CYLINDER HEAD

24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) *
T.R
.
New
(3) 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
*
T.R
.
15 N•m (1.5 kgf•m, 11 lb•ft) LS
T.R
.
New 1 New
2
New
New
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
(4)
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)
T.R
.
3
M 4
**2nd 16 N•m (1.6 kgf•m, 12 lb•ft) 6
T.R
.

25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
5 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)

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


Intake manifold Refer to “THROTTLE BODY” on page 7-13.
1 Crankshaft end cover 1
2 Timing mark accessing bolt 1
3 O2 sensor coupler 1 Disconnect.
TIP
4 O2 sensor 1 Remove the O2 sensor only when neces-
sary.
5 Spark plug cap 1 Disconnect.

6 Spark plug 1
5-14
CYLINDER HEAD
9 24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) *
T.R
.
New
(3) 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
15 New 13 N•m (1.3 kgf•m, 9.6 lb•ft) New
*
T.R
.
15 N•m (1.5 kgf•m, 11 lb•ft) LS
T.R
14
.
13 New 7 New
11 8 New
12 New
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
(4)
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4) 10
T.R
.

**2nd 16 N•m (1.6 kgf•m, 12 lb•ft) M
T.R
.

25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)

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


7 Coolant temperature sensor coupler 1 Disconnect.
8 Coolant temperature sensor 1
9 Cylinder head breather hose 1
10 Bracket 1 1
11 Bracket 2 1
12 Cylinder head cover 1
13 Cylinder head cover gasket 1
14 Cylinder head breather cover 1
15 Cylinder head breather cover gasket 1
5-15
CYLINDER HEAD

24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
16
10 N•m (1.0 kgf•m, 7.4 lb•ft) *
T.R
.
17 New
(3) 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
.
*
T.R
.
15 N•m (1.5 kgf•m, 11 lb•ft) LS
T.R
.
New 18
New
New
New
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4) 21
T.R
.
19 M 23
19
M 20
24
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
(4) 23
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4) 22
T.R
.

**2nd 16 N•m (1.6 kgf•m, 12 lb•ft) M
T.R
.

25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)

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


16 Timing chain tensioner cap bolt 1
17 Timing chain tensioner 1
18 Timing chain tensioner gasket 1
19 Camshaft sprocket bolt 2
20 Camshaft sprocket 1
21 Cylinder head 1
22 Cylinder head gasket 1
23 Dowel pin 2
24 Engine oil check bolt 1
5-16
CYLINDER HEAD
EAS30276
REMOVING THE CYLINDER HEAD

1. Remove:
• Crankshaft end cover
• Timing mark accessing bolt
1
2. Align:
2
• Mark “a” on the generator rotor
(with the slots “b” in the generator rotor cover)
a. Turn the crankshaft clockwise.
tor on both sides of the slots “b” in the gen-
4. Remove:
erator rotor cover.
• Cylinder head
b TIP
• Loosen the bolts and nuts in the proper se-
quence as shown.
• Loosen each bolt and nuts 1/2 of a turn at a
time. After all of the bolts and nuts are fully
loosened, remove them.
a 3 6
TIP ×4
When the piston is at TDC on the compression
stroke, align the “I” mark “c” on the camshaft
sprocket with the match mark “d” on the cylinder 5 4 ×2
head.
1 2
d c
EAS30277
CHECKING THE CYLINDER HEAD

1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
3. Remove: • Spark plug bore threads
• Camshaft sprocket bolts “1” • Valve seats
• Camshaft sprocket
TIP
• Use the camshaft sprocket stopper “2” and
loosen the camshaft sprocket bolts.
• To prevent the timing chain from falling into the
crankcase, fasten it with a wire.

90890-04182
YM-04182 2. Check:
• Cylinder head
Damage/scratches → Replace.
5-17
CYLINDER HEAD
• Cylinder head water jacket

Mineral deposits/rust → Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
Warpage limit
0.05 mm (0.0020 in)
a. Place a straightedge “1” and a thickness

a. 1/4 tooth
gauge “2” across the cylinder head.
b. Correct
1. Timing chain roller
2. Camshaft sprocket
EAS30279
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
2. Check:
• One-way cam operation
Rough movement → Replace the timing
1 2 chain tensioner assembly.
3. Check:
• Timing chain tensioner cap bolt “1”
• Washer “2”
• Timing chain tensioner spring “3”
• One-way cam “4”
• Timing chain tensioner gasket “5”
• Timing chain tensioner rod “6”
Damage/wear → Replace the defective
b. Measure the warpage. part(s).
c. If the limit is exceeded, resurface the cylin-
der head as follows.
5 3 2 1
d. Place 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder 4 6
head several times.
EAS31232
CHECKING THE CAMSHAFT SPROCKET EAS30282
INSTALLING THE CYLINDER HEAD

1. Check:
1. Tighten:
• Camshaft sprocket
• Cylinder head nuts “1”
More than 1/4 tooth wear “a” → Replace the
• Cylinder head bolts “2”
camshaft sprocket, timing chain and crank-
shaft as a set.
5-18
CYLINDER HEAD
a. Install the timing chain onto the camshaft

Cylinder head nut sprocket, then the camshaft sprocket onto
1st: 16 N·m (1.6 kgf·m, 12 lb·ft) the camshaft, and then finger tighten the
T.
R.
*2nd: 16 N·m (1.6 kgf·m, 12 lb·ft), camshaft sprocket bolts.

and then tighten the bolts to the ECA20600
specified angle 180° NOTICE
Cylinder head bolt
Do not turn the crankshaft when installing
10 N·m (1.0 kgf·m, 7.4 lb·ft)
the camshaft sprocket to avoid damage or
*Following the tightening order, loosen the improper valve timing.
bolt one by one, and then retighten it to the TIP
specific torque (after loosening the bolt, re-
Align the “I” mark “a” on the camshaft sprocket
tighten it before loosening the next bolt).
with the match mark “b” on the cylinder head.
TIP
• Lubricate the cylinder head nuts and washers b a 2
with molybdenum disulfide grease.
1
• Replace the cylinder head bolts, nuts and
washers with new ones.
• Tighten the cylinder head nuts and bolts in the
proper tightening sequence as shown.
4 1
1 1
×4 b. While holding the camshaft, temporarily
tighten the camshaft sprocket bolts.
4. Install:
2 3
×2 • Timing chain tensioner gasket New
• Timing chain tensioner
6 2 5 a. Remove the timing chain tensioner cap
bolt “1”, washer “2” and spring “3”.
2. Align: b. Release the timing chain tensioner one-
• Mark “a” on the generator rotor way cam “4” and push the timing chain
(with the slots “b” in the generator rotor cover) tensioner rod “5” all the way into the timing
a. Turn the crankshaft clockwise. chain tensioner housing.
tor on both sides of the slots “b” in the gen-
erator rotor cover. 1
b
4 2 New
5 3
New
c. Install the gasket and the timing chain ten-

a sioner “6” onto the cylinder.
EWA17620
3. Install: WARNING
• Camshaft sprocket “1” Always use a new gasket.
• Timing chain “2”
• Camshaft sprocket bolts
5-19
CYLINDER HEAD
TIP
• Install the timing chain tensioner gasket so that b
the tab “a” on the gasket is protruding in the di-
rection shown in the illustration.
• The mark “b” on the timing chain tensioner
should face in the direction shown in the illus-
tration.
• Apply Yamaha bond No. 1215 to the threads of
the timing chain tensioner bolts. a
Yamaha bond No. 1215 d c

90890-85505
Timing chain tensioner bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
a
7. Tighten:
6 • Camshaft sprocket bolts “1”
Camshaft sprocket bolt

b 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.

d. Install the spring, washer, and timing chain 90890-04182
tensioner cap bolt. Camshaft sprocket stopper
YM-04182
Timing chain tensioner cap bolt
24 N·m (2.4 kgf·m, 18 lb·ft) TIP
T.
R.
Tighten the camshaft sprocket bolts with the

5. Turn: camshaft sprocket stopper “2”.
• Crankshaft
(several turns clockwise)
6. Check:
• Mark “a”
Make sure that the mark “a” on the generator
rotor is positioned between the slots “b” in the 1
generator rotor cover. 2
• “I” mark “c”
Make sure the “I” mark “c” on the camshaft
sprocket is aligned with the match mark “d”
on the cylinder head.
Out of alignment → Correct. 8. Measure:
Refer to the installation steps above. • Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
9. Install:
• Bracket 1 “1”
5-20
CYLINDER HEAD
Bracket bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
While holding the bracket 1 so that the bracket 1
the portion “a” of the cylinder head, tighten the
bolt to specification.
5-21
CAMSHAFT
EAS20043
CAMSHAFT
Removing the rocker arms and camshaft
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
1
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
E
7
New
LT 8
3
E
4
M
M
2
4
M
2
8 N•m (0.8 kgf•m, 5.9 lb•ft)
6
T.R
.

Cylinder head Refer to “CYLINDER HEAD” on page 5-13.
1 Camshaft stopper plate 1
2 Collar 2
3 Rocker arm shaft retainer 1
4 Rocker arm shaft 2
5 Exhaust rocker arm 1
6 Intake rocker arm 1
7 Camshaft assembly 1
8 Bearing 1
5-22
CAMSHAFT
EAS30256
3. Measure:
REMOVING THE CAMSHAFT
• Camshaft runout
1. Remove:
Out of specification → Replace the camshaft
• Camshaft assembly “1”
assembly.
TIP
Screw the M6 bolts “2” into the threaded end of Camshaft runout limit
the camshaft assembly, and then pull out the 0.030 mm (0.0012 in)
camshaft.
4. Check:
EAS32364 • Camshaft oil passage
CHECKING THE CAMSHAFT ASSEMBLY Obstruction → Blow out with compressed air.
1. Check: 5. Check:
• Camshaft lobes • Decompression system
Blue discoloration/pitting/scratches → Re-
TIP
place the camshaft assembly.
2. Measure: • Check that the decompression lever moves
• Camshaft lobe dimensions “a” smoothly.
Out of specification → Replace the camshaft • Check that the operating range “a” of the de-
assembly. compression lever is the same as the range
Camshaft lobe dimensions
Lobe height (Intake) a
40.017–40.117 mm (1.5755–
1.5794 in)
Limit
39.917 mm (1.5715 in)
Lobe height (Exhaust)
39.954–40.054 mm (1.5730–
1.5769 in)
Limit
39.854 mm (1.5691 in)
a. 9.69°
EAS30259
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
• Rocker arm
• Rocker arm roller “1”
5-23
CAMSHAFT
2. Check: 5. Calculate:
• Rocker arm shaft • Rocker-arm-to-rocker-arm-shaft clearance
Blue discoloration/excessive wear/pitting/ TIP
scratches → Replace or check the lubrication Calculate the clearance by subtracting the rock-
system. er arm shaft outside diameter from the rocker
3. Measure: arm inside diameter.
• Rocker arm inside diameter “a”
Out of specification → Replace. Out of specification → Replace the defective
part(s).
Rocker arm inside diameter
11.985–12.000 mm (0.4719– Rocker-arm-to-rocker-arm-shaft
0.4724 in) clearance
Limit 0.009–0.034 mm (0.0004–0.0013
12.015 mm (0.4730 in) in)
Limit
0.080 mm (0.0032 in)
EAS30269
INSTALLING THE CAMSHAFT

a 1. Lubricate:
• Camshaft assembly
Camshaft
Molybdenum disulfide oil
Camshaft bearing
4. Measure: Engine oil
• Rocker arm shaft outside diameter “a”
Out of specification → Replace. 2. Lubricate:
• Rocker arms
Rocker arm shaft outside diame- • Rocker arm shafts
ter
11.966–11.976 mm (0.4711– Recommended lubricant
0.4715 in) Rocker arm shaft
Limit Rocker arm roller
11.935 mm (0.4699 in) Molybdenum disulfide oil
3. Install:
• Rocker arm shaft retainer “1”
Rocker arm shaft retainer bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
LOCTITE®
5-24
CAMSHAFT
TIP
• Before installing the rocker arm shaft retainer,
make sure that the notches “a” in the rocker
arm shafts face inward.
• While holding the rocker arm shaft retainer so
that the portion “b” of the retainer contact the
cylinder head, tighten the bolt to specification.
5-25
VALVES AND VALVE SPRINGS
EAS20045

Removing the valves and valve springs
1 2 3 6
4
7 New
8
M
M
M
E
9 New
9 New
M 5
7 New
4
3
2 E
1
M

Camshaft/Rocker arms Refer to “CAMSHAFT” on page 5-22.
1 Valve pad 4
2 Valve cotter 8
3 Valve spring retainer 4
4 Valve spring 4
5 Intake valve 2
6 Exhaust valve 2
7 Valve stem seal 4
8 Valve spring seat 4
9 Valve guide 4
5-26
EAS30283
REMOVING THE VALVES

valves and related components.
TIP
1
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check: 2
• 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 5-29. • Valve “3”
a. Pour a clean solvent “a” into the intake and • Valve stem seal “4”
exhaust ports. • Valve spring seat “5”
b. Check that the valves properly seal. TIP
TIP Identify the position of each part very carefully so
There should be no leakage at the valve seat “1”. that it can be reinstalled in its original place.
1
5
2
3
4
2. Remove: EAS30284
• Valve pads CHECKING THE VALVES AND VALVE

• Valve cotters “1” GUIDES
TIP
valves and valve guides.
Remove the valve cotters by compressing the 1. Measure:
valve spring with the valve spring compressor • Valve-stem-to-valve-guide clearance
and the valve spring compressor attachment “2”. Out of specification → Replace the valve
guide.
Valve spring compressor Valve-stem-to-valve-guide clearance =
90890-04019 Valve guide inside diameter “a” -
Valve spring compressor Valve stem diameter “b”
YM-04019
Valve spring compressor attach-
ment
90890-06320
5-27
b. Install the new valve guide with the valve

Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remov-
ance (intake) er “1”.
0.010–0.037 mm (0.0004–0.0015
in) Valve guide position
Limit 11.98–12.02 mm (0.471–0.473 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
0.100 mm (0.0039 in)
a. Valve guide position

c. After installing the valve guide, bore the
valve guide with the valve guide reamer
“3” to obtain the proper valve-stem-to-
valve-guide clearance.
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
a. Remove the valve guide with the valve Valve guide installer (ø5)
guide remover “1”. 90890-04098
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)
5-28
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
the valve guide. face.
• 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
impression.
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.
4. Lap:
1. Eliminate:
• Valve face
• Carbon deposits
• Valve seat
(from the valve face and valve seat)
2. Check: TIP
• Valve seat After replacing the cylinder head or replacing the
Pitting/wear → Replace the cylinder head. valve and valve guide, the valve seat and valve
3. Measure: face should be lapped.
• Valve seat width “a” a. Apply a coarse lapping compound “a” to
Out of specification → Replace the cylinder the valve face.
head. ECA13790
NOTICE
Valve seat contact width (intake)
Do not let the lapping compound enter the
0.90–1.20 mm (0.0354–0.0472 in)
Limit gap between the valve stem and the valve
1.7 mm (0.07 in) guide.
Valve seat contact width (ex-
haust)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.7 mm (0.07 in)
5-29
j. Measure the valve seat width again. If the

valve seat width is out of specification, re-
face and lap the valve seat.
EAS30286
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
b. Apply molybdenum disulfide oil onto the spring.
valve stem.
c. Install the valve into the cylinder head. Free length (intake)
d. Turn the valve until the valve face and 35.87 mm (1.41 in)
valve seat are evenly polished, and then Limit
clean off all of the lapping compound. 34.07 mm (1.34 in)
TIP
Free length (exhaust)
35.87 mm (1.41 in)
For the best lapping results, lightly tap the valve Limit
seat while rotating the valve back and forth be- 34.07 mm (1.34 in)
tween your hands.
e. Apply a fine lapping compound to the EAS30288
INSTALLING THE VALVES

valve face and repeat the above steps.
f. After every lapping procedure, be sure to
valves and related components.
clean off all of the lapping compound from
1. Deburr:
the valve face and valve seat.
• Valve stem end
g. Apply blue layout fluid “b” onto the valve
(with an oil stone)
face.
2. Lubricate:
h. Install the valve into the cylinder head.
• Valve stem “1”
i. Press the valve through the valve guide
and onto the valve seat to make a clear Recommended lubricant
impression. Molybdenum disulfide oil
5-30
• Valve stem seal “2” TIP

(with the recommended lubricant) Install the valve cotters by compressing the
valve spring with the valve spring compressor
Engine oil and the valve spring compressor attachment “2”.

90890-04019
YM-04019
E Valve spring compressor attach-
ment
90890-06320
3. Install:
• Valve spring seat “1”
1
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head) 2
TIP 5. To secure the valve cotters onto the valve
• Make sure each valve is installed in its original stem, lightly tap the valve tip with a soft-face
place. hammer.
ECA13800
• Install the valve springs with the larger pitch “a”
NOTICE
facing up.
Hitting the valve tip with excessive force
could damage the valve.
5
1
4
3
2 New
6. Install:
• Valve pads
b. Smaller pitch
4. Install:
• Valve cotters “1”
5-31
CYLINDER AND PISTON
EAS20046
CYLINDER AND PISTON

Removing the cylinder and piston
4
3 New
2
1
4
5 New 7
10
9 E
8
E 6
5 New
E
E

Water pump outlet pipe Refer to “WATER PUMP” on page 6-8.
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
5-32
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
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 wall
piston pin puller set “4”.
• Cylinder wall
Vertical scratches → Replace the cylinder,
Piston pin puller set piston, and piston rings as a set.
90890-01304 2. Measure:
Piston pin puller
• Piston-to-cylinder clearance
YU-01304
a. Measure cylinder bore “D” with the cylin-
der bore gauge.
3 TIP
1 Measure cylinder bore “D” between the intake
and exhaust sides of the cylinder.
Bore
70.000–70.025 mm (2.7559–
2 2.7569 in)
b
a
D
a. 40 mm (1.57 in) from the top of the cylinder

2. Remove: b. Intake side
• Top ring c. Exhoust side
• 2nd ring b. If out of specification, replace the cylinder,
• Oil ring piston, and piston rings as a set.
c. Measure piston skirt diameter D “a” with
the micrometer.
5-33
CYLINDER AND PISTON
a
Piston ring
Top ring
Ring side clearance
0.030–0.065 mm (0.0012–
b 0.0026 in)
Side clearance limit
0.115 mm (0.0045 in)
2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–
b. 8.0 mm (0.31 in) from the bottom edge of the 0.0022 in)
piston Side clearance limit
0.115 mm (0.0045 in)
Piston
Diameter
69.962–69.985 mm (2.7544–
2.7553 in)
d. If out of specification, replace the piston

and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “D” 2. Install:
• Piston ring
(into the cylinder)
Piston-to-cylinder clearance
TIP
0.031–0.047 mm (0.0012–0.0019
in) Use the piston crown to level the position ring
near the bottom of the cylinder “a” where the cyl-
f. If out of specification, replace the cylinder, inder wear is lowest.
and replace the piston and piston rings as
a set.
EAS30292 a
CHECKING THE PISTON RINGS
1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
b
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston b. Top of cylinder
ring grooves and piston rings.
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
TIP
The oil ring expander spacer end gap cannot be
measured. If the oil ring rail gap is excessive, re-
place all three piston rings.
5-34
CYLINDER AND PISTON
4. Calculate:
Piston ring • Piston-pin-to-piston-pin-bore clearance
Top ring Out of specification → Replace the piston pin
End gap limit and piston as a set.
0.50 mm (0.0197 in)
2nd ring Piston-pin-to-piston-pin-bore clearance =
End gap limit Piston pin bore diameter “b” -
Piston pin outside diameter “a”
1.15 mm (0.0453 in)
EAS30293 Piston-pin-to-piston-pin-bore
CHECKING THE PISTON PIN clearance
1. Check: 0.002–0.018 mm (0.0001–0.0007
• Piston pin in)
Blue discoloration/grooves → Replace the
piston pin, and then check the lubrication sys- EAS30290
tem. CHECKING THE TIMING CHAIN GUIDE

2. Measure: (EXHAUST SIDE)
• Piston pin outside diameter “a” 1. Check:
Out of specification → Replace the piston pin. • Timing chain guide (exhaust side)
Piston pin outside diameter
EAS30294
15.995–16.000 mm (0.6297– INSTALLING THE PISTON AND CYLINDER
0.6299 in)
1. Install:
Limit
15.975 mm (0.6289 in) • Lower oil ring rail “1”
• Oil ring expander “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
Be sure to install the piston rings so that the
manufacturer marks face up.
3. Measure:
• Piston pin bore diameter “b” 4
Out of specification → Replace the piston. 3
2
Piston pin bore inside diameter
16.002–16.013 mm (0.6300– 1
0.6304 in)
Limit 2. Install:
16.043 mm (0.6316 in) • Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
TIP
• Apply engine oil to the piston pin and connect-
ing rod.
• Make sure the punch mark “a” on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover the
the clips from falling into the crankcase.
5-35
CYLINDER AND PISTON
• When installing a piston pin clip, make sure 5. Install:

that the clip ends “b” are positioned away from • Dowel pins
the cutout “c” in the piston as shown in the illus- • Cylinder gasket New
tration. • Cylinder “1”
TIP
2
• While holding the piston “2” with one hand, in-
1 stall the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
a
3 New
New 3 2
1
b 2
1
3. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
Engine oil
4. Offset:
• Piston ring end gaps
A
d 45° 45° e
45° 45°
135°
a b
c
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
A. Exhaust side
5-36
V-BELT AUTOMATIC TRANSMISSION
EAS20050

Removing the V-belt case
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
4
7 New
8
(12)
6
1
New 5
(4)
(4)
2
New
New
(4) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Storage box 4-10.
Air filter case Refer to “AIR FILTER CASE” on page 7-11.
1 V-belt case air filter element cover 1
2 V-belt case air duct 1
3 V-belt case air filter element 1
4 V-belt case 1
5 V-belt case gasket 1
6 Dowel pin 1
7 Circlip 1
8 Bearing 1
5-37
Removing the V-belt, primary sliding sheave assembly and secondary sheave assembly
85 N•m (8.5 kgf•m, 63 lb•ft)
T.R
.
75 N•m (7.5 kgf•m, 55 lb•ft)
T.R
.
15
14 13
12
8
6
7
11 9
16
8
5
4 10 New
M
3
2
* 115 N•m (11.5 kgf•m, 85 lb•ft)
1
T.R
.
** 120 N•m (12 kgf•m, 89 lb•ft)

T.R
.
* Tightening torque when reusing the primary fixed sheave bolt and washer
** Tightening torque when installing a new primary fixed sheave bolt and washer

1 Primary fixed sheave bolt 1
2 Washer 1
3 Primary fixed sheave 1
4 Primary sliding sheave assembly 1
5 Collar 1
6 Cam 1
7 Primary sheave weight 6
8 Slider 3
9 Primary sliding sheave 1
10 Oil seal 1
11 Washer 1
12 Clutch housing nut 1
13 Clutch housing 1
14 Secondary sheave nut 1 Loosen.
15 Secondary sheave assembly 1
16 V-belt 1
5-38
Disassembling the secondary sheave assembly

4
*
5
3
2
12
11
6
7
1
10 New
10 New
9 New
*
*
*
* Apply Shell dolium grease R®.

