Service Manual: YZF155D-A YZF155-A

BCWF8197E0.
book Page 1 Thursday, November 18, 2021 9:18 AM
2022
SERVICE MANUAL
YZF155D-A
YZF155-A
BCW-F8197-E0
BCWF8197E0.book Page 1 Thursday, November 18, 2021 9:18 AM
EAS200071
IMPORTANT
This manual was produced by the India Yamaha Motor Pvt. Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
India Yamaha Motor Pvt. Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EAS20081
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.
EAS00000
YZF155D-A & YZF155-A

SERVICE MANUAL
©2022 by India Yamaha Motor Pvt. Ltd.
First edition, September 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
India Yamaha Motor Pvt. 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.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
3
7
4
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 Molybdenum disulfide oil

M
Filling fluid Brake fluid

BF
Lubricant B Wheel bearing grease
Special tool LS Lithium-soap-based grease
Tightening torque M Molybdenum disulfide grease

T.
R.
Wear limit, clearance S Silicone grease
Engine speed Apply locking agent (LOCTITE®).

LT
Electrical data New Replace the part with a new one.
Engine oil
E
EAS10003
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9
GENERAL INFORMATION
IDENTIFICATION ...........................................................................................1-1
VEHICLE IDENTIFICATION NUMBER ....................................................1-1
ENGINE SERIAL NUMBER .....................................................................1-1
FEATURES .....................................................................................................1-2
1
OUTLINE OF THE TCS (Traction Control System) ..................................1-2
OUTLINE OF THE FI SYSTEM ................................................................1-6
FEATURES ..............................................................................................1-7
OUTLINE OF THE ABS ............................................................................1-8
ABS COMPONENT FUNCTIONS .......................................................... 1-12
ABS OPERATION .................................................................................. 1-18
ABS WARNING LIGHT AND OPERATION ............................................ 1-21
CCU (Communication Control Unit) ....................................................... 1-22
HANDLEBAR SWITCHES ...................................................................... 1-23
INDICATOR LIGHTS AND WARNING LIGHTS ..................................... 1-24
DISPLAY ................................................................................................ 1-25
MENU MODE ......................................................................................... 1-31
IMPORTANT INFORMATION ...................................................................... 1-34

PREPARATION FOR REMOVAL AND DISASSEMBLY ........................ 1-34
REPLACEMENT PARTS ........................................................................ 1-34
GASKETS, OIL SEALS AND O-RINGS ................................................. 1-34
LOCK WASHERS/PLATES AND COTTER PINS .................................. 1-34
BEARINGS AND OIL SEALS ................................................................. 1-35
CIRCLIPS ............................................................................................... 1-35
RUBBER PARTS .................................................................................... 1-35
BASIC SERVICE INFORMATION ................................................................ 1-36

QUICK FASTENERS .............................................................................. 1-36
ELECTRICAL SYSTEM .......................................................................... 1-37
SPECIAL TOOLS ......................................................................................... 1-42

GEN
IDENTIFICATION INFO
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the steering head pipe.
XXX
XXX
XX
EAS30004
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
crankcase.
1-1
GEN
FEATURES INFO
EAS20008
FEATURES
EAS30855
OUTLINE OF THE TCS (Traction Control System)

The traction control system controls excessive spinning (slipping) of the rear wheel when accelerating
on slippery surfaces, such as unpaved or wet roads.
The ECU monitors the front and rear wheel speeds using the signals from the front and rear wheel sen-
sors, and detects rear wheel slipping according to the difference between the wheel speeds. If the slip-
ping exceeds the preset value, the ECU controls the slipping using integrated control of the ignition
timing and fuel cut-off.
The traction control system can be set to “ON” operation modes or turned “OFF”.
TCS (Traction control system) layout
1. Traction control system indicator light

2. Trip / information switch (To “ON” or “OFF”
TCS mode)
3. ABS ECU
4. ECU (Engine Control Unit)
5. Rear wheel sensor
6. Fuel injector
7. Spark plug
8. Front wheel sensor
9. Ignition coil
1-2
GEN
FEATURES INFO
TCS (Traction control system) block diagram
The signals from the front and rear wheel sensors are sent to the ECU through the ABS ECU, and the
ECU calculates the amount of slip according to the difference between the detected front and rear
wheel speeds.
If the amount of slip exceeds the preset value, the ECU controls the ignition timing and fuel cut-off so
that the amount of slip is less than the preset value. The traction control system indicator light in the
meter assembly flashes when the traction control system has activated.
3 E
1 A
B C F
D
2 A
G

3. ABS ECU
TCS mode)
5. ECU
A. Signal conversion
B. Slip amount calculation
C. Exceeds preset value
D. Actuator control
E. Fuel cut-off
F. Ignition timing (retarded)
G. Traction control system indicator light
(flashes)
1-3
GEN
FEATURES INFO
Traction control system
The traction control system (TCS) helps maintain traction when accelerating on slippery surfaces, such
as unpaved or wet roads. If sensors detect that the rear wheel is starting to slip (uncontrolled spinning),
the traction control system assists by regulating engine power as needed until traction is restored.
EWA15433
WARNING
The traction control system is not a substitute for riding appropriately for the conditions. Trac-
tion control cannot prevent loss of traction due to excessive speed when entering turns, when
accelerating hard at a sharp lean angle, or while braking, and cannot prevent front wheel slip-
ping. As with any vehicle, approach surfaces that may be slippery with caution and avoid espe-
cially slippery surfaces.
Setting the traction control system
When the key is turned to “ON”, traction control is turned on automatically.
The “ ” indicator light flashes when traction control has engaged. You may notice slight changes in
engine and exhaust sounds when the system has engaged.
When the traction control system has been set to “OFF”, the “ ” indicator light will come on.
TCS “OFF”
TCS “OFF” turns the traction control system off.
TCS “ON”
TCS “ON” turns the traction control system on.
ECA19650
NOTICE
Use only the specified tires. Using different sized tires will prevent the traction control system
from controlling tire rotation accurately.
TIP
• The current TCS setting is shown in the TCS display.
• Traction control can be turned on or off only when the vehicle is stopped.
• When the key is turned to “ON”, traction control is turned on.
• Turn the traction control system off to help free the rear wheel if the vehicle gets stuck in mud, sand,
or other soft surfaces.
• When the vehicle is on the centerstand, do not rev the engine for an extended period of time. Other-
wise, the traction control system will automatically disable and need to be reset.
3
TCS mode)
2. TCS display
3. “TCS” indicator light
• In normal operation, “ ” indicator light flashes when traction control has engaged.
• When the traction control system has been turned off, “ ” indication light will come on.
• If the traction control system becomes disabled while riding, “ ” indicator light and the engine trouble
warning light will come on.
1-4
GEN
FEATURES INFO
Resetting the traction control system
The traction control system will automatically disable when:
• the front wheel or rear wheel comes off the ground while riding.
• excessive rear wheel spin is detected while riding.
• either wheel is rotated with the key turned to “ON” (such as when performing maintenance).
• When a sensor fault is detected, or when only one wheel is allowed to rotate for more than a few sec-
onds. Should this happen, the “ ” indicator light will come on.
If the traction control system is disabled, both the “ ” indicator light and the “ ” warning light will come
on.
Should this occur, try resetting the system as follows.
1. Stop the vehicle and turn the key to “OFF”.
2. Wait a few seconds and then turn key back to “ON”.
3. The “ ” indicator light should turn off and the system be enabled.
4. Check the vehicle and turn off the “ ” warning light.
TIP
If the “ ” indicator light or the “ ” warning light remains on after resetting, the vehicle may still be
ridden. Check the fuel injection system (Refer to “FUEL INJECTION SYSTEM” on page 8-28).
Quick shift system

The quick shift system (QS) allows for full-throttle, clutch lever-less, electronically-assisted upshifts.
When the quick shift switch detects motion in the shift pedal, engine power and drive torque are mo-
mentarily adjusted to allow the upshift to occur.
TIP
• The quick shift system operates when traveling at least 20 km/h (12 mi/h) with an engine speed of
2000 r/min or higher, and only when accelerating.
• It does not operate when the clutch lever is pulled.
1-5
GEN
FEATURES INFO
OUTLINE OF THE FI SYSTEM
The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1. Engine trouble warning light

2. Ignition coil
3. Spark plug
4. Fuel pump
5. FID (fast idle solenoid)
6. Throttle body sensor assembly (consisting of
throttle position sensor, intake air pressure
sensor, intake air temperature sensor)
7. ECU (engine control unit)
8. Lean angle sensor
9. Crankshaft position sensor
10.Fuel injector
11.Coolant temperature sensor
12.O2 sensor
13.Radiator fan motor
1-6
GEN
FEATURES INFO
FEATURES
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 250 kPa (2.50 kg/cm², 36.3 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. There-
fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol-
ume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature
sensor, lean angle sensor, coolant temperature sensor and O2 sensor enable the ECU to determine
the injection duration. The injection timing is determined through the signals from the crankshaft posi-
tion sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times in
accordance with the driving conditions.
5 6
2
4
1 3
9
10
12 13 7
14
15
11
1. Fuel pump 11.Throttle body

2. Fuel injector 12.Throttle body sensor assembly
3. Ignition coil 13.Intake air temperature sensor
4. Coolant temperature sensor 14.Throttle position sensor
5. ECU (engine control unit) 15.Intake air pressure sensor
7. O2 sensor A. Fuel system
8. Crankshaft position sensor B. Air system
9. FID (fast idle solenoid) C. Control system
10.Air filter case
1-7
GEN
FEATURES INFO
EAS30683
OUTLINE OF THE ABS

1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the
front and rear brakes independently.
2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of
the vehicle.
ABS layout
1. Yamaha diagnostic tool coupler/ ABS test

coupler
2. ABS control unit fuse
3. ABS solenoid fuse
4. ABS motor fuse
5. ABS warning light
6. Front wheel sensor rotor
8. Hydraulic unit assembly
9. Rear wheel sensor rotor
1-8
GEN
FEATURES INFO
ABS
The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with
a brake lever for operating the front brake and a brake pedal for operating the rear brake.
When wheel lock is detected during braking, hydraulic control is performed by the hydraulic system on
the front and rear brakes independently.
Useful terms
• Wheel speed:
The rotation speed of the front and rear wheels.
• Chassis speed:
The speed of the chassis.
When the brakes are applied, wheel speed and chassis speed are reduced. However, the chassis
travels forward by its inertia even though the wheel speed is reduced.
• Brake force:
The force applied by braking to reduce the wheel speed.
• Wheel lock:
A condition that occurs when the rotation of one or both of the wheels has stopped, but the vehicle
continues to travel.
• Side force:
The force on the tires which supports the vehicle when cornering.
• Slip ratio:
When the brakes are applied, slipping occurs between the tires and the road surface. This causes a
difference between the wheel speed and the chassis speed.
Slip ratio is the value that shows the rate of wheel slippage and is defined by the following formula.
Slip ratio = (Chassis speed – Wheel speed)/Chassis speed × 100 (%)
0%: There is no slipping between the wheel and the road surface. The chassis speed is equal to the
wheel speed.
100%: The wheel speed is “0”, but the chassis is moving (i.e., wheel lock).
Brake force and vehicle stability

When the brake pressure is increased, wheel speed is reduced. Slipping occurs between the tire and
the road surface and brake force is generated. The limit of this brake force is determined by the friction
force between the tire and the road surface and is closely related to wheel slippage. Wheel slippage is
represented by the slip ratio.
Side force is also closely related to wheel slippage. See figure “A”. If the brakes are applied while keep-
ing the proper slip ratio, it is possible to obtain the maximum brake force without losing much side force.
ABS allows full use of the tires’ capabilities even on slippery road surfaces or less slippery road surfac-
es. See figure “B”.
A B
b e
f
a a
c
g
(%) d (%) d
a. Friction force between the tire and road e. Less slippery road surface
surface f. Controlling zone
b. Brake force g. Slippery road surface
c. Side force
d. Slip ratio
1-9
GEN
FEATURES INFO
Wheel slip and hydraulic control
The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from
the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and
the rate of speed reduction based on the wheel speed values.
The difference between the chassis speed and the wheel speed calculated in the slip ratio formula is
equal to the wheel slip. When the wheel speed is suddenly reduced, the wheel has a tendency to lock.
When the wheel slip and the wheel speed reduction rate exceed the preset values, the ABS ECU de-
termines that the wheel has a tendency to lock.
If the slip is large and the wheel has a tendency to lock (point “A” in the following figure), the ABS ECU
reduces the hydraulic pressure in the brake caliper. Once the ABS ECU determines that the tendency
of the wheel to lock has diminished after the hydraulic pressure is reduced, it increases the hydraulic
pressure (point “B” in the following figure). The hydraulic pressure is initially increased quickly, and then
it is increased gradually.
b A
A
B
B A
B
A
c A
A
B B B
d e d e d e
a. Chassis speed d. Depressurizing phase

b. Wheel speed e. Pressurizing phase
c. Brake force
ABS operation and vehicle control

If the ABS starts operating, there is a tendency of the wheel to lock, and the vehicle is approaching the
limit of control. To make the rider aware of this condition, the ABS has been designed to generate a
reaction-force pulsating action in the brake lever and brake pedal independently.
TIP
When the ABS is activated, a pulsating action may be felt at the brake lever or brake pedal, but this
does not indicate a malfunction.
The higher the side force on a tire, the less traction there is available for braking. This is true whether
the vehicle is equipped with ABS or not. Therefore, sudden braking while cornering is not recommend-
ed. Excessive side force, which ABS cannot prevent, could cause the tire to slip sideways.
1-10
GEN
FEATURES INFO
EWA16510
WARNING
The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even in vehicles equipped with ABS, overturning of the vehicle cannot be prevented
if it is braked suddenly.
The ABS functions to prevent the tendency of the wheel to lock by controlling the hydraulic pressure.
However, if there is a tendency of the wheel to lock on a slippery road surface, due to engine braking,
the ABS may not be able to prevent the wheel from locking.
EWA13870
WARNING
The ABS controls only the tendency of the wheel to lock caused by applying the brakes. The
ABS cannot prevent wheel lock on slippery surfaces, such as ice, when it is caused by engine
braking, even if the ABS is operating.
(%)
a. Friction force between the tire and road c. Side force

surface d. Slip ratio
b. Brake force
Electronic ABS features

The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic
technology.
The ABS control is processed with good response under various vehicle travel conditions.
The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con-
dition and allows normal braking even if the ABS is not operating properly.
When this occurs, the ABS warning light on the meter assembly comes on.
The ABS stores the fault codes in the memory of the ABS ECU for easy problem identification and trou-
bleshooting.
1-11
GEN
FEATURES INFO
ABS block diagram
3
2
4 4
6 5 6
7 7
8
9 9
10 13
11 14
12
1. Rear brake master cylinder 9. Buffer chamber

2. Hydraulic unit assembly 10. Rear brake caliper
3. Front brake master cylinder 11. Rear wheel sensor
4. Inlet solenoid valve 12. ABS warning light
5. ABS motor 13. Front brake caliper
6. Hydraulic pump 14. Front wheel sensor
7. Outlet solenoid valve
8. ABS ECU
EAS30684
ABS COMPONENT FUNCTIONS
Wheel sensors and wheel sensor rotors

Wheel sensors “1” detect the wheel speed and transmit the rotation signal to the ABS ECU.
Each wheel sensor is composed of a permanent magnet and a hall IC. The sensor rotors “2” rotate with
the wheels. The sensor rotors “2” have 40 slots and are installed close to the wheel sensors. As the
sensor rotor rotates, the hall element in the hall IC installed in the wheel sensor generates pulses. The
pulse frequency, which is proportional to the wheel speed, is converted into a wave in the hall IC so that
it can be output.
The ABS ECU calculates the wheel rotation speed by detecting the pulse frequency.
1-12
GEN
FEATURES INFO
7 3 7 4
8 8
5
3. At low speed 7. Voltage

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

The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs.
When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit
and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function
check is properly completed at a speed of about 10 km/h (6.3 mi/h)).
TIP
After all checks and servicing are completed, the ABS warning light will go off when the vehicle is ridden
or pushed at a speed of 10 km/h (6.3 mi/h) or faster.
ECA20950
NOTICE
If the rear wheel is raced with the vehicle on a suitable stand, the ABS warning light may flash
or come on. If this occurs, turn the main switch to “OFF”, then back to “ON”. The ABS operation
is normal if the ABS warning light goes off after the vehicle starts off. If the fault codes are not
deleted, the ABS warning light goes off after the vehicle is ridden at a speed of about 30 km/h
(19 mi/h).
1-13
GEN
FEATURES INFO
LAP
Hydraulic unit assembly

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

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

4. Brake caliper
2. When the ABS is activated, the inlet solenoid valve “1” closes and the outlet solenoid valve “2” opens
using the power supplied from the ABS ECU signals. This reduces the hydraulic pressure.
1-14
GEN
FEATURES INFO
3. Brake caliper
4. ABS motor
3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve
“2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic
pressure difference between the brake fluid in the upper brake lines (brake master cylinder side) and
the brake fluid in the lower brake lines (brake caliper side).
Buffer chamber
The buffer chamber accumulates the brake fluid that is depressurized while the ABS is operating.
1. Buffer chamber (pressurizing phase) 3. Raised piston

2. Buffer chamber (depressurizing phase)
ABS ECU
The ABS ECU is integrated with the hydraulic unit to achieve a compact and lightweight design.
As shown in the following block diagram, the ABS ECU receives wheel sensor signals from the front
and rear wheels and also receives signals from other monitor circuits.
1-15
GEN
FEATURES INFO
1. Battery 14. ABS ECU

2. AC magneto 15. ABS motor relay
3. Rectifier/regulator 16. Solenoid relay
4. Main fuse 17. Front brake outlet solenoid
5. ABS motor fuse 18. Front brake inlet solenoid
6. ABS solenoid fuse 19. Rear brake outlet solenoid
7. Main switch 20. Rear brake inlet solenoid
8. ABS control unit fuse 21. ABS motor
9. Rear brake light switch 22. Meter assembly
10. Front brake light switch 23. ABS warning light
11. Tail/brake light 24. ECU (Engine Control Unit)
12. ABS test coupler 25. Front wheel sensor
13. Hydraulic unit assembly 26. Rear wheel sensor
The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the
hydraulic unit assembly.
ABS control operation

The ABS control operation performed in the ABS ECU is divided into the following two parts.
• Hydraulic control
• Self-diagnosis
When a malfunction is detected in the ABS, a fault code is stored in the memory of the ABS ECU for
easy problem identification and troubleshooting.
1-16
GEN
FEATURES INFO
TIP
• Some types of malfunctions are not recorded in the memory of the ABS ECU (e.g., a blown ABS con-
trol unit fuse).
• The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and
if the brake lever or brake pedal is even slightly operated, a vibration can be felt at the lever and pedal,
but these do not indicate a malfunction.
1
2
1. Software operation flow

2. Main switch “ON”
3. Initialize
4. Self-diagnosis (when static)
5. Self-diagnosis (when riding)
6. Receive signals
7. Control operation
8. Depressurize/pressurize
1-17
GEN
FEATURES INFO
EAS30710
ABS OPERATION
The ABS hydraulic circuit consists of two systems: the front wheel, and rear wheel. The following de-
scribes the system for the front wheel only.
Normal braking (ABS not activated)

When the ABS is not activated, the inlet solenoid valve is opened and the outlet solenoid valve is closed
because a control signal has not been transmitted from the ABS ECU. Therefore, when the brake lever
is squeezed, the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent
to the brake caliper.
At this time, the inlet and outlet check valves of the hydraulic pump are closed. As a result of eliminating
the orifice, the brake master cylinder directly pressurizes the brake caliper during normal braking. When
the brake lever is released, the brake fluid in the brake caliper returns to the brake master cylinder.
7 6
5
8
9
10
11
12
13
1. Brake master cylinder 12. Brake fluid pressure
2. Brake light switch 13. Time
3. ABS motor
4. Hydraulic pump
5. Buffer chamber
7. Inlet solenoid valve
8. Brake caliper
9. Wheel sensor
10. ABS ECU
1-18
GEN
FEATURES INFO
Emergency braking (ABS activated)
1. Depressurizing phase
When the front wheel is about to lock, the outlet solenoid valve is opened by the “depressurization”
signal transmitted from the ABS ECU. When this occurs, the inlet solenoid valve compresses the
spring and closes the brake line from the brake master cylinder. Because the outlet solenoid valve
is opened, the brake fluid is sent to the buffer chamber. As a result, the hydraulic pressure in the
brake caliper is reduced.
The brake fluid stored in the buffer chamber is pumped back to the brake master cylinder by the hy-
draulic pump linked to the ABS motor.

2. Brake light switch
3. ABS motor
4. Hydraulic pump
5. Buffer chamber
8. Brake caliper
9. Wheel sensor
10. ABS ECU
12. Brake fluid pressure
13. Time
1-19
GEN
FEATURES INFO
2. Pressurizing phase
The outlet solenoid valve is closed by the “pressurization” signal transmitted from the ABS ECU. At
this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve
opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the
brake caliper.

2. Brake light switch
3. ABS motor
4. Hydraulic pump
5. Buffer chamber
8. Brake caliper
9. Wheel sensor
10. ABS ECU
12. Brake fluid pressure
13. Time
1-20
GEN
FEATURES INFO
EAS30712
ABS WARNING LIGHT AND OPERATION
ABS warning light

• If the ABS warning light comes on while riding, stop the vehicle, and then turn the main switch to
“OFF”, then back to “ON”. The ABS operation is normal if the ABS warning light goes off after the ve-
hicle starts off.
• If the rear wheel is raced with the vehicle on a suitable stand, the ABS warning light may flash or come
on. If this occurs, turn the main switch to “OFF”, then back to “ON”. The ABS operation is normal if the
ABS warning light goes off after the vehicle starts off.
• The ABS operation is normal if the ABS warning light flashes.
• Even if the ABS warning light remains on and does not go off, or if it comes on after riding, conven-
tional braking performance of the vehicle is maintained.
ABS function
EWA16521
WARNING
• When hydraulic control is performed by the ABS, the brake system alerts the rider that the
wheels have a tendency to lock by generating a reaction-force pulsating action in the brake
lever or brake pedal. When the ABS is activated, the grip between the road surface and tires
is close to the limit. The ABS cannot prevent wheel lock* on slippery surfaces, such as ice,
when it is caused by engine braking, even if the ABS is activated.
Use extreme care when operating the vehicle under these conditions.
• The ABS is not designed to shorten the braking distance or improve the cornering perfor-
mance.
• Depending on the road conditions, the braking distance may be longer compared to that of
vehicles not equipped with ABS. Therefore, ride at a safe speed and keep a safe distance be-
tween yourself and other vehicles.
• The braking of the vehicle, even in the worst case, is principally executed when the vehicle is
advancing straight ahead. During a turn, sudden braking is liable to cause a loss of traction of
the tires. Even vehicles equipped with ABS cannot be prevented from falling over if braked
suddenly.
• The ABS does not work when the main switch is turned to “OFF”. The conventional braking
function can be used.
* Wheel lock: A condition that occurs when the rotation of one or both of the wheels has
stopped, but the vehicle continues to travel.
1-21
GEN
FEATURES INFO
EAUE4660
2. Remove the passenger seat.
CCU (Communication Control Unit)
3. Pull out the CCU and scan its QR code with
This model is equipped with a CCU that allows
the Yamaha Motorcycle Connect app.
your vehicle and smartphone to connect using
Bluetooth wireless technology and the Yamaha TIP
Motorcycle Connect smartphone app. Pairing can also be done using the vehicle iden-
With this connection, notifications from SNS (so- tification number. Refer to the login screen in the
cial network service) apps, incoming phone calls Yamaha Motorcycle Connect app.
and missed calls are signaled to you, and the
battery level of your smartphone is displayed.
The Yamaha Motorcycle Connect app also pro-
vides other information such as your last parking
location, etc.
EWAN0070 2
WARNING
• Always stop the vehicle before operating
your smartphone.
• Never take your hands off the handlebars 1
ZAUE4462
while riding.
• Always concentrate on riding by keeping 1. CCU (Communication Control Unit)
your eyes and mind on the road. 2. CCU QR Code
ECAN0150
4. When pairing is complete, the Yamaha Mo-
NOTICE torcycle Connect icon and smartphone bat-
The Bluetooth connection may not work in tery level meter will come on.
the following situations.
• In a location exposed to strong radio waves 12
or other electromagnetic noise. GEAR STREET TRACK QS App
• At facilities nearby that are emitting strong

radio waves (TV or radio towers, power MPH
x1000r/min
plants, broadcasting stations, airports,

etc.). km/h F
ODO mile
LAP TRIP 12F km
BATTLATESTFASTEST km/hMPGMPH
COOLANTAVGTCS km/L/100km E
Pairing the CCU and your smartphone ZAUE4463
1. Scan the QR code below and download the
Yamaha Motorcycle Connect app. 1. Yamaha Motorcycle Connect icon
2. Smartphone battery level meter
TIP
• Once paired, the smartphone is registered in
the CCU. The next time the vehicle is turned on
and the Yamaha Motorcycle Connect app is
active, the connection will be automatically es-
tablished.
ZAUE4381
• Only one smartphone can be connected to the
CCU at one time.
• If more than one phone has been registered in
TIP the CCU, then the first phone within reach will
Yamaha Motorcycle Connect may not work on be connected.
all smartphone models and OS (operating sys-
5. Install the CCU in its original position and
tem) versions.
then install the passenger seat.
1-22
GEN
FEATURES INFO
EAU1234R EAU54213
HANDLEBAR SWITCHES Stop/Run/Start switch “ / / ”

Left To crank the engine with the starter, set this
switch to “ ”, and then push the switch down
towards “ ”.
Set this switch to “ ” to stop the engine in case
of an emergency, such as when the vehicle
1
1 overturns or when the throttle cable is stuck.
EAUN2211
2
2 Hazard lights switch “ /OFF”
3
3 The hazard lights (simultaneous flashing of all
ZAUE3356
turn signal lights) are used in case of an emer-
gency, such as to warn other drivers when your
1. Dimmer/Pass switch “ / /PASS” vehicle is stopped where it might be a traffic haz-
2. Turn signal switch “ / ” ard.
3. Horn switch “ ” Set this switch to “ ” to turn on the hazard lights.
Right To turn off the hazard lights, set the switch to
“OFF”.
ECA10062
NOTICE
1 Do not use the hazard lights for an extended
length of time with the engine not running,
otherwise the battery may discharge.
EAU78491
2 “TRIP/INFO” switch
ZAUE4507 3 This switch is used to make setting and display
changes in the multi-function meter unit.
1. Stop/Run/Start switch “ / / ” To use the “TRIP” switch, move the “TRIP/INFO”
2. Hazard lights switch “ / ” switch in direction (a). To use the “INFO” switch,
3. “TRIP/INFO” switch move the “TRIP/INFO” switch in direction (b).
EAU54203
Dimmer/Pass switch “ / /PASS”

Set this switch to “ ” for the high beam and
to “ ” for the low beam.
To flash the high beam, push the switch down
towards “PASS” while the headlights are on low
beam. 1
EAU12461
(a) (b)
ZAUE4465
Turn signal switch “ / ”
To signal a right-hand turn, push this switch 1. “TRIP/INFO” switch
to “ ”. To signal a left-hand turn, push this
switch to “ ”. When released, the switch re-
turns to the center position. To cancel the turn
signal lights, push the switch in after it has re-
turned to the center position.
EAU12501
Horn switch “ ”
Press this switch to sound the horn.
1-23
GEN
FEATURES INFO
EAU4939R ECA10022
INDICATOR LIGHTS AND WARNING LIGHTS NOTICE

Do not continue to operate the engine if it is
6 overheating.
5 TCS ABS
7
GEAR STREET TRACK QS App
EAU73172
Engine trouble warning light “ ”

4 MPH
x1000r/min
8
3 km/h F 9 This warning light comes on if a problem is de-
2 ODO
LAP TRIP 12F
BATTLATESTFASTEST
mile
km
km/hMPGMPH
10 tected in the engine or other vehicle control sys-
1 11
COOLANTAVGTCS km/L/100km E
tem. If this occurs, have a Yamaha dealer check

ZAUE4464
the on-board diagnostic system.
TIP
1. Coolant temperature warning light “ ”
2. Incoming call indicator light “ ” When the vehicle is turned on, the light will come
3. Incoming notification indicator light “ ” on for a few seconds and then go off. If the light
4. Left turn signal indicator light “ ” does not come on, or if the light remains on,
5. Traction control system indicator light “ ” have a Yamaha dealer check the vehicle.
6. Shift timing indicator light
7. Anti-lock Brake System (ABS) warning light
EAU69895
8. Right turn signal indicator light “ ” ABS warning light “ ” ABS
9. High beam indicator light “ ”

This warning light comes on when the vehicle is
10.Neutral indicator light “ ”
first turned on, and goes off after starting riding.
11.Engine trouble warning light “ ”
If the warning light comes on while riding, the
EAU11033 anti-lock brake system may not work correctly.
Turn signal indicator lights “ ” and “ ” EWA16043
Each indicator light will flash when its corre- WARNING

sponding turn signal lights flash. If the ABS warning light does not turn off af-
ter reaching 10 km/h (6 mi/h), or if the warn-
EAU11061
ing light comes on while riding:
Neutral indicator light “ ”
• Use extra caution to avoid possible wheel
This indicator light comes on when the transmis-
lock during emergency braking.
sion is in the neutral position.
• Have a Yamaha dealer check the vehicle as
EAU11081 soon as possible.
High beam indicator light “ ”
This indicator light comes on when the high EAU77004
beam of the headlight is switched on. Traction control system indicator light “ ”
This indicator light flashes when traction control
EAU11449
has engaged. When the traction control system
Coolant temperature warning light “ ”
is turned off, the indicator light will come on.
This warning light comes on when the engine is
overheating. If this occurs, stop the engine im- TIP
mediately and allow the engine to cool. When the vehicle is turned on, the light will come
For vehicles with a radiator fan, the radiator on for a few seconds and then go off. If the light
fan(s) automatically switch on or off according to does not come on during the circuit check, or if
the coolant temperature. the light remains on, Yamaha dealer check the
TIP vehicle.
When the vehicle is turned on, the light will come
EAU67434
on for a few seconds, and then go off. If the light Shift indicator light “ ”
does not come on, or if the light remains on, This indicator light comes on when it is time to
have a Yamaha dealer check the vehicle. shift to the next higher gear. The engine speeds
at which it comes on or goes off can be adjusted.
1-24
GEN
FEATURES INFO
EAUE4751
TIP DISPLAY
When the vehicle is turned on, this light should The display has two different main screen dis-
come on for a few seconds and then go off. If the play modes, STREET MODE and TRACK
light does not come on, or if the light remains on, MODE. Most of the functions are viewable in ei-
have a Yamaha dealer check the vehicle. ther mode, but the layout differs slightly. The fol-
lowing items can be found on the display:
EAUN2781
Incoming call indicator light “ ” STREET MODE

This indicator light flashes when there is an in-
coming call to the connected smartphone. If you 1 2 3 4 56 7
do not answer the call, the indicator light stays GEAR STREET QS App
on until you turn the vehicle off. 8

x1000r/min
MPH
TIP
9
km/h F
This function works only when the smartphone is ODO mile
TRIP 12F km
connected to the vehicle. BATTLATESTFASTEST
COOLANTAVGTCS
km/hMPGMPH
km/L/100km E 10
ZAUE4512 11
EAUN2792
Incoming notification indicator light “ ” 1. Transmission gear display

This indicator light flashes for 10 seconds when 2. STREET MODE
the connected smartphone receives an SNS, 3. Quick shifter indicator “QS” (if equipped)
E-mail or other notification. After that, the indica- 4. VVA (variable valve actuation) indicator
tor light stays on until you turn the vehicle off. 5. Yamaha Motorcycle Connect icon
TIP
7. Clock
• This function works only when the smartphone 8. Tachometer
is connected to the vehicle. 9. Speedometer
• Notification setting is needed for each applica- 10.Fuel meter
tion at the connected smartphone in advance. 11.Information display
TRACK MODE
1 2 3 4 56 7
GEAR TRACK QS App
8
x1000r/min
MPH
9
km/h F
LAP
LATESTFASTEST
E 10
ZAUE4513 11
1. Transmission gear display

2. TRACK MODE
3. Quick shifter indicator “QS” (if equipped)
4. VVA (variable valve actuation) indicator
5. Yamaha Motorcycle Connect icon
7. Clock
8. Tachometer
9. Speedometer
10.Fuel meter
11.Lap timer
1-25
GEN
FEATURES INFO
EWA18210
Clock
WARNING The clock uses a 12-hour time system.
Stop the vehicle before making any setting
changes. Changing settings while riding can To set the clock:
distract the operator and increase the risk of 1. Set the upper information display to the
an accident. odometer (ODO).
2. Press and hold (long push) the TRIP switch
TIP until the hour digits of the clock begin to flash.
The display units can be switched between kilo- 3. Use the TRIP/INFO switches to cycle the
meters/miles and celcius/farenheit. numbers. Press and hold (long push) the
TRIP/INFO switch to confirm the hour value.
4. Use the TRIP/INFO switches to cycle the
Speedometer numbers. Press and hold (long push) the
The speedometer shows the vehicle’s traveling TRIP/INFO switch to confirm the minute val-
speed. ue and exit the clock setting function.
Tachometer TIP
The tachometer shows the engine speed, as The clock automatically updates when a con-
measured by the rotational velocity of the crank- nection is established between a smartphone
shaft, in revolutions per minute (r/min). and the CCU.
TIP
• In TRACK MODE, the tachometer starts at Transmission gear display
6000 r/min. This shows which gear the transmission is in.
• The tachometer has a revolution peak hold in- This model has 6 gears and a neutral position.
dicator which can be turned on or off. The neutral position is indicated by the neutral
indicator light “ ” and by the transmission gear
ECA23050
display “ ”.
NOTICE
Do not operate the engine in the tachometer Revolution peak hold indicator
high-r/min zone. This small bar momentarily appears within the
High-r/min zone: 11500 r/min and above tachometer to mark the most recent peak engine
speed.
Fuel meter It can be turned on/off in the menu mode.
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter VVA indicator
disappear from “F” (full) towards “E” (empty) as This model is equipped with variable valve actu-
the fuel level decreases. ation (VVA) for good fuel economy and acceler-
When the last segment starts flashing, the fuel ation in both the low-speed and high-speed
tank reserve level has been reached. Refuel as ranges. The VVA indicator comes on when the
soon as possible. variable valve actuation system has switched to
the high-speed range.
TIP
If all the fuel meter display segments flash re- Quick shifter icon (if equipped)
peatedly, have a Yamaha dealer check the relat- This icon comes on when the quick shifter is ac-
ed circuits. tive and able to shift. When the icon is not visi-
ble, the quick shifter will not operate. See page
1-5 for quick shifter information.
Yamaha Motorcycle Connect icon

This icon comes on when CCU and smartphone
are connected via the Yamaha Motorcycle Con-
nect.
1-26
GEN
FEATURES INFO
TIP TIP
Even if the smartphone is not connected, when • LAP, FASTEST, and LATEST are only avail-
the vehicle is turned on, this icon should come able in TRACK mode
on for a few seconds. Otherwise have a Yamaha • TRIP1, TRIP 2, TRIP F, FASTEST, LATEST,
dealer check the CCU and the electrical circuit. and the two AVG items can be individually re-
set.
Smartphone battery level meter • The fuel reserve tripmeter (TRIP F) will only be
This meter indicates the current battery level of available when active due to low fuel level
the connected smartphone. The display seg- The display items are grouped into 2 separate
ments of the meter disappear from full to blank displays. The upper display is controlled using
as the battery level decreases. When approxi- the TRIP switch and the lower display is con-
mately 10% or less of the battery remains, the trolled using the INFO switch.
last segment starts flashing.
TIP STREET MODE: Pressing the TRIP or INFO
Even if the smartphone is not connected, when switches will cycle the display items in the fol-
the vehicle is turned on, this icon should come lowing order:
on for a few seconds. Otherwise have a Yamaha 1. Upper display:  Odometer  Tripmeter 1
dealer check the CCU and the electrical circuit.  Tripmeter 2  Fuel reserve tripmeter 
2. Lower display:  Current fuel consumption
 AVG fuel consumption  AVG speed 
Information display Traction control setting  Battery voltage 
Coolant temp.  TRACK mode function 
QS
GEAR STREET TRACK App
TRACK MODE: Pressing the INFO switch will
cycle the display items in the following order:
 Latest lap time  Fastest lap time 
x1000r/min
MPH
km/h F
ODO mile
TIP
LAP TRIP 12F km
BATTLATESTFASTEST km/hMPGMPH
COOLANTAVGTCS km/L/100km E In TRACK mode, the upper information display
ZAUE4514 1 will always show the current lap timer.
1. Information display
To reset information display items
The information display items are: 1. Use the TRIP/INFO switches to cycle through
ODO: odometer the display items until the item you want to re-
TRIP1: tripmeter 1 set appears.
TRIP 2: tripmeter 2 2. Press and hold (long push) either the TRIP
TRIP F: fuel reserve tripmeter switch (for upper information display items) or
Current fuel consumption the INFO switch (for lower information display
AVG: average fuel consumption items) until the item resets.
AVG: average speed
TCS: traction control system ON/OFF
BATT: battery voltage
COOLANT: coolant temperature
TRACK: change to track mode
LAP: current lap time
FASTEST: fastest lap time
LATEST: latest lap time
1-27
GEN
FEATURES INFO
Odometer: When the fuel tank reserve level has been
reached, TRIP F appears automatically and be-
gins recording distance traveled from that point.
GEAR STREET App
Press and hold (long push) the TRIP switch
while TRIP F is displayed to reset the tripmeter
x1000r/min after refueling.
km/h F TIP
ODO
km
BATT
E
After refueling and traveling 5 km, TRIP F will
automatically disappear.
ZAUE4515 1
1. Odometer Current fuel consumption:
The odometer shows the total distance traveled
by the vehicle.
GEAR STREET App
TIP
ODO will lock at 999999 and cannot be reset. x1000r/min
km/h F
ODO
Tripmeters: km
km/L E
ZAUE4518 1
GEAR STREET App
1. Current fuel consumption display
x1000r/min The current fuel consumption display can be set

km/h F
to “km/L” or “L/100km”.
TRIP 1 km TIP
BATT
E
If traveling at speeds under 10 km/h, “--.-” will be
ZAUE4516 1 displayed.
1. Tripmeter
TRIP1 and TRIP 2 show the distance traveled Average fuel consumption:
since they were last reset.
TIP GEAR STREET App
TRIP1 and TRIP 2 will reset to 0 and begin

counting again after 9999.9 has been reached. x1000r/min
km/h F
ODO
Fuel reserve tripmeter: km
AVG km/L E
ZAUE4519 1
GEAR STREET App
1. Average fuel consumption display
x1000r/min Shows the average amount of fuel consumed

km/h F
since last reset.
TRIP F km
The average fuel consumption display can be
BATT
E set to “km/L” or “L/100km”.
ZAUE4517 1 TIP
1. Fuel reserve tripmeter “F”

After resetting the average fuel consumption dis-
play, “--.-” will be shown until the vehicle has
traveled 1 km.
1-28
GEN
FEATURES INFO
Average speed: Battery voltage:
GEAR STREET App GEAR STREET App
x1000r/min x1000r/min
km/h F km/h F
ODO ODO
km km
km/h BATT
AVG E E
ZAUE4520 1 ZAUE4522 1
1. Battery voltage display
1. Average speed display
This display shows the current charge state of
Shows the average speed travelled since last re-
the battery.
set.
• Over 12.8 V = Full charge.
TIP • Under 12.7 V = Charging is required.
After resetting the average speed display, “--.-” TIP
will be shown until the vehicle has traveled 1 km.
If the battery voltage is less than 9.0 V, “_ _._” is
displayed.
Traction control system setting:
Coolant temperature:
GEAR STREET App
GEAR STREET App

x1000r/min
km/h F x1000r/min
ODO
km
TCS E km/h F
ODO
km
ZAUE4521 1 COOLANT E
1. Traction control system display ZAUE4523 1

This setting allows the traction control system to
1. Coolant temperature display
be turned ON/OFF.
TIP
The coolant temperature is displayed from
-30 °C (-22 °F) to 114 °C (237 °F) in 1 °C (1 °F)
• The traction control system can only be turned increments.
off when the vehicle is stopped.
• The traction control system resets to “ON” TIP
whenever the main switch is turned off/on. If the vehicle coolant temperature is above
114 °C (237 °F) the coolant temperature display
will read “HI”.
1-29
GEN
FEATURES INFO
TRACK mode: Latest lap time:
GEAR STREET App

GEAR TRACK App
x1000r/min
x1000r/min
km/h F km/h F
ODO
km LAP
E LATEST
E
ZAUE4524 1 ZAUE4528 1
1. TRACK MODE 1. Latest lap time
Allows switching to track mode from the main Shows the last lap time recorded.
display screen.
TRACK mode/Lap timer
TIP
TRACK mode can also be entered via the menu To use the lap timer:
mode. 1. Enter TRACK mode. The lap timer is now in
standby mode.
Current lap timer: 2. Press the PASS switch to start the timer.
3. Press the PASS switch again to count each
lap and reset the lap timer.
4. Press the TRIP switch to pause the timer and
GEAR TRACK App
return to standby mode. Press the PASS
x1000r/min
switch to resume the timer.
5. Press and hold (long push) the TRIP/INFO
km/h F
switch to reset the timer, lap number and re-
LAP
LATEST
turn to standby mode.
E
6. From standby mode press and hold (long
ZAUE4525 1 push) the TRIP/INFO switch to return to
1. Current lap timer
STREET mode.
Shows the current lap time when in TRACK

mode.
Fastest lap time:
GEAR TRACK App
x1000r/min
km/h F
LAP
FASTEST
E
ZAUE4526 1
1. Fastest lap
Shows the fastest lap time recorded since enter-

ing TRACK mode or since last reset.
1-30
GEN
FEATURES INFO
EAUN3423
MODE
MENU MODE
km/h
km/h
ZAUE4530 1
ZAUE4529 1
1. MODE display
1. Menu mode display
Cycle between the two main screen display
The menu mode contains the following setting
modes, STREET MODE and TRACK MODE.
modules in order:
The icon for the currently selected mode will
Module Description
flash at the top of the screen.
Switch the main screen display
MODE between STREET mode and TRACK
mode BACKLIGHT BRIGHTNESS
BACKLIGHT Adjust the display backlight
BRIGHTNESS brightness
MESSAGE Change the welcome message
SHIFT
Change shift indicator settings
INDICATOR
PEAK REV
Change peak rev indicator settings
INDICATOR
km/h
UNIT Set measurement units
ALL RESET Return all settings to factory defaults
Exit menu mode and returns to the
EXIT
main display ZAUE4531 1
1. Brightness level display
Menu access and operation
• With the main switch off, press and hold either This module allows you to adjust the general
the TRIP or INFO switch. Turn the main switch brightness level of the display screen.
on while still holding the TRIP/INFO switch. The display has 6 brightness level settings. The
The main display will appear and after a few brightness level is represented by a segmented
seconds will switch to the menu mode. bar at the bottom of the screen.
• Briefly press the INFO switch (short push) to TIP
cycle forward in the menus and adjust settings
values upward (increase). The screen brightness will adjust as the levels
Briefly press the TRIP switch (short push) to are changed in this menu.
cycle backward in the menus and adjust set-
tings values downward (decrease). MESSAGE
• Press and hold the TRIP/INFO switch (either
side of the switch) for 1 second (long push) to
select a menu item or confirm a setting.
• Use the EXIT option of the main menu to return
to the main display screen.
TIP km/h
Should vehicle motion be detected, the menu

mode will automatically exit and return to the
main display. ZAUE4532 1
1. Message display
1-31
GEN
FEATURES INFO
A 6 digit message appears on the bottom infor- TIP
mation display when the main switch is turned
on. The default message is 000000. Customize The shift indicator lights will come on/off and
the message one digit at time with this module. flash as the settings are adjusted.
Change the flashing digits value in the following
order: RPM
This module allows the r/min range of the shift
indicator lights to be adjusted in increments of
200 r/min. The values are represented by flash-
A B C Y Z
ing segments of the tachometer and also by
9 2 1 0 numbers at the bottom of the display.
- (HYPHEN) SPACE
ZAUE4533
x1000r/min
1
Long push the TRIP/INFO switch to confirm the km/h
digit and move to the next digit.

TIP
ZAUE4535
After the 6th and final digit is confirmed, the dis-
play will return to the main menu. 1. Shift timing indicator light activation
range
SHIFT INDICATOR First the initial r/min at which the shift indicator
This module has 3 sub-menus and an exit to lights begin coming on must be set. The mini-
main menu option: TYPERPMBRIGHT- mum value is 6000 r/min and the maximum val-
NESSEXIT ue is 12800 r/min.
Long push either the TRIP/INFO switch to enter
a sub-module 1
TYPE
x1000r/min
km/h
ZAUE4536
km/h
1. Shift timing indicator light ON r/min
Once the initial value is set, the final r/min value

ZAUE4534 1 at which the shift indicator lights are all on can be
set. The minimum value is 6200 r/min and the
1. Shift indicator type
maximum value is 13000 r/min.
This module allows you to change the shift indi- TIP
cator between 3 settings (OFF  TYPE 1 
TYPE 2 ). The initial r/min value must be at least 200 r/min
• TYPE 1 causes the shift indicator lights to below the final r/min value.
shine solid without flashing when the final set r/
min is reached.
• TYPE 2 causes the shift indicator lights to flash
when the final set r/min is reached.
• OFF disables the shift indicator light.
1-32
GEN
FEATURES INFO
BRIGHTNESS ALL RESET
This module resets everything, except the
odometer and clock, to its factory preset or de-
TCS ABS
fault setting.
Select YES to reset all items. Select NO to return
to the main menu.
km/h
EXIT
Use this to exit the menu mode and return to the
main display.
ZAUE4537 1
1. Shift timing indicator light brightness
The brightness level of the shift indicator lights

can be adjusted between 6 settings which are
represented by a segmented bar at the bottom
of the display.
TIP
The shift indicator lights come on and adjust to
the brightness levels as they are changed.
PEAK REV INDICATOR

The peak rev indicator marks the most recent
maximum engine r/min on the tachometer. It can
be turned ON/OFF in this module.
UNIT
This module has 3 sub-menus and an exit to
main menu option: SPEEDFUELCON-
SUMPTIONTEMPERATUREEXIT
Long push the TRIP/INFO switch to enter a
sub-module.
SPEED
The speed measurement units can be changed
between km/h and MPH. The selected unit type
will flash.
FUEL CONSUMPTION
• If the speed measurement units are set to km/
h, the fuel consumption units can be changed
between km/l and L/100km. The selected unit
will flash.
• If the speed measurement units are set to
MPH, only MPG is available as a fuel con-
sumption unit.
TEMPERATURE
The temperature units can be switched between
Celsius and Fahrenheit. The selected unit will
flash.
1-33
GEN
IMPORTANT INFORMATION INFO
EAS20009
IMPORTANT INFORMATION
EAS2000901
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS2000903
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS2000904
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
“1” and cotter pins. After the bolt or nut has been
4. During disassembly, clean all of the parts and tightened to specification, bend the lock tabs
place them in trays in the order of disassem- along a flat of the bolt or nut.
bly. This will speed up assembly and allow for
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS2000902
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but 1
inferior in quality.
1-34
GEN
IMPORTANT INFORMATION INFO
EAS20230 EAS1MC1085
BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in-
manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECA13300
NOTICE
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1
3
2
1-35
GEN
BASIC SERVICE INFORMATION INFO
EAS30380
BASIC SERVICE INFORMATION

EAS30390
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with
Screw type
a screwdriver, then pull the fastener out.
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver/Phillip screwdriver, then pull
the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and
push the pin in with a screwdriver. Make sure
that the pin is flush with the fastener's head. 2. Install:
• Quick fastener
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-36
GEN
TIP
If a battery lead is difficult to disconnect due to
rust on the battery terminal, remove the rust us-
ing hot water.
EAS30402
ECA16760
ELECTRICAL SYSTEM
NOTICE
Electrical parts handling Be sure to connect the battery leads to the
ECA16600
correct battery terminals. Reversing the
NOTICE battery lead connections could damage the
Never disconnect a battery lead while the electrical components.
engine is running; otherwise, the electrical
components could be damaged.
ECA16771
NOTICE
ECA16751
NOTICE When connecting the battery leads to the

battery, be sure to connect the positive bat-
When disconnecting the battery leads from
tery lead first, then the negative battery
the battery, be sure to disconnect the nega-
lead. If the negative battery lead is con-
tive battery lead first, then the positive bat-
nected first and a tool or similar item con-
tery lead. If the positive battery lead is
tacts the vehicle while the positive battery
disconnected first and a tool or similar item
lead is being connected, a spark could be
contacts the vehicle, a spark could be gen-
generated, which is extremely dangerous.
erated, which is extremely dangerous.
1-37
GEN
ECA16610
TIP
NOTICE
When resetting the ECU by turning the main
Turn the main switch to “OFF” before dis-
switch to “OFF”, be sure to wait approximately
connecting or connecting an electrical
5 seconds before turning the main switch back
component.
to “ON”.
ECA16620
NOTICE
Checking the electrical system
Handle electrical components with special TIP
care, and do not subject them to strong
Before checking the electrical system, make
shocks.
sure that the battery voltage is at least 12 V.
ECA16630
ECA14371
NOTICE
NOTICE
Electrical components are very sensitive to
Never insert the tester probes into the cou-
and can be damaged by static electricity.
pler terminal slots. Always insert the
Therefore, never touch the terminals and
probes from the opposite end “a” of the
be sure to keep the contacts clean.
coupler, taking care not to loosen or dam-
age the leads.
1-38
GEN
ECA16640 ECA16790
NOTICE NOTICE
For waterproof couplers, never insert the When disconnecting a connector, do not
tester probes directly into the coupler. pull the leads. Hold both sections of the
When performing any checks using a connector securely, and then disconnect
waterproof coupler, use the specified test the connector.
harness or a suitable commercially avail-
able test harness.
2. Check:
• Lead
• Coupler
Checking the connections • Connector
Check the leads, couplers, and connectors for Moisture → Dry with an air blower.
stains, rust, moisture, etc.
• Rust/stains → Connect and disconnect sev-
1. Disconnect:
eral times.
• Lead
• Coupler
• Connector
ECA16780
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the
coupler securely, and then disconnect the
coupler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the cou- 3. Check:
pler. • All connections
Loose connections → Connect properly.
TIP
• If the pin “1” on the terminal is flattened, bend
it up.
• After disassembling and assembling a cou-
pler, pull on the leads to make sure that they
are installed securely.
1-39
GEN
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
4. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector,
push both sections of the coupler or connec-
tor together until they are connected securely.
• Make sure all connections are tight.
6. Check:
• Resistance
Multimeter
INS-003
(90890-03189)
TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not
20 °C (68 °F), the specified measuring condi-
tions will be shown.
5. Check: Coolant temperature sensor

• Continuity resistance
(with the Multimeter) 210–221 Ω at 100 °C (210–221 Ω
at 212 °F)
Multimeter
INS-003
(90890-03189)
1-40
GEN
1-41
GEN
SPECIAL TOOLS INFO
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.
Tool name/Tool No. Illustration
Piston pin replacer
YSST-207
(90890-01304)
8.5
This tool is use to replace the piston pin.
Crankshaft removing tool
YSST-265
(90890-01135)
Ø9.5
This tool is used to remove the crankshaft from the M8
crankcase. M8
Crankshaft installing tool with spacer
YSST-266 YSST-266 YSST-767
(90890-01284)
YSST-767
These tools are used for installing the crankshaft.

Valve spring compressor
YSST-603
(90890-04019)
This tool is used when removing or installing the

valve, valve spring and cotter.
Valve spring compressor attachment
YSST-603 A
(90890-04109)
This tool is used when removing or installing the

valve, valve spring and cotter.
Piston base
YSST-604
(90890-01067)
12
0
This tool is used to support the piston. .0
12
Small screw driver
YSST-609
Thickness=1 mm
This tool is used to adjust throttle screw/retract timing
chain tensioner.
1-42
GEN
SPECIAL TOOLS INFO
Torx bit (T-30)
YSST-611
This tool is used to loosen or tighten the cam shifter

segment screw. 13sq
Main switch steering lock (T-30)

YSST-611 A
This tool is used to loosen or tighten the ignition lock.

Scraper
YSST-612
This tool is used to scrap the sealant from crankcase

surface.
Cup-B
YSST-620-B
OD-48
ID-38
This tool is used to remove the bearing.