1 Secondary sheave nut 1
2 Clutch carrier assembly 1
3 Compression spring 1
4 Spring seat 1 1
5 Spring seat 2 1
6 Guide pin 4
7 Collar 4
8 Secondary sliding sheave 1
9 O-ring 2
10 Oil seal 2
11 Bearing 1
12 Secondary fixed sheave 1
5-39
EAS32357 ECA21820
REMOVING THE PRIMARY FIXED SHEAVE NOTICE

1. Remove: Do not remove the secondary sheave nut at
• Primary fixed sheave bolt “1” this stage.
• Washer
• Primary fixed sheave “2” TIP
TIP While holding the secondary sheave with the ro-
While holding the primary fixed sheave with the tor holding tool “2”, loosen the secondary
rotor holding tool “3”, loosen the primary fixed sheave nut one full turn with the locknut wrench
sheave bolt. “3”.
Rotor holding tool Rotor holding tool

90890-01235 90890-04166
Universal magneto and rotor Rotor holding tool
holder YM-04166
YU-01235 Locknut wrench
90890-01348
Locknut wrench
YM-01348
3
2
1
2 3
EAS30311 1
REMOVING THE SECONDARY SHEAVE
1. Remove:
EAS30312
• Clutch housing nut “1”
DISASSEMBLING THE SECONDARY
• Clutch housing “2”
SHEAVE
TIP 1. Remove:
While holding the clutch housing with the rotor • Secondary sheave nut “1”
holding tool “3”, loosen the clutch housing nut. TIP
Install the sheave spring compressor “2” and
Rotor holding tool sheave fixed block “3” onto the secondary
90890-04166 sheave as shown. Then, compress the spring,
Rotor holding tool
and remove the secondary sheave nut.
YM-04166
Sheave spring compressor

90890-04134
3 Sheave spring compressor
YM-04134
Sheave fixed block
90890-04135
2 Sheave fixed bracket
YM-04135
1
2. Loosen:
• Secondary sheave nut “1”
5-40
2 Clutch shoe thickness

3.0 mm (0.12 in)
1 Limit
1.5 mm (0.06 in)
a a
a
a
3
a
EAS30313
CHECKING THE CLUTCH HOUSING

a a
1. Check:
• Clutch housing
Damage/wear → Replace. a
a a
2. Measure:
• Clutch housing inside diameter “a” EAS30315
CHECKING THE V-BELT

Out of specification → Replace the clutch
1. Check:
housing.
• V-belt “1”
Clutch housing inside diameter Cracks/damage/wear → Replace.
150.0 mm (5.91 in) Grease/oil → Clean the primary and second-
Limit ary sheave.
150.5 mm (5.93 in) 2. Measure:
• V-belt width “a”
TIP
Measure the V-belt width as illustration.
a
V-belt width
27.7 mm (1.09 in)
Limit
26.7 mm (1.05 in)
EAS30314
a 2 1
CHECKING THE CLUTCH SHOES
clutch shoes.
1. Check:
• Clutch shoe 3
Damage/wear → Replace the clutch shoes
and springs as a set.
Glazed areas → Sand with coarse sandpa-
per.
2. Plastic board
TIP 3. Ruler
After sanding the glazed areas, clean the clutch
with a cloth. EAS30316
CHECKING THE PRIMARY SHEAVE

2. Measure: 1. Check:
• Clutch shoe thickness “a” • Primary sliding sheave
Out of specification → Replace the clutch • Primary fixed sheave
shoes and springs as a set.
5-41
• Collar
Cracks/damage/wear → Replace the primary
sliding sheave, primary fixed sheave, and 1
collar as a set.
EAS30317
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri- a
mary sheave weights.
1. Check:
• Primary sheave weight 4. Check:
Cracks/damage/wear → Replace. • Spring free length
2. Measure: Out of specification → Replace the spring.
• Primary sheave weight outside diameter “a”
Compression spring free length
Out of specification → Replace. 111.0 mm (4.37 in)
Limit
Weight outside diameter
99.9 mm (3.93 in)
23.0 mm (0.91 in)
Limit
22.5 mm (0.89 in)
EAS30321
ASSEMBLING THE SECONDARY SHEAVE

1. Install:
EAS31233
CHECKING THE PRIMARY SHEAVE • Bearing “1”

SLIDERS (into the secondary fixed sheave “2”)
1. Check:
Install depth “a”
• Primary sheave slider 1.0–2.0 mm (0.04–0.08 in)
EAS30319
CHECKING THE SECONDARY SHEAVE

1. Check:
1
• Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set. a
2. Check:
2
• Torque cam groove “a”
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set. 2. Lubricate:
3. Check: • Secondary sliding sheave inner surface
• Guide pins “1” • Oil seals “1” New
Damage/wear → Replace the secondary (with the recommended lubricant)
fixed and sliding sheaves as a set.
5-42
Recommended lubricant Recommended lubricant

Shell dolium grease R® Shell dolium grease R®
TIP
1
Do not apply grease to the inner surface “a” of 2 New
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. a
6. Install:
• Spring seat 2
• Spring seat 1
2 1 New
• Compression spring
New 1 • Clutch carrier assembly
3. Install: TIP
• Oil seals New • Install the sheave spring compressor “2” and
• Secondary sliding sheave “1” sheave fixed block “3” onto the secondary
TIP sheave as shown. Then, compress the spring,
• Make sure the mark side of the oil seal out- and install the secondary sheave nut.
ward. • Install the secondary sheave nut with its ta-
• Install the secondary sliding sheave onto the pered side facing the clutch carrier.
secondary fixed sheave “2” with the oil seal
guide “3”. Sheave spring compressor
90890-04134
Oil seal guide (40mm) Sheave spring compressor
90890-01590 YM-04134
Sliding sheave guide 40mm Sheave fixed block
YM-01590 90890-04135
Sheave fixed bracket
YM-04135
1
2
1
3
4. Install: 3
• Guide pins “1”
5. Lubricate: EAS32361
• Guide pin grooves “a” ASSEMBLING THE PRIMARY FIXED

SHEAVE
• O-rings “2” New 1. Clean:
(with the recommended lubricant) • Primary fixed sheave
• Primary sliding sheave
• Primary sheave weights
5-43
• Cam
2. Install:
• Oil seal “1” New
(into the primary sliding sheave “2”)
Installed depth “a”

0–0.4mm (0–0.02 in)
1
a 2
2. Tighten:
1 New
Secondary sheave nut
85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.
2 TIP
While holding the secondary sheave with the ro-
EAS31234
tor holding tool “2”, tighten the secondary
INSTALLING THE PRIMARY SHEAVE, V- sheave nut with the locknut wrench “3”.
BELT AND SECONDARY SHEAVE
1. Install:
• V-belt “1” Rotor holding tool
90890-04166
(to the secondary sheave assembly)
Rotor holding tool
• Secondary sheave assembly “2” YM-04166
TIP Locknut wrench
Before installing the secondary sheave assem- 90890-01348
bly, check that there is no grease on the splines Locknut wrench
“a” of the primary drive gear. If there is any YM-01348
grease on the splines, be sure to wipe it off thor-
oughly.
ECA21720 3
NOTICE
Do not allow grease to come in contact with 2
the V-belt.
TIP
• Install the V-belt with the printed arrow mark on 1
the V-belt facing in the direction shown in the il-
lustration.
3. Install:
• Install the V-belt onto the primary sheave side.
• Clutch housing “1”
• Clutch housing nut “2”
Clutch housing nut

75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.
a TIP
While holding the clutch housing with the rotor
holding tool “3”, tighten the clutch housing nut.
5-44
TIP
Rotor holding tool
90890-04166 Install the V-belt in the primary sheave (when the
Rotor holding tool pulley is at its widest position) and in the second-
YM-04166 ary sheave (when the pulley is at its narrowest
position), and make sure the V-belt is tight.
7. Tighten:
• Primary fixed sheave bolt “1”
* Primary fixed sheave bolt

3
115 N·m (11.5 kgf·m, 85 lb·ft)
T.
R.
1 ** Primary fixed sheave bolt
120 N·m (12 kgf·m, 89 lb·ft)
2 * Tightening torque when reusing the primary
fixed sheave bolt and washer
4. Install: ** Tightening torque when installing a new
• Primary sliding sheave assembly “1” primary fixed sheave bolt and washer
TIP TIP
When installing the primary sliding sheave as- While holding the primary fixed sheave with the
sembly, hold the cam to prevent the primary rotor holding tool “2”, tighten the primary fixed
sheave weights from falling out of the primary sheave bolt.
sliding sheave.
Rotor holding tool
90890-01235
Universal magneto and rotor
holder
YU-01235
1
5. Lubricate: 1
• Primary fixed sheave bolt threads and mating
surface
Molybdenum disulfide grease
6. Install:
• Primary fixed sheave
• Washer
• Primary fixed sheave bolt
ECA21730
NOTICE
Do not allow grease to contact the primary
sheave assembly.
5-45
GENERATOR AND STARTER CLUTCH
EAS20140

Removing the stator coil, generator rotor and starter clutch
D
FW
10 N•m (1.0 kgf•m, 7.4 lb•ft) * 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
T.R
.
New 13 N•m (1.3 kgf•m, 9.6 lb•ft)
(3)
T.R
.
New LS
LT
New
(10)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
LS
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.
M
LT
LT
E (6)
75 N•m (7.5 kgf•m, 55 lb•ft) 13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
T.R
.
.

Lower side cover (left) 4-10.
Radiator cover 4-13.
Drain.
page 3-21.
Drain.
page 3-19.
Water pump inlet hose/water pump outlet pipe Refer to “WATER PUMP” on page 6-8.
5-46

1
D
FW
2
10
T.R
.
T.R
.
New 7 13 N•m (1.3 kgf•m, 9.6 lb•ft)
(3) 9
T.R
.
New LS
LT
5
6
E
New
8
3
4
(10)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
8 LS
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.
M
LT
LT
E (6)
T.R
T.R
.
.

3 Crankshaft end cover 1
4 Timing mark accessing bolt 1
5 Engine oil filler cap 1
6 Generator cover 1
7 Generator cover gasket 1
8 Dowel pin 2
9 Plate 1
Stator coil assembly (Stator coil/Crankshaft po-
10 1
sition sensor)
5-47
D
FW
T.R
.
T.R
.
New 13 N•m (1.3 kgf•m, 9.6 lb•ft)
(3)
T.R
.
New LS
LT
12
New
11
14
15
13
(10)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
LS
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.
M
LT
LT
16
E 17 (6)
T.R
T.R
.
.

11 Starter clutch idle gear shaft 1
12 Starter clutch idle gear 1
13 Generator rotor assembly 1
14 Woodruff key 1
15 Starter clutch gear 1
16 Starter clutch 1
17 Generator rotor 1
5-48
EAS30867
REMOVING THE GENERATOR 1

1. Remove:
• Generator rotor bolt “1”
• Washer 2
TIP 3
While holding the generator rotor “2” with the ro-
tor holding tool “3”, loosen the generator rotor
bolt.
Rotor holding tool EAS30868
90890-04166 REMOVING THE STARTER CLUTCH

Rotor holding tool 1. Remove:
YM-04166 • Starter clutch bolts “1”
• Generator rotor “2”
• Starter clutch
TIP
While holding the generator rotor with the rotor
holding tool “3”, loosen the starter clutch bolts.
3
Rotor holding tool
90890-04166
2 Rotor holding tool
1 YM-04166
2. Remove:
• Generator rotor assembly “1” 2
(with the flywheel puller “2” and rotor puller
1
bolt “3”) 3
• Woodruff key
ECA13880
NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller set center bolt and the crank- 1
shaft.
EAS30869
CHECKING THE STARTER CLUTCH

Flywheel puller 1. Check:
90890-01404 • Starter clutch rollers “1”
Flywheel puller Damage/wear → Replace the starter clutch.
YM-01404
Rotor puller bolt M14 X L80
90890-04183
Rotor puller bolt M14 X L80 1
YM-04183
2. Check:
• Starter clutch idle gear
5-49
• Starter clutch gear

Burrs/chips/roughness/wear → Replace the Rotor holding tool
defective part(s). 90890-04166
3. Check: Rotor holding tool
YM-04166
• Starter clutch gear contact surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check: a
• Starter clutch operation
a. Install the starter clutch and starter clutch
gear “1” onto the generator rotor “2” and
hold the generator rotor. Refer to “IN-
STALLING THE STARTER CLUTCH” on 1
page 5-50. 2
b. When turning the starter clutch gear coun-
terclockwise “A”, it should turn freely, oth-
erwise the starter clutch is faulty and must 4
be replaced. 2
3
c. When turning the starter clutch gear clock-
wise “B”, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be re-
placed.
B 1 4
EAS30872
INSTALLING THE GENERATOR

1. Install:
• Starter clutch gear
• Woodruff key
A • Generator rotor assembly
2 • Washer
• Generator rotor bolt
EAS30871
INSTALLING THE STARTER CLUTCH TIP

1. Install: • Clean the tapered portion of the crankshaft and
• Starter clutch “1” the generator rotor hub.
(to the generator rotor “2”) • When installing the generator rotor assembly,
make sure the woodruff key is properly seated
Starter clutch bolt in the keyway of the crankshaft.
13 N·m (1.3 kgf·m, 9.6 lb·ft) • Lubricate the generator rotor bolt threads and
T.
R.
LOCTITE® washer mating surfaces with molybdenum di-

sulfide grease.
TIP
2. Tighten:
• Starter clutch with the arrow mark “a” is toward
• Generator rotor bolt “1”
the generator rotor.
• While holding the generator rotor with the rotor Generator rotor bolt
holding tool “3”, tighten the starter clutch bolts 75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.
“4”.
5-50
TIP
While holding the generator rotor “2” with the ro-
1
tor holding tool “3”, tighten the generator rotor
bolt. d c
Rotor holding tool

90890-04166
Rotor holding tool
YM-04166
1 a a
2
3
b b
3. Apply: 5. Connect:
• Sealant • Stator coil coupler
(onto the stator coil lead grommet) • Crankshaft position sensor coupler
TIP
Yamaha bond No. 1215
90890-85505 To route the stator coil/crankshaft position sen-
(Three bond No.1215®) sor lead, refer to “CABLE ROUTING” on page
2-13.
4. Install:
• Generator cover gasket New
• Generator cover “1”
Generator cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Align the projections “a” and “b” on the water
pump with the respective projections “a” and
“b” on the oil pump.
• Align the slit “c” on the impeller shaft with the
projection “d” on the oil pump shaft.
• Tighten the generator cover bolts in stages and
in a crisscross pattern.
5-51
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

T.R
.
1
LS
New
2
3

Storage box 4-10.
1 Starter motor bracket 1
2 Starter motor 1
3 Starter motor lead 1 Disconnect.
5-52
ELECTRIC STARTER
Disassembling the starter motor

11
12
13 10
9
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
11
T.R
.
10 8 New
7
New 6
New 2 New
4
New 3
1
New
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

T.R
.

1 Starter motor front cover 1
2 Gasket 1
3 Oil seal 1
4 Bearing 1
5 Armature assembly 1
6 Circlip 1
7 Stator 1
8 Gasket 1
9 Brush holder 1
10 Brush spring 4
11 Brush 2
12 Brush and holder set 1
13 Starter motor rear cover 1
5-53
ELECTRIC STARTER
EAS30325
CHECKING THE STARTER MOTOR Digital circuit tester (CD732)

1. Check: 90890-03243
• Commutator Model 88 Multimeter with ta-
Dirt → Clean with 600 grit sandpaper. chometer
2. Measure: YU-A1927
• Commutator diameter “a”
Out of specification → Replace the starter
Armature coil resistance
motor.
0.063–0.077 Ω
Commutator diameter
24.5 mm (0.96 in)
Limit
23.5 mm (0.93 in)
1. Armature coil resistance

a
b. If the resistance is out of specification, re-
place the starter motor.
3. Measure: 5. Measure:
• Mica undercut “a” • Brush length “a”
Out of specification → Scrape the mica to the Out of specification → Replace the brushes
proper measurement with a hacksaw blade as a set.
that has been grounded to fit the commutator. Brush overall length
7.0 mm (0.28 in)
Mica undercut (depth)
Limit
1.50 mm (0.06 in)
3.00 mm (0.12 in)
TIP
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
a
6. Measure:
• Brush spring force
Out of specification → Replace the brush
4. Measure: springs as a set.
• Armature assembly resistance
Brush spring force
Out of specification → Replace the starter 6.08–9.12 N (620–930 gf, 21.89–
motor. 32.83 oz)
a. Measure the armature assembly resis-
tance with the digital circuit tester.
5-54
ELECTRIC STARTER
TIP
Connect the starter motor lead to the starter mo-
tor so that the lead is parallel to the starter motor
axis “a”.
1
2
7. Check: a
• Gear teeth
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”
• Stator “3”
Starter motor cover bolt

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
TIP
Align the match marks “a” on the starter motor
front cover and rear cover with the match marks
“b” on the stator.
b a
a
1
3
2
EAS30327
INSTALLING THE STARTER MOTOR

1. Connect:
• Starter motor lead “1”
(to the starter motor “2”)
Starter motor lead screw

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
5-55
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump assembly
D
FW
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Lower side cover (left) 4-10.
Drain.
page 3-21.
Drain.
page 3-19.
5-56
OIL PUMP
Removing the oil pump assembly
D
FW
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Water pump inlet hose/water pump outlet pipe Refer to “WATER PUMP” on page 6-8.
Refer to “GENERATOR AND STARTER
Generator rotor assembly/Starter clutch gear CLUTCH” on page 5-46.
1 Oil pump assembly 1
2 Oil pump drive chain 1
3 Oil strainer (feed) 1
5-57
OIL PUMP
Disassembling the oil pump assembly

7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1 6
2
3
4
E 7
9
5
10
13
12
E 11 8

1 Oil pump housing cover 1
2 Dowel pin 2
3 Oil pump outer rotor (scavenge) 1
4 Oil pump inner rotor (scavenge) 1
5 Pin 1
6 Oil pump housing (scavenge) 1
7 Washer 1
8 Dowel pin 2
9 Oil pump outer rotor (feed) 1
10 Oil pump inner rotor (feed) 1
11 Pin 1
12 Oil pump driven gear 1
13 Oil pump housing (feed) 1
5-58
OIL PUMP
EAS30340
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer (feed)
Damage → Replace.
Contaminants → Clean with solvent.
EAS30337
CHECKING THE OIL PUMP

1. Check:
• Oil pump driven gear
• Oil pump housings EAS30785
• Oil pump housing cover CHECKING THE OIL PUMP DRIVE CHAIN
Cracks/damage/wear → Replace the oil 1. Check:
pump. • Oil pump drive chain
2. Measure: Cracks/stiffness → Replace the oil pump
• Inner-rotor-to-outer-rotor-tip clearance “a” chain and oil pump assembly as a set.
• Outer-rotor-to-oil-pump-housing clearance
“b”
Out of specification → Replace the oil pump.
Inner-rotor-to-outer-rotor-tip
clearance
0.100–0.150 mm (0.0039–0.0059
in)
Limit
0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing
clearance EAS30342
0.10–0.15 mm (0.0039–0.0059 in) ASSEMBLING THE OIL PUMP

Limit 1. Lubricate:
0.22 mm (0.0087 in) • Inner rotors
• Outer rotors
• Oil pump shaft
Engine oil
2. Install:
• Inner rotors
TIP
When installing the inner rotor, align the pins “1”
1. Inner rotor in the oil pump shaft with the grooves “a” in the
2. Outer rotor inner rotor.
3. Check:
• Oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the oil pump.
5-59
OIL PUMP
A B
a 1 a
1
A. Scavenge
B. Feed
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-59.
EAS30343
INSTALLING THE OIL PUMP

1. Install:
• Oil pump assembly
Oil pump bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
ECA13890
NOTICE
After tightening the bolts, make sure the oil
pump turns smoothly.
5-60
CRANKCASE
EAS20059
CRANKCASE
Separating the crankcase
10 N•m (1.0 kgf•m, 7.4 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
.
LT
LT
(5)
LS
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
LS
New (8)
New
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
(3)
LS
New 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-7.
Refer to “CYLINDER AND PISTON” on page
Cylinder/Pistons 5-32.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-52.
Refer to “GENERATOR AND STARTER
Generator rotor assembly CLUTCH” on page 5-46.
Oil pump assembly Refer to “OIL PUMP” on page 5-56.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-37.
Swingarm assembly SEMBLIES AND SWINGARM” on page
4-91.
Rear wheel/Rear wheel sensor Refer to “REAR WHEEL” on page 4-34.
5-61
CRANKCASE
Separating the crankcase

10 N•m (1.0 kgf•m, 7.4 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
.
7
LT
LT
(5) 13
LS
3 9
8
New
2
10
9
12
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
11
1 LS
New (8)
New
6
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
5
(3)
LS
New 4 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Primary driven gear Refer to “TRANSMISSION” on page 5-73.
1 Timing chain 1
2 Timing chain guide (intake side) 1
3 Timing chain guide retainer 1
4 Oil filter element cover 1
5 Oil filter element 1
6 Engine oil drain bolt 1
7 Final transmission oil filler cap 1
8 Crankcase (left) 1
9 Dowel pin 2
10 Oil nozzle 1
11 Relief valve assembly 1
12 Oil strainer (scavenge) 1
13 Crankcase (right) 1
5-62
CRANKCASE
EAS30389
2. Check:
DISASSEMBLING THE CRANKCASE
• Timing chain guide (intake side)
1. Remove:
• Crankcase bolts
TIP EAS30338
CHECKING THE RELIEF VALVE

Loosen each bolt 1/4 of a turn at a time, in stag-
1. Check:
es and in a crisscross pattern. After all of the
• Relief valve body
bolts are fully loosened, remove them.
A B EAS31069
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer (scavenge)
Damage → Replace.
EAS30397
ASSEMBLING THE CRANKCASE

1. Install:
• Relief valve assembly “1”
A. Left side
(to the crankcase (left) “2”)
B. Right side
TIP
2. Remove: Align the end of the pin “a” in the relief valve as-
• Crankcase (left) sembly with the projection “b” on the left crank-
ECA13900
NOTICE case.
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase 2
mating surfaces. Work slowly and carefully b
and make sure the crankcase halves sepa- a
rate evenly.
EAS30390 1
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a
mild solvent. 2. Thoroughly clean all the gasket mating sur-
2. Thoroughly clean all the gasket surfaces and faces and crankcase mating surfaces.
crankcase mating surfaces. 3. Apply:
3. Check: • Sealant
• Crankcase (onto the crankcase mating surfaces)
• Oil delivery passages Yamaha bond No. 1215
Obstruction → Blow out with compressed air. 90890-85505
EAS30391
CHECKING THE TIMING CHAIN AND TIMING

TIP
CHAIN GUIDE
1. Check: Do not allow any sealant to come into contact
• Timing chain with the oil gallery.
Damage/stiffness → Replace the timing
chain, camshaft and crankshaft sprocket as a
set.
5-63
CRANKCASE
4. Install:
• Dowel pins
• Crankcase (left)
• Crankcase bolts
Crankcase bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Thoroughly wipe off any sealant that protrudes
from between the left crankcase and the right
crankcase.
• Tighten each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
5. Check:
• Crankshaft operation
Rough movement → Repair.
5-64
CRANKSHAFT
EAS20061
CRANKSHAFT
Removing the crankshaft assembly and balancer shaft assembly
6
E 2
4
E
E
4
6 E
3
1
E
E
5 New
E LS

Separate.
Crankcase Refer to “CRANKCASE” on page 5-61.
1 Crankshaft assembly 1
2 Balancer shaft assembly 1
3 Crankshaft journal bearing (left crankcase side) 2
Crankshaft journal bearing (right crankcase
4 2
side)
5 Oil seal 1
6 Bearing 2
5-65
CRANKSHAFT
Removing the connecting rod
1st 18 N•m (1.8 kgf•m, 13 lb•ft)
T.R
2nd Specified angle 180°
.
New
New
M 1 M
2
E
New
4
3
E
New
M

1 Connecting rod cap 1
2 Big end lower bearing 1
3 Connecting rod 1
4 Big end upper bearing 1
5-66
CRANKSHAFT
EAS30419
REMOVING THE CRANKSHAFT JOURNAL

BEARINGS
crankshaft journal bearings.
1. Remove:
• Crankshaft assembly
• Balancer shaft assembly
• Crankshaft journal bearings “1”
TIP
Remove the crankshaft journal bearings using 2. Check:
the pressure tool “2”. • Crankshaft journal surfaces
• Crankshaft pin surfaces
Crankshaft metal installation • Bearing surfaces
base set Scratches/wear → Replace the crankshaft.
90890-04181 3. Measure:
Crankshaft metal installation • Crankshaft-pin-to-big-end-bearing clearance
base set Out of specification → Replace the big end
YM-04181 bearings.
Connecting rod
2 Oil clearance
0.033–0.057 mm (0.0013–0.0022
in)
1 a. Clean the big end bearings, crankshaft
pins, and the inside of the connecting rod
halves.
b. Install the big end upper bearing into the
connecting rod and the big end lower
TIP bearing into the connecting rod cap.
Identify the position of each crankshaft journal TIP
bearing so that it can be reinstalled in its original Align the projections “a” on the big end bearings
place. with the notches “b” in the connecting rod and
connecting rod cap.
EAS30423
CHECKING THE CRANKSHAFT AND

CONNECTING ROD
1. Measure:
• Crankshaft runout
Out of specification → Replace the crank-
shaft.
Runout limit
0.030 mm (0.0012 in)
c. Put a piece of Plastigauge® “1” on the

crankshaft pin.
5-67
CRANKSHAFT
d. Assemble the connecting rod halves. 4. Select:

TIP • Big end bearings (P1)
• Do not move the connecting rod or crankshaft TIP
until the clearance measurement has been The numbers “A” stamped into the crankshaft
completed. web and the numbers “B” on the connecting rods
• Lubricate the bolts threads and nut seats with are used to determine the replacement big end
molybdenum disulfide oil. bearing sizes.
• Make sure the “Y” mark “c” on the connecting
rod faces towards the left side of the crank- A P1
shaft.
• Make sure the characters “d” on both the con-
necting rod and connecting rod cap are
aligned.
• Make sure that the projection “e” on the con-
necting rod cap faces the same direction as the
“Y” mark “c” on the connecting rod.
d B
c e
e. Tighten the connecting rod nuts.

Refer to “INSTALLING THE CONNECT- For example, if the connecting rod P1 and the
ING ROD” on page 5-70.
crankshaft web P1 numbers are 5 and 1 re-
f. Remove the connecting rod and big end
bearings. spectively, then the bearing size for P1 is:
g. Measure the compressed Plastigauge® P1 (connecting rod) - P1 (crankshaft)
width “f” on the crankshaft pin. =5-1
If the crankshaft-pin-to-big-end-bearing = 4 (green)
clearance is out of specification, select re-
placement big end bearings.
5-68
CRANKSHAFT
Bearing color code a

Code 1
Blue
Code 2
Black
Code 3
Brown
Code 4
Green
5. Measure: d. Measure the crankshaft journal bearing in-

• Crankshaft-journal-to-crankshaft-journal side diameter “b” of each crankshaft jour-
bearing clearance. nal bearing.
Out of specification → Replace the crank-
shaft journal bearings. Crankshaft journal bearing inside
diameter
Journal oil clearance 40.015–40.056 mm (1.5754–
0.031–0.064 mm (0.0012–0.0025 1.5770 in)
in)
TIP
TIP Measure the crankshaft journal bearing inside
On the journal, the larger value is used as a ba- diameter at the distance “a” shown in the illustra-
sis for calculation of the oil clearance, and on the tion.
journal bearing, the smaller value is used.
b
The following procedure applies to all of the a
crankshaft journal bearings.
ECA13920
NOTICE
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank- a
b
shaft journal bearings must be installed in
their original positions. a. 5.8 mm (0.24 in)
a. Clean the crankshaft journal bearings, e. If crankshaft journal bearing inside diame-
crankshaft journals, and bearing portions ter is “40.03” and crankshaft journal diam-
of the crankcase. eter is “39.98”, then the journal oil
b. Check the bearing surface. If the bearing clearance is:
surface is worn or scratched, both bear-
Journal oil clearance:
ings should be replaced. Crankshaft journal bearing inside diameter -
TIP Crankshaft journal diameter
If either of the right or left journal bearing is worn = 40.03 - 39.98
= 0.05 mm
or scratched, both bearings should be replaced
as a set. If the oil clearance is out of specification,
c. Measure the crankshaft journal diameter select replacement bearings.
“a” of each crankshaft journal. If it is out of 6. Select:
specification, replace the crankshaft. • Crankshaft journal bearings (J1–J2)
TIP
Crankshaft journal diameter • The numbers “A” stamped into the crankshaft
39.976–40.000 mm (1.5739–
web and the numbers “B” on the crankcase are
1.5748 in)
used to determine the replacement crankshaft
journal bearing size.
5-69
CRANKSHAFT
• J1–J2 refer to the bearings shown in the crank-

shaft illustration. Bearing color code
Code 0
White
Code 1
Blue
Code 2
Black
Code 3
Brown
J1 J2 Code 4
Green
Code 5
Yellow
Code 6
A J2
J1 Pink
EAS31142
CHECKING THE BALANCER SHAFT

ASSEMBLY
1. Check:
• Balancer shaft assembly
Scratches/wear/damage → Replace the bal-
ancer shaft assembly.
EAS31316
B INSTALLING THE CONNECTING ROD
1. Lubricate:
• Bolt threads New
J1 • Nut seats New
Molybdenum disulfide oil
2. Lubricate:
• Crankshaft pins
J2 • Big end bearings inner surface
• Balancer big end bearings inner surface
Engine oil
3. Install:
• Big end bearings
• Connecting rods
For example, if the crankcase J1 and the • Connecting rod caps
crankshaft web J1 numbers are 4 and 2 re- (onto the crankshaft pins)
spectively, then the bearing size for J1 is: TIP
J1 (crankcase) - J1 (crankshaft web) • Be sure to reinstall each big end bearing in its
=4-2 original place.
= 2 (black) • Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rods
and connecting rod caps.
5-70
CRANKSHAFT
• Make sure the “Y” marks “c” on the connecting

rods face towards the left side of the crank-
shaft.
• Make sure the characters “d” on both the con-
necting rod and connecting rod cap are
aligned.
• Make sure that the projection “e” on the con-
necting rod cap faces the same direction as the
“Y” mark “c” on the connecting rod.
c. Tighten the connecting rod nuts further to

reach the specified angle 180°.
Connecting rod nut (2nd)

T.
R.
180˚
c e EWA13400
WARNING
If the connecting rod nut is tightened more
than the specified angle, do not loosen the
4. Tighten: nut and then retighten it. Instead, replace the
• Connecting rod nuts connecting rod bolt and nut with a new one
EWA13390
and perform the procedure again.
WARNING
ECA19930
• Replace the connecting rod bolts and nuts NOTICE
with new ones.
• Do not use a torque wrench to tighten the
• Clean the connecting rod bolts and nuts.
connecting rod nut to the specified angle.
TIP • Tighten the nut until it is at the specified an-
Tighten the connecting rod nuts using the follow- gle.
ing procedure. TIP
a. Tighten the connecting rod nuts with a On a hexagonal nut, note that the angle from
torque wrench. one corner to another is 60°.
Connecting rod nut (1st) EAS31446

18 N·m (1.8 kgf·m, 13 lb·ft) INSTALLING THE CRANKSHAFT JOURNAL
T.
R.
BEARINGS
b. Put a mark “1” on the corner of the con- The following procedure applies to both of the
necting rod nut “2” and the connecting rod crankshaft journal bearings.
cap “3”. 1. Install:
• Crankshaft journal bearing
5-71
CRANKSHAFT
Crankshaft metal installation

base set 3
90890-04181
Crankshaft metal installation
base set
YM-04181
a. Set the bearing installer “1” on the crank-

case.
TIP
2. Measure:
• Align the mark “a” on the bearing installer with
• Install depth of crankshaft journal bearings
the punch mark “b” on the crankcase.
• Install depth of oil seal
• The arrow mark “c” on the bearing installer
should point in the direction shown in the illus- Installed depth “a”
tration. 2.3–3.1 mm (0.09–0.12 in)
Installed depth “b”
1.0–2.0 mm (0.04–0.08 in)
a c
b
1 a
b. Fit the crankshaft journal bearings “2” into

the bearing installer. b
TIP EAS32341
• Lubricate the crankshaft journal bearings with INSTALLING THE CRANKSHAFT

engine oil. ASSEMBLY AND BALANCER SHAFT
• Align the parting edges “a” of the crankshaft ASSEMBLY
journal bearings with the marks “b” on the bear- 1. Install:
ing installer. • Balancer shaft assembly “1”
• Crankshaft assembly “2”
(to the right crankcase)
a TIP
2
Align the punch mark “a” on the crankshaft as-
sembly with the punch mark “b” on the balancer
shaft assembly when installing the parts into the
right crankcase.
b b
2 b a
1 2
c. Press the crankshaft journal bearings into
the crankcase using the pressure tool “3”
and a press.
5-72
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission
New
New
E New
LS
New
LS
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
New
New
E (6)
E
E
LS
E New
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.

Drain.
Final transmission oil Refer to “CHANGING THE FINAL TRANS-
MISSION OIL” on page 3-20.
Storage box 4-10.
Swingarm SEMBLIES AND SWINGARM” on page
4-91.
Rear wheel Refer to “REAR WHEEL” on page 4-34.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-37.
5-73
TRANSMISSION
Removing the transmission

14
13 New
12 New
1 9
E 8 New
LS 7
5
New 14
LS
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
14
11
5 E
10 4 New
14
3
New
2
14 E (6)
E
E
LS
E 6 12 New
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
14
.

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
6 Primary drive gear 1
7 1st wheel gear 1
8 Circlip 1
9 Drive axle 1
10 Main axle 1
11 Primary driven gear 1
12 Oil seal 2
13 Circlip 1
14 Bearing 6
5-74
TRANSMISSION
EAS30433
CHECKING THE TRANSMISSION

1. Check: 1 New
• Transmission gears
Blue discoloration/pitting/wear → Replace New 1
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
2. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
3. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
EAS30438
1 New 1 New
INSTALLING THE TRANSMISSION
1. Install: 3. Install:
• Oil seal “1” New • Transmission case cover “1”
(to the transmission case cover “2”)
Transmission case cover bolt
• Oil seal “3” New 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
(to the left crankcase “4”)

TIP
Installed depth “a”
1.3–2.0 mm (0.05–0.08 in) Tighten the transmission case cover bolts in the
Installed depth “b” proper tightening sequence as shown.
43.0–44.0 mm (1.69–1.73 in)
4
TIP 1
Lubricate the oil seal with lithium-soap-based 5
grease.
3
6
4
2
3 New LS
b
8 7
LS
New 1 a 2
2. Install:
• Circlips “1” New
TIP
Install the circlip with its chamfered side facing
as shown.
5-75
COOLING SYSTEM
COOLING SYSTEM DIAGRAMS .................................................................... 6-1
RADIATOR ...................................................................................................... 6-2

CHECKING THE RADIATOR.................................................................... 6-4
INSTALLING THE RADIATOR..................................................................6-4
THERMOSTAT ................................................................................................6-6
CHECKING THE THERMOSTAT ASSEMBLY ......................................... 6-7
INSTALLING THE THERMOSTAT ASSEMBLY ....................................... 6-7
WATER PUMP.................................................................................................6-8
DISASSEMBLING THE WATER PUMP.................................................. 6-10
CHECKING THE WATER PUMP ............................................................ 6-10
ASSEMBLING THE WATER PUMP........................................................ 6-10
INSTALLING THE GENERATOR COVER.............................................. 6-10
6
COOLING SYSTEM DIAGRAMS
EAS20299
COOLING SYSTEM DIAGRAMS

1 2
6 5
1. Water pump inlet hose

2. Thermostat assembly
6. Water pump outlet pipe
7. Water pump assembly
6-1
RADIATOR
EAS20063
RADIATOR
Removing the radiator
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
New
1
5
3
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
New
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
1.6 N•m (0.16 kgf•m, 1.2 lb•ft)

T.R
.

Drain.
page 3-21.
1 Coolant reservoir hose 1
2 Coolant reservoir 1
3 Coolant reservoir cap 1
4 Coolant reservoir breather hose 1
TIP
5 Radiator cap 1 Remove/Install it with the radiator filler pipe
held.
6-2
RADIATOR
Removing the radiator

8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
New
15
6
7 11
8 14
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9
12
New
13 10
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
1.6 N•m (0.16 kgf•m, 1.2 lb•ft)

T.R
.

6 Cooling system air bleed hose 1
7 Radiator filler pipe 1
8 Radiator filler hose 1
9 Radiator inlet hose 1
10 Radiator outlet hose 1
11 Radiator fan motor coupler 1 Disconnect.
12 Radiator 1
13 Coolant drain bolt 1
14 Radiator fan 1
15 Radiator rear cover 1
6-3
RADIATOR
EAS30439
CHECKING THE RADIATOR 2

1. Check: 1
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace. 3
TIP
Straighten any flattened fins with a thin, flathead
screwdriver. b. Apply the specified pressure for ten sec-
onds and make sure there is no drop in
pressure.
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-27.
EAS30440
INSTALLING THE RADIATOR

1. Install:
2. Check: • Radiator cap “1”
• Radiator hoses TIP
Cracks/damage → Replace. Make sure that the projection “a” on the radiator
3. Measure: cap contacts the projection “b” on the radiator fill-
• Radiator cap opening pressure er pipe.
Below the specified pressure → Replace the
radiator cap. a 1
Radiator cap valve opening pres-
sure
108.0–137.4 kPa (1.08–1.37 kgf/ b
cm², 15.7–19.9 psi)
a. Install the radiator cap tester “1” and radi-

ator cap tester adapter “2” to the radiator
cap “3”.
Radiator cap tester 2. Install:

90890-01325 • Coolant reservoir cap “1”
Mityvac cooling system tester kit TIP
YU-24460-A Point the tab “a” on the coolant reservoir cap
Radiator cap tester adapter rearward.
31mm
90890-05375
Radiator cap tester adapter
31mm 1
YM-05375 a
D
FW
6-4
RADIATOR
3. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-21.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
a. Attach the radiator cap tester “1” and radi-
ator cap tester adapter “2” to the radiator.
Radiator cap tester

90890-01325
Mityvac cooling system tester kit
YU-24460-A
31mm
90890-05375
31mm
YM-05375
b. Apply 196 kPa (1.96 kgf/cm², 27.9 psi) of

pressure.
c. Measure the indicated pressure with the
gauge.
6-5
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat assembly
1
5
S
New
2
4
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

Drain.
page 3-21.
1 Water pump inlet hose 1 Disconnect.
2 Cooling system air bleed hose 1 Disconnect.
3 Radiator inlet hose 1 Disconnect.
4 Radiator outlet hose 1 Disconnect.
5 Thermostat assembly 1
6-6
THERMOSTAT
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
1
76˚C 90˚C
(169˚F) (194˚F)
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, re-
a. Suspend the thermostat “1” in a container place it. A faulty thermostat could cause serious
“2” filled with water. overheating or overcooling.
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 ASSEMBLY
thermostat and thermometer’s indicated 1. Fill:
temperature. • Cooling system
3 mended coolant)
page 3-21.
2. Check:
4 • Cooling system
1
2 Refer to “INSTALLING THE RADIATOR” on
page 6-4.
3. Measure:
e. Check the thermostat element position • Radiator cap opening pressure
“5”. Below the specified pressure → Replace the
Same level for the thermostat element up- radiator cap.
per end “a” and the hole center line “b” at Refer to “CHECKING THE RADIATOR” on
90 °C (194 °F). page 6-4.
b 5
a
6-7
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
10 N•m (1.0 kgf•m, 7.4 lb•ft)

3 D
T.R
.
LS
FW
New
LS
2
New
New
New
1
LS
New
(10)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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

T.R
.

Drain.
page 3-21.
Drain.
page 3-19.
1 Water pump inlet hose 1 Disconnect.
2 Water pump outlet pipe 1
6-8
WATER PUMP
Removing the water pump
10 N•m (1.0 kgf•m, 7.4 lb•ft)

D
T.R
.
LS
FW
4 New
LS
7
New
11 New
New 9 12
LS
10
8
New 6
5 (10)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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

T.R
.

5 Generator cover 1
6 Generator cover gasket 1
7 Dowel pin 2
8 Water pump housing 1
9 Circlip 1
10 Impeller shaft 1
11 Water pump seal 1
12 Bearing 1
6-9
WATER PUMP
EAS30446
DISASSEMBLING THE WATER PUMP A

1. Remove:
• Water pump seal “1” 4
TIP
3
Remove the water pump seal from the outside of
the generator cover “2”. 2 1 New
2 1
A. Push down
3. Mechanical seal installer
4. Middle driven shaft bearing driver
1
EAS30447
CHECKING THE WATER PUMP

1. Check:
• Water pump housing
• Generator cover 2
• Impeller shaft
a. Installed depth of water pump seal
EAS30448
ASSEMBLING THE WATER PUMP 2. Lubricate:

1. Install: • Water pump seal
• Water pump seal “1” New
(into the generator cover “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.
0.2–0.7 mm (0.01–0.03 in)
Mechanical seal installer

90890-04145
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058 1
EAS32358
INSTALLING THE GENERATOR COVER

1. Install:
• Dowel pins
• Generator cover gasket New
6-10
WATER PUMP
• Generator cover “1” 5. Measure:

• Radiator cap opening pressure
Generator cover bolt Below the specified pressure → Replace the
10 N·m (1.0 kgf·m, 7.4 lb·ft) radiator cap.
T.
R.
Refer to “CHECKING THE RADIATOR” on

TIP page 6-4.
• Align the projections “a” and “b” on the water
pump with the respective projections “a” and
“b” on the oil pump.
• Align the slit “c” on the impeller shaft with the
projection “d” on the oil pump shaft.
• Tighten the generator cover bolts in stages and
in a crisscross pattern.
d c
a a
b b
2. Connect:
• Stator coil coupler
• Crankshaft position sensor coupler
TIP
To route the stator coil/crankshaft position sen-
sor lead, refer to “CABLE ROUTING” on page
2-13.
3. Fill:
• Cooling system
mended coolant)
page 3-21.
4. Check:
• Cooling system
Refer to “INSTALLING THE RADIATOR” on
page 6-4.
6-11
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-5
REMOVING THE FUEL PUMP .................................................................7-5
REMOVING THE FUEL FILTER ............................................................... 7-5
CHECKING THE FUEL PUMP BODY.......................................................7-5
CHECKING THE FUEL FILTER................................................................7-5
CHECKING THE ROLLOVER VALVE ......................................................7-5
INSTALLING THE FUEL FILTER.............................................................. 7-6
INSTALLING THE FUEL PUMP................................................................7-6
INSTALLING THE FUEL TANK.................................................................7-6
CHECKING THE FUEL PRESSURE ........................................................7-7
FUEL INJECTOR............................................................................................. 7-8

REMOVING THE FUEL HOSE .................................................................7-9
CHECKING THE FUEL INJECTOR .......................................................... 7-9
INSTALLING THE FUEL INJECTOR ........................................................7-9
INSTALLING THE FUEL HOSE ................................................................7-9
AIR FILTER CASE ........................................................................................ 7-11

INSTALLING THE AIR FILTER CASE ....................................................7-12
THROTTLE BODY......................................................................................... 7-13

REMOVING THE THROTTLE BODY......................................................7-15
CHECKING THE THROTTLE BODY ......................................................7-15
CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND
THROTTLE BODY ................................................................................. 7-15
REPLACING THE THROTTLE BODY ....................................................7-18
INSTALLING THE THROTTLE BODY ....................................................7-18
7
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
(4)
New
New
(6) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

T.R
.

Battery 4-1.
Meter assembly 4-7.
Leg shield assembly 4-16.
Seat damper/Seat damper bracket 4-21.
Canister Refer to “FUEL TANK” on page 7-1.
7-1
FUEL TANK
Removing the fuel tank
6
16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
(4)
3
9 New
10 11 New 12
4
8
5
7
(6) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

T.R
.

1 Fuel tank cap 1
2 Fuel tank overflow tray 1
Fuel tank breather hose (fuel tank to rollover
3 1 Disconnect.
valve)
4 Fuel pump coupler 1 Disconnect.
5 Fuel hose 1 Disconnect.
6 Fuel tank 1
7 Fuel pump bracket 1
8 Fuel pump assembly 1
9 Fuel pump gasket 1
10 Fuel filter holder 1
11 Fuel filter 1
12 Fuel pump 1
7-2
FUEL TANK
Removing the canister
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
3
2

Battery 4-1.
Meter assembly 4-7.
Footrest board assembly 4-13.
Leg shield assembly 4-16.
Fuel tank breather hose (rollover valve to canis-
1 1
ter)
2 Rollover valve holder 1
3 Rollover valve 1
Fuel tank breather hose (fuel tank to rollover
4 1
valve)
7-3
FUEL TANK
Removing the canister
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7
6

5 Canister purge hose 1
6 Canister bracket 2
7 Canister 1
8 Canister breather hose 1
7-4
FUEL TANK
EAS30450
• Fuel filter “2”
REMOVING THE FUEL TANK
• O-ring “3”
1. Extract the fuel in the fuel tank through the
a. Unhook the projections “a” on fuel filter
fuel tank cap with a pump.
holder from the fuel pump, and then slide
2. Disconnect:
the holder sideways to remove it.
• Fuel hose
EWA18020
WARNING 1
Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in a
the fuel lines could cause fuel to spurt out
when removing the hose. a
1
ECA20020
NOTICE
Although the fuel has been removed from a
the fuel tank, be careful when removing the b. Remove the projections “b” on the fuel fil-
fuel hose, since there may be fuel remaining ter from the slots “c” in the fuel pump, and
in it. then remove the filter.
TIP
• To remove the fuel hose from the fuel pump,
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow 2
shown, press the two buttons “2” on the sides
of the connector, and then remove the hose.
b c
• Remove the fuel hose manually without using
any tools. 3
• Before removing the hose, place a few rags in b
the area under where it will be removed.
EAS30454
CHECKING THE FUEL PUMP BODY

1. Check:
• Fuel pump body
Obstruction → Clean.
1 Cracks/damage → Replace fuel pump as-
sembly.
EAS31249
CHECKING THE FUEL FILTER

2 1. Check:
• Fuel filter
EAS30451
Damage → Replace.
REMOVING THE FUEL PUMP
1. Remove:
• Fuel pump EAS30699
ECA14721 CHECKING THE ROLLOVER VALVE

NOTICE 1. Check:
• Do not drop the fuel pump or give it a • Rollover valve “1”
strong shock. Damage/faulty → Replace.
• Do not touch the base section of the fuel TIP
sender. • Check that air flows smoothly only in the direc-
tion of the arrow shown in the illustration.
EAS31376
• The rollover valve must be in an upright posi-
REMOVING THE FUEL FILTER
tion when checking the airflow.
1. Remove:
• Fuel filter holder “1”
7-5
FUEL TANK
• Always use a new fuel pump gasket.

• When installing the fuel pump gasket, make
sure that there is no foreign material between
the gasket and the surrounding parts.
1 • The gasket lip “a” shall face toward the fuel
pump.
• Align the projections “b” (three locations) on
the fuel pump gasket with the slots “c” in the
fuel pump.
• Align the projection “d” on the fuel pump with
EAS31377 the slot in the fuel pump bracket.
INSTALLING THE FUEL FILTER • Align the projection “d” on the fuel pump with
1. Install: the projection “e” on the fuel tank.
• O-ring “1” New • Tighten the fuel pump bolts in the proper tight-
• Fuel filter “2” ening sequence as shown.
• Fuel filter holder “3”
a. Fit the projections “a” on the fuel filter into a
2
the slots “b” in the fuel pump.
2
1 New
b b
a
New 1 3 e
a d
1
b. Hook the projections “c” on fuel filter hold-
3 5 2
er onto the fuel pump.
3 4
c 2
6
c
EAS30457
3 INSTALLING THE FUEL TANK
1. Install:
c • Fuel hose
ECA17500
EAS30456 NOTICE
INSTALLING THE FUEL PUMP When installing the fuel hose, make sure that
1. Install: it is securely connected, and that the fuel
• Fuel pump gasket “1” New hose connector cover on the fuel hose is in
• Fuel pump “2” the correct position, otherwise the fuel hose
• Fuel pump bracket “3” will not be properly installed.
Fuel pump bracket bolt TIP
4.0 N·m (0.40 kgf·m, 3.0 lb·ft) • Install the fuel hose securely onto the fuel
T.
R.
pump until a distinct “click” is heard.

TIP
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
7-6
FUEL TANK
• To install the fuel hose, slide the fuel hose con- TIP
nector cover “1” on each end of the hose in the Before removing the hose, place a few rags in
direction of the arrow shown. the area under where it will be removed.
b. Connect the pressure gauge “1” and fuel
pressure adapter “2” to the fuel hose “3”.
1 Pressure gauge
90890-03153
Pressure gauge
YU-03153
90890-03186
YM-03186
2. Install:
• Fuel tank overflow tray “1”
TIP
1
Align the pipe “a” on the fuel tank with the slot “b”
in the fuel tank overflow tray.
1
2
b 3
c. Start the engine.

a d. Measure the fuel pressure.
Fuel line pressure (at idle)

220–300 kPa (2.2–3.0 kgf/cm²,
EAS30703 31.9–43.5 psi)
CHECKING THE FUEL PRESSURE
1. Remove: Faulty → Replace the fuel pump.
• Storage box e. Connect the fuel hose.
Refer to “GENERAL CHASSIS (4)” on page Refer to “INSTALLING THE FUEL TANK”
4-10. on page 7-6.
2. Check: 3. Install:
• Pressure regulator operation • Storage box
a. Disconnect the fuel hose from the fuel in- Refer to “GENERAL CHASSIS (4)” on page
jector. 4-10.
EWA18020
WARNING
Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in
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.
7-7
FUEL INJECTOR
EAS20191
FUEL INJECTOR
Removing the fuel injector
3
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
4
2
New
1
E
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

1 Fuel hose holder 1
2 Fuel hose 1
3 Fuel injector coupler 1 Disconnect.
4 Fuel injector 1
7-8
FUEL INJECTOR
EAS31250 EAS31617
REMOVING THE FUEL HOSE INSTALLING THE FUEL INJECTOR

1. Disconnect: 1. Install:
• Fuel hose • O-ring “1” New
EWA17610
(to the fuel injector)
WARNING
• Fuel injector “2”
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres- Fuel injector bolt
sure in the fuel lines could cause fuel to 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
spurt out when removing the hoses.
ECA20020 TIP
NOTICE • Lubricate the O-ring with engine oil.
Although the fuel has been removed from • Align the projection “a” on the fuel injector with
the fuel tank, be careful when removing the the hole “b” in the intake manifold.
fuel hose, since there may be fuel remaining
in it.
TIP 2
• To remove the fuel hose from the fuel injector, a 1 New
slide the fuel hose connector cover “1” on the b
end of the hose in the direction of the arrow
shown, press the two buttons “2” on the sides
of the connector, and then remove the hose.
• Remove the fuel hose manually without using
any tools.
• Before removing the hose, place a few rags in EAS31253
the area under where it will be removed. INSTALLING THE FUEL HOSE
1. Install:
• Fuel hose
ECA17500
NOTICE
When installing the fuel hose, make sure that
1 it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
2 will not be properly installed.
TIP
EAS31251
• Install the fuel hose securely onto the fuel in-
CHECKING THE FUEL INJECTOR jector until a distinct “click” is heard.
1. Check: • To install the fuel hose onto the fuel injector,
• Injector slide the fuel hose connector cover “1” on the
Obstruction → Replace and check the fuel end of the hose in the direction of the arrow
pump/fuel supply system. shown.
Deposit → Replace.
Damage → Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJEC-
TOR” on page 8-137. 1
7-9
FUEL INJECTOR
2. Install:
• Fuel hose holder “1”
Fuel hose holder bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
TIP
While holding the fuel hose holder so that the
portion “a” of the holder contacts the portion “b”
of the cylinder head cover.
b
1
7-10
AIR FILTER CASE
EAS20068
AIR FILTER CASE

Removing the air filter case
11
7 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.
6
1
12 8
3
(5) 4
(5)
9
* New 2
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
(3)
.
New
(3)
5
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.
* Apply three Bond 1521.

Storage box 4-10.
1 Air filter case cover 1
2 Pre air filter element 1
3 Sub air filter element 1
4 Air filter case duct cover 1
5 Air filter case duct 1
6 Air filter element 1
7 Transmission case breather hose 1
8 Cylinder head breather hose 1 Disconnect.
9 Air filter case joint clamp screw 1 Loosen.
10 Air filter case 1
11 Air filter check hose 1
12 Air filter case joint 1
7-11
AIR FILTER CASE
EAS31618
INSTALLING THE AIR FILTER CASE

1. Install: 2
• Air filter case joint “1”
(to the air filter case “2”)
TIP
b
• Apply Three Bond 1521 “3” onto the mating
surfaces of the air filter case joint and air filter
case. 1
• Fit the projection “a” on the air filter case joint a
between the projections “b” on the air filter 4. Install:
case. • Pre air filter element “1”
TIP
1 Fit pre air filter element into the slot “a” in the air
filter case duct cover and the slot “b” in the air fil-
2 ter case cover.
a
a
3
b 1
2. Install:
• Air filter case joint clamp “1”
(to the air filter case joint “2”) b
Air filter case joint clamp screw

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
TIP
Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.
a
b
1
3. Install:
• Air filter case duct “1”
(to the air filter case cover “2”)
TIP
Fit the projection “a” on the air filter case duct be-
tween the projections “b” on the air filter case
cover.
7-12
THROTTLE BODY
EAS20070
THROTTLE BODY
Removing the throttle body
T.R
.
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
1 2
6
New
5
4
8
3
7
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
New 9 LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Storage box 4-10.
1 ISC (Idle Speed Control) unit coupler 1 Disconnect.
2 Throttle body sensor assembly coupler 1 Disconnect.
3 Throttle cable 2 Disconnect.
4 Throttle cable holder 1
5 Canister purge hose 1 Disconnect.
6 Intake manifold clamp screw 1 Loosen.
7 Throttle body 1
8 Intake manifold 1
9 Intake manifold joint 1
7-13
THROTTLE BODY
Removing the throttle body

T.R
.
T.R
10
.
12 N•m (1.2 kgf•m, 8.9 lb•ft) 11

T.R
.
New
12
12 N•m (1.2 kgf•m, 8.9 lb•ft)

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

10 ISC (Idle Speed Control) unit holder 1
11 ISC (Idle Speed Control) unit 1
12 Spring 1
7-14
THROTTLE BODY
EAS30979 EAS31254
REMOVING THE THROTTLE BODY CLEANING THE ISC (IDLE SPEED

1. Remove: CONTROL) UNIT AND THROTTLE BODY
• Throttle body 1. Remove the throttle body from the vehicle.
ECA20500
TIP
NOTICE
Before removing the throttle body, disconnect
Do not remove the throttle body sensor as-
the throttle cables, canister purge hose, and
sembly from the throttle body.
couplers.
EAS30479 2. Remove:
CHECKING THE THROTTLE BODY • Screw “1”
TIP • ISC (Idle Speed Control) unit holder “2”
Before checking the throttle body, check the fol- • ISC (Idle Speed Control) unit “3”
ECA21780
lowing items:
NOTICE
• Valve clearance
• Spark plug Because the force of the spring may push
• Air filter element out the ISC unit unexpectedly, be sure to
• Intake manifold hold the ISC unit when removing the compo-
• Fuel hose nents.
• Exhaust system
• Cylinder head breather hose
EWA18030 2
WARNING
If the throttle body is subjected to strong
shocks or dropped during, replace it.
3
1. Check:
• Throttle body
Cracks/damage → Replace the throttle body. 1
2. Check: 3. Remove:
• Butterfly valve • Spring “1”
Damage/scratches/wear → Replace the • O-ring “2”
throttle body.
ECA21770
NOTICE
Do not adjust the stop screw “1”. 2
1
4. Check:
• ISC (Idle Speed Control) unit
1 Plunger “1” does not rotate smoothly/plunger
rotates together with the motor shaft “2” →
Replace.
7-15
THROTTLE BODY
Recommended cleaning agent

1 Yamaha oil & brake cleaner
ECA21790
NOTICE
• Be sure to use the recommended cleaning
agent.
• Do not spray the cleaning agent directly
2 onto the ISC unit or throttle body and do
not immerse them in the cleaning agent.
5. Check: • To prevent scratching the components, do
• Spring not use a brush, metal file, or other abra-
Damage/bent → Replace. sive tool.
6. Clean: • Do not clean with compressed air.
• Area “a” of the ISC unit • Do not allow the removed deposits or for-
• Areas “b” and “c” of the throttle body eign materials to adhere to the sealing sur-
Clogs or foreign materials cannot be re- faces of the O-ring.
moved → Replace. • Do not scratch or deform the ISC valve or
air passage; otherwise, poor starting per-
formance, an unstable engine idling speed,
a 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”
3.0–6.0 mm (0.12–0.24 in)
a
8. Install:
• Spring
• O-ring “1” New
(to the ISC (Idle Speed Control) unit)
• ISC (Idle Speed Control) unit “2”
ECA21800
a. Use a rag soaked in the recommended NOTICE

cleaning agent to wipe off any deposits • Do not use the ISC unit if it was dropped.
and foreign materials. • Do not allow water to enter the ISC unit and
do not allow foreign materials to adhere to
the assembly.
7-16
THROTTLE BODY
• Do not touch the terminals of the coupler

directly. b
• Because the force of the spring may push 1
out the ISC unit unexpectedly, be sure to
hold the motor assembly when installing
the components.
2
TIP
• Install the new O-ring until it contacts the raised
portion of the ISC unit body. a
• When installing the ISC unit, be sure to align 10.Install the throttle body to the vehicle.
the oval portion “a” of the ISC unit with the oval 11.Reset:
hole “b” in the throttle body. • ISC learning values
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
2 1 New AND DIAGNOSTIC CODE TABLE” on page
9-1.
• ISC valve position
AND DIAGNOSTIC CODE TABLE” on page
9-1.
Yamaha diagnostic tool USB

90890-03256
90890-03254
b 12.Reset:
• A/F control learning values
a
9-1.
9. Install:
• ISC (Idle Speed Control) unit holder “1” Yamaha diagnostic tool USB
• Screw 90890-03256
ISC (Idle Speed Control) unit 90890-03254
holder screw
T.
13.Place the vehicle on the centerstand so that

R.
5 N·m (0.5 kgf·m, 3.7 lb·ft)

the rear wheel is elevated.
TIP 14.Check:
Align the slot “a” in the ISC unit holder with the • Engine idling speed
projection “b” on the ISC unit “2”. 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 7-18.
Engine idling speed

1500–1700 r/min
7-17
THROTTLE BODY
EAS31160
REPLACING THE THROTTLE BODY TIP

1. Remove the throttle body from the vehicle. • Make sure that the groove “a” in the intake
2. Install a new throttle body to the vehicle. manifold joint is facing toward the cylinder
3. Reset: head.
• ISC learning values • Align the projection “b” on the intake manifold
Use the diagnostic code number “67”. with slot “c” in the intake manifold clamp “3”.
Refer to “SELF-DIAGNOSTIC FUNCTION • Be sure to fit the projections “d” on the throttle
AND DIAGNOSTIC CODE TABLE” on page body between the projections “e” on the intake
9-1. manifold.
• ISC valve position
Use the diagnostic code number “54”
2
AND DIAGNOSTIC CODE TABLE” on page 1
9-1.