Cup-C
YSST-620-C
OD-53
ID-48
This tool is used to remove the bearing.

Bearing puller
YSST-623
This tool is used to remove the camshaft bearing.

Bearing puller
YSST-624
This tool is used to remove the bearing of main axle/

front wheel and rear wheel (LH&RH).
Bearing puller
YSST-624 A 17
This tool is used to remove the bearing of balancer/

drive axle/rear wheel hub.
Center plug spanner
YSST-625
1.5
This tool is used to remove/install the timing mark ac-

cessing screw/crankshaft end accessing screw from
magneto cover.
1-43
GEN
SPECIAL TOOLS INFO
Upper and lower race installer
YSST-626
M20
300
This tool is used to install upper and lower races.
Magneto holder
YSST-701 M30
(90890-01701) M8
(90890-01481)
This tool is used to hold the magneto.

Magneto puller
YSST-702
(90890-04141)
This tool is used to remove the magneto rotor with the

help of magneto holder.
Tappet screw holder
YSST-706
(90890-04154)
This tool is used to adjust valve clearance.

Tappet adjusting socket
YSST-706A
This tool is used to loosen and tighten the valve clear-

ance adjust screw locknut.
Steering nut socket
YSST-721
This tool is used to loosen and tighten the steering

ring nut.
Mechanical seal/bearing installer

YSST-722
Ø30
This tool is used to install the seal and bearing in wa- Ø10
ter pump assy.

Water pump bearing remover
YSST-723
This tool is used to remove the bearing from water

pump.
1-44
GEN
SPECIAL TOOLS INFO
Front fork damper rod locknut holder (Left & right leg)
YSST-778
(90890-01953)
This tool is used to hold the damper rod locknut/spe-

cial nut when removing or installing the front fork cap
bolt.
Front fork dumper rod stopper tool (Right leg)
YSST-779
(90890-01592) 2 mm
Ø2
This tool is used to remove/install front fork dumper
rod stopper nut of right leg.
Clutch hub holder
YSST-733A
(90890-04086) Ø99.5 mm
This tool is used to hold the Clutch boss while loosen-

ing & tightening clutch boss nut.
Drive chain cutter & riveting tool
YSST-734
This tool is used to dismantling the drive chain.

Fixing tool bearing steering lower
YSST-870
38
48
36
This tool is used to install under bracket 285

bearing steering lower.
Front fork oil seal installer
YSST-775A Ø38.5 mm
(90890-01442)
These tools are used to install the oil seal and the dust
seal of the front fork legs.
Disc brake face out
YSST-890
This tool is used to check the runout.

Plate bearing installer
YSST-891
This tool is used to remove the camshaft bearing.
1-45
GEN
SPECIAL TOOLS INFO
Scissor jack
YSST-892A
This tool is used to support the vehicle.
TIP
While removeing the front wheel, put the scissor jack
under the engine of the vehicle so that there is no
danger of it falling over.
Bush
ODØ18
YSST-893 IDØ12
This tool is used as an attachment with magneto hold-

er & magneto puller and crankshaft removing tool.
Funnel with long tail
S 1119
This funnel is used to fillengine oil in crankcase.

Bearing punch with pilot driver
YSST-951
This tool is used to install bearings & oil seals.

Rotor holder tool
S1113
(90890-01235)
6.5
This tool is used to hold the drive sprocket.

Multimeter
INS-003
(90890-03189)
This tool is used to check the electrical

system.
Radiator cap tester
INS-004
(90890-01325)
This tool is used to test the radiator cap functionality.
1-46
GEN
SPECIAL TOOLS INFO
Radiator leakage tester adapter/Radiator cap tester
adapter
INS-005/INS-005A Ø30
(90890-01352)
INS-005:- This tool is used along with INS-004 to test

radiator leakage.
INS-005A:- This tool is used along with INS-004 to INS-005 INS-005A
test radiator cap valve opening pressure.
Fuel pressure gauge
INS-006
(90890-03181)
(90890-03176)
(90890-03186)
This tool is used to measure the fuel pressure.

Ignition checker
INS-007
(90890-06754)
This tool is used to check efficiency of ignition at spark

plug.
Compression gauge
INS-009
(90890-03081)
This tool is used to measure engine compression.

Injector coupler
INS-017
(90890-03210)
This tool is used to connect injector to injector cleaner.

Yamaha diagnostic tool (USB)
INS-018
(90890-03267)
This tool is used to diagnose electrical fault in ad-

vance fuel injection system.
Yamaha diagnostic tool (Ver.3)
INS-019
(90890-03264)
This tool is used to diagnose electrical fault in ad-

vance fuel injection system.
Sub harness 3
(90890-03266)
This tool is used to connect FI YDT coupler to adapter
interface (BS-VI models).
1-47
GEN
SPECIAL TOOLS INFO
Fuel injector plate
INS-020
This tool is used to hold the fuel infector on injector

cleaning machine.
Yamaha bond No. 1215
90890-85505
(Three bond No.1215-B)
This bond is used to seal two mating surfaces (e.g.,

crankcase mating surfaces).
1-48
GEN
SPECIAL TOOLS INFO
1-49
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................2-1
MAINTENANCE SPECIFICATION (ENGINE) ................................................2-2
MAINTENANCE SPECIFICATION (CHASSIS) .............................................2-6
MAINTENANCE SPECIFICATION (ELECTRICAL) .......................................2-8
TIGHTENING TORQUES ............................................................................. 2-10

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS ........................ 2-10
ENGINE TIGHTENING TORQUES ........................................................ 2-11
CHASSIS TIGHTENING TORQUES ...................................................... 2-15
LUBRICATION POINTS AND LUBRICANT TYPES ................................... 2-20

ENGINE .................................................................................................. 2-20
CHASSIS ................................................................................................ 2-22
LUBRICATION SYSTEM CHART AND DIAGRAMS ................................... 2-24
COOLING SYSTEM DIAGRAMS ................................................................. 2-27
CABLE ROUTING ........................................................................................ 2-31

GENERAL SPECIFICATIONS SPEC

EAS20013
GENERAL SPECIFICATIONS
Model
Model BCW1,BCW2,BCW4
Dimensions
Overall length 1990 mm (78.3 in)
Overall width 725 mm (28.5 in)
Overall height 1135 mm (44.7 in)
Wheelbase 1325 mm (52.2 in)
Ground clearance 170 mm (6.69 in)
Minimum turning radius 2.8 m (9.19 ft)
Weight
Curb weight 142 kg (313 lb)
Loading
Maximum load 163 kg (359 lb)
Riding capacity 2 person
2-1
MAINTENANCE SPECIFICATION (ENGINE) SPEC

MAINTENANCE SPECIFICATION (ENGINE)
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train SOHC
Displacement 155 cm³
Number of cylinders Single cylinder
Bore × stroke 58.0 × 58.7 mm (2.28 × 2.31 in)
Compression ratio 11.6 : 1
Compression pressure 696–896 kPa/550 r/min (7.0–9.0 kgf/cm²/
550 r/min, 99.0–127.4 psi/550 r/min)
Fuel
Recommended fuel Unleaded gasoline (E10 acceptable)
Minimum research octane 90
Fuel tank capacity 11 L (2.9 US gal, 2.4 Imp.gal)
Fuel reserve amount 1.2 L (0.32 US gal, 0.26 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40
Recommended engine oil grade API service SL type, JASO standard MA
Lubrication system Wet sump
Engine oil quantity

Oil change 1.00 L (1.06 US qt, 0.88 Imp.qt)
With oil filter removal 1.00 L (1.06 US qt, 0.88 Imp.qt)
Quantity (disassembled) 1.05 L (1.11 US qt, 0.92 Imp.qt)
Oil filter
Oil filter type Paper
Cooling system
Coolant quantity
Radiator (including all routes) 0.49 L (0.52 US qt, 0.43 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.15 L (0.16 US qt, 0.13 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm²,
15.6–19.9 psi)
Cooling system leak test pressure 137.3 kPa (1.37 kgf/cm², 19.9 psi)
Thermostat
Valve opening temperature 74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature 90.0 °C (194.00 °F)
Water pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug(s)
Manufacturer/model NGK/MR8E9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
2-2
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Camshaft lobe dimensions
Lobe height limit (Intake) 32.268 mm (1.2704 in)
Lobe height limit (Intake high speed) 32.332 mm (1.2729 in)
Lobe height limit (Exhaust) 29.516 mm (1.1620 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter limit 14.015 mm (0.5518 in)
Rocker arm shaft outside diameter limit 13.935 mm (0.5486 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve seat contact width limit (intake) 1.3 mm (0.05 in)
Valve seat contact width limit (exhaust) 1.7 mm (0.07 in)
Valve stem diameter limit (intake) 4.945 mm (0.1947 in)
Valve stem diameter limit (exhaust) 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 limit
(intake) 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance limit
(exhaust) 0.100 mm (0.0039 in)
Valve stem runout 0.020 mm (0.0008 in)
Valve spring
Free length limit (intake) 32.11 mm (1.26 in)
Free length limit (exhaust) 32.11 mm (1.26 in)
Cylinder
Bore 58.000–58.010 mm (2.2835–2.2839 in)
Wear limit 58.060 mm (2.2858 in)
Piston
Diameter 57.962–57.985 mm (2.2820–2.2829 in)
Measuring point (from piston skirt bottom) 6.0 mm (0.24 in)
Piston-to-cylinder clearance 0.015–0.048 mm (0.0006–0.0019 in)
Piston pin bore inside diameter limit 14.043 mm (0.5529 in)
Piston pin outside diameter limit 13.975 mm (0.5502 in)
Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 0.85 mm (0.0335 in)
Side clearance limit 0.115 mm (0.0045 in)
2-3
Crankshaft
Crank assembly width 47.95–48.00 mm (1.888–1.890 in)
Runout limit 0.050 mm (0.0020 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)
Assembly width 13.0–14.0 mm (0.51–0.55 in)
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Plate quantity 1 pcs
Clutch plate thickness 2.18–2.42 mm (0.086–0.095 in)
Clutch plate thickness 2.20–2.40 mm (0.087–0.094 in)
Clutch spring free length limit 39.51 mm (1.56 in)
Drivetrain
Transmission type Constant mesh 6-speed
Gear ratio
Primary reduction ratio 3.042 (73/24)
1st 2.833 (34/12)
2nd 1.875 (30/16)
3rd 1.364 (30/22)
4th 1.143 (24/21)
5th 0.957 (22/23)
6th 0.840 (21/25)
Secondary reduction ratio 3.429 (48/14)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Main axle assembly width 106.85–107.05 mm (4.21–4.21 in)
Shifting mechanism
Installed shift rod length 243.0–245.0 mm (9.57–9.65 in) (YZF155D-A)
243.5–244.5 mm (9.59–9.63 in) (YZF155-A)
Air filter
Air filter element Oil-coated paper element
Fuel injector
Resistance 12.2 Ω
2-4
Idling condition
Engine idling speed 1300–1500 r/min
O2 feedback control Active
Coolant temperature 80–100 °C (176–212 °F)
CO% 0.0–1.3 %
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)
2-5
MAINTENANCE SPECIFICATION (CHASSIS) SPEC

MAINTENANCE SPECIFICATION (CHASSIS)
Chassis
Caster angle 25.5 °
Trail 88 mm (3.5 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/C × MT2.5
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C × MT4.0
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Front tire
Type Tubeless
Size 100/80-17M/C 52P
Manufacturer/model MRF/NYLOGRIP ZAPPER-FX1
Rear tire
Type Tubeless
Size 140/70R17M/C 66H
Manufacturer/model MRF/MRF REVZ-S
Tire air pressure (measured on cold tires)

1 person
Front 200 kPa (2.00 kgf/cm², 29 psi, 2.00 bar)
Rear 225 kPa (2.25 kgf/cm², 33 psi, 2.25 bar)
2 persons
Front 200 kPa (2.00 kgf/cm², 29 psi, 2.00 bar)
Rear 225 kPa (2.25 kgf/cm², 33 psi, 2.25 bar)
Front brake
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 0.6 mm (0.02 in)
Master cylinder inside diameter 12.70 mm (0.50 in)
Caliper cylinder inside diameter (Right) 28.00 mm, 28.00 mm (1.10 in, 1.10 in)
Specified brake fluid DOT 4
Rear brake
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 limit 1.5 mm (0.06 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 30.23 mm (1.19 in)
Specified brake fluid DOT 4
2-6
MAINTENANCE SPECIFICATION (CHASSIS) SPEC
Steering
Front suspension
Shock absorber Hydraulic damper
Fork spring free length limit 283.2 mm (11.15 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil 01
Quantity (left) 300.0 cm³ (10.14 US oz, 10.58 Imp.oz)
Quantity (right) 363.0 cm³ (12.27 US oz, 12.80 Imp.oz)
Level (left) 100 mm (3.9 in)
Level (right) 119 mm (4.7 in)
Rear suspension
Shock absorber Hydraulic damper
Drive chain
Size 428
Chain type Sealed type
Number of links 128
Drive chain slack (Sidestand) 30.0–40.0 mm (1.18–1.57 in)
15-link length limit 191.5 mm (7.54 in)
2-7
MAINTENANCE SPECIFICATION (ELECTRICAL) SPEC

MAINTENANCE SPECIFICATION (ELECTRICAL)
Voltage
System voltage 12 V
Ignition system
Ignition timing (B.T.D.C.) 0.0–4.0 °/1400 r/min
High altitude ignition timing (B.T.D.C.) 9.2 °/1400 r/min
Engine control unit

Model BCW0 (YZF155D-A)
BCW1 (YZF155-A)
Ignition coil
Primary coil resistance 2.34–2.86 Ω
Secondary coil resistance 9.45–11.55 kΩ
Spark plug cap

Resistance 4.00–6.00 kΩ
Lean angle sensor

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
Stator coil resistance 0.360–0.540 Ω
Rectifier/regulator
Regulated voltage (DC) 14.0–14.8 V
Battery
Model ETZ-5
Voltage, capacity 12 V, 4.0 Ah (10 HR)
Bulb wattage
Headlight LED
Brake/tail 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
2-8
MAINTENANCE SPECIFICATION (ELECTRICAL) SPEC
Indicator light
Neutral indicator light LED
High beam indicator light LED
Turn signal indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
ABS warning light LED
Shift timing indicator light LED
Traction control system indicator light LED
Incoming notification indicator light LED
Incoming call indicator light LED
Starter motor
Brush overall length limit 3.5 mm (0.14 in)
Mica undercut (depth) 1.35 mm (0.05 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)
Atmospheric pressure sensor output voltage 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at
1.01 kgf/cm², 3.88–4.12 V at 14.7 psi)
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 15.0 A
ABS ECU fuse 2.0 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
Terminal fuse 2.0 A
2-9
TIGHTENING TORQUES SPEC

EAS20017
TIGHTENING TORQUES
EAS30002
GENERAL TIGHTENING TORQUE

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

B. Outside thread diameter
General tightening
A (nut) B (bolt) torques
N·m kgf·m lb·ft
10 mm 6 mm 6 0.6 4.4
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 41
19 mm 14 mm 85 8.5 63
22 mm 16 mm 130 13.0 96
2-10

EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Cylinder head bolt (Inside) (Initial
12 N·m (1.2 kgf·m, 8.9 lb·ft)
torque)
M8 4 M
Cylinder head bolt (Inside) (Final
24 N·m (2.4 kgf·m, 18 lb·ft)
torque)
Cylinder head bolt (Chain side) M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) M
Spark plug M10 1 13 N·m (1.3 kgf·m, 9.6 lb·ft)

Cylinder head cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Oil check bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft) With gasket
Exhaust pipe stud bolt M8 2 15 N·m (1.5 kgf·m, 11 lb·ft)
Coolant drain bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Balancer driven gear nut M10 1 35 N·m (3.5 kgf·m, 26 lb·ft)
Valve adjusting screw locknut M5 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Camshaft sprocket bolt M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Camshaft retainer bolt M6 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Camshaft retainer bolt M5 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Timing chain guide (intake side) bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Apply
Yamaha bond
Timing chain tensioner bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) No.1215-B,
1215 to screw
thread
Radiator bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator fan bolt M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Coolant reservoir bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Water pump assembly bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator hose clamp screw - 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Water pump housing cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Thermostat assembly bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Oil pump assembly screw M5 2 4 N·m (0.4 kgf·m, 3.0 lb·ft)
Engine oil drain plug M35 1 32 N·m (3.2 kgf·m, 24 lb·ft)
Oil filter element cover bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Cover, pump gear bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Intake manifold bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Fuel injector bolt M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT
Throttle body mounting bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Air filter case joint clamp bolt M4 1 2 N·m (0.2 kgf·m, 1.5 lb·ft)
Air filter case bolt M6 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Exhaust pipe nut M8 2 15 N·m (1.5 kgf·m, 11 lb·ft)
2-11

Thread
size
Exhaust assembly bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Exhaust protector bolt M6 3 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Exhaust end cap bolt M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Crankcase bolt M6 13 10 N·m (1.0 kgf·m, 7.4 lb·ft)
AC Magneto cover bolt M6 7 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Timing mark accessing screw M14 1 3 N·m (0.3 kgf·m, 2.2 lb·ft)
Crankshaft end accessing screw M32 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Clutch cover bolt M6 10 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Drive sprocket cover bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Reference
tightening
Engine oil level plug M20 1 Contact closely spot face torque: 3 N·m
(0.3 kgf·m,
2.2 lb·ft)
Under cover bracket bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Starter clutch bolt M6 3 14 N·m (1.4 kgf·m, 10 lb·ft) LT
Primary drive gear nut M12 1 60 N·m (6.0 kgf·m, 44 lb·ft)

Clutch spring bolt M6 3 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Short clutch push rod locknut M6 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Clutch boss nut M14 1 70 N·m (7.0 kgf·m, 52 lb·ft)
Clutch cable locknut (engine side) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Drive sprocket retainer bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Crankcase bearing retainer screw M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) LT
Shift drum segment screw M6 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT
Stopper lever bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Stator coil bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Crankshaft position sensor bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
AC Magneto rotor nut M12 1 70 N·m (7.0 kgf·m, 52 lb·ft)

Gear position switch M5 2 3.5 N·m (0.35 kgf·m, 2.6 lb·ft) LT
Starter motor bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Coolant temperature sensor M10 1 15 N·m (1.5 kgf·m, 11 lb·ft)
O² sensor M12 1 25 N·m (2.5 kgf·m, 18 lb·ft)
Solenoid motor bolt (VVA) M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Crankcase and plug bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
2-12

TIP
Cylinder head bolt
Tighten the cylinder head bolts “1”–“6” in the proper tightening sequence as follows:
1. Lubricate the cylinder head bolts “1”–“4” threads and mating surface with molybdenum disulfide
grease.
2. Tighten the cylinder head bolts “1”–“4” to 12 N·m (1.2 kgf·m, 8.9 lb·ft).
3. Tighten the cylinder head bolts “1”–“4” to 24 N·m (2.4 kgf·m, 18 lb·ft).
4. After loosing each 4 bolt according to tightening order, and tightening bolts at process step 2 and 3
again (it is tighten after loosening all bolts).
5. Tighten the cylinder head bolts “5” and “6” to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
2-13
3 4
×2 1 2
×4
6 5
Magneto cover tightening sequence:
Clutch cover tightening sequence:
6
1,7
8
5
9
4 10
3,13 11
2,12
Crankcase tightening sequence:
A B
15
1,7
8
16
9
6
10
2,13
5
4 11
3,14 12
A. Left crankcase
B. Right crankcase
2-14

EAS30017
CHASSIS TIGHTENING TORQUES

Thread
size
Handle crown pinch bolt M8 2 21 N·m (2.1 kgf·m, 15 lb·ft)
Lower bracket pinch bolt M10 2 30 N·m (3.0 kgf·m, 22 lb·ft)
Lower ring nut (initial tightening) M25 1 48 N·m (4.8 kgf·m, 35 lb·ft) See TIP.
Lower ring nut (final tightening) M25 1 18 N·m (1.8 kgf·m, 13 lb·ft) See TIP.
Steering stem bolt M10 1 18 N·m (1.8 kgf·m, 13 lb·ft)
Handlebar pinch bolt M8 2 21 N·m (2.1 kgf·m, 15 lb·ft)
Handle crown and handlebar bolt M6 2 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Front brake master cylinder holder bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Throttle cable locknut M6 2 4 N·m (0.40 kgf·m, 3.0 lb·ft)
Throttle cable plate screw M5 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
Throttle cable adjusting nut - 1 4 N·m (0.40 kgf·m, 3.0 lb·ft)
Right handlebar switch screw M5 2 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
Left handlebar switch screw M5 2 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
Grip end bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Clutch lever holder bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Clutch lever nut M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Clutch lever switch screw - 1 0.6 N·m (0.06 kgf·m, 0.4 lb·ft) LT
Main switch bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) LT
Engine mounting nut M10 2 45 N·m (4.5 kgf·m, 33 lb·ft) LS
Engine mounting bolt M10 2 45 N·m (4.5 kgf·m, 33 lb·ft)

Pivot shaft nut M12 1 70 N·m (7.0 kgf·m, 52 lb·ft) LS
Rear shock absorber assembly lower

M10 1 44 N·m (4.4 kgf·m, 32 lb·ft) LS
nut
Rear shock absorber assembly upper
M10 1 44 N·m (4.4 kgf·m, 32 lb·ft)
nut
Relay arm and frame nut M10 1 44 N·m (4.4 kgf·m, 32 lb·ft) LS
Connecting arm and relay arm nut M10 1 44 N·m (4.4 kgf·m, 32 lb·ft) LS
Connecting arm and swingarm nut M10 1 44 N·m (4.4 kgf·m, 32 lb·ft) LS
Drive chain case bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Rear fender bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Drive chain seal guard bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Rearview mirror bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front fender bolt M6 5 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front wheel axle nut M14 1 38 N·m (3.8 kgf·m, 28 lb·ft) LS
Front brake hose holder bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
2-15

Thread
size
Horn 2 bracket bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)
Front brake hose union bolt (caliper) M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
Rear wheel axle nut M14 1 59 N·m (5.9 kgf·m, 44 lb·ft) LS
Drive chain adjusting nut locknut M8 2 16 N·m (1.6 kgf·m, 12 lb·ft)

Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rectifier/regulator bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Horn 1 bracket bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Inner fender side cowling bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Upper side cowling (LH & RH) bolt
M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
(Lower side)
Upper side cowling (LH & RH) bolt
M6 2 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
(Upper side)
Lower side cowling (LH & RH) bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Upper side cowling screw M5 6 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Lower side cowling (LH & RH) screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Inner fender screw M5 4 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Side cowling stay bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Headlight stay bolt M8 2 35 N·m (3.5 kgf·m, 26 lb·ft)
Headlight mounting screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Front upper side cowling assembly
M5 6 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
screw
Headlight assembly bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Headlight cover screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Auxiliary light and Front upper side
M5 6 1 N·m (0.10 kgf·m, 0.73 lb·ft)
cowling screw
Auxiliary light and headlight stay screw M5 4 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Meter screw M5 3 1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
Meter bracket & stay bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Meter cover and meter bracket bolt M5 2 3 N·m (0.3 kgf·m, 2.2 lb·ft)
Windshield screw M5 6 0.4 N·m (0.04 kgf·m, 0.29 lb·ft)
Passenger seat lock bolt M6 1 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
Seat bracket nut M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Side panel screw (M5) M5 4 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Side panel screw (M6) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rear side cowling bolt (with collar) M6 2 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Rear side cowling bolt M6 4 11 N·m (1.1 kgf·m, 21 lb·ft) LT
2-16

Thread
size
Rear side cowling and rear panel bolt
M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) LT
(M5)
Seat bracket cover screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Rear panel screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Battery box bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Rear fender cowling screw M6 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Passenger seat bracket bolt M8 2 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Mud guard nut (upper side) M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rear fender bracket and mud guard
M5 4 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
(upper) bolt
Lean angle sensor screw M4 2 2 N·m (0.2 kgf·m, 1.5 lb·ft)
Reflector nut M5 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
Tail light assembly screw M5 2 1 N·m (0.10 kgf·m, 0.73 lb·ft)
License light assembly screw M4 1 0.25 N·m (0.025 kgf·m, 0.18 lb·ft)
License light bulb screw - 2 0.4 N·m (0.04 kgf·m, 0.29 lb·ft)
Fuel tank bracket bolt (front) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fuel tank bracket bolt (Rear) M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fuel tank mounting bolt (Front) M8 2 25 N·m ( 2.5 kgf·m, 18 lb·ft)
Fuel tank mounting bolt (Rear) M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Fuel pump retainer bolt M5 4 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Fuel tank cap bolt M5 3 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Fuel tank cap and filler box bolt M5 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Fuel tank fitting bracket bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fuel tank component & cover bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Fuel tank fitting & side cover bolt M5 2 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
Fuel tank side cover screw M5 6 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Fuel tank side cover & frame screw M5 2 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
Canister assembly bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Mud protector assembly bolt M6 4 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Mud guard and stay bolt M6 4 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Rear stay assembly bolt (LH & RH) M6 8 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Front fork cap bolt M30 2 23 N·m (2.3 kgf·m, 17 lb·ft)
Front fork piston rod locknut - 2 17 N·m (1.7 kgf·m, 13 lb·ft)
Front fork piston rod stopper (RH) - 1 18 N·m (1.8 kgf·m, 13 lb·ft)
Damper rod bolt (LH front Fork) - 1 23 N·m (2.3 kgf·m, 17 lb·ft) LT
Shift arm bolt M6 1 15 N·m (1.5 kgf·m, 11 lb·ft)

Sidestand nut M10 1 44 N·m (4.4 kgf·m, 32 lb·ft)
2-17

Thread
size
Side stand switch bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft) LT
Rear footrest bracket bolt M8 4 28 N·m (2.8 kgf·m, 21 lb·ft)

Rider footrest bracket bolt M8 4 34 N·m (3.4 kgf·m, 25 lb·ft)
Rider footrest bolt M10 1 56 N·m (5.6 kgf·m, 41 lb·ft) LT
Brake pedal Bolt M10 1 30 N·m (3.0 kgf·m, 22 lb·ft) LT
Rider footrest pin bolt M8 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) LT
Rear brake switch stay bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Shift rod and rod joint nut M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Shift rod and quick shift switch
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
assembly nut
Rod joint and quick shift switch
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
assembly nut
Shift pedal and rod joint bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Rod joint and shift arm bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Air filter assembly cover screw M5 4 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
Engine ground bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake hose union bolt (master
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
cylinder)
Front brake hose union bolt (Hydraulic
M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
unit side)
Front brake master cylinder reservoir
M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
cap screw
Brake lever bolt M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft) S
Brake lever nut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)

Front brake light switch screw M4 1 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
Front brake caliper sliding pin bolt
- 1 14 N·m (1.4 kgf·m, 10 lb·ft)
(small)
Front brake caliper sliding pin bolt
- 1 23 N·m (2.3 kgf·m, 17 lb·ft)
(long)
Front brake caliper bleed screw - 1 14 N·m (1.4 kgf·m, 10 lb·ft)
Front brake disc bolt M8 5 23 N·m (2.3 kgf·m, 17 lb·ft) LT
Front wheel sensor rotor screw M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Front wheel speed sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake hose and frame (Master
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
cylinder to Hydraulic unit) bolt
Front brake hose and frame (Hydraulic
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
unit to caliper) bolt
Rear brake hose union bolt (Caliper
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
side)
Rear brake hose union bolt (Master
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
cylinder side)
2-18

Thread
size
Rear brake master cylinder bolt M8 2 23 N·m (2.3 kgf·m, 17 lb·ft)
Rear brake master cylinder rod locknut M8 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Brake fluid reservoir bolt M6 1 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Rear wheel sprocket nut M8 6 43 N·m (4.3 kgf·m, 32 lb·ft)
Rear brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft) LT
Rear brake caliper pin bolt (small) - 1 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Rear brake caliper pin bolt (long) - 1 22 N·m (2.2 kgf·m, 16 lb·ft)
Rear brake pad retaining bolt - 2 17 N·m (1.7 kgf·m, 13 lb·ft)
Rear brake caliper bleed screw - 1 5 N·m (0.5 kgf·m, 3.7 lb·ft)
Rear wheel sensor and rear caliper
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
bolt
Rear wheel sensor rotor screw M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Rear brake hose union bolt (Hydraulic

M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
unit side)
Hydraulic unit and hydraulic unit
M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
bracket bolt
Hydraulic unit bracket and frame bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rear brake hose holder and frame bolt
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
(Rear side)
Rear brake hose holder and bracket
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
(lower side of frame)
Rear brake hose holder and rear brake
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
hose bolt (lower side of frame)
TIP
• Tighten the lower steering ring nut 48 N·m (4.8 kgf·m, 35 lb·ft) with a torque wrench.
• Turn the steering shaft to left or right several times and make sure the steering shaft turns smoothly.
• Loosen the lower steering ring nut 1/4 turn.
• Re-tighten the lower steering ring nut to 18 N·m (1.8 kgf·m, 13 lb·ft) with a torque wrench.
2-19
LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS20299
LUBRICATION POINTS AND LUBRICANT TYPES

EAS1MC1085
ENGINE
Lubrication point Lubricant
Oil seal lips LS
Bearings E
O-rings LS
Cylinder head bolt seats, cylinder head bolt threads and washers M
Water pump seal and impeller shaft LS
Connecting rod big end E
Crankshaft bearing inner surface M
Piston pin E
Cylinder inner surface, piston, ring grooves, and piston rings E
Balancer driven gear inner surface E
Camshaft lobes and camshaft O-ring M
Rocker arm rollers/Spring M
Decompression cam M
Valve stem seals E
Valve stem and valve stem ends M
Rocker arm shafts/Intake rocker arm stopper pin M
Rocker arm inner surface M
Decompression arm pivoting point M
Oil pump driven gear shaft E
Oil pump inner and outer rotor E
Fuel injector O-ring E
Starter clutch gear thrust surfaces and washer E
Starter clutch rollers and starter clutch gear boss E
Starter clutch idle gear shaft and starter clutch idle gear inner surface E
Starter clutch idle gear thrust surfaces and washer E
Clutch push lever E
Clutch plates and friction plates E
Primary driven gear inner surface E
Long clutch push rod E
Solenoid motor plunger M
2-20

Short clutch push rod E
Clutch push rod ball E
Clutch boss nut seat and clutch boss nut thread E
Main axle and pinion gears M
Drive axle and wheel gears M
Shift drum assembly E
Shift forks and shift fork guide bar E
Shift shaft E
Yamaha bond
No. 1215
Crankshaft position sensor/stator assembly lead grommet
(Three bond
No.1215-B)
Yamaha bond
No. 1215
Crankcase mating surfaces
(Three bond
No.1215-B)
Yamaha bond
No. 1215
Timing chain tensioner bolt threads
(Three bond
No.1215-B)
2-21

EAS1MC1085
CHASSIS
Front wheel axle nut thread LS
Front wheel oil seal lip LS
Front wheel axle nut seat LS
Rear wheel axle and nut thread LS
Rear wheel axle nut seat LS
Rear wheel drive hub oil seal lip LS
Rear wheel drive hub mating surface LS
Rear wheel oil seal lip LS
Brake lever pivot bolt outer surface S
Brake lever and master cylinder contact point S
Front brake caliper bracket boots inner surface S
Front brake caliper piston oil seal BF
Front brake caliper dust seal S
Rear brake caliper bracket boots inner surface S
Rear brake caliper piston oil seal BF
Rear brake caliper dust seal S
Rear brake master cylinder boot S
Rear brake master cylinder piston surface BF
Rear brake master cylinder rod and piston contact point S
Tube guide (throttle grip) inner surface and throttle cable LS
Clutch cable end at the clutch lever LS
Clutch lever pivoting point and metal-to-metal moving parts LS
Passenger footrest pivoting point and ball LS
Sidestand pivoting point and metal-to-metal moving parts LS
Sidestand spring-to-hook mating point LS
Shift pedal pivoting point and metal-to-metal moving parts LS
Shift pedal rod joint sliding surface LS
Rear brake pedal pivoting point and metal-to-metal moving parts LS
Steering bearings upper bearing cover lip LS
2-22

Steering head dust seal lip LS
Bolt outer surface (relay arm) LS
Nut seats (relay arm and swingarm) LS
Bolt and nut thread (relay arm and flame) LS
Bolt and nut thread (relay arm and connecting arm) LS
Bolt and nut thread (relay arm and rear shock absorber) LS
Bolt and nut thread (swingarm and connecting arm) LS
Oil seal lips (relay arm and swingarm) LS
Collars (relay arm and swingarm) LS
Pivot shaft outer surface LS
Pivot shaft and nut thread LS
Swingarm bushing outer surface LS
Swingarm dust cover lips LS
Seat lock moving parts LS
Engine mounting bolt threads LS
2-23
LUBRICATION SYSTEM CHART AND DIAGRAMS SPEC

EAS20021
LUBRICATION SYSTEM CHART AND DIAGRAMS

ENGINE OIL LUBRICATION CHART
1. Oil pan
2. Oil strainer
3. Oil pump
4. Oil filter element
5. Main axle
6. Drive axle
7. Crankshaft
8. Camshaft
9. Cylinder head cover
2-24

EAS32363
LUBRICATION DIAGRAMS

2. Camshaft
3. Crankshaft
4. Oil filter assembly
5. Oil pump assembly 2
6. Oil strainer
7. Main axle
8. Drive axle
9. Clutch push lever
8
4
2-25

1. Drive axle
2. Main axle
4. Camshaft
5. Crankshaft
6. Oil filter
7. Oil pump
8. Oil strainer
2-26
COOLING SYSTEM DIAGRAMS SPEC

EAS20299
COOLING SYSTEM DIAGRAMS

1 Thermostat assembly È Insert the pipe to root.
2 Coolant reservoir hose É White paint of hose (thermostat to water pump) face
3 Radiator inlet hose should be right side of the vehicle.
4 Radiator cap Ê Recommend installing before throttle body assembly.
5 Radiator
6 Radiator outlet hose
7 Hose (Thermostat to water pump)
2-27

1 Air bleed bolt
2 Water pump assembly
3 Water pump inlet hose
2-28

1 Coolant reservoir hose È Insert the pipe to root.
2 Radiator inlet hose É Fix the clip before 2-4 mm from water pump inlet hose
3 O-ring end as shown.
4 Clip Ê Direction of the clip up-side of the vehicle.
5 Water pump inlet hose Ë Direction of the clip right-side of the vehicle.
6 Radiator
7 Radiator outlet hose
2~4 mm
45
º
2-29

1 Hose clamp È Direction up-side of the vehicle.
2 Thermostat assembly É Direction right-side of the vehicle.
Ê Ensure clearance is more than 10 mm.
Ë Push in dropped clamp after tightening.
Ì Shall not be on spool.
Í Hose clamp should be in this direction.
2-30
CABLE ROUTING SPEC

EAS20021
CABLE ROUTING
Front top view
2-31
CABLE ROUTING SPEC

1. Headlight assembly lead A. Fuel pump assembly lead and fuel sender lead
2. Meter assembly lead shall pass above ABS hydraulic unit.
3. Auxiliary light assembly lead (Right) B. ABS hydraulic unit lead shall be touched with wire
main harness assembly.
4. Throttle cable (Pull)
C. The plastic band shall be tighten after joint
5. Throttle cable (Return) connector lead clamp insert into the frame
6. VVA (Variable valve actuation) lead component.
7. Ignition coil D. This connector is prepare for accessory.
8. Turn signal relay E. Clamp left auxiliary light lead on surface of
9. Fuel injector lead headlight stay.
10. Radiator fan motor relay F. Meter assembly lead and headlight assembly lead
shall be set as shown in this drawing.
11. ABS hydraulic unit lead
G. Pass the headlight control unit lead into headlight
12. Fuel injector assembly guide.
13. Fuel hose H. Plastic band shall not be cut, tip of plastic band
14. Starter motor lead shall be directed front, wire harness assembly shall
15. Air filter assembly be clamped to frame component on white tape.
16. Speed sensor lead I. Wire harness assembly shall be clamped to frame
component at outside of engine stay. Tip direction
17. Fuel drain hose of plastic band shall be same as “J”. Do not cut
18. Fuel pump assembly plastic band .
19. Breather hose J. Plastic band shall be set as shown in this drawing.
20. Joint connector tip of plastic band shall not come out of hatching
area.
21. Rectifier regulator assembly
K. Plastic band of wire harness shall be inserted into
22. Radiator fan motor lead 4th hole of frame component.
23. Horn lead L. Do not cut plastic band, direct tip of plastic band
24. Clutch cable forward.
25. Left handlebar switch lead M. Pass the radiator fan motor lead through hole of
26. Front left turn signal light lead radiator cover.
27. Auxiliary light assembly lead (Left) N. Pass the front turn signal light lead (Left & Right)
in the structure of left & right side inner panel. After
28. Headlight stay connected with main wire harness assembly lead
29. Front right turn signal light lead of front turn signal light (left & right) shall pull in
30. Meter bracket direction of arrow.
31. Meter assembly O. Connector of auxiliary light assembly (left & right)
shall be inserted into headlight stay.
32. Meter assembly cover
P. Clamp of wire harness shall be inserted into
33. Headlight Light control unit headlight stay.
34. Headlight assembly
35. Wire harness
36. Frame component
37. Engine stay
38. Plastic band
39. Radiator cover
40. Front turn signal light lead (Left & Right)
41. Left & right side inner panel
2-32
CABLE ROUTING SPEC

Rear top view
2-33
CABLE ROUTING SPEC

1. Starter relay A. Lead wires shall be clamped by hook of right side
2. Rear brake light switch lead fender. (In any random order)
3. Positive battery lead B. Wire harness assembly shall be clamped to right
side of fender at the claw.
4. Fuse box
C. Hook of fuse box shall be inserted into right side
5. Lean angle sensor lead fender.
6. Taillight assembly lead D. Band of ECU shall be inserted to right side fender.
7. OBD lead E. After connecting OBD lead and S-CCU (Simple
8. Rear right turn signal light lead communication control unit), OBD lead shall put in
9. License plate light assembly lead under S-CCU.
10. Rear left turn signal light lead F. Lead and connector of taillight assembly (3 pin
connector), license light assembly (2 pin
11. S-CCU (Simple communication control unit) connector) and rear turn signal light assembly (left
12. Lean angle sensor & right) shall be covered by connector cover.
13. ECU (Engine control unit)
14. Negative battery lead
15. Battery box
16. Starter relay lead
17. Rear speed sensor lead
18. Fender
19. Wire harness
20. Fuse box lead
21. ECU band
22. Connector cover
2-34
CABLE ROUTING SPEC

Front left view
2-35
CABLE ROUTING SPEC

1. Clutch cable A. Joint connector shall be placed so that rubber
2. Left side tank rail opening face downward as shown in drawing.
3. Horn lead B. Clamp shall be touched with left side tank rail.
4. Fuel sender lead C. No slack within the span illustrated by arrows when
clamp the wire.
5. Fuel pump lead
D. Clamp of side stand switch lead shall be inserted
6. Fuel hose
into left under cover bracket (Left).
7. Radiator cover
E. Pass the clutch cable through engine assembly
8. Gear position switch lead guide.
9. Sidestand switch lead F. Sidestand switch lead shall be clamped at the
10. Under cover bracket (Left) center of wire guide of stay.
11. Quick shift switch lead G. Pass the clutch cable through guide.
12. Radiator hose (Overflow) H. To headlight assembly, meter assembly, front turn
13. Stay signal & auxiliary light.
14. O2 sensor lead I. Terminal of horn lead shall be directed to outside
of motorcycle.
15. Throttle cable (Return)
J. Left handlebar switch lead shall pass outside of
16. Throttle cable (Pull)
throttle cables and clutch cable.
17. Horn bracket
K. Pass the fuel drain hose above the cylinder head
18. Left handlebar switch lead breather hose of air filter assembly.
19. Wire guide L. AC magneto lead shall be clamped to frame on
20. Frame component white tape. Tip of plastic band shall be directed
21. Cylinder head breather hose inside of vehicle. Do not cut plastic band.
22. Air filter assembly M. Clamp of quick shift switch lead shall be inserted
23. Fuel drain hose into left under cover bracket (Left).
24. Plastic band N. Cut tip of the plastic band to 10 mm maximum. Tip
direction of plastic band needs not be controlled.
25. Wire harness assembly
O. Either plastic band install direction shall be
26. AC magneto lead
allowed. Plastic band shall not be cut. Direct tip of
27. Rectifier regulator assembly plastic band in forward direction.
28. Radiator inlet hose P. Plastic band shall not be cut. Direct tip of plastic
band in downward direction. Sidestand switch lead
and quick shift switch lead shall be clamped to stay
on white tape.
2-36
CABLE ROUTING SPEC

Rear left view
40
mi
n.
40
mi
n.
2-37
CABLE ROUTING SPEC

1. AC magneto connector cover A. Route rear turn signal light lead and license plate
2. Air filter assembly light lead as shown.
3. CCU (Communication control unit) B. AC magneto lead and neural switch lead and
4. Tail light unit lead negative battery lead shall clamped to the frame
component. Tip of plastic band shall be parallel
5. Fender with back stay.
6. Negative battery lead C. Negative battery lead shall be touched with engine
7. Back stay stay.
8. Engine stay D. Tip of fuel drain hose and canister breather hose
9. AC magneto lead shall be directed as shown in drawing. (Cutted
10. Frame component surface shall be directed backward).
11. Lean angle sensor lead E. Gear position switch lead and AC magneto lead
12. Rear brake light switch lead shall not slack.
13. Wire harness assembly F. AC magneto and neutral connector shall be
covered by connector cover.
14. OBD lead
G. Negative battery lead shall be clamped at lower
15. Cross tube side of wire harness assembly.
16. Gear position switch lead H. Plastic band shall not be cut. Tip of plastic band
17. Battery band shall be directed outside. Plastic band shall be
18. Battery through hole of frame components.
19. Rear arm component I. Negative battery lead, AC magneto and gear
20. Engine assembly position switch lead shall be clamped to cross tube
21. Fuel drain hose on protector at outside of engine stay mounting
bracket.
22. Canister breather hose
J. Clamp of wire harness shall be inserted to frame
23. Main stand bracket component.
K. Each hose shall not be stacked with each other.
L. Pass fuel drain pipe through inside of engine stay.
M. Pass fuel drain hose and breather hose through
the slit of mud guard.
2-38
CABLE ROUTING SPEC

Rear right view
2-39
CABLE ROUTING SPEC

1. Fuse box A. Clamp shall be touched with welding bead of fuel
2. Positive battery lead tank fitting bracket.
3. Starter relay B. Route the rear brake light switch lead through wire
guide.
4. Fuel tank fitting bracket
C. Direct insert direction.
5. Canister assembly
D. Connector shall be inserted on plate.
6. Rear brake light switch
E. Insert the starter relay assembly to rear frame.
7. Rear wheel speed sensor lead
F. Wire harness shall be clamped to frame
8. Rear frame component on white tape.
9. Fuse box lead G. Tip of plastic band shall be directed downward.
10. Plate Positive battery lead shall be clamped to frame
11. Starter relay lead component on white tape.
12. Frame component
13. Rear brake light switch lead
2-40
CABLE ROUTING SPEC

Front right view
2-41
CABLE ROUTING SPEC

1. Fuel tank assembly A. Insert spark plug lead of ignition coil into spark plug
2. Fuel tank breather hose cap.
3. Throttle cable (Pull) B. Clamped coolant temperature sensor lead to frame
component on white tape.
4. Throttle cable (Return)
C. O2 sensor connector shall be bottom side of plate.
5. Left handlebar switch lead
D. Plastic band shall not be cut. Direct tip of plastic
6. Front wheel speed sensor
band upper side and inside of ignition coil. Ignition
7. VVA lead coil lead shall be clamped on white tape with frame
8. Spark plug lead component.
9. O2 sensor lead E. Plastic band shall not be cut. Direct tip of plastic
band forward and inside ignition coil. Ignition coil
10. Coolant temperature sensor lead lead shall be clamped on white tape with frame.
11. Starting motor F. Insert the rubber cover into frame component.
12. Radiator hose (Thermostat to water pump) G. Cover the main switch lead, left handlebar switch
13. Starting motor lead lead & connector, right handlebar switch connector
14. Purge hose (Canister to throttle body) and front wheel speed sensor connector with
rubber cover.
15. Throttle body sensor assembly lead
H. Rubber cover shall include lead and be clamped.
16. FID (Fast idle solenoid device) lead Clamp shall be clamped so as not to be rotated.
17. FID (Fast idle solenoid device) Tip of plastic band shall be directed downward.
18. Ignition coil lead Plastic band shall not be cut.
19. Frame component I. Tip of plastic band shall be directed backward.
Plastic band shall not be cut. Positive battery lead
20. Ignition coil shall be clamped to frame component on white
21. Rubber cover tape.
22. Main switch lead J. Tighten clamp on white paint of O2 sensor lead,
23. Rubber cover clamp shall be inserted on to hole of right side
under cover bracket. Protector twisting shall be
24. Right handlebar switch lead
allowed after insertion of clamp into right side
25. Negative battery lead under cover bracket.
26. Right side under cover bracket K. Tip of plastic band shall be 10 mm max. direction
of clamp needs not be controlled.
L. Coolant temperature sensor lead through inside of
radiator hose (thermostat to water pump)
M. Plastic band shall not be cut. Direct tip of plastic
backward.
2-42
CABLE ROUTING SPEC

Steering system
FR
90 º
2-43
CABLE ROUTING SPEC

1. Rubber cover A. Right handlebar switches (blue & black connector)
2. Right handlebar switch lead & main switch (white connector) shall be connect
under rubber cover not into rubber cover.
3. Main switch lead
B. Main switch lead routing shall be parallel with right
4. Left handlebar switch lead handlebar switch lead.
5. Left handlebar switch C. Clutch cable, throttle cables and left handlebar
6. Cable guide switch lead shall pass through cable guide.
7. Throttle cable (Pull) D. Pass the throttle cables front side of clutch cable.
8. Throttle cable (Return) E. Pass the throttle cables above front brake hose
9. Clutch switch connector (Master cylinder to ABS hydraulic unit).
10. Lever holder F. Pass the main switch lead through cable guide.
11. Clutch switch lead G. No slack between each clamps.
12. Crown handle H. Left handlebar switch lead shall be clamped on
tape.
13. Clutch cable
I. Pass the throttle cables through hole of radiator
14. Radiator cover cover.
15. Front brake hose (Master cylinder to ABS hydraulic J. Left handlebar switch lead shall be clamped to
unit) front fork assembly.
16. Horn K. Left handlebar switch lead shall be clamped in this
17. Horn lead area. (target position shall be center of this area.
18. Frame component
19. Radiator assembly
2-44
CABLE ROUTING SPEC

Front brake system
45°
°
45
2-45
CABLE ROUTING SPEC

1. Frame component
2. Front fork assembly
3. Front wheel sensor assembly lead
4. Front fender
5. Front brake hose
6. Front brake hose (ABS hydraulic unit to front brake
caliper)
7. Front brake hose clamp
A. Front wheel sensor lead shall be passed to fit to
front brake hose assembly profile.
B. Stopper of front brake hose holder shall be
touched with front fork assembly.
C. When assembling front wheel sensor lead to lead
holder, application of silicone oil to front wheel
sensor lead assembly shall be allowed.
D. Fix clamp on white tape of front wheel sensor.
E. When assembling front wheel sensor lead to
frame, application of silicone oil to front wheel
sensor lead assembly shall be allowed.
F. Front wheel sensor assembly shall be passed as
shown on this drawing.
G. Attach the clamp part to the rear side.
H. Front wheel sensor assembly lead should be in the
range shown in illustration.
I. Front brake hose (ABS hydraulic unit to front brake
caliper) shall be conformed to stopper of front
caliper assembly.
2-46
CABLE ROUTING SPEC

Canister Assembly
1. Fuel tank assembly A. Insert the pipe until the step of hose (Fuel tank to
2. Hose (Fuel tank to canister assembly) canister assembly).
3. Frame component B. Clip knob shall be directed backward of the vehicle.
4. Canister assembly C. Insert the hose till this surface.
5. Hose (canister to atmosphere)
6. Check valve
7. Hose (canister to throttle body)
8. Throttle body assembly
2-47
CABLE ROUTING SPEC

Canister Assembly
1. Hose (Fuel tank to canister assembly) A. Insert the hose till this end.
2. Throttle body
3. Hose (canister to atmosphere)
4. Canister assembly
5. Frame component
6. Clip
2-48
CABLE ROUTING SPEC

Canister Assembly
1. Frame component A. Insert the hose (Fuel tank to canister) and hose
2. Hose (Fuel tank to canister) (canister to check valve) until this surface.
3. Check valve B. White mark shall be directed upward.
4. Hose (Canister to throttle body) C. Clip knob shall be directed upward.
5. Hose (Canister to check valve) D. Clip knob shall be set mark.
E. Blue mark shall be directed outside of the vehicle.
6. Canister assembly F. The end of pipe shall be installed until contact.
G. Clip knob shall be directed downword.
H. Collar should be installed from the front direction.
2-49
CABLE ROUTING SPEC

ABS System
1. ABS hydraulic unit
2. ABS hydraulic unit bracket
3. Front brake hose (ABS hydraulic unit to master
cylinder)
4. Front brake hose (ABS hydraulic unit to brake caliper)
5. Rear brake hose (ABS hydraulic unit to brake master
cylinder)
6. Rear brake hose (ABS hydraulic unit to brake caliper)
2-50
CABLE ROUTING SPEC

ABS System
1. ABS hydraulic unit bracket A. To rear brake master cylinder.
2. ABS hydraulic unit B. To rear brake caliper.
3. Rear brake hose (ABS hydraulic unit to brake caliper)
4. Rear brake hose (ABS hydraulic unit to brake master
cylinder)
2-51
CABLE ROUTING SPEC

ABS System
2-52
CABLE ROUTING SPEC

1. Clamp
2. Rear brake hose holder
3. Rear brake hose (ABS hydraulic unit to brake
caliper)
4. Rear brake hose (ABS hydraulic unit to master
cylinder)
5. Front brake hose (ABS hydraulic unit to master
cylinder)
6. Front brake hose (ABS hydraulic unit to brake
caliper)
7. ABS hydraulic unit
8. Frame component
A. Clamp shall be touched with flare nut.
B. To front brake master cylinder.
C. To front brake caliper assembly.
D. Front brake hose shall be touched with frame
assembly.
E. Both rear brake hose shall be touched with brake
hose holder.
F. To rear brake master cylinder.
G. Assembling direction no need to be controlled.
H. Front brake hose (ABS hydraulic unit to master
cylinder) shall be touched with frame component.
I. Rotation stopper of rear brake hose holder shall be
touched with frame component.
2-53
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
ENGINE ..........................................................................................................3-4
CHECKING THE VEHICLE USING THE
YAMAHA DIAGNOSTIC TOOL ...............................................................3-4
ADJUSTING THE VALVE CLEARANCE .................................................3-4
ADJUSTING THE ENGINE IDLING SPEED ............................................3-6
CHECKING THE THROTTLE GRIP .........................................................3-7
ADJUSTING THE THROTTLE GRIP FREE PLAY ..................................3-7
CHECKING THE SPARK PLUG ..............................................................3-8
MEASURING THE COMPRESSION PRESSURE ...................................3-8 3
CHECKING THE ENGINE OIL LEVEL .....................................................3-9
CHANGING THE ENGINE OIL .............................................................. 3-10
ADJUSTING THE CLUTCH LEVER FREE PLAY .................................. 3-11
REPLACING THE AIR FILTER ELEMENT ............................................ 3-12
CHECKING THE THROTTLE BODY JOINT AND
AIR FILTER CASE JOINT ..................................................................... 3-14
CHECKING THE FUEL LINE ................................................................. 3-14
CHECKING THE CANISTER ................................................................. 3-14
CHECKING THE CYLINDER HEAD BREATHER HOSE ...................... 3-14
CHECKING THE EXHAUST SYSTEM ................................................... 3-15
CHECKING THE COOLANT LEVEL ...................................................... 3-15
CHECKING THE COOLING SYSTEM ................................................... 3-15
CHANGING THE COOLANT .................................................................. 3-16
CHASSIS ...................................................................................................... 3-18

CHECKING THE BRAKE OPERATION ................................................. 3-18
CHECKING THE BRAKE LEVER FREE PLAY ...................................... 3-18
CHECKING THE BRAKE FLUID LEVEL ................................................ 3-18
CHECKING THE FRONT BRAKE PADS ............................................... 3-19
CHECKING THE REAR BRAKE PADS ................................................. 3-19
CHECKING THE FRONT BRAKE HOSE ............................................... 3-19
CHECKING THE REAR BRAKE HOSE ................................................. 3-19
ADJUSTING THE REAR BRAKE LIGHT SWITCH ................................ 3-20
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) ........................ 3-20
ADJUSTING THE DRIVE CHAIN SLACK ..............................................3-21
LUBRICATING THE DRIVE CHAIN ....................................................... 3-22
CHECKING AND ADJUSTING THE STEERING HEAD ........................ 3-23
CHECKING THE FRONT FORK ............................................................ 3-24
CHECKING THE TIRES ......................................................................... 3-24
CHECKING THE WHEELS ....................................................................3-26
CHECKING THE WHEEL BEARINGS ................................................... 3-26
CHECKING THE SWINGARM OPERATION ......................................... 3-26
LUBRICATING THE SWINGARM PIVOT ..............................................3-26
CHECKING AND LUBRICATING THE CABLES END ........................... 3-26
LUBRICATING THE STEERING HEAD ................................................. 3-26

CHECKING THE CHASSIS FASTENERS ............................................. 3-26
LUBRICATING THE CLUTCH LEVER ................................................... 3-26
LUBRICATING THE BRAKE LEVER ..................................................... 3-26
LUBRICATING THE PEDALS ................................................................ 3-27
CHECKING THE SIDESTAND ............................................................... 3-27
LUBRICATING THE SIDESTAND .......................................................... 3-27
LUBRICATING SHIFT PEDAL ROD JOINT ........................................... 3-27
LUBRICATING THE REAR SUSPENSION ............................................ 3-27
ELECTRICAL SYSTEM ................................................................................ 3-28

CHECKING AND CHARGING THE BATTERY ...................................... 3-28
CHECKING THE FUSES ....................................................................... 3-28
REPLACING TURN SIGNAL INDICATOR LIGHT BULB ....................... 3-28
REPLACING LICENSE PLATE LIGHT BULB ........................................ 3-28
ADJUSTING THE HEADLIGHT BEAMS ................................................ 3-28
CHK
PERIODIC MAINTENANCE ADJ
EAS20022
PERIODIC MAINTENANCE
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAUE0173
TIP
l From 25000 km (15000 mi), repeat the maintenance intervals starting from 5000 km (3000 mi).
l Items marked with an asterisk (*) should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
EAUE0222
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE JOB 1000 km 5000 km 9000 km 13000 km 17000 km 21000 km
(600 mi) (3000 mi) (5400 mi) (7800 mi) (10200 mi) (12600 mi)
• Check fuel hoses for cracks or

1 * Fuel line √ √ √ √ √ √
damage.
• Check condition.
2 * Fuel filter Every 9000 km (5400 mi)
• Replace if necessary.
• Check condition.
√ √ √ √ √
3 * Spark plug • Clean and regap.
• Replace. √
• Check valve clearance. Adjust if
4 * Valves √ √ √ √ √ √
necessary.
5 * Fuel injection • Adjust engine idling speed. √ √ √ √ √ √
• Check for leakage.
6 * Exhaust system • Tighten if necessary. √ √ √ √ √
• Replace gasket(s) if necessary.
• Check control system for dam-
Evaporative emis-
7 * age. √ √
sion control system
• Replace if necessary.
EAUE0885
GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
(600 mi) (3000 mi) (5400 mi) (7800 mi) (10200 mi) (12600 mi)
• Perform dynamic inspection us-

Diagnostic system
1 * ing Yamaha diagnostic tool. √ √ √ √ √ √
check
• Check the error codes.
2 * Air filter element • Replace. Every 17000 km (10200 mi)
• Check voltage.
3 * Battery √ √ √ √ √ √
• Charge if necessary.
• Check operation.
4 Clutch √ √ √ √ √ √
• Adjust.
• Check operation, fluid level and
√ √ √ √ √ √
5 * Front brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level and
√ √ √ √ √ √
6 * Rear brake vehicle for fluid leakage.
• Replace brake pads. Whenever worn to the limit
3-1
CHK
ODOMETER READING
(600 mi) (3000 mi) (5400 mi) (7800 mi) (10200 mi) (12600 mi)
• Check for cracks or damage.

• Check for correct routing and √ √ √ √ √ √
7 * Brake hose clamping.
• Replace. Every 4 years
8 * Brake fluid • Change. Every 2 years
9 * Wheels • Check runout and for damage. √ √ √ √ √ √
• Check tread depth and for dam-
age.
10 * Tires • Replace if necessary. √ √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness or
√ √ √ √ √ √
damage. Replace if necessary.
11 * Wheel bearings
• Lubricate with lithium-soap-
Every 13000 km (7800 mi)
based grease.
• Check operation and for exces-
√ √ √ √ √ √
sive play.
12 * Swingarm
Every 13000 km (7800 mi)
based grease.
• Check chain slack, alignment and
condition.
Every 500 km (300 mi) and after washing the motorcycle, riding in
13 Drive chain • Adjust and lubricate chain with a
the rain or riding in wet areas
special O-ring chain lubricant
thoroughly.
• Check bearing play and steering
√ √ √ √ √ √
for roughness.
14 * Steering bearings
Every 13000 km (7800 mi)
based grease.
• Make sure that all nuts, bolts and
15 * Chassis fasteners √ √ √ √ √ √
screws are properly tightened.
Brake lever pivot
16 • Lubricate with silicone grease. √ √ √ √ √ √
shaft
Brake pedal pivot • Lubricate with lithium-soap-
17 √ √ √ √ √ √
shaft based grease.
Clutch lever pivot • Lubricate with lithium-soap-
18 √ √ √ √ √ √
shaft based grease.
Shift pedal pivot • Lubricate with lithium-soap-
19 √ √ √ √ √ √
shaft based grease.
20 Shift pedal rod joint √ √ √ √ √ √
based grease.
21 Sidestand • Lubricate with lithium-soap- √ √ √ √ √ √
based grease.
• Check operation and replace if
22 * Sidestand switch √ √ √ √ √ √
necessary.
• Check operation and for oil leak-
√ √ √ √ √ √
23 * Front fork age. Repair if necessary.
• Replace oil. Every 13000 km (7800 mi)
Shock absorber as- • Check operation and shock ab-
24 * √ √ √ √ √ √
sembly sorber for oil leakage.
• Change.
25 Engine oil • Check oil level and vehicle for oil √ √ √ √ √ √
leakage.
Engine oil filter ele-
26 • Replace. √ √ √ √ √ √
ment
3-2
CHK
ODOMETER READING
(600 mi) (3000 mi) (5400 mi) (7800 mi) (10200 mi) (12600 mi)
• Check coolant level and vehicle

√ √ √ √ √ √
27 * Cooling system for coolant leakage.
• Change coolant. Every 2 years
Front and rear brake
28 * • Check operation. √ √ √ √ √ √
switches
Moving parts and ca-
29 • Lubricate. √ √ √ √ √ √
ble ends
• Check throttle grip free play, and
30 * Throttle grip adjust if necessary. √ √ √ √ √ √
• Lubricate cable end and grip
housing.
Lights, signals and • Check operation.
31 * √ √ √ √ √ √
switches • Adjust headlight beam.
EAU59350
TIP
l Air filter
• This model’s air intake system is equipped with a disposable oil-coated paper element. The air
filter element cannot be cleaned with compressed air, it must be replaced.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
l Hydraulic brake service
• After disassembling the brake master cylinder and caliper, always change the fluid. Regularly
check the brake fluid level and fill the reservoir as required.
• Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
• Replace the brake hose every four years and if cracked or damaged.
3-3
CHK
ENGINE ADJ
EAS30622
ADJUSTING THE VALVE CLEARANCE
ENGINE The following procedure applies to all of the
EAS32024 valves.
CHECKING THE VEHICLE USING THE TIP
YAMAHA DIAGNOSTIC TOOL
• Valve clearance adjustment should be made
Use the Yamaha diagnostic tool and check the
on a cold engine, at room temperature.
vehicle according to the following procedure.
• When the valve clearance is to be measured or
1. Remove:
adjusted, the piston must be at top dead center
• Passenger seat
(TDC) on the compression stroke.
Refer to “GENERAL CHASSIS (1)” on page
4-1. 1. Remove:
2. Connect: • Inner fender
• Yamaha diagnostic tool. • Lower side cowling (left and right)
Refer to “YAMAHA DIAGNOSTIC TOOL” on Refer to “GENERAL CHASSIS (3)” on page
page 8-32. 4-3.
• Fuel tank
Yamaha diagnostic tool Refer to “FUEL TANK” on page 7-1.
INS-018 • Radiator
(90890-03267) Refer to “RADIATOR” on page 6-1.
INS-019 2. Disconnect:
(90890-03264)
• Spark plug cap
3. Check: 3. Remove:
• Fault codes • Cylinder head cover
• Cylinder head cover gasket
TIP
Refer to “CYLINDER HEAD” on page 5-7.
Use the “Diagnosis of malfunction” function of
TIP
the Yamaha diagnostic tool to check the fault
codes. For information about using the Yamaha When removing the cylinder head cover, lift it out
diagnostic tool, refer to the operation manual from between the frame tubes.
that is included with the tool. 4. Remove:
Fault code number is displayed → Check and • Timing mark accessing screw “1”
repair the probable cause of the malfunction. • Crankshaft end accessing screw “2” (With
Refer to “TROUBLESHOOTING DETAILS center plug spanner)
(FAULT CODE)” on page 8-35.
4. Perform:
• Dynamic inspection
TIP
Use the “Dynamic inspection” function of the
Yamaha diagnostic tool version 3.0 to perform
the dynamic inspection. For information about
using the Yamaha diagnostic tool, refer to the
operation manual that is included with the tool.
5. Install:
• Passenger seat Center plug spanner
Refer to “GENERAL CHASSIS (1)” on page YSST-625
4-1.
5. Measure:
• Valve clearance
Out of specification → Adjust.
3-4
CHK
ENGINE ADJ
Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 in)
a. Turn the crankshaft counterclockwise.

b. Align the TDC mark “a” on the magneto ro-
tor with the stationary pointer “b” on the
magneto cover.
c. When the piston is at TDC on the com-
pression stroke, align the “I” mark “c” on
6. Adjust:
the camshaft sprocket with the mark “d” on
• Valve clearance
the camshaft stopper plate.
a. Loosen the locknut “1”.
b. Insert a feeler gauge “2” between the end
of the adjusting screw and the valve tip.
c. Turn the adjusting screw “3” in direction

“a” or “b” until the specified valve clear-
ance is obtained.
d. Check that the cam lobes are positioned (a)

as shown in the illustration.
(b)
Direction “a”
Valve clearance is increased.
e. Measure the valve clearance with a feeler Direction “b”
gauge “1”. Valve clearance is decreased.
3-5
CHK
ENGINE ADJ
NOTICE
Tappet screw holder
YSST-706 Check the RPM when coolant temperature is
(90890-04154) at 80–100°C.
Tappet adjusting socket 5. Remove:
YSST-706A
• Lower side cowling (left)
• Hold the adjusting screw to prevent it from Refer to “GENERAL CHASSIS (3)” on page
4-3.
moving and tighten the locknut to specifi-
cation. 6. Adjust:
• Engine idling speed
Valve adjusting screw locknut a. Turn the idle adjusting screw “1” in direc-
7 N·m (0.7 kgf·m, 5.2 lb·ft) tion “a” or “b” until the specified engine
T.
R.
idling speed is obtained.

d. Measure the valve clearance again.
e. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
7. Install:
• All removed parts
EAS30031
ADJUSTING THE ENGINE IDLING SPEED

TIP
• Prior to adjusting the engine idling speed, the Direction “a”
air filter element should be clean, and the en- Engine idling speed is increased.
gine should have adequate compression. Direction “b”
• Engine should be warm. Engine idling speed is decreased.
1. Start the engine and let it warm up for several TIP

minutes. Preferably set the RPM on lower side of specifi-
2. Remove: cation.
• Rider seat
Refer to “GENERAL CHASSIS (1)” on page WARNING
4-1. Never adjust RPM by screw at pulley “1”.
3. Connect:
• Yamaha diagnostic tool
Refer to “YAMAHA DIAGNOSTIC TOOL” on
page 8-32.
Yamaha diagnostic tool

INS-018
(90890-03267)
INS-019
(90890-03264)
4. Check:
Engine idling speed

1300–1500 r/min
3-6
CHK
ENGINE ADJ
7. Set the main switch to “OFF”. G088895
8. Disconnect:
• Yamaha diagnostic tool
9. Connect:
• Yamaha diagnostic tool coupler/ABS test
coupler to SCCU. a
10.Install:
• Passenger and rider seat
4-3.
EAS30815
Throttle grip free play (at the
CHECKING THE THROTTLE GRIP inner edge of the throttle grip)
1. Check: 3.0–5.0 mm (0.12–0.20 in)
• Throttle cables
2. Adjust:
Damage/deterioration → Replace.
• Throttle grip free play
• Throttle cable installation
Incorrect → Reinstall the throttle cables.
Handlebar end
Refer to “HANDLEBARS” on page 4-57.
a. Slide back the rubber cover at the throttle
2. Check:
cable.
• Throttle grip movement
b. Loosen the locknut “1”.
Rough movement → Lubricate or replace the
c. Turn the adjusting nut “2” in direction “a” or
defective part(s).
“b” until the specified throttle grip free play
Recommended lubricant is obtained.
Lithium-soap-based grease
TIP
With the engine stopped, turn the throttle grip
slowly and release it. Make sure that the throttle
grip turns smoothly and returns properly when
released.
Repeat this check with the handlebar turned all
the way to the left and right.
EAS30661
ADJUSTING THE THROTTLE GRIP FREE Direction “a”

PLAY Throttle grip free play is increased.
Direction “b”
TIP Throttle grip free play is decreased.
• Prior to adjusting the throttle grip free play, the
engine idling speed should be adjusted. d. Tighten the locknut.
e. Slide the rubber cover to its original position.
1. Check: EWA18900
• Throttle grip free play “a” WARNING

Out of specification → Adjust. After adjusting the throttle grip free play,
start the engine and turn the handlebar to the
right or left to ensure that this does not
cause the engine idling speed to change.
3-7
CHK
ENGINE ADJ
EAS30620
CHECKING THE SPARK PLUG Spark plug

1. Remove: 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
• Lower side cowling (right)
Refer to “GENERAL CHASSIS (3)” on page TIP
4-3. Before installing the spark plug, clean the spark
2. Disconnect: plug and gasket surface.
• Spark plug cap
3. Remove: 9. Connect:
• Spark plug • Spark plug cap
ECA13330 10.Install:
NOTICE • Lower side cowling (right) & other removed
Before removing the spark plug, blow away parts
any dirt accumulated in the spark plug well Refer to “GENERAL CHASSIS (3)” on page
with compressed air to prevent it from falling 4-3.
into the cylinder. EAS30037
4. Check: MEASURING THE COMPRESSION

• Spark plug type PRESSURE
Incorrect → Change. TIP
Insufficient compression pressure will result in a
Manufacturer/model loss of performance.
NGK/MR8E9
1. Measure:
5. Check: • Valve clearance
• Electrode “1” Out of specification → Adjust.
Damage/wear → Replace the spark plug. Refer to “ADJUSTING THE VALVE CLEAR-
• Insulator “2” ANCE” on page 3-4.
Abnormal color → Replace the spark plug. 2. Start the engine, warm it up for several min-
Normal color is medium-to-light tan. utes, and then turn it off.
6. Clean: 3. Remove:
• Spark plug • Rider seat
(with a spark plug cleaner or wire brush) • Lower side cowling (right)
7. Measure: Refer to “GENERAL CHASSIS (3)” on page
• Spark plug gap “a” 4-3.
(with a wire thickness gauge) 4. Disconnect:
Out of specification → Regap. • Spark plug cap “1”
Spark plug gap

0.8–0.9 mm (0.031–0.035 in)
2
5. Remove:
1 • Spark plug
8. Install:
• Spark plug
3-8
CHK
ENGINE ADJ
ECA13350
Piston, valves, cylinder
NOTICE
head gasket or piston
Same as without oil
Before removing the spark plug, use com- possibly defective →
pressed air to blow away any dirt accumulat- Repair/Replace.
ed in the spark plug well to prevent it from 8. Remove:
falling into the cylinder. • Compression gauge
6. Install: 9. Install:
• Compression gauge “1” • Spark plug
Compression gauge Spark plug

INS-009 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
(90890-03081)
10.Connect:
• Spark plug cap
11.Install:
• Upper panel (right)
• Rider seat
4-3.
EAS30656
CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle on a level surface.
7. Measure: TIP
• Compression pressure • Place the vehicle on a maintenance stand.
Out of specification → Refer to steps (c) and • Make sure the vehicle is upright.
(d).
2. Start the engine, warm it up for several min-
Compression pressure utes, and then turn it off.
696-896 kPa/550 r/min (7.0-9.0 3. Check:
kgf/cm2/550 r/min, 99.0-127.4 • Engine oil level
psi/550 r/min) The engine oil level should be between the
minimum level mark “a” and maximum level
a. Set the main switch to “ON”. mark “b”.
b. With the throttle wide open, crank the en- Below the minimum level mark → Add the
gine until the reading on the compression recommended engine oil to the proper level.
gauge stabilizes. TIP
c. If the compression pressure is above the • Before checking the engine oil level, wait a few
maximum specification, check the cylinder minutes until the oil has settled.
head, valve surfaces and piston crown for • Do not screw the engine oil filler cap (dipstick)
carbon deposits. “1” in when checking the oil level.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure (with oil applied into the
cylinder)
Reading Diagnosis
Piston ring(s) wear or
Higher than without oil
damage → Repair.
3-9
CHK
ENGINE ADJ
Recommended brand
YAMALUBE
SAE viscosity grades
10W-40
Recommended engine oil grade
API service SL type, JASO
standard MA
ECA13361
NOTICE
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
clutch slippage. Therefore, do not add any
chemical additives or use engine oils with a
grade of “CD” or higher and do not use oils
labeled “ENERGY CONSERVING II”.
• Do not allow foreign materials to enter the
crankcase.
utes, and then turn it off.
5. Check the engine oil level again. 5. Drain:
TIP • Engine oil
Before checking the engine oil level, wait a few (completely from the crankcase)
minutes until the oil has settled. 6. If the oil filter element is also to be replaced,
perform the following procedure.
EAS30657 a. Remove the oil filter element cover “1” by
CHANGING THE ENGINE OIL removing the bolts “2”.
1. Remove:
4-3.
3. Place a oil pan “a” under the engine oil drain
bolt to collect the used oil.
4. Remove:
• Engine oil filler cap (dipstick) “1”
• Engine oil drain plug “2”
b. Remove and replace the oil filter element
• O-ring “3”
“3” and new O-ring “4”.
• Spring “4”
• Engine oil strainer “5”
ECA26350
NOTICE
When removing the engine oil drain bolt, the New 3
O-ring, compression spring, and oil strainer
will fall out. Take care not to lose these parts.
New 4
3-10
CHK
ENGINE ADJ
c. Install the oil filter element cover by install- 14.Check:
ing the bolts, then tightening them to the • Engine oil pressure
specified torque. a. Slightly loosen the oil check bolt “1”.
Oil filter element cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Make sure that the O-ring is properly seated.
7. Check:
• Engine oil strainer
Dirt → Clean.
8. Install:
• Engine oil strainer
• Spring b. Start the engine and keep it idling until en-
gine oil starts to seep from the oil check
• O-ring New
bolt. If no engine oil comes out after one
• Engine oil drain plug
minute, turn the engine off so that it will not
Engine oil drain plug seize.
32 N·m (3.2 kgf·m, 24 lb·ft) c. Check the engine oil passages, the oil fil-
T.
R.
ter element and the oil pump for damage

9. Fill: or leakage.
• Crankcase d. Start the engine after solving the prob-
(with the specified amount of the recom- lem(s) and check the engine oil pressure
mended engine oil) again.
TIP e. Tighten the oil check bolt to specification.
Fill crankcase with recommended engine oil by
Oil check bolt
using funnel with long tail.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Funnel with long tail 15.Install:

S1119 • Lower side cowling (right)
4-3.
Engine oil quantity
Quantity (disassembled) EAS30629
1.05 L (1.11 US qt, 0.92 Imp.qt) ADJUSTING THE CLUTCH LEVER FREE
Oil change PLAY
1.00 L (1.06 US qt, 0.88 Imp.qt) 1. Check:
With oil filter removal • Clutch lever free play “a”
1.00 L (1.06 US qt, 0.88 Imp.qt)
10.Install:
Clutch lever free play
• Engine oil filler cap (dipstick) 10.0–15.0 mm (0.39–0.59 in)
11.Start the engine, warm it up for several min-
12.Check:
• Engine
(for engine oil leaks)
13.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-9.
3-11
CHK
ENGINE ADJ
2. Adjust:
• Clutch lever free play
(a)
Handlebar end
a. Pull back the rubber cover “1”.
b. Loosen the locknut “2”.
1
c. Turn the adjusting bolt “3” until the speci- (b)
fied clutch lever free play is obtained. 2
3 (a) c. Tighten the locknut.

2 1
Clutch cable locknut
7 N·m (0.7 kgf·m, 5.2 lb·ft)
(b)
T.
R.
4. Install:
4-3.
Direction “a”
Clutch lever free play is increased. EAS30050
Direction “b” REPLACING THE AIR FILTER ELEMENT

Clutch lever free play is decreased. TIP
There is a check hose “1” at the bottom of the air
d. Tighten the locknut. filter case. If dust and/or water collects in this
e. Place the rubber cover in its original posi- hose, clean the air filter element and air filter
tion. case.
TIP
If the specified clutch lever free play cannot be
obtained on the handlebar end of the cable, use
the adjusting nut on the engine end.
3. Remove:
4-3.
Engine end
a. Loosen the locknut “1”.
The air filter element should be replaced at the
b. Turn the adjusting nut “2” in direction “a” or
intervals specified in the periodic maintenance
“b” until the specified clutch lever free play
and lubrication chart. Replace the air filter ele-
is obtained.
ment more frequently if you are riding in unusu-
Direction “a” ally wet or dusty areas.
Clutch lever free play is increased. 1. Remove the rider seat.
Direction “b” Refer to “GENERAL CHASSIS (1)” on page
Clutch lever free play is decreased. 4-1.
2. Remove the side cover (left and right).
4-2.
3. Remove the fuel tank cover bolts (left/right).
Refer to “FUEL TANK” on page 7-1.
3-12
CHK
ENGINE ADJ
4. Lift the fuel tank to disconnect the fuel pump 8. Check:
lead, fuel pump coupler, fuel hose, canister • Air filter element
hoses and fuel drain hose, and then remove Damage/clogged → Replace.
the fuel tank. TIP
Refer to “FUEL TANK” on page 7-1. • Replace the air filter element every 17000 kms.
5. Remove the fuel hose holder from air filter • Do not clean the air filter element.
case cover by pulling it outward.
ECA21220
NOTICE
• The air filter element must be replaced at
the intervals specified in the periodic main-
tenance chart.
• The air filter element should be replaced
more frequently if often ride in the rain or
dusty areas.
• The air filter cannot be cleaned by blowing
it with compressed air. It must be replaced.
1. Fuel hose holder
2. Air filter case cover
6. Remove the air filter case cover by removing
the screws.
1. Air filter element

9. Insert a new air filter element into the air filter
case.
TIP
1. Screw
When installing the air filter element into the air
7. Pull the air filter element out. filter case cover, make sure that the sealing sur-
faces are aligned to prevent any air leaks.
ECA10482
NOTICE
• Make sure that the air filter element is prop-
erly seated in the air filter case. The engine
should never be operated without the air fil-
ter element installed, otherwise the pis-
ton(s) and/or cylinder(s) may become
excessively worn.
1. Air filter element • Disposable oil-coated paper element must
not be touched with hand.
TIP
While removing the filter case cover, make sure 10.Install the air filter case cover by installing the
their sealing surfaces and dust seal should not screws.
11.Install the fuel hose holder on it’s original po-
damage.
sition.
3-13
CHK
ENGINE ADJ
TIP
If dust or water collects in the air filter check
hose, remove the clamp, and then remove the
plug to drain the hose.
12.Connect the fuel hose, fuel pump coupler,
fuel pump lead, canister hoses and fuel drain
hose.
13.Install the fuel tank and tighten the bolts.
14.Install the panel B.
15.Install the rider seat.
TIP
EAS30966
CHECKING THE THROTTLE BODY JOINT Before removing the fuel hose, place a few rags
AND AIR FILTER CASE JOINT in the area under where it will be removed.
1. Remove: NOTICE
• Side covers
Refer to “GENERAL CHASSIS (2)” on page Make sure the fuel line hose is routed prop-
4-2. erty.
• Fuel tank 3. Install:
Refer to “FUEL TANK” on page 7-1. • Fuel tank
2. Check: Refer to “FUEL TANK” on page 7-1.
• Air filter case joint “1” • Rider seat
Cracks/damage → Replace. Refer to “GENERAL CHASSIS (1)” on page
4-1.
EAS30626
CHECKING THE CANISTER

1. Remove:
• Fuel tank
2. Check:
• Canister
• Canister purge hose
• Canister hose (Canister to atmosphere)
3. Install: • Fuel tank breather hose
• All removed parts Cracks/damage → Replace.
• Check valve
EAS30619
CHECKING THE FUEL LINE Refer to “CHECKING THE ROLLOVER

1. Remove: VALVE” on page *-**.
• Rider seat 3. Install:
• Fuel tank
4-1.
• Fuel tank EAS30059
Refer to “FUEL TANK” on page 7-1. CHECKING THE CYLINDER HEAD

2. Check: BREATHER HOSE
• Fuel hose “1” 1. Remove:
Cracks/damage → Replace. • Rider seat
Loose connection → Connect properly. Refer to “GENERAL CHASSIS (1)” on page
4-1.
• Fuel tank
3-14
CHK
ENGINE ADJ
2. Check: TIP
• Cylinder head breather hose “1” To access the coolant reservoir cap “1”, remove
Cracks/damage → Replace. the inner fender. Refer to “GENERAL CHASSIS
Loose connection → Connect properly. (3)” on page 4-3.
ECA14920
NOTICE
Make sure the cylinder head breather hose is Recommended coolant:
routed correctly. YAMAHA GENUINE COOLANT
3. Install: ECA13470
• All removed parts NOTICE

• Adding water instead of coolant lowers the
EAS30625
CHECKING THE EXHAUST SYSTEM antifreeze content of the coolant. If water is

1. Check: used instead of coolant check, and if nec-
• Exhaust assembly essary, correct the antifreeze concentra-
Cracks/damage → Replace. tion of the coolant.
• Exhaust pipe gasket • Use only distilled water. However, if dis-
Exhaust gas leaks → Replace. tilled water is not available, soft water may
2. Check: be used.
• Tightening torques of the exhaust pipe nuts, 3. Start the engine, warm it up for several min-
exhaust assembly bolt. utes, and then turn it off.
Refer to “ENGINE REMOVAL” on page 5-1. 4. Check:
TIP • Coolant level
If the exhaust assembly is removed, be sure to TIP
install and tighten the nuts and bolts in the prop- Before checking the coolant level, wait a few
er order. Refer to “ENGINE REMOVAL” on page minutes until it settles.
5-1. EAS30812
CHECKING THE COOLING SYSTEM

EAS30811
1. Remove:
CHECKING THE COOLANT LEVEL
• Lower side cowling (left and right)
TIP 4-3.
• Place the vehicle on a maintenance stand. 2. Check:
• Make sure the vehicle is upright. • Radiator “1”
2. Check: • Radiator inlet hose “2”
• Coolant level • Radiator outlet hose “3”
The coolant level should be between the • Coolant reservoir hose “4”
maximum level mark “2” and minimum level • Thermostat assembly “5”
mark “3”. • Water pump inlet hose “6”
Below the minimum level mark → Add the Cracks/damage → Replace.
recommended coolant to the proper level. Refer to “RADIATOR” on page 6-1.
3-15
CHK
ENGINE ADJ
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
2
move.
5
3. Remove:
• Coolant drain bolt “1”
6 (along with the copper washer New )
4. Drain:
3. Install: • Coolant
• Lower side cowling (left and right) (from the engine and radiator)
Refer to “GENERAL CHASSIS (3)” on page 5. Disconnect:
4-3. • Coolant reservoir hose “1”
EAS30813
6. Remove:
CHANGING THE COOLANT • Coolant reservoir cap “2”
1. Remove: • Coolant reservoir “3”
• Lower side cowling (left and right)
4-3.
2. Remove:
• Radiator cap “1”
7. Drain:
• Coolant
(from the coolant reservoir)
8. Connect:
• Coolant reservoir hose
EWA13030
9. Install:
WARNING • Coolant reservoir
A hot radiator is under pressure. Therefore, • Coolant drain bolt
do not remove the radiator cap when the en- (along with the copper washer New )
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in- Coolant drain bolt
jury. When the engine has cooled, open the 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
radiator cap as follows: Coolant reservoir bolt

Place a thick rag or a towel over the radiator 7 N·m (0.7 kgf·m, 5.2 lb·ft)
cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
3-16
CHK
ENGINE ADJ
10.Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Coolant quantity
Radiator (including all routes)
0.49 L (0.52 US qt, 0.43 Imp.qt)
Coolant reservoir (up to the maxi-
mum level mark)
0.15 L (0.16 US qt, 0.13 Imp.qt)
Handling notes for coolant Recommended coolant:

Coolant is potentially harmful and should be YAMAHA GENUINE COOLANT
handled with special care.
EWA13040 13.Install:
WARNING • Coolant reservoir cap
• If coolant splashes in your eyes, thorough- 14.Start the engine, warm it up for several min-
ly wash them with water and consult a doc- utes, and then loosen the coolant air bleed
tor. bolt “1” and wait until all air bubbles disap-
• If coolant splashes on your clothes, quickly peared from the coolant.
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
ECA13481
NOTICE
• Adding water instead of coolant lowers the
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. 15.Tighten the coolant air bleed bolt to their
• Use only distilled water. However, if dis- specified torques and then turn off the
tilled water is not available, soft water may engine.
be used.
• If coolant comes into contact with painted Coolant air bleed bolt
surfaces, immediately wash them with wa- 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
ter.
16.Check:
• Do not mix different types of antifreeze.
• Coolant level
11.Install: Refer to “CHECKING THE COOLANT LEV-
• Radiator cap EL” on page 3-15.
12.Fill: TIP
• Coolant reservoir
Before checking the coolant level, wait a few
(with the recommended coolant to the maxi-
minutes until the coolant has settled.
mum level mark “1”)
17.Clean the surface around the coolant air
bleed bolt with clean cloth.
18.Install:
• Lower side cowling (left and right) & other re-
moved parts
4-3.
3-17
CHK
CHASSIS ADJ
EAS20024
CHASSIS Specified brake fluid

DOT 4
EAS30801
CHECKING THE BRAKE OPERATION

1. Check: A
• Brake operation
Brake not working properly → Check the
brake system.
Refer to “FRONT BRAKE” on page 4-26 and
“REAR BRAKE” on page 4-38.
TIP
Drive on the dry road, operate the front and rear 1
brake separately and check to see if the brakes
are operating properly.
B
CHECKING THE BRAKE LEVER FREE PLAY
There should be no free play at the brake lever 1
end “1”. If there is free play, inspect the brake
system.
A. Front brake
B. Rear brake
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
WARNING deteriorate, causing leakage and poor
A soft or spongy feeling in the brake lever brake performance.
can indicate the presence of air in the hy- • Refill with the same type of brake fluid that
draulic system. If there is air in the hydraulic is already in the system. Mixing brake fluids
system, bleed the system before operating may result in a harmful chemical reaction,
the vehicle. Air in the hydraulic system will leading to poor brake performance.
diminish the braking performance, which • When refilling, be careful that water does
may result in loss of control and an accident. not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
EAS30074 the brake fluid and could cause vapor lock.
CHECKING THE BRAKE FLUID LEVEL ECA13540
1. Stand the vehicle on a level surface. NOTICE

TIP Brake fluid may damage painted surfaces
• Place the vehicle on a maintenance stand. and plastic parts. Therefore, always clean up
• Make sure the vehicle is upright. any spilt brake fluid immediately.
2. Check: TIP
• Brake fluid level In order to ensure a correct reading of the brake
Below the minimum level mark “1” → Add the fluid level, make sure the top of the brake fluid
specified brake fluid to the proper level. reservoir is horizontal.
3-18
CHK
CHASSIS ADJ
EAS30633
CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicator groove “1” has almost disap-
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-26.
3. Hold the vehicle upright and apply the front

brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-26.
EAS30636
CHECKING THE REAR BRAKE HOSE

EAS30634
1. Check:
CHECKING THE REAR BRAKE PADS • Brake hoses “1”
The following procedure applies to all of the Cracks/damage/wear → Replace.
brake pads. 2. Check:
1. Operate the brake. • Brake hose holder “2”
2. Check: Loose connection → Tighten the holder bolt.
• Rear brake pad Loose or open holder → Fasten properly.
Wear indicator groove “1” has almost disap-
peared → Replace the brake pads as a set.
Refer to “REAR BRAKE” on page 4-38.
1 1
3. Hold the vehicle upright and apply the front
brake several times.
4. Check:
EAS30635
• Brake hoses
CHECKING THE FRONT BRAKE HOSE Brake fluid leakage → Replace the damaged
1. Check: hose.
• Brake hose “1” Refer to “REAR BRAKE” on page 4-38.
Cracks/damage/wear → Replace.
2. Check:
• Brake hose holder “2”
Loose connection → Tighten the holder bolt.
3-19
CHK
CHASSIS ADJ
EAS21330 EWA15740
ADJUSTING THE REAR BRAKE LIGHT WARNING

SWITCH Bleed the ABS whenever:
TIP • the system is disassembled.
The rear brake light switch is operated by move- • a brake hose is loosened, disconnected or
ment of the brake pedal. The rear brake light replaced.
switch is properly adjusted when the brake light • the brake fluid level is very low.
comes on just before the braking effect starts. • brake operation is faulty.
1. Check: TIP
• Rear brake light operation timing • Be careful not to spill any brake fluid or allow
Incorrect → Adjust. the brake master cylinder reservoir or brake
2. Adjust: fluid reservoir to overflow.
• Rear brake light operation timing • When bleeding the hydraulic brake system,
a. Hold the main body “1” of the rear brake make sure there is always enough brake fluid
light switch so that it does not rotate and before applying the brake. Ignoring this pre-
turn the adjusting nut “2” in direction “a” or caution could allow air to enter the hydraulic
“b” until the rear brake light comes on at brake system, considerably lengthening the
the proper time. bleeding procedure.
Direction “a” • If bleeding is difficult, it may be necessary to let
Brake light comes on sooner. the brake fluid settle for a few hours. Repeat
Direction “b” the bleeding procedure when the tiny bubbles
Brake light comes on later. in the hose have disappeared.
1. Bleed:
• ABS
a. Fill the brake fluid reservoir to the proper
level with the specified brake fluid.
b. Install the diaphragm (brake master cylin-
der reservoir or brake fluid reservoir).
c. Connect a clear plastic hose “1” tightly to
the bleed screw “2”.
EAS30893
BLEEDING THE HYDRAULIC BRAKE

SYSTEM (ABS)
EWA13100
WARNING
Always bleed the brake system when the
brake related parts are removed.
ECA18050
NOTICE
• Bleed the brake system in the following or-
der.
• 1st step: Front brake calipers
• 2nd step: Rear brake caliper
A. Front
B. Rear
3-20
CHK
CHASSIS ADJ
d. Place the other end of the hose into a con- EAS30644
ADJUSTING THE DRIVE CHAIN SLACK

tainer.
e. Slowly apply the brake several times. TIP
f. Fully pull the brake lever or fully press The drive chain slack must be checked at the
down the brake pedal and hold it in posi- tightest point on the chain.
tion. ECA13550
g. Loosen the bleed screw. NOTICE

TIP A drive chain that is too tight will overload
Loosening the bleed screw will release the pres- the engine and other vital parts, and can lead
sure and cause the brake lever to contact the to chain slippage or breakage. If the drive
throttle grip or the brake pedal to fully extend. chain slack is more than the specified limit,
the chain can damage the frame, swingarm,
h. Tighten the bleed screw, and then release and other parts or cause an accident. To pre-
the brake lever or brake pedal. vent this from occurring, keep the drive
i. Repeat steps (e) to (h) until all of the air chain slack within the specified limits.
bubbles have disappeared from the brake
fluid in the plastic hose. 1. Stand the vehicle on a level surface.
EWA13120
j. Check the operation of the hydraulic unit.
WARNING
Refer to “HYDRAULIC UNIT OPERA-
TION TESTS” on page 4-53. Securely support the vehicle so that there is
ECA18060 no danger of it falling over.
NOTICE
2. Shift the transmission into the neutral posi-
Make sure that the main switch is turned to tion.
“OFF” before checking the operation of the TIP
hydraulic unit.
Place the vehicle on a maintenance stand so
k. After operating the ABS, repeat steps (e) that the rear wheel is elevated.
to (i), and then fill the brake master cylin-
der reservoir or brake fluid reservoir to the 3. Turn the rear wheel several times and find the
proper level with the specified brake fluid. tightest position on the drive chain.
l. Tighten the bleed screw to specification. 4. Check:
• Drive chain slack “a”
Front brake caliper bleed screw Out of specification → Adjust.
14 N·m (1.4 kgf·m, 10.0 lb·ft)
T.
R.
Rear brake caliper bleed screw

5 N·m (0.5 kgf·m, 3.7 lb·ft)
m. Fill the brake master cylinder or brake fluid

reservoir to the proper level with the spec-
ified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
Specified brake fluid

DOT 4
Drive chain slack
EWA13110 30.0–40.0 mm (1.18–1.57 in)
WARNING
After bleeding the hydraulic brake system, TIP
check the brake operation. Measure the drive chain slack halfway between
the drive axle and the rear wheel axle.
3-21
CHK
CHASSIS ADJ
5. Adjust: b. After adjusting, be sure to tighten each
• Drive chain slack chain adjust locknut. Then tighten the axle
a. Loosen the wheel axle nut “1”. nut to the specified torque.
b. Loosen both drive chain adjusting lock- c. Tighten both the locknuts.
nuts “2”.
c. Turn both adjusting bolts “3” until the spec- Drive chain adjusting locknut
ified drive chain slack is obtained. 16 N·m (1.6 kgf·m, 12 lb·ft)
T.
R.
d. Tighten the wheel axle nut
Rear wheel axle nut

59 N·m (5.9 kgf·m, 44 lb·ft)
T.
R.
NOTICE
Make sure that the drive chain pullers are in
the same position, the drive chain slack is
correct, and the drive chain moves smooth-
ly.
d. To tighten the drive chain, turn the adjust-
ing bolt in direction (a). EAS30803
e. To loosen the drive chain, turn the adjust- LUBRICATING THE DRIVE CHAIN
ing bolt in direction (b). The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only Yamalube
chain clean to clean the drive chain. Wipe the
drive chain dry and thoroughly lubricate it with
TIP Yamalube chain lube that is suitable for O-ring
• To maintain the proper wheel alignment, adjust chains. Do not use any other lubricants on the
both sides evenly. drive chain since they may contain solvents that
• Push the rear wheel forward to make sure could damage the O-rings.
there is no clearance between the drive chain
pullers and the ends of the adjusting bolts. Recommended Chain cleaner
Yamalube Chain Clean
6. Align the rear axle. Recommended lubricant
a. To maintain correct axle alignment. Refer- Yamalube Chain Lube
ence lines “1” on the swingarm should be
matched with an outer diameter of the a. Remove all deposits of dust, soil, mud, oil
washer “2” at both the sides. etc during washing and dry it with air blow.
b. Spray the chain cleaning solvent to re-
move grease deposition for 5 minutes.
c. Wipe the chain with clean cloth and wait.
3-22
CHK
CHASSIS ADJ
d. Spray the lubricant inside the chain be- b. Tighten the lower ring nut “4” with a steer-
tween inner/outer plates, roller and bushing nut socket “5”.
es.
TIP
e. After spraying wait for 15 minutes.
f. Excess lubricant should be wiped with a • Set the torque wrench at a right angle to the
clean cloth before riding. steering nut socket.
• Move the steering to the left and right a couple
EAS30645
of times to check that it moves smoothly.
CHECKING AND ADJUSTING THE
STEERING HEAD
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
that the front wheel is elevated.
2. Check:
• Steering head Steering nut socket
Grasp the bottom of the front fork legs and YSST-721
gently rock the front fork.
Binding/looseness → Adjust the steering
Lower ring nut (initial tightening
head.
torque)
T.
R.
48 N·m (4.8 kgf·m, 35 lb·ft)
c. Loosen the lower ring nut “4” completely,

and then tighten it to specification with a
steering nut socket.
EWA13140
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening

3. Remove: torque)
T.
R.
• Handle crown 18 N·m (1.8 kgf·m, 13 lb·ft)

Refer to “STEERING HEAD” on page 4-75.
4. Adjust:
• Steering head
a. Remove the lock washer “1”, the upper
ring nut “2”, and the rubber washer “3”.
3-23
CHK
CHASSIS ADJ
d. Check the steering head for looseness or 4. Check:
binding by turning the front fork all the way • Front fork operation
in both directions. If any binding is felt, re- Push down hard on the handlebar several
move the lower bracket and check the up- times and check if the front fork rebounds
per and lower bearings. smoothly.
Refer to “STEERING HEAD” on page Rough movement → Repair.
4-75. Refer to “FRONT FORK” on page 4-62.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, and
then align the slots of both ring nuts. If nec-
essary, hold the lower ring nut and tighten
the upper ring nut until their slots are
aligned.
h. Install the lock washer “1”.
TIP
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”. EAS30640
CHECKING THE TIRES

The following procedure applies to both of the
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.
5. Install:
• Handle crown
Refer to “STEERING HEAD” on page 4-75.
EAS30653
CHECKING THE FRONT FORK

1. Stand the vehicle on a level surface. EWA13181
EWA13120
WARNING
WARNING
• The tire pressure should only be checked
Securely support the vehicle so that there is and regulated when the tire temperature
no danger of it falling over. equals the ambient air temperature.
2. Check: • The tire pressure and the suspension must
• Inner tube be adjusted according to the total weight
Damage/scratches → Replace. (including cargo, rider, passenger and ac-
• Oil seal cessories) and the anticipated riding
Oil leakage → Replace. speed.
3. Hold the vehicle upright and apply the front • Operation of an overloaded vehicle could
brake. cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
3-24
CHK
CHASSIS ADJ
EWA14090
Tire air pressure (measured on WARNING

cold tires) After extensive tests, the tires listed below
1 person have been approved by India Yamaha Motor
Front Pvt. Ltd. for this model. The front and rear
200 kPa (2.00 kgf/cm2, 29 psi)
tires should always be by the same manufac-
Rear
turer and of the same design. No guarantee
225 kPa (2.25 kgf/cm2, 33 psi)
2 persons concerning handling characteristics can be
Front given if a tire combination other than one ap-
200 kPa (2.00 kgf/cm2, 29 psi) proved by Yamaha is used on this vehicle.
Rear
225 kPa (2.25 kgf/cm2, 33 psi) Front tire
Maximum load Size
163 kg (359 lb) 100/80–17M/C 52P
* Total weight of rider, passenger, cargo Manufacturer/model
and accessories MRF/NYLOGRIP ZAPPER-FX1
EWA13190
WARNING Rear tire

It is dangerous to ride with a worn-out tire. Size
When the tire tread reaches the wear limit, re- 140/70R17M/C 66H
Manufacturer/model:
place the tire immediately.
MRF/MRF REVZ-S
2. Check:
EWA13210
• Tire surfaces
WARNING
Damage/wear → Replace the tire.
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.
TIP
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the di-
rection of wheel rotation.
• Align the mark “2” with the valve installation
1. Tire sidewall point.
2. Tire tread depth
Minimum tire tread depth (front

and rear)
1.0 mm (0.04 in)
EWA14080
WARNING
• Do not use a tube tire on a wheel designed
only for tubeless tires to avoid tire failure
and personal injury from sudden deflation.
3-25
CHK
CHASSIS ADJ
EAS30638
1. Check:
CHECKING THE WHEELS
• Outer cable
Damage → Replace.
wheels.
2. Check:
1. Check:
• Cable operation
• Wheel
Rough movement → Lubricate cable end/Re-
Damage/out-of-round → Replace.
EWA13260
place.
WARNING
Recommended lubricant
Never attempt to make any repairs to the Lithium-soap-based grease
wheel.
TIP
EAS30641
CHECKING THE WHEEL BEARINGS Hold the cable end upright and pour a few drops
The following procedure applies to all of the of lubricant into the cable sheath or use a suit-
wheel bearings. able lubricating device.
1. Check:
• Wheel bearings EAS30646
LUBRICATING THE STEERING HEAD

Refer to “CHECKING THE FRONT WHEEL”
1. Lubricate:
on page 4-15 and “CHECKING THE REAR
• Upper bearing
WHEEL” on page 4-22.
• Lower bearing
EAS30802 • Bearing race
CHECKING THE SWINGARM OPERATION
1. Check: Recommended lubricant
• Swingarm operation Lithium-soap-based grease
Swingarm not working properly → Check the
swingarm. To remove upper, lower bearing & bearing race.
Refer to “SWINGARM” on page 4-82. Refer to “STEERING HEAD” on page 4-75.
2. Check: EAS31186
• Swingarm excessive play CHECKING THE CHASSIS FASTENERS

Refer to “SWINGARM” on page 4-82. Make sure that all nuts, bolts, and screws are
EAS30643
properly tightened.
LUBRICATING THE SWINGARM PIVOT Refer to “CHASSIS TIGHTENING TORQUES”
1. Lubricate: on page 2-15.
• Oil seals EAS30805
• Collars LUBRICATING THE CLUTCH LEVER

Lubricate the pivoting point and metal-to-metal
Recommended lubricant moving parts of the lever.
Refer to “CHECKING THE SWINGARM” on Lithium-soap-based grease
page 4-83.
EAS30804
EAS30660
CHECKING AND LUBRICATING THE LUBRICATING THE BRAKE LEVER

CABLES END Lubricate the pivoting point and metal-to-metal
The following procedure applies to all of the in- moving parts of the lever.
ner and outer cables. Recommended lubricant
EWA13270
WARNING
Silicone grease
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.
3-26
CHK
CHASSIS ADJ
EAS30649
LUBRICATING THE PEDALS

moving parts of the pedals.
CHECKING THE SIDESTAND

1. Check:
• Sidestand operation
Check that sidestand moves smoothly.
Rough movement → Lubricate, repair or re-
place.
EAS30651
LUBRICATING THE SIDESTAND

Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the sides-
tand.
LUBRICATING SHIFT PEDAL ROD JOINT

Lubricate shift pedal rod joint sliding surface.
EAS30119
LUBRICATING THE REAR SUSPENSION

moving parts of the rear suspension.
3-27
CHK
ELECTRICAL SYSTEM ADJ
EAS20025
ELECTRICAL SYSTEM
EAS30816
CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-143.
EAS30121
CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page
8-142.
c. License plate light burnt-out bulb “3” by
REPLACING TURN SIGNAL INDICATOR pulling it out.
LIGHT BULB
1. Remove:
• Screw “1” from indicator light
• Lens “2”
2. Push the bulb “3” and remove by rotating
counterclockwise.
2. Insert a new bulb into the socket.