90890-03256
90890-03254 a
4. Reset:
• A/F control learning values
c
Refer to “SELF-DIAGNOSTIC FUNCTION 2
AND DIAGNOSTIC CODE TABLE” on page 3
9-1.
b
90890-03256
90890-03254
d
5. Place the vehicle on the centerstand so that
the rear wheel is elevated.
6. Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed. e
Engine idling speed
1500–1700 r/min
EAS30980
INSTALLING THE THROTTLE BODY

1. Install:
• Intake manifold joint “1”
• Intake manifold “2”
• Throttle body
Intake manifold clamp screw

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
7-18
THROTTLE BODY
7-19
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
SIGNALING SYSTEM ...................................................................................8-19

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

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

CIRCUIT DIAGRAM ................................................................................ 8-31
ECU SELF-DIAGNOSTIC FUNCTION....................................................8-33
TROUBLESHOOTING METHOD............................................................ 8-33
YAMAHA DIAGNOSTIC TOOL ...............................................................8-34
TROUBLESHOOTING DETAILS ............................................................ 8-34
FUEL PUMP SYSTEM...................................................................................8-77

CIRCUIT DIAGRAM ................................................................................ 8-77
8
ABS (ANTI-LOCK BRAKE SYSTEM)........................................................... 8-81
CIRCUIT DIAGRAM ................................................................................ 8-81
ABS COUPLER LOCATION CHART ......................................................8-83
MAINTENANCE OF THE ABS ECU .......................................................8-84
ABS TROUBLESHOOTING OUTLINE....................................................8-84
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 8-85
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 8-86
[A] CHECKING THE ABS WARNING LIGHT..........................................8-87
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............. 8-87
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................8-87
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 8-87
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................... 8-88
[B-2] DIAGNOSIS USING THE FAULT CODES ..................................... 8-88
[B-3] DELETING THE FAULT CODES..................................................8-110
[C-1] FINAL CHECK ..............................................................................8-110
SMART KEY SYSTEM ................................................................................8-111

CIRCUIT DIAGRAM ..............................................................................8-111
TROUBLESHOOTING ..........................................................................8-113
SMART KEY SYSTEM SELF-DIAGNOSIS...........................................8-117
SMART KEY SYSTEM EMERGENCY MODE ......................................8-119
REGISTERING A SMART KEY.............................................................8-120
DISABLING A SMART KEY ..................................................................8-122
DISABLING THE POWER-ON ALARM.................................................8-123
REPLACEMENT PARTS LIST ..............................................................8-124
ELECTRICAL COMPONENTS....................................................................8-125
CHECKING THE SWITCHES ...............................................................8-127
CHECKING THE FUSES ......................................................................8-128
REPLACING THE ECU (Engine Control Unit) ......................................8-128
CHECKING AND CHARGING THE BATTERY.....................................8-128
CHECKING THE RELAYS ....................................................................8-129
CHECKING THE TURN SIGNAL/HAZARD RELAY..............................8-130
CHECKING THE DIODES.....................................................................8-131
CHECKING THE IGNITION SPARK GAP.............................................8-132
CHECKING THE SPARK PLUG CAP ...................................................8-132
CHECKING THE IGNITION COIL .........................................................8-132
CHECKING THE LEAN ANGLE SENSOR............................................8-133
CHECKING THE CRANKSHAFT POSITION SENSOR........................8-134
CHECKING THE STARTER MOTOR OPERATION .............................8-134
CHECKING THE STATOR COIL ..........................................................8-134
CHECKING THE RECTIFIER/REGULATOR ........................................8-135
CHECKING THE FUEL SENDER .........................................................8-135
CHECKING THE FUEL METER............................................................8-135
CHECKING THE RADIATOR FAN MOTOR .........................................8-136
CHECKING THE COOLANT TEMPERATURE SENSOR.....................8-136
CHECKING THE FUEL INJECTOR ......................................................8-137
CHECKING THE SMART KEY BATTERY ............................................8-137
CHECKING THE BUZZER ....................................................................8-137
CHECKING THE MAIN SWITCH SOLENOID.......................................8-137
EAS30490
B/L W
R W/R EAS20072
W B/L
W/R R
1
R
R
R/B
R/B R/W
R R R R/W
R L/W G/Y
6 R R R/W
ON 24 (R) R/W
OPEN R
OFF G/Y P L L R/W W Br/R B/L O/B B/L Y/B B/W
LOCK Sb Gy L/Y G/R Y Y/G L/R B/L W/Y
Br/L R/Y R/Y Br/L R/W
CIRCUIT DIAGRAM
P L/B Y/L B/W P/W Br/WGy/R R/B B/L W/R B W/B O

Br/R Br/R
L R/W R/W
(B)
Br/R
R/W
W/R R/W
B/L 45
R/B
IGNITION SYSTEM
O O
10
R/B R 46
L/Y L/Y L/Y
11 L/G
Br/R
Br/R L/G B B
R
30 B L/G
B B
(B) (B)
22
B L/Y 44
Br/R
Br/R Br/R
B/W B/W
8-1
B/W B/W
54
B B B
B
B
67 67
IGNITION SYSTEM
IGNITION SYSTEM
1. Crankshaft position sensor

6. Main switch
10.Backup fuse
11.Main fuse
22.Battery
24.Main fuse 2
30.Sidestand switch
44.ECU (Engine Control Unit)
45.Ignition coil
46.Spark plug
54.Engine ground
67.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 assembly
2. Storage box
3. Lower side cover
4. Exhaust pipe
1. Check the fuse. NG →

(Main, main 2, backup)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-128.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-128.
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 8-132.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 8-132.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-132.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the stator coil assembly.
SHAFT POSITION SENSOR” on
page 8-134.
OK ↓
8-3
IGNITION SYSTEM
8. Check the main switch. NG →

Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-127.
OK ↓
9. Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
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 8-128.
8-4
EAS30493
EAS20073
R
R
R
R/W
R R R R/B
L/W G/Y
6 R R
ON 24 (R)
OPEN R
OFF
LOCK G/Y G/Y G/Y
CIRCUIT DIAGRAM
P
Br/R Br/R
25
L R/W L/W Br/W
L/W
Br/W Br/W
Br/R B 28
L/W R/W
29 L/W
Br/W L/G,L/Y
L/W
11 L/G
Br/R Br/R
Br/R L/G B B
R
30 B L/G
B B
13 Br/R L/W
31 (B) (B)
R/W 22 B
Br/R Y/W Y/W R 32 35 L/W L/W
Br/W R/W R/W Br/W TRIP
Dg Ch Ch Dg
26 P/W R/B R/B P
B INFO B G/Y G/Y B
(B) (B)
R P
R/B R/W G/Y

Br/R
ELECTRIC STARTING SYSTEM
Br/R
Br/R
R/W
R/W
R/W
8-5
70 R/W
Br
Y Y
Br/W P P Br/W
Dg Ch Ch Dg
Br/R R/W R/W Br PASS 74 B G/Y G/Y B
(B) (B) (R) (R)
G/Y
G/Y
G/Y G/Y
B B B
B
B
67 67
6. Main switch
11.Main fuse
13.Signaling system fuse
22.Battery
24.Main fuse 2
25.Starter relay
26.Starter motor
28.Diode 3
29.Starting circuit cut-off relay
30.Sidestand switch
31.Handlebar switch (right)
32.Start/engine stop switch
35.Front brake light switch
67.Frame ground
70.Handlebar switch (left)
74.Rear brake light switch
8-6
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter
motor can only operate if at least one of the following conditions is met:
• 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).
10
M
11 12 9
2
13
3
4 7
5
8
6
1. Battery
2. Main fuse
3. Main switch
4. Main fuse 2
5. Start/engine stop switch
6. Diode 3
8. Sidestand switch
9. Starter relay
10. Starter motor
11. Front brake light switch
12. Rear brake light switch
13. Signaling system fuse
8-7
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
2. Front cowlings
3. Footrest board assemblies
4. Lower side cover
1. Check the fuses. NG →

(Main, main 2 and signaling sys-
tem) Replace the fuse(s).
OK ↓
page 8-128.
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.
8-134.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-54.
OK ↓
5. Check the starting circuit cut-off re- NG →
lay.
Replace the starting circuit cut-off relay.
Refer to “CHECKING THE RE-
LAYS” on page 8-129.
OK ↓
6. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
7. Check the diode 3. NG →
Refer to “CHECKING THE DI- Replace the diode 3.
ODES” on page 8-131.
OK ↓
8-8

OK ↓
9. Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
10.Check the start/engine stop switch. NG →
The start/engine stop switch is faulty. Re-
Refer to “CHECKING THE
place the right handlebar switch.
OK ↓
11.Check the brake light switches. NG →
(Front and rear)
Replace the brake light switch(es).
OK ↓
12.Check the entire starting system NG →
page 8-5.
OK ↓
The starting system circuit is OK.
8-9
8-10
CHARGING SYSTEM
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
67
B
B
L/W G/Y
R R
(R)
24
R
22
R
B
W
R
R
B
W
B
3
W
W
W
W
W
R
2
W
W W
W
8-11
CHARGING SYSTEM
2. AC magneto
3. Rectifier/regulator
22.Battery
24.Main fuse 2
67.Frame ground
8-12
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
2. Lower side cover (left)
3. Radiator cover
4. Exhaust pipe
1. Check the fuse. NG →

(Main 2)
Replace the fuse.
OK ↓
page 8-128.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator coil assembly.
COIL” on page 8-134.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
8-135.
OK ↓
5. Check the entire charging system NG →
page 8-11.
OK ↓
The charging system circuit is OK.
8-13
CHARGING SYSTEM
8-14
EAS30498
EAS20075
R
R
R/B
R/B
R R R
R L/W G/Y
6 R R
ON 24 (R)
OPEN R
R/Y Sb Gy L/Y G/R Y Y/G L/R B/L W/Y
LOCK
Br/L R/Y R/Y Br/L
CIRCUIT DIAGRAM

Br/R Br/R
L R/W
(B)
R/Y Br/R
17
R/Y R/B
10
LIGHTING SYSTEM
R/B R
11
Br/R Br/R
Br/R
R
22
B
44
Br/R
Br/R Br/R
Br/R
L/R L/R
L/R Y/B
Br/R
Br/R
Br/R
Br/R
B B/W B/W
8-15
B/W B/W
70 Br/R
Br 54
71
Y Y
Br/W P P Br/W
Dg Ch Ch Dg
Br/R R/W R/W Br PASS B G/Y G/Y B
(B) (B) (R) (R)
R/Y
Y
Br/R
92 Br/R Br/R B
Br/R Br/R B
L
60
L
B
B
54
G/BBr/R B B R/B Br/R 64 Br/R 61
Y Br/R B
Br/R W/LG/B L/R B/L G Y/W P/W Dg Ch Br/R
81 L/R G/B 77 L/R L/R B
(Gy)
G/B
78 79 66 63
B B
B B
90 Y Br/R Dg Dg
83 Ch Ch
87 B Y/B L/R Br/R
G/B
80 Br/R L/R
(B) (B)
Y/B B B B
B
B B
B
B B
B
B B B
67 67 67 67
LIGHTING SYSTEM
LIGHTING SYSTEM
6. Main switch
10.Backup fuse
11.Main fuse
17.Answer back fuse
22.Battery
24.Main fuse 2
54.Engine ground
60.License plate light
61.Tail/brake light assembly (right)
63.Tail/brake light (right)
64.Tail/brake light assembly (left)
66.Tail/brake light (left)
67.Frame ground
71.Dimmer switch
77.Headlight assembly
78.Headlight (low beam)
79.Headlight (high beam)
80.Auxiliary light
81.Meter assembly
83.Multi-function meter
87.Meter light
90.High beam indicator light
92.Storage box light
8-16
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li-
cense plate light, meter light or storage box light.
TIP
2. Front cowling assemblies
3. Meter panel assembly
4. Lower side covers
6. Leg shield 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” in “BASIC
INFORMATION” (separate volume).
OK ↓
(Main, main 2, backup and answer
back) Replace the fuse(s).
OK ↓
page 8-128.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
left handlebar switch.
OK ↓
8-17
LIGHTING SYSTEM
6. Check the entire lighting system NG →

page 8-15.
OK ↓
Replace the ECU, meter assembly,
tail/brake light assembly, storage box
light or headlight assembly. Refer to
“REPLACING THE ECU (Engine Con-
trol Unit)” on page 8-128.
8-18
EAS30500
B/L W
R W/R EAS20076
W B/L
W/R R
1
R
R
R/B
R Br/L
R/B 16 Br/R
R R R
Br/R Br/L R L/W G/Y
6 R R
ON 24 (R)
OPEN R
Br/L G/Y P L L R/W W Br/R B/L O/B B/L Y/B B/W
OFF
Br/L R/Y R/Y Br/L
CIRCUIT DIAGRAM

Br/R Br/R
L R/W
(B)
Br/R
19
W/R
Br/R B/L
R/B
10 G/R B/L G/R G/R
R/B R
(B)
36 B/L B/L
11
Br/R Br/R
SIGNALING SYSTEM
Br/R Br/R
12 R G B
Br/W
13 Br/R
48
Br/R
31 G B
R/W 22 Br/W B
Br/R Y/W Y/W R 33 35 L/W L/W (B)
Dg Ch Ch Dg
P/W R/B R/B P 44
BB INFO B G/Y G/Y B
(B) (B)
R P
Dg Ch R/W G/Y
Br/R Br/W
Br/R Br/R
L/R L/R
L/R
Br/R W/B
Br/R
Br/R W
R/W
R/W R/W
R/W Br/R B/W B/W
R/W
Br/W
Br/R
68
Br/W
8-19
69 (B) B/W B/W
Br/W Br/W
Br/W
P
70 P Br/W R/W
Br 54
72 73
Y Y
Br/W P P Br/W
Dg Ch Ch Dg
(B) (B) (R) (R)
G/Y
G/Y G/Y G/Y
B Ch Dg
G/Y Br/R
Br/R B B/W
Br/R
Dg
Dg Dg Dg Dg
Ch Dg Dg
Ch Ch Ch Ch 54 54
Ch Ch R G L Br Y W W/L W/B B/W
G/Y G/Y
G/BBr/R B B R/B Ch Br/R 64 Dg Br/R 61 R/L G/Y Y/B Y/B Br/W L/R L/B B/W B
Br/R W/LG/B L/R B/L G Y/W P/W Dg Ch Ch Dg W
81 L/R Dg Ch L/R L/R W/B (B)
(Gy)
B B
76 75
65 66 62 63
B Br/W
B B B B/W
B B B B G G B
B Dg Dg
83 (G) Ch Ch 55 W B G L
88 89 L/R Br/R L L W
Br/R L/R
B B (B) (B)
B B
Ch Dg B B Br Br B
B 56 W B Br Y
(G) Y Y W
B/L G B B 59
B
B/L
57
B
B/W B/W B/W
B B/L B
B B B
91 (B) (B) B B B
B
B
B B
B B
67 67 67 67
SIGNALING SYSTEM
SIGNALING SYSTEM

6. Main switch
10.Backup fuse
11.Main fuse
12.ABS control unit fuse
16.Diode 1
19.Turn signal light and hazard fuse
22.Battery
24.Main fuse 2
33.Hazard switch
36.Coolant temperature sensor
48.Fuel sender
54.Engine ground
55.Front wheel sensor
56.Rear wheel sensor
57.Joint connector
59.ABS ECU
62.Rear turn signal light (right)
65.Rear turn signal light (left)
67.Frame ground
68.Turn signal/hazard relay
69.Horn
72.Horn switch
73.Turn signal switch
75.Front turn signal light (right)
76.Front turn signal light (left)
81.Meter assembly
88.Turn signal indicator light (right)
89.Turn signal indicator light (left)
91.Air temperature sensor
8-20
SIGNALING SYSTEM
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, tail/brake light or indicator lights.
• The horn fails to sound.
• The fuel meter fails to flash.
• The speedometer fails to operate.
• The instantaneous fuel consumption meter fails to operation.
• The tachometer fails to operate.
• The coolant temperature meter fails to operate.
• The ambient temperature meter fails to operate.
• The V-belt replacement meter fails to operate.
• The oil change meter fails to operate.
• The traction control system meter fails to operate.
TIP
3. Meter panel assembly

(Main, main 2, backup, turn signal/
light and hazard, signaling system,
and ABS control unit)
OK ↓
page 8-128.
OK ↓
OK ↓
4. Check the entire signaling system NG →
page 8-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system” on
page 8-22.
8-21
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
handlebar switch.
OK ↓
page 8-19.
OK ↓
Replace the horn.
The tail/brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
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.
OK ↓
2. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
8-22
SIGNALING SYSTEM
3. Check the hazard switch. NG →

The hazard switch is faulty. Replace the
right handlebar switch.
OK ↓
4. Check the turn signal/hazard relay. NG →
Refer to “CHECKING THE TURN
Replace the turn signal/hazard relay.
SIGNAL/HAZARD RELAY” on page
8-130.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The coolant temperature meter fails to operate.

1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-136.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly or ECU.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-128.
The speedometer 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 4-30.
OK ↓
8-23
SIGNALING SYSTEM
2. Check the entire wheel sensor wir- NG →

Properly connect or replace the wire har-
ing.
ness.
Refer to TIP.
OK ↓
Replace the hydraulic unit assembly,
ECU or meter assembly.
TIP
Replace 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.
(blue/red–blue/red)
The tachometer fails to operate.

1. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the stator coil assembly.
SHAFT POSITION SENSOR” on
page 8-134.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly or ECU.
The ambient temperature meter fails to operate.

1. Check the air temperature sensor. NG →
Refer to “CIRCUIT DIAGRAM” on Replace the air temperature sensor.
page 8-19.
OK ↓
page 8-19.
OK ↓
8-24
SIGNALING SYSTEM
The fuel meter fails to operate.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
SENDER” on page 8-135.
OK ↓
page 8-19.
OK ↓
The traction control system meter fails to operate.

1. Check the rear wheel sensor. NG →
Refer to “MAINTENANCE OF THE
Replace the rear wheel sensor.
REAR WHEEL SENSOR AND
SENSOR ROTOR” on page 4-35.
OK ↓
2. Check the entire wheel sensor wir- NG →
Properly connect or replace the wire har-
ing.
ness.
Refer to TIP.
OK ↓
Replace the hydraulic unit assembly,
ECU or meter assembly.
TIP
Replace if there is an open or short circuit.
• Between rear wheel sensor coupler and ABS ECU coupler.
(brown–brown)
(yellow–yellow)
• Between ABS ECU coupler and ECU coupler.
(white/black–white/black)
• Between ECU coupler and meter assembly coupler.
(blue/red–blue/red)
The V-belt replacement indicator, engine oil change indicator, instantaneous fuel consumption meter
fails to operate.
1. Check the entire wiring. NG →
Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on
ness.
page 8-19.
OK ↓
8-25
SIGNALING SYSTEM
8-26
EAS30502
EAS20077
R
R
R/B
R/B
R R R
R L/W G/Y
6 R R
ON 24 (R)
OPEN R
Br/L R/Y R/Y Br/L
CIRCUIT DIAGRAM

Br/R Br/R
L R/W
(B)
Br/R
9
R/L
R/B
10
COOLING SYSTEM
G/R B/L G/R G/R

R/B R
(B)
36 B/L B/L
11
Br/R
Br/R Br/R
R
13 Br/R
R/W 22
B
44
Br/R
Br/R Br/R
W/Y W/Y R/W

L R/L
52 R/L
L L
R/W W/Y
B B
53 L L
R/W (B) (B)
R/W B/W B/W B
8-27
B/W B/W
54
B
B B
B
B
67 67
COOLING SYSTEM
COOLING SYSTEM
6. Main switch
9. Radiator fan motor fuse
10.Backup fuse
11.Main fuse
22.Battery
24.Main fuse 2
52.Radiator fan motor relay
53.Radiator fan motor
54.Engine ground
67.Frame ground
8-28
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
TIP
4. Radiator cover

(Main, main 2, signaling system ra-
diator fan motor and backup) Replace the fuse(s).
OK ↓
page 8-128.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 8-136.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK ↓
6. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-136.
OK ↓
8-29
COOLING SYSTEM
7. Check the entire cooling system’s NG →

page 8-27.
OK ↓
Replace the ECU.
8-30
EAS30504
B/L W
R W/R EAS20078
W B/L
W/R R
1
R
R
R/B
R
R/B
R/B R/W
R R R R/B R/W
R L/W G/Y
6 R R R/W R/W
ON 24 (R) R/W
OPEN R
CIRCUIT DIAGRAM

Br/R Br/R
L R/W Br/W R/W
Br/W (B)
28 Br/W
Br/R
L/W R/W R/W
9 W/R R/W O/B R/W
R/L 29 L/W
B/L 45
Br/W L/G,L/Y R/B O O
10 (B)
G/R B/L G/R G/R
R/B R 46
L/Y L/Y L/Y 36
(B) B/L B/L 47
11 L/G
O/B O/B R/W
Br/R Br/R
Br/R Br/R L/G B B 37 38 39 40
12 R
B L/G
P/W P/W
Br/W 30 Br/W Br/W
B B/L Y L P/W Br/W B/L B/L
B Y Y
13 Br/R (B) L L
31 (B) (B)
R/W 22 B Gy/R Gy/R
Br/R Y/W Y/W R 32 Gy/R B
L/W L/W
Dg Ch Ch Dg (B) (B)
41
P/W R/B R/B P 44
INFO L/Y
FUEL INJECTION SYSTEM
BBB B G/Y G/Y B

(B) (B)
B R P L L
B/L Y/G L 42 Y/G Y/G
R/B B/L B/L P P
B
Br/R Br/R (B) G/Y G/Y
Br/R Br/R Gy Gy 51 P G/Y Sb Gy
Br/R Sb Sb
B
R/B Y/L Y/L (B)
B R/B
W/Y W/Y R/W
43 Y/L
L R/L
L/R L/R
L/R Y/B R/L
L
52
L
Br/R W/B
Br/R Br/R R/W W/Y
W B B
Br/R
53 L L
R/W (B) (B)
R/W B B/W B/W B
8-31
B/W B/W
70 Br/R
Br 54
71
Y Y
Br/W P P Br/W
Dg Ch Ch Dg
Br/R R/W R/W Br PASS B G/Y G/Y B
(B) (B) (R) (R)
B B/W
B
54 54 R G L Br Y W W/L W/B B/W
G/BBr/R B B R/B R/L G/Y Y/B Y/B Br/W L/R L/B B/W B
Br/R W/LG/B L/R B/L G Y/W P/W Dg Ch Y Br/R W
81 L/R G/B 77 W/B (B)
(Gy)
G/B
78 79 Y/B
Y/B Br/W
B/W
90 Y Br/R B G G B
83 55 W B G L
84 86 B Y/B L L W
G/B
Br Br B
Y/B 56 W B Br Y
Y Y W
B W/L 59
57
B/W B/W B/W
B
B B B
B
B
67 67

6. Main switch
9. Radiator fan motor fuse
10.Backup fuse
11.Main fuse
22.Battery
24.Main fuse 2
28.Diode 3
29.Starting circuit cut-off relay
30.Sidestand switch
37.Throttle body sensor assembly
38.Throttle position sensor
39.Intake air pressure sensor
40.Intake air temperature sensor
41.O2 sensor
42.Lean angle sensor
43.Yamaha diagnostic tool coupler
45.Ignition coil
46.Spark plug
47.Fuel injector
51.ISC (Idle Speed Control) unit
54.Engine ground
57.Joint connector
59.ABS ECU
67.Frame ground
71.Dimmer switch
77.Headlight assembly
78.Headlight (low beam)
79.Headlight (high beam)
81.Meter assembly
84.Traction control system indicator light
86.Engine trouble warning light
90.High beam indicator light
8-32
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.
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”. If the warning light does not come on, 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 numbers that have a condition of “Malfunction” using the Yamaha diagnostic
tool.
b. Identify the faulty system with the fault code number.
c. Identify the probable cause of the malfunction.
2. Check and repair the probable cause of the malfunction.
Fault code No. No fault code No.
Check and repair. Check and repair.
Refer to “TROUBLESHOOTING DETAILS” on page
8-34.
Monitor the operation of the sensors and actuators in
the diagnostic mode.
Refer to “TROUBLESHOOTING DETAILS” on page
8-34 and “SELF-DIAGNOSTIC FUNCTION AND DI-
AGNOSTIC CODE TABLE” on page 9-1.
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 8-34.
TIP
• If another fault code number is displayed, repeat steps (1) to (3) until no fault code number is dis-
played.
• 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 “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-8 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-9.
8-33
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.