3. Install the socket (together with the bulb) by
pushing it in.
1 4. Place the license plate light unit in the original
2 position, and then install the screw.
5. Tighten:
• License plate light screw
Turn signal indicator light screw
0.9 N·m (0.09 kgf·m, 0.6 lb·ft) License plate light screw
T.
R.
0.5 N·m (0.05 kgf·m, 0.66 lb·ft)

T.
R.
REPLACING LICENSE PLATE LIGHT BULB

EAS30664
1. Remove: ADJUSTING THE HEADLIGHT BEAMS
a. Screw “1” from license plate light. 1. Adjust:
• Headlight beam (vertically)
Adjust the headlight beam by rotating the head-
light beam adjusting screw “1” with the help of
Phillip screwdriver “2” in direction “a” or “b” from
bottom side of headlight.
b. License plate light bulb socket “2” (togeth-

er with the bulb) by pulling it out.
3-28
CHK
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
TIP
Headlight beam adjusting condition
• Headlight should be in low beam.
• Rider weight : 75 kg (1 Person).
• Height at low beam line “a” : 74.3 cm
• Limit “b” : 20.0 cm
3-29
CHK
3-30
CHASSIS
GENERAL CHASSIS (1) ................................................................................4-1
GENERAL CHASSIS (2) ................................................................................4-2
GENERAL CHASSIS (3) ................................................................................4-3
GENERAL CHASSIS (4) ................................................................................4-4
GENERAL CHASSIS (5) ................................................................................4-5

REMOVING THE REAR VIEW MIRROR ASSEMBLY .............................4-7
INSTALLING THE REAR VIEW MIRROR ASSEMBLY ...........................4-7
GENERAL CHASSIS (6) ................................................................................4-8

INSTALLING THE AIR FILTER CASE .....................................................4-9
GENERAL CHASSIS (7) .............................................................................. 4-10

4
GENERAL CHASSIS (8) .............................................................................. 4-12
FRONT WHEEL ............................................................................................ 4-13

REMOVING THE FRONT WHEEL .........................................................4-15
DISASSEMBLING THE FRONT WHEEL ............................................... 4-15
CHECKING THE FRONT WHEEL .........................................................4-15
ASSEMBLING THE FRONT WHEEL ..................................................... 4-16
MAINTENANCE OF THE WHEEL SENSOR AND
SENSOR ROTOR ................................................................................. 4-16
INSTALLING THE FRONT WHEEL ....................................................... 4-18
REAR WHEEL .............................................................................................. 4-20

REMOVING THE REAR WHEEL ........................................................... 4-22
DISASSEMBLING THE REAR WHEEL ................................................. 4-22
CHECKING THE REAR WHEEL ............................................................ 4-22
CHECKING THE REAR BRAKE CALIPER BRACKET .......................... 4-22
CHECKING THE REAR WHEEL DRIVE HUB ....................................... 4-22
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ........ 4-23
ASSEMBLING THE REAR WHEEL ....................................................... 4-23
MAINTENANCE OF THE REAR WHEEL SENSOR AND
SENSOR ROTOR ................................................................................. 4-23
INSTALLING THE REAR WHEEL .......................................................... 4-23
FRONT BRAKE ............................................................................................ 4-26

INTRODUCTION .................................................................................... 4-31
CHECKING THE FRONT BRAKE DISC ................................................ 4-31
REPLACING THE FRONT BRAKE PADS ............................................. 4-32
REMOVING THE FRONT BRAKE CALIPER ......................................... 4-33
DISASSEMBLING THE FRONT BRAKE CALIPER ............................... 4-33
CHECKING THE FRONT BRAKE CALIPER ......................................... 4-34
ASSEMBLING THE FRONT BRAKE CALIPER ..................................... 4-34
INSTALLING THE FRONT BRAKE CALIPER ....................................... 4-34
REMOVING THE FRONT BRAKE MASTER CYLINDER ...................... 4-35
CHECKING THE FRONT BRAKE MASTER CYLINDER ....................... 4-35
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER .................. 4-36
INSTALLING THE FRONT BRAKE MASTER CYLINDER ..................... 4-36
REAR BRAKE .............................................................................................. 4-38

INTRODUCTION .................................................................................... 4-43
CHECKING THE REAR BRAKE DISC ................................................... 4-43
REPLACING THE REAR BRAKE PADS ................................................ 4-43
REMOVING THE REAR BRAKE CALIPER ........................................... 4-44
DISASSEMBLING THE REAR BRAKE CALIPER ................................. 4-45
CHECKING THE REAR BRAKE CALIPER ............................................ 4-45
CHECKING THE REAR BRAKE CALIPER BRACKET .......................... 4-45
ASSEMBLING THE REAR BRAKE CALIPER ....................................... 4-46
INSTALLING THE REAR BRAKE CALIPER .......................................... 4-46
REMOVING THE REAR BRAKE MASTER CYLINDER ........................ 4-47
CHECKING THE REAR BRAKE MASTER CYLINDER ......................... 4-47
ASSEMBLING THE REAR BRAKE MASTER CYLINDER ..................... 4-47
INSTALLING THE REAR BRAKE MASTER CYLINDER ....................... 4-47
REAR BRAKE HOSE INSTALLATION ................................................... 4-48
ABS (ANTI-LOCK BRAKE SYSTEM) .......................................................... 4-49

REMOVING THE HYDRAULIC UNIT ASSEMBLY ................................ 4-51
CHECKING THE HYDRAULIC UNIT ASSEMBLY ................................. 4-51
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ............................... 4-52
HYDRAULIC UNIT OPERATION TESTS ............................................... 4-53
CHECKING THE ABS WARNING LIGHT ..............................................4-56
HANDLEBARS ............................................................................................. 4-57

REMOVING THE HANDLEBARS .......................................................... 4-59
CHECKING THE HANDLEBARS ........................................................... 4-59
INSTALLING THE HANDLEBARS .........................................................4-59
FRONT FORK ............................................................................................... 4-62

REMOVING THE FRONT FORK LEGS ................................................. 4-65
DISASSEMBLING THE FRONT FORK LEG (LEFT) ............................. 4-65
CHECKING THE FRONT FORK LEGS ................................................. 4-66
ASSEMBLING THE FRONT FORK LEG (LEFT) ................................... 4-67
INSTALLING THE FRONT FORK LEGS ............................................... 4-70
ASSEMBLING THE FRONT FORK LEG (RIGHT) ................................. 4-71
STEERING HEAD ......................................................................................... 4-75

REMOVING THE LOWER BRACKET .................................................... 4-77
CHECKING THE STEERING HEAD ...................................................... 4-77
INSTALLING THE STEERING HEAD .................................................... 4-77
REAR SHOCK ABSORBER ASSEMBLY ................................................... 4-79

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY .................. 4-80
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................. 4-80
CHECKING THE CONNECTING ARMS AND RELAY ARM ................. 4-80
INSTALLING THE RELAY ARM ............................................................. 4-80
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................ 4-80
SWINGARM .................................................................................................. 4-82

REMOVING THE SWINGARM ............................................................... 4-83
CHECKING THE SWINGARM ............................................................... 4-83
INSTALLING THE SWINGARM ............................................................. 4-83
CHAIN DRIVE ............................................................................................... 4-85

REMOVING THE DRIVE CHAIN BY USING CHAIN CUTTER .............. 4-86
CHECKING THE DRIVE CHAIN ............................................................ 4-86
CHECKING THE DRIVE SPROCKET .................................................... 4-87
CHECKING THE REAR WHEEL SPROCKET ....................................... 4-87
CHECKING THE REAR WHEEL DRIVE HUB ....................................... 4-87
INSTALLING THE DRIVE CHAIN BY
USING CHAIN RIVETING TOOL .......................................................... 4-87
CLEANING AND LUBRICATING THE DRIVE CHAIN ........................... 4-89
GENERAL CHASSIS (1) CHAS

EAS20026
GENERAL CHASSIS (1)

Removing the seats and battery
Order Job/Parts to remove Q’ty Remarks

1 Passenger seat 1
2 Center cover (between rider & passenger seat) 1
3 Rider seat 1
4 Negative battery lead 1 Disconnect.
5 Positive battery lead 1 Disconnect.
6 Battery band 1
7 Battery 1
For installation, reverse the removal
procedure.
4-1

GENERAL CHASSIS (2)
Removing the rear side cowlings

Passenger seat and rider seat
4-1.
1 Side cover (Left and right) 2
2 Rear side cowling (Left and right) 2
3 Tail/brake light outer cover 1
procedure.
4-2

GENERAL CHASSIS (3)
Removing the inner panel and cowlings

4-1.
Side cover (Left and right)
4-2.
Fuel tank cover (Left and right) Refer to “FUEL TANK” on page 7-1.
1 Inner fender 1
2 Upper panel (Left and right) 1/1
3 Turn signal light connector (Left and right) 2/2 Disconnect.
4 Upper side cowling (Left and right) 2
5 Lower side cowling (Left and right) 2
For installation, reverse the removal proce-
dure.
4-3

GENERAL CHASSIS (4)
Removing the meter assembly

Upper panel (Left and right)
4-3.
1 Meter assembly mounting bolt / quick fastener 2/1
Disconnect.
TIP
2 Meter coupler 1
After connect the coupler slide the rubber
cover in original position.
3 Meter assembly 1
4 Meter assembly bracket 1
5 Meter cover 1
6 Meter 1
dure.
4-4

GENERAL CHASSIS (5)
Removing the headlight assembly

Meter assembly
4-4.
Upper side cowling (Left and right)
4-3.
1 Left rear view mirror 1
2 Right rear view mirror 1
3 License plate bracket 1
4 Coupler (Headlight control unit/headlight) 1/1 Disconnect.
5 Headlight control unit belt 1
6 Headlight control unit 1 Skip step 1 to 3.
7 Coupler (Auxiliary light) 2 Disconnect.
8 Headlight cowling assembly 1 Skip step 1 to 6.
9 Windshield 1
10 Auxiliary light 2
11 Headlight cowling 1
4-5

Removing the headlight assembly

12 Front upper body (Auxiliary light) 1
13 Rubber cover 1
14 Headlight cover 1
15 Headlight assembly 1
16 Headlight stay 1
dure.
4-6

REMOVING THE REAR VIEW MIRROR INSTALLING THE REAR VIEW MIRROR
ASSEMBLY ASSEMBLY
1. Remove the rear view mirror bolt caps “1” 1. Install the collars “1” and rubber plates “2”.
from the rear view mirror bolts.
CW
FR B
W
FR BC
W
FR BC
TIP
2. Remove the left side rear view mirror “2” by When installing the rear view mirror assembly.
removing the bolts “3”. make sure rubber plate indication mark “a”
3. Remove the right side rear view mirror “4” by should be same as shown.
removing the bolts “5” along with license
plate bracket “6”. 2. Install the rear view mirror assembly along
with license plate bracket and tighten the
bolts as per specified torque.
Rear view mirror assembly bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
3. Install the rear view mirror bolt caps.

4. Adjust the rear view mirror “1” according to
need as shown.
4. Remove the rubber plates “7” and collars

“8”.
W
BC
W
BC
FR
FR
TIP
Before opening the right side rear view mirror
bolts, hold the license plate bracket to avoid the
scratches at head light cowling.
4-7

GENERAL CHASSIS (6)
Removing the air filter case

4-1.
4-2.
Fuel tank Refer to “FUEL TANK” on page 7-1
1 Bracket rider seat fitting 1
2 Fuel hose 1
3 Air filter case cover 1
4 Air filter element 1
5 Air filter case joint clamp screw 1
6 Cylinder head breather hose 1
7 Air filter case 1
dure.
4-8

EAS30968
INSTALLING THE AIR FILTER CASE

1. Install:
• Air filter case joint clamp
TIP
Align the projection “a” on the air filter case with
the slot “b” in the air filter case joint clamp.
4-9

GENERAL CHASSIS (7)
Removing the taillight assembly/rear fender
0 f·m, 0.73 lb·ft)
N·m
38 38 f·m, 2.8 lb·ft)
9 N·m 9 66
9 N·m 9 66 0.2 02 f·m, 0.18 lb·ft)
f·m, 1.1 lb·ft)
0.89 N·m 0.089 0.65 2 2 f·m, 1.8 lb·ft)

4-1.
4-2.
Rear side cowling (Left and right) & Tail/brake Refer to “GENERAL CHASSIS (2)” on page
light upper cover 4-2.
1 CCU (Communication control unit) 1
2 Flap guard along with tool (Screwdriver grip) 1
3 Tail/brake light coupler 1
License plate light coupler/turn signal light con-
4 1/4
nector
5 Upper mud guard stay nut 4
6 Upper mud guard assembly 1
7 Turn signal light (Left and right) 2
4-10

Removing the taillight assembly/rear fender
0 f·m, 0.73 lb·ft)
N·m
38 38 f·m, 2.8 lb·ft)
9 N·m 9 66
9 N·m 9 66 0.2 02 f·m, 0.18 lb·ft)
f·m, 1.1 lb·ft)
0.89 N·m 0.089 0.65 2 2 f·m, 1.8 lb·ft)

8 Rear side reflector (Left and right) 1 Skip step 1 to 7.
9 Upper mud guard bracket 1
10 Rear reflector 1
11 License plate light 1
12 Upper mud guard 1
13 Rear fender along with tail light 1
14 Tail/brake light 1 For remove rear fender, skip step 7 to 11.
15 Rear fender 1
dure.
4-11

GENERAL CHASSIS (8)
Removing the QSS (Quick shift system)
7
2

Lower side cowling (left)
4-3.
1 QSS (Quick shift system) coupler 1 Disconnect.
2 Shift arm bolt 1
3 Footrest bracket bolt (left) 2
QSS (Quick shift system) assembly along with
4 1
footrest
5 Footrest bolt (left) 1
6 Footrest assembly (left) 1
7 QSS (Quick shift system) 1
8 Footrest bracket 1
dure.
4-12
FRONT WHEEL CHAS

AS20028
FRONT WHEEL
Removing the front wheel and brake disc
38 N·m (3.8 kgf·m, 28 lb·ft)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
23 N·m (2.3 kgf·m, 17 lb·ft)

8 N·m (0.8 kgf·m, 5.9 lb·ft)
35 N·m (3.5 kgf·m, 26 lb·ft) 7 N·m (0.7 kgf·m, 5.2 lb·ft)
TIP
• Place the vehicle on a maintenance
stands “a”.
• While removing the front wheel, put the
scissor jack (YSST-892A) “b” under the
engine as shown.
1 Sensor lead holder 1

2 Front brake caliper 1
3 Front wheel sensor 1
4 Front wheel axle nut 1
5 Front wheel axle 1
6 Front wheel 1
7 Collar 2
8 Front brake disc 1
TIP
9 Front wheel sensor rotor 1 Use “Torx bit T-25” for opening/tightening
wheel sensor rotor bolt.

dure.
4-13
FRONT WHEEL CHAS

Disassembling the front wheel
LS
New 1
2
New 3 New
2
1
New
LS

1 Oil seal 2
2 Bearing 2 Use bearing puller YSST-624
3 Spacer 1
For assembly, reverse the disassembly pro-
cedure.
4-14
FRONT WHEEL CHAS

EAS30145
REMOVING THE FRONT WHEEL

1. Stand the vehicle on a level surface by using
maintenance front wheel stand.
EWA13120
WARNING
2. Elevate:
• Front wheel
TIP
• Place the vehicle on a maintenance stand so
that the front wheel is elevated.
• While removing the front wheel, put the scissor c. Front wheel sensor rotor.
jack (YSST-892A) under the engine. d. Remove the brake disc.
3. Remove: e. Remove the wheel bearing “3” with a bear-
• Front wheel sensor ing puller “4” from both sides.
• Front brake hose holder f. Remove the spacer.
• Front brake caliper
ECA20981
NOTICE
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor; otherwise, the
sensor or rotor may be damaged, resulting
in improper performance of the ABS sys-
tem.
• Do not drop the front wheel sensor rotor or
subject it to shocks. Bearing puller
• If any solvent gets on the front wheel sen- YSST-624
sor rotor, wipe it off immediately.
ECA21700
Cup-B
NOTICE
YSST-620-B
Do not apply the brake lever when removing
the brake calipers. EAS30147
CHECKING THE FRONT WHEEL

4. Remove:
1. Check:
• Front wheel axle nut
• Front wheel axle
Roll the wheel axle on a flat surface.
• Front wheel
Bends → Replace.
EWA13460
EAS30146
DISASSEMBLING THE FRONT WHEEL WARNING

1. Remove: Do not attempt to straighten a bent wheel ax-
• Oil seals le.
• Wheel bearings
a. Clean the surface of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.
4-15
FRONT WHEEL CHAS

EAS30151
ASSEMBLING THE FRONT WHEEL

1. Install:
• Wheel bearings New
• Oil seals New
a. Install the new wheel bearings and oil
seals in the reverse order of disassembly.
ECA18110
NOTICE
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made
2. Check:
only with the outer race “3”.
• Tire
• Front wheel TIP
Damage/wear → Replace. Use a socket “4” or bearing punch and suitable
Refer to “CHECKING THE TIRES” on page attachment that matches the diameter of the
3-24 and “CHECKING THE WHEELS” on wheel bearing outer race and oil seal.
page 3-26.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)

YSST-951
EAS31151
MAINTENANCE OF THE WHEEL SENSOR

AND SENSOR ROTOR
ECA21070
NOTICE
• Handle the ABS components with care
since they have been accurately adjusted.
4. Check:
Keep them away from dirt and do not sub-
• Wheel bearings
ject them to shocks.
Front wheel turns roughly or is loose → Re-
• The wheel sensor cannot be disassembled.
place the wheel bearings.
Do not attempt to disassemble it. If faulty,
• Oil seals
replace with a new one.
Damage/wear → Replace.
etc.) away from the wheel sensor or wheel
sensor rotor.
• Do not drop or shock the wheel sensor or
the wheel sensor rotor.
4-16
FRONT WHEEL CHAS

1. Check: TIP
• Wheel sensor “1” Do not touch the surface of the wheel sensor ro-
Cracks/bends/distortion → Replace. tor with a sharp object.
Iron powder/dust → Clean.
1
1
2. Check:
• Wheel sensor rotor “1”
Cracks/damage/scratches → Replace the
wheel sensor rotor.
Iron powder/dust/solvent → Clean.
TIP
• The wheel sensor rotor is installed on the inner
side of the wheel hub.
• When cleaning the wheel sensor rotor, be
careful not to damage the surface of the sensor
rotor.
c. If the runout is above specification, re-
move the sensor rotor from the wheel, ro-
1 tate it by one or two bolt holes, and then
install it.
Front wheel sensor rotor bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
LOCTITE®
ECA18100
NOTICE
Replace the wheel sensor rotor bolts with
new ones.
3. Measure:
d. If the runout is still above specification, re-
• Wheel sensor rotor runout
place the wheel sensor rotor.
Out of specification → Clean the installation
surface of the wheel sensor rotor and correct TIP
the wheel sensor rotor runout, or replace the • Install the wheel sensor rotor with the stamped
wheel sensor rotor. mark “a” facing outward.
• Use “Torx bit T-25” for opening/tightening
Wheel sensor rotor runout limit wheel sensor rotor bolt.
0.25 mm (0.0098 in)
a. Hold the dial gauge at a right angle against

the wheel sensor rotor surface.
b. Measure the wheel sensor rotor runout.
4-17
FRONT WHEEL CHAS

4. Install:
• Collars
a
a
• Front wheel
• Front wheel axle nut
A TIP
• Install the front wheel with the mark “a” on the
front tire pointing in the direction of wheel rota-
tion.
• Apply lithium-soap-based grease to the con-
EAS30932
tact surface and threads of the front wheel axle
INSTALLING THE FRONT WHEEL nut.
1. Install:
• Front brake disc “1” a
• Front wheel sensor rotor “2”
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®
TIP
Tighten the brake disc bolts and front wheel sen- 5. Tighten:
sor rotor bolts in stages and in a crisscross pat- • Front wheel axle
tern.
Front wheel axle
38 N·m (3.8 kgf·m, 28 lb·ft)
T.
R.
2
EWA13500
WARNING
Make sure the brake hose is routed properly.
ECA19760
NOTICE
Before tightening the wheel axle, push down
hard on the handlebar several times and
check if the front fork rebounds smoothly.
1 6. Install:
• Front wheel sensor
2. Check:
• Front brake disc Front wheel sensor bolt
Refer to “CHECKING THE FRONT BRAKE 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
DISC” on page 4-31.

ECA21020
3. Lubricate:
NOTICE
• Oil seal lip Make sure there are no foreign materials in
the front wheel sensor rotor and front wheel
Recommended lubricant sensor. Foreign materials cause damage to
Lithium-soap-based grease the front wheel sensor rotor and front wheel
sensor.
4-18
FRONT WHEEL CHAS

TIP
• When installing the front wheel sensor, check a
the wheel sensor lead for twists.
• To route the front wheel sensor lead, refer to
“CABLE ROUTING” on page 2-31.
7. Install:
• Front brake caliper along with wheel sensor
lead holder 3
• Front brake hose holder
Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
Front brake hose holder bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
8. Measure:
• Distance “a”
(between the front wheel sensor rotor “1” and
front wheel sensor “2”)
Out of specification → Check the wheel bear-
ing for looseness, and the front wheel sensor
and sensor rotor installation conditions
(warpage caused by overtorque, wrong in-
stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
vice and caught foreign materials). If there is
any defective part, repair or replace the de-
fective part.
Distance “a” (between the front

wheel sensor rotor and front
wheel sensor)
1.29 mm (0.050 in)
TIP
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
places in one rotation of the front wheel. Do not
turn the front wheel while the feeler gauge “3” is
installed. This may damage the front wheel sen-
sor rotor and the front wheel sensor.
Feeler gauge (Thickness gauge)
4-19
REAR WHEEL CHAS

EAS20029
REAR WHEEL
Removing the rear wheel
59 N·m (5.9 kgf·m, 44 lb·ft) 10

T.
R.
LS
11
6
7 3
9
11
1 8 N·m (0.8 kgf·m, 5.9 lb·ft)

T.
R.
4 5 2
9
8
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R
.
16 N·m (1.6 kgf·m, 12 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft) 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
T.
R
R.
T.
.
R.
TIP
Place the vehicle on a maintenance stand
so that the rear wheel is elevated.
1 Mud protector assembly 1

2 Drive chain case 1
3 Rear wheel sensor 1
4 Drive chain adjusting locknut 2 Loosen.
5 Drive chain adjusting bolt 2 Loosen.
6 Rear wheel axle nut 1
7 Washer 1
8 Rear wheel axle 1
9 Drive chain puller 2
10 Rear wheel 1
11 Collar 2
dure.
4-20
REAR WHEEL CHAS

Removing the rear brake disc and rear wheel sprocket
(6)
11 New New
New 6
2 5
4
(3) (3)
10 New 1
7
9 New
8
7
3 New

1 Rear wheel sprocket 1
2 Rear wheel drive hub 1
3 Rear wheel drive hub damper 6
4 Rear brake disc 1
5 Rear wheel sensor rotor 1
6 Oil seal 1
7 Bearing 2 Use bearing puller YSST-624
8 Collar 1
9 Oil seal 1
10 Bearing 1 Use bearing puller YSST-624 A
11 Collar 1
dure.
4-21
REAR WHEEL CHAS

EAS30156
REMOVING THE REAR WHEEL TIP

ECA21030 Push the rear wheel forward and remove the
NOTICE drive chain from the rear wheel sprocket.
netic pick-up tools, magnetic screwdrivers, DISASSEMBLING THE REAR WHEEL
etc.) away from the rear wheel sensor or 1. Remove:
rear wheel sensor rotor; otherwise, the sen- • Oil seals
sor or rotor may be damaged, resulting in • Wheel bearings
improper performance of the ABS system. Refer to “DISASSEMBLING THE FRONT
• Do not drop the rear wheel sensor rotor or WHEEL” on page 4-15.
subject it to shocks.
• If any solvent gets on the rear wheel sensor CHECKING THE REAR WHEEL
rotor, wipe it off immediately. 1. Check:
1. Stand the vehicle on a level surface by using • Rear wheel axle
maintenance stand. • Rear wheel
EWA13120 • Wheel bearings
WARNING • Oil seals
Securely support the vehicle so that there is Refer to “CHECKING THE FRONT WHEEL”
no danger of it falling over. on page 4-15.
2. Check:
TIP
• Tire
Place the vehicle on a maintenance stand so • Rear wheel
that the rear wheel is elevated. Damage/wear → Replace.
2. Remove: Refer to “CHECKING THE TIRES” on page
• Rear wheel sensor 3-24 and “CHECKING THE WHEELS” on
ECA21470 page 3-26.
NOTICE 3. Measure:
Do not depress the brake pedal when remov- • Radial wheel runout
ing the brake caliper. • Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
3. Loosen:
on page 4-15.
• Wheel axle nut “1”
• Drive chain puller locknuts “2” Radial wheel runout limit
• Drive chain adjusting bolts “3” 1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
EAS31577
CHECKING THE REAR BRAKE CALIPER

BRACKET
1. Check:
• Rear brake caliper bracket
Cracks/damage → Replace.
CHECKING THE REAR WHEEL DRIVE HUB

4. Remove:
1. Check:
• Rear wheel axle nut
• Rear wheel drive hub
• Washer
• Rear wheel axle along with washer
• Rear wheel drive hub dampers
• Drive chain puller
• Collars
• Rear wheel along with rear brake caliper
4-22
REAR WHEEL CHAS

EAS30161
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
etc.) away from the wheel sensor or wheel
1. Check:
sensor rotor.
• Rear wheel sprocket
• Do not drop or shock the wheel sensor or
More than 1/4 tooth “a” wear → Replace the
the wheel sensor rotor.
rear wheel sprocket.
Refer to “MAINTENANCE OF THE WHEEL
Bent teeth → Replace the rear wheel sprock-
SENSOR AND SENSOR ROTOR” on page
et.
4-16.
EAS30165
INSTALLING THE REAR WHEEL

1. Install:
• Rear wheel sensor rotor
• Rear brake disc
Rear wheel sensor rotor bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
LOCTITE®
b. Correct Rear brake disc bolt
1. Drive chain roller 23 N·m (2.3 kgf·m, 17 lb·ft)
2. Rear wheel sprocket LOCTITE®
2. Replace: ECA21011
• Rear wheel sprocket NOTICE

a. Remove the self-locking nuts and the rear • Do not drop the wheel sensor rotor or sub-
wheel sprocket. ject it to shocks.
b. Clean the rear wheel with a clean cloth, • If any solvent gets on the wheel sensor ro-
especially the surfaces that contact the tor, wipe it off immediately.
sprocket. • Replace the brake disc bolts and wheel
c. Install the new rear wheel sprocket. sensor rotor bolts with new ones.
Rear wheel sprocket self-locking TIP

nut • Install the wheel sensor rotor with the stamped
T.
R.
43 N·m (4.3 kgf·m, 32 lb·ft) mark “a” facing outward.

• Tighten the brake disc bolts in stages and in a
ASSEMBLING THE REAR WHEEL crisscross pattern.
1. Install:
• Wheel bearings New
a
• Oil seals New
Refer to “ASSEMBLING THE FRONT
WHEEL” on page 4-16.
A
MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR
NOTICE
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
• The wheel sensor cannot be disassembled.
Do not attempt to disassemble it. If faulty,
replace with a new one.
4-23
REAR WHEEL CHAS
LT
b
c b
1. Install: 5. Lubricate:
• Rear wheel sprocket • Rear brake caliper bolt
Refer to “REAR WHEEL” on page 4-20.
2. Check: Recommended lubricant
• Rear brake disc Silicone grease
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-31. 6. Install:
3. Lubricate: • Rear brake caliper
• Rear wheel axle 7. Adjust:
• Contact surface of rear wheel • Drive chain slack
• Contact surface wheel bearings Refer to “ADJUSTING THE DRIVE CHAIN
• Oil seal lips SLACK” on page 3-21.
Recommended lubricant Drive chain slack

Lithium-soap-based grease 30.0–40.0 mm (1.18–1.57 in)
4. Install: 8. Tighten:
• Collar (right) • Rear wheel axle nut
• Collar (left) • Rear brake caliper bolt
• Brake caliper Rear wheel axle nut
• Rear wheel 59 N·m (5.9 kgf·m, 44 lb·ft)
T.
R.
• Rear wheel axle

• Washers EWA13500
• Rear wheel axle nut WARNING

TIP Make sure the brake hose is routed properly.
• Install the rear wheel with the mark “a” on the 9. Install:
rear tire pointing in the direction of wheel rota- • Rear wheel sensor
tion.
• Align the projection “b” in the swingarm with the Rear wheel sensor bolt
slot “c” of the brake caliper bracket. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Apply lithium-soap-based grease to the con- ECA21080
tact surface and threads of the rear wheel axle NOTICE

nut. Make sure there are no foreign materials in
the rear wheel sensor rotor and rear wheel
sensor. Foreign materials cause damage to
a the rear wheel sensor rotor and rear wheel
sensor.
TIP
To route the rear wheel sensor lead, refer to
4-24
REAR WHEEL CHAS

10.Measure:
• Distance “a”
(between the rear wheel sensor rotor “1” and
rear wheel sensor “2”)
Out of specification → Check the wheel bear-
ing for looseness, and the rear wheel sensor
and sensor rotor installation conditions
(warpage caused by overtorque, wrong in-
stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
vice and caught foreign materials). If there is
any defective part, repair or replace the de-
fective part.
Distance “a” (between the rear

wheel sensor rotor and rear
wheel sensor)
1.29 mm (0.050 in)
TIP
Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
places in one rotation of the rear wheel. Do not
turn the rear wheel while the thickness gauge is
installed. This may damage the rear wheel sen-
sor rotor and the rear wheel sensor.
Feeler gauge (Thickness gauge)
1
2
2
1
G088906
4-25
FRONT BRAKE CHAS

EAS20030
FRONT BRAKE
Removing the front brake pads
8 4
6
5
35 N·m (3.5 kgf·m, 26 lb·ft)
7 3
T.
R
.

1 Front brake caliper bolt 2
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 pad support 1
dure.
4-26
FRONT BRAKE CHAS

Removing the front brake master cylinder
(2) 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)

6 N·m (0.6 kgf·m, 4.4 lb·ft)
1
8 2
3
New
6 10
4
7
6 N·m (0.6 kgf·m, 4.4 lb·ft)
1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
9.0 N·m (0.9 kgf·m, 6.6 lb·ft)

T.
R.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-20.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Front brake light switch 1
5 Brake hose union bolt 1
6 Copper washer 2
7 Front brake hose 1
8 Brake lever 1
9 Front brake master cylinder holder 1
10 Front brake master cylinder 1
dure.
4-27
FRONT BRAKE CHAS

Disassembling the front brake master cylinder
1 New

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
cedure.
4-28
FRONT BRAKE CHAS

Removing the front brake caliper
3
5
29 N·m (2.9 kgf·m, 21 lb·ft)

T.
R.
1 2 New

Drain.
1 Front brake hose union bolt (brake caliper side) 1
2 Brake hose gasket 2
Front brake hose (brake hose joint to brake
3 1
caliper)
4 Front brake caliper bolt 2
dure.
4-29
FRONT BRAKE CHAS

Disassembling the front brake caliper
New New
New

The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Front brake pad 2
5 Brake pad support 1
6 Brake caliper bracket 1
7 Brake caliper piston 2
8 Brake caliper piston dust seal 2
9 Brake caliper piston seal 2
10 Bleed screw 1
cedure.
4-30
FRONT BRAKE CHAS

EAS30168
d. Install the disc brake face out tool on
INTRODUCTION
EWA14101
mounting “1”.
WARNING e. Install the dial gauge on the other side of
Disc brake components rarely require disas- the tool.
sembly. Therefore, always follow these pre- f. Tighten dial gauge “2” properly by screw
ventive measures: “3”.
• Never disassemble brake components un- TIP
less absolutely necessary. The gauge should be perpendicular to the disc
• If any connection on the hydraulic brake plate.
system is disconnected, the entire brake g. Set the dial at zero position.
system must be disassembled, drained, h. Reset the wheel by hand slowly.
cleaned, properly filled, and bled after reas- i. Measure the runout 5 mm below the edge
sembly. of the brake disc.
• Never use solvents on internal brake com-
TIP
ponents.
• Use only clean or new brake fluid for clean- Note down the measurement at four different
ing brake components. points (A, B, C & D) and compare with given
• Brake fluid may damage painted surfaces specification.
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. Front wheel 1 Rear wheel
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES: 2
• Flush with water for 15 minutes and get im- 2
mediate medical attention.
EAS30169 3
CHECKING THE FRONT BRAKE DISC
1. Check: Dics brake face out
• Brake disc YSST-890
Damage/galling → Replace.
2. Measure: 3. Measure:
• Brake disc runout limit • Brake disc thickness
Out of specification → Correct the brake disc Measure the brake disc thickness at a few dif-
runout or replace the brake disc. ferent locations.
Out of specification → Replace.
Brake disc runout limit (as mea-
sured on wheel)
0.15 mm (0.0059 in)
a. Place the vehicle on a maintenance stand

so that the front wheel is elevated.
b. Before measuring the front brake disc run-
out, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. For front wheel:- Remove the brake cali-
per, front wheel sensor and lead holder.
Refer to “FRONT WHEEL” on page 4-13. Brake disc thickness limit
For rear wheel:- Remove the mud protec- 3.5 mm (0.14 in)
tor assembly and rear wheel sensor.
4-31
FRONT BRAKE CHAS

4. Adjust:
• Brake disc runout
a. Remove front wheel and then remove the
brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
Front brake disc bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
LOCTITE®
2. Install:
TIP
• Brake pads New
Tighten the brake disc bolts in stages and in a
crisscross pattern. • Brake pad springs New
• Brake pad support
TIP
Always install new brake pads and new brake
pad springs as a set.
LT
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake caliper
with your fingers.
d. Measure the brake disc runout.
e. If out of specification, repeat the adjust-
ment steps until the brake disc runout is
within specification.
f. If the brake disc runout cannot be brought 2
within specification, replace the brake 1
disc.
5. Install:
• Front wheel
Refer to “FRONT WHEEL” on page 4-13.
c. Tighten the bleed screw.
EAS30170
REPLACING THE FRONT BRAKE PADS

Front brake caliper bleed screw
TIP 14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
When replacing the brake pads, it is not neces-

sary to disconnect the brake hose or disassem- d. Install new brake pads and new brake pad
ble the brake caliper. springs.
3. Install:
1. Measure:
• Brake pad pins
• Brake pad wear limit “a”
• Brake pad clips
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness limit 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
0.6 mm (0.02 in)

R.
4-32
FRONT BRAKE CHAS

4. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
EAS30172
DISASSEMBLING THE FRONT BRAKE

CALIPER
1. Remove:
• Brake caliper pistons “1”
• Brake caliper piston dust seals “2”
5. Check: • Brake caliper piston seals “3”
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-20. 1
3
2
EAS30m724
REMOVING THE FRONT BRAKE CALIPER

TIP 1
Before disassembling the brake caliper, drain 3
the brake fluid from the entire brake system. a. Blow compressed air into the brake hose
ECA20981 joint opening “a” to force out the pistons
NOTICE from the brake caliper.
EWA13560
WARNING
etc.) away from the rear wheel sensor or • Cover the brake caliper pistons with a rag.
rear wheel sensor rotor; otherwise, the sen- Be careful not to get injured when the pis-
sor or rotor may be damaged, resulting in tons are expelled from the brake caliper.
improper performance of the ABS system. • Never try to pry out the brake caliper pis-
• Do not drop the rear wheel sensor rotor or tons.
• If any solvent gets on the rear wheel sensor a
rotor, wipe it off immediately.
1. Remove:
• Brake hose union bolt “1”
• Brake hose gaskets “2”
• Front brake hose (brake hose joint to brake
caliper) “3”
• Wheel sensor holder
• Brake caliper
TIP b. Remove the brake caliper piston seals
and dust seals.
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
4-33
FRONT BRAKE CHAS

EAS30173
• Whenever a brake caliper is disassembled,
CHECKING THE FRONT BRAKE CALIPER
replace the brake caliper piston kits.
Recommended brake component replacement
schedule
Brake pads If necessary DOT 4
Brake caliper piston kits If necessary
EAS30934
Brake hose Every four years INSTALLING THE FRONT BRAKE CALIPER
Every two years and 1. Install:
Brake fluid whenever the brake is • Front brake caliper “1”
disassembled (temporarily) along with wheel sensor holder
1. Check: • Copper washer New
• Brake caliper pistons “1” • Front brake hose (brake hose joint to brake
Rust/scratches/wear → Replace the brake caliper) “2”
caliper piston kits. • Brake hose union bolt “3”
• Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper Front brake hose union bolt
(brake caliper side)
T.
assembly.
R.
29 N·m (2.9 kgf·m, 21 lb·ft)

• Brake caliper body “3”
Cracks/damage → Replace the brake caliper EWA13531
assembly. WARNING
• Brake fluid delivery passages Proper brake hose routing is essential to in-
(brake caliper body) sure safe vehicle operation.
Obstruction → Blow out with compressed air.
EWA20670 Refer to “CABLE ROUTING” on page 2-31.
ECA14170
WARNING
NOTICE
Whenever a brake caliper is disassembled,
When installing the brake hose onto the
replace the brake caliper piston kits.
brake caliper “1”, make sure the brake pipe
“a” passes between the projections “b” on
3
the brake caliper.
2 2
1
2. Check:
• Brake caliper bracket
EAS30174
ASSEMBLING THE FRONT BRAKE CALIPER 2. Remove:

EWA20680
WARNING • Brake caliper

3. Install:
• Before installation, all internal brake com-
• Brake pad support
ponents should be cleaned and lubricated
• Brake pads
with clean or new brake fluid.
• Brake pad springs
• Brake pad pins
ponents as they will cause the brake caliper
• Brake pad clips
dust seals and piston seals to swell and
distort.
• Sensor lead holder
4-34
FRONT BRAKE CHAS

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
Sensor lead holder bolt

7 N·m (0.7 kgf·m, 5.2lb·ft)
Refer to “REPLACING THE FRONT BRAKE

PADS” on page 4-32.
4. Fill: 1
• Brake master cylinder reservoir
(with the specified amount of the specified
7. Check:
brake fluid)
Specified brake fluid Soft or spongy feeling → Bleed the brake sys-
DOT 4 tem.
EWA13540
WARNING
EAS30179
REMOVING THE FRONT BRAKE MASTER
brake fluids may cause the rubber seals to CYLINDER
deteriorate, causing leakage and poor
TIP
brake performance.
• Refill with the same type of brake fluid that Before removing the front brake master cylinder,
is already in the system. Mixing brake fluids drain the brake fluid from the entire brake sys-
may result in a harmful chemical reaction, tem.
leading to poor brake performance. 1. Disconnect:
• When refilling, be careful that water does • Front brake light switch leads
not enter the brake master cylinder reser- 2. Remove:
voir. Water will significantly lower the boil- • Brake hose union bolt
ing point of the brake fluid and could cause
• Copper washers New
vapor lock.
• Brake hose
ECA13540
TIP
NOTICE
To collect any remaining brake fluid, place a
Brake fluid may damage painted surfaces
container under the master cylinder and the end
and plastic parts. Therefore, always clean up
of the brake hose.
any spilt brake fluid immediately.
5. Bleed: EAS30725
• Brake system CHECKING THE FRONT BRAKE MASTER

Refer to “BLEEDING THE HYDRAULIC CYLINDER
BRAKE SYSTEM (ABS)” on page 3-20. 1. Check:
6. Check: • Brake master cylinder
• Brake fluid level Damage/scratches/wear → Replace.
Below the minimum level mark “1” → Add the • Brake fluid delivery passages
specified brake fluid to the proper level. (brake master cylinder body)
Refer to “CHECKING THE BRAKE FLUID Obstruction → Blow out with compressed air.
LEVEL” on page 3-18. 2. Check:
• Brake master cylinder reservoir
Cracks/damage → Replace the brake master
cylinder.
• Brake master cylinder reservoir diaphragm
4-35
FRONT BRAKE CHAS

3. Check:
• Brake hose Front brake hose union bolt
Cracks/damage/wear → Replace. (master cylinder)
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft)
EAS30181
ASSEMBLING THE FRONT BRAKE MASTER EWA13531
CYLINDER WARNING
EWA13520
Proper brake hose routing is essential to in-
WARNING sure safe vehicle operation.
Refer to “CABLE ROUTING” on page 2-31.
ponents should be cleaned and lubricated
with clean or new brake fluid. TIP
• Never use solvents on internal brake com- • Install the brake hose to the front brake master
ponents. cylinder within the angle shown in the illustra-
tion.
Specified brake fluid • While holding the brake hose, tighten the brake
DOT 4 hose union bolt as shown.
• Turn the handlebar to the left and right to make
EAS30182 sure the brake hose does not touch other parts
INSTALLING THE FRONT BRAKE MASTER (e.g., wire harness, cables, and leads). Correct
CYLINDER if necessary.
1. Install:
• Brake master cylinder “1”
• Brake master cylinder holder “2”
1 New
Front brake master cylinder hold- 3
er bolt
T.
2
R.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
TIP
• Install the brake master cylinder holder with the
“UP” mark facing up.
• Align the end of the brake master cylinder hold- 3. Fill:
er with the punch mark “a” on the handlebar. • Brake master cylinder reservoir
• First, tighten the bolt on the upper side of the (with the specified amount of the specified
handlebar holder, and then on the lower side. brake fluid)

DOT 4
EWA13540
WARNING
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
2. Install: may result in a harmful chemical reaction,
• Copper washers “1” New leading to poor brake performance.
• Brake hose “2” • When refilling, be careful that water does
• Brake hose union bolt “3” not enter the brake master cylinder reser-
• Front brake light switch voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
4-36
FRONT BRAKE CHAS

ECA13540
NOTICE
4. Bleed:
• Brake system
5. Check:
recommended brake fluid to the proper level.
6. Check:
tem.
4-37
REAR BRAKE CHAS

EAS20031
REAR BRAKE
Removing the rear brake pads

1 Rear brake pad retaining bolt 2
2 Rear brake pad 2
3 Brake pad shim 2
dure.
4-38
REAR BRAKE CHAS

Removing the rear brake master cylinder
1
2
3
6
2
4
5
7
8
9
10
11

Drain.
1 Brake hose union bolt 1
2 Copper washer 2
3 Rear brake hose 1
4 Footrest plate assembly 1
5 Brake fluid reservoir hose 1
6 Rear brake master cylinder 1
7 Brake fluid reservoir assembly 1
8 Brake fluid reservoir cap 1
9 Brake fluid reservoir diaphragm holder 1
10 Brake fluid reservoir diaphragm 1
11 Brake fluid reservoir 1
dure.
4-39
REAR BRAKE CHAS

Disassembling the rear brake master cylinder

1 Brake hose joint 1
2 Brake master cylinder kit 1
3 Brake master cylinder body 1
cedure.
4-40
REAR BRAKE CHAS

Removing the rear brake caliper
4
3
1

Rear wheel sensor Refer to “REAR WHEEL” on page 4-20.
Drain.
Rear wheel Refer to “REAR WHEEL” on page 4-20.
1 Rear brake hose union bolt 1
2 Brake hose gasket 2
3 Rear brake hose 1
4 Rear brake caliper 1
dure.
4-41
REAR BRAKE CHAS

Disassembling the rear brake caliper
5
7 New 4
S 3
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
6 New
2
1
3
S
9
S LT
LT
22 N·m (2.2 kgf·m, 16 lb·ft)

T.
R.
8
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.

1 Brake pad retaining bolts 2
2 Rear brake pad 2
3 Brake pad shims 2
5 Brake caliper piston 1
6 Brake caliper piston dust seal 1
7 Brake caliper piston seal 1
8 Brake caliper bracket 1
9 Bleed screw 1 Skip step 1 to 8.
cedure.
4-42
REAR BRAKE CHAS

EAS30183
INTRODUCTION Brake disc thickness limit

EWA14101
4.0 mm (0.16 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc runout
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISC” on page 4-31.
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-
6. Install:
sembly.
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-20.
• 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. Remove:
THE EYES: • Rear brake pad retaining bolts
• Flush with water for 15 minutes and get im- • Brake pad
mediate medical attention. Refer to “REAR BRAKE” on page 4-38.
2. Measure:
EAS30184
• Brake pad wear limit “a”
CHECKING THE REAR BRAKE DISC Out of specification → Replace the brake
1. Remove: pads as a set.
• Rear wheel
Refer to “REAR WHEEL” on page 4-20. Brake pad lining thickness limit
2. Check: 1.5 mm (0.06 in)
• Brake disc
Damage/galling → Replace.
3. Measure:
• Brake disc runout
Out of specification → Correct the brake disc
runout or replace the brake disc.
Brake disc runout limit (as mea-

sured on wheel)
0.15 mm (0.0059 in) 3. Install:
• Brake pad spring
4. Measure: • Brake pad shims
• Brake disc thickness • Brake pads
Measure the brake disc thickness at a few dif-
ferent locations.
4-43
REAR BRAKE CHAS

TIP
Always replace the brake pads, brake pad shims
and brake pad spring as a set.
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
6. Check:
• Brake pedal operation
tem.
EAS30186
b. Loosen the bleed screw and push the REMOVING THE REAR BRAKE CALIPER
brake caliper pistons into the brake caliper TIP
with your finger.
Before disassembling the brake caliper, drain
c. Tighten the bleed screw.
the brake fluid from the entire brake system.
Rear brake caliper bleed screw ECA20981
5 N·m (0.5 kgf·m, 3.7 lb·ft) NOTICE

T.
R.

d. Install a new brake pad shim “3” onto each netic pick-up tools, magnetic screwdrivers,
new brake pad “4”. etc.) away from the rear wheel sensor or
e. Install new brake pads and a new brake rear wheel sensor rotor; otherwise, the sen-
pad spring “5”. sor or rotor may be damaged, resulting in
improper performance of the ABS system.
• Do not drop the rear wheel sensor rotor or
• If any solvent gets on the rear wheel sensor
rotor, wipe it off immediately.
1. Remove:
• Rear wheel sensor
• Rear brake hose union bolt “1”
• Brake hose gaskets “2”
• Rear brake hose (hydraulic unit to brake cali-
4. Install: per) “3”
• Rear brake pad retaining bolt
Rear brake pad retaining bolt

17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
5. Check:
4-44
REAR BRAKE CHAS

EAS30188
TIP CHECKING THE REAR BRAKE CALIPER
Put the end of the brake hose into a container
Recommended brake component
and pump out the brake fluid carefully. replacement schedule
2. Remove: Brake pads If necessary
• Rear wheel
Piston seals Every two years
• Brake caliper Piston dust seals Every two years
Refer to “REMOVING THE REAR BRAKE Brake hose Every four years
CALIPER” on page 4-44. Every two years and
EAS30187
Brake fluid whenever the brake is
DISASSEMBLING THE REAR BRAKE disassembled
CALIPER 1. Check:
1. Remove: • Brake caliper piston “1”
• Brake caliper piston “1” Rust/scratches/wear → Replace the brake
• Brake caliper piston dust seal “2” caliper piston.
• Brake caliper piston seal “3” • Brake caliper cylinder “2”
Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
3 assembly.
2 • Brake fluid delivery passages
1
(brake caliper body)
a. Blow compressed air into the brake hose

3
joint opening “a” to force out the piston
from the brake caliper. 2 1
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
EWA17070
ton.
WARNING
Whenever a brake caliper is disassembled,
a replace the brake caliper piston dust seal
and brake caliper piston seal.
EAS32685
CHECKING THE REAR BRAKE CALIPER

BRACKET
1. Check:
• Rear brake caliper bracket
b. Remove the brake caliper piston seal and
dust seal.
4-45
REAR BRAKE CHAS

EAS30189 EWA13531
ASSEMBLING THE REAR BRAKE CALIPER WARNING

EWA17080
WARNING Proper brake hose routing is essential to in-

sure safe vehicle operation.
ponents should be cleaned and lubricated Refer to “CABLE ROUTING” on page 2-31.
ECA26360
with clean or new brake fluid.
NOTICE
ponents as they will cause the brake caliper When installing the brake hose onto the
piston dust seal and brake caliper piston brake caliper, be sure to position the brake
seal to swell and distort. pipe “a” touches the projection “b” in the
• Whenever a brake caliper is disassembled, brake caliper.
replace the brake caliper piston dust seal
and brake caliper piston seal.

DOT 4
EAS30190
INSTALLING THE REAR BRAKE CALIPER

1. Install:
• Brake pad spring and shims (onto the brake
pads)
• Brake pads 3. Fill:
• Brake pad retaining bolt • Brake fluid reservoir
• Refer to “REPLACING THE REAR BRAKE (with the specified amount of the specified
PADS” on page 4-43. brake fluid)
Rear brake pad retaining bolt Specified brake fluid

17 N·m (1.7 kgf·m, 13 lb·ft) DOT 4
T.
R.
EWA13090
2. Install:
WARNING
• Rear brake caliper “1” along with rear wheel
• Rear wheel sensor • Use only the designated brake fluid. Other
Refer to “REAR BRAKE” on page 4-38. brake fluids may cause the rubber seals to
• Brake hose gaskets “2” New
brake performance.
• Rear brake hose (hydraulic unit to brake cali-
per) “3”
• Rear brake hose union bolt “4”
may result in a harmful chemical reaction,
Rear brake hose union bolt leading to poor brake performance.
(brake caliper side) • When refilling, be careful that water does
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft) not enter the brake fluid reservoir. Water
the brake fluid and could cause vapor lock.
ECA13540
NOTICE
4. Bleed:
• Brake system
4-46
REAR BRAKE CHAS

5. Check: EAS30194
CHECKING THE REAR BRAKE MASTER

CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace the
brake master cylinder assembly.
• Brake fluid delivery passages
(brake master cylinder body)
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace the
brake master cylinder kit.
3. Check:
• Brake fluid reservoir
Cracks/damage → Replace the reservoir tank.
• Brake fluid reservoir diaphragm
6. Check:
Cracks/damage → Replace the brake fluid
• Brake pedal operation
reservoir diaphragm.
Soft or spongy feeling → Bleed the brake system.
4. Check:
• Brake hoses
BRAKE SYSTEM (ABS)” on page 3-20. Cracks/damage/wear → Replace the brake
EAS30193 hose.
REMOVING THE REAR BRAKE MASTER EAS30195
CYLINDER ASSEMBLING THE REAR BRAKE MASTER

TIP CYLINDER
EWA13520
Before removing the rear brake master cylinder, WARNING
drain the brake fluid from the entire brake system.
1. Remove: ponents should be cleaned and lubricated
• Brake hose union bolt “1” with clean or new brake fluid.
• Copper washers “2” New • Never use solvents on internal brake com-
• Brake hose “3” ponents.
• Footrest plate assembly
TIP Specified brake fluid
To collect any remaining brake fluid, place a DOT 4
container under the master cylinder and the end
EAS30196
of the brake hose. INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• Footrest plate assembly
• Brake hose “1”
• Copper washers “2” New
• Brake hose union bolt “3”
• Brake fluid reservoir hose “4”
EWA13531
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
4-47
REAR BRAKE CHAS

ECA14160
4. Check:
NOTICE • Brake fluid level
When installing the brake hose onto the Below the minimum level mark “a” → Add the
brake master cylinder, make sure the brake recommended brake fluid to the proper level.
pipe “a” touches the projection “b” as Refer to “CHECKING THE BRAKE FLUID
shown. LEVEL” on page 3-18.
2. Fill: 5. Check:
• Brake fluid reservoir • Brake pedal operation
(with the specified amount of the recom- Soft or spongy feeling → Bleed the brake sys-
mended brake fluid) tem.
Specified brake fluid BRAKE SYSTEM (ABS)” on page 3-20.
DOT 4
REAR BRAKE HOSE INSTALLATION
EWA13090
1. Install:
WARNING
• Brake hose (reserve) “1”
• Use only the designated brake fluid. Other TIP
Rear brake hose should be installed in the up-
right direction. If not upright, possible touching to
brake performance.
rear arm.
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
the brake fluid and could cause vapor lock.
ECA13540
NOTICE
3. Bleed:
• Brake system
4-48
ABS (ANTI-LOCK BRAKE SYSTEM) CHAS

EAS20033
ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly
29 N·m (2.9 kgf·m, 21 lb·ft)
New
New
7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 29 N·m (2.9 kgf·m, 21 lb·ft)
New
7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
New
New 7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
29 N·m (2.9 kgf·m, 21 lb·ft)
New
7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
New
7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
29 N·m (2.9 kgf·m, 21 lb·ft)

New
7.0 N·m (0.7 kgf·m, 5.2 lb·ft)

Drain.
Brake fluid Refer to“BLEEDING THE HYDRAULIC
Rider seat
4-1.
4-2.
Fuel tank Refer to “FUEL TANK” on page 7-1.
4-49

Removing the hydraulic unit assembly
29 N·m (2.9 kgf·m, 21 lb·ft)
New
New
5
7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 29 N·m (2.9 kgf·m, 21 lb·ft)
4 New
7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
2
New
New 7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
29 N·m (2.9 kgf·m, 21 lb·ft)
3
4 1 New
7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
New 7 8
6
7.0 N·m (0.7 kgf·m, 5.2 lb·ft) 7.0 N·m (0.7 kgf·m, 5.2 lb·ft)
29 N·m (2.9 kgf·m, 21 lb·ft)

New
7.0 N·m (0.7 kgf·m, 5.2 lb·ft)

1 ABS ECU coupler 1
Front brake hose (hydraulic unit to front brake
2 1
master cylinder)
Front brake hose (hydraulic unit to front brake
3 1
caliper)
Rear brake hose (hydraulic unit to rear brake
4 1
master cylinder)
Rear brake hose (hydraulic unit to rear brake
5 1
caliper)
6 Hydraulic unit assembly with bracket 1
7 Hydraulic unit assembly 1
8 Hydraulic unit bracket 1
dure.
4-50

EAS30197
2. Remove:
REMOVING THE HYDRAULIC UNIT
• Brake hoses
ASSEMBLY
ECA21091 TIP
NOTICE Do not operate the brake lever and brake pedal
Unless necessary, avoid removing and in- while removing the brake hoses.
stalling the brake hoses of the hydraulic unit ECA14530
assembly. NOTICE
EWA13930 When removing the brake hoses, cover the
WARNING area around the hydraulic unit to catch any
Refill with the same type of brake fluid that is spilt brake fluid. Do not allow the brake fluid
already in the system. Mixing fluids may re- to contact other parts.
sult in a harmful chemical reaction, leading 3. Remove:
to poor braking performance. • Hydraulic unit assembly “1”
ECA18241
TIP
NOTICE
• To avoid brake fluid leakage and to prevent for-
• Handle the ABS components with care eign materials from entering the hydraulic unit
since they have been accurately adjusted. assembly, insert a rubber plug “a” or a bolt
Keep them away from dirt and do not sub- (M10 × 1.25) into each brake hose union bolt
hole.
• Do not turn the main switch to “ON” when
• When using a bolt, do not tighten the bolt until
removing the hydraulic unit assembly.
the bolt head touches the hydraulic unit. Other-
• Do not clean with compressed air. wise, the brake hose union bolt seating surface
• Do not reuse the brake fluid. could be deformed.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. 1
• Do not allow any brake fluid to contact the
couplers. Brake fluid may damage the cou- a
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.
1. Disconnect:
• ABS ECU coupler “1” EAS30198
TIP CHECKING THE HYDRAULIC UNIT

ASSEMBLY
Push the lock “a” and pull the lock lever “2” of the
1. Check:
ABS ECU coupler in the direction of the arrow
• Hydraulic unit assembly
shown, and then disconnect the coupler “1” by
Cracks/damage → Replace the hydraulic unit
puling it backward.
assembly and the brake hoses that are con-
nected to the assembly as a set.
4-51

EAS30200
tighten the union bolt for the brake hose
INSTALLING THE HYDRAULIC UNIT
(front brake master cylinder to hydraulic
ASSEMBLY
unit).
1. Install:
c. Temporarily tighten the union bolt for the
• Hydraulic unit assembly
rear brake hose (hydraulic unit to rear
Hydraulic unit assembly bolt brake master cylinder) “1”.
7 N·m (0.7 kgf·m, 5.2 lb·ft) TIP
T.
R.
Make sure that the pipe section “b” of the brake

TIP hose (rear brake master cylinder to hydraulic
Do not allow any foreign materials to enter the unit) does not contact the hydraulic unit.
hydraulic unit assembly or the brake hoses d. Position the front brake hose (hydraulic
when installing the hydraulic unit assembly.
unit to front brake master cylinder) “3” so
ECA21110
that its projection “c” contacts the rear
NOTICE brake hose (hydraulic unit to rear brake
Do not remove the rubber plugs or bolts master cylinder) “1”, and then temporarily
(M10 × 1.25) installed in the brake hose union tighten the union bolt for the front brake
bolt holes before installing the hydraulic unit hose (hydraulic unit to brake caliper).
assembly. e. Position the front brake hose (hydraulic
2. Remove: unit to front brake caliper) “4” so that its
• Rubber plugs or bolts (M10 × 1.25) projection “d” contacts the front brake
3. Install: hose (hydraulic unit to front brake master
• Rear brake hose (hydraulic unit to rear brake cylinder) “3”, and then temporarily tighten
master cylinder) “1” the union bolt for the rear brake hose (hy-
• Rear brake hose (hydraulic unit to rear brake draulic unit to brake caliper).
caliper) “2” f. Tighten the brake hose union bolts to
• Front brake hose (hydraulic unit to front brake specification.
master cylinder) “3”
• Front brake hose (hydraulic unit to front brake
caliper) “4”
Front brake hose union bolt