90890-03256
90890-03254
TIP
A generic scan tool can also be used to identify malfunctions.
OBD/ GST Leadwire kit

90890-03249
Connecting the Yamaha diagnostic tool

Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
EAS30508
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given.
After the check and service of the malfunctioning part have been completed, delete the fault codes dis-
played on the Yamaha diagnostic tool according to the reinstatement method.
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool 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 9-1.
8-34
Parts connected to the ECU

The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Main switch
• AC magneto • Handlebar switch (right)
• Fuel injector • Headlight
• Fuel pump • Meter assembly
• Ignition coil • Rectifier/regulator
• ISC (Idle Speed Control) unit • Front wheel sensor
• Coolant temperature sensor • Rear wheel sensor
• Throttle body sensor assembly • Lean angle sensor
• O2 sensor • Fuel pump relay
• ABS ECU • Radiator fan motor relay
• Sidestand switch
Fault code No. P0106

ECA20500
NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
TIP
If fault code numbers “P0106” and “P0107/P0108” are both indicated, take the actions specified for fault
code number “P0107/P0108” first.
Intake air pressure sensor: system malfunction (clogged 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 pulling the brake lever and pushing the “ ”
Procedure side of the start/engine stop switch. (If the display value changes, the
performance is OK.)
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- Start the engine and let it idle for
body sensor assembly. ing. approximately 5 seconds, and
Improperly installed sensor → then check the condition of the
Reinstall the throttle body. fault code using the malfunction
Refer to “THROTTLE BODY” on mode of the Yamaha diagnostic
page 7-13. tool.
Condition is “Recover” → Go to
item 3 and finish the service.
Condition is “Malfunction” → Go
to item 2.
8-35
Intake air pressure sensor: system malfunction (clogged or de-

Item
tached).
2 Defective intake air pressure Execute the diagnostic mode. Service is finished.
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)
mmHg, 23.6 inHg)
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.
Refer to “REPLACING THE
THROTTLE BODY” on page
7-18.
3 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of “Recover” using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.
Fault code No. P0107, P0108

ECA20500
NOTICE
TIP
If fault code numbers “P0106” and “P0107/P0108” are both indicated, take the actions specified for fault
code number “P0107/P0108” first.
No normal signals are received from the intake air pressure sensor.
[P0107] Intake air pressure sensor: open or ground short circuit de-
Item tected.
[P0108] Intake air pressure sensor: open or power short circuit de-
tected.
Fail-safe system
Tool display Displays the intake air pressure.
8-36
Item tected.
tected.
Operate the throttle while pulling the brake lever and pushing the “ ”
Procedure side of the start/engine stop switch. (If the display value changes, the
performance is OK.)
1 Connection of throttle body sen- Improperly connected → Con- Turn the main switch to “ON”,
sor assembly coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is “Recover” → Go to
terminals and locking condition item 7 and finish the service.
of the pins). Condition is “Malfunction” → Go
to item 2.
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 check the condition of
the coupler. place the wire harness. the fault code using the mal-
Disconnect the coupler and function mode of the Yamaha di-
check the pins (bent or broken agnostic tool.
terminals and locking condition Condition is “Recover” → Go to
of the pins). item 7 and finish the service.
to item 3.
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”,
the wire harness. and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
to item 4.
3-1
3
1 5V
L
4 L
Y Y
5
2 P/W P/W
5V
Br/W Br/W
B/L B/L
6
1. Throttle body sensor assembly

2. Intake air pressure sensor
3. ECU
4. Sensor input lead
5. Sensor output lead
6. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the throttle body sensor assembly coupler from the throttle body.
8-37
Item tected.
tected.
3-3 [For P0107] Ground short circuit
Between throttle body sensor assembly coupler and ground: pink/white–ground
If there is continuity, replace the wire harness.
B/L Y L P/W Br/W
3-4 [For P0107] Open circuit

Between throttle body sensor assembly coupler and ECU coupler: blue–blue
If there is no continuity, replace the wire harness.
G/Y P L L R/W W Br/R B/L O/B B/L Y/B B/W

B/L Y L P/W Br/W
Sb Gy L/Y G/R Y Y/G L/R B/L W/Y
L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B W/B O

Between throttle body sensor assembly coupler and ECU coupler: pink/white–pink/white

B/L Y L P/W Br/W
8-38
Item tected.
tected.
Between throttle body sensor assembly coupler and ECU coupler: black/blue–black/blue

B/L Y L P/W Br/W
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-35.
3-8 [For P0107, P0108] Short circuit
Between intake air pressure sensor output terminal (pink/white) “a” of ECU coupler and any other
ECU coupler terminal “b”.

4 Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”,
body sensor assembly. ing. and then check the condition of
Improperly installed sensor → the fault code using the mal-
Reinstall the throttle body. function mode of the Yamaha di-
Refer to “THROTTLE BODY” on agnostic tool.
page 7-13. Condition is “Recover” → Go to
to item 5.
8-39
Item tected.
tected.
5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”,
sensor. (Code No. 03) and then check the condition of
When engine is stopped: the fault code using the mal-
Atmospheric pressure at the function mode of the Yamaha di-
current altitude and weather agnostic tool.
conditions is indicated. Condition is “Recover” → Go to
At sea level: Approx. 101 kPa item 7 and finish the service.
(757.6 mmHg, 29.8 inHg) Condition is “Malfunction” → Go
1000 m (3300 ft) above sea lev- to item 6.
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
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.
7-18.
6 Malfunction in ECU. Replace the ECU. Service is finished.
ECU (Engine Control Unit)” on
page 8-128.

TIP
Perform this procedure when the engine is cold.
No normal signals are received from the intake air temperature sen-
sor.
Item [P0112] Intake air temperature sensor: ground short circuit detected.
[P0113] Intake air temperature sensor: open or power short circuit
detected.
Fail-safe system
8-40
sor.
detected.
When engine is cold: Displays temperature closer to air temperature.
Tool display
When engine is hot: Air temperature + approx. 20 °C (68 °F).
Compare the actually measured air temperature with the tool display val-
Procedure
ue.
to item 2.
to item 3.
agnostic tool.
to item 4.
3-1
3
1 5V
L L
Y Y
P/W P/W
5V
2 4
Br/W Br/W
B/L B/L
5

2. Intake air temperature sensor
3. ECU
8-41
sor.
detected.
Between throttle body sensor assembly coupler and ground: brown/white–ground
B/L Y L P/W Br/W

Between throttle body sensor assembly coupler and ECU coupler: brown/white–brown/white

B/L Y L P/W Br/W


B/L Y L P/W Br/W
8-42
sor.
detected.
Between intake air temperature sensor output terminal (brown/white) “a” of ECU coupler and any
other ECU coupler terminal “b”.

to item 5.
5 Defective intake air tempera- Execute the diagnostic mode. Turn the main switch to “ON”,
ture sensor. (Code No. 05) and then check the condition of
When engine is cold: the fault code using the mal-
Displayed temperature is close function mode of the Yamaha di-
to the ambient temperature. agnostic tool.
The displayed temperature is Condition is “Recover” → Go to
not close to the ambient tem- item 7 and finish the service.
perature. → Replace the throttle Condition is “Malfunction” → Go
body. to item 6.
7-18.
page 8-128.
8-43

TIP
Perform this procedure when the engine is cold.
No normal signals are received from the coolant temperature sensor.

[P0117] Coolant temperature sensor: ground short circuit detected.
Item
[P0118] Coolant temperature sensor: open or power short circuit de-
tected.
Fail-safe system
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 tool display
Procedure
value.
1 Connection of coolant tempera- Improperly connected → Con- Turn the main switch to “ON”,
ture sensor coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
agnostic tool.
to item 4.
8-44

Item
tected.
3-1
2
5V
1
G/R
3 G/R
B/L B/L
4
1. Coolant temperature sensor

2. ECU
Disconnect the coolant temperature sensor coupler from the coolant temperature sensor.
Between coolant temperature sensor coupler and ground: green/red–ground
G/R B/L

Between coolant temperature sensor coupler and ECU coupler: green/red–green/red

G/R B/L Sb Gy L/Y G/R Y Y/G L/R B/L W/Y
8-45

Item
tected.
Between coolant temperature sensor coupler and ECU coupler: black/blue–black/blue

G/R B/L Sb Gy L/Y G/R Y Y/G L/R B/L W/Y
Between coolant temperature sensor output terminal (green/red) “a” of ECU coupler and any other
ECU coupler terminal “b”.

4 Installed condition of coolant Check for looseness or pinch- Turn the main switch to “ON”,
temperature sensor. ing. and then check the condition of
Reinstall or replace the sensor. function mode of the Yamaha di-
Refer to “CYLINDER HEAD” on agnostic tool.
to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to “ON”,
sensor. (Code No. 06) and then check the condition of
When engine is cold: the fault code using the mal-
Displayed temperature is close function mode of the Yamaha di-
to the ambient temperature. agnostic tool.
The displayed temperature is Condition is “Recover” → Go to
not close to the ambient tem- item 7 and finish the service.
perature. → Replace the cool- Condition is “Malfunction” → Go
ant temperature sensor. to item 6.
Refer to “CYLINDER HEAD” on
page 5-13.
8-46

Item
tected.
page 8-128.

ECA20500
NOTICE
No normal signals are received from the throttle position sensor.

[P0122] Throttle position sensor: open or ground short circuit de-
Item tected.
[P0123] Throttle position sensor: open or power short circuit detect-
ed.
Fail-safe system
Throttle position sensor signal
Tool display • 13–21 (fully closed position)
• 97–107 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
to item 2.
to item 3.
8-47

Item tected.
ed.
agnostic tool.
to item 4.
3-1
3
1 5V
L
4 L
2 Y Y
5
P/W P/W
5V
Br/W Br/W
B/L B/L
6

2. Throttle position sensor
3. ECU
Between throttle body sensor assembly coupler and ground: yellow–ground
B/L Y L P/W Br/W
8-48

Item tected.
ed.
Between throttle body sensor assembly coupler and ECU coupler: blue–blue

B/L Y L P/W Br/W

Between throttle body sensor assembly coupler and ECU coupler: yellow–yellow

B/L Y L P/W Br/W


B/L Y L P/W Br/W
8-49

Item tected.
ed.
Between throttle position sensor output terminal (yellow) “a” of ECU coupler and any other ECU cou-
pler terminal “b”

to item 5.
5 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ON”,
sor. signal. and then check the condition of
Execute the diagnostic mode. the fault code using the mal-
(Code No. 01) function mode of the Yamaha di-
When the throttle valves are ful- agnostic tool.
ly closed: Condition is “Recover” → Go to
A value of 13–21 is indicated. item 7 and finish the service.
When throttle valves are fully Condition is “Malfunction” → Go
open: to item 6.
A value of 97–107 is indicated.
An indicated value is out of the
specified range. → Replace the
throttle body.
7-18.
page 8-128.
8-50

O2 sensor: power short circuit detected (no normal signals are re-
Item
ceived from the O2 sensor).
Fail-safe system
Diagnostic code No. —
Tool display —
Procedure —
1 Installed condition of O2 sensor. Check for looseness or pinch- Turn the main switch to “ON”,
ing. and then check the condition of
Reinstall or replace the sensor. function mode of the Yamaha di-
Refer to “CYLINDER HEAD” on agnostic tool.
to item 2.
2 Connection of O2 sensor cou- Improperly connected → Con- Turn the main switch to “ON”,
pler. nect the coupler securely or re- and then check the condition of
to item 3.
3 Connection of wire harness Improperly connected → Con- Turn the main switch to “ON”,
ECU coupler. nect the coupler securely or re- and then check the condition of
to item 4.
4 Wire harness continuity. Open or short circuit → Properly Turn the main switch to “ON”,
connect or replace the wire har- and then check the condition of
ness. the fault code using the mal-
Between O2 sensor coupler and function mode of the Yamaha di-
ECU coupler. agnostic tool.
gray/red–gray/red Condition is “Recover” → Go to
to item 5.
8-51
O2 sensor: power short circuit detected (no normal signals are re-
Item
ceived from the O2 sensor).
5 Defective O2 sensor. Check the O2 sensor. Turn the main switch to “ON”,
Defective → Replace the O2 and then check the condition of
sensor. the fault code using the mal-
Refer to “CYLINDER HEAD” on function mode of the Yamaha di-
page 5-13. agnostic tool.
to item 6.
6 Malfunction in ECU. Replace the ECU.
page 8-128.

Fuel injector: no normal signals are received from the fuel injector
Item
circuit.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Actuates fuel injector five times at one-second intervals.
Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on
each time the fuel injector is actuated.
Disconnect the fuel pump coupler. Check that fuel injector is actuated
Procedure
five times by listening for the operating sound.
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)
Refer to “CHECKING THE Operating sound → Go to item
FUEL INJECTOR” on page 6.
8-137. No operating sound → Go to
Replace if out of specification. item 3.
8-52
Fuel injector: no normal signals are received from the fuel injector
Item
circuit.
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).
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 start/engine stop switch.
red/white–red/black
Between start/engine stop
switch and main fuse.
brown/red–brown/red
5 Malfunction in ECU. Replace the ECU.
page 8-128.
6 Delete the fault code and check Start the engine and let it idle for
that the engine trouble warning approximately 5 seconds.
light goes off. Confirm that the fault code has
a condition of “Recover” using
the malfunction mode of the
Yamaha diagnostic tool, and

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
Fail-safe system
Tool display —
Procedure —
1 Connection of crankshaft posi- Improperly connected → Con- Crank the engine, and then
tion sensor coupler. nect the coupler securely or re- check the condition of the fault
Check the locking condition of place the wire harness. code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler and tool.
to item 2.
8-53
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, and then
Check the locking condition of nect the coupler securely or re- check the condition of the fault
the coupler. place the wire harness. code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
to item 3.
3 Wire harness continuity. Open or short circuit → Replace Crank the engine, and then
the wire harness. check the condition of the fault
Between crankshaft position code using the malfunction
sensor coupler and ECU cou- mode of the Yamaha diagnostic
pler. tool.
white/red–white/red Condition is “Recover” → Go to
black/blue–black/blue item 7 and finish the service.
to item 4.
4 Installed condition of crankshaft Improperly installed sensor → Crank the engine, and then
position sensor. Reinstall or replace the sensor. check the condition of the fault
Check for looseness or pinch- Refer to “GENERATOR AND code using the malfunction
ing. STARTER CLUTCH” on page mode of the Yamaha diagnostic
5-46. tool.
to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine, and then
sensor. sensor. check the condition of the fault
Refer to “CHECKING THE code using the malfunction
CRANKSHAFT POSITION mode of the Yamaha diagnostic
SENSOR” on page 8-134. tool.
Replace if defective. Condition is “Recover” → Go to
to item 6.
page 8-128.

Item Ignition coil: no normal signals are received from the ignition circuit.
Fail-safe system
8-54
Actuates the ignition coil five times at one-second intervals.
Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on
each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
1 Connection of ignition coil cou- Improperly connected → Con- Start the engine and let it idle for
pler. nect the coupler securely or re- approximately 5 seconds.
Check the locking condition of place the wire harness. Check the condition of the fault
the coupler. code using the malfunction
to item 2.
2 Connection of ECU coupler. Improperly connected → Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
the coupler. place the wire harness. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is “Recover” → Go to
to item 3.
3 Wire harness continuity. Open or short circuit → Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between ignition coil coupler Check the condition of the fault
and ECU coupler. code using the malfunction
orange–orange mode of the Yamaha diagnostic
Between ignition coil coupler tool.
and start/engine stop switch. Condition is “Recover” → Go to
red/white–red/black item 7 and finish the service.
Between start/engine stop Condition is “Malfunction” → Go
switch and main fuse. to item 4.
4 Installed condition of ignition Check for looseness or pinch- Start the engine and let it idle for
coil. ing. approximately 5 seconds.
Improperly installed ignition coil Check the condition of the fault
→ Reinstall or replace the igni- code using the malfunction
tion coil. mode of the Yamaha diagnostic
tool.
to item 5.
8-55
5 Defective ignition coil. Measure the primary coil resis- Start the engine and let it idle for
tance of the ignition coil. approximately 5 seconds.
Refer to “CHECKING THE IG- Check the condition of the fault
NITION COIL” on page 8-132. code using the malfunction
Replace if out of specification. mode of the Yamaha diagnostic
tool.
to item 6.
6 Malfunction in ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark → Replace the ECU.
page 8-128.

No normal signals are received from the radiator fan motor relay.
Item
Radiator fan motor relay: open circuit detected.
Fail-safe system
Tool display —
Procedure —
1 Connection of radiator fan motor Improperly connected → Con- Turn the main switch to “ON”,
relay coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
8-56
No normal signals are received from the radiator fan motor relay.
Item
Radiator fan motor relay: open circuit detected.
Between radiator fan motor re- the fault code using the mal-
lay coupler and ECU coupler. function mode of the Yamaha di-
white/yellow–white/yellow agnostic tool.
Between radiator fan motor re- Condition is “Recover” → Go to
lay and signaling system fuse. item 6 and finish the service.
red/white–red/white Condition is “Malfunction” → Go
Between radiator fan motor re- to item 4.
lay and radiator fan motor fuse.
red/blue–red/blue
4 Defective radiator fan motor re- Check the radiator fan motor re- Turn the main switch to “ON”,
lay. lay. and then check the condition of
Refer to “CHECKING THE RE- the fault code using the mal-
LAYS” on page 8-129. function mode of the Yamaha di-
Replace if defective. agnostic tool.
to item 5.
5 Defective radiator fan motor re- Replace the ECU. Service is finished.
lay driver. Refer to “REPLACING THE
page 8-128.

Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
Fail-safe system
Front wheel speed 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.
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 Value does not increase → Go
of the pins). to item 2.
8-57
Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
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 Value does not increase → Go
of the pins). to item 3.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
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). Value does not increase → Go
to item 4.
4 Front wheel sensor lead conti- Open or short circuit, or defec- Execute the diagnostic mode.
nuity, or defective front wheel tive sensor → Replace the front (Code No. 07)
sensor. wheel sensor. Rotate the front wheel by hand
Between front wheel sensor and check that the indicated val-
coupler and ABS ECU coupler. ue increases.
green–green Value increases → Go to item 7.
blue–blue Value does not increase → Go
Between ABS ECU coupler and to item 5.
ECU coupler.
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 8-128. and check that the indicated val-
ue increases.
Value increases → Go to item 7.
Value does not increase → Go
to item 6.
6 Malfunction in ABS ECU. Replace the ABS ECU. Go to item 7.
Refer to “ABS (ANTI-LOCK
BRAKE SYSTEM)” on page
4-63.
7 Delete the fault code and check Turn the main switch to “ON”,
that the engine trouble warning and then rotate the front wheel
light goes off. by hand.
Confirm that the fault code has
the malfunction mode of the
Yamaha diagnostic tool, and
8-58

TIP
• If fault code numbers “P0507” and “P0560” are both indicated, take the actions specified for fault code
number “P0560” first.
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).
Fail-safe system
Actuates and fully closes the ISC valve, then opens it to the standby
opening position. This operation takes approximately 3 seconds until it is
Action
completed.
The “check” indicator on the Yamaha diagnostic tool screen come on.
Procedure The ISC unit vibrates when the ISC valve operates.
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) Check the condition of the fault
Front wheel stop: The pulse in- code using the malfunction
tegrated value should be con- mode of the Yamaha diagnostic
stant. tool.
Rotate the front wheel by hand Condition is “Recover” → Go to
and check that the indicated val- item A-9 and finish the service.
ue increases. Condition is “Malfunction” → Go
Value does not increase → Go to item A-3.
to fault code No. P0500.
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- Check the condition of the fault
TION” on page 3-24. code using the malfunction
mode of the Yamaha diagnostic
tool.
item A-9 and finish the service.
to item A-4.
8-59

A
Item
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 Check the condition of the fault
7-15. code using the malfunction
tool.
to item A-5.
A-5 Air leak from the ISC (Idle Improperly installed ISC (Idle Start the engine and let it idle for
Speed Control) unit. Speed Control) unit → Reinstall approximately 10 seconds.
the ISC (Idle Speed Control) Check the condition of the fault
unit. code using the malfunction
Refer to “THROTTLE BODY” on mode of the Yamaha diagnostic
page 7-13. tool.
Check the intake air passages Condition is “Recover” → Go to
for air leaks. item A-9 and finish the service.
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 Check the condition of the fault
(IDLE SPEED CONTROL) UNIT code using the malfunction
AND THROTTLE BODY” on mode of the Yamaha diagnostic
page 7-15. tool.
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 Check the condition of the fault
(IDLE SPEED CONTROL) UNIT code using the malfunction
AND THROTTLE BODY” on mode of the Yamaha diagnostic
page 7-15 and “REPLACING tool.
THE THROTTLE BODY” on Condition is “Recover” → Go to
page 7-18. item A-9 and finish the service.
to item A-8.
A-8 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
ECU (Engine Control Unit)” on Return the ISC (Idle Speed
page 8-128. Control) valve to the initial open-
ing position.
A-9 Delete the fault code and check Confirm that the fault code has
8-60

A
Item
B
not heard).
Fail-safe system
Actuates and fully closes the ISC valve, then opens it to the standby
opening position. This operation takes approximately 3 seconds until it is
Action
completed.
The “check” indicator on the Yamaha diagnostic tool screen come on.
Procedure The ISC unit vibrates when the ISC valve operates.
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.
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) fault code.
unit. ISC operating sound is not
Refer to “THROTTLE BODY” on heard → Go to item B-6.
page 7-13.
Check the intake air passages
for air leaks.
8-61

A
Item
B
not heard).
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 8-128. 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 7-15. ISC operating sound is not
heard → Go to item B-8.
B-8 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
ECU (Engine Control Unit)” on Return the ISC (Idle Speed
page 8-128. Control) valve to the initial open-
ing position.
B-9 Delete the fault code and check Start the engine and let it idle for
that the engine trouble warning approximately 10 seconds.
light goes off. Confirm that the fault code has
the Yamaha diagnostic tool, and

Item ISC (Idle Speed Control) unit: ISC unit does not operate.
Fail-safe system
Action —
Procedure —
1 Connection of ISC unit coupler. Improperly connected → Con- Turn the main switch to “ON”,
Disconnect the coupler and function mode of the Yamaha
check the pins (bent or broken diagnostic tool.
to item 2.
8-62
Item ISC (Idle Speed Control) unit: ISC unit does not operate.
2 Connection of wire harness Improperly connected → Con- Turn the main switch to “ON”,
ECU coupler. nect the coupler securely or re- and then check the condition of
the coupler. function mode of the Yamaha
Disconnect the coupler and diagnostic tool.
to item 3.
Between ISC unit coupler and the fault code using the mal-
ECU coupler. function mode of the Yamaha
pink–pink diagnostic tool.
green/yellow–green/yellow Condition is “Recover” → Go to
gray–gray item 6 and finish the service.
sky blue–sky blue Condition is “Malfunction” → Go
to item 4.
4 Faulty ISC unit operation. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. D54) and then check the condition of
ISC unit operation sound is not the fault code using the mal-
heard. → Replace the ISC unit. function mode of the Yamaha
Refer to “CLEANING THE ISC diagnostic tool.
(IDLE SPEED CONTROL) Condition is “Recover” → Go to
UNIT AND THROTTLE BODY” item 6 and finish the service.
on page 7-15. Condition is “Malfunction” → Go
to item 5.
5 Malfunction in ECU Replace the ECU. Service is finished.
page 8-128.

Item Charging voltage is abnormal.

Fail-safe system
Tool display —
Procedure —
8-63
Item Charging voltage is abnormal.

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. Check the condition of the fault
Defective rectifier/regulator or code using the malfunction
stator coil assembly → Replace. mode of the Yamaha diagnostic
Defective connection in the tool.
charging system circuit → Prop- Condition is “Recover” → Go to
erly connect or replace the wire item 2 and finish the service.
harness. Condition is “Malfunction” →
Repeat item 1.

Item Faulty ECU memory.

Fail-safe system
Tool display —
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ON”.
Refer to “REPLACING THE Check that the engine trouble
ECU (Engine Control Unit)” on warning light does not come on.
page 8-128.
Fault code No. P062F

EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
Fail-safe system
00
• No malfunctions detected (If the self-diagnosis fault code P062F is indi-
cated, the ECU is defective.)
Tool display 01 (CO adjustment value)
11 (Data error for ISC (Idle Speed Control) learning values)
12 (O2 feedback learning value)
14 Tire diameter learning value
Procedure —
8-64

Item
writing on EEPROM.
1 Locate the malfunction. Execute the diagnostic mode.
(Code No. 60)
00: Go to item 6.
01: Go to item 2.
11–12: Go to item 3.
2 “01” is indicated in diagnostic Change the CO concentration, Turn the main switch to “ON”,
mode (Code No. 60). EEPROM and rewrite in EEPROM. and then check the condition of
data error for adjustment of CO Refer to “ADJUSTING THE EX- the fault code using the mal-
concentration. HAUST GAS VOLUME” on function mode of the Yamaha di-
page 3-8. agnostic tool.
After this adjustment is made, Condition is “Recover” → Go to
turn the main switch to “OFF”. item 7 and finish the service.
Condition is “Malfunction” →
Repeat item 1.
If the same number is indicated,
go to item 6.
3 “11” is indicated in diagnostic Turn the main switch to “OFF”. Turn the main switch to “ON”,
mode (Code No. 60). EEPROM and then check the condition of
data error for ISC (Idle Speed the fault code using the mal-
Control) learning values. function mode of the Yamaha di-
agnostic tool.
Condition is “Malfunction” → Ex-
ecute the diagnostic mode
(Code No. 67) and then repeat
item 1.
go to item 6.
4 “12” is indicated in the diagnos- Turn the main switch to “OFF”. Turn the main switch to “ON”,
tic mode. (Code No. 60) EE- and then check the condition of
PROM data error for A/F control the fault code using the mal-
learning values. function mode of the Yamaha di-
agnostic tool.
item 1.
go to item 6.
5 “14” is indicated in the diagnos- Turn the main switch to “OFF”. Turn the main switch to “ON”,
tic mode. (Code No. 60) EE- and then check the condition of
PROM data error for tire the fault code using the mal-
diameter learning values. function mode of the Yamaha di-
agnostic tool.
item 1.
go to item 6.
8-65

Item
writing on EEPROM.
page 8-128.

Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
Fail-safe system
Fuel system voltage (battery voltage)
Tool display
Approximately 12.0
09
Compare the actually measured battery voltage with the tool display val-
Procedure
ue. (If the actually measured battery voltage is low, recharge the battery.)
1 Connection of ECU coupler. Improperly connected → Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
to item 2.
2 Wire harness continuity. Open or short circuit → Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between battery terminal and Check the condition of the fault
main fuse 2. code using the malfunction
red–red mode of the Yamaha diagnostic
Between main fuse 2 and main tool.
switch. Condition is “Recover” → Go to
red–red item 4 and finish the service.
Between main switch and main Condition is “Malfunction” → Go
fuse. to item 3.
Between main fuse and ECU.
page 8-128.
8-66
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.

No normal signals are received from the sidestand switch.

Item
Sidestand switch: open or short circuit detected.
Fail-safe system
Sidestand switch
Tool display • “ON” (sidestand retracted)
• “OFF” (sidestand extended)
Procedure Extend and retract the sidestand.
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. Check the condition of the fault
to item 2.
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 Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
to item 3.
3 Connection of main switch cou- Improperly connected → Con- Turn the main switch to “ON”,
pler. nect the coupler securely or re- and then extend and retract the
Check the locking condition of place the wire harness. sidestand.
to item 4.
8-67
No normal signals are received from the sidestand switch.

Item
Sidestand switch: open or short circuit detected.
the wire harness. and then extend and retract the
Between starting circuit cut-off sidestand.
relay coupler and ECU coupler. Check the condition of the fault
blue/yellow–blue/yellow code using the malfunction
Between starting circuit cut-off mode of the Yamaha diagnostic
relay coupler and sidestand tool.
switch coupler. Condition is “Recover” → Go to
blue/green–blue/green item 7 and finish the service.
to item 5.
5 Defective sidestand switch. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 20) and then extend and retract the
Sidestand retracted: “ON” sidestand.
Sidestand extended: “OFF” Check the condition of the fault
Replace if defective. code using the malfunction
tool.
to item 6.
page 8-128.

[P1604] Lean angle sensor: ground short circuit detected.

Item
[P1605] Lean angle sensor: open or power short circuit detected.
Fail-safe system
Tool display • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 50 degrees.
8-68

Item
1 Connection of lean angle sensor Improperly connected → Con- Turn the main switch to “ON”,
coupler. nect the coupler securely or re- then to “OFF”, and then back to
Check the locking condition of place the wire harness. “ON”.
to item 2.
Check the locking condition of nect the coupler securely or re- then to “OFF”, and then back to
the coupler. place the wire harness. “ON”.
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
to item 3.
the wire harness. then to “OFF”, and then back to
“ON”.
Check the condition of the fault
code using the malfunction
tool.
to item 4.
3-1
2
1 5V
L
3 L
Y/G
4 Y/G
B/L
5 B/L
1. Lean angle sensor

2. ECU
Disconnect the lean angle sensor coupler from the lean angle sensor.
8-69

Item
Between lean angle sensor coupler and ground: yellow/green–ground
B/L Y/G L

Between lean angle sensor coupler and ECU coupler: blue–blue

B/L Y/G L Sb Gy L/Y G/R Y Y/G L/R B/L W/Y

Between lean angle sensor coupler and ECU coupler: yellow/green–yellow/green

8-70

Item
Between lean angle sensor coupler and ECU coupler: black/blue–black/blue

3-8 [For P1604/P1605] Short circuit
Between lean angle sensor output terminal (yellow/green) “a” of ECU coupler and any other ECU
coupler terminal “b”.

4 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. D08) then to “OFF”, and then back to
Upright 0.4–1.4 V “ON”.
Overturned 3.7–4.4 V Check the condition of the fault
An indicated value is out of the code using the malfunction
specified range. → Replace the mode of the Yamaha diagnostic
lean angle sensor. tool.
to item 5.
page 8-128.
8-71

Rear wheel sensor: no normal signals are received from the rear
Item
wheel sensor.
Fail-safe system
Diagnostic code No. –
Tool display –
Procedure –
1 Locate the malfunction. If the ABS warning light is on,
refer to “BASIC INSTRUC-
TIONS FOR TROUBLESHOOT-
ING” on page 8-85.
If the ABS warning light is off,
perform the following procedure.
Use the monitoring function of
the Yamaha diagnostic tool to
check the rear wheel speed
pulse. For information about us-
ing the Yamaha diagnostic tool,
refer to the operation manual
that is included with the tool.
Rotate the rear wheel by hand
and check the display value for
the rear wheel speed pulse. Dis-
play value for the rear wheel
speed pulse is greater than 0
(km/h) → Go to item 9 and de-
lete the fault code.
Display value for the rear wheel
speed pulse is 0 (km/h) → Go to
item 2.
2 Connection of rear wheel sen- Improperly connected → Con- Rotate the rear wheel by hand
sor coupler. Check the locking nect the coupler securely or re- and check the display value for
condition of the coupler. Discon- place the wire harness. the rear wheel speed pulse us-
nect the coupler and check the ing the monitoring function.
pins (bent or broken terminals Display value for the rear wheel
and locking condition of the speed pulse is greater than 0
pins). (km/h) → Go to item 9 and de-
item 3.
3 Connection of ABS ECU cou- Improperly connected → Con- Rotate the rear wheel by hand
pler. Check the locking condition nect the coupler securely or re- and check the display value for
of the coupler. Disconnect the place the wire harness. the rear wheel speed pulse us-
coupler and check the pins ing the monitoring function.
(bent or broken terminals and Display value for the rear wheel
locking condition of the pins). speed pulse is greater than 0
item 4.
8-72
Rear wheel sensor: no normal signals are received from the rear
Item
wheel sensor.
4 Connection of ECU coupler. Improperly connected → Con- Rotate the rear wheel by hand
Check the locking condition of nect the coupler securely or re- and check the display value for
the coupler. Disconnect the cou- place the wire harness. the rear wheel speed pulse us-
pler and check the pins (bent or ing the monitoring function.
broken terminals and locking Display value for the rear wheel
condition of the pins). speed pulse is greater than 0
item 5.
5 Wire harness continuity. Open or short circuit → Replace Rotate the rear wheel by hand
the wire harness. and check the display value for
Between rear wheel sensor cou- the rear wheel speed pulse us-
pler and ECU coupler. ing the monitoring function.
brown–brown Display value for the rear wheel
yellow–yellow speed pulse is greater than 0
Between ABS ECU coupler and (km/h) → Go to item 9 and de-
ECU coupler. lete the fault code.
white/black–white/black Display value for the rear wheel
item 6.
6 Defective rear wheel sensor. Improperly installed sensor → Rotate the rear wheel by hand
Reinstall or replace the sensor. and check the display value for
Refer to “INSTALLING THE the rear wheel speed pulse us-
REAR WHEEL (REAR BRAKE ing the monitoring function.
DISC)” on page 4-36. Display value for the rear wheel
item 7.
7 Malfunction in ECU. Replace the ECU. Rotate the rear wheel by hand
Refer to “REPLACING THE and check the display value for
ECU (Engine Control Unit)” on the rear wheel speed pulse us-
page 8-128. ing the monitoring function.
item 8.
8 Malfunction in ABS ECU. Replace the ABS ECU. Go to item 9.
Refer to “ABS (ANTI-LOCK
BRAKE SYSTEM)” on page
4-63.
8-73

No normal signals are received from the O2 sensor.

Item
O2 sensor: open circuit detected.
Fail-safe system
Tool display —
Procedure —
1 Installed condition of O2 sensor. Check for looseness or pinch- Start the engine, warm it up,
ing. and then race it.
Improperly installed sensor → Check the condition of the fault
Reinstall or replace the sensor. code using the malfunction
Refer to “CYLINDER HEAD” on mode of the Yamaha diagnostic
page 5-13. tool.
to item 2.
Also, delete this fault code,
which has a condition of “Mal-
function”.
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.
Check the locking condition of place the wire harness. Check the condition of the fault
the coupler. code using the malfunction
to item 3.
function”.
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.
to item 4.
function”.
8-74
No normal signals are received from the O2 sensor.

Item
O2 sensor: open circuit detected.
4 Wire harness continuity. Open or short circuit → Replace Start the engine, warm it up,
the wire harness. and then race it.
Between O2 sensor coupler and Check the condition of the fault
ECU coupler. code using the malfunction
gray/red–gray/red mode of the Yamaha diagnostic
tool.
to item 5.
function”.
5 Check fuel pressure. Refer to “CHECKING THE Start the engine, warm it up,
FUEL PRESSURE” on page and then race it.
7-7. Check the condition of the fault
code using the malfunction
tool.
to item 6.
function”.
6 Defective O2 sensor. Check the O2 sensor. Start the engine, warm it up,
Replace if defective. and then race it.
Refer to “CYLINDER HEAD” on Check the condition of the fault
page 5-13. code using the malfunction
tool.
to item 7.
function”.
page 8-128.
8-75
8-76
EAS30513
EAS20081
R
R
R/B
R/B R/W
R R R R/B
R L/W G/Y
6 R R
ON 24 (R)
OPEN R
Br/L R/Y R/Y Br/L
CIRCUIT DIAGRAM

Br/R Br/R
L R/W
(B)
Br/R
R/B
10 B B
R/B R
R/B
11
Br/R Br/R
Br/R
FUEL PUMP SYSTEM
R
L/B Br/W B
31 G B
22 Br/W B
Br/R Y/W Y/W R 32 49
L/W L/W (B)
Dg Ch Ch Dg Br/W R/B
P/W R/B R/B P 44 L/B R/W
B INFO B G/Y G/Y B
(B) (B)
R P
Br/W
R/B R/B 50
R/B Br/R Br/R R/B
Br/R Br/R L/B R/W
Br/R
Br/R
B/W B/W
8-77
B/W B/W
54
B B
67 67
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
6. Main switch
10.Backup fuse
11.Main fuse
22.Battery
24.Main fuse 2
49.Fuel pump
50.Fuel pump relay
54.Engine ground
67.Frame ground
8-78
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
4. Bottom cover assembly

(Main, main 2 and backup)
OK ↓
page 8-128.
OK ↓
OK ↓
4. Check the start/engine stop switch. NG →
The start/engine stop switch is faulty. Re-
place the right handlebar switch.
OK ↓
5. Check the fuel pump relay. NG →
Refer to “CHECKING THE RE- Replace the fuel pump relay.
OK ↓
6. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-7.
OK ↓
7. Check the entire fuel pump system NG →
wiring. Properly connect or replace the wiring har-
page 8-77.
OK ↓
Replace the ECU. Refer to “REPLAC-
ING THE ECU (Engine Control Unit)”
on page 8-128.
8-79
FUEL PUMP SYSTEM
8-80
EAS30843
EAS20085
R
R
R/B
R/B
R
R/B
R R R
R L/W G/Y
6 R R
ON 24 (R)
OPEN R
OFF G/Y G/Y P L L R/W W Br/R B/L O/B B/L Y/B B/W
R R/L G/Y G/Y G/Y Sb Gy L/Y G/R Y Y/G L/R B/L W/Y
LOCK
Br/L R/Y R/Y Br/L
CIRCUIT DIAGRAM

Br/R Br/R
L R/W
(B)
R/Y Br/R
20 21
Br/L
R
R/B
10
R/B R
11
Br/R Br/R
Br/R Br/R
12 R
R
Br/W
13 Br/R 31
R/W 22
Br/R Y/W Y/W R
35 L/W L/W
Dg Ch Ch Dg
P/W R/B R/B P 44
BB INFO B G/Y G/Y B
(B) (B)
R P
R/W G/Y
Br/R
Br/R Br/R
L/R L/R
L/R
Br/R W/B
Br/R
W
R/W
R/W
B/W B/W
R/W
8-81
B/W B/W
70 R/W
Br 54
Y Y
Br/W P P Br/W
Dg Ch Ch Dg
(B) (B) (R) (R)
G/Y
G/Y
G/Y G/Y G/Y
G/Y
B B/W

G/Y G/Y
G/BBr/R B B R/B 64 61 R/L G/Y Y/B Y/B Br/W L/R L/B B/W B
Br/R W/LG/B L/R B/L G Y/W P/W Dg Ch W
81 L/R L/R L/R W/B (B)
(Gy)
R/L
66 63 Y/B R
B Y/B Br/W
B B/W
B B B G G B
Dg Dg
83 Ch Ch G/Y 55 W B G L
85 L/R Br/R L L W
Br/R L/R
(B) (B)
B B Br Br B
B 56 W B Br Y
Y Y W
B W/L 59
B
W/L 57
B/W B/W B/W
R/B
L/B L/B B
L/R L/R
L/R L/B
58 R/B B
B
B B
67 67 67
6. Main switch
10.Backup fuse
11.Main fuse
20.ABS solenoid fuse
21.ABS motor fuse
22.Battery
24.Main fuse 2
54.Engine ground
57.Joint connector
58.ABS test coupler
59.ABS ECU
67.Frame ground
81.Meter assembly
85.ABS warning light
8-82
EAS30844
ABS COUPLER LOCATION CHART
1
5
L/R L/B
W B G L R/B B
4 2
R G L Br Y W W/L W/B B/W

G/BBr/R B B R/B
W/LG/B L/R B/L G Y/W P/W Dg Ch R/L G/Y Y/B Y/B Br/W L/R L/B B/W B
(Gy)
(B)
3
W B Br Y
1. ABS test coupler

2. ABS ECU coupler
3. Rear wheel sensor coupler
4. Meter assembly coupler
5. Front wheel sensor coupler
8-83
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 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 8-88. 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 8-110.
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 8-85.
8-84
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
8-110. 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.
8-85
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 main 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.
[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.
8-86
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 8-110.
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 blue/red terminal of the ABS ECU coupler and
blue/red 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 8-127.
• 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 8-128.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-128.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 8-81.
• 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.
1. Yamaha diagnostic tool
• Check if the Yamaha diagnostic tool is connected correctly.
8-87
2. ABS control unit fuse

• Check the ABS control unit fuse for continuity.
• If the ABS control unit fuse is blown, replace the fuse.
3. 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 4-65.
4. 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/red terminal of the main switch coupler and brown/white termi-
nal 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)
5. ABS ECU malfunction
Replace the hydraulic unit assembly.
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.

90890-03256
90890-03254

Remove the battery cover assembly. Refer to “GENERAL CHASSIS (1)” on page 4-1.
8-88
Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.
Fault code 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
rotor
• Defective rear wheel sen-
of the sensor
13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
front wheel
rotor
of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered
27* mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
rear wheel
rotor
of the sensor
8-89

15 Front wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the front wheel sen- the front wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
sor or hydraulic unit as-
sembly
16 Rear wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the rear wheel sen- the rear wheel sensor and
sor. the hydraulic unit assembly
rear wheel sensor and the
hydraulic unit assembly
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
rotor
of the sensor
18* Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
46* pulses) not received properly. (Miss- around the rear wheel sen-
traveling.) rear wheel
rotor
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.
8-90

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
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
battery and the hydraulic
unit assembly
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
unit assembly
sembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS motor the motor power supply cir- sembly
power supply circuit) cuit in the hydraulic unit as-
sembly.
41 Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- front wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. front wheel
• Front wheel will not recover • Front brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
8-91

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-
traveling.) front wheel
rotor
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-
traveling.) rear wheel
rotor
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)
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lic unit assembly is too low. the battery and the hydrau-
lic unit assembly
unit assembly
• Defective charging system
8-92

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
unit assembly
• Defective charging system
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
sor
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
sor
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).
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
4-29.
8-93
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

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 4-30.
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.
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

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-35.
Refer to “MAINTENANCE OF THE REAR WHEEL
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
8-94

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.
• 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.)

bends.
4-29.
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.

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

bends.
4-35.
8-95
14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)
Rear wheel sensor signal is not received properly. (The pulse period
Symptom

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.

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.
8-96
Fault code No. 15
Item Front wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the front wheel sensor.

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 termi-
hydraulic unit assembly nal “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.
• Check that there is no short circuit between the black/
white terminal “3” and the green terminal “4” and be-
tween the black/white terminal “3” and the blue termi-
nal “5”.
1 2 3
4 5
G L W B
R/L G/Y Y/B Y/B Br/W L/R L/B B/W B
6
7
6. ABS ECU
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 4-27 and “ABS (AN-
TI-LOCK BRAKE SYSTEM)” on page 4-63.
Fault code No. 16

TIP
Fault code No. 16
Item Rear wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the rear wheel sensor.

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.
pler securely.
See TIP.
8-97
Fault code No. 16
Item Rear wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the rear wheel sensor.

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 ter-
hydraulic unit assembly minal “2” and the yellow terminal “5”.
• If there is no continuity, the wire harness is defective.
• 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”.
• Check that there is no short circuit between the black/
white terminal “3” and the brown terminal “4” and be-
tween the black/white terminal “3” and the yellow ter-
minal “5”.
1 2 3
4 5
Br Y 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 4-34 and “ABS (ANTI-
LOCK BRAKE SYSTEM)” on page 4-63.
8-98

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.
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.)

bends.
4-29.

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.)

bends.
4-35.
8-99
18
Fault code No.
46
Symptom

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.

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-63.
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).

1 Defective signaling system (brake light or Check the brake light switches.
brake light switch) Refer to “CHECKING THE SWITCHES” on page 8-127.
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 red/white–red/white
• Between ABS ECU coupler and rear brake light switch
connector.
green/yellow–green/yellow
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
4-63.
8-100
Fault code No. 31

TIP
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.

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.
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)
4-63.
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.

4-63.
Fault code No. 33

TIP
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.

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.
8-101
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.

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.
pler securely.
See TIP.
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
4-63.
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.

4-63.
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.

sensor bends.
4-29.
8-102
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
pressure.

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.
4-29 and “CHECKING THE FRONT BRAKE DISC” on
page 4-44.
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 4-44.
4-63.

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
pressure.

sensor (for fault code No. 42) bends.
4-35.
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.
4-35.
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 4-57.
8-103
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
pressure.

4-63.
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.)

bends.
4-29.
Fault code No. 44

Fault code No. 44
Symptom

8-104
Fault code No. 44
Symptom

bends.
4-35.

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)

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-128.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
8-105
Fault code No. 53

TIP
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.

on page 8-128.
pler securely.
See TIP.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS control unit fuse.
assembly (brown/white–brown/white)
Fault code No. 54

TIP
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.

on page 8-128.
pler securely.
See TIP.
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)
Refer to “CHARGING SYSTEM” on page 8-11.
8-106
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.

4-63.
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.

4-63.
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.

4-63.
8-107
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.

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.
3
1 2
G L W B
4
5
4. ABS ECU
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
G L W B
3
4
3. ABS ECU
4-63.
8-108
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.

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.
3
2 1
Br Y W B
4
5
4. ABS ECU
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
Br Y W B
3
4
3. ABS ECU
4-63.
8-109
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.

90890-03256
90890-03254

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 3-11.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)” on page 4-31 and “INSTALL-
ING THE REAR WHEEL (REAR BRAKE DISC)” on page 4-36.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-67.
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 8-110.
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 4-70.
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.
8-110
EAS31452
EAS20201
R
R
R/B
B G/W B G R/B
R
(B)
R/B
R R R
L B R/W B R L/W G/Y
6 R R
(B) ON 24 (R)
OPEN R
4 5 Br/L G/Y P L L R/W W Br/R B/L O/B B/L Y/B B/W
OFF
R/Y Sb Gy L/Y G/R Y Y/G L/R B/L W/Y
LOCK
Br/L R/Y R/Y Br/L
CIRCUIT DIAGRAM

Br/R Br/R
L R/W
(B)
G/W B G B R/Y Br/R
17 19
Br/L
Br/R
R/B
10 R/Y
L/Y
R/B R
R/B L/Y L/Y L/Y
R/Y L/R R/G L/Y B Ch 11 L/G
R/B G/W G/B R/W G Dg Br/R Br/R
Br/R Br/R L/G B B
SMART KEY SYSTEM
(B) R
30 B L/G
B B
G R/B
G/W L/Y 13 Br/R 31 (B) (B)
R/W R/W
22
Br/R Y/W Y/W R 33 L/W L/W
Dg Ch Ch Dg
P/W R/B R/B P 44
R/Y B INFO B G/Y G/Y B L/Y
(B) (B)
Dg R P
Ch
7 Dg Ch
R/G R/G B R R/B R/B Br/R Br/W
8 Br/R Br/R
B R/G
R R/B
L/R L/R L/R L/R

G/B L/R
B
Br/R
Br/R
Br/R B/W B/W
Br/W
Br/R
68
Br/W B/W B/W
(B)
Br/W Br/W
8-111
54
B
B
Dg
Dg Dg Dg
Ch Dg Dg
B Ch Ch Ch 54 54
B
Ch Ch
G/BBr/R B B R/B Ch Dg
Br/R W/LG/B L/R B/L G Y/W P/W Dg Ch Ch Dg
81 G/B L/R L/R L/R
(Gy)
B B
76 75
65 62
B
82 B B B
B B B
B Dg Dg
83 (G) Ch Ch
L/R Br/R
Br/R L/R
B B (B) (B)
B B
Ch Dg B B
B
B (G)
B
B
B B B B B B
B B
B B
B B
67 67 67 67
SMART KEY SYSTEM
SMART KEY SYSTEM
4. Request switch
5. Main switch solenoid
6. Main switch
7. Smart key unit
8. Buzzer
10.Backup fuse
11.Main fuse
17.Answer back fuse
19.Turn signal light and hazard fuse
22.Battery
24.Main fuse 2
30.Sidestand switch
33.Hazard switch
54.Engine ground
62.Rear turn signal light (right)
65.Rear turn signal light (left)
67.Frame ground
68.Turn signal/hazard relay
75.Front turn signal light (right)
76.Front turn signal light (left)
81.Meter assembly
82.Smart key indicator light
8-112
SMART KEY SYSTEM
EAS31453
TROUBLESHOOTING
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
Engine does not start even though vehicle power is turned on.
Seat does not open. (Vehicle power is turned on.)
Left front storage box does not open. (Vehicle power is turned on.)
Fuel tank cap lid does not open.
Answer back function does not operate.
TIP
Before troubleshooting, remove the following part(s):
Checking the vehicle power

1. Check the smart key. NG →
→ The smart key indicator light
comes on when the smart key but-
Replace the button cell battery of the
ton is pushed.
smart key. Standard battery: CR2032
→ Check the button cell battery.
Refer to “CHECKING THE SMART
KEY BATTERY” on page 8-137.
OK ↓
(Main, main 2, backup, signaling
system, turn signal and hazard, and
answer back)
OK ↓
page 8-128.
OK ↓
4. Check the main switch and request NG →
switch.
Replace the main switch.
OK ↓
5. Check the main switch solenoid. NG →
Refer to “CHECKING THE MAIN
Replace the main switch.
SWITCH SOLENOID” on page
8-137.
OK ↓
8-113
SMART KEY SYSTEM
6. Check the entire smart key sys- NG →

tem’s wiring. Properly connect or replace the wire har-
page 8-111.
OK ↓
Replace the smart key unit.
Checking the smart key system

Before checking the smart key system, make sure that the smart key is located within the operating
range of the smart key system and that the key is turned on.
Vehicle power does not turn on. (Meter light and tail light do not come on.)
TIP
• Before performing this procedure, make sure that there are no sources of strong electromagnetic
waves in the vicinity. (Because the amount of electromagnetic waves will change if the vehicle is
moved a short distance, move the vehicle away from sources of strong electromagnetic waves before
performing the procedure.)
• Use the smart key that is registered to the vehicle.
1. Check the vehicle power. NG →

Refer to “Checking the vehicle pow- Repair or replace any defective parts.
er” on page 8-113.
OK ↓
• There are sources of strong electro-
magnetic waves in the vicinity →
Move the vehicle.
• Smart key malfunction → Register
and use a different smart key.
• Smart key unit malfunction → Re-
place the smart key unit.
Engine does not start even though vehicle power is turned on.
1. When the vehicle power is turned NO →
on, the smart key indicator light “ ” Check and repair the electric starting sys-
flashes 4 times. tem. Refer to “ELECTRIC STARTING
Refer to “SMART KEY SYSTEM SYSTEM” on page 8-5.
SELF-DIAGNOSIS” on page 8-117.
YES ↓
2. Turn the main switch to “OFF”, and NG →
Repair or replace any defective parts. Re-
then push the main switch and
fer to “Checking the vehicle power” on
check that it can be turned back to
page 8-113.
“ON”.
OK ↓
8-114
SMART KEY SYSTEM
3. Check for continuity in the commu- NG →

nication line between the ECU and
the smart key unit (blue/red – blue/
red).
OK ↓
• Replace the ECU.
Refer to “REPLACING THE ECU
(Engine Control Unit)” on page
8-128.
• Replace the smart key unit.
Seat does not open. (Vehicle power is turned on.)

OK ↓
• Check the mechanical components
of the lock for malfunctions. Repair or
replace any defective parts.
• Adjust or replace the seat lock cable.
Left front storage box does not open. (Vehicle power is turned on.)
OK ↓
• Adjust or replace the left front stor-
age box lock cable.
Fuel tank cap lid does not open.

1. Check that the main switch can be NG →
Repair or replace any defective parts.
turned counterclockwise.
OK ↓
• Adjust or replace the fuel tank cap lid
lock cable.
8-115
SMART KEY SYSTEM
Answer back function does not operate.