29 N·m (2.9 kgf·m, 21 lb·ft)
T.
R.
Rear brake hose union bolt

29 N·m (2.9 kgf·m, 21 lb·ft)
ECA21121
NOTICE
If the brake hose union bolt does not turn 4. Connect:
easily, replace the hydraulic unit assembly, • ABS ECU coupler “1”
brake hoses, and related parts as a set. TIP
a. Temporarily install the brake hoses as • Connect the ABS ECU coupler, and then push
shown in the illustration. the lock lever “a” of the coupler in the direction
b. Position the rear brake hose (hydraulic of the arrow shown.
unit to rear brake caliper) “2” so that its • Make sure that the ABS ECU coupler is con-
projection “a” contacts the rear brake hose nected in the correct position.
(hydraulic unit to rear brake master cylin-
der) “1” also position the rear brake hose
(hydraulic unit to rear brake master cylin-
der) “1” so that its projection “b” contacts
the rear brake hose (hydraulic unit to rear
brake caliper) “2”, and then temporarily
4-52

8. Delete the fault codes. (Refer to “[B-3] DE-
LETING THE FAULT CODES” on page
8-136.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-56.)
EAS30930
HYDRAULIC UNIT OPERATION TESTS

The reaction-force pulsating action generated in
the brake lever and brake pedal when the ABS
is activated can be tested when the vehicle is
5. Fill: stopped.
• Brake master cylinder reservoir The hydraulic unit operation can be tested using
• Brake fluid reservoir the following two methods.
(with the specified amount of the specified • Brake line routing confirmation: this test
brake fluid) checks the function of the ABS after the sys-
tem was disassembled, adjusted, or serviced.
Specified brake fluid • ABS reaction-force confirmation: this test gen-
DOT 4 erates the same reaction-force pulsating action
EWA13090
that is generated in the brake lever and brake
WARNING pedal when the ABS is activated.
• Use only the designated brake fluid. Other Brake line routing confirmation
brake fluids may cause the rubber seals to EWA13120
deteriorate, causing leakage and poor WARNING

brake performance. Securely support the vehicle so that there is
• Refill with the same type of brake fluid that no danger of it falling over.
may result in a harmful chemical reaction, TIP
leading to poor brake performance. • For the brake line routing confirmation, use the
• When refilling, be careful that water does diagnosis 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
1. Place the vehicle on a maintenance stand.
Brake fluid may damage painted surfaces 2. Turn the main switch to “OFF”.
and plastic parts. Therefore, always clean up 3. Remove:
any spilt brake fluid immediately. • Rider seat
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 3-20. • Battery voltage
7. Check the operation of the hydraulic unit ac- Lower than 12.8 V → Charge or replace the
cording to the brake lever and the brake ped- battery.
al response. (Refer to “HYDRAULIC UNIT
Battery voltage
OPERATION TESTS” on page 4-53.)
ECA14770
Higher than 12.8 V
NOTICE
TIP
Always check the operation of the hydraulic
unit according to the brake lever and the If the battery voltage is lower than 12.8 V, charge
brake pedal response. the battery, and then perform brake line routing
confirmation.
4-53
2 3
5. Connect the Yamaha diagnostic tool. 9. Check:
Refer to “YAMAHA DIAGNOSTIC TOOL” on • Hydraulic unit operation
page 8-32. Click “Actuator Check”, a single pulse will be
generated in the brake lever “1”, brake pedal
“2”, and again in the brake lever “1”, in this or-
INS-018
90890-03267 der.
INS-019
90890-03264
6. Start the Yamaha diagnostic tool and display

the diagnosis mode screen.
7. Select code No. 2, “Brake line routing confir-
mation”.
8. Click “Actuator Check” “1”, and then operate
the brake lever “2” and brake pedal “3” simul-
taneously.
1 2
TIP TIP
• The hydraulic unit operates 1 second after the “ON” and “OFF” on the tool screen indicate
brake lever and brake pedal are operated si- when the brakes are being applied and released
multaneously and continues for approximately respectively.
5 seconds.
ECA18280
• The operation of the hydraulic unit can be con-
NOTICE
firmed using the indicator.
On: The hydraulic unit is operating. • Check that the pulse is felt in the brake le-
Flashing: The conditions for operating the hy- ver, brake pedal, and again in the brake le-
draulic unit have not been met. ver, in this order.
Off: The brake lever and brake pedal are not • If the pulse is felt in the brake pedal before
being operated. it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
10.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
ABS reaction-force confirmation

EWA13120
WARNING
4-54

TIP 6. Start the Yamaha diagnostic tool and display
• For the ABS reaction-force confirmation, use the diagnosis mode screen.
the diagnosis mode of the Yamaha diagnostic 7. Select code No. 1, “ABS reaction-force con-
tool. For more information, refer to the opera- firmation”.
tion manual of the Yamaha diagnostic tool. 8. Click “Actuator Check” “1”, and then operate
• Before performing the ABS reaction-force con- the brake lever “2” and brake pedal “3” simul-
firmation, make sure that no malfunctions have taneously.
been detected in the ABS ECU and that the TIP
wheels are not rotating. • The hydraulic unit operates 1 second after the
brake lever and brake pedal are operated si-
1. Place the vehicle on a maintenance stand.
multaneously and continues for approximately
2. Turn the main switch to “OFF”.
5 seconds.
3. Remove:
• The operation of the hydraulic unit can be con-
• Passenger seat
firmed using the indicator.
• Rider seat
On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
4-1.
draulic unit have not been met.
4. Check:
Off: The brake lever and brake pedal are not
• Battery voltage
being operated.
Lower than 12.8 V → Charge or replace the
battery.
Battery voltage
Higher than 12.8 V
TIP
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform ABS reaction-
force confirmation.
5. Connect the Yamaha diagnostic tool. 2 3

Refer to “YAMAHA DIAGNOSTIC TOOL” on 9. A reaction-force pulsating action is generated
page 8-32. in the brake lever “1” and continues for a few
seconds.
INS-018 TIP
90890-03267 • The reaction-force pulsating action consists of
INS-019 quick pulses.
90890-03264 • Be sure to continue operating the brake lever
and brake pedal even after the pulsating action
has stopped.
4-55

• “ON” and “OFF” on the tool screen indicate ECA18280
when the brakes are being applied and re- NOTICE

leased respectively. • Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le-
ver, in this order.
• If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
1 hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
12.Turn the main switch to “OFF”.
10.After the pulsating action has stopped in the 13.Remove the Yamaha diagnostic tool from the
brake lever, it is generated in the brake pedal Yamaha diagnostic tool coupler, and then in-
“1” and continues for a few seconds. stall the protective cap.
TIP 14.Turn the main switch to “ON”.
• The reaction-force pulsating action consists of 15.Set the start/engine stop switch to “ ”.
quick pulses. 16.Check for brake fluid leakage around the hy-
• Be sure to continue operating the brake lever draulic unit.
and brake pedal even after the pulsating action Brake fluid leakage → Replace the hydraulic
has stopped. unit, brake hoses, and related parts as a set.
• “ON” and “OFF” on the tool screen indicate 17.If the operation of the hydraulic unit is normal,
when the brakes are being applied and re- delete all of the fault codes.
leased respectively.
EAS30202
CHECKING THE ABS WARNING LIGHT

After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 10 km/h
(6.3 mi/h) or performing a trial run.
1
11.After the pulsating action has stopped in the
brake pedal, it is generated in the brake lever
and continues for a few seconds.
TIP
• The reaction-force pulsating action consists of
quick pulses.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
4-56
HANDLEBARS CHAS
EAS20033
HANDLEBARS
Removing the handlebars

Handle crown Refer to “STEERING HEAD” on page 4-75.
1 Grip end (left) 1
2 Handlebar weight (left) 1
3 Handlebar grip 1
4 Clutch switch coupler 1 Disconnect.
5 Handlebar switch (left) 1
6 Clutch switch 1
7 Clutch cable 1 Disconnect.
8 Clutch lever 1
9 Clutch lever holder 1
10 Handlebar pinch bolt 1 Loosen.
11 Handlebar (left) 1
12 Grip end (right) 1
4-57
HANDLEBARS CHAS
Removing the handlebars

13 Handlebar weight (right) 1
14 Handlebar switch (right) 1
15 Throttle cable 2 Disconnect.
16 Throttle grip 1
17 Front brake master cylinder holder 1
18 Front brake master cylinder 1
20 Handlebar (right) 1
dure.
4-58
HANDLEBARS CHAS
EAS30203
REMOVING THE HANDLEBARS TIP

1. Stand the vehicle on a level surface. • Install the brake master cylinder holder with the
EWA13120 “UP” mark facing up.
WARNING • Align the end of the brake master cylinder hold-
Securely support the vehicle so that there is er with the punch mark “a” on the handlebar.
no danger of it falling over. • First, tighten the upper bolt, then the lower bolt.
2. Remove:
• Handlebar grip “1”
TIP
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
3. Install:
• Throttle grip “1”
• Throttle cables
• Handlebar switch (right) “2”
1
TIP
• Lubricate the end of the throttle cables and the
inside of the throttle grip with a thin coat of the
EAS30204
lithium-soap-based grease, and then install the
CHECKING THE HANDLEBARS
throttle grip onto the right handlebar.
1. Check:
• Route the throttle cables through the slots in
• Handlebar (left)
the throttle grip, and then install the cables.
• Handlebar (right)
• Align the projection “a” on the right handlebar
Bends/cracks/damage → Replace.
EWA13690 switch with the hole “b” on the right handlebar.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS30205
INSTALLING THE HANDLEBARS

EWA13120
WARNING
2. Install: 4. Install:
• Front brake master cylinder “1” • Handlebar weight (right)
• Front brake master cylinder holder “2” • Grip end (right) “1”
TIP
Front brake master cylinder hold- There should be 2.9–4.5 mm (0.11–0.17 in) of
er bolt clearance “a” between the throttle grip and the
T.
R.
10 N·m (1.0 kgf·m, 7.4 lb·ft) right grip end.
4-59
HANDLEBARS CHAS
TIP
Lubricate the end of the clutch cable with a thin
coat of lithium-soap-based grease.
8. Install:
• Handlebar switch (left) “1”
TIP
1 Align the projection “a” on the left handlebar
switch with the hole “b” in the left handlebar.
5. Install: 1 a
• Clutch lever holder “1”
b
Clutch lever holder bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
TIP
Align the end of the clutch lever holder with the
punch mark “a” on the left handlebar. 1
a 9. Connect:
• Clutch switch coupler
10.Install:
• Handlebar grip “1”
• Handlebar weight (left)
• Grip end (left) “2”
a. Apply a thin coat of rubber adhesive onto
1 the end of the left handlebar.
b. Slide the handlebar grip over the end of
the left handlebar.
6. Install: c. Wipe off any excess rubber adhesive with
• Clutch lever a clean rag.
EWA13700
• Clutch switch “1”
WARNING
TIP
Do not touch the handlebar grip until the rub-
Align the projection “a” on the clutch switch with ber adhesive has fully dried.
the slit “b” in the clutch lever holder.
TIP
There should be 0.4–4.5 mm (0.02–0.17 in) of
a clearance “a” between the handlebar grip and
the left grip end.
1
b
7. Connect:
• Clutch cable
4-60
HANDLEBARS CHAS
11.Check:
• Cable routing
TIP
Make sure the main switch lead, brake hose,
throttle cables, clutch cable, and handlebar
switch leads are routed properly. Refer to
12.Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-11.
Clutch lever free play

10.0–15.0 mm (0.39–0.59 in)
13.Adjust:
Refer to “ADJUSTING THE THROTTLE
GRIP FREE PLAY” on page 3-7.
Throttle grip free play

3.0–5.0 mm (0.12–0.20 in)
4-61
FRONT FORK CHAS

EAS20034
FRONT FORK
Removing the front fork legs
Before removing the front wheel, place the scissor jack “a” YSST-892A under the engine as shown and stand
the vehicle on maintenance stand.
The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-13.
To remove the front fender, no need to re-
1 Front fender 1
move front wheel.
3 Upper bracket pinch bolt 1 Loosen.
TIP
For easy removal of cap bolt, loosen the up-
4 Front fork cap bolt 1 per pinch bolt first then loosen the cap bolt
slightly before loosening the lower pinch
bolt.
5 Lower bracket pinch bolt 1 Loosen.

6 Front fork assembly 1
dure.
4-62
FRONT FORK CHAS

Disassembling the front fork leg (right)
LS

1 Cap bolt 1
2 O-ring 1 After removal cap bolt, drain front fork oil.
3 Special nut 1
4 Rubber 1
5 Dust seal 1
6 Oil seal clip 1
7 Outer tube 1
8 Inner tube bushing 1
9 Outer tube bushing 1
10 Washer 1
11 Oil seal 1
12 Dumper rod stopper 1
13 Dumper rod spring 1
14 Damper rod 1
15 Front fork spring 1
16 Spacer 1
17 Inner tube 1
cedure.
4-63
FRONT FORK CHAS

Disassembling the front fork leg (left)
LT
TIP
1 Cap bolt 1
After removal cap bolt, drain front fork oil.
2 O-ring 1
3 Collar 1
4 Locknut 1
5 Spacer 1
6 Fork spring 1
7 Dust seal 1
8 Oil seal clip 1
9 Outer tube 1
10 Inner tube bushing 1
11 Outer tube bushing 1
12 Washer 1
13 Oil seal 1
14 Damper rod assembly bolt 1
15 Copper washer 1
16 Damper red assembly 1
17 Inner tube 1
cedure.
4-64
FRONT FORK CHAS

EAS30206
a. Gently press collar “2” downward as direc-
REMOVING THE FRONT FORK LEGS
tion shown in illustration.
b. Hold locknut “3” with front fork damper
front fork legs.
rod locknut holder “4” YSST-778 between
EWA13120
cap bolt “1” and collar “2” and loosen the
WARNING locknut.
• Securely support the vehicle so that there c. Remove the cap bolt.
is no danger of it falling over.
Front fork damper rod locknut
• Before removing the front wheel, place the
holder (left & right leg)
scissor jack YSST-892A under engine and YSST-778
stand the vehicle on maintenance stand. (90890-01953)
2. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-13
• Front fender
3. Loosen:
• Handlebar pinch bolt “1”
• Cap bolt “2”
• Handle crown pinch bolt “3”
• Lower bracket pinch bolt “4”
3. Remove:
• Collar
• Locknut
• Spacer
• Front fork spring
4. Drain:
• Fork oil
TIP
EWA13640
Stroke the damper rod assembly “1” several
WARNING times while draining the fork oil.
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
TIP
For easy removal of cap bolt, loosen the upper
pinch bolt first, then loosen the cap bolt slightly
without loosening the lower pinch bolt while front
fork is fitted on vehicle.
4. Remove:
• Front fork leg 5. Remove:
EAS30207
• Dust seal “1”
DISASSEMBLING THE FRONT FORK LEG • Oil seal clip “2”
(LEFT) (with a flat-head screwdriver)
ECA14190
1. Remove:
NOTICE
• Cap bolt
(from the outer tube) Do not scratch the inner tube.
2. Remove:
• Cap bolt with O-ring “1”
(from the damper rod assembly)
4-65
FRONT FORK CHAS

8. Remove:
• Damper rod assembly bolt “1”
• Copper washer “2”
• Damper rod assembly
TIP
• Securely clamp the fender bracket in a vise
with soft jaws.
• Loosen the damper rod assembly bolt “1” by
using 8mm T-handle “3”.
6. Remove:
• Outer tube
a. Hold the front fork leg horizontally.
b. Securely clamp the fender bracket in a
vise with soft jaws. Put cloth between
vise jaws.
c. Separate the outer tube from the inner
tube by pulling the outer tube forcefully
but carefully.
ECA19880
NOTICE EAS30206
CHECKING THE FRONT FORK LEGS

• Excessive force will damage the bushings.
Damaged bushings must be replaced.
front fork legs.
1. Check:
• Inner tube
• Outer tube
• Bends/damage/scratches → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• Fork spring free length “a”
7. Remove: Out of specification → Replace.
(from inner tube)
• Inner tube bushing “1” Fork spring free length
• Outer tube bushing “2” Limit
• Washer “3” 283.2 mm (11.15 in)
• Oil seal “4”
• Oil seal clip “5”
a
4-66
FRONT FORK CHAS

3. Check: 3. Lubricate:
• Damper rod assembly • Inner tube’s outer surface
Obstruction → Blow out all of the oil passag- Recommended oil
es with compressed air. (right front fork leg Yamaha Suspension Oil 01
only)
ECA20650 4. Install:
NOTICE • Dust seal “1” New
When disassembling and assembling the • Oil seal clip “2” New
front fork leg, do not allow any foreign mate- • Oil seal “3” New
rial to enter the front fork. • Washer “4”
EAS31055
• Outer tube bushing “5” New
ASSEMBLING THE FRONT FORK LEG • Inner tube bushing “6” New
(LEFT) ECA19170
NOTICE
TIP
• When assembling the front fork leg, be sure to Make sure the numbered side of the oil seal
replace the following parts: faces bottom side.
– Inner tube bushing TIP
– Outer tube bushing • Before installing the oil seal, lubricate its lips
– Oil seal with lithium-soap-based grease.
– Dust seal • Lubricate the outer surface of the inner tube
– O-ring New with fork oil.
– Oil seal clip • Before installing the oil seal, cover the top of
–Copper washer the front fork leg with a plastic bag to protect
• Before assembling the front fork leg, make the oil seal during installation.
sure all of the components are clean.
1. Install:
• Damper rod assembly “1”
ECA19120
NOTICE
Allow the damper rod assembly to slide
slowly down the inner tube “2” until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Tighten:
• Damper rod assembly bolt 5. Install:
(along with the copper washer New ) • Outer tube (into the inner tube)
6. Install:
Damper rod assembly bolt • Oil seal “1”
23 N·m (2.3 kgf·m, 17 lb·ft) (with the front fork oil seal installer “2”)
T.
R.
LOCTITE®
4-67
FRONT FORK CHAS

9. Install:
Front fork oil seal installer • Fork spring“1”
YSST-775A • Spacer “2”
(90890-01442) • Locknut “3”
• Collar “4”
• Cap bolt “5”
(along with the O-ring New )
3 2
4
7. Install: 1
• Oil seal clip “1” New
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove. Front fork damper rod locknut
YSST-778
(90890-01953)
a. Install the fork spring “1”.

New
TIP
Install the fork spring with its smaller pitch “a”
downward.
8. Install:
(with the front fork oil seal installer “2”)

YSST-775A
(90890-01442)
b. Install the spacer.

c. Tighten the locknut (till end of threads).
d. Install the collar.
4-68
FRONT FORK CHAS

e. Install the cap bolt (along with O-ring), and 12.Before measuring the fork oil level, wait ten
then finger tighten the cap bolt on the minutes until the oil has settled and the air
damper rod by tilting the assembly slightly bubbles have dispersed.
downward and pressing collar against TIP
front fork spring. Be sure to bleed the front fork leg of any resid-
EWA13670
WARNING ual air.

Always use a new cap bolt O-ring. 13.Measure:
• Front fork leg oil level “a”
f. Hold the cap bolt and tighten the locknut to
(from the top of the outer tube, with the outer
specification.
tube fully compressed and without the fork
Locknut spring)
17 N·m (1.7 kgf·m, 13 lb·ft) Out of specification → Correct.
T.
R.
10.Fill: Level (left)

• Front fork leg 100 mm (3.9 in)
mended fork oil)
Recommended oil
Yamaha Suspension Oil 01
Quantity
300.0 cm3 (10.14 US oz,
10.58 Imp.oz)
NOTICE
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on 14.Install:
front fork performance. • Cap bolt
• When disassembling and assembling the (to the outer tube)
front fork leg, do not allow any foreign ma- TIP
terial to enter the front fork. • Before installing the front fork cap, lubricate
11.After filling the front fork leg, slowly stroke the its O-ring with grease.
damper rod “1” up and down (at least ten • Insert the front fork cap bolt into the outer tube,
times) to distribute the fork oil. and make sure that the cap is securely held in
TIP
place.
• Temporarily tighten the cap bolt.
Be sure to stroke the damper rod slowly be-
• Tighten the cap bolt to the specified torque only
cause the fork oil may spurt out.
after installing the front fork leg to the vehicle
and tightening the lower bracket pinch bolts.
4-69
FRONT FORK CHAS

INSTALLING THE FRONT FORK LEGS
front fork legs.
1. Install:
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
2. Tighten:
• Cap bolt
Front fork cap bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
Front fork damper rod locknut

R.

• Lower bracket pinch bolt
YSST-778
Lower bracket pinch bolt (90890-01953)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
3. Drain:
R.
• Upper bracket pinch bolt • Fork oil

TIP
Upper bracket pinch bolt Stroke the damper rod “1” several times while
21 N·m (2.1 kgf·m, 15 lb·ft) draining the fork oil.
T.
R.
• Handlebar pinch bolt
Handlebar pinch bolt

21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
EWA20690
WARNING
Make sure the brake hose, clutch cable, and
leads are routed properly.
3. Check:
• Check front fork operation
Refer to “CHECKING THE FRONT FORK” 4. Remove:
on page 3-24. • Dust seal “1”
EAS20207
DISASSEMBLING THE FRONT FORK LEG (with a flat-head screwdriver)
(RIGHT) ECA14150
1. Remove: NOTICE
• Cap bolt with O-ring Do not scratch the inner tube.
(from outer tube)
2. Remove:
• Cap bolt with O-ring “1”
(from damper rod assembly)
a. Remove cap bolt “1” by holding the special
nut with front fork damper rod locknut
holder YSST-778 “2”.
4-70
FRONT FORK CHAS

5. Remove:
• Outer tube
a. Hold the front fork leg horizontally.
b. Securely clamp the fender bracket in a
vise with soft jaws.
c. Separate the outer tube from the inner
tube by pulling the outer tube forcefully but
carefully.
ECA19660
NOTICE
Excessive force will damage the bushings. 8. Remove:
Damaged bushings must be replaced. • Damper rod assembly along with damper
spring
• Spacer
CHECKING THE FRONT FORK LEG

(RIGHT)
Refer to “CHECKING THE FRONT FORK
LEGS” on page 4-66
ASSEMBLING THE FRONT FORK LEG

(RIGHT)
TIP
6. Remove: • When assembling the front fork leg, be sure to
(from inner tube) replace the following parts:
• Inner tube bushing “1” – Inner tube bushing
• Outer tube bushing “2”
– Outer tube bushing
• Washer “3”
– Oil seal
– Dust seal
• Oil seal clip “5” – O-ring New
• Dust seal “6” – Oil seal clip
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Lubricate:
• Inner tube’s outer surface
Recommended oil
Yamaha Suspension Oil 01
2. Install:
• Dust seal “1” New
7. Remove:
• Damper rod stopper bolt • Oil seal clip “2” New
TIP • Oil seal “3” New
• Washer “4”
Secure the front brake caliper bracket in a vise,
and then loosen the damper rod stopper with the • Outer tube bushing “5” New
damper rod holder “1”. • Inner tube bushing “6” New
Front fork damper rod stopper

tool (Right leg)
YSST-779
(90890-01592)
4-71
FRONT FORK CHAS

ECA19660
4. Install:
NOTICE • Front fork spring “1”
Make sure to face the numbered side of the TIP
oil seal toward the bottom end of the inner
Install the fork spring with its smaller pitch “a”
tube.
downward.
TIP
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Before installing the oil seal, cover the top of
the inner tube with a plastic bag to protect the
oil seal during installation.
5. Install:
• Damper rod assembly “1” along with short
spring “2” into inner tube as shown.
3. Install:
• Spacer “1”
TIP
• Insert the collar side “a” of spacer upward into
the inner tube.
• Allow the spacer to slide slowly down the inner
tube “2” until it protrudes from the bottom of the
inner tube. Be careful not to damage the inner
tube.
4-72
FRONT FORK CHAS

6. Tighten: 9. Install:
• Damper rod stopper bolt “1” into inner tube by • Cap bolt with finger tighten
using front fork damper rod stopper tool 10.Tighten:
(Right leg) YSST-779 “2”. • Tighten special nut by holding cap bolt.
Special nut
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
11.Tighten:
• Front fork cap bolt in to outer tube by finger
tighten.
12.Install:
(with front fork oil seal installer YSST-775 A
“2”).
•
Front fork damper rod stopper

tool (Right leg)
YSST-779
(90890-01592)
7. Install:
• Rubber “1” into damper rod “2”.

YSST-775A
(90890-01442)
13.Tighten:
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
•
8. Install:
• Outer tube New
• Special nut “1” into damper rod “2” till the end
of thread by facing flat surface upward as
shown in illustration.
14.Install:
(with front fork oil seal installer YSST-775 A
“2”)

YSST-775A
(90890-01442)
4-73
FRONT FORK CHAS

18.Measure:
• Front fork leg oil level “a”
(from the top of the outer tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification → Correct.
Oil level (right leg)

119 mm (4.7 in)
15.Fill:
• Front fork leg
mended fork oil)
Recommended oil
Yamaha Suspension Oil G01
Quantity
363.0 cm3 (12.27 US oz, 12.80
lmp.oz)
19.Install:
NOTICE • Cap bolt
• Be sure to use the recommended fork oil. (to the outer tube)
Other oils may have an adverse effect on TIP
front fork performance. • Before installing the front fork cap, lubricate its
• When disassembling and assembling the O-ring with grease.
front fork leg, do not allow any foreign ma- • Insert the front fork cap bolt into the outer tube,
terial to enter the front fork. and make sure that the cap is securely held in
16.After filling the front fork leg, slowly stroke the place.
damper rod “1” up and down (at least ten • Temporarily tighten the cap bolt.
times) to distribute the fork oil. • Tighten the cap bolt to the specified torque only
TIP after installing the front fork leg to the vehicle
and tightening the lower bracket pinch bolts.
Be sure to stroke the damper rod slowly be-
cause the fork oil may spurt out.
INSTALLING THE FRONT FORK LEG
(RIGHT)
Install the front fork leg on vehicle.
Refer to “INSTALLING THE FRONT FORK
LEGS” on page 4-70
17.Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual
air.
4-74
STEERING HEAD CHAS

EAS20035
STEERING HEAD
Removing the lower bracket
� 7.0 N-m (0.7 kgf.m, 5.2 lb-ft)
1st 48 N-m (4.8 kgf.m, 35 lb-ft)

�
2nd 18 N-m (1.8 k f.m, 13 lb-ft)
* Removing and installing the ignition lock screw by using special tool [Main switch steering lock YSST-611 A
(T-30)].

Front fork legs Refer to “FRONT FORK” on page 4-62.
1 Horn lead 2 Disconnect.
2 Horn 1
3 Steering stem bolt/washer 1/1
Gently remove handle crown along with
4 Handle crown 1
handlebar.
5 Lock washer 1
6 Upper ring nut 1
4-75
STEERING HEAD CHAS

Removing the lower bracket
1st 48 N-m (4.8 kgf-m, 35 lb-ft)

X 2nd 18 N-m (1.8 kgf-m, 13 lb-ft)
* Removing and installing the ignition lock screw by using special tool [Main switch steering lock YSST-611 A
(T-30)].

7 Rubber washer 1
8 Lower ring nut 1
9 Lower bracket 1
10 Bearing cover 1
11 Upper bearing inner race 1
12 Upper bearing 1
13 Lower bearing 1
14 Upper bearing outer race 1
15 Lower bearing outer race 1
16 Lower bearing inner race 1
17 Dust seal 1
For disconnection, remove lower side cowl-
18 Main switch coupler 1
ing (right).
19 Main switch 1 Skip step 1 to 17.
dure.
4-76
STEERING HEAD CHAS

EAS30213
a. Remove the bearing races from the steer-
REMOVING THE LOWER BRACKET
ing head pipe with a long rod “1” and ham-
EWA13120
mer.
WARNING b. Remove the bearing race from the lower
Securely support the vehicle so that there is bracket with a floor chisel “2” and hammer.
no danger of it falling over. c. Install a new dust seal and new bearing
races.
2. Remove: ECA14270
• Lock washer NOTICE

• Upper ring nut If the bearing race is not installed properly,
• Rubber washer the steering head pipe could be damaged.
• Lower ring nut “1”
• Lower bracket TIP
TIP
• Always replace the bearings and bearing races
as a set.
Remove the lower ring nut with the steering nut
• Whenever the steering head is disassembled,
wrench “2”.
replace the dust seal.
Steering nut socket

YSST-721
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS30214
CHECKING THE STEERING HEAD

1. Wash:
• Bearings 4. Check:
• Bearing races • Upper bracket
Recommended cleaning solvent • Lower bracket
Kerosene (along with the steering stem)
Bends/cracks/damage → Replace.
2. Check: EAS30216
• Bearings INSTALLING THE STEERING HEAD
• Bearing races 1. Lubricate:
Damage/pitting → Replace. • Upper bearing
3. Replace: • Lower bearing
• Bearings • Bearing races
• Bearing races
4-77
STEERING HEAD CHAS

3. Install:
Recommended lubricant • Upper bracket
Lithium-soap-based grease • Washer
• Steering stem bolt
2. Install:
TIP
• Lower ring nut
• Rubber washer Temporarily tighten the steering stem bolt.
• Upper ring nut 4. Install:
• Lock washer • Front fork legs
Refer to “CHECKING AND ADJUSTING Refer to “FRONT FORK” on page 4-62.
THE STEERING HEAD” on page 3-23.
TIP
TIP
Temporarily tighten the upper and lower bracket
Install bearing steering lower on under bracket pinch bolts.
with fixing tool bearing steering lower “1” as
shown in the illustration. 5. Tighten:
• Steering stem bolt
Fixing tool bearing steering lower Steering stem bolt
YSST-870 18 N·m (1.8 kgf·m, 13 lb·ft)
T.
R.
TIP
Install the upper and lower bearing outer races
by using special tool upper and lower race in-
staller “2”.
Upper and lower race installer

YSST-626
4-78
REAR SHOCK ABSORBER ASSEMBLY CHAS

EAS20036
REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber assembly
9
8
44 N·m (4.4 kgf·m, 32 lb·ft) 2
3 10
5
1 2 9
3 7
9
44 N·m (4.4 kgf·m, 32 lb·ft)
8 1
9
6
8
9
8 10
4
9 10
10
9
9
3
6
3 7
NOTE : Apply “Lithium-soap-based grease” on part serial number :- 1,2,3,6,8,9,10

1 Rear shock absorber assembly lower nut/bolt 1/1
2 Rear shock absorber assembly upper nut/bolt 1/1
3 Connecting arm nut/bolt 2/2 M10 × 63 mm
4 Relay arm along with connecting arm 1
5 Rear shock absorber assembly 1
6 Relay arm nut/bolt 1/1
7 Connecting arm 2
8 Spacer 4
9 Oil seal 8
10 Bearing 4
dure.
4-79

EAS31304
2. Install:
REMOVING THE REAR SHOCK ABSORBER
• Bearing “1”
ASSEMBLY
(to the relay arm)
EWA13120 • Oil seal “2” New
WARNING (to the relay arm)
Oil seal installed depth “a”
0.5 mm (0.02 in)
TIP
that the rear wheel is elevated. a
a
EAS31305
CHECKING THE REAR SHOCK ABSORBER 1

ASSEMBLY
1. Check: a a
2 2
• Rear shock absorber
Oil leaks → Replace the rear shock absorber 1
A B
assembly. 5 a a 5
• Spring
Damage/wear → Replace the rear shock ab- 1 3
sorber assembly.
• Bushing 2 a a 2
4
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bolts
Bends/damage/wear → Replace.
EAS32678
CHECKING THE CONNECTING ARMS AND

RELAY ARM
3. Rear shock absorber assembly
1. Check:
4. Relay arm
• Connecting arms
5. Connecting arm
• Relay arm
A. Left side
B. Right side
2. Check:
• Bearings EAS31366
• Oil seals INSTALLING THE REAR SHOCK

Damage/pitting → Replace. ABSORBER ASSEMBLY
3. Check: 1. Install:
• Spacers • Rear shock absorber assembly
Damage/scratches → Replace. • Relay arm “1”
TIP
EAS30212
INSTALLING THE RELAY ARM Install the relay arm as shown in the illustration.
1. Lubricate:
• Spacers
• Bearings
• Oil seals
• Bolts (unthreaded shaft portion only)
4-80
FWD
2. Tighten:
• Rear shock absorber assembly upper nut
Rear shock absorber assembly

upper nut
T.
R.
44 N·m (4.4 kgf·m, 32 lb·ft)
• Relay arm nut
Relay arm nut

44 N·m (4.4 kgf·m, 32 lb·ft)
T.
R.
• Rear shock absorber assembly lower nut
Rear shock absorber assembly

lower nut
T.
R.
44 N·m (4.4 kgf·m, 32 lb·ft)
3. Install:
• Connecting arms “1”
TIP
• When installing the connecting arms, lift up the
swingarm.
• Install the connecting arms as shown in the il-
lustration. Punch mark “1” should be outside.
4. Tighten:
• Connecting arm nuts
Connecting arm nut

44 N·m (4.4 kgf·m, 32 lb·ft)
T.
R.
4-81
SWINGARM CHAS
EAS20037
SWINGARM
Removing the swingarm

Rear wheel Refer to “REAR WHEEL” on page 4-20.
Refer to “REAR SHOCK ABSORBER
Rear shock absorber assembly/Relay arm
ASSEMBLY” on page 4-79.
Drive chain Refer to “CHAIN DRIVE” on page 4-85.
1 Brake hose holder 1
2 Rear fender 1
3 Drive chain guide 1 Skip step 1 and 2.
4 Drive chain adjusting bolt/locknut 2/2 Skip step 1 and 3.
5 Pivot shaft nut 1
6 Pivot shaft 1
7 Swingarm 1
8 Dust cover 2
9 Spacer 2
10 Bearing 2
dure.
4-82
SWINGARM CHAS
EAS30226
REMOVING THE SWINGARM

EWA13120
WARNING
TIP
that the rear wheel is elevated.
2. Measure: 3. Wash:
• Swingarm side play • Pivot shaft
a. Measure the tightening torque of pivot • Dust covers
shaft nut. • Spacers
Pivot shaft nut Recommended cleaning solvent

70 N·m (7.0 kgf·m, 52 lb·ft) Kerosene
T.
R.
b. Measure the swingarm side play “A” by 4. Check:

moving the swingarm from side to side. • Dust covers
c. if the swingarm side play is observed, • Spacers
check the thrust covers, bearings, and • Oil seals
spacer. Damage/wear → Replace.
• Bearings
Damage/pitting → Replace.
EAS30228
INSTALLING THE SWINGARM

1. Lubricate:
• Bearings
• Spacers
• Dust covers
• Pivot shaft
EAS30227
CHECKING THE SWINGARM
• Swingarm • Bearings “1”
Bends/cracks/damage → Replace. • Spacer
2. Check: • Dust covers
• Pivot shaft • Drive chain guide
Roll the pivot shaft on a flat surface. • Chain
Bends → Replace. • Swingarm “2”
EWA13770
WARNING
Bearing installed depth “a”
Do not attempt to straighten a bent pivot 1–2 mm (0.39–0.78 in)
shaft.
TIP
Step on spacer should be outside.
4-83
SWINGARM CHAS
a 1 2 1 a
A B
A. Left side
B. Right side
3. Install:
• Rear shock absorber assembly
• Relay arm
• Connecting arms
• Rear wheel
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” on page 4-79.
4. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-21.
Drive chain slack

30.0–40.0 mm (1.18–1.57 in)
4-84
CHAIN DRIVE CHAS

EAS20038
CHAIN DRIVE
Removing the drive chain
3 4 New 2
7
6 1
New 4
5
New

Loose the drive chain adjusting locknut and
wheel axle nut and push the wheel forward.
1 Drive sprocket cover 1
2 Drive chain 1
3 Chain link 1
4 O-ring 4
5 Outer plate 1
6 Drive sprocket retainer 1
Use rotor holder tool (S 1113) to hold drive
7 Drive sprocket 1
sprocket.
dure.
4-85
CHAIN DRIVE CHAS

EAS32683
REMOVING THE DRIVE CHAIN BY USING

CHAIN CUTTER 1 3
EWA13120
WARNING
2
TIP
TIP
Do ensure that link pin is coming out while tight-
Drive chain cutter & riveting tool ening the pressure bolt.
YSST-734
EAS30230
1. Install pressure bolt “1” and cutter pin to “2” to
CHECKING THE DRIVE CHAIN
clamp holder “3”.
1. Measure:
• 15-link section “a” of the drive chain
2
Out of specification → Replace the drive
chain.
15-link length limit

3 191.5 mm (7.54 in)
a. Measure the length “a” between the inner

1 sides of the pins and the length “b” be-
tween the outer sides of the pins on a 15-
link section of the drive chain as shown in
2. Attach Clamp “1” and clamp holder “2” as-
the illustration.
sembly on drive chain “3”.
TIP
During assembly clamp holder locking screw
should be tight on “A” position.
3
A
b. Calculate the length “c” of the 15-link sec-

tion of the drive chain using the following
2 1 formula.
Drive chain 15-link section length “c” =
3. By holding the clamping “1”, tighten the (length “a” between pin inner sides +
pressure bolt “2” to remove the link pin “3”. length “b” between pin outer sides)/2
TIP
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a different
location each time.
4-86
CHAIN DRIVE CHAS
2. Check: b. Correct
• Drive chain 1. Drive chain roller
Stiffness → Clean and lubricate or replace. 2. Drive chain sprocket
EAS30232
CHECKING THE REAR WHEEL SPROCKET

Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-23.
EAS30233
CHECKING THE REAR WHEEL DRIVE HUB

Refer to “CHECKING THE REAR WHEEL
DRIVE HUB” on page 4-22.
EAS32684
3. Check: INSTALLING THE DRIVE CHAIN BY USING

• O-rings “1” CHAIN RIVETING TOOL
Damage → Replace the drive chain. 1. Install Cutter pin “1” with pressure bolt on
• Drive chain rollers “2” clamp holder “2”.
Damage/wear → Replace the drive chain. Drive chain cutter & riveting tool
• Drive chain side plates “3” YSST-734
Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain.
1 1
2. Lubricate:
EAS30231 • Drive chain
CHECKING THE DRIVE SPROCKET • Chain link
1. Check: • O-ring
• Drive sprocket
More than 1/4 tooth “a” wear → Replace the Recommended lubricant
drive chain sprockets as a set. Yamalube chain lube
Bent teeth → Replace the drive chain sprock-
ets as a set.
4-87
CHAIN DRIVE CHAS

3. Install new chain link “1” with O-rings “2” and TIP
fix on drive chain “3”. Clamp holder locking screw should be set on “A”
position.
1 2 7. After installing the joint plate “1” from special
3
tool, remove pressure plate and adjust the
clamp to “B” position and screw in the pres-
sure bolt for flaring of rivet of both the link pins
by tightening the pressure bolt.
TIP
During flaring, Ensure Cutter pin is in line with
chain link pin.
4. Install O-rings “1” and outer plate “2” with joint
“3”. A B
1
2 2
1
5. During installation of outer plate “1” remem- A. Drive chain roller
ber writing side “DID” should be outward. B. Drive chain sprocket
IMPORTANT:
1. Remove the special tool and measure
1 flaring size of riveted pins.
Flaring size of riveted pins

DID 4.65–4.95 mm (0.18–0.19 in)
6. Attach pressure plate “1” with pressure bolt

holder set “2” and screw it for locking.
• Install pressure plate as shown in illustration
and fixing of link plate in drive chain.
2
A
8. Tighten the axle nut, and then tighten the
chain adjuster locknuts to the specified
torque.
Tightening torque:
1 Rear wheel axle nut:
T.
R.
59 N·m (5.9 kgf·m, 44 lb·ft)

Drive chain adjusting locknut:
16 N·m (1.6 kgf·m, 12 lb·ft)
4-88
CHAIN DRIVE CHAS

9. Install: TIP
• Drive chain sprocket cover • Shake the cleaner well before use.
TIP • During washing of vehicle, never use kero-
Be sure not to pinch the gear position switch sene, petrol or any other solvent for cleaning.
lead when installing the drive sprocket cover.
b. Wipe the drive chain with a clean cloth.
10.Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-21.
Drive chain slack

30.0–40.0 mm (1.18–1.57 in)
ECA13550
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing- NOTICE
arm or cause an accident. Therefore, keep This motorcycle has a drive chain with
the drive chain slack within the specified lim- small rubber O-rings “1” between the drive
its. chain side plates. Never use high-pressure
water or air, steam, gasoline, certain sol-
vents (e.g., benzine), or a coarse brush to
CLEANING AND LUBRICATING THE DRIVE clean the drive chain. High-pressure meth-
CHAIN ods could force dirt or water into the drive
1. Stand the vehicle on a level surface. chain’s internals, and solvents will deterio-
rate the O-rings. A coarse brush can also
WARNING
damage the O-rings. Therefore, use only
Securely support the vehicle so that there is chain cleaning solvent to clean the drive
no danger of it falling over. chain.
TIP 3. Lubricate:
Place the vehicle on a maintenance stand so • Drive chain
Recommended cleaner
2. Clean: Yamalube chain cleaner
• Drive chain Recommended lube
a. Remove all deposits of dust, soil, mud, oil Yamalube chain lube
etc. during washing and dry it with air
blow. Spray the chain cleaning solvent a. Spray the lubricant inside the chain be-
and wait 5 minutes to remove grease de- tween inner/outer plates roller and bushes
position. as shown in illustration.
b. After spraying wait for 15 minutes.

c. Wipe the drive chain with a clean cloth.
4-89
ENGINE
ENGINE REMOVAL .......................................................................................5-1

INSTALLING THE ENGINE ......................................................................5-5
INSTALLING THE SHIFT ARM ................................................................5-5
INSTALLING THE EXHAUST ASSEMBLY ..............................................5-5
CYLINDER HEAD ...........................................................................................5-7

REMOVING THE CYLINDER HEAD ...................................................... 5-10
CHECKING THE CYLINDER HEAD ...................................................... 5-11
CHECKING THE CAMSHAFT SPROCKET AND
TIMING CHAIN GUIDE ......................................................................... 5-11
CHECKING THE TIMING CHAIN TENSIONER ..................................... 5-12
CHECKING THE DECOMPRESSION SYSTEM .................................... 5-12
INSTALLING THE CYLINDER HEAD .................................................... 5-12
CAMSHAFT .................................................................................................. 5-16

REMOVING THE CAMSHAFT ............................................................... 5-17
CHECKING THE CAMSHAFT ................................................................ 5-17
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ....... 5-18
REMOVING AND INSTALLING THE CAMSHAFT BEARING ............... 5-18
INSTALLING THE CAMSHAFT AND ROCKER ARMS ......................... 5-19
VALVES AND VALVE SPRINGS ................................................................. 5-21

REMOVING THE VALVES ..................................................................... 5-22
CHECKING THE VALVES AND VALVE GUIDES ................................. 5-22
CHECKING THE VALVE SEATS ........................................................... 5-23
5
CHECKING THE VALVE SPRINGS ....................................................... 5-25
INSTALLING THE VALVES ................................................................... 5-25
CYLINDER AND PISTON ............................................................................. 5-27

REMOVING THE PISTON ..................................................................... 5-28
CHECKING THE CYLINDER AND PISTON .......................................... 5-28
CHECKING THE PISTON RINGS .......................................................... 5-29
CHECKING THE PISTON PIN ............................................................... 5-29
INSTALLING THE PISTON AND CYLINDER ........................................ 5-30
MAGNETO AND STARTER CLUTCH .........................................................5-32

REMOVING THE MAGNETO ................................................................. 5-34
REMOVING THE STARTER CLUTCH .................................................. 5-34
CHECKING THE STARTER CLUTCH ................................................... 5-34
INSTALLING THE STARTER CLUTCH ................................................. 5-35
INSTALLING THE MAGNETO ............................................................... 5-35
ELECTRIC STARTER .................................................................................. 5-37

CHECKING THE STARTER MOTOR .................................................... 5-39
ASSEMBLING THE STARTER MOTOR ................................................ 5-40
CLUTCH ....................................................................................................... 5-41

REMOVING THE CLUTCH ....................................................................5-45
CHECKING THE FRICTION PLATES .................................................... 5-45
CHECKING THE CLUTCH PLATES ...................................................... 5-45
CHECKING THE CLUTCH SPRINGS .................................................... 5-46
CHECKING THE CLUTCH HOUSING ................................................... 5-46
CHECKING THE CLUTCH BOSS .......................................................... 5-46
CHECKING THE PRESSURE PLATE ................................................... 5-46
CHECKING THE CLUTCH PUSH LEVER AND
SHORT CLUTCH PUSH ROD ............................................................... 5-46
CHECKING THE PRIMARY DRIVE GEAR ............................................ 5-47
CHECKING THE PRIMARY DRIVEN GEAR ......................................... 5-47
CHECKING THE CLUTCH PUSH RODS ..............................................5-47
INSTALLING THE CLUTCH ................................................................... 5-47
OIL PUMP ..................................................................................................... 5-50

CHECKING THE OIL PUMP .................................................................. 5-51
INSTALLING THE OIL PUMP ................................................................ 5-51
SHIFT SHAFT ............................................................................................... 5-52

CHECKING THE SHIFT SHAFT ............................................................ 5-53
CHECKING THE STOPPER LEVER ..................................................... 5-53
INSTALLING THE SHIFT SHAFT .......................................................... 5-53
BALANCER GEAR ....................................................................................... 5-54

REMOVING THE PRIMARY DRIVE GEAR AND B
ALANCER GEARS ................................................................................ 5-55
CHECKING THE BALANCER GEARS AND
PRIMARY DRIVE GEAR ....................................................................... 5-55
ASSEMBLING THE BALANCER DRIVEN GEAR .................................. 5-55
INSTALLING THE PRIMARY DRIVE GEAR AND
BALANCER GEARS .............................................................................. 5-55
CRANKCASE ............................................................................................... 5-57

SEPARATING THE CRANKCASE .........................................................5-60
REMOVING THE CRANKCASE BEARING ........................................... 5-60
CHECKING THE CRANKCASE ............................................................. 5-61
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE ............ 5-61
CHECKING THE OIL STRAINER .......................................................... 5-61
CHECKING THE BEARINGS AND OIL SEAL ....................................... 5-61
INSTALLING THE BEARING RETAINER ..............................................5-61
ASSEMBLING THE CRANKCASE .........................................................5-61
CRANKSHAFT ............................................................................................. 5-63

REMOVING THE CRANKSHAFT .......................................................... 5-64
CHECKING THE CRANKSHAFT ........................................................... 5-64
INSTALLING THE CRANKSHAFT .........................................................5-64
TRANSMISSION ........................................................................................... 5-66

CHECKING THE SHIFT FORKS ............................................................ 5-68
CHECKING THE SHIFT DRUM ASSEMBLY ......................................... 5-68
CHECKING THE TRANSMISSION ........................................................ 5-68
ASSEMBLING THE DRIVE AXLE .......................................................... 5-69
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ..... 5-69
ENGINE REMOVAL ENG

EAS20042
ENGINE REMOVAL
Removing the exhaust assembly
1 New
LT
2
8 N·m (0.8 kgf·m, 5.9 lb·ft) 25 N·m (2.5 kgf·m, 18 lb·ft)

LT 15 N·m (1.5 kgf·m, 11 lb·ft)

Inner fender 4-3.
Upper side cowling (left) 4-3.
1 O2 Sensor coupler Disconnect.
2 Exhaust pipe nut 2
3 Exhaust assembly bolt 1
4 Exhaust assembly 1
5 Exhaust pipe gasket 1
procedure.
TIP
While installing exhaust assembly, first tighten all bolts temporarily, then tighten cylinder head side nuts
as per specified torque value. Now, tighten remaining bolts as per specified torque value.
5-1
ENGINE REMOVAL ENG

Disconnecting the leads and couplers
7 N·m (0.7 kgf·m, 5.2 lb·ft)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
LS

Lower side cowling (Left and right) 4-3.
Refer to “CHECKING AND CHARGING
THE BATTERY” on page 8-143.
Negative battery lead/Positive battery lead NOTICE

First, disconnect the negative battery
lead, and then the positive battery lead.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-10.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-16.
Throttle body/Intake manifold Refer to “THROTTLE BODY” on page 7-7.
Water pump breather hose/Radiator outlet
hose/Radiator inlet hose/Radiator/Coolant Refer to “RADIATOR” on page 6-1.
reservoir
Canister hose Refer to “FUEL TANK” on page 7-1.
Drive sprocket cover/Drive sprocket Refer to “CHAIN DRIVE” on page 4-85.
5-2
ENGINE REMOVAL ENG

Disconnecting the leads and couplers
12
2 11
3
1 5 3
13
7 N·m (0.7 kgf·m, 5.2 lb·ft)

14
7
10
6
9
7 N·m (0.7 kgf·m, 5.2 lb·ft)
4
15
LS

1 Spark plug cap 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
Stator coil coupler/Crankshaft position sensor
3 1/1 Disconnect.
coupler
Disconnect.
4 Gear position switch coupler 2 (Route the harness properly while installa-
tion)
5 Starter motor lead 1 Disconnect.
7 Negative battery lead 1 Disconnect.
8 Quick shift system (QSS) coupler 1 Disconnect.
Disconnect.
TIP
9 Shift arm along with quick shift system (QSS) 1
Loosen the left footrest bracket bolts for
easy removal.
10 O2 sensor lead 1 Disconnect.

11 Injector lead 1 Disconnect.
12 Throttle position sensor lead 1 Disconnect.
13 FID (fast idle solenoid) coupler 1 Disconnect.
14 VVA (variable valve actuation) solenoid lead 1 Disconnect.
15 Sidestand switch coupler 1 Disconnect.
For connection, reverse the disconnection
procedure.
5-3
ENGINE REMOVAL ENG

Removing the engine
45 N·m (4.5 kgf·m, 33 lb·ft)
45 N·m (4.5 kgf·m, 33 lb·ft)

LS
TIP
Place a maintenance stand under the en-
gine.
1 Engine mounting bolt (front side) 2

2 Engine mounting bolt/nut (rear upper side) 1/1
3 Engine mounting bolt/nut (rear lower side) 1/1
4 Engine 1
procedure.
5-4
ENGINE REMOVAL ENG

EAS30251
INSTALLING THE ENGINE Shift pedal distance “a”

1. Install: 15.5 mm (0.61 in)
• Engine “1” Shift pedal distance “b”
• Engine mounting bolt/nut (rear lower side) “2” 15.4 mm (0.60 in)
• Engine mounting bolt (front side) “3”
• Engine mounting bolt/nut (rear upper side)
“4” Shift arm bolt
15 N·m (1.5 kgf·m, 11 lb·ft)
T.
TIP
R.
• Lubricate the engine mounting nut threads with
Lithium-soap-based grease or engine oil.
• Do not fully tighten the bolts and nuts.
3
4
2
• Make sure that quick shift system assembly
has same dimensions as shown in below
illustration.
3
2
1
2. Tighten:
• Engine mounting nut (rear lower side)
Engine mounting nut (lower side)

45 N·m (4.5 kgf·m, 33 lb·ft) EAS32676
T.
R.
INSTALLING THE EXHAUST ASSEMBLY

• Engine mounting nut (rear upper side) 1. Install:
• Exhaust pipe gasket “1” New
Engine mounting nut (rear upper • Exhaust assembly “2”
side) • Exhaust pipe nuts “3”
T.
R.
45 N·m (4.5 kgf·m, 33 lb·ft)

• Exhaust assembly bolt “4”
• Engine mounting bolt (front side) TIP
Do not fully tighten the nuts and bolts.
Engine mounting bolt (front side)
45 N·m (4.5 kgf·m, 33 lb·ft) 2. Tighten:
T.
R.
• Exhaust pipe nuts “3”

EAS31589
INSTALLING THE SHIFT ARM Exhaust pipe nut

1. Install: 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
• Shift arm “1”

3. Tighten:
TIP
• Exhaust assembly bolt “4”
Make sure that the distance “a” and “b” between
the center of the swing arm bolt “2” and the cen- Exhaust assembly bolt (middle)
ter of the shift pedal “3” are within specification. 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
5-5
ENGINE REMOVAL ENG

TIP
Install exhaust gasket with a claw at the cylinder
head side.
5-6
CYLINDER HEAD ENG

EAS20044
CYLINDER HEAD
Removing the cylinder head
Lower side cowling (Left and right) Refer to “GENERAL CHASSIS (3)” on page
4-3.
Drain.
page 3-16.
Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-1.
Disconnect.
Clutch cable
Refer to “CLUTCH” on page 5-41.
Throttle body/Intake manifold Refer to “THROTTLE BODY” on page 7-7.
Radiator/Coolant reservoir hose/Thermostat Refer to “RADIATOR” on page 6-1.
Water pump Refer to “WATER PUMP” on page 6-6.
* Yamaha bond No. 1215 90890-85505 (Three bond No.1215-B)
5-7
CYLINDER HEAD ENG

4
10
3
7 5
6
8
9
10
11

Refer to “ENGINE REMOVAL” on page 5-1.
TIP
Engine mounting bolt/nut (Front side, rear upper • Gently tilt the engine front side for easy ac-
side) cess of cylinder head.
• Securely support the engine by putting
scissor jack 892A under the engine, so
that there is no danger of it falling over.
1 Crankshaft end accessing screw 1

2 Timing mark accessing screw 1
3 Spark plug 1
4 Coolant temperature sensor 1
5 Cylinder head breather hose 1
6 VVA solenoid 1
7 VVA solenoid gasket 1
8 Cylinder head cover 1
9 Cylinder head cover gasket 1
10 Dowel pin 2
11 VVA solenoid rod 1
5-8
CYLINDER HEAD ENG

19 18
17
21
14
15
16
20
21
12
13

12 Cylinder head cover breather plate 1
13 Cylinder head cover breather plate gasket 1
14 Oil seal 1
15 Timing chain tensioner 1
16 Timing chain tensioner gasket 1
17 Camshaft sprocket 1
18 Decompression cam 1
19 Cylinder head 1
20 Cylinder head gasket 1
21 Dowel pin 2
procedure.
5-9
CYLINDER HEAD ENG

EAS30276
4. Loosen:
REMOVING THE CYLINDER HEAD
• Camshaft sprocket bolt “1”
1. Remove:
• Crank shaft end accessing screw “1” and tim- TIP
ing mark accessing screw “2” with its cap While holding the magneto rotor nut with a
O-ring by using a special tool center plug wrench “2”, loosen the camshaft sprocket bolt.
spanner “3”. • Retract chain tensioner to loss the tension by
using the small screwdriver.
Center plug spanner
YSST-625
Small screw driver

2. Remove: YSST-609
• Cylinder head cover by removing the bolt in
crisscross pattern. 5. Remove:
• Cylinder head cover along with its gasket. • Camshaft sprocket
• Decompression cam
3. Align:
TIP
• “I” mark “a” on the magneto rotor
(with the stationary pointer “b” on the magne- To prevent the timing chain from falling into the
to cover) crankcase, fasten it with a wire “1”.
NOTICE
b. When the piston is at TDC on the com-
pression stroke, align the “I” mark “c” on Be careful about bolt falling into the crankcase.
the camshaft sprocket with the mark “d” on
the camshaft bearing stopper plate.
6. Remove:
• Clutch cable holder
• Timing chain tensioner by removing the bolts
• Cylinder head
5-10
CYLINDER HEAD ENG

TIP a. Place a straightedge “1” and a feeler
• Loosen the bolts in the proper sequence as gauge “2” across the cylinder head.
shown.
• Loosen each bolt 1/2 of a turn at a time. After
all of the bolts are fully loosened, remove bolts
1, 2, 4, and 6, and then remove the cylinder
head with bolts 3 and 5 installed in the bolt
holes.
6 4
4 2
b. Measure the warpage.

c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400–600 grit wet sandpaper on
the surface plate and resurface the cylin-
3 der head using a figure-eight sanding pat-
4
5 1
tern.
EAS30277
TIP
CHECKING THE CYLINDER HEAD
1. Eliminate: To ensure an even surface, rotate the cylinder
• Combustion chamber carbon deposits head several times.
(with a rounded scraper)
EAS32677
TIP CHECKING THE CAMSHAFT SPROCKET
Do not use a sharp instrument to avoid damag- AND TIMING CHAIN GUIDE
ing or scratching: 1. Check:
• Spark plug bore threads • Camshaft sprocket
• Valve seats More than 1/4 tooth wear “a” → Replace the
camshaft sprocket, timing chain and crank-
shaft as a set.
2. Check:
• Cylinder head
Damage/scratches → Replace. a. 1/4 tooth
• Cylinder head water jacket b. Correct
Mineral deposits/rust → Eliminate. 1. Timing chain roller
3. Measure: 2. Camshaft sprocket
• Cylinder head warpage 2. Check:
Out of specification → Resurface the cylinder • Timing chain guide (exhaust side)
head. Damage/wear → Replace.
Warpage limit
0.05 mm (0.0020 in)
5-11
CYLINDER HEAD ENG

EAS30266
c. Without operating the decompression le-
CHECKING THE TIMING CHAIN TENSIONER
ver, check that the decompression cam
1. Check:
“2” projects from the camshaft (exhaust
• Timing chain tensioner
cam) as shown in the illustration “A”.
Cracks/damage/rough movement → Re-
d. Move the decompression lever “1” in the
place.
direction of the arrow shown and check
a. Lightly press the timing chain tensioner
that the decompression cam does not
rod into the timing chain tensioner housing
project from the camshaft (exhaust cam)
by hand.
as shown in the illustration “B”.
TIP
While pressing the timing chain tensioner rod, 1
wind it clockwise with a small screwdriver “1”
until it stops.
Small screw driver

YSST-609
b. Remove the screwdriver and slowly re-

lease the timing chain tensioner rod.
c. Make sure that the timing chain tensioner
rod comes out of the timing chain tension- 2
er housing smoothly. If there is rough
movement, replace the timing chain ten-
sioner.
EAS30282
INSTALLING THE CYLINDER HEAD

1. Install:
• Cylinder head
TIP
EAS30267
CHECKING THE DECOMPRESSION SYSTEM Pass the timing chain through the timing chain
1. Check: cavity.
• Decompression system 2. Tighten:
a. Check the decompression system with the • Cylinder head bolt (Inside) “a”
camshaft sprocket and the decompres-
sion cam installed to the camshaft.
b. Check that the decompression lever “1”
moves smoothly.
5-12
CYLINDER HEAD ENG
Cylinder head bolt (1st)

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
Cylinder head bolt (final)

24 N·m (2.4 kgf·m, 18 lb·ft)
• Cylinder head bolt (Chain side) “b”
Cylinder head bolt (Chain side)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP TIP
• Lubricate the cylinder head bolts and washers When installing the camshaft sprocket, be sure
with engine oil. to keep the timing chain as tight as possible on
• Tighten the cylinder head bolts in the proper the exhaust side.
tightening sequence as shown and torque
ECA13740
them in two stages.
NOTICE
Do not turn the crankshaft when installing
the camshaft(s) to avoid damage or improper
valve timing.
a e. While holding the camshaft, temporarily

b tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
4. Install:
• Timing chain tensioner gasket New
• Timing chain tensioner
3. Install: a. Apply sealant to the timing chain tensioner
• Camshaft sprocket bolt threads.
b. Align the “I” mark “a” on the magneto rotor Yamaha bond No. 1215
90890-85505
with the stationary pointer “b” on the mag-
neto cover.
c. When the piston is at TDC on the com- b. While lightly pressing the timing chain ten-
pression stroke, align the “I” mark “c” on sioner rod by hand, turn the tensioner rod
the camshaft sprocket with the mark “d” on fully clockwise with a small screwdriver “1”.
the camshaft stopper plate. c. With the timing chain tensioner rod turned
d. Install the timing chain onto the camshaft all the way into the timing chain tensioner
sprocket, and then install the camshaft housing (with the small screwdriver still in-
sprocket onto the camshaft. stalled), install the gasket and the timing
chain tensioner “2” onto the cylinder block.
d. Tighten the timing chain tensioner bolts “3”
to the specified torque.
Timing chain tensioner bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Small screw driver

YSST-609
5-13
CYLINDER HEAD ENG
7. Tighten:
• Camshaft sprocket bolt
Camshaft sprocket bolt

30 N·m (3.0 kgf·m, 22 lb·ft)
T.
3
ECA20610 R.
NOTICE
2 Be sure to tighten the camshaft sprocket bolt
to the specified torque to avoid the possibil-
ity of the bolt coming loose and damaging
the engine.
e. Remove the screwdriver, make sure the 8. Install:
timing chain tensioner rod releases, and • Water pump assembly with its new O-ring
then install the timing chain tensioner cap. and tighten the water pump housing bolts
5. Turn: with specified tightening torque.
• Crankshaft
(several turns counterclockwise) Water pump bolt
6. Check: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• “I” mark “a”

Align the “I” mark on the magneto rotor with • Radiator and radiator hoses. Fill the coolant
the stationary pointer “b” on the magneto cov- to the radiator.
er. • Crankshaft end accessing screw and Tim-
• “I” mark “c” ing mark accessing screw with its new
Align the “I” mark on the camshaft sprocket O-ring
with the stationary pointer “d” on the camshaft • All removed parts
stopper plate. Refer to “CYLINDER HEAD” on page 5-7.
Out of alignment → Correct. • Rider seat
Refer to the installation steps above. Refer to “GENERAL CHASSIS (1)” on page
4-1.
9. Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.

Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 in)
5-14
CYLINDER HEAD ENG

10.Install:
• All removed parts
4-1.
• Seats
4-1.
5-15
CAMSHAFT ENG
EAS20043
CAMSHAFT
Removing the rocker arms and camshaft
7 N·m (0.7 kgf·m, 5.2 lb·ft)
8 N·m (0.8 kgf·m, 5.9 lb·ft)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
Cylinder head cover Refer to “CYLINDER HEAD” on page 5-7.

1 Camshaft stopper plate 1
2 Locknut 4
3 Rocker arm shaft 2
4 Exhaust rocker arm 1
5 Adjusting screw (exhaust side) 2
6 Plate 1
7 Spring 1
8 Washer 1
9 Intake rocker arm 1
10 Adjusting screw (intake side) 2
11 Camshaft assembly 1
12 Bearing 1
procedure.
5-16
CAMSHAFT ENG
EAS30256 EAS30257
REMOVING THE CAMSHAFT CHECKING THE CAMSHAFT

1. Loosen: 1. Check:
• Locknut “1” • Camshaft lobes
• Valve clearance adjusting screw “2” (intake/ Blue discoloration/pitting/scratches → Re-
exhaust) place the camshaft.
2. Measure:
2 • Camshaft lobe dimensions “a”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions

1 Lobe height (Intake)
Limit
32.268 mm (1.2704 in)
Lobe height (Intake high speed)
Limit
2. Remove: 32.332 mm (1.2729 in)
• Camshaft assembly “1” Lobe height (Exhaust)
Limit
• Align the holes “a” in intake rocker arm 1 “2”
29.516 mm (1.1620 in)
and intake rocker arm 2 “3”, and then push
the intake rocker arm stopper pin “4” in the di-
rection of the arrow shown in the illustration.
• While pushing intake rocker arm 1 “5” and in-
take rocker arm 2 “6” in the direction of the ar-
row shown in the illustration, remove the
camshaft assembly.
4
a G088946
3 3. Check:
• Camshaft oil passage
2
TIP
Screw the long cylinder head bolt “7” into the
threaded end of the camshaft and then pull out
the camshaft.
5
6
5-17
CAMSHAFT ENG
EAS30259
4. Measure:
CHECKING THE ROCKER ARMS AND
• Rocker arm shaft outside diameter “a”
ROCKER ARM SHAFTS
rocker arms and rocker arm shafts. Rocker arm shaft outside diame-
1. Check: ter
• Rocker arm Limit
• Rocker arm roller “1” 13.935 mm (0.5486 in)
• Rocker arm pad “2”
REMOVING AND INSTALLING THE

CAMSHAFT BEARING
1. Remove:
• Camshaft bearing with bearing puller “1” and
plate bearing installer “2” as shown in the il-
lustration.
Bearing puller
YSST-623
Plate bearing installer
YSST-891
2. Check:
• Rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrication
system.
3. Measure:
• Rocker arm inside diameter “a”
Rocker arm inside diameter

Limit
14.015 mm (0.5518 in) TIP
Make sure the bearing puller is centered over
the camshaft bearing.
2. Check:
• Clean and lubricate the bearings, then rotate
a the inner race with finger.
Rough movement → Replace.
Damage/Wear → Replace.
G088951
5-18
CAMSHAFT ENG
Rocker arm shaft
Intake rocker arm stopper pin
Molybdenum disulfide oil
Spring
Rocker arm roller
3. Install:
• Spring “1”
TIP
Install the spring so that the ends “a” of the
spring are positioned at the locations shown in
the illustration.
3. Install: a 1
• Camshaft bearing New
With bearing punch and suitable attachment
“1” as shown in the illustration.

YSST-951
4. Install:
• Camshaft assembly “1”
a. Align the holes “a” in intake rocker arm 1
“2” and intake rocker arm 2 “3”, and then
push the intake rocker arm stopper pin “4”
in the direction of the arrow shown in the
illustration.
EAS30270
INSTALLING THE CAMSHAFT AND ROCKER 4

a
ARMS
1. Lubricate: 3
• Camshaft assembly O-ring
Recommended lubricant 2
Camshaft O-ring
Camshaft bearing b. While pushing intake rocker arm 1 “2” and
Engine oil intake rocker arm 2 “3” in the direction of
the arrow shown in the illustration, install
2. Lubricate: the camshaft assembly.
• Rocker arms
TIP
• Rocker arm shafts
• Spring Install the camshaft with the punch mark “a” fac-
• Intake rocker arm stopper pin ing upward.
5-19
CAMSHAFT ENG
5. Install:
• Camshaft stopper plate
Camshaft stopper plate bolt

(M5×16)
T.
R.
8 N·m (0.8 kgf·m, 5.9 lb·ft)

Camshaft stopper plate bolt
(M6×14)
8 N·m (0.8 kgf·m, 5.9 lb·ft)
TIP
Before installing the camshaft stopper plate,
make sure that the slots “a” in the rocker arm
shafts “1” are parallel with the edge “b” of the cyl-
inder head and that the camshaft stopper plate
bolt holes in the cylinder head and rocker arm
shafts are aligned.
b
1
a
5-20
VALVES AND VALVE SPRINGS ENG

EAS20045
VALVES AND VALVE SPRINGS

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

Cylinder head Refer to “CYLINDER HEAD” on page 5-7.
Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-16.
1 Valve cotter 8
2 Upper spring seat 4
3 Valve spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Lower spring seat 4
procedure.
5-21

EAS30283
REMOVING THE VALVES

valves and related components.
TIP
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check:
• Valve sealing
Leakage at the valve seat → Check the valve 3. Remove:
face, valve seat, and valve seat width. • Upper spring seat “1”
Refer to “CHECKING THE VALVE SEATS” • Valve spring “2”
on page 5-23. • Valve “3”
a. Pour a clean solvent “a” into the intake and • Valve stem seal “4”
exhaust ports. • Lower 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
G088958
2. Remove: EAS30284
• Valve cotters “1” CHECKING THE VALVES AND VALVE

GUIDES
TIP
Remove the valve cotters by compressing the valves and valve guides.
valve spring with the valve spring compressor 1. Measure:
and the valve spring compressor attachment “2”. • Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
Valve spring compressor guide.
YSST-603 • Valve-stem-to-valve-guide clearance =
(90890-04019) Valve guide inside diameter “a” -
Valve spring compressor attach- Valve stem diameter “b”
ment
YSST-603 A
(90890-04109) Valve-stem-to-valve-guide clear-
ance (intake)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
Limit
0.100 mm (0.0039 in)
5-22

EAS30285
CHECKING THE VALVE SEATS

valves and valve seats.
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Check:
• Valve seat
G088960
Pitting/wear → Replace the cylinder head.
3. Measure:
• Valve seat contact width “a”
Out of specification → Replace the cylinder
head.
Valve seat contact width (intake)

Limit
1.3 mm (0.05 in)
Valve seat contact width
(exhaust)
G088961
Limit
1.7 mm (0.07 in)
Valve and valve guide clearance = a-b
2. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
3. 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. G088966
4. Measure: a. Apply blue layout fluid “b” onto the valve

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

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

c. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
d. Measure the valve seat width.
5-23

TIP TIP
Where the valve seat and valve face contacted For the best lapping results, lightly tap the valve
one another, the blue layout fluid will have been seat while rotating the valve back and forth be-
removed. tween your hands.
4. Lap:
• Valve face
• Valve seat
TIP
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
a. Apply a coarse lapping compound “a” to
the valve face.
ECA13790
e. Apply a fine lapping compound to the
NOTICE
valve face and repeat the above steps.
Do not let the lapping compound enter the f. After every lapping procedure, be sure to
gap between the valve stem and the valve clean off all of the lapping compound from
guide. the valve face and valve seat.
g. Apply blue layout fluid “b” onto the valve
face.
G088968
b. Apply molybdenum disulfide oil onto the

G088967
valve stem.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
j. Measure the valve seat width “c” again. If
the valve seat width is out of specification,
reface and lap the valve seat.
c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the lapping compound.
G088970
5-24

EAS30286
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
• Valve spring free length “a” E
Out of specification → Replace the valve
spring.
Free length (intake)

Limit
32.11 mm (1.26 in) 3. Install:
Free length (exhaust) • Lower spring seat “1”
Limit • Valve stem seal “2” New
32.11 mm (1.26 in) • Valve “3”
• Valve spring “4”
• Upper spring seat “5”
(into the cylinder head)
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
G088971
5
EAS30288
1
INSTALLING THE VALVES
The following procedure applies to all of the 4
valves and related components.
1. Deburr: 3
• Valve stem end
2 New
(with an oil stone)
G088972
2. Lubricate:
• Valve stem “1”
b. Smaller pitch
• Valve stem seal “2” New
(with the recommended lubricant) 4. Install:
• Valve cotters “1”
Recommended lubricant TIP
Valve stem seal Install the valve cotters by compressing the
Engine oil valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.
5-25
Valve spring compressor

YSST-603
(90890-04019)
Valve spring compressor attach-
ment
YSST-603 A
(90890-04109)
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-26
CYLINDER AND PISTON ENG

EAS20046
CYLINDER AND PISTON

Removing the cylinder and piston
8 E
9 6
E
1 5
E
New 4 4 New
New
E
2 New
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
D 3
FW

1 Cylinder 1
2 Cylinder gasket 1
3 Dowel pin 2
4 Piston pin clip 2
5 Piston pin 1
6 Piston 1
7 Top ring 1
8 2nd ring 1
9 Oil ring 1
procedure.
5-27

EAS30289 EAS30291
REMOVING THE PISTON CHECKING THE CYLINDER AND PISTON

1. Remove: 1. Check:
• Piston pin clips “1” • Piston wall
• Piston pin “2” • Cylinder wall
• Piston “3” Vertical scratches → Replace the cylinder, and
ECA13810
replace the piston and piston rings as a set.
NOTICE 2. Measure:
Do not use a hammer to drive the piston pin • Piston-to-cylinder clearance
out. a. Measure cylinder bore “C” with the cylin-
der bore gauge “1”.
TIP
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar-
ea.
Piston pin replacer

YSST-207
(90890-01304) TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average measurements.
2 1 Bore
58.000–58.010 mm (2.2835–
2.2839 in)
Wear limit
58.060 mm (2.2858 in)
3
Cylinder bore “C” = maximum of Diameter
2. Remove: Taper limit “T” = maximum of D1 or D2 - maximum
• Top ring of D5 or D 6
• 2nd ring
• Oil ring Out of round limit “R” = maximum of D1, D3 or D5 -
maximum of D2, D4 or D6
TIP
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.
G089000
b. If out of specification, replace the cylinder,

and replace the piston and piston rings as
a set.
c. Measure piston skirt diameter D “a” with
the micrometer.
5-28
b. 6.0 mm (0.24 in) from the bottom edge of the 2. Install:

piston • Piston ring
(into the cylinder)
Piston TIP
Diameter Level the piston ring into the cylinder with the
57.962–57.985 mm (2.2820– piston crown.
2.2829 in)
d. If out of specification, replace the piston

and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
a
with the following formula.
• Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “D”
Piston-to-cylinder clearance
0.015–0.048 mm (0.0006–0.0019 a. 40 mm (1.57 in)
in)
3. Measure:
f. If out of specification, replace the cylinder, • Piston ring end gap
and replace the piston and piston rings as Out of specification → Replace the piston
a set. ring.
TIP
EAS30292
CHECKING THE PISTON RINGS The oil ring expander spacer end gap cannot be
1. Measure: measured. If the oil ring rail gap is excessive, re-
• Piston ring side clearance place all three piston rings.
Out of specification → Replace the piston
and piston rings as a set. Piston ring
TIP Top ring
Before measuring the piston ring side clearance, End gap limit
0.50 mm (0.0197 in)
eliminate any carbon deposits from the piston
2nd ring
ring grooves and piston rings.
End gap limit
0.85 mm (0.0335 in)
Piston ring
Top ring EAS30293
Side clearance limit CHECKING THE PISTON PIN

0.115 mm (0.0045 in) 1. Check:
2nd ring • Piston pin
Side clearance limit Blue discoloration/grooves → Replace the
0.115 mm (0.0045 in) piston pin and then check the lubrication sys-
tem.
5-29

2. Measure:
• Piston pin outside diameter “a” a
Out of specification → Replace the piston pin.
Piston pin outside diameter

Limit
13.975 mm (0.5502 in)
2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
TIP
G089004
• Apply engine oil to the piston pin.
• Make sure the punch mark “a” on the piston
3. Measure: points towards the exhaust side of the cylinder.
• Piston pin bore diameter “b” • Before installing the piston pin clips, cover the
Out of specification → Replace the piston. crankcase opening with a clean rag to prevent
the clips from falling into the crankcase.
Piston pin bore inside diameter • When installing the circlip, the circlip installing
Limit groove “4” and the circlip shit “5” should not
14.043 mm (0.5529 in)
overlap.
b
G089005
EAS30294
INSTALLING THE PISTON AND CYLINDER

1. Install:
• Oil ring expander “1”
• Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
3. Lubricate:
TIP
• Piston
Be sure to install the piston rings so that the • Piston rings
manufacturer marks or numbers “a” face up. • Cylinder
(with the recommended lubricant)
Engine oil
5-30

4. Offset:
• Piston ring end gaps
A 1
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
A. Exhaust side
5. Install:
• Dowel pins
• Cylinder head gasket New
• Cylinder “1”
TIP
• Use the piston base “a” as shown in the illus-
tration.
• While compressing the piston rings with one
hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
Piston base
YSST-604
(90890-01067)
5-31
MAGNETO AND STARTER CLUTCH ENG

EAS20140
MAGNETO AND STARTER CLUTCH

Removing the magneto and starter clutch

Drain.
page 3-10.
Upper side cowling (left)
4-3.
Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-85.
1 Crankshaft position sensor coupler 1 Disconnect.
2 Stator coil coupler 1 Disconnect.
3 Gear position switch lead coupler 2 Disconnect.
4 Timing mark accessing screw 1
5 Crankshaft end accessing screw 1
6 Magneto cover 1
7 Magneto cover gasket 1
5-32

Removing the magneto and starter clutch
12
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
.
(3) (2)
15 14
17 16
13
New New
14 N·m (1.4 kgf·m, 10 lb·ft)
T.
R.
18
11
70 N·m (7.0 kgf·m, 52 lb·ft) 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
T.
R.
R.

8 Dowel pin 2
9 Crankshaft position sensor 1
10 Stator coil 1
11 Magneto rotor 1
12 Woodruff key 1
13 Starter clutch gear 1
14 Bearing 1
15 Washer 1
16 Starter clutch idle gear shaft 1
17 Starter clutch idle gear 1
18 Starter clutch assembly 1
procedure.
5-33

EAS30867
REMOVING THE MAGNETO Magneto puller

1. Remove: YSST-702
• Magneto rotor nut “1” (90890-04141)
• Washer Bush
TIP YSST-893
• While holding the magneto rotor “2” with the mag-
neto holder “3”, loosen the magneto rotor nut.
• Do not allow the magneto holder to touch the
projection on the magneto rotor.
Magneto holder
YSST-701
(90890-01701)
(90890-01481)
EAS30868
REMOVING THE STARTER CLUTCH

1. Remove:
• Starter clutch bolts “1”
TIP
• While holding the magneto rotor “2” with the
magneto holder “3”, remove the starter clutch
bolts.
projection on the magneto rotor.
Magneto holder
YSST-701
(90890-01701)
(90890-01481)
2. Remove: 3
• Magneto rotor “1” 1
(with the magneto puller “2” and magneto
holder “3”) 2
• Woodruff key
ECA13880
NOTICE
To protect the end of the crankshaft, place a EAS30869
bush “4” between the magneto puller set CHECKING THE STARTER CLUTCH
center bolt and the crankshaft. 1. Check:
• Starter clutch rollers “1”
TIP
• Starter clutch spring caps “2”
Make sure the magneto puller is centered over • Starter clutch springs “3”
the magneto rotor. Damage/wear → Replace the starter clutch
assembly.
5-34

TIP
1 2 3 • While holding the magneto rotor “2” with the
magneto holder “3”, tighten the starter clutch
1 bolts.
2 projection on the magneto rotor.
• Stake the end “a” of each starter clutch bolt.
3
3
2 1 Magneto holder
YSST-701
2. Check: (90890-01701)
• Starter clutch idle gear (90890-01481)
• Starter clutch gear
Burrs/chips/roughness/wear → Replace the
defective part(s).
3
3. Check:
• Starter clutch gear contacting surfaces 1
Damage/pitting/wear → Replace the starter
clutch gear. 2
4. Check:
• Starter clutch operation
a. Install the starter clutch gear “1” onto the
starter clutch and hold the magneto rotor a
“2”.
b. When turning the starter clutch gear clock- a
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
starter clutch is faulty and must be re-
placed. a
c. When turning the starter clutch gear coun-
terclockwise “B”, it should turn freely, oth- EAS30872
erwise the starter clutch is faulty and must INSTALLING THE MAGNETO
be replaced. 1. Install:
1 • Washer
A • Bearing
• Starter clutch idle gear shaft
• Starter clutch idle gear
• Starter clutch gear
• Woodruff key
• Magneto rotor
B • Washer
2 • Magneto rotor nut
G088978
TIP
EAS30871
• Clean the tapered portion of the crankshaft and
INSTALLING THE STARTER CLUTCH the magneto rotor hub.
1. Install: • When installing the magneto rotor, make sure
• Starter clutch assembly the woodruff key is properly sealed in the key-
• Starter clutch bolts “1” New way of the crankshaft.
Starter clutch bolt 2. Tighten:
14 N·m (1.4 kgf·m, 10 lb·ft) • Magneto rotor nut “1”
T.
R.
LOCTITE®
5-35
Magneto rotor nut

70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
TIP
• While holding the magneto rotor “2” with the
magneto holder “3”, tighten the magneto rotor
nut.
projection on the magneto rotor. G088980
4. Install:
Magneto holder • Magneto cover
YSST-701
(90890-01701) Magneto cover bolt
(90890-01481) 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Tighten the magneto cover bolts in the proper
tightening sequence as shown.
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
assembly lead grommet)
Yamaha bond No. 1215

(90890-85505)
5-36
ELECTRIC STARTER ENG

EAS20052
ELECTRIC STARTER
Removing the starter motor

Lower side cowling 4-3.
1 Starter motor 1
2 Starter motor lead 1 Disconnect.
procedure.
5-37

Disassembling the starter motor
1 New
5 6
LS
7 8
3 New
4
2
8
7

1 O-ring 1
2 Starter motor yoke 1
3 Gasket 1
4 Commutator 1
5 Starter motor front cover/brush holder set 1
6 Brush set 1
7 Brush 2
8 Brush spring 2
For assembly, reverse the disassembly
procedure.
5-38

EAS30325
CHECKING THE STARTER MOTOR Multimeter

1. Check: INS-003
• Commutator (90890-03189)
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Commutator diameter “a” Armature coil resistance
Out of specification → Replace the starter 0.028–0.034 Ω
motor.
b. If any resistance is out of specification, re-
Commutator diameter limit place the starter motor.
16.6 mm (0.65 in)
G088987
5. Measure:
• Brush length “a”
3. Measure: Out of specification → Replace the starter
• Mica undercut “a” motor front cover/brush holder set.
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade Brush overall length limit
that has been grounded to fit the commutator. 3.5 mm (0.14 in)
Mica undercut (depth)

1.35 mm (0.05 in)
TIP
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
G088989
6. Measure:
• Brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force

G088985 3.92–5.88 N (400–600 gf, 14.11–
4. Measure: 21.17 oz)
• Armature assembly resistances (commutator
and insulation) 7. Check:
• Gear teeth
Out of specification → Replace the starter
Damage/wear → Replace the gear.
motor.
a. Measure the armature assembly resis- 8. Check:
tances with the multimeter. • Bearing
5-39

• Oil seal
Damage/wear → Replace the starter motor
front cover/brush holder set.
EAS30326
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor front cover/brush holder set “1”
• Starter motor yoke “2”
TIP
Align the marks “a” on the starter motor yoke and
starter motor front cover/brush holder set.
5-40
CLUTCH ENG
EAS20055
CLUTCH
Removing the clutch cover

Drain.
page 3-10.
Lower side cowling (right)
4-3.
2 Oil filter element cover 1
3 Oil filter element 1
4 Clutch cover 1
5 Clutch cover gasket 1
6 Dowel pin 2
7 Oil seal 1
procedure.
5-41
CLUTCH ENG
Removing the clutch

Clutch cover Refer to “CLUTCH” on page 5-41.
1 Locknut & washer 1/1
2 Pressure plate 1 1
3 Clutch spring 3
4 Pressure plate 2 1
5 Short clutch push rod 1
6 Clutch push rod holder 1
7 Ball 1
TIP
8 Long clutch push rod 1
Take out with the help of magnetic driver.
9 Friction plate 1 (Black color - Thinner width) 1

10 Clutch plate 1 (Thinner width) 1
11 Friction plate 2 (Brown color - Thinner width) 1
12 Clutch plate 2 (Thicker width) 1
13 Friction plate 3 (Black color - Thicker width) 1
Before removing clutch boss nut, straighten
14 Clutch boss nut 1 the lock washer.
5-42
CLUTCH ENG
Removing the clutch

15 Lock washer 1
16 Clutch boss 1
17 Thrust washer 1
18 Clutch housing 1
19 Conical spring washer 1
procedure.
5-43
CLUTCH ENG
Removing the push lever

Pressure plate 2 Refer to “CLUTCH” on page 5-41.
1 Clutch push lever 1
2 Clutch push lever spring 1
3 Circlip 1
4 Oil seal 1
5 Bearing 1
procedure.
5-44
CLUTCH ENG
EAS30346
REMOVING THE CLUTCH

1. Straighten the lock washer tab.
2. Loosen:
• Clutch boss nut “1”
TIP
While holding the clutch boss “2” with the clutch
hub holder “3”, loosen the clutch boss nut.
Clutch hub holder

YSST-733A A. Friction plate 1 (Black color - Thinner
(90890-04086) width)
B. Friction plate 2 (Brown color - Thinner
width)
C. Friction plate 3 (Black color - Thicker
width)
X = The gap between the friction lining mate-
rial in friction plate 1.
Y = The gap between the friction lining mate-
Z = The gap between the friction lining mate-
TIP
EAS30348
CHECKING THE FRICTION PLATES The gap X must be less then Z and the gap Y
The following procedure applies to all of the fric- same as gap X.
tion plates.
1. Check: EAS30349
• Friction plate CHECKING THE CLUTCH PLATES

Damage/wear → Replace the friction plates The following procedure applies to all of the
as a set. clutch plates.
2. Measure: 1. Check:
• Friction plate thickness • Clutch plate
Out of specification → Replace the friction Damage → Replace the clutch plates as a
plates as a set. set.
2. Measure:
TIP
• Clutch plate thickness
Measure the friction plate at four places. (with a vernier caliper “1”)
Friction plate 1, 2, 3 thickness

2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in)
3. Measure:
• Clutch plate warpage
(with a surface plate and feeler gauge “1”)
Out of specification → Replace the clutch
plates as a set.
5-45
CLUTCH ENG
TIP
Clutch plate thickness 1
2.18–2.42 mm (0.085–0.095 in) Pitting on the clutch housing dogs will cause er-
Warpage limit ratic clutch operation.
0.10 mm (0.004 in)
Clutch plate thickness 2
2.20–2.40 mm (0.086–0.094 in) 1
Warpage limit
0.10 mm (0.0039 in)
2. Check:
• Bush
Damage/wear → Replace the clutch housing.
1 EAS30353
CHECKING THE CLUTCH BOSS

EAS30351 1. Check:
CHECKING THE CLUTCH SPRINGS • Clutch boss splines
The following procedure applies to all of the Damage/pitting/wear → Replace the clutch
clutch springs. boss.
1. Check: TIP
• Clutch spring
Pitting on the clutch boss splines will cause er-
Damage → Replace the clutch springs as a
ratic clutch operation.
set.
2. Measure:
• Clutch spring free length “a”
Out of specification → Replace the clutch
springs as a set.
Clutch spring free length

Limit
39.51 mm (1.56 in)
EAS30354
CHECKING THE PRESSURE PLATE

1. Check:
• Pressure plate
EAS30974
CHECKING THE CLUTCH PUSH LEVER AND

SHORT CLUTCH PUSH ROD
EAS30352
1. Check:
CHECKING THE CLUTCH HOUSING • Clutch push lever
1. Check: • Short clutch push rod
• Clutch housing dogs “1” Damage/wear → Replace the defective
Damage/pitting/wear → Deburr the clutch part(s).
housing dogs or replace the clutch housing.
5-46
CLUTCH ENG
EAS30356
CHECKING THE PRIMARY DRIVE GEAR TIP

1. Remove: Install the conical spring washer as shown in the
• Primary drive gear illustration.
Refer to “BALANCER GEAR” on page 5-54.
2. Check: 1
• Primary drive gear
Damage/wear → Replace the primary drive
gear and clutch housing as a set.
Excessive noise during operation → Replace
the primary drive gear and clutch housing as
a set.
3. Install:
Refer to “BALANCER GEAR” on page 5-54. 2. Install:
EAS30357
• Clutch housing
CHECKING THE PRIMARY DRIVEN GEAR • Thrust washer “1”
1. Check: TIP
• Primary driven gear “1” Be sure the thrust washer sharp-edged corner
Damage/wear → Replace the primary drive “a” is positioned opposite side to the clutch boss.
gear and clutch housing as a set.
Excessive noise during operation → Replace
the primary drive gear and clutch housing as 1
a set.
1 a
3. Install:
• Clutch boss “1”
• Lock washer “2” New
EAS32680 • Clutch boss nut
CHECKING THE CLUTCH PUSH RODS TIP
1. Check:
Lubricate the clutch boss nut threads and lock
• Long clutch push rod
washer mating surfaces with engine oil.
Cracks/damage/wear → Replace the long
clutch push rod.
2. Measure: 1
2
• Push rod bending limit
Out of specification → Replace the long
clutch push rod.
Push rod bending limit

0.30 mm (0.012 in)
EAS30363
INSTALLING THE CLUTCH

1. Install: 4. Tighten:
• Conical spring washer “1” • Clutch boss nut “1”
5-47
CLUTCH ENG
8. Lubricate:
Clutch boss nut • Bearing
70 N·m (7.0 kgf·m, 52 lb·ft) • Oil seal
T.
R.
• Clutch push lever

TIP 9. Install:
While holding the clutch boss “2” with the clutch • Bearing
hub holder “3”, tighten the clutch boss nut. • Oil seal
• Lock
Clutch hub holder • Clutch push lever along with spring
YSST-733A 10.Lubricate:
(90890-04086) • Long push rod
• Ball
11.Install:
• Long push rod
• Ball
12.Install:
• Pressure plate
• Clutch springs “1”
• Clutch spring bolts “2”
Clutch spring bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
5. Bend the lock washer tab along a flat side of

the nut.
6. Lubricate:
• Friction plates
• Clutch plates
OUT
FR
(with the recommended lubricant)
Engine oil
7. Install:
• Friction plate “3” (Black color thicker width)
• Clutch plate “b” (Thicker width) 13.Adjust:
• Friction plate “2” (Brown color - Thinner • Clutch mechanism free play
width) a. Check that projection “a” on the clutch
• Clutch plate “a” (Thinner width) push lever “1” aligns with mark “b” shown
• Friction plate “1” (Black color - Thinner width) on the crankcase in the illustration by
pushing the clutch push lever manually in
TIP
direction “c” until it stops.
First, install a friction plate and then alternate be-
tween a clutch plate and a friction plate. c
b
a
a 1
b
3
2 b. If projection “a” is not aligned with mark
1 “b”, align them as follows:
5-48
CLUTCH ENG
• Loosen the locknut “2”. TIP
• With the clutch push lever fully pushed in • Apply engine oil to inside surface of cover boss
direction “c”, turn the short clutch push rod and outside surface of oil seal.
“3” in or out until projection “a” aligns with • Oil seal spring direction “b” shall be cover in-
mark “b”. side.
• Hold the short clutch push rod to prevent it • Oil seal lip shall be free from damage.
from moving and then tighten the locknut
to specification.
Locknut (short clutch push rod) YSST-951
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
15.Install:
R.
• Clutch cover
2 Clutch cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Tighten the clutch cover bolts in the proper tight-
ening sequence as shown.
3
14.Install:
• Clutch cover oil seal “1”
(with a help of bearing punch “2” and suitable
attachment)
Installed depth of oil seal from

the end face “a”
35.9–36.4 mm (1.41–1.43 in)
16.Adjust:
• Clutch cable free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-11.
1
b
a
2
5-49
OIL PUMP ENG

EAS20054
OIL PUMP
Removing the oil pump

Clutch housing Refer to “CLUTCH” on page 5-41.
Balancer drive gear Refer to “BALANCER GEAR” on page 5-54.
1 Oil pump baffle plate 1
2 Oil pump assembly 1
3 Oil pump drive gear 1
procedure.
5-50
OIL PUMP ENG

EAS30337
CHECKING THE OIL PUMP

1. Check:
• Oil pump drive gear
• Oil pump driven gear
• Oil pump housing cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Check:
• Oil pump operation
Rough movement → Replace
EAS30343
INSTALLING THE OIL PUMP

1. Install:
• Oil pump assembly
Oil pump assembly screw

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
ECA20620
NOTICE
After tightening the screws, make sure the
oil pump turns smoothly.
2. Install:
• Oil pump baffle plate bolt
Oil pump baffle plate bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Apply locking agent (LOCTITE ®) to the threads
of the oil pump baffle plate bolts.
5-51
SHIFT SHAFT ENG

EAS20057
SHIFT SHAFT
Removing the shift shaft and stopper lever

Shift pedal Refer to “ENGINE REMOVAL” on page 5-1.
1 Shift shaft 1
2 Circlip 1
3 Shift shaft spring 1
4 Stopper lever 1
5 Stopper lever spring 1
6 Oil seal 1
procedure.
5-52
SHIFT SHAFT ENG

EAS30377
CHECKING THE SHIFT SHAFT

1. Check:
• Shift shaft
Bends/damage/wear → Replace.
• Shift shaft spring
3
EAS30378
CHECKING THE STOPPER LEVER

1. Check: 2 1
• Stopper lever 3. Tighten the stopper lever bolt “1”.
Bends/damage → Replace. TIP
Roller turns roughly → Replace the stopper
Apply locking agent (LOCTITE®) to the threads
lever.
off the oil stopper lever bolt.
• Stopper lever spring
EAS30381
INSTALLING THE SHIFT SHAFT

1. Install:
• Oil seal “1” New
(to the left crankcase)
Install depth “a” 1

0–1.2 mm (0–0.04 in)
4. Install:
a • Shift shaft “1”
TIP
Hook the end of the shift shaft spring onto the
shift shaft spring stopper “2”.
New 1
2. Install:
• Stopper lever “1”
• Stopper lever spring “2”
TIP
• Install the stopper lever spring as shown in the 2 1
illustration.
• Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss “3”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
5-53
BALANCER GEAR ENG

EAS20219
BALANCER GEAR
Removing the primary drive gear and balancer gears

1 Primary drive gear nut 1
2 Balancer driven gear nut 1
3 Washer 1
4 Primary drive gear 1
5 Spacer 1
6 Balancer drive gear 1
7 Straight key 1
8 Lock washer 1
9 Balancer driven gear plate 1 1
10 Balancer driven gear assembly 1
11 Straight key 1
12 Balancer driven gear plate 2 1
13 Spacer 1
14 Balancer driven gear 1
15 Buffer boss 1
16 Spring 4
17 Dowel pin 2
dure.
5-54
BALANCER GEAR ENG

EAS32459
ASSEMBLING THE BALANCER DRIVEN
REMOVING THE PRIMARY DRIVE GEAR
GEAR
AND BALANCER GEARS
1. Assemble:
1. Loosen:
• Buffer boss “1”
• Primary drive gear nut “1”
• Balancer driven gear “2”
TIP
TIP
Place the aluminum plate “a” between the bal-
Align the punch mark “a” on the buffer boss with
ancer drive gear “2” and the balancer driven
the punch mark “b” on the balancer driven gear.
gear “3”, and then loosen the primary drive gear
nut.
1
a EAS32461
INSTALLING THE PRIMARY DRIVE GEAR

2. Straighten the lock washer tab. AND BALANCER GEARS
3. Loosen: 1. Install:
• Balancer driven gear nut “1” • Balancer driven gear “1”
TIP
• Lock washer New
Place the aluminum plate “a” between the bal- • Balancer drive gear “2”
ancer drive gear “2” the and the balancer driven • Primary drive gear
gear “3”, and then loosen the balancer driven • Washer “3”
gear nut. • Balancer driven gear nut
• Primary drive gear nut
a
2 TIP
• Align the punch mark “a” in the balancer drive
gear “2” with the punch mark “b” in the balancer
1
driven gear “1”.
• Be sure to install the washer so that its sharp
edge “c” is facing the primary drive gear.
3
2
EAS32460
1
CHECKING THE BALANCER GEARS AND
PRIMARY DRIVE GEAR
1. Check:
• Balancer drive gear
• Balancer driven gear a b
Cracks/damage/wear → Replace.
2. Check:
Refer to “CHECKING THE PRIMARY DRIVE
GEAR” on page 5-47.
5-55
BALANCER GEAR ENG
2. Tighten:
• Balancer driven gear nut “1”
• Primary drive gear nut “2”
Balancer driven gear nut

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
Primary drive gear nut

60 N·m (6.0 kgf·m, 44 lb·ft)
TIP
• Place the aluminum plate “a” between the bal-
gear “4”, and then tighten the balancer driven
gear nut.
• Place the aluminum plate “b” between the bal-
gear “4”, and then tighten the primary drive
gear nut.
1
a
b
3
2
1
3. Bend the lock washer tab along a flat side of

the nut.
5-56
CRANKCASE ENG
EAS20059
CRANKCASE
Separating the crankcase

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER AND PISTON” on
Cylinder/Piston page 5-27.
Oil pump assembly Refer to “OIL PUMP” on page 5-50.
Shift shaft Refer to “SHIFT SHAFT” on page 5-52.
Refer to “ELECTRIC STARTER” on page
Starter motor
5-37.
Balancer gears Refer to “BALANCER GEAR” on page 5-54.
Refer to “MAGNETO AND STARTER
Magneto rotor CLUTCH” on page 5-32.
5-57
CRANKCASE ENG
Separating the crankcase
New
New
New

1 Plug with O-ring 1
2 Timing chain guide (intake side) 1
3 Chain cover 1
4 Timing chain 1
5 Engine oil drain plug 1
6 Spring 1
7 Engine oil strainer 1
8 Gear position switch 1
9 Crankcase (right) 1
10 Dowel pin 2
11 Crankcase (left) 1
procedure.
5-58
CRANKCASE ENG
Removing the oil seal and bearings

Crankshaft/Balancer Refer to “CRANKSHAFT” on page 5-63.
Transmission Refer to “TRANSMISSION” on page 5-66.
1 Oil seal 1
2 Bearing retainer 1
3 Bearing 7
procedure.
5-59
CRANKCASE ENG
EAS32673 ECA13900
SEPARATING THE CRANKCASE NOTICE

1. Remove: Tap on one side of the crankcase with a
• Crankcase bolts soft-face hammer. Tap only on reinforced
TIP portions of the crankcase, not on the crank-
Loosen each bolt 1/4 of a turn at a time, in stag- case mating surfaces. Work slowly and care-
es and in a crisscross pattern. After all of the fully and make sure the crankcase halves
bolts are fully loosened, remove them. separate evenly.
A
REMOVING THE CRANKCASE BEARING
1. Remove:
Following bearings with help of the bearing
puller or with help of bearing punch and suit-
able attachment as mentioned below:
Bearing puller
YSST-624A/YSST-624
B Cup-C/Cup-B
YSST-620-C/YSST-620-B
Left crankcase Right crankcase

D
A
E
F
A. Crankcase (right)
B
B. Crankcase (left) C
2. Turn: G
• Shift drum segment
TIP A. Balancer bearing.
Turn the shift drum segment “1” to the position Remove with help of bearing puller
YSST 624 A and Cup-C YSST-620-C.
shown in the illustration. In this position, the shift
drum segment teeth will not contact the crank- B. Main axle bearing.
Remove with help of bearing puller
case during crankcase separation. YSST 624 and Cup-B YSST-620-B.
C. Drive axle bearing.
Remove with a help of bearing punch and
1 suitable attachment YSST-951.
D. Balancer bearing.
suitable attachment YSST-951.
E. Crankshaft bearing.
F. Main axle bearing.
3. Remove:
G. Drive axle bearing.
• Crankcase (right)
Remove with help of bearing puller
YSST 624 A and Cup-C YSST-620-C.
5-60
CRANKCASE ENG
EAS31766
Bearing punch with pilot driver CHECKING THE BEARINGS AND OIL SEAL
YSST-951 1. Check:
• Bearings
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement → Replace.
• Oil seal
EAS31603
INSTALLING THE BEARING RETAINER

EAS30390 1. Install:
CHECKING THE CRANKCASE • Bearing retainer “1”
1. Thoroughly wash the crankcase halves in a TIP
mild solvent.
• Install the bearing retainer “1” with its “OUT”
2. Thoroughly clean all the gasket surfaces and
mark “a” facing outward.
crankcase mating surfaces.
• Apply locking agent (LOCTITE®) to the
3. Check:
threads of the bearing retainer bolt.
• Crankcase
• Oil delivery passages Bearing retainer screw
Obstruction → Blow out with compressed air. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
LOCTITE®
EAS30391
CHECKING THE TIMING CHAIN AND TIMING

CHAIN GUIDE
a
1. Check:
• Timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set. 1
EAS30397
ASSEMBLING THE CRANKCASE

1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces with a
scraper “1”.
NOTICE
2. Check:
• Timing chain guide (intake side) Do not use a screw driver or any sharp in-
Damage/wear → Replace. struments for removing the gasket.
EAS31069
Scraper
CHECKING THE OIL STRAINER YSST-612
1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
5-61
CRANKCASE ENG
Crankcase bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Tighten each bolt 1/4 of a turn at a time, in stag-
es and in the proper sequence as shown.
• M6 × 70 mm: “8–10”, “12”
• M6 × 55 mm: “15”, “16”
• M6 × 45 mm: “1–6”, “11”
2. Apply:
A
• Sealant
(onto the crankcase mating surfaces) 1,7
8
Yamaha bond No. 1215 9
90890-85505 6 10
(Three bond No.1215-B) 2,13
5
4 11
TIP
• Do not allow any sealant to come into contact 3,14 12
with the oil gallery. B
• Wipe-off extra sealant to matching surface be- 15
fore setting up gasket.
16
A. Crankcase (left)
B. Crankcase (right)
3. Install:
• Crankcase (right)
TIP
Turn the shift drum segment “1” to the position
shown in the illustration. In this position, the shift
drum segment teeth will not contact the crank-
case during crankcase installation.
4. Install:
• Crankcase bolts
5-62
CRANKSHAFT ENG
EAS20061
CRANKSHAFT
Removing the crankshaft and balancer

Separate.
Crankcase Refer to “CRANKCASE” on page 5-57.
1 Balancer 1
2 Crankshaft 1
procedure.
5-63
CRANKSHAFT ENG
EAS30416
2. Measure:
REMOVING THE CRANKSHAFT
• Crankshaft width
1. Remove:
Out of specification → Replace the crank-
• Crankshaft “1”
shaft.
TIP
• Remove the crankshaft with the crankcase Crank assembly width
separating tool “2”. 47.95–48.00 mm (1.888–1.890 in)
• Make sure the crankcase separating tool is
centered over the crankshaft. 3. Check:
• Crankshaft sprocket
Damage/wear → Replace the crankshaft.
ECA20630
NOTICE
• Bearing
• To protect the end of the crankshaft, place Cracks/damage/wear → Replace the crank-
a bush between the crankcase separating shaft.
tool bolt and the crankshaft. 4. Check:
• Do not tap on the crankshaft. • Crankshaft journal
Scratches/wear → Replace the crankshaft.
Crankshaft removing tool • Crankshaft journal oil passage
YSST-265 Obstruction → Blow out with compressed air.
(90890-01135)
Bush EAS31077
YSST-893 INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft “1”
TIP
2 Install the crankshaft with the crankshaft installer
pot “2”, crankshaft installer bolt “3”, adapter
(M12) “4” and spacer (crankshaft installer) “5”.
Crankshaft installing tool with

spacer
1 YSST-266
(90890-01284)
EAS31075
Spacer (crankshaft installer)
CHECKING THE CRANKSHAFT YSST-767
1. Measure:
• Crankshaft runout
shaft, bearing or both.
TIP
Turn the crankshaft slowly.
1
2
Runout limit
0.050 mm (0.0020 in)
5 4 3
ECA13970
NOTICE
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
5-64
CRANKSHAFT ENG
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft bot-
toms against the bearing.
5-65
TRANSMISSION ENG
EAS20062
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
10

Separate.
Crankcase Refer to “CRANKCASE” on page 5-57.
1 Shift fork guide bar 1
2 Spring 2
Use torx bit (T-30) YSST-611 for dismantling
3 Shift drum assembly 1 shift drum assembly and cam shifter seg-
ment.
4 Neutral point 1
5 Spring 1
6 Shift fork-R 1
7 Shift fork-C 1
8 Shift fork-L 1
9 Drive axle assembly 1
10 Main axle assembly 1
procedure.
5-66
TRANSMISSION ENG
Disassembling the drive axle
5
6
7
8
9
10
11
12
13
3
2
1

1 Circlip 1
2 Washer 1
3 2nd wheel gear 1
4 6th wheel gear 1
5 Washer 1
6 1st wheel gear 1
7 Spacer 1
8 5th wheel gear 1
9 Circlip 1
10 Toothed washer 1
11 4th wheel gear 1
12 3rd wheel gear 1
13 Drive axle 1
procedure.
5-67
TRANSMISSION ENG
EAS30431 EAS30432
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY

The following procedure applies to all of the shift 1. Check:
forks. • Shift drum groove
1. Check: Damage/scratches/wear → Replace the shift
• Shift fork cam follower “1” drum assembly.
• Shift fork pawl “2” • Shift drum segment “1”
Bends/damage/scoring/wear → Replace the Damage/wear → Replace the shift drum as-
shift fork. sembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly.
2. Check:
• Shift fork guide bar
G089024
Roll the shift fork guide bar on a flat surface.
Bends → Replace. EAS30433
EWA12840
CHECKING THE TRANSMISSION
WARNING 1. Measure:
Do not attempt to straighten a bent shift fork • Main axle runout
guide bar. (with a centering device and dial gauge “1”)
Out of specification → Replace the main axle.
Main axle runout limit

0.08 mm (0.0032 in)
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
2. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
Drive axle runout limit