OK ↓
2. Check the buzzer operation. NG →
Refer to “CHECKING THE BUZZ- Replace the buzzer.
ER” on page 8-137.
OK ↓
3. Check the turn signal light bulbs NG →
and sockets.
Replace the turn signal light bulb, socket or
Refer to “CHECKING THE BULBS
both.
OK ↓
Replace the smart key unit.
8-116
SMART KEY SYSTEM
EAS31534
SMART KEY SYSTEM SELF-DIAGNOSIS

The smart key system is equipped with a self-diagnostic function. If a malfunction is detected in the sys-
tem, the malfunction will be indicated by the flash pattern of the smart key indicator light “ ”.
TIP
The smart key indicator light “ ” comes on for about 2 seconds when the vehicle power is on. If one of
the following malfunctions is detected, the indicator light starts flashing.
Flashing time/number Malfunction and check

Item Flash pattern
of flashes point
0.5 (s)
a Replace the button cell
battery of the smart key.
Low voltage of smart b
0.5 (s)
20 (seconds) Refer to “SMART KEY
key button cell battery
SYSTEM” on page
a.LED on 8-111.
b.LED off
The smart key cannot
0.15 (s) be recognized.
a Check that there are no
sources of strong elec-
Vehicle power off verifi- b
0.15 (s)
30 (seconds) tromagnetic waves in
cation error
the vicinity, the smart
a.LED on key is not lost, and the
b.LED off battery is not dis-
charged.
The smart key cannot
0.15 (s) be recognized.
a Check that there are no
Flashes continuously sources of strong elec-
Running detection er- b
0.15 (s)
until the error is re- tromagnetic waves in
ror*
solved. the vicinity, the smart
a.LED on key is not lost, and the
b.LED off battery is not dis-
charged.
0.3 (s)
• ECU communication a Flashes continuously Check the wire harness.
error b until the error is re- Check the ECU.
• Data error 0.3 (s) 1.0 (s) solved./flashes 4 times Check the smart key
• ECU malfunction in a repeating cycle. unit.
a.LED on
b.LED off
* The running detection error

If the smart key is dropped or can no longer be recognized while the vehicle is traveling. If the vehicle
travels while the smart key cannot be recognized, the smart key indicator light “ ” flashes in 0.15-
second intervals.
The vehicle can be ridden, but the vehicle power cannot be turned off.
Although a forced shutdown can be performed to turn off the vehicle power (the main switch is
pushed for 4 times within 2 seconds while the smart key indicator light “ ” is flashing in 0.15-second
intervals), the vehicle power cannot be turned back on.
8-117
SMART KEY SYSTEM
SMART KEY SYSTEM SELF-DIAGNOSIS

If a communication error between the ECU and the smart key unit is detected, the following fault code
numbers will be displayed on the meter to indicate the location of the malfunction.
TIP
These fault code numbers are not stored in the memory of the ECU. Note all of the displayed fault code
numbers, and then check the vehicle.
Device that de-

Fault code Check or maintenance
tected the mal- Symptom Cause
No. job
function
51 Smart key unit Communication error Radio wave noise inter- Perform the checks and
between the smart key ference. maintenance job for
and the smart key unit. • Lock condition in the “Engine does not start
smart key even though vehicle
• Defective smart key power is turned on.”
• Defective smart key
unit
53 Smart key unit Communication error Radio wave noise inter- Perform the checks and
between the ECU and ference or disconnect- maintenance job for
the smart key unit. ed lead. “Engine does not start
• Obstruction due to ra- even though vehicle
dio wave noise power is turned on.”
• Disconnection in the
wire harness
• Defective ECU
unit
54 Smart key unit Codes transmitted be- Radio wave noise inter- Perform the checks and
tween the ECU and the ference or disconnect- maintenance job for
smart key unit do not ed lead. “Engine does not start
match. • Obstruction due to ra- even though vehicle
dio wave noise. power is turned on.”
wire harness
• Defective ECU (when
the ECU or smart key
unit is replaced with a
unit from a different
vehicle)
unit
56 ECU Unidentified code is re- Radio wave noise inter- Perform the checks and
ceived. ference or disconnect- maintenance job for
ed lead. “Engine does not start
• Obstruction due to ra- even though vehicle
dio wave noise power is turned on.”
wire harness
• Defective ECU
unit
8-118
SMART KEY SYSTEM
EAS31535
SMART KEY SYSTEM EMERGENCY MODE

If the smart key is lost or if it cannot be used due a discharged battery or malfunction, this mode can be
used to turn on the smart key system.
TIP
The emergency mode operation will be canceled if the respective steps are not carried out within the
time set for each operation.
1. Stop the vehicle in a safe place and turn the main switch to “OFF”.
2. Push the main switch for 5 seconds until the smart key indicator light flashes once, then release it.
Repeat two more times. The smart key indicator light “1” will come on for 3 seconds to indicate the
transition to emergency mode.
1
3. After the smart key indicator light “ ” goes off, use the main switch to enter the smart key identifica-
tion number “1” located inside the smart key case (open the smart key case as shown) or the iden-
tification number “2” located on the identification number card. (Refer to the following procedure on
how to input the identification number.)
1 2
868588
868588
4. The input identification number is indicated by the number of flashes of the smart key indicator light
“ ” while the main switch is pushed.
For example, if the smart key identification number is 123456:
Push and hold the main switch. →
The smart key indicator light “ ” will start to flash. →
8-119
SMART KEY SYSTEM
Release the main switch after the smart key indicator light “ ” flashes 1 time. →
The first digit of the identification number has been set as 1. →
Push and hold the main switch again. →
Release the main switch after the smart key indicator light “ ” flashes 2 times. →
The second digit of the identification number has been set as 2. →
Repeat the above procedure until all 6 digits of the identification number have been set.
5. The smart key indicator light “ ” will come on for 10 seconds if the correct 6-digit identification num-
ber was entered.
TIP
When one of the following situations applies, emergency mode will be terminated and the smart key
indicator light will flash quickly for 3 seconds. In this case, start over again from step 2.
• When there are no main switch operations for 10 seconds during the identification number input pro-
cess.
• When the smart key indicator light is allowed to flash nine or more times.
• The identification number is not entered correctly.
6. While the smart key indicator light is on, push the main switch once more to complete emergency
mode access. The smart key indicator light will go off and then come back on for approximately 4
seconds.
7. While the smart key indicator light is on, turn the main switch to “ON”. The vehicle can now be oper-
ated normally.
EAS31536
REGISTERING A SMART KEY

The following procedure can be used to register additional smart keys or a new smart key in case the
original smart key is lost.
TIP
• A maximum of 6 smart keys can be registered to the smart key unit.
• Be sure to register the smart keys one at a time. Do not register multiple smart keys at the same time.
8-120
SMART KEY SYSTEM
1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.
1
2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-119.
3. While the smart key indicator light “ ” is on for 10 seconds, push the main switch “1” for 5 seconds
until buzzer sounds once.
4. The smart key indicator light (red) “1” on the new smart key comes on for 10 seconds.
TIP
While the smart key indicator light on the smart key is on, the smart key indicator light “ ” flashes ac-
cording to the number of currently registered smart keys. (For example, if 5 smart keys are registered,
the indicator light flashes 5 times.)
5. While the smart key indicator light is on for 10 seconds, push the button on the smart key to transmit
a signal from the smart key to the smart key unit.
6. If the smart key is registered successfully, the smart key indicator light “ ” will come on for 3 sec-
onds, and then the smart key system will turn off.
If the smart key was not registered successfully, the smart key indicator light “ ” will flash for 3 sec-
onds, and then the smart key system will turn off.
TIP
If this registration procedure is performed for a smart key that is already registered, the smart key indi-
cator light “ ” will flash for 7 seconds (on for 0.2 second and off for 0.8 second).
8-121
SMART KEY SYSTEM
EAS31537
DISABLING A SMART KEY

If a smart key is lost or stolen, the smart key can be disabled.
1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com-
munication.
1
2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-119.
3. While the smart key indicator light “ ” is on for 10 seconds, perform the following procedure.
a. Push the main switch “1” 5 times or more until buzzer sounds 3 times.
4. Check that the smart key indicator light “ ” goes off (the smart key disable mode is activated).
5. Turn on (unlocked setting) the smart keys that you want to enable and place them within 80 cm (31.5
in) of the smart key unit.
6. Push the main switch for 5 seconds or more to start the communication between the smart key unit
and the smart keys that are located within 80 cm (31.5 in) of the unit.
TIP
The number of smart keys that currently can be used will be indicated.
Number of flashes = Number of verified smart keys. (1 cycle of on for 0.3 second and off for 0.3 second
= 1 smart key)
7. Push the main switch for 5 seconds or more. The use of only the verified smart keys will be enabled.
The use of all other smart keys will be disabled.
TIP
• If the procedure was not completed successfully, repeat the procedure from step 1.
• To enable a smart key after its use has been disabled, perform this procedure again.
8-122
SMART KEY SYSTEM
EAS32347
DISABLING THE POWER-ON ALARM

1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.
1
2. Push the main switch and the smart key indicator light will come on for approximately 4 seconds.
3. While the smart key indicator light is on, turn the main switch to “ON”.
4. Extend and retract the sidestand by hand for 10 times or more within 15 seconds from vehicle power
on.
5. When the buzzer sounds, the setting is complete.
• If the buzzer sounds 2 times: The power-on alarm is turned off.
• If the buzzer sounds 1 times: The power-on alarm is turned on.
8-123
SMART KEY SYSTEM
EAS31719
REPLACEMENT PARTS LIST

TIP
When replacing the parts, refer to the following sections.
• Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 8-119.
• Refer to “REGISTERING A SMART KEY” on page 8-120.
• Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-128.
Required item Replacement parts (when

when replacing an item is required in order
parts to replace parts)
 : Required.  : Replace.
Smart key
identification
 : number or × : Do not replace.
smart key is
Faulty part Remarks
required.
This part must be re-

× : Not required. * : placed even if it is not
faulty.
Smart
key iden- Smart Smart Smart
ECU
tification key key key unit
number
Register the smart key identifi-
Smart key  ×  × × cation number in the emergency
mode.
Replace the smart key, smart
Smart key unit × × *  *
key unit, and ECU as a set.
When the vehicle system is
turned on, the smart key identifi-
ECU   × × 
cation number is automatically
registered to the ECU.
Replace the smart key, smart
Smart key unit/ECU × × *  
key unit, and ECU as a set.
Smart key/Smart Replace the smart key, smart
× ×   *
key unit key unit, and ECU as a set.
Register the smart key identifi-
cation number in the emergency
mode.
Smart key/ECU  ×  ×  When the vehicle system is
turned on, the smart key identifi-
cation number is automatically
registered to the ECU.
Smart key/Smart Replace the smart key, smart
× ×   
key unit/ECU key unit, and ECU as a set.
8-124
ELECTRICAL COMPONENTS
EAS20089
3 6
4 5
7
2
1
8
20
10
19
11
18
17 14 12
16 13
15
1. Smart key unit 19.Crankshaft position sensor

2. Coolant temperature sensor 20.Rear wheel sensor
3. Main switch
5. Rear brake light switch
6. ABS ECU
7. Turn signal/hazard relay
8. Battery
10.Buzzer
13.Rectifier/regulator
14.Fuel pump
15.Fuel sender
16.O2 sensor
17.Ignition coil
18.AC magneto
8-125
7 8 10
6 9
1,2,3,4 5
11
12
13
14
15
16
20
17
19
18

2. Throttle position sensor
3. Intake air pressure sensor
5. ISC (Idle Speed Control) unit
6. Fuel injector
7. Spark plug
9. Diode 1
10.Fuel pump relay
11.Fuse box 1
12.Starter relay
13.Fuse box 2
14.Diode 2
15.Diode 3
17.Horn
19.Sidestand switch
20.Starter motor
8-126
EAS30549
CHECKING THE SWITCHES

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
8 1
Y Br Y R R/Y Br/L Br/R R
P Br/W
ON
R/W Br OPEN
PASS OFF Br/L R/Y
LOCK Br/R
Y
9 Dg Ch
P
P B
B G/Y
2
10 L B
Ch Br/W Dg
L B
11
3
R/W R R/B L/W B
Y/W R
R/W Br/W
G/Y R/B P
(B)
4
Dg Br/W Ch
L/W
Dg Ch
7 B G/Y
5
B B Y/W B P
TRIP
B
B
INFO
(B)
6
R/W G/Y
1. Main switch
2. Request switch
3. Start/engine stop switch
4. Hazard switch
5. “TRIP/INFO” switch
7. Sidestand switch
8. Dimmer switch
9. Horn switch
10.Turn signal switch
8-127
EAS30551 EWA13310
CHECKING THE FUSES WARNING

The following procedure applies to all of the fus- Never use a fuse with an amperage rating
es. other than that specified. Improvising or us-
ECA20520
NOTICE ing a fuse with the wrong amperage rating

may cause extensive damage to the electri-
To avoid a short circuit, always turn the main
cal system, cause the lighting and ignition
switch to “OFF” when checking or replacing
systems to malfunction and could possibly
a fuse.
cause a fire.
1. Remove:
4. Install:
4-1.
4-1.
2. Check:
• Fuse EAS31006
a. Connect the digital circuit tester to the fuse REPLACING THE ECU (Engine Control Unit)
and check the continuity. 1. Turn the main switch to “OFF”.
2. Replace the ECU (Engine Control Unit).
Digital circuit tester (CD732) 3. Clean the throttle body.
90890-03243 Refer to “CLEANING THE ISC (IDLE SPEED
Model 88 Multimeter with ta- CONTROL) UNIT AND THROTTLE BODY”
chometer on page 7-15.
YU-A1927 4. Reset:
• A/F control learning value
b. If the no continuity, replace the fuse.
3. Replace:
• Fuse (blown fuse)
a. Turn the main switch to “OFF”.
9-1.
b. Install a new fuse of the correct amperage
rating. Yamaha diagnostic tool USB
c. Set on the switches to verify if the electri- 90890-03256
cal circuit is operational. Yamaha diagnostic tool (A/I)
d. If the fuse immediately blows again, check 90890-03254
the electrical circuit.
5. Check:
Amperage
Fuses Q’ty • Engine idling speed
rating
Start the engine, warm it up, and then mea-
Main 20 A 1 sure the engine idling speed.
Main 2 7.5 A 1
Engine idling speed
Terminal 2.0 A 1
1500–1700 r/min
Signaling system 10 A 1
Signaling system 2 7.5 A 1 EAS30552
CHECKING AND CHARGING THE BATTERY

Backup 7.5 A 1
TIP
Radiator fan motor 7.5 A 1
Refer to “CHECKING AND CHARGING THE
Turn signal and hazard 7.5 A 1 BATTERY” in “BASIC INFORMATION” (sepa-
ABS motor 30 A 1 rate volume).
ABS control unit 7.5 A 1 1. Remove:
ABS solenoid 15 A 1 • Battery cover assembly
Answer back 2.0 A 1 Refer to “GENERAL CHASSIS (1)” on page
4-1.
8-128
2. Disconnect: 10.Install:
• Battery leads • Battery cover assembly
(from the battery terminals) Refer to “GENERAL CHASSIS (1)” on page
ECA13640
4-1.
NOTICE
EAS30553
First, disconnect the negative battery lead
CHECKING THE RELAYS
“1”, and then positive battery lead “2”.
Check each switch for continuity with the digital
circuit tester. If the continuity reading is incor-
1 rect, replace the relay.
Digital circuit tester (CD732)

2 90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
1. Disconnect the relay from the wire harness.

2. Connect the digital circuit tester and battery
3. Remove: (12 V) to the relay terminals as shown.
• Battery Check the relay operation.
4. Check: Out of specification → Replace.
• Battery charge
5. Charge: Starting circuit cut-off relay
• Battery
(refer to the appropriate charging method) 3
6. Install: 4 +
• Battery
7. Connect:
• Battery leads 2 1
(to the battery terminals) L/G,L/Y Br/W
ECA13630
L/W
NOTICE
L/W
First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
1. Positive battery terminal
2. Negative battery terminal
2 3. Positive tester probe
4. Negative tester probe
1
Result
Continuity
(between “3” and “4”)
8. Check:
• Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• Battery terminals
Dielectric grease
8-129
Starter relay 2. Negative battery terminal

3. Positive tester probe
3
R 2 1
Result
L/W G/Y
Continuity
R R (between “3” and “4”)
B
EAS30794
CHECKING THE TURN SIGNAL/HAZARD

4 RELAY
1. Positive battery terminal 1. Check:
2. Negative battery terminal • Turn signal/hazard relay input voltage
3. Positive tester probe Out of specification → The wiring circuit from
4. Negative tester probe the main switch to the turn signal/hazard re-
lay coupler is faulty and replace the wire har-
ness.
Result
Continuity Turn signal/hazard relay input
(between “3” and “4”) voltage
DC 12V
Fuel pump relay
a. Connect the digital circuit tester to the turn
4 signal/hazard relay terminal as shown.
3 + Digital circuit tester (CD732)
90890-03243
1 2 Model 88 Multimeter with ta-
chometer
R/W L/B YU-A1927
R/B
Br/W • Positive tester probe
brown/red “1”
1. Positive battery terminal • Negative tester probe
2. Negative battery terminal Ground
3. Positive tester probe
Result
Continuity
(between “3” and “4”) Br/W
Br/R
Radiator fan motor relay 1
3
4 + b. Turn the main switch to “ON”.
c. Measure the turn signal/hazard relay input
voltage.
2 1 2. Check:
W/Y R/W • Turn signal/hazard relay output voltage
L Out of specification → Replace.
R/L
1. Positive battery terminal
8-130
Turn signal/hazard relay output Diode 1

voltage Continuity
DC 12V Positive tester probe → brown/
red “1”
a. Connect the digital circuit tester to the turn Negative tester probe → brown/
signal/hazard relay terminal as shown. blue “2”
No continuity
Digital circuit tester (CD732) Positive tester probe → brown/
90890-03243 blue “2”
Model 88 Multimeter with ta- Negative tester probe → brown/
chometer red “1”
YU-A1927 Diode 2
Continuity
• Positive tester probe Positive tester probe → blue/
brown/white “1” white “3”
• Negative tester probe Negative tester probe →
Ground green/yellow “4”
No continuity
Positive tester probe →
green/yellow “4”
Negative tester probe → blue/
1 white “3”
Diode 3
Br/W Continuity
Positive tester probe → red/
Br/R
white “5”
Negative tester probe → brown/
white “6”
No continuity
b. Turn the main switch to “ON”. Positive tester probe → brown/
c. Measure the turn signal/hazard relay out- white “6”
put voltage. Negative tester probe → red/
EAS30555
white “5”
CHECKING THE DIODES
1. Check: A
• Diodes
2
Digital circuit tester (CD732) Br/L

90890-03243 Br/R
chometer
YU-A1927 1
B
4
G/Y
L/W
8-131
C
6
Br/W
R/W
A. Diode 1 2. Ignition coil

B. Diode 2 c. Turn the main switch to “ON”.
C. Diode 3 d. Measure the ignition spark gap “a”.
a. Disconnect the diode from the wire har- e. Crank the engine by “ ” side of the start/
ness. engine stop switch is pushed and gradual-
b. Connect the digital circuit tester to the di- ly increase the spark gap until a misfire oc-
ode terminals. curs.
c. Check the diode for continuity. EAS30557
d. Check the diode for no continuity. CHECKING THE SPARK PLUG CAP
EAS30556
1. Check:
CHECKING THE IGNITION SPARK GAP • Spark plug cap resistance
1. Check: Out of specification → Replace.
• Ignition spark gap
Resistance
Out of specification → Perform the ignition
3.75–6.25 kΩ
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page a. Remove the spark plug cap from the spark
8-3. plug lead.
b. Connect the digital circuit tester to the
Minimum ignition spark gap
6.0 mm (0.24 in) spark plug cap as shown.

TIP 90890-03243
If the ignition spark gap is within specification, Model 88 Multimeter with ta-
the ignition system circuit is operating normally. chometer
YU-A1927
a. Disconnect the spark plug cap from the
spark plug.
b. Connect the ignition checker “1” as
shown.
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487
c. Measure the spark plug cap resistance.

EAS30558
CHECKING THE IGNITION COIL

1. Check:
• Primary coil resistance
8-132
Primary coil resistance

2.16–2.64 Ω
a. Disconnect the ignition coil connectors

from the ignition coil terminals.
b. Connect the digital circuit tester to the igni-
tion coil as shown.

90890-03243
Model 88 Multimeter with ta- b. Measure the secondary coil resistance.
chometer EAS30561
YU-A1927 CHECKING THE LEAN ANGLE SENSOR
1. Remove:
• Positive tester probe → • Lean angle sensor
red/white “1”
• Negative tester probe →
2. Check:
orange “2” • Lean angle sensor output voltage

Less than 50°: 0.4–1.4 V
More than 50°: 3.7–4.4 V
a. Connect the lean angle sensor coupler to

the wire harness.
b. Connect the digital circuit tester to the lean
angle sensor coupler as shown.

c. Measure the primary coil resistance. 90890-03243
2. Check: Model 88 Multimeter with ta-
• Secondary coil resistance chometer
Out of specification → Replace. YU-A1927
Secondary coil resistance • Positive tester probe →

8.64–12.96 kΩ blue
a. Connect the digital circuit tester to the igni- black/blue
tion coil as shown.

90890-03243
chometer
YU-A1927
• Positive tester probe →

red/white “1”
50° 50°
High tension cord “2”
c. Turn the main switch to “ON”.
d. Tilt the lean angle sensor to 50°.
e. Measure the lean angle sensor output
voltage.
8-133
EAS30560 EWA13810
CHECKING THE CRANKSHAFT POSITION WARNING

SENSOR • A wire that is used as a jumper lead must
1. Disconnect: have at least the same capacity of the bat-
• Crankshaft position sensor coupler tery lead, otherwise the jumper lead may
(from the wire harness) burn.
2. Check: • This check is likely to produce sparks,
• Crankshaft position sensor resistance therefore, make sure no flammable gas or
Out of specification → Replace the stator coil fluid is in the vicinity.
assembly.
Crankshaft position sensor resis-

tance
228–342 Ω
a. Connect the digital circuit tester to the

crankshaft position sensor coupler as
shown.

90890-03243
Model 88 Multimeter with ta- b. Check the starter motor operation.
chometer EAS30566
YU-A1927 CHECKING THE STATOR COIL
1. Disconnect:
• Positive tester probe → • Stator coil coupler
red “1” (from the wire harness)
2. Check:
white “2”
• Stator coil resistance
Out of specification → Replace the stator coil.
2 Stator coil resistance

0.360–0.540 Ω
W
a. Connect the digital circuit tester to the sta-
tor coil coupler as shown.
R
1 Digital circuit tester (CD732)

90890-03243
b. Measure the crankshaft position sensor chometer
resistance. YU-A1927
EAS30562
CHECKING THE STARTER MOTOR
white “1”
OPERATION • Negative tester probe →
1. Check: white “2”
• Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting with
step 4.
Refer to “TROUBLESHOOTING” on page
8-8.
a. Connect the positive battery terminal “1”
and starter motor lead “2” with a jumper
lead “3”.
8-134
2. Check:
• Fuel sender resistance
1 Out of specification → Replace the fuel pump
assembly.
W
Fuel sender
W
Sender unit resistance (full)
2 10.0–14.0 Ω
Sender unit resistance (empty)
267.0–273.0 Ω
b. Measure the stator coil resistance. a. Connect the digital circuit tester to the fuel
EAS30680 sender terminals as shown.
CHECKING THE RECTIFIER/REGULATOR
1. Check: Digital circuit tester (CD732)
• Charging voltage 90890-03243
Out of specification → Replace the rectifier/ Model 88 Multimeter with ta-
chometer
regulator.
YU-A1927
Charging voltage
14–15 V at 5000 r/min • Positive tester probe →
green “1”
a. Connect the digital circuit tester to the bat- • Negative tester probe →
black “2”
tery terminals as shown.

90890-03243
Model 88 Multimeter with ta- 2 1
chometer
YU-A1927 G B
Br/W B

positive battery terminal “1”
negative battery terminal “2”
b. Move the fuel sender float to minimum “3”
and maximum “4” level position.
2
4
1
b. Start the engine and let it run at approxi-

mately 5000 r/min.
c. Measure the fuel sender resistance.
c. Measure the charging voltage.
EAS31372
EAS30573
CHECKING THE FUEL METER
CHECKING THE FUEL SENDER
This model is equipped with a self-diagnosis de-
1. Remove:
vice for the fuel level detection circuit.
• Fuel pump
1. Check:
(from the fuel tank)
• Fuel meter “1”
(Turn the main switch to “ON”.)
8-135
Fuel meter comes on for a few seconds, then • Never subject the coolant temperature sen-
goes off → Fuel meter is OK. sor to strong shocks. If the coolant tem-
Fuel meter does not come on → Replace the perature sensor is dropped, replace it.
meter assembly. 2. Check:
Fuel meter flashes repeatedly → Replace the • Coolant temperature sensor resistance
fuel pump assembly. Out of specification → Replace.
Coolant temperature sensor re-

1 sistance
2513–2777 Ω at 20 °C (2513–
2777 Ω at 68 °F)
Coolant temperature sensor re-
sistance
210–221 Ω at 100 °C (210–221 Ω
at 212 °F)
a. Connect the digital circuit tester to the

EAS30577
coolant temperature sensor terminals as
CHECKING THE RADIATOR FAN MOTOR
shown.
1. Check:
• Radiator fan motor Digital circuit tester (CD732)
Faulty/rough movement → Replace. 90890-03243
a. Disconnect the radiator fan motor coupler Model 88 Multimeter with ta-
from the wire harness. chometer
b. Connect the battery (DC 12 V) as shown. YU-A1927
• Positive tester probe
blue “1” b. Immerse the coolant temperature sensor
• Negative tester probe “1” in a container filled with coolant “2”.
black “2” TIP
Make sure that the coolant temperature sensor
terminals do not get wet.
2 c. Place a thermometer “3” in the coolant.
B
3
1 L
1
c. Measure the radiator fan motor move- 2

ment.
EAS30578
CHECKING THE COOLANT TEMPERATURE d. Heat the coolant or let it cool down to the
SENSOR specified temperatures.
1. Remove: e. Measure the coolant temperature sensor
• Coolant temperature sensor resistance.
Refer to “CYLINDER HEAD” on page 5-13. 3. Install:
EWA14130
• Coolant temperature sensor
WARNING
• Handle the coolant temperature sensor Coolant temperature sensor
with special care. 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
8-136
EAS30681
CHECKING THE FUEL INJECTOR Digital circuit tester (CD732)

1. Check: 90890-03243
• Fuel injector resistance Model 88 Multimeter with ta-
Out of specification → Replace the fuel injec- chometer
tor. YU-A1927
Resistance • Positive tester probe →

12.2 Ω positive battery terminal “1”
a. Disconnect the fuel injector coupler from negative battery terminal “2”
fuel injector.
b. Connect the digital circuit tester to the fuel
injector terminals as shown.
Digital circuit tester (CD732) 1

90890-03243
Model 88 Multimeter with ta- 2
chometer
YU-A1927

Injector terminal “1” c. Measure the smart key battery voltage.
Injector terminal “2” EAS31555
CHECKING THE BUZZER

1. Check:
2 1 • Buzzer operation
Buzzer does not sound → Replace.
a. Disconnect the buzzer coupler from the
wire harness.
b. Connect the battery (12 V) to the buzzer
coupler as shown.
• Positive battery lead →
red “1”
• Negative battery lead →
c. Measure the fuel injector resistance. black “2”
EAS31553
CHECKING THE SMART KEY BATTERY 2 1

1. Check:
• Smart key battery voltage B R
Out of specification → Replace the smart key
battery.
Smart key battery voltage

2.7–3.2 V
a. Remove the smart key battery from the

smart key. c. Check that the buzzer sounds.
b. Connect the digital circuit tester to the EAS31257
smart key battery as shown. CHECKING THE MAIN SWITCH SOLENOID

1. Check:
• Main switch solenoid
a. Disconnect the main switch solenoid cou-
pler from the wire harness.
8-137
b. Connect the digital circuit tester to the

main switch solenoid as shown.