0.08 mm (0.0032 in)
G089023
5-68
TRANSMISSION ENG
b
New 2
a 1 c
• Transmission gears • 2nd pinion gear “1”
Blue discoloration/pitting/wear → Replace TIP
the defective gear(s). Press the 2nd pinion gear into the main axle “2”,
• Transmission gear dogs as shown in the illustration.
Cracks/damage/rounded edges → Replace
the defective gear(s).
Main axle assembly width “a”
106.85–107.05 mm (4.207–
4.215 in)
G089025
4. Check: 2
• Transmission gear engagement
(each pinion gear to its respective wheel 1
gear) EAS30437
Incorrect → Reassemble the transmission INSTALLING THE SHIFT FORKS AND SHIFT
axle assemblies. DRUM ASSEMBLY
• Transmission gear movement • Shift fork-L “1”
Rough movement → Replace the defective • Shift fork-C “2”
part(s). • Shift fork-R “3”
EAS30435
• Shift drum assembly “4”
ASSEMBLING THE DRIVE AXLE • Springs
1. Install: • Shift fork guide bar “5”
• Toothed washer “1” TIP
• Circlip “2” New The embossed marks on the shift forks should
TIP face towards the right side of the engine and be
• Be sure to install the circlip so that its sharp in the following sequence: “R”, “C”, “L”.
edge “a” is facing away from the toothed wash-
er and gear.
• Be sure the circlip ends “b” are positioned at
the axle spline groove “c”.
5-69
TRANSMISSION ENG
2. Check:
• Transmission
Rough movement → Repair.
TIP
• Apply engine oil to each gear and bearing thor-
oughly.
• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-70
TRANSMISSION ENG
5-71
COOLING SYSTEM
RADIATOR .....................................................................................................6-1
CHECKING THE RADIATOR ...................................................................6-3
INSTALLING THE RADIATOR .................................................................6-3
THERMOSTAT ...............................................................................................6-5
CHECKING THE THERMOSTAT ASSEMBLY ........................................6-5
INSTALLING THE THERMOSTAT ASSEMBLY ......................................6-5
WATER PUMP ................................................................................................6-6

DISASSEMBLING THE WATER PUMP ...................................................6-8
CHECKING THE WATER PUMP .............................................................6-8
ASSEMBLING THE WATER PUMP .........................................................6-8
INSTALLING THE WATER PUMP ...........................................................6-8
6
RADIATOR COOL
EAS20063
RADIATOR
Removing the radiator

Lower side cowling (left and right)
4-3.
Drain.
page 3-16.
Throttle cables Refer to “THROTTLE BODY” on page 7-7.
1 Coolant reservoir breather hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir 1
4 Radiator outlet hose 1
5 Radiator inlet hose 1
6 Water pump hose 1
7 Radiator fan coupler 1 Disconnect.
6-1
RADIATOR COOL
Removing the radiator

8 Radiator cap 1
9 Radiator 1
10 Radiator fan 1
11 Radiator cover 1
12 Thermostat 1
procedure.
6-2
RADIATOR COOL
EAS30439
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head
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 8-24.
EAS30440
INSTALLING THE RADIATOR

1. Fill:
2. Check: • Cooling system
• Radiator hoses (with the specified amount of the recom-
Cracks/damage → Replace. mended coolant)
3. Measure: • Coolant air bleed from engine
• Radiator cap opening pressure Refer to “CHANGING THE COOLANT” on
Below the specified pressure → Replace the page 3-16.
radiator cap. 2. Check:
• Cooling system
Radiator cap valve opening pres- Leaks → Repair or replace any faulty part.
sure a. Attach the radiator cap taster “1” and radi-
107.9–137.3 kPa (1.08–1.37 kgf/ ator leakage taster adapter “2” to the radi-
cm2, 15.6–19.9 psi)
ator.
a. Install the radiator cap tester “1” and radi- Radiator cap tester
ator cap tester adapter “2” to the radiator INS-004
cap “3”. (90890-01325)
Radiator leakage tester adapter
Radiator cap tester INS-005
INS-004 (90890-01352)
(90890-01325)
Radiator cap tester adapter
INS-005A
(90890-01352)
b. Apply 137.3 kPa (1.37 kgf/cm², 19.9 psi) of

pressure.
6-3
RADIATOR COOL
c. Measure the indicated pressure with the
gauge.
3. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-4
THERMOSTAT COOL
EAS20065
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
74 – 78˚C 90˚C
(165 – 172˚F) (194˚F)
1
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, re-
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)
• Coolant air bleed from engine
Refer to “CHANGING THE COOLANT” on
page 3-16.
4 2. Check:
1
• Cooling system
2 Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
e. Check the thermostat element position 3. Measure:
“5”. • Radiator cap opening pressure
Same level for the thermostat element up- Below the specified pressure → Replace the
per end and the hole lower line “a” at 90 °C radiator cap.
(194 °F) Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-5
WATER PUMP COOL

EAS20066
WATER PUMP
Removing the water pump
10 N·m (1.0 kgf·m, 7.4 lb·ft)

2
10 N·m (1.0 kgf·m, 7.4 lb·ft)

It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.
Drain.
page 3-16.
Lower side cowling (left) 4-3.
1 Radiator bracket bolt 2
2 Coolant reservoir hose 1 Remove from radiator bracket.
3 Clutch cable 1 Remove from radiator bracket.
4 Water pump hose 1
5 Water pump assembly 1
procedure.
6-6
WATER PUMP COOL

Disassembling the water pump
New
New
New
New
New
3

1 O-ring 2
2 Radiator bracket 1
3 Water pump housing cover 1
4 Water pump housing cover gasket 1
5 Circlip 1
6 Impeller shaft 1
7 Water pump seal 1
TIP
8 Bearing 1
For removing, use YSST-723
9 Water pump housing 1

procedure.
6-7
WATER PUMP COOL

EAS30446
DISASSEMBLING THE WATER PUMP A

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

1. Check:
• Water pump housing cover
• Water pump housing
• Impeller shaft
Cracks/damage/wear → Replace. a. Installed depth of water pump seal
EAS30448
2. Lubricate:
ASSEMBLING THE WATER PUMP • Water pump seal
1. Install:
• Water pump seal “1” New Lithium-soap-based grease
(into the water pump housing “2”)
TIP 3. Install:
Install the water pump seal with the special tools • Impeller shaft “1”
to the specified depth as shown in the illustra- • Circlip New
tion. TIP
After installation, check that the impeller shaft ro-
Installed depth of water pump tates smoothly.
seal
0–0.5 mm (0–0.02 in)
Mechanical seal/bearing installer

YSST-722
EAS30449
INSTALLING THE WATER PUMP

1. Install:
• O-rings “1” New
• Water pump assembly “2”
6-8
WATER PUMP COOL
Water pump assembly bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Align the projection “a” on the impeller shaft
with the slit “b” on the camshaft sprocket bolt.
• Lubricate the O-ring with a thin coat of lithium-
soap-based grease.
a b
2
New 1
LS
2. Fill:
• Cooling system
mended coolant)
page 3-16.
• Coolant air bleed from engine
page 3-16.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-9
FUEL SYSTEM
FUEL TANK ....................................................................................................7-1

REMOVING THE FUEL TANK .................................................................7-4
REMOVING THE FUEL PUMP ................................................................7-4
CHECKING THE FUEL PUMP BODY ......................................................7-4
INSTALLING THE FUEL PUMP ASSEMBLY ..........................................7-4
INSTALLING THE FUEL TANK ................................................................7-5
CHECKING THE FUEL PRESSURE .......................................................7-5
THROTTLE BODY ..........................................................................................7-7

REMOVING THE THROTTLE BODY .......................................................7-9
CHECKING THE FUEL INJECTOR .........................................................7-9
INSTALLING THE FUEL INJECTOR .......................................................7-9
CHECKING THE THROTTLE BODY .......................................................7-9
INSTALLING THE THROTTLE BODY .....................................................7-9
7
FUEL TANK FI
EAS20067
FUEL TANK
Removing the fuel tank and fuel pump
LE
YCT
RCEC
TONN
MOCO

Passenger and rider seat 4-1.
Side cover (left and right)
4-2.
1 Fuel tank cover bolts (left/ right) 5/5
2 Fuel tank cover (left/ right) 1/1
3 Fuel tank top cover 1
4 Fuel tank mounting bolt 4
5 Fuel pump coupler 1 Disconnect.
6 Fuel sender coupler 1 Disconnect.
7 Hose (fuel tank to canister) 1
8 Fuel overflow hose 1
9 Fuel hose 1 Disconnect (Place cloth under hose)
Disconnect fuel hose before removing the
fuel tank assembly.
10 Fuel tank assembly 1
(For remove the fuel tank assembly skip
stem 1 & 2).
7-1
FUEL TANK FI
Removing the fuel tank and fuel pump
LE
YCT
RCEC
TONN
MOCO

11 Fuel tank mounting bracket 2
12 Fuel pump retainer 1
13 Fuel pump assembly 1
14 Fuel pump gasket 1
15 Fuel sender unit assembly 1
dure.
7-2
FUEL TANK FI
Removing the canister

Side cover (left and right)
4-2.
Lower side cowling (left and right)
4-3.
1 Canister mounting bolt / Collar 2/2
2 Hose (canister to throttle body) 1 Disconnect.
3 Hose (fuel tank to canister) 1 Disconnect.
4 Hose (canister to atmosphere) 1
5 Canister 1 Remove from Magneto side
dure.
7-3
FUEL TANK FI
EAS26630 EAS26640
REMOVING THE FUEL TANK REMOVING THE FUEL PUMP

1. Extract the fuel in the fuel tank through the 1. Remove:
fuel tank cap with a pump. • Fuel pump retainer
2. Remove • Fuel pump
• Fuel tank assembly mounting bolt & screws • Fuel pump gasket
Refer to “FUEL TANK” on page 7-1. ECA14720
3. Disconnect: NOTICE
• Fuel pump coupler • Do not drop the fuel pump or give it a
• Fuel sender coupler strong shock.
4. Disconnect: • Do not touch the base section of the fuel
• Hose (fuel tank to canister) sender.
• Fuel overflow hose EAS26670
5. Remove: CHECKING THE FUEL PUMP BODY
• Fuel hose 1. Check:
EWA3C11
• Fuel pump body
NOTICE
Obstruction → Clean.
Cover fuel hose connections with a cloth Cracks/damage → Replace the fuel pump
when disconnecting them. Residual pres- assembly.
sure in the fuel lines could cause fuel to EAS26700
spurt out when removing the hoses. INSTALLING THE FUEL PUMP ASSEMBLY
ECA20020 1. Install:
NOTICE • Fuel pump gasket “1” New
Although the fuel has been removed from • Fuel pump “2”
the fuel tank, be careful when removing the • Fuel pump retainer “3”
fuel hose, since there may be fuel remaining
in it. Fuel pump retainer bolt
4 N·m (0.4 kgf·m, 3.0 lb·ft)
TIP
• To remove the fuel hose from the fuel pump, TIP
slide the fuel hose lock “1” upside as arrow • Do not damage the installation surfaces of the
shown, and then remove the hose. fuel tank when installing the fuel pump.
• Remove the fuel hose manually without using • Always use a new fuel pump gasket.
any tools. • The gasket lip “a” shall face toward the fuel
• Before removing the hose, place a few rags in pump.
the area under where it will be removed. • Align the projections “b” (two locations) on the
fuel pump gasket with the slots “c” in the fuel
pump.
1 • Align the projection “d” on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in stages in a criss-
cross pattern.
TIP
Do not set the fuel tank down on the installation
surface of the fuel pump. Be sure to lean the fuel
tank against a wall or the like.
7-4
FUEL TANK FI
2
1
3
a 2
c
b
3
3 4
2
a
b 1
4 4 N·m (0.4 kgf·m,3.0 lb·ft)
ECA3C11005 3. Connect:
INSTALLING THE FUEL TANK • Fuel hose
1. Install: • Fuel overflow hose
• Fuel tank • Hose (fuel tank to canister)
2. Connect: • Fuel sender coupler
• Fuel hose • Fuel pump coupler
ECA3C11005
NOTICE EAS3C11005
CHECKING THE FUEL PRESSURE

When installing the fuel hose, make sure that
1. Check:
it is securely connected, and that the fuel
• Fuel pressure
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose a. Remove:
will not be properly installed. • Rider seat
Refer to “GENERAL CHASSIS (1)” on
TIP page 4-1.
• Install the fuel hose securely onto the fuel • Side cover (left and right)
pump until a distinct “click” is heard. Refer to “GENERAL CHASSIS (3)” on
• To install the fuel hose “1” onto the fuel pump page 4-3.
“2”, slide the fuel hose lock “3” upside. • Fuel tank assembly mounting bolt &
• After inserting, press fuel hose lock “3” in the screws
direction of the arrow show “4”. Refer to “FUEL TANK” on page 7-1.
2. Lift the front of the fuel tank.
3. Check:
• Pressure regulator operation
a. Disconnect the fuel hose “1” from the fuel
pump “2”.
EWA3C11008
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to
spurt out when removing the hoses.
7-5
FUEL TANK FI
ECA20020
4. Install:
NOTICE • Fuel tank assembly mounting bolt & screws
Although the fuel has been removed from Refer to “FUEL TANK” on page 7-1.
the fuel tank, be careful when removing the • Side covers
fuel hose, since there may be fuel remaining Refer to “GENERAL CHASSIS (3)” on page
in it. 4-3.
• Passenger and rider seat
2 4-1.
b. Connect the fuel pressure gauge “1” be-

tween the fuel hose “2” and fuel pump “3”.
Fuel pressure gauge

INS-006
(90890-03181)
(90890-03176)
(90890-03186)
2
c. Start the engine.
d. Measure the fuel pressure.
Fuel pressure
220-300 kPa
Below specification → Replace the fuel

pump.
e. Connect the fuel hose.
Refer to “INSTALLING THE FUEL TANK” on
page 7-5.
7-6
THROTTLE BODY FI
EAS20070
THROTTLE BODY
Removing the throttle body

Air filter case
4-8.
1 Fuel hose 1 Disconnect.
2 Fuel injector cover 1
3 Fuel injector coupler 1 Disconnect.
4 Fuel injector 1
5 Fuel injector O-ring 1
6 FID (fast idle solenoid) coupler 1 Disconnect.
7 Throttle body sensor assembly coupler 1 Disconnect.
7-7
THROTTLE BODY FI
Removing the throttle body

8 Throttle cable (accelerator cable) 1 Disconnect.
9 Throttle cable (decelerator cable) 1 Disconnect.
10 Hose (Throttle body to canister) 1 Disconnect.
ECA22690
NOTICE
11 Throttle body 1
The throttle body should not disassem-
bled.
12 Intake manifold 1
procedure.
7-8
THROTTLE BODY FI
EAS3C11025 EAS3C11028
REMOVING THE THROTTLE BODY CHECKING THE FUEL INJECTOR

1. Extract the fuel in the fuel tank through the 1. Check:
fuel tank filler hole with a pump. • Fuel injector
2. Disconnect: Damage → Replace.
• Fuel hose
WARNING INSTALLING THE FUEL INJECTOR

1. Install:
Cover fuel hose connections with a cloth
• Fuel injector
when disconnecting them. Residual pres-
TIP
sure in the fuel lines could cause fuel to
spurt out when removing the hoses. • Lubricate the fuel injector O-ring with engine
oil.
TIP • Replace the O-ring when taking out of fuel in-
• To remove the fuel hose from the fuel injector, jector from throttle body.
slide the fuel hose lock “1” upside as arrow • Insert the dowel “a” of injector into the hole of
shown, and then remove the hose. throttle body.
• Remove the fuel hose manually without using
any tools.
• Before removing the hose, place a few rags in
the area under where it will be removed.
1
a
EAS26990
CHECKING THE THROTTLE BODY

1. Check:
• Throttle body
3. Remove: Cracks/damage → Replace the throttle body.
• Throttle body 2. Check:
ECA20590
• Fuel passages
NOTICE Obstruction → Clean.
Do not remove the throttle body sensor a. Wash the throttle body in a petroleum-
assembly “1” from the throttle body. based solvent.
Do not use any caustic carburetor clean-
ing solution.
b. Blow out all of the passages with com-
pressed air.
EAS3C11006
INSTALLING THE THROTTLE BODY

1 1. Install:
• Throttle body joint clamps
TIP
Align the projections “a” on the throttle body joint
with the slot “b” in throttle body joint clamp.
7-9
THROTTLE BODY FI
4. Check:
• Sensor assembly
• Throttle body with Yamaha diagnostic tool

b INS-018
(90890-03267)
a INS-019
(90890-03264)
2. Adjust:
Refer to “ADJUSTING THE THROTTLE
GRIP FREE PLAY” on page 3-7.
3. Connect:
• Fuel hose
NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel in-
jector until a distinct “click” is heard.
• To install the fuel hose “1” onto the fuel injector
“2”, slide the fuel hose lock “3” upside.
• After inserting, press fuel hose lock “3” in the
direction of the arrow show “4”.
3 1
2
7-10
THROTTLE BODY FI
7-11
ELECTRICAL SYSTEM
IGNITION SYSTEM ........................................................................................8-1

CIRCUIT DIAGRAM .................................................................................8-1
ENGINE STOPPING DUE TO SIDESTAND OPERATION ......................8-2
TROUBLESHOOTING .............................................................................8-3
ELECTRIC STARTING SYSTEM ...................................................................8-5

CIRCUIT DIAGRAM .................................................................................8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .........................8-6
TROUBLESHOOTING .............................................................................8-7
CHARGING SYSTEM .....................................................................................8-9

CIRCUIT DIAGRAM .................................................................................8-9
TROUBLESHOOTING ........................................................................... 8-10
LIGHTING SYSTEM ..................................................................................... 8-12

CIRCUIT DIAGRAM ...............................................................................8-12
SIGNALING SYSTEM .................................................................................. 8-16

CIRCUIT DIAGRAM ...............................................................................8-16
COOLING SYSTEM ...................................................................................... 8-24

CIRCUIT DIAGRAM ...............................................................................8-24
FUEL INJECTION SYSTEM ......................................................................... 8-28

CIRCUIT DIAGRAM ...............................................................................8-28
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ......... 8-37

DIAGNOSTIC CODE: SENSOR OPERATION TABLE .......................... 8-44
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ..................... 8-46
FUEL INJECTION SYSTEM TROUBLESHOOTING ................................... 8-47

FAULT CODE TABLE ............................................................................ 8-47
FUEL INJECTION SYSTEM TROUBLESHOOTING ............................. 8-50
8
EVENT CODE TABLE .................................................................................. 8-97
FUEL PUMP SYSTEM .................................................................................. 8-99

CIRCUIT DIAGRAM ...............................................................................8-99
TROUBLESHOOTING .........................................................................8-100
ABS (ANTI-LOCK BRAKE SYSTEM) ........................................................8-101

CIRCUIT DIAGRAM .............................................................................8-101
ABS COUPLER LOCATION CHART ...................................................8-103
MAINTENANCE OF THE ABS ECU ....................................................8-104
ABS TROUBLESHOOTING OUTLINE .................................................8-104
BASIC INSTRUCTIONS FOR TROUBLESHOOTING .........................8-105
BASIC PROCESS FOR TROUBLESHOOTING ..................................8-107
[A] CHECKING THE ABS WARNING LIGHT .......................................8-108
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON ..........8-108
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ...........................8-108
[A-3] THE ABS WARNING LIGHT COMES ON ...................................8-108
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE
(The select unit screen does not appear.) ...........................................8-109
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE
(Cannot connect due to a tool error.) ...................................................8-109
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................8-109
[B-2] DIAGNOSIS USING THE FAULT CODES ..................................8-109
[B-3] DELETING THE FAULT CODES .................................................8-136
[C-1] FINAL CHECK .............................................................................8-136
ELECTRICAL COMPONENTS ...................................................................8-137

CHECKING THE SWITCHES ..............................................................8-139
CHECKING THE BULBS AND BULB SOCKETS ................................8-141
CHECKING THE FUSES .....................................................................8-142
REPLACING THE ECU (engine control unit) .......................................8-142
REMOVING THE ECU (engine control unit) ........................................8-142
INSTALLING THE ECU (engine control unit) .......................................8-143
CHECKING AND CHARGING THE BATTERY ....................................8-143
CHECKING THE RELAYS ...................................................................8-146
CHECKING THE DIODES ....................................................................8-147
CHECKING THE SPARK PLUG CAP ..................................................8-147
CHECKING THE IGNITION COIL ........................................................8-148
CHECKING THE IGNITION SPARK GAP ............................................8-148
CHECKING THE CRANKSHAFT POSITION SENSOR .......................8-149
CHECKING THE LEAN ANGLE SENSOR ...........................................8-149
CHECKING THE STARTER MOTOR OPERATION ............................8-149
CHECKING THE STATOR COIL .........................................................8-150
CHECKING THE RECTIFIER/REGULATOR .......................................8-150
CHECKING THE HORN .......................................................................8-151
CHECKING THE FUEL SENDER ........................................................8-151
CHECKING THE FUEL METER ...........................................................8-151
CHECKING THE SPEED SENSOR .....................................................8-152
CHECKING THE RADIATOR FAN MOTOR ........................................8-152
CHECKING THE COOLANT TEMPERATURE SENSOR ....................8-152
CHECKING THE THROTTLE BODY SENSOR ASSEMBLY ...............8-153
CHECKING THE FID (FAST IDLE SOLENOID) ..................................8-153
CHECKING THE VVA SOLENOID .......................................................8-153
CHECKING THE FUEL INJECTOR .....................................................8-154
IGNITION SYSTEM ELEC

– +
EAS20072
IGNITION SYSTEM
EAS30490
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
R
5
8
1
MAIN
15A
2
R W/R
R
W B/L
Ch Y/B B/R R/W L/G R/B V P/W Or/B W/Y B/L W/R Y
G Br R Lg/L W Y/R G/R Y/G Y/L B/L L B
B/Y L Lg/W W/B B/L B/W Br/W Gy/G Y/W B/L B/L P/B Or
R/W
R R R 24
Or Or
R
R W/R
25
R R R/W B/L
12
14
15
B OFF
RUN
B B START
B
B
39
B B B/W
Br
B/W B
23
R
R
40
ON L/G
OFF 30
Y/G
R B/L
Br Br L
Sb
Sb
Br
Br
Br
B/W B
B/W B
Br Br
Br Br Br Br/L Gy Gy 68
Br Br Br Br Gy Gy
Sb W W Sb Or
Or P P Or
W/R Y/W Y/W W/R
1. AC magneto assembly
CONNECTED
82 Sb 2. Crankshaft position sensor

56 L/G
Sb
Sb L/G
L/G L/G L/G 5. Fuse box
81 L/G
8. Main fuse
L/G B
B/W
L
B 12.Battery
B/W
14.Handlebar switch (right)
15.Engine stop / start switch
23.ECU (Engine control unit)
24.Ignition coil
25.Spark plug
30.Lean angle sensor
39.Engine ground
40.Main switch
56.Gear position switch
68.Junction 1
81.Sidestand switch
82.Diode 2
8-1

– +
EAS30491
ENGINE STOPPING DUE TO SIDESTAND OPERATION

When the engine is running and the transmission is in gear, the engine will stop if the sidestand is
moved down. This is because the electric current from the ignition coils does not flow to the ECU when
both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing
the spark plugs from producing a spark. However, the engine continues to run under the following con-
ditions:
• The transmission is in gear (the neutral circuit of the gear position switch is opened) and the sidestand
is up (the sidestand switch circuit is closed).
• The transmission is in neutral (the neutral circuit of the gear position switch is closed) and the sides-
tand is down (the sidestand switch circuit is opened).
1. Battery
2. Main fuse
3. Main switch
4. Engine stop / start switch
5. Ignition coil
6. Spark plug
7. ECU (Engine Control Unit)
8. Sidestand switch
9. Diode 2
10.Gear position switch (neutral circuit)
8-2

– +
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Passenger seat and rider seat
2. Side cover (left and right)
3. Fuel tank cover (left and right)
4. Upper panel (left and right)
5. Upper side cowling (left and right)
6. Lower side cowling (left and right)
1. Check the fuses. NG →

(Main fuse)
Replace the fuse(s).
Refer to “CHECKING THE FUSES”
on page 8-142.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-143.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-8.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 8-148.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 8-147.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-148.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Replace the crankshaft position sensor/
Refer to “CHECKING THE CRANK-
stator assembly.
SHAFT POSITION SENSOR” on
page 8-149.
OK ↓
8-3

– +
8. Check the main switch. NG →

Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-139.
OK ↓
9. Check the engine stop / start NG →
switch. The engine stop / start switch is faulty.
Refer to “CHECKING THE Replace the right handlebar switch.
OK ↓
10.Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 8-149.
OK ↓
11.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
12.Check the gear position switch NG →
(neutral switch continuity).
Replace the gear position switch.
Refer to “CHECKING THE
OK ↓
13.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.
8-4
ELECTRIC STARTING SYSTEM ELEC

– +
EAS20073
ELECTRIC STARTING SYSTEM

EAS30493
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
R
5
8
MAIN
15A
R R R
13
R
R R R/W R/W
R
R R/W B
L/W L/W Br/L L/W Br/W
12 L/W
R/W 14
15 Br/L L/W Br/W
B B/W Gy Gy B OFF
R/B R/B RUN
B B Ch Dg Dg Ch START
B
39
B R/B Br
B/W
R/W R/W R/B
B R/B
R
CONNECTED
40 38 Sb 37
R/B
ON
OFF
Sb
Br
Sb
Sb
Sb
R/W R/W
69
Ch Y/B
Br R/B P
B/R Dg W/B R/B
60 Br R/B P
B/W Dg Y/B 65 R/B
Ch Y/B B B B/Y B R/W R/W R/W
B B B/R B B/W R/W
Or
B/W
B/W
Sb
82
Sb
L/G
B/W 5. Fuse box
L/G L/G L/G
81 L/G
8. Main fuse
L/G
B/W
B
B
12.Battery
Sb W W Sb
Or P
W/R Y/W
P Or
Y/W W/R
L
B/W 13.Starter relay
N
56 37.Diode 1
Sb
38.Starter motor
39.Engine ground
40.Main switch
60.Handlebar switch (left)
65.Clutch switch
69.Junction 2
81.Sidestand switch
82.Diode 2
8-5

– +
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop/start switch is set to “ ” and the main switch is set to “ON” (both switches are closed),
the starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the clutch switch is opened/closed) and (the sidestand switch is
opened/closed) engine will start.
• The transmission is in gear, the clutch lever is pulled (the clutch switch is closed) and the sidestand
is closed (the sidestand switch is closed) engine will start.
The sidestand switch prevents the starter motor from operating when neither of these conditions has
been met. In this instance, the sidestand switch is opened so current cannot reach the starter motor.
When at least one of the above conditions has been met, the sidestand switch is closed and the engine
can be started by pressing the start switch “ ”.
STOP START
a. WHEN THE TRANSMISSION IS IN

NEUTRAL
b. WHEN CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Main fuse
3. Main switch
4. Engine stop / start switch
5. Gear position switch (Neutral switch)
6. Clutch switch
7. Sidestand switch
8. Diode 1
9. Diode 2
10.Starter relay
11.Starter motor
8-6

– +
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
4. Upper panel (left and right)
5. Upper side cowling (left and right)
6. Lower side cowling (left and right)

(Main fuse)
on page 8-142.
OK ↓
page 8-143.
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.
8-149.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-39.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 8-146.
OK ↓
OK ↓
OK ↓
8-7

– +
8. Check the gear position switch NG →

(neutral switch). Replace the gear position switch (neutral
Refer to “CHECKING THE switch).
OK ↓
9. Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
10.Check the engine stop / start NG →
switch. The start engine stop / start switch.
OK ↓
11.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
12.Check the entire starting system NG →
page 8-5.
OK ↓
The starting system circuit is OK.
8-8
CHARGING SYSTEM ELEC

– +
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
R
5
8 3. AC magneto
1
MAIN
4. Rectifier/regulator
15A
R 5. Fuse box
W
W
W
W 3
8. Main fuse
12.Battery
R
R R R
W R R
W 4 R
R
B
12
B
B
B
8-9

– +
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
2. Side cover (left)
3. Fuel tank cover (left) and upper panel (left)
4. Upper side cowling (left) and lower side cowling (left)
1. Check the fuse. NG →

(Main)
Replace the fuse.
on page 8-142.
OK ↓
page 8-143.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STA-
stator assembly.
TOR COIL” on page 8-150.
OK ↓
4. Check the rectifier/regulator. NG →
RECTIFIER/REGULATOR” on Replace the rectifier/regulator.
page 8-150.
OK ↓
5. Check the entire charging system NG →
page 8-9.
OK ↓
The charging system circuit is OK.
8-10

– +
8-11
LIGHTING SYSTEM ELEC

– +
EAS20075
LIGHTING SYSTEM
EAS30498
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
Br R
5
6 8
MAIN
15A
2A
Br R
11 Br
R R R
R
Y/L
R
R/W
B R/W
12
14
15
B OFF
RUN
B B START
B B
B
B
39
B B B/W
B Br
B B
B
23
R R
40
ON
OFF
R
Br Br
Y/B
B/R
B/Y
Br
R Br Br
R Br
R Br Br
Br
B/W B
Gy Or W/R Y/W Y/L P G Or/W W Br

B/W B
R W/L Sb Y/R Dg Ch P/W Y/W B
Gy
41
Br
R
43
Br Br
Y/L
R/W R/W
Br Br Br Br
69
Y/B Y/B
60
61
Br Br Br Br/L Gy Gy B B B/Y B R/W R/W R/W
68 B B B B B/R B/Y B
HI Br Br Br Br Gy Gy B B/R B B/W R/W
LO
Or Or
HI_BEAM 50 PASS
Y/R
Ch Y/B
B/R Dg W/B
B/W Dg Y/B Y
Ch Y/B
B
Br
L
L
Br
83 Br Y
74 Br
86
L
Br L
12V 5W
B B
84
B
B
85
L L Y/R
88 87 G Y B R B B 76
B Y/B
B L L B L B B L Y/R Y Y/B B Br B
B
B B
B B
Y/B
Y/B
B Y/B Y/B
B B
8-12

– +
5. Fuse box
6. Accessories fuse
8. Main fuse
11.Accessories socket
12.Battery
23.ECU (Engine Control Unit)
39.Engine ground
40.Main switch
41.Meter assembly
43.Multi-function display
50.High beam indicator light
61.Dimmer / pass switch
68.Junction 1
69.Junction 2
74.Brake/Taillight assembly
76.Taillight
83.Headlight assembly
84.Headlight (High beam)
85.Headlight (Low beam)
86.License plate light
87.Auxiliary light (Right)
88.Auxiliary light (Left)
8-13

– +
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlights, high beam indicator light, taillight, license plate light, auxiliary
light or meter lights.
TIP
2. Side cover (right)
3. Fuel tank cover (right)
4. Upper panel (right) and upper side cowling (left)
5. Lower side cowling (right)
1. Check the condition of each LED/ NG →

bulb and bulb socket.
Replace the LED/bulb(s) and bulb sock-
Refer to “CHECKING THE BULBS
et(s).
AND BULB SOCKETS” on page
8-141.
OK ↓

Refer to “CHECKING THE FUSES” Replace the fuse(s).
on page 8-142.
OK ↓
page 8-143.
OK ↓
OK ↓
5. Check the dimmer / pass switch. NG →
The dimmer / pass switch is faulty.
Replace the left handlebar switch.
OK ↓
6. Check the entire lighting system NG →
page 8-12.
OK ↓
Replace the ECU, meter assembly,
license plate light, auxiliary light or
tail/brake light assembly.
8-14

– +
8-15
SIGNALING SYSTEM ELEC

– +
EAS20076
SIGNALING SYSTEM
EAS30500
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
R
5
8
MAIN
R
15A
R R
R R R
R
Y/L
R
R/W B L
Br/L L/W Br/W P/W Y/W Br/L R/W
12
14
15 Br/L L/W Br/W P Y/W
B/W Gy Gy B OFF TRIP OFF

B N
R/B R/B RUN ON
B START INFO
B Ch Dg Dg Ch
B
16 17 18
B B
B B B 39
B B B/W Lg/W Or/W G
B Y/W B/W P/W Br/W Dg Ch Gy
Br Lg/L
B B/W B G/R
B/W
B
B
B
23 28 32
B/L G
B/W R
40
ON
OFF
Or/W
Sb Sb
Br Br
B/W V V
Sb
Sb 36 Lg/L W
R Lg/W
B R B/R
Lg/W
35 Lg/L
B/Y
Br V B/W
R B
Br Br
R Br
R Br Br Br Lg/L B
Br
R Lg/W
B/W B

34
B/W B
Gy
41
42
Br Sb
Br
R
43 Gy Br Br
Y/W
P/W
Y/L
Br/W 66 B B/W
Br
59 Br R/W R/W
67
EG_ALARM 45 Br/W
Br Br Br Br/L
P 69
WATER 46 Br/W
Gy
Br/W
Br P
SHIFT 47
INCOMING_NOTIFICATION_1
48 60 62 63
64
Gy Gy Gy
49 OFF L
68 B B B B/R B/Y B/W
N B B B/Y B R/W R/W R/W

ON
R B B/R B B/W R/W
Br Br Br Br/L Gy Gy Or
Ch Y/B
Br R/B P Br Br Br Br Gy Gy
51 TURN_R
B/R Dg W/B
Or
Dg
52 TURN_L
B/W Dg Y/B Br R/B P B Ch Dg
Ch Ch Y/B
G B
Or/W 53
Ch
Ch Ch
55 Ch
Ch 70
W
W P Y/W W/R Or Gy
Sb W W Sb Dg Dg Dg
Or P P Or
W/R Y/W Y/W W/R Dg
1 Dg
W Gy
N 74 G G 71
2
P W B
3 R R G R
Y/W Ch Dg Ch Dg Shield S
4
W/R
5
Or
80 79 78 77
6
Gy
75
Gy Ch Dg Ch Dg
12V 10W
12V 10W
12V 10W
12V 10W
56
Sb B B B B
B B B B 76
R G R Br Y W W/L W/B B/W

R/L Gy Br/W L/R L/B B/W B
8-16

– +
5. Fuse box
8. Main fuse
12.Battery
16.Trip / information switch
17.Hazard switch
18.Front brake light switch
32.Fuel sender
34.Yamaha diagnostic tool coupler/ABS test
coupler
35.CCU (Communication control unit)
36.Quick shift switch
39.Engine ground
40.Main switch
41.Meter assembly
42.Neutral indicator light
45.Engine trouble warning light
46.Coolant temperature warning light
47.Shift indicator light
48.Incoming notification indicator light 1
49.Incoming notification indicator light 2
51.Turn signal indicator light (Right)
52.Turn signal indicator light (Left)
53.Fuel meter
55.Gear position indicator
59.Horn 1
62.Horn 2
63.Horn switch
64.Turn signal switch
66.Turn signal relay
67.Rear brake light switch
68.Junction 1
69.Junction 2
70.ABS ECU (Hydraulic control unit)
71.Front wheel sensor
74.Brake/Taillight assembly
75.Brake light
76.Taillight
77.Rear turn signal light (Right)
78.Rear turn signal light (Left)
79.Front turn signal light (Right)
80.Front turn signal light (Left)
8-17

– +
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light or indicator lights.
• The horn fails to sound.
• The fuel meter fails to operate.
• The speedometer fails to operate.
TIP
3. Fuel tank cover (right)
4. Upper panel (right)
5. Upper side cowling (right)
6. Lower side cowling (right)

(Main fuse)
on page 8-142.
OK ↓
page 8-143.
OK ↓
OK ↓
4. Check the entire signaling system NG →
page 8-16.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system” on
page 8-18.
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 ↓
8-18

– +
2. Check the horn. NG →

Refer to “CHECKING THE HORN” Replace the horn.
on page 8-151.
OK ↓
page 8-16.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
page 8-16.
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 bulb and NG →
socket.
Replace the turn signal light bulb, socket
Refer to “CHECKING THE BULBS
or both.
AND BULB SOCKETS” on page
8-141.
OK ↓
2. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
3. Check the hazard switch. NG →
Refer to “CHECKING THE Replace the handlebar switch (left).
OK ↓
8-19

– +
4. Check the turn signal relay. NG →

Refer to “CHECKING THE Replace the turn signal relay.
RELAYS” on page 8-146.
OK ↓
page 8-16.
OK ↓
Replace the meter assembly.
The neutral indicator light fails to come on.

1. Check the gear position switch. NG →
Refer to “CHECKING THE Replace the gear position switch.
OK ↓
page 8-16.
OK ↓
Replace the meter assembly.
The fuel meter fails to operate.

1. Check the fuel sender. NG →
The fuel sender is faulty. Replace the fuel
Refer to “CHECKING THE FUEL
pump assembly.
SENDER” on page 8-151.
OK ↓
page 8-16.
OK ↓
Replace the ECU meter assembly.
Refer to “REPLACING THE ECU
(engine control unit)” on page 8-142.
8-20

– +
QS (Quick Shift System) does not operate.

1. Check that the engine trouble and NG →
system warning light does not come Repair the faulty parts.
on.
OK ↓
NG → Check the QS operating conditions
2. Check that the QS is working under
explained in the owner’s manual and
normal QS operating conditions.
operate the QS accordingly.
OK ↓
3. Make sure that the QS is effective. NG →

Activate the QS. (Set the QS to a setting
(Check whether the “QS” icon is
other than “OFF”.)
displayed at the top of the meter.)
OK ↓
4. Check that the quick shift switch NG →

Connect the quick shift switch coupler.
coupler is connected.
OK ↓
5. Check the quick shift switch. NG →

Refer to “DIAGNOSTIC CODE:
SENSOR OPERATION TABLE” on Replace the quick shift switch.
page 8-44 and “CHECKING THE
OK ↓
6. Check the gear position switch. NG →

Refer to “DIAGNOSTIC CODE:
SENSOR OPERATION TABLE” on Replace the gear position switch.
page 8-44 and “CHECKING THE
OK ↓
7. Check the entire signaling system’s NG →

wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 8-16.
OK ↓
Replace the ECU.
8-21

– +
The speedometer fails to operate.

1. Check the front wheel sensor. NG →
Refer to “CHECKING THE SPEED Replace the front wheel sensor.
SENSOR” on page 8-152.
OK ↓
page 8-16.
OK ↓
Replace the hydraulic unit assembly,
ECU, meter assembly.
TIP
Repair or replace if there is an open or short circuit.
• Between front wheel sensor coupler and ABS ECU coupler.
(white–red)
(black–green)
• Between ABS ECU coupler and ECU coupler.
(white–white)
• Between ECU coupler and meter assembly.
(yellow–blue)
The tachometer fails to operate.

1. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK-
stator assembly.
SHAFT POSITION SENSOR” on
page 8-149.
OK ↓
page 8-16.
OK ↓
Replace the ECU or meter assembly.
8-22

– +
The coolant temperature warning light fails to come on.

1. Check the coolant temperature NG →
sensor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-152.
OK ↓
2. Check the entire signaling system’s NG →
wiring. Properly connect or repair the signaling
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 8-16.
OK ↓
(engine control unit)” on page 8-142
8-23
COOLING SYSTEM ELEC

– +
EAS20077
COOLING SYSTEM
EAS30502
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
R
5
8
MAIN
15A
R R R
12
B B
B
B
B
39
B B B/W
B
B B G/R
23 28
B/L
R R
40
ON
OFF
R
Br
Br
R Br Br
R Br
W/Y
R Br
B/W B
B/W B
R Br
58
Br Br
L
W/Y
L
Br Br Br Br/L Gy Gy 68
Br Br Br Br Gy Gy
L L Or
B
57
B
5. Fuse box
8. Main fuse
12.Battery
39.Engine ground
40.Main switch
58.Radiator fan motor relay
68.Junction 1
8-24
COOLING SYSTEM ELEC

– +
EAS27320
TROUBLESHOOTING
• The radiator fan motor fails to turn.
• The coolant temperature warning light fails to come on.
TIP
4. Fuel tank
5. Upper panel (right)
6. Upper side cowling (right) and lower side cowling (right)

(Main fuse)
on page 8-142.
OK ↓
page 8-143.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 8-152.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
LAYS” on page 8-146.
OK ↓
6. Check the coolant temperature NG →
sensor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-152.
OK ↓
8-25
COOLING SYSTEM ELEC

– +
7. Check the entire cooling system NG →

wiring. Properly connect or replace the cooling
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 8-24.
OK ↓
8-26
COOLING SYSTEM ELEC

– +
8-27
FUEL INJECTION SYSTEM ELEC

– +
EAS20078
FUEL INJECTION SYSTEM

EAS30504
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
R
5
8
1
MAIN
R R
15A
R
2
R W/R
R R
W B/L
R/W
R R R 24
R
Or Or 26
B/L Y/W L P/W Br/W Y/L P/B Br
R W/R
25 B B
Gy/G B/L
B/L W L
R/W R/W
19 R/W
B
12 P/B P/B Br
14 20 L
P/W
L
P/W
Gy/G Gy/G B/L
15 21 B/L
B/L
B/L
Br/W Br/W
B B OFF
RUN Y/W Y/W
Br 27
B B START
B
B
39 22 Y/R L
B
B B B/W Lg/W
B Br Lg/L
B B/W B G/R
B/W
B/W B
B
23 28
B/L
B/W R R
29 31
G
40 R
ON Ch
OFF 30
Y/G
R B/L
Br Br L
Y
B/W V V Y Y R
36 Lg/L W
R Lg/W
B R
Lg/W B/R 33
35 Lg/L
B/Y
Br V B/W Or/B Or/B R/W
R B
Br Br
R Br
W/Y
R R Br Lg/L B
R Lg/W R/W
B/W B

34
B/W B
Gy
41
R
43
R Br
Y/L
TCS 44 58
R/W R/W R/W
EG_ALARM 45 Br Br Br Br
69
L
W/Y
L Br Br Br Br/L Gy Gy 68 B B B/R B/Y B B B/Y B R/W R/W R/W
Br Br Br Br Gy Gy B B/R B B/W R/W
Or Or
L L 57
B B
W
70
B/W
B G G 71
W B
R R G R
Shield S

8-28

– +
5. Fuse box
8. Main fuse
12.Battery
19.Throttle body sensor assembly
20.Intake air pressure assembly
21.Intake air temperature sensor
22.Throttle position sensor
24.Ignition coil
25.Spark plug
26.O2 sensor
27.FID (Fast idle device)
29.VVA (variable valve actuation) solenoid
31.Fuel pump
33.Fuel injector
coupler
39.Engine ground
40.Main switch
41.Meter assembly
44.Traction control indicator light
45.Engine trouble warning light
58.Radiator fan motor relay
68.Junction 1
69.Junction 2
8-29

– +
EAS30505
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code
number is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
gets “ON” while the main switch is turned on.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation
Operated with substitute
Can or cannot be operat-
characteristics in accor-
Remains on Malfunction detected ed depending on the fault
dance with the descrip-
code
tion of the malfunction
ECU internal malfunction

P0335: Crankshaft position sensor P0601:
(memory check error)
Fuel injector
P0201:
(short circuit)
Checking the engine trouble warning light

The engine trouble warning light comes on for around 2 seconds after the main switch has been set to
“ON” and it comes on while the start switch is being pushed. If the warning light does not come on under
these conditions, the warning light (LED) may be defective.
ECU detects an abnormal signal from a sensor

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
8-30

– +
EAS30506
TROUBLESHOOTING METHOD
TIP
• If any of the following have been performed, reset the A/F control learning data (code No. D87).
- Replace the ECU.
- Replace or clean the throttle body.
- Replace the TPS.
• Reset the A/F control learning data even in the case of poor starting (refer to the flowchart below).
There is no engine operation signal or the engine trouble warning light is lit.
*If there is no engine operation signal, the engine trouble warning light may not be able to light up.
The engine trouble warning light lights up. The engine trouble warning light is not lit.
Check the error code displayed on the FI diag-

In the diagnostic mode, inspect and operate
nostic tool.
the following sensors and actuators. Refer to
“SENSOR AND ACTUATOR OPERATION
Find the system malfunction. TABLE”.
Refer to “SELFDIAGNOSTIC FUNCTION TA- 30: Ignition coil
36: Fuel injector
Find the possible reason for the system malfunction.

Normal
Refer to “DIAGNOSTIC CODE TABLE”. Abnormal
Reset ECU learning data.(Diagnostic code

Inspecting and repairing the possible cause of No.087)
error
Fault code No. No fault code No.
Inspect and repair. Inspect engine situation.

Refer to “TROUBLE- Abnormal Normal
SHOOTING DE- Inspect and repair.
TAILS”. Refer to “SELFDI-
In the diagnostic AGNOSTIC FUNC-
mode, view and op- TION GUIDE”. Faulty sensor or
erate the sensors Engine malfunction.
actuator.
and actuators.
Refer to “SENSOR
AND ACTUATOR
Inspecting and re- Sensors and actua-
pairing internal parts. tors conform to in-
Refer to “ENGINE” in spection and
For ECU reinstallation, refer to recovering initial chapter 5. repair.
status in “TROUBLESHOOTING DETAILS”.
Normal Abnormal Normal
Inspect engine situation.

Turn the main switch to “OFF” and then back to
“ON”. Check if an error code is displayed.
Error code displays.
Normal
There is no error code displayed.
Repair complete.
Erase the malfunction history:

Turning the main switch to “OFF” will not erase the malfunction history.
Erase the malfunction history in the diagnostic mode. Refer to “Operation of the Yamaha diagnostic tool
(Fault diagnosis mode) (Step no. 12)”.
*For when engine trouble warning light is lit.
8-31

– +
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “DIAG-
NOSTIC CODE: SENSOR OPERATION TABLE” on page 8-44 and “DIAGNOSTIC CODE: ACTU-
ATOR OPERATION TABLE” on page 8-46.
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

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.