90890-03243
chometer
YU-A1927

red/white “1”
black “2”
1 2
R/W B
c. Check the main switch solenoid continuity.

d. If there is no continuity, replace the main
switch assembly.
8-138
8-139
TROUBLESHOOTING
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE............9-1

SELF-DIAGNOSTIC FUNCTION TABLE .................................................. 9-1
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ............................. 9-8
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ........................9-9
EVENT CODE TABLE...................................................................................9-11
9
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20116

EAS31118
SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-33.
Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P0106 Intake air pressure • Detached throttle Engine idling speed is Intake air pressure
sensor body sensor assem- high. difference is fixed to 0
(pipes and hoses sys- bly. Engine idling speed is [kPa].
tem) • Improperly installed unstable. Load is detected ac-
throttle body. Engine response is cording to the throttle
• Clogged intake air poor. opening.
pressure sensor Loss of engine power. Intake manifold pres-
hole. Increased exhaust sure is calculated us-
emissions. ing the throttle
position sensor.
Transient control ac-
cording to the intake
air pressure is not
carried out.
Intake air pressure is
fixed to 101.3 [kPa].
O2 feedback is not
carried out.
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure
P0108 pressure sensor of the intake air pres- high. difference is fixed to 0
(open or ground short sure sensor circuit Engine idling speed is [kPa].
circuit detected) (0.2 V or less) unstable. Load is detected ac-
[P0108] Intake air [P0108] High voltage Engine response is cording to the throttle
pressure sensor of the intake air pres- poor. opening.
(power short circuit sure sensor circuit Loss of engine power. Intake manifold pres-
detected) (4.9 V or more) Increased exhaust sure is calculated us-
(no normal signals are • Defective coupler emissions. ing the throttle
received from the in- between throttle position sensor.
take air pressure sen- body sensor assem- Transient control ac-
sor) bly and ECU. cording to the intake
• Open or short cir- air pressure is not
cuit in wire harness carried out.
between throttle Intake air pressure is
body sensor assem- fixed to 101.3 [kPa].
bly and ECU. O2 feedback is not
• Defective intake air carried out.
pressure sensor.
• Malfunction in ECU.
9-1

P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tem-
P0113 temperature sensor of the intake air tem- start. perature is fixed to 20
(ground short circuit perature sensor circuit Increased exhaust [°C].
detected) (0.2 V or less) emissions. O2 feedback is not
[P0113] Intake air [P0113] High voltage Engine idling speed is carried out.
temperature sensor of the intake air tem- unstable. ISC learning is not
(open or power short perature sensor circuit carried out.
circuit detected) (4.8 V or more)
(no normal signals are • Defective coupler
received from the in- between throttle
take air temperature body sensor assem-
sensor) bly and ECU.
• Open or short cir-
cuit in wire harness
between throttle
body sensor assem-
bly and ECU.
• Improperly installed
throttle body sensor
assembly.
• Defective intake air
temperature sensor.
P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to O2 feedback is not
P0118 perature sensor of the coolant tem- start. carried out.
(ground short circuit perature sensor circuit Increased exhaust ISC learning is not
detected) (0.1 V or less) emissions. carried out.
[P0118] Coolant tem- [P0118] High voltage Engine idling speed is Coolant temperature
perature sensor (open of the coolant tem- unstable. is fixed to 30 [°C]
or power short circuit perature sensor circuit when the main switch
detected) (4.8 V or more) is turned to “ON” and
(no normal signals are • Defective coupler 80 [°C] when the vehi-
received from the between coolant cle is traveling.
coolant temperature temperature sensor
sensor) and ECU.
between coolant
temperature sensor
and ECU.
coolant temperature
sensor.
• Defective coolant
temperature sensor.
9-2

P0122 [P0122] Throttle posi- [P0122] Low voltage Engine idling speed is Change in the throttle
P0123 tion sensor (open or of the throttle position high. opening is 0 (transient
ground short circuit sensor circuit (0.2 V Engine idling speed is control is not carried
detected) or less) unstable. out).
[P0123] Throttle posi- [P0123] High voltage Engine response is Throttle opening is
tion sensor (power of the throttle position poor. fixed to 15 [°].
short circuit detected) sensor circuit (4.8 V Loss of engine power. Intake air pressure is
(no normal signals are or more) Deceleration is poor. fixed to 101.3 [kPa].
received from the • Defective coupler Increased exhaust Fuel is not cut off due
throttle position sen- between throttle emissions. to the throttle open-
sor) body sensor assem- ing.
bly and ECU. O2 feedback is not
• Open or short cir- carried out.
between throttle
body sensor assem-
bly and ECU.
throttle body sensor
assembly.
• Defective throttle po-
sition sensor.
P0132 O2 sensor (power • High voltage of the Increased exhaust O2 feedback is not
short circuit detected) O2 sensor circuit emissions. carried out.
(no normal signals are (4.8 V or more)
received from the O2 • Improperly installed
sensor) O2 sensor.
• Defective coupler
between O2 sensor
and ECU.
• Power short circuit
in wire harness be-
tween O2 sensor
and ECU.
• Defective O2 sensor.
P0201 Fuel injector • Defective coupler Loss of engine power. When engine is run-
(no normal signals are between fuel injector Engine is difficult to ning: Engine is force-
received from the fuel and ECU. start. fully stopped.
injector circuit) • Open or short cir- Engine cannot be When engine is
cuit in wire harness started. stopped: Engine can-
between fuel injector Engine stops. not be started.
and ECU. Injection is not car-
• Defective fuel injec- ried out.
tor.
fuel injector.
9-3

P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor between crankshaft started.
(no normal signals are position sensor and
received from the ECU.
crankshaft position • Open or short cir-
sensor) cuit in wire harness
between crankshaft
position sensor and
ECU.
crankshaft position
sensor.
• Defective stator coil.
• Defective crank-
shaft position sen-
sor.
P0351 Ignition system • Defective coupler Engine stops. When engine is run-
(no normal signals are between ignition coil Loss of engine power. ning: Engine is force-
received from the igni- and ECU. Engine is difficult to fully stopped.
tion circuit) • Open or short cir- start. When engine is
cuit in wire harness Engine cannot be stopped: Engine can-
between ignition coil started. not be started.
and ECU. Injection is not car-
• Improperly installed ried out.
ignition coil.
• Defective ignition
coil.
P0480 Radiator fan motor re- • Open circuit in wire Engine is difficult to —
lay harness between ra- start.
(open circuit detect- diator fan motor re- Loss of engine power.
ed) lay and ECU. Engine overheats.
(no normal signals are • Defective coupler Increased exhaust
received from the ra- between radiator fan emissions.
diator fan motor relay) motor relay and
ECU.
• Defective driver.
• Open circuit in radi-
ator fan motor relay.
P0500 Front wheel sensor • Open or short cir- Vehicle speed is not O2 feedback is not
(no normal signals are cuit in wire harness displayed on the me- carried out.
received from the between front wheel ter. ISC feedback is not
front wheel sensor) sensor and ABS Engine stalls when carried out.
unit. the vehicle is deceler- ISC learning is not
• Open or short cir- ating to a stop. carried out.
cuit in wire harness Engine idling speed is
between ABS unit high.
and ECU. Engine idling speed is
• Defective front unstable.
wheel sensor. Increased exhaust
• Malfunction in ABS emissions.
unit.
9-4

P0507 ISC valve • Defective front Engine idling speed is Idle speed control is
(stuck fully open) wheel sensor. high. not carried out.
between ISC and
ECU.
between front wheel
sensor and ABS
unit.
between ABS unit
and ECU.
between ISC and
ECU.
between front wheel
sensor and ABS
unit.
between ABS unit
and ECU.
ISC and front wheel
sensor.
• Disconnected hose
or air leak from in-
take air passage.
• Defective throttle
valve or throttle ca-
ble.
• Defective ISC unit
(ISC valve stuck ful-
ly open).
P0511 ISC (Idle Speed Con- • Defective coupler Engine is difficult to Power is not supplied
trol) unit between ISC and start. to the ISC unit.
(ISC unit does not op- ECU. Engine idling speed is
erate) • Open or short cir- unstable.
cuit in wire harness Engine idling speed is
between ISC and high.
ECU.
• Defective ISC step-
ping motor.
9-5

P0560 Charging voltage is • Battery overcharg- Engine is difficult to O2 feedback is not
abnormal. ing (defective rectifi- start. carried out.
er/regulator). Increased exhaust ISC learning is not
• Battery overcharg- emissions. carried out.
ing (broken or dis- Battery performance
connected rectifier/ has deteriorated or
regulator lead). battery is defective.
• Battery over-dis-
charging (broken or
disconnected lead in
charging system).
• Battery over-dis-
charging (defective
rectifier/regulator).
P0601 Faulty ECU memory. • Malfunction in ECU. Engine cannot be Engine cannot be
(ROM data error) started. started.
Ignition and injection
are not carried out.
Judgment for other
fault codes is not car-
ried out.
Writing to EEPROM is
not carried out.
P062F EEPROM writing error • ISC learning value is Increased exhaust ISC learning values =
not properly written. emissions. Default values
• O2 feedback learn- Engine cannot be O2 feedback learning
ing value is not started or is difficult to value is initialized.
properly written. start. CO adjustment value
• CO adjustment val- Engine idling speed is is initialized.
ue is not properly unstable. OBD memory value is
written. OBD memory value is initialized.
• OBD memory value not correct. Tire diameter learn-
is not properly writ- Traction control sys- ing values = Default
ten. tem does not operate values
• Malfunction in ECU. properly.
• Tire diameter learn-
ing values are not
properly written.
P0657 Fuel system voltage • Open or short cir- Engine is difficult to Monitor voltage = 12
(incorrect voltage sup- cuit in wire harness start. [V]
plied to the fuel injec- between main Increased exhaust O2 feedback is not
tor and fuel pump) switch and ECU. emissions. carried out.
• Open circuit in wire
harness between
battery and ECU.
P1601 Sidestand switch • Defective coupler Engine cannot be Engine is forcefully
(open or short circuit between sidestand started. stopped.
detected) switch and ECU.
(no normal signals are • Open or short cir-
received from the cuit in wire harness
sidestand switch) between sidestand
switch and ECU.
• Defective sidestand
switch.
9-6

P1604 [P1604] Lean angle [P1604] Low voltage Engine cannot be When engine is run-
P1605 sensor (ground short of the lean angle sen- started. ning: Engine is force-
circuit detected) sor circuit (0.2 V or Engine stops. fully stopped.
[P1605] Lean angle less) When engine is
sensor (open or pow- [P1605] High voltage stopped: Engine can-
er short circuit detect- of the lean angle sen- not be started.
ed) sor circuit (4.8 V or
more)
• Defective connec-
tion of lean angle
sensor coupler.
• Defective connec-
tion of ECU coupler.
between lean angle
sensor and ECU.
• Defective lean an-
gle sensor.
P2158 Rear wheel sensor • Open or short cir- Traction control sys- Traction control sys-
(no normal signals are cuit in wire harness tem does not operate. tem does not operate.
received from the rear between rear wheel Traction control sys-
wheel sensor) sensor and ABS tem indicator light on
unit. the multi-function me-
• Open or short cir- ter comes on.
cuit in wire harness “TCS” indicator light
between ABS unit on the multi-function
and ECU. meter cannot be used
• Defective rear wheel (the traction control
sensor. system is turned off).
• Defective ABS unit.
P2195 O2 sensor (open cir- • Signal voltage is Increased exhaust O2 feedback is not
cuit detected) (no nor- 0.25–0.53 V. emissions. carried out.
mal signals are • Improperly installed
received from the O2 O2 sensor.
sensor) • Defective coupler
between O2 sensor
and ECU.
between O2 sensor
and ECU.
• Defective O2 sensor.
9-7
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 97–107 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 “ ” side of the
start/engine stop 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 tool 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 tool display value.
When engine is hot: Displays
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.
08 Lean angle sensor Lean angle sensor output Remove the lean angle sen-
• Upright voltage sor and incline it more than
• Overturned 0.4–1.4 50 degrees.
3.7–4.4
09 Fuel system voltage Approximately 12.0 Compare the actually mea-
(battery voltage) sured battery voltage with
the tool display value. (If the
actually measured battery
voltage is low, recharge the
battery.)
20 Sidestand switch Extend and retract the side-
stand.
• Stand retracted ON
• Stand extended OFF
9-8
Diagnostic
Item Tool display Procedure
code No.
60 EEPROM fault code display
• No history 00 —
• No malfunctions detected
(If the self-diagnosis fault
code P062F is indicated,
the ECU is defective.)
• History exists 01 (CO adjustment value) —
Display the EEPROM writ- 11 (Data error for ISC (Idle
ing error for fault code No. Speed Control) learning val-
P062F. ues)
If more than one item is de- 12 (O2 feedback learning val-
fective, the displays alter- ue)
nates every two seconds to 14 (Tire diameter learning
show all the detected num- values)
bers.
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 the Yamaha diagnostic tool
learning data erasure erased. “Actuator Check” button
01 three times in 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 [-] —
87 A/F control learning data era- 00 To erase the ECU learning
sure ECU learning data has been data, click the Yamaha diag-
erased. nostic tool “Actuator Check”
01 button three times in 5 sec-
ECU learning data has not onds.
been erased.
EAS31121
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the 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 on the er.
Yamaha diagnostic tool
screen come on each time
the ignition coil is actuated.
36 Fuel injector Actuates the injector five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that injector is actuat-
The “check” indicator on the ed five times by listening for
Yamaha diagnostic tool the operating sound.
the fuel injector is actuated.
9-9
Diagnostic
Item Actuation Procedure
code No.
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
second intervals. times by listening for the op-
The “check” indicator on the erating sound.
screen comes on each time
the relay is actuated.
52 Headlight Actuates the headlight five Check that the headlight is
times at five-second inter- on five times.
vals.
The “check” indicator on the
the relay is actuated.
54 ISC (Idle Speed Control) unit Actuates and fully closes the The ISC unit vibrates when
ISC valve, then opens it to the ISC valve operates.
the standby opening position.
This operation takes approxi-
mately 3 seconds until it is
completed.
The “check” indicator on the
screen come on.
9-10
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 P0107 and maintenance jobs for
sure sensor P0108 fault code number
P0107 and P0108.
193 Throttle position sensor Brief abnormality de- Same as for fault code Perform the checks and
tected in throttle posi- number P0122 and maintenance jobs for
tion sensor P0123 fault code number
P0122 and P0123.
196 Coolant temperature Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in coolant tem- number P0117 and maintenance jobs for
perature sensor P0118 fault code number
P0117 and P0118.
197 Intake air temperature Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in intake air tem- number P0112 and maintenance jobs for
perature sensor P0113 fault code number
P0112 and P0113.
203 Lean angle sensor Brief abnormality de- Same as for fault code Perform the checks and
tected in lean angle number P1604 and maintenance jobs for
sensor P1605 fault code number
P1604 and P1605.
218 Crankshaft position Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in crankshaft po- number P0335 maintenance jobs for
sition sensor fault code number
P0335.
240 O2 sensor Correction value re- • Open or short circuit • If a fault code is indi-
(Correction value remains 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 remains at lower limit in the wire harness cated, perform the
mains at lower 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 241 may be indicated
• Sensor malfunction even if the system is
• Defective fuel injec-
tion system
9-11
EVENT CODE TABLE
No. Item Symptom Possible cause Remarks

242 ISC (idle speed control) Correction value re- Low engine idling • Execute the diagnos-
(Correction value remains 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.
243 ISC (idle speed control) Correction value re- High engine idling • If a fault code is indi-
(Correction value remains 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 difficult/ • Empty fuel tank • If a fault code is indi-
engine unable condition detect- • Defective fuel injec- cated, perform the
ed 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
9-12
EAS20091
57. Joint connector EAS30613
WIRING DIAGRAM 58. ABS test coupler COLOR CODE

CZD300-A/CZD300-AH 2017 59. ABS ECU B Black
1. Crankshaft position sensor 60. License plate light Br Brown
2. AC magneto 61. Tail/brake light assembly (right) Ch Chocolate
3. Rectifier/regulator 62. Rear turn signal light (right) Dg Dark green
4. Request switch 63. Tail/brake light (right) G Green
5. Main switch solenoid 64. Tail/brake light assembly (left) Gy Gray
65. Rear turn signal light (left) L Blue
6. Main switch
66. Tail/brake light (left) O Orange
7. Smart key unit
P Pink
8. Buzzer 67. Frame ground
R Red
9. Radiator fan motor fuse 68. Turn signal/hazard relay
Sb Sky blue
10. Backup fuse 69. Horn
W White
11. Main fuse 70. Handlebar switch (left) Y Yellow
12. ABS control unit fuse 71. Dimmer switch B/L Black/Blue
13. Signaling system fuse 72. Horn switch B/W Black/White
14. Signaling system fuse 2 73. Turn signal switch Br/L Brown/Blue
15. Grip warmer coupler 74. Rear brake light switch Br/R Brown/Red
16. Diode 1 75. Front turn signal light (right) Br/W Brown/White
17. Answer back fuse 76. Front turn signal light (left) G/B Green/Black
18. Terminal fuse 77. Headlight assembly G/R Green/Red
19. Turn signal light and hazard 78. Headlight (low beam) G/W Green/White
fuse 79. Headlight (high beam) G/Y Green/Yellow
20. ABS solenoid fuse 80. Auxiliary light Gy/R Gray/Red
21. ABS motor fuse 81. Meter assembly L/B Blue/Black
22. Battery 82. Smart key indicator light L/G Blue/Green
23. Auxiliary DC jack 83. Multi-function meter L/R Blue/Red
24. Main fuse 2 84. Traction control system indica- L/W Blue/White
25. Starter relay tor light L/Y Blue/Yellow
26. Starter motor 85. ABS warning light O/B Orange/Black
86. Engine trouble warning light P/W Pink/White
27. Diode 2
87. Meter light R/B Red/Black
28. Diode 3
R/G Red/Green
29. Starting circuit cut-off relay 88. Turn signal indicator light (right)
R/L Red/Blue
30. Sidestand switch 89. Turn signal indicator light (left)
R/W Red/White
31. Handlebar switch (right) 90. High beam indicator light
R/Y Red/Yellow
32. Start/engine stop switch 91. Air temperature sensor W/B White/Black
33. Hazard switch 92. Storage box light W/L White/Blue
34. “TRIP/INFO” switch W/R White/Red
35. Front brake light switch W/Y White/Yellow
36. Coolant temperature sensor Y/B Yellow/Black
37. Throttle body sensor assembly Y/G Yellow/Green
38. Throttle position sensor Y/L Yellow/Blue
39. Intake air pressure sensor Y/W Yellow/White
41. O2 sensor
44. ECU (Engine Control Unit)
45. Ignition coil
46. Spark plug
47. Fuel injector
48. Fuel sender
49. Fuel pump
50. Fuel pump relay
51. ISC (Idle Speed Control) unit
52. Radiator fan motor relay
53. Radiator fan motor
54. Engine ground
CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
R W/R
B/L W W B/L
W/R R
1 B
W
R
W
W W B
W W 2 W W 3 R
W W R
R/B
B G/W B G R/B R/B
R Br/L
(B) R/B
R R
R/B 16 Br/R
R
G/Y R/W
R/B
R/W
R/W
L B R/W B
6 Br/R Br/L R L/W G/Y
R R
27 L/W
R/W R/W
(B) ON 24 (R)
G/Y L/W R/W
G/Y
4 5 OPEN
OFF
R/Y
Br/LBr/L
R R/L
R
G/Y G/Y P L L R/W W Br/R B/L O/B B/L Y/B B/W
G/Y G/Y G/Y Sb Gy L/Y G/R Y Y/G L/R B/L W/Y
LOCK
P
Br/L R/Y
Br/R
R/Y Br/L
Br/R
25 L/W
R/W
L/B Y/L B/W P/W Br/WGy/R R/B B/L W/R B W/B O
L R/W L/W Br/W R/W
L/W (B)
G/W B G B R/Y Br/R
17 18 19 20 21 B
Br/W
28 Br/W
Br/L
9 L/W R/W R/W
R/W
R/L
Br/L Br/R R
29 L/W W/R
B/L 45 O/B R/W
10 R/Y
R/Y B B
Br/W L/G,L/Y R/B O O (B)
R/B R
L/Y G/R B/L
36
G/R G/R 46
R/Y L/R R/G L/Y B Ch
R/B
11
L/W
L/G
L/Y L/Y L/Y
(B) B/L B/L 47
O/B O/B R/W
R/B G/W G/B R/W G Dg Br/R Br/R
Br/R Br/R L/G B B 37 38 39 40
(B) 12 R
R P/W P/W G B
Br/W 30 B L/G Br/W Br/W
L/B Br/W B
G R/B
13
B B B/L Y L P/W Br/W B/L
Y
B/L
Y 48
G/W L/Y
R/W R/W
Br/R
Br/R
31 L/W
(B) (B) (B)
L L
G B
R/W
14 22 B
49 Br/W B
R
Br/R Y/W Y/W R 32 33 34 35 L/W L/W
Gy/R B
B Gy/R Gy/R
(B)
Dg Ch Ch Dg (B) (B)
41 Br/W R/B
R/Y BBB
26 P/W R/B R/B P
INFO B G/Y G/Y B L/Y 44 L/B R/W
(B) (B)
Dg B R P L L
7
Ch
R/B R/B B Dg Ch Y/W P/W R/W G/Y
B/L Y/G L 42 Y/G
B/L
Y/G
B/L P P 50 Br/W
B
R/G R/G B 8 R R/B
R/B
R/B Br/R
Br/R
Br/R Br/W (B)
Br/R
G/Y
Gy
G/Y
Gy 51 P G/Y Sb Gy L/B
R/B
R/W
Br/R Sb Sb
B R B
B R/G Br/L Br 23 R/B Y/L Y/L (B)
R R/B R
B 15 Br Br/L
B B R/B
B B 43 Y/L
W/Y W/Y
L
R/W
R/L
L/R L/R L/R L/R
G/B
B
L/R Y/B
L
52 R/L
L
Br/R W/B
Br/R Br/R R/W W/Y
Br/R W B B
Br/R
53 L L
R/W (B) (B)
R/W R/W
R/W Br/R R/W B B/W B/W B
R/W
Br/W
Br/R
68
69 (B)
Br/W B/W B/W
Br/W Br/W
Br/W
P
70 Br/R P Br/W R/W
54
71 Br
72 73
Y Y
Br/W P P Br/W
Ch Dg
Br/R R/W R/W Br PASS 74 Dg Ch
B G/Y G/Y B
(B) (B) (R) (R)
R/Y
G/Y
G/Y
G/Y G/Y G/Y
Y B Ch Dg
B 92 G/Y
Br/R
Br/R
Br/R B B/W
Br/R Br/R B B
Dg Dg
L
60
Dg Dg Dg Dg
Ch Ch Dg Dg
B
B
Ch
Ch
Ch Ch
Ch
Ch
L
B
G/Y G/Y
G/BBr/R B B R/B Ch Br/R 64 Dg Br/R 61 B
R/B P/W Br/R W/LG/B L/R B/L G Y/W P/W Dg Ch Y Br/R Ch Dg Br/R W
81 G/B Y/W L/R (Gy) Dg Ch G/B 77 L/R L/R B W/B (B)
G/B
78 76 B
75 B
79 65 66 62 63 Y/B
R/L
R
82 B
B
B B Y/B
B/W
Br/W
90 Y Br/R
B B B Dg Dg B G G B
83 84 85 86 87 88 89
B
(G) Ch Ch G/Y 55 W B G L
B Y/B
G/B
80 B B
Br/R L/R
L/R Br/R L L W
B B (B) (B)
Ch Dg B B Br Br B
B/L G B B W/L
Y/B B
(G)
B
B 59 Y Y W 56 W B Br Y
B/L
W/L 57
B
B/W B/W B/W
B B
91 B B
(B)
B B/L
(B)
B B B
R/B
B B B B B B
L/B L/B B
B B L/R L/R
B
58 L/R L/B
R/B B
B B B B B
B B B B B
67 67 67 67 67
CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017 CZD300-A/CZD300-AH 2017
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
1
2 3
(B)
16
6 27
(B) ON 24 (R)
4 5 OPEN
OFF
LOCK
P 25
(B)
17 18 19 20 21 28
9
29 45
10 (B)
36 46
11 (B) 47
37 38 39 40
(B) 12
30
13 48
31 (B) (B) (B)
14 22 49
32 33 34 35 (B)
TRIP
(B) (B)
41
26 INFO 44
(B) (B)
7 42 50
8 (B)
51
23 (B)
15
43
52
53
(B) (B)
68
69 (B)
70
54
71 72 73
PASS 74
(B) (B) (R) (R)
92
60
54 54
64 61
81 (Gy) 77 (B)
78 76 75
79 65 66 62 63
82
90
83 84 85 86 87 88 89 (G) 55
80
(B) (B)
(G) 59 56
57
91 (B) (B)
58
67 67 67 67 67

Service Manual: X-MAX 300 Evolis 300

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Service Manual: X-MAX 300 Evolis 300

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2017

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could result

A NOTICE indicates special precautions that must be taken to avoid damage to

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

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

SPECIAL TOOLS ............................................................................................ 1-8

VEHICLE IDENTIFICATION NUMBER

WARNING The clock uses a 24-hour time system.

Odo → Trip → Trip Time → Oil Trip → V-Belt

Time tripmeter “Time” Oil change tripmeter “Oil Trip”

1. Time tripmeter 1. Oil change indicator “Oil”

F Trip → Oil Trip → V-Belt Trip → Odo → Trip → 1

1 Air-temp → Battery → TCS ON or TCSOFF →

Navigating the information display

Air temperature display Traction control system mode display

1. Air temperature display 1. Traction control system mode display

Battery voltage display 1

1. Average fuel consumption display

TIP The average speed “Average_ _ _kmh” or “Av-

Warning message function

1. Average speed display

Yamaha diagnostic tool (A/I) 3-4, 3-7, 3-8,

Steering nut wrench 3-16, 4-89

Thickness gauge 4-32, 4-36

T-handle 4-82, 4-84

Fork seal driver weight 4-85, 4-85, 4-85

Fork seal driver attachment (ø33) 4-85, 4-85

Camshaft sprocket stopper 5-17, 5-20

Yamaha bond No. 1215 5-20, 5-51, 5-63

Valve spring compressor 5-27, 5-31

Valve spring compressor attachment 5-27, 5-31

Valve guide remover (ø5) 5-28

Valve guide installer (ø5) 5-28

Valve guide reamer (ø5) 5-28

Rotor holding tool 5-40, 5-45

Rotor holding tool 5-40, 5-40, 5-44,

Locknut wrench 5-40, 5-44

Sheave spring compressor 5-40, 5-43

Oil seal guide (40mm) 5-43

Rotor puller bolt M14 X L80 5-49

Digital circuit tester (CD732) 5-54, 8-128,

Radiator cap tester adapter 31mm 6-4, 6-5

Mechanical seal installer 6-10

Middle driven shaft bearing driver 6-10

Pressure gauge 7-7

Fuel pressure adapter 7-7

OBD/ GST Leadwire kit 8-34