INS-018
(90890-03267)
INS-019
(90890-03264)
Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth-
ods.
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying mal-
functions and for maintenance to display on the computer. The displayed information includes the sen-
sor output data and information recorded in the ECU.
8-32

– +
Connecting the Yamaha diagnostic tool

• Turn the main switch to off condition.
• Remove the passenger seat. Refer to “GENERAL CHASSIS (1)” on page 4-1.
• Disconnect the Yamaha diagnostic tool coupler/ABS test coupler “1” from CCU (communication con-
trol unit).
• Connect the Yamaha diagnostic tool “2” to the coupler “3”.
Functions of the Yamaha diagnostic tool

Diagnosis of malfunction: Fault codes recorded on the ECU are read, and the contents are dis-
played.
The freeze frame data (FFD) is the operation data when a malfunction
was detected. This data can be used to identify when the malfunction
occurred and check the engine conditions and running conditions
when it occurred.
Diagnosis of function: Check the operation of the output value of each sensor and actuator.
Dynamic inspection: Check the electric component condition automatically.
Maintenance record: Store the inspection history into the Yamaha diagnostic tool applica-
tion.
Recall search: Search the recall campaign information.
Monitoring: Displays a graph of sensor output values for actual operating condi-
tions.
Logging: Records and saves the sensor output value in actual driving condi-
tions.
Writing VIN/frame number: Write the VIN/frame number in the ECU.
View logs: Displays the logging data.
However, the Yamaha diagnostic tool cannot be used to freely change the basic vehicle functions, such
as adjusting the ignition timing.
8-33

– +
Operation of the Yamaha diagnostic tool (Fault diagnosis mode)

Malfunction results are displayed in the top part of the window area.
7 3 8 5 5 2
13 12 11 10 9
1. Detected
The malfunction currently occurred are displayed.
2. Recovered
The malfunction detected in the past (already recovered) are displayed.
3. Diagnosis code the diagnosis codes related to the detected malfunction are displayed.
A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed. (e.g., FI, ABS)
5. Status of malfunction
The current conditions are displayed. (Malfunction/Recover)
6. Item
If a fault code is detected, the symptoms are displayed along with the item name.
7. Trouble list
The item list of the “detected malfunction” or “recover malfunction” are displayed.
8-34

– +
8. Trouble Information
This appears to click on “detected malfunction (1)” for the details of the diagnosis are displayed.
Click [Service Manual/F10] to open the service manual and check the details of the fault.
9. Save
To save the result of diagnosis of malfunction, click [Save/F12].
TIP
Must save the result for future reference.
10.Update
To run the diagnosis of malfunction again, click [Update/F11].
11.Service Manual
To view the service manual, click [Service Manual/F10].
TIP
Service Manual of related model can be downloaded when system is connected with YMC server.
12.Erase all (Only recovered item can be Erased)
To delete all of the fault codes, click [Erase All/F2].
13.Delete selected items (Only recovered item can be Deleted)
To delete the selected fault codes, click [Delete selected items/F1].
NOTICE
Must erase all recovered items to turn off engine trouble warning indicator light.
AS31791
TROUBLESHOOTING DETAILS (FAULT CODE)

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 8-37.
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 • Meter assembly
• Fuel injector • ABS ECU (Hydraulic control unit)
• Fuel pump • Sidestand switch
• Ignition coil • VVA (variable valve actuator) solenoid
• FID (Fast idle device) • Radiator fan motor relay
• Coolant temperature sensor • Coolant temperature sensor
• Throttle body sensor assembly • Gear position switch
• O2 sensor • Lean angle sensor
• Main switch • Front wheel sensor
• Handlebar switch (left and right) • Quick shift switch
• Headlight • CCU (Communication control unit)
8-35

– +
NOTICE
This model is equipped with OBD1 (On Board Diagnostic), due to OBD1 system adoption, en-
gine trouble warning light will glow continuously even the fault has been rectified.
To turn off engine trouble warning light, use YDT (Yamaha diagnostic tool) to erase all fault
codes.
For erase the fault codes follow below steps.
1 2
Connect YDT Ver.3 & After troubleshooting erase
rectify all the errors fault code by YDT ver.3
Diagnosis of Diagnosis of
malfunction malfunction
Select function Trouble List Trouble Information FFD data FFD graph OBD readiness status
ME1RG591BJ0000130 MTN155 : 12 Km Deendayal
ECU 203 Event FFD P1605 Recover FFD

FI Lean angle sensor Lean angle sensor (open or power short
circuit)
ABS
Delete Erase All Service Update Save

selected item s Manual
F3 F4 F9 F10 F11 F12
8-36
SELF-DIAGNOSTIC FUNCTION AND

DIAGNOSTIC CODE TABLE ELEC
– +
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code
Item Symptom Possible cause Remarks
No.
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor: normal sig- between crankshaft started.
nals are not received position sensor and
from the crankshaft ECU.
position sensor. • Open or short cir-
cuit in wire harness
between crankshaft
position sensor and
ECU.
• Improperly installed
crankshaft position
sensor.
• Malfunction in stator
coil assembly.
• Defective crank-
shaft position sen-
sor.
• Malfunction in ECU.
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure dif-
P0108 pressure sensor of the intake air pres- high. ference is fixed to
(open or short to sure sensor circuit Engine idling speed is 0 [kPa].
ground circuit is de- (0.23 V or less) unstable. Load is detected ac-
tected) [P0108] High voltage Engine response is cording to the throttle
[P0108] Intake air of the intake air pres- poor. opening.
pressure sensor sure sensor circuit Loss of engine power. Intake manifold pres-
(short to power circuit (4.86 V or more) Increased exhaust sure is calculated us-
is detected) • Defective coupler emissions. ing the throttle posi-
between throttle tion sensor.
body sensor assem- Transient control ac-
bly and ECU. cording to the intake
• Open or short cir- air pressure is not car-
cuit in wire harness ried 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.
P0106 Intake air pressure • Detached throttle Engine idling speed is Intake air pressure dif-
sensor (clogged hole body sensor assem- high. ference is fixed to
or sensor installation bly. Engine idling speed is 0 [kPa].
improperly) • 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 car-
ried out.
Intake air pressure is
fixed to 101.3 [kPa].
O2 feedback is not
carried out.
8-37

– +
Fault code
No.
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 value is 0
short to ground circuit sensor circuit (0.2 V Engine idling speed is (transient control is
is detected) or less) unstable. not carried out).
[P0123] Throttle posi- [P0123] High voltage Engine response is Throttle opening value
tion sensor (short to of the throttle position poor. is fixed to 15 [°].
power circuit is detect- sensor circuit (4.8 V Loss of engine power. Intake air pressure is
ed. or more) Deceleration is poor. fixed to 101.3 [kPa].
• Defective coupler Increased exhaust Fuel is not cut off due
between throttle emissions. to the throttle opening.
body sensor assem- O2 feedback is not
bly and ECU. carried out.
• Open or short cir-
between throttle
body sensor assem-
bly and ECU.
throttle body sensor
assembly.
• Defective throttle
position sensor.
P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to O2 feedback is not
P0118 perature sensor (short of the coolant temper- start. carried out.
to ground circuit is de- ature sensor circuit Increased exhaust The coolant tempera-
tected) (0.2 V or less) emissions. ture is fixed to 30 [°C]
[P0118] Coolant tem- [P0118] High voltage Engine idling speed is (when key is ON) or
perature sensor (open of the coolant temper- unstable. 80 [°C] (when riding).
or short to power cir- ature sensor circuit
cuit is detected. (4.8 V or more)
• Defective coupler
between coolant
temperature sensor
and ECU.
between coolant
temperature sensor
and ECU.
coolant temperature
sensor.
• Defective coolant
temperature sensor.
8-38

– +
Fault code
No.
P00D1 O2 sensor: heater per- O2 sensor voltage: Increased exhaust O2 feedback is not
formance deteriorat- 0.25 V or less and emissions. carried out.
ed. (normal signal is 0.4 V or more.
not received from the • Open or short cir-
O2 sensor heater cuit in wire harness
while driving the O2 between O2 sensor
sensor.) and ECU.
between O2 sensor
and ECU.
• Disconnected cou-
pler.
O2 sensor.
• Defective O2 sen-
sor.
P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air temper-
P0113 temperature sensor of the intake air tem- start. ature is fixed to 20
(short to ground circuit perature sensor circuit Increased exhaust [°C].
is 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.
(open or short to pow- perature sensor circuit
er circuit is detected) (4.8 V or more)
between throttle
body sensor assem-
bly and ECU.
between throttle
body sensor assem-
bly and ECU.
throttle body sensor
assembly.
• Defective intake air
temperature sensor.
P2195 O2 sensor (open cir- O2 sensor voltage: Increased exhaust O2 feedback is not
cuit is detected) 0.25 V or less and emissions. carried out.
0.4 V or more. O2 feedback learning
• Improperly installed value is not carried
O2 sensor. out.
between O2 sensor
and ECU.
between O2 sensor
and ECU.
sor.
8-39

– +
Fault code
No.
P0351 Ignition system (nor- • Defective coupler Engine stops. When engine is run-
mal signal is not re- between ignition coil Loss of engine power. ning:
ceived from the and ECU. Engine is difficult to Engine is forcefully
ignition circuit) • Open or short cir- start. stopped.
cuit in wire harness Engine cannot be When engine is
between ignition coil started. stopped:
and ECU. Engine cannot be
• Improperly installed started.
ignition coil. Injection is not car-
• Defective ignition ried out.
coil.
P0030 O2 sensor • Short to power cir- (When the O2 sensor If the O2 sensor does
(Defective heater or cuit in wire harness does not operate not operate, O2 feed-
heater driver ON/OFF between O2 sensor because the exhaust back is not carried
command and error and ECU. temperature is low) out.
signal is mismatch- • Defective coupler Increased exhaust
ing.) between O2 sensor emissions.
and ECU. Fuel learning cannot
• Broken or discon- be carried out.
nected lead in O2
sensor heater.
P0201 Fuel injector (normal • Defective coupler Loss of engine power. When engine is run-
signal is not received between fuel injector Engine is difficult to ning:
from the injector cir- and ECU. start. Engine is forcefully
cuit.) • Open or short cir- Engine cannot be stopped.
cuit in wire harness started. When engine is
between fuel injector Engine stops. stopped:
and ECU. Engine cannot be
• Defective fuel injec- started.
tor. Injection is not car-
• Malfunction in ECU. ried out.
fuel injector.
P062F EEPROM fault code • Malfunction in ECU. Increased exhaust O2 feedback learning
number (an error is • O2 feedback learn- emissions. value is initialized.
detected while reading value is not Engine cannot be CO adjustment value
ing or writing on properly written. started or is difficult to is initialized.
EEPROM) • CO adjustment val- start. OBD memory value is
ue is not properly Engine idling speed is initialized.
written. unstable.
• OBD memory value OBD memory value is
is not properly writ- not correct.
ten.
P0500 Front wheel sensor • Open or short cir- Vehicle speed is not O2 feedback is not
(normal signal is not cuit in wire harness displayed on the me- carried out.
received from the between front wheel ter.
front wheel sensor) sensor and ABS Increased exhaust
ECU. emissions.
between ABS ECU
and ECU.
• Defective front
wheel sensor.
8-40

– +
Fault code
No.
P2158 Rear wheel sensor • Open or short cir- TCS (Traction Con- TCS (Traction Con-
(normal signal is not cuit in wire harness trol System) does not trol System) does not
received from the rear between rear wheel work. work.
wheel sensor) sensor and ABS TCS indicator light
unit. comes ON.
• Open or short cir- TCS switch disabled.
cuit in wire harness (TCS switch to mode
between ABS unit OFF.)
and ECU.
• Defective rear wheel
sensor.
P0480 Radiator fan motor re- • Open circuit in wire Engine is difficult to —
lay harness. start.
Open circuit is detect- • Disconnected cou- Loss of engine power.
ed in radiator fan relay pler. Engine overheats.
(normal signal is not • Defective driver. Increased exhaust
received from the ra- • Defective radiator emissions.
diator fan relay) fan motor relay.
• Malfunction in ECU
P0657 Fuel system voltage • Open or short cir- Engine is difficult to Fuel system voltage is
(incorrect voltage sup- cuit in wire harness start. 12 [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 line
for monitoring ECU
voltage.
P0511 FID (Fast Idle De- • Defective coupler Engine is difficult to Power is not supplied
vice) solenoid between FID sole- start. to the FID solenoid.
FID solenoid does not noid and ECU. Engine idling speed is
operate • Open or short cir- unstable.
cuit in wire harness Engine idling speed is
between FID sole- high.
noid and ECU.
• Defective FID sole-
noid.
P0560 Charging voltage is • Battery discharging. Engine is difficult to O2 feedback learning
abnormal (dis- • Battery discharging start. is not carried out.
charged condition) (broken or discon- Increased exhaust
nected lead in rectifi- emissions.
er/regulator system). Battery performance
has deteriorated or
battery is defective.
P0563 Charging voltage is • Battery overcharg- Engine is difficult to O2 feedback learning
abnormal. (Over- ing. start. is not carried out.
charged condition) • Battery overcharg- Increased exhaust
ing (broken or dis- emissions.
connected lead in Battery performance
rectifier/regulator has deteriorated or
system). battery is defective.
8-41

– +
Fault code
No.
P1601 Sidestand switch • Defective coupler Engine cannot be Engine is forcefully
Open or short circuit between sidestand started. stopped (Ignition and
in wire of the ECU is switch and ECU. injector output are
detected. (normal sig- • Open or short cir- stopped.)
nal is not received cuit in wire harness
from the sidestand between sidestand
switch) switch and ECU.
• Defective sidestand
switch.
P0601 Internal malfunction in • Malfunction in ECU. Engine cannot be Ignition and injection
ECU. (When this mal- started. are not carried out.
function is detected in Judgment for other
the ECU, the fault fault codes are not
code might not appear carried out.
on the tool display.) Writing to EEPROM is
not carried out.
P0132 O2 sensor (short to [P0132] High voltage Increased exhaust O2 feedback is not
power circuit is de- of the O2 sensor cir- emissions. carried out.
tected) cuit (4.8 V or more)
O2 sensor.
between O2 sensor
and ECU.
• Short to power cir-
between O2 sensor
and ECU.
sor.
P2645 VVA solenoid mal- • Defective coupler Decreased engine Fixed to the low
function (normal sig- between VVA sole- torque in the high speed cam position.
nal is not received noid and ECU. speed range. Upper limit for the en-
from the VVA solenoid • Open or short cir- gine speed is de-
circuit while driving cuit in wire harness creased.
the VVA solenoid) between VVA sole-
noid and ECU.
• Open circuit in VVA
solenoid.
P1602 Malfunction in ECU in- • Improperly connect- Engine idling speed is —
ternal circuit (normal ed battery lead. high.
backup voltage is not • Defective coupler Engine idling speed is
supplied to the ECU) between main unstable.
switch and ECU. Increased exhaust
• Open circuit in wire emissions.
harness between Engine is difficult to
main switch and start.
ECU.
8-42

– +
Fault code
No.
P1604 [P1604] Lean angle [P1604] Low voltage Engine cannot be When engine is run-
P1605 sensor (short to of the lean angle sen- started. ning: Engine is force-
ground circuit is de- sor circuit (0.2 V or Engine stops. fully stopped.
tected) less) When engine is
[P1605] Lean angle [P1605] High voltage stopped: Engine can-
sensor (short to power of the lean angle sen- not be started.
circuit is detected) sor circuit (4.8 V or
more)
between lean angle
sensor and ECU.
between lean angle
sensor and ECU.
• Defective lean an-
gle sensor.
8-43

– +
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor sig- 0–125
nal
• Fully closed position 13–21 Check the fully closed throt-
tle valve.
• Fully opened position 92–107 Check the fully opened throt-
tle valve.
03 Intake air pressure Displays the intake air pres- Check the intake air pressure
sure. when cranking the engine. (If
When engine is stopped: At- the displaying value chang-
mospheric pressure at the es, the performance is OK.)
current altitude and weather
conditions is indicated.
At sea level: Approx. 101
kPa
3000 m above sea level: Ap-
prox. 70 kPa
05 Intake air temperature Displays the intake air tem- Compare the actually mea-
perature. sured air temperature with
-30–120 [°C] the tool displayed value.
When engine is cold: Dis-
plays temperature closer to
air temperature
When engine is hot: Air tem-
perature + approx. 20 [°C]
06 Coolant temperature Displays the coolant temper- Compare the actually mea-
ature. sured coolant temperature
-30–120 [°C] with the tool displayed value.
When engine is cold: Dis-
plays temperature closer to
air temperature.
When engine is hot: Displays
current coolant temperature.
07 Vehicle 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-
voltage sor and incline it more than
50 degrees.
• Upright 0.4–1.4 [V]
• Overturned 3.7–4.4 [V]
09 Fuel system voltage Displays the fuel system volt- Compare the actually mea-
(battery voltage) age. sured battery voltage with
0–18.7 [V] the tool displayed value. (If
Standard voltage: the actually measured bat-
Approximately 12.0 [V] tery voltage is low, recharge
the battery.)
20 Sidestand switch Check the sidestand switch
condition.
• Stand retracted Indicated ON
• Stand extended Indicated OFF
8-44

– +
Diagnostic
Item Tool display Procedure
code No.
21 Neutral switch & Clutch Neutral: Indicated ON Check the neutral switch &
switch Squeeze the clutch lever and clutch switch condition.
put in gear with sidestand re-
tracted: Indicated ON
Release the clutch lever and
put in gear: Indicated OFF
Squeeze the clutch lever and
put in gear with sidestand ex-
tended: Indicated OFF
60 EEPROM fault code display —
• Defective EEPROM fault 00
code is indicated. • No malfunctions detected
(If the self-diagnosis fault
code P062F is indicated,
the ECU is defective.)
• Multiple fault codes are in- 01 (CO adjustment value) —
dicated 2-second interval. 12 (O2 feedback learning val-
Display the EEPROM writ- ue)
ing error for fault code No.
P062F.
If more than one item is de-
fective, the displays alter-
nates every two seconds to
show all the detected num-
bers.
70 Programmed unit ver. num- 0–254 [-] —
ber
86 Quick shift switch When operating the shift Check the quick shift switch
pedal to shift up : Indicated condition.
ON
When the shift pedal is not
operated : Indicated OFF
87 O2 feedback learning data 00 To erase the O2 feedback
erasure O2 feedback learning data learning data, click the
has been erased. Yamaha diagnostic tool
01 “Actuator Check” button
O2 feedback learning data three times within 5 seconds.
has not been erased.
8-45

– +
EAS32426
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil five Check the energization of
times at one-second inter- the ignition coil.
vals. Check the sparking perfor-
The “CHECK” indicator “ ” mance on the spark plug.
on the YDT screen comes on
each time the ignition coil is
actuated.
36 Fuel injector Actuates the fuel injector five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that the injector is ac-
The “CHECK” indicator “ ” tuated five times by listening
on the YDT screen comes on for the operating sound.
each time the fuel injector is
actuated.
45 VVA solenoid Actuates the VVA solenoid Check that the VVA solenoid
five times at five-second in- is operated five times.
tervals.
The “CHECK” indicator “ ”
each time the VVA solenoid
is actuated.
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
seconds intervals. times by listening for the op-
The “check” indicator on the erating sound.
YDT screen comes on each
time the relay is actuated.
52 Headlight Actuates the headlight five Check that the headlight
times at five-second inter- comes on five times.
vals.
each time the headlight is
actuated.
54 FID (Fast Idle Device) sole- Fully closes the FID solenoid Check that the FID solenoid
noid valve, and then opens the is actuated five times by lis-
valve to the standby opening tening for operating sound.
position.
Actuates the FID solenoid
five times at one-second in-
tervals.
during the operation.
8-46
FUEL INJECTION SYSTEM TROUBLESHOOTING ELEC

– +
FUEL INJECTION SYSTEM TROUBLESHOOTING

EAS33149
FAULT CODE TABLE

Fail-safe system
Fault code Diagnostic
Symptom Starting the Driving the
no. code
engine vehicle
O2 sensor heater: defective heater or heater
“P0030” driver ON / OFF command and error signal is Able Able —
mismatching.
• [P00D1] O2 sensor: heater performance de-
“P00D1, teriorated. Normal signal is not received from
the O2 sensor while driving the O2 sensor. Able Able —
P2195”
• [P2195] O2 sensor: open circuit is detected.
• [P0106] Intake air pressure sensor : clogging
of hole or senser installation improperly.
• [P0107] Intake air pressure sensor : open or
“P0106,
short to ground circuit is detected.
P0107, Able Able 03
• [P0108] Intake air pressure sensor : short to
P0108”
power circuit is detected.
• Normal signal is not received from the intake
air pressure sensor.
• [P0112] Intake air temperature sensor: short
“P0112, to ground circuit is detected.
Able Able 05
P0113” • [P0113] Intake air temperature sensor: open
or short to power circuit is detected.
• [P0117] Coolant temperature sensor: short
“P0117, to ground circuit is detected.
Able Able 06
P0118” • [P0118] Coolant temperature sensor: open
or short to power circuit is detected.
• [P0122] Throttle position sensor: open or
“P0122, short to ground circuit is detected.
Able Able 01
P0123” • [P0123] Throttle position sensor: short to
O2 sensor: short to power circuit is detected.
“P0132” Normal signal is not received from the O2 sen- Able Able —
sor.
“P0201” Fuel injector: malfunction in fuel injector. Unable Unable 36
Crankshaft position sensor: normal signal is
“P0335” not received from the crankshaft position sen- Unable Unable —
sor.
Ignition coil: normal signal is not received from
“P0351” Unable Unable 30
the ignition circuit.
Normal signal is not received from the radiator
“P0480” Able Able 51
fan motor relay.
Front wheel sensor: normal signal is not re-
ceived from the front wheel sensor.
FID solenoid valve malfunction is detected.
“P0511” (Open or short circuit is detected between FID Able Able 54
solenoid valve and ECU.)
• [P0560] Battery charging voltage is abnor-
“P0560, mal. (Discharged condition)
Able Able —
P0563” • [P0563] Battery charging voltage is abnor-
mal. (Overcharged condition)
8-47

– +
Fail-safe system
no. code
engine vehicle
Internal malfunction in ECU. (When this mal-
“P0601” function is detected in the ECU, the fault code Unable Unable —
might not appear on the tool display.)
EEPROM fault code: an error is detected
“P062F” Able Able 60
while reading or writing on EEPROM.
Normal signal is not received from the sides-
“P1601” Unable Unable 20
tand switch.
Fuel system voltage: normal voltage is not
supplied to the fuel injector and fuel pump.
Malfunction in ECU internal circuit (malfunc-
tion of ECU power cut-off function).
“P1602” Able Able —
Normal backup power is not supplied to the
ECU.
[P1604] Lean angle sensor : short to ground
“P1604, circuit is detected.
Unable Unable 08
P1605” [P1605] Lean angle sensor : open or short to
Normal signal is not received from the rear
“P2158” Able Able —
wheel sensor.
Normal signal is not received from the VVA
solenoid circuit while driving the VVA solenoid.
COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL

Fail-safe system
no. code
engine vehicle
Meter communication error due to ECU inter-
Er-1 Able Able —
nal malfunction (Output signal error)
Er-2 Able Able —
Er-3 Able Able —
Er-4 Able Able —
nal malfunction (Input signal error)
8-48

– +
COMMUNICATION ERROR WITH THE METER

Fault code Probable cause of Fail-safe system
Item Vehicle symptom
no. malfunction operation
ECU internal • Open or short circuit Signals cannot be Normally operated
malfunction (Output in wire harness be- transmitted between except for the meter.
signal error) tween meter and the ECU and the
ECU. meter.
• Defective coupler Meter operation is
Er-1
between meter and impossible.
ECU.
• Defective meter
unit.
ECU internal • Open or short circuit Signals are not Normally operated
malfunction (Output in wire harness be- received from the except for the meter.
signal error) tween meter and ECU within the
ECU. specified duration.
• Defective coupler Meter operation is
Er-2
between meter and impossible.
ECU.
• Defective meter
unit.
ECU internal • Open or short circuit Sending data from Normally operated
malfunction (Output in wire harness be- the ECU cannot be except for the meter.
signal error) tween meter and received correctly.
ECU. Meter operation is
• Defective coupler impossible.
Er-3
between meter and
ECU.
• Defective meter
unit.
ECU internal • Open or short circuit Registered data is Normally operated
malfunction (Input in wire harness be- not received from the except for the meter.
signal error) tween meter and meter.
ECU. Meter operation is
• Defective coupler impossible.
Er-4
between meter and
ECU.
• Defective meter
unit.
8-49

– +
FUEL INJECTION SYSTEM TROUBLESHOOTING

Fault code No. P0106
NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
TIP
If fault code numbers “P0107/P0108” and “P0106” are indicated at the same time, perform the check/
service for fault code number “P0107/P0108” first.
Intake air pressure sensor: clogged hole or sensor installation im-

Item
properly.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Operate the throttle while pushing the start switch “ ”. (If the display val-
Procedure
ue changes, the performance is OK.)
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Installed condition of throttle Improperly installed sensor → Start the engine and let it idle for
body sensor assembly. Reinstall the throttle body as- approximately 5 seconds.
Check for detached or pinching. sembly. Check the fault code using the
malfunction mode of the
YDT.
Condition is “Recover” → Go to
item 3 and finish the service.
Condition is “Malfunction” → Go
to item 2.
2 Defective intake air pressure Execute the diagnostic mode. Go to item 3 and finish the
sensor. (Code No. 03) service.
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) 3.98
volt 1000 m (3300 ft) above sea
level: Approx. 90 kPa (675.1
mmHg, 26.6 inHg) 3.55 volt
2000 m (6700 ft) above sea lev-
el: Approx. 80 kPa (600.0
When engine is cranking: Make
sure that the indication value
changes.
The value does not change when
engine is cranking. → Replace
the throttle body assembly.
8-50

– +
Intake air pressure sensor: clogged hole or sensor installation im-

Item
properly.
3 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of “Recovered” us-
light goes off. ing the Yamaha diagnostic tool,
and then delete the fault code.
Fault code No. P0107, P0108
NOTICE
TIP
If fault code numbers “P0107/P0108” and “P0106” are indicated at the same time, perform the check/
service for fault code number “P0107/P0108” first.
[P0107] Intake air pressure sensor: open or short to ground circuit is

Item detected.
[P0108] Intake air pressure sensor: short to power circuit is detected.
Fail-safe system
Tool display Displays the intake air pressure.
Check the intake air pressure when cranking engine. (If the displaying
Procedure
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 fault code
Check the locking condition of place the wire harness. using the malfunction mode of
the coupler. the YDT.
Disconnect the coupler and Condition is “Recover” → Go to
check the pins (bent or broken item 7 and finish the service.
terminals and locking condition Condition is “Malfunction” → Go
of the pins). 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 fault code
the coupler. place the wire harness. using the malfunction mode of
Disconnect the coupler and the YDT.
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 3.
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”,
the wire harness. and then check the fault code
using the malfunction mode of
the YDT.
to item 4.
8-51

– +

Item detected.
3-1
3
1
L
4 L
Y/W Y/W
5
2 P/W P/W
Br/W Br/W
B/L B/L
6
1. Throttle body sensor assembly

2. Intake air pressure sensor
3. ECU
4. Sensor power supply 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 assembly.
3-3 [For P0107] Ground short circuit
Between intake air pressure sensor coupler and ground: pink/white–ground
If there is continuity, replace the wire harness.
Y/W
3-4 [For P0107] Open circuit

Between intake air pressure sensor coupler and ECU coupler: blue–blue
If there is no continuity, replace the wire harness.
Y/W G Br R Lg/L W Y/R G/R Y/G Y/L B/L L B
8-52

– +

Item detected.
Between intake air pressure sensor coupler and ECU coupler: pink/white–pink/white

Between intake air pressure sensor coupler and ECU coupler: black/blue–black/blue
3-7 Disconnect the couplers from the parts that are connected to the ECU.
3-8 [For P0108] Short circuit
Between intake air pressure sensor output terminal (pink/white) “a” of ECU coupler and any other
ECU coupler terminal “b”.
8-53

– +

Item detected.
4 Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”,
body sensor assembly. ing. and then check the fault code
Improperly installed sensor → using the malfunction mode of
Reinstall. the YDT.
to item 5.
5 Defective intake air pressure Execute the diagnostic mode. Crank the engine, and then
sensor. (Code No. 03) check the fault code using the
When engine is stopped: malfunction mode of the
Atmospheric pressure at the YDT.
current altitude and weather Condition is “Recover” → Go to
conditions is indicated. item 7 and finish the service.
At sea level: Approx. 101 kPa Condition is “Malfunction” → Go
(757.6 mmHg, 29.8 inHg) 3.98V to item 6.
mmHg, 26.6 inHg) 3.55V
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 assem-
bly.
6 Malfunction in ECU. Replace the ECU. Service is finished.
that the engine trouble warning a condition of “Recover” using
light goes off. the YDT, and then delete the
fault code.
8-54

– +
NOTICE
TIP
Perform this procedure when the engine is cold.
[P0112] Intake air temperature sensor: short to ground circuit is de-

tected.
Item
[P0113] Intake air temperature sensor: open or short to power circuit
is detected.
Fail-safe system
Tool display Displays the intake air temperature.
Compare the actually measured air temperature with the tool display val-
Procedure
ue.
sor assembly. 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 YDT.
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 YDT.
to item 3.
the wire harness. and then check the condition of
the fault code using the mal-
function mode of the YDT.
to item 4.
8-55

– +

tected.
Item
is detected.
3-1
3
1. Throttle body sensor assembly 1
2. Intake air temperature sensor L L
3. ECU Y/W Y/W

5. Sensor ground lead P/W P/W
2 4
Br/W Br/W
B/L B/L
5

Disconnect the throttle body sensor assembly sensor coupler from the throttle body.
Between intake air temperature sensor coupler and ground: brown/white–ground
B/L Y/W L P/W Br/W

Between intake air temperature sensor coupler and ECU coupler: brown/white–brown/white
8-56

– +

tected.
Item
is detected.
Between intake air temperature sensor coupler and ECU coupler: black/blue–black/blue
Between intake air temperature sensor output terminal (brown/white) “a” of ECU coupler and any
other ECU coupler terminal “b”.
Reinstall. the YDT.
to item 5.
5 Defective intake air temperature Execute the diagnostic mode. Turn the main switch to “ON”,
sensor. (Code No. 05) and then check the fault code
When engine is cold: using the malfunction mode of
Displayed temperature is close the YDT.
to the ambient temperature. Condition is “Recover” → Go to
The displayed temperature is item 7 and finish the service.
not close to the ambient temper- Condition is “Malfunction” → Go
ature. → Replace the throttle to item 6.
body assembly.
8-57

– +

tected.
Item
is detected.
fault code.
TIP
Perform this procedure when the engine is cold.
[P0117] Coolant temperature sensor: short to ground circuit is de-

tected.
Item
[P0118] Coolant temperature sensor: open or short to power circuit
is detected.
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 fault code
to item 3.
the YDT.
to item 4.
8-58

– +

tected.
Item
is detected.
3-1
2
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

Between coolant temperature sensor coupler and ECU coupler: green/red–green/red
8-59

– +

tected.
Item
is detected.
Between coolant temperature sensor coupler and ECU coupler: black/blue–black/blue
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 fault code
Reinstall or replace the sensor. the YDT.
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 fault code
When engine is cold: Displayed using the malfunction mode of
temperature is close to the am- the YDT.
bient temperature. The dis- Condition is “Recover” → Go to
played temperature is not close item 7 and finish the service.
to the ambient temperature → Condition is “Malfunction” → Go
Replace the coolant tempera- to item 6.
ture sensor.
8-60

– +

tected.
Item
is detected.
fault code.
NOTICE
[P0122] Throttle position sensor: open or short to ground circuit is

Item detected.
[P0123] Throttle position sensor: short to power circuit is detected.
Fail-safe system
Throttle position sensor signal
Tool display • 13–21 (fully closed position)
• 92–107 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
sor assembly coupler. nect the coupler securely or re- and then check the fault code
to item 3.
the YDT.
to item 4.
8-61

– +

Item detected.
3-1
3
1
L
4 L
2 Y/W Y/W
5
P/W P/W
Br/W Br/W
B/L B/L
6
1. Throttle body position sensor assembly

2. Throttle position sensor
3. ECU
Disconnect the throttle body sensor assembly coupler from the throttle body.
Between throttle position sensor coupler and ground: yellow/white–ground
B/L Y/W L P/W Br/W

Between throttle position sensor coupler and ECU coupler: blue–blue
8-62

– +

Item detected.
Between throttle position sensor coupler and ECU coupler: yellow/white–yellow/white

Between throttle position sensor coupler and ECU coupler: black/blue–black/blue
Between throttle position sensor output terminal (yellow/white) “a” of ECU coupler and any other
ECU coupler terminal “b”
8-63

– +

Item detected.
Reinstall. the YDT.
to item 5.
5 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ON”,
sor. signal. and then check the fault code
Execute the diagnostic mode. using the malfunction mode of
(Code No. 01) the YDT.
When the throttle valves are ful- Condition is “Recover” → Go to
ly closed: item 7 and finish the service.
A value of 13-21 is indicated. Condition is “Malfunction” → Go
When throttle valves are fully to item 6.
open:
A value of 92-107 is indicated.
An indicated value is out of the
specified range → Replace the
throttle body.
fault code.
8-64

– +

O2 sensor: defective heater or heater driver ON/OFF command and

Item
error signal is mismatching.
Fail-safe system
Diagnostic code No. —
Tool display —
Procedure —
1 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 fault code
terminals and locking condition Condition is “Malfunction” →
of the pins). Start the engine, and then
check the fault code.
to item 2.
TIP
For this check, also set the
engine stop/start switch to “ON”.
of the pins). Condition is “Malfunction” →
Start the engine, and then
to item 3.
TIP
8-65

– +
O2 sensor: defective heater or heater driver ON/OFF command and

Item
error signal is mismatching.
3 Wire harness continuity. Open or short circuit → Properly Turn the main switch to “ON”,
connect or replace the wire har- and then check the fault code
ness. using the malfunction mode of
Between ECU coupler and O2 the YDT.
sensor coupler. Condition is “Recover” → Go to
pink/black–pink/black
Condition is “Malfunction” →
Between O2 sensor coupler and
joint coupler #1. check the fault code.
brown–brown Condition is “Recover” → Go to
Between joint coupler #1 and item 6 and finish the service.
main switch coupler. Condition is “Malfunction” → Go
brown–brown to item 4.
Between main switch and main TIP
fuse. For this check, also set the
red–red engine stop/start switch to “ON”.
Between main fuse and battery
terminal.
red-red
4 Defective O2 sensor heater. Replace the O2 sensor. Turn the main switch to “ON”,
and then check the fault code
the YDT.
to item 5.
TIP

6 Delete the fault code and check Confirm that the fault code has —
fault code.
8-66

– +


Item
Normal signal is not received from the O2 sensor.

Fail-safe system
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 fault code
Reinstall or replace the sensor. the YDT.
to item 2.
2 Connection of O2 sensor cou- Improperly connected → Con- Turn the main switch to “ON”,
to item 4.
4 Wire harness continuity. Short circuit in lines → Properly Turn the main switch to “ON”,
connect or replace the wire har- and then check the fault code
ness. using the malfunction mode of
Between O2 sensor coupler and the YDT.
ECU coupler. Condition is “Recover” → Go to
gray/green–any other ECU cou- item 7 and finish the service.
pler terminals Condition is “Malfunction” → Go
to item 5.
5 Defective O2 sensor. Check the O2 sensor. Turn the main switch to “ON”,
Defective → Replace the O2 and then check the fault code
sensor. using the malfunction mode of
the YDT.
to item 6.
6 Malfunction in ECU. Replace the ECU.
8-67

– +

Item
Normal signal is not received from the O2 sensor.
fault code.

Item Fuel injector: malfunction in fuel injector.

Unable to start engine
Fail-safe system
Unable to drive vehicle
Actuates fuel injector five times at one-second intervals.
Tool display The “check” indicator on the YDT screen comes on each time the fuel in-
jector is actuated.
Disconnect the fuel pump coupler. The fuel injector is actuated five times
Procedure
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 re- Execute the diagnostic mode.
sistance. (Approx.12 Ω). (Code No. 36)
Replace the fuel injector, if Operating sound → Go to item
out of specification. 6.
No operating sound → Go to
item 3.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 36)
the coupler. place the wire harness. Operating sound → Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound → Go to
terminals and locking condition item 4.
of the pins).
8-68

– +
Item Fuel injector: malfunction in fuel injector.

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 right handlebar switch cou-
pler.
red/white-red/white
Between right handlebar switch
coupler and main switch cou-
pler.
brown-brown
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
YDT, and then delete the fault
code.

Crankshaft position sensor: normal signals are not received from

Item
the 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 fault code using the
Check the locking condition of place the wire harness. malfunction mode of the YDT.
the coupler. Condition is “Recover” → Go to
Disconnect the coupler and item 7 and finish the service.
check the pins (bent or broken Condition is “Malfunction” → Go
terminals and locking condition to item 2.
of the pins).
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 fault code using the
the coupler. place the wire harness. malfunction mode of the YDT.
8-69

– +
Crankshaft position sensor: normal signals are not received from

Item
the crankshaft position sensor.
3 Wire harness continuity. Open or short circuit → Replace Crank the engine, and then
the wire harness. check the fault code using the
Between crankshaft position malfunction mode of the YDT.
sensor coupler and ECU cou- Condition is “Recover” → Go to
pler. item 7 and finish the service.
black/blue–black/blue Condition is “Malfunction” → Go
white/red–white/red to item 4.
4 Installed condition of crankshaft Improperly installed sensor → Crank the engine, and then
position sensor. Reinstall or replace the sen- check the fault code using the
Check for looseness or pinch- sor. malfunction mode of the YDT.
ing. Condition is “Recover” → Go to
Inspect the specified clearance item 7 and finish the service.
(0.85mm) between the sensor Condition is “Malfunction” → Go
and sensor rotor. to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine, and then
sensor. sensor. check the fault code using the
Replace the sensor, if it is de- malfunction mode of the YDT.
fective. Condition is “Recover” → Go to
to item 6.
fault code.
8-70

– +

Ignition coil: open or short circuit is detected in the lead of the igni-
Item
tion coil.
Fail-safe system
Actuates the ignition coil five times at one-second intervals.
Tool display The check indicator on the YDT 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 fault code using the
the coupler. malfunction mode of the YDT.
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 fault code using the
Disconnect the coupler and malfunction mode of the YDT.
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 fault code using the
and ECU coupler. malfunction mode of the YDT.
orange–orange Condition is “Recover” → Go to
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 fault code using the
→ Reinstall or replace the igni- malfunction mode of the YDT.
tion coil. Condition is “Recover” → Go to
to item 5.
8-71

– +
Ignition coil: open or short circuit is detected in the lead of the igni-
Item
tion coil.
5 Defective ignition coil. Measure the primary coil resis- Start the engine and let it idle for
tance of the ignition coil (2.2– approximately 5 seconds.
2.6 Ω). Check the fault code using the
Replace the ignition coil, if out of malfunction mode of the YDT.
specification. Condition is “Recover” → Go to
to item 6.
6 Malfunction in ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark → Replace the ECU.
fault code.

Item Normal signal is not received from the radiator fan motor relay.
Fail-safe system
Actuates the radiator fan motor relay five times at five-second intervals.
Tool display The check indicator on the YDT screen come on each time the radiator
fan motor relay is actuated.
Check that the radiator fan motor relay is actuated five times by listening
Procedure
for the operating sound.
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
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the YDT.
the coupler. place the wire harness. the fault code using the mal-
Disconnect the coupler and function mode of the YDT.
to item 3.
8-72

– +
Item Normal signal is not received from the radiator fan motor relay.
Between ECU coupler and radi- the fault code using the mal-
ator fan motor relay coupler. function mode of the YDT.
white/yellow–white/yellow Condition is “Recover” → Go to
Between radiator fan motor re- item 6 and finish the service.
lay coupler and main switch Condition is “Malfunction” → Go
coupler. to item 4.
brown–brown
Between main switch coupler
and main fuse.
red–red
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
Replace if defective. the fault code using the mal-
function mode of the YDT.
to item 5.
fault code.

Front wheel sensor: normal signals are not received from the front
Item
wheel sensor.
Fail-safe system
Vehicle 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 front 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 the condition of the
Disconnect the coupler and fault code using the malfunction
check the pins (bent or broken mode of the YDT.
terminals and locking condition Condition is “Recover” → Go to
of the pins). item 8 and finish the service.
to item 2.
8-73

– +
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 the condition of the
Disconnect the coupler and fault code using the malfunction
to item 3.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 07)
the coupler. place the wire harness. Rotate the front wheel by hand
Disconnect the coupler and and check the condition of the
check the pins (bent or broken fault code using the malfunction
terminals and locking condition mode of the YDT.
of the pins). Condition is “Recover” → Go to
to item 4.
4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 07)
Between front wheel sensor Rotate the front wheel by hand
coupler and ABS ECU coupler. and check the condition of the
red–red fault code using the malfunction
green–green mode of the YDT.
Between ABS ECU coupler and Condition is “Recover” → Go to
ECU coupler. item 8 and finish the service.
white–white Condition is “Malfunction” → Go
to item 5.
5 Defective front wheel sensor. Installed condition of front wheel Execute the diagnostic mode.
sensor. (Code No. 07)
Improperly installed front wheel Rotate the front wheel by hand
sensor → Reinstall or replace and check the condition of the
the front wheel sensor. Execute fault code using the malfunction
the diagnostic mode. (Code No. mode of the YDT.
07) Condition is “Recover” → Go to
Front wheel stopped: Check item 8 and finish the service.
that the cumulative pulse value Condition is “Malfunction” → Go
does not increase. to item 6.
Front wheel is rotated several
turns by hand: Check that the
cumulative pulse value increas-
es.
Incorrect → Replace the front
wheel sensor.
8-74

– +
Item
wheel sensor.
6 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
(Code No. 07)
Rotate the front wheel by hand
and check the condition of the
fault code using the malfunction
mode of the YDT.
to item 7.
7 Malfunction in ABS ECU. Replace the ABS ECU. Go to item 8 and delete the fault
code.
fault code.

FID solenoid valve malfunction is detected. (Open or short circuit is

Item
detected between FID solenoid valve and ECU.)
Fail-safe system
Actuates the FID solenoid five times at one-second intervals. The check
Tool display indicator on the YDT screen comes on each time the FID solenoid is ac-
tuated.
Check that the FID solenoid is actuated five times by listening for the op-
Procedure
erating sound.
1 Connection of FID solenoid cou- Improperly connected → Con- Turn the main switch to “ON”,
to item 3.
8-75

– +
FID solenoid valve malfunction is detected. (Open or short circuit is

Item
detected between FID solenoid valve and ECU.)
Between FID solenoid coupler using the malfunction mode of
and ECU coupler. the YDT.
yellow/red–yellow/red Condition is “Recover” → Go to
Between FID solenoid coupler item 6 and finish the service.
and main switch coupler. Condition is “Malfunction” → Go
brown–brown to item 4.
and main fuse.
red–red
Between main fuse and battery
terminal.
red–red
4 Faulty FID solenoid operation. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 54) and then check the fault code
FID solenoid operation sound is using the malfunction mode of
not heard. → Replace the FID the YDT.
solenoid. Condition is “Recover” → Go to
to item 5.
fault code.

[P0560] Battery charging voltage is abnormal. (Discharged condi-

tion)
Item
[P0563] Battery charging voltage is abnormal. (Overcharged condi-
tion)
Fail-safe system
Tool display —
Procedure —
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle for
Defective rectifier/regulator or approximately 5 seconds.
stator coil, check the around Check the fault code using the
wire harness → Replace the de- malfunction mode of the YDT.
fective parts. Condition is “Recover” → Go to
Defective connection in the item 2 and finish the service.
charging system circuit → Prop- Condition is “Malfunction” →
erly connect or replace the wire Repeat item 1.
harness.
8-76

– +
[P0560] Battery charging voltage is abnormal. (Discharged condi-

tion)
Item
[P0563] Battery charging voltage is abnormal. (Overcharged condi-
tion)
fault code.

Internal malfunction in ECU. (When this malfunction is detected in

Item the ECU, the fault code number might not appear on the tool dis-
play.)
Fail-safe system
Tool display —
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ON”.
Check that the engine trouble
warning light does not come on.
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-
Tool display cated, the ECU is defective.)
01 (CO adjustment value)
12 (O2 feedback learning value)
Procedure —
1 Locate the malfunction. Execute the diagnostic mode.
(Code No. 60)
00: Go to item 4.
01: Go to item 2.
12: Go to item 3.
8-77

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

Item
writing on EEPROM.
2 “01” is indicated in the diagnos- Activate the CO volume adjust- Turn the main switch to “ON”,
tic mode (Code No. 60). ment mode using the YDT. and then check the fault code
EEPROM data error for adjust- Click the “Step up” or “Step using the malfunction mode of
ment of CO concentration. down” button 1 time. (Clicking the YDT.
the “Step up” or “Step down” Condition is “Recover” → Go to
button during this procedure item 5 and finish the service.
does not change the CO vol- Condition is “Malfunction” →
ume.) Repeat item 1.
Then, turn the main switch to If the same number is indicated,
“OFF”. go to item 4.
For more information, refer to
the operation manual of the
YDT.
3 “12” is indicated in the diagnos- Turn the main switch to “OFF”. Turn the main switch to “ON”,
tic mode (Code No. 60). and then check the fault code
EEPROM data error for O2 using the malfunction mode of
feedback learning values. the YDT.
Repeat item 1.
If the same number is indicated,
go to item 4.
fault code.
8-78

– +

Fuel system voltage: normal voltage is not supplied to the fuel injec-
Item
tor and fuel pump.
Fail-safe system
Fuel system voltage (battery voltage)
Tool display
Approximately 12.0
Compare the actually measured battery voltage with the tool displayed
Procedure value.
(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 fuse box and fuel Check the fault code using the
pump coupler. malfunction mode of the YDT.
red–red Condition is “Recover” → Go to
Between ECU coupler and right item 4 and finish the service.
handlebar switch coupler. Condition is “Malfunction” → Go
red/white–red/white to item 3.
Between right handlebar switch
coupler and main switch cou-
pler.
brown–brown
and fuse box.
red–red
Between fuse box and battery
terminal.
red–red
fault code.
8-79

– +

Item Sidestand switch: open or short circuit is 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- extend and retract the sides-
Check the locking condition of place the wire harness. tand. And then check the fault
the coupler. code using the malfunction
Disconnect the coupler and mode of the YDT.
to item 2.
Check the locking condition of nect the coupler securely or re- extend and retract the sides-
the coupler. place the wire harness. tand. And then check the fault
Disconnect the coupler and code using the malfunction
to item 3.
3 Wire harness continuity. Open or short circuit → Properly Turn the main switch to “ON”,
connect or replace the wire har- extend and retract the sides-
ness. tand. And then check the fault
Between ECU coupler and Sid- code using the malfunction
estand switch coupler. mode of the YDT.
blue/green–blue/green Condition is “Recover” → Go to
Between Sidestand switch cou- item 6 and finish the service.
pler and ground. Condition is “Malfunction” → Go
blue/black–black to item 4.
4 Defective Sidestand switch. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 20) extend and retract the sides-
Sidestand retracted: “ON” tand. And then check the fault
Sidestand extended: “OFF” code using the malfunction
Replace if defective. mode of the YDT.
to item 5.
6 Delete the fault code and check Confirm that the fault code has -
fault code.
8-80

– +

Malfunction in ECU internal circuit (malfunction of ECU power cut-

Item
off function).
Fail-safe system
Tool display —
Procedure —
1 Ability to start engine using Turn the main switch to “ON”, Engine could not be started →
starter motor. crank the engine, and then turn Go to item 2.
the main switch to “OFF”. Per- Engine could be started → Turn
form this procedure 2 times. the main switch to “ON”, and
then check the fault code using
YDT.
to item 2.
2 Discharged battery. Charge the battery. Engine could not be started →
Battery could be charged → Re- Go to item 3.
peat item 1. Engine could be started → Turn
Battery could not be charged → the main switch to “ON”, and
Replace the battery. then check the fault code using
YDT.
to item 3.
3 Installed condition of battery Check the installed condition of Turn the main switch to “ON”,
leads. the battery and battery leads crank the engine, and then turn
(loose bolts). the main switch to “OFF”.
Improperly installed battery or Perform this procedure 2 times,
battery leads → Reinstall or re- and then check the fault code
place the battery leads. using the malfunction mode of
the YDT.
to item 4.
the wire harness. crank the engine, and then turn
Between ECU coupler and main the main switch to “OFF”.
fuse. Perform this procedure 2 times,
red–red and then check the fault code
Between main fuse and battery using the malfunction mode of
terminal. the YDT.
red–red Condition is “Recover” → Go to
to item 5.
8-81

– +
Malfunction in ECU internal circuit (malfunction of ECU power cut-

Item
off function).
Check the locking condition of nect the coupler securely or re- crank the engine, and then turn
the coupler. place the wire harness. the main switch to “OFF”.
Disconnect the coupler and Perform this procedure 2 times,
check the pins (bent or broken and then check the fault code
terminals and locking condition using the malfunction mode of
of the pins). the YDT.
to item 6.
fault code.

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

Item
[P1605] Lean angle sensor: open or short to power circuit is detected.
Fail-safe system
Lean angle sensor output voltage
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.
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”.
the coupler. Check the fault code using the
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 fault code using the
check the pins (bent or broken malfunction mode of the YDT.
to item 3.
8-82

– +

Item
the wire harness. then to “OFF”, and then back to
“ON”.
Check the fault code using the
malfunction mode of the YDT.
to item 4.
3-1
2
1
L
3 L
Y/G
4 Y/G
B/ L
5 B/ L

2. ECU
Disconnect the lean angle sensor coupler from the lean angle sensor.
Between lean angle sensor coupler and ground: yellow/green–ground
L Y/G B/L
8-83

– +

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

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

Between lean angle sensor coupler and ECU coupler: black/blue–black/blue
8-84

– +

Item
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. 08) then to “OFF”, and then back to
Upright: 0.4 - 1.4 “ON”.
Overturned: 3.7 - 4.4 Check the fault code using the
The display is out of the speci- malfunction mode of the
fied range → Replace the lean YDT.
angle sensor. Condition is “Recover” → Go to
to item 5.
fault code.
8-85

– +

Rear wheel sensor: normal signals are not received from the rear
Item
wheel sensor.
Fail-safe system
Vehicle speed pulse
Tool display
0–999
Check that the number increases when the rear wheel is rotated. The
Procedure number is cumulative and does not reset each time the rear wheel is
stopped.
1 Locate the malfunction. ABS warning light does on. Check the rear wheel speed
Refer to “ABS TROUBLE- with YDT monitor item.
SHOOTING OUTLINE” on page Rotate the rear wheel by hand
8-104. and check that the indicated val-
ue.
Rear wheel speed exceeds
0 km/h. → Go to item 9 and fin-
ish the service.
Rear wheel speed remains
0 km/h. → Go to item 2.
2 Connection of rear wheel sen- Improperly connected → Con- Check the rear wheel speed
sor coupler. nect the coupler securely or re- with YDT monitor item.
Check the locking condition of place the wire harness. Rotate the rear wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue.
check the pins (bent or broken Rear wheel speed exceeds
terminals and locking condition 0 km/h. → Go to item 9 and fin-
of the pins). ish the service.
3 Connection of ABS ECU cou- Improperly connected → Con- Check the rear wheel speed
pler. nect the coupler securely or re- with YDT monitor item.
Check the locking condition of place the wire harness. Rotate the rear wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue.
check the pins (bent or broken Rear wheel speed exceeds
terminals and locking condition 0 km/h. → Go to item 9 and fin-
of the pins). ish the service.
4 Connection of ECU coupler. Improperly connected → Con- Check the rear wheel speed
Check the locking condition of nect the coupler securely or re- with YDT monitor item.
the coupler. place the wire harness. Rotate the rear wheel by hand
Disconnect the coupler and and check that the indicated val-
check the pins (bent or broken ue.
terminals and locking condition Rear wheel speed exceeds
of the pins). 0 km/h. → Go to item 9 and fin-
ish the service.
8-86

– +
Rear wheel sensor: normal signals are not received from the rear
Item
wheel sensor.
5 Wire harness continuity. Open or short circuit → Replace Check the rear wheel speed
the wire harness. with YDT monitor item.
Between rear wheel sensor cou- Rotate the rear wheel by hand
pler and ABS ECU coupler. and check that the indicated val-
brown–brown ue.
yellow–yellow Rear wheel speed exceeds
Between ABS ECU coupler and 0 km/h. → Go to item 9 and fin-
ECU coupler. ish the service.
white/black–white/black Rear wheel speed remains
6 Defective rear wheel sensor. Installed condition of rear wheel Check the rear wheel speed
sensor. with YDT monitor item.
Improperly installed rear wheel Rotate the rear wheel by hand
sensor → Reinstall or replace and check that the indicated val-
the rear wheel sensor. ue.
ish the service.
7 Malfunction in ECU. Replace the ECU. Check the rear wheel speed
with YDT monitor item.
Rotate the rear wheel by hand
and check that the indicated val-
ue.
ish the service.
8 Malfunction in ABS ECU. Replace the ABS ECU. Go to item 9 and delete the fault
code.
fault code.
8-87

– +
Fault code No. P00D1, P2195

[P00D1] O2 sensor: heater performance deteriorated. Normal signal

Item is not received from the O2 sensor while driving the O2 sensor.
[P2195] O2 sensor: Open circuit is 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 fault code using the
Reinstall or replace the sensor. malfunction mode of the YDT.
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 fault code using the
the coupler. malfunction mode of the YDT.
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”.
8-88

– +
[P00D1] O2 sensor: heater performance deteriorated. Normal signal

Item is not received from the O2 sensor while driving the O2 sensor.
[P2195] O2 sensor: Open circuit is 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 fault code using the
ECU coupler. malfunction mode of the YDT.
gray/green–gray/green Condition is “Recover” → Go to
black/blue–black/blue
pink/black–pink/black
to item 5.
function”.
5 Check fuel pressure. Check the fuel pressure. Start the engine, warm it up,
and then race it.
Check the fault code using the
to item 6.
function”.
6 Defective O2 sensor. Check the O2 sensor. Start the engine, warm it up,
Replace the O 2 sensor, if it is and then race it.
defective. Check the fault code using the
to item 7.
function”.
fault code.
8-89

– +

VVA (Variable Valve Actuator): Normal signal is not received from

Item
the VVA solenoid circuit while driving the VVA solenoid.
Fail-safe system
Actuates the VVA solenoid five times at five-second intervals. The check
Tool display indicator on the YDT screen come on each time the VVA solenoid is ac-
tuated.
Remove the VVA solenoid from the cylinder head, and then connect the
VVA solenoid coupler.
Procedure
Refer to “CYLINDER HEAD” on page 5-7.
Visually check that the VVA solenoid is actuated five times.
1 Connection of VVA solenoid Improperly connected → Con- Set the main switch to “ON”.
coupler. nect the coupler securely or re- Start the engine and accelerate
Check the locking condition of place the wire harness. to 7400 r/min.
the coupler. Check the condition of the fault
to item 2.
2 Connection of wire harness Improperly connected → Con- Set the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Start the engine and accelerate
Check the locking condition of place the wire harness. to 7400 r/min.
the coupler. Check the condition of the fault
to item 3.
3 Wire harness continuity. Open or short circuit → Properly Set the main switch to “ON”.
connect or replace the wire har- Start the engine and accelerate
ness. to 7400 r/min.
Between VVA (variable valve Check the condition of the fault
actuator) solenoid coupler and code using the malfunction
ECU coupler. mode of the YDT.
green–green & chocolate-choc- Condition is “Recover” → Go to
olate item 6 and finish the service.
to item 4.
8-90

– +
VVA (Variable Valve Actuator): Normal signal is not received from

Item
the VVA solenoid circuit while driving the VVA solenoid.
4 Faulty VVA solenoid operation. Measure the VVA solenoid re- Set the main switch to “ON”.
sistance. Start the engine and accelerate
Replace if out of specification. to 7400 r/min.
Check the condition of the fault
code using the malfunction
mode of the YDT.
to item 5.
fault code.
Event code No. 30

Event code No. 30
Item Latch up detected.

Fail-safe system
Lean angle sensor output voltage
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.
1 The vehicle has overturned. Raise the vehicle upright. Turn the main switch to “ON”,
then to “OFF”, and then back to
“ON”, and then check the
condition of the MIL.
MIL does not light on → Finish
the service.
MIL lights on → Go to item 2.
2 Installed condition of lean angle Improperly installed sensor → Turn the main switch to “ON”,
sensor. Reinstall the sensor. then to “OFF”, and then back to
“ON”, and then check the
the service.
8-91

– +
Event code No. 30
Item Latch up detected.

3 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 08) then to “OFF”, and then back to
Replace if defective. “ON”, and then check the
the service.
fault code.
8-92

– +
COMMUNICATION ERROR WITH THE METER
Fault code No. Er-1

Fault code No. Er-1
Item Normal signal is not received from the ECU.

Able to start engine (Unable when ECU is malfunctioning)
Fail-safe system
Able to drive vehicle (Unable when ECU is malfunctioning)
Tool display —
Procedure —
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ON”,
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.
the coupler. Fault code is not displayed →
Disconnect the coupler and Service is finished.
check the pins (bent or broken Fault code is displayed → Go to
of the pins).
the coupler. place the wire harness. the fault code.
Disconnect the coupler and Fault code is not displayed →
check the pins (bent or broken Service is finished.
terminals and locking condition Fault code is displayed → Go to
of the pins). item 3.
Between meter assembly cou- the fault code.
pler and ECU coupler. Fault code is not displayed →
yellow/blue–yellow/blue Service is finished. Fault code is
displayed → Go to item 4.
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”,
and then check the condition of
the fault code.
Fault code is not displayed →
Service is finished.
Fault code is displayed → Go to
item 5.
5 Malfunction in ECU. Replace ECU.
8-93

– +
Fault code No. Er-2

Fault code No. Er-2
Normal signal is not received from the ECU within the specification
Item
duration.
Fail-safe system
Tool display —
Procedure —
of the pins).
the fault code.
item 5.
8-94

– +
Fault code No. Er-3

Fault code No. Er-3
Item Data from the ECU cannot be received correctly.

Fail-safe system
Tool display —
Procedure —
of the pins).
the fault code.
item 5.
8-95

– +
Fault code No. Er-4

Fault code No. Er-4
Item Normal signal is not received from the meter assembly.

Fail-safe system
Tool display —
Procedure —
of the pins)
the fault code.
item 5.
8-96
EVENT CODE TABLE ELEC

– +
EAS20164
EVENT CODE TABLE

Fuel injection system
No. Item Symptom Possible cause Remarks
30 Latch up detected Detects a vehicle fall • Vehicle fall down Perform the checks and
(Lean angle sensor) down (Latch up detect- • Sensor installation im- maintenance jobs for
ed condition) properly event code 30.
• Sensor malfunction
• Defective ECU
192 Intake air pressure sen- Brief abnormality de- Same as for fault code Perform the checks and
sor tected in intake air P0107 and P0108 maintenance jobs for
pressure sensor fault code P0107 and
P0108.
193 Throttle position sensor Brief abnormality de- Same as for fault code Perform the checks and
tected in throttle posi- P0122 and P0123 maintenance jobs for
tion sensor fault code P0122 and
P0123.
196 Coolant temperature Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in coolant tem- P0117 and P0118 maintenance jobs for
perature sensor fault code 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- P0112 and P0113 maintenance jobs for
perature sensor fault code P0112 and
P0113.
203 Lean angle sensor Brief abnormality de- Same as for fault code Perform the checks and
tected in lean angle P1604 and P1605 maintenance jobs for
sensor fault code P1604 and
P1605.
218 Crankshaft position Brief abnormality de- Same as for fault code Perform the checks and
sensor tected in crankshaft po- P0335 maintenance jobs for
sition sensor fault code 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 dur- in the wire harness cated, perform the
mains at lower limit) ing O2 feedback between the sensor checks and mainte-
and the ECU nance jobs for the
gray/red–gray/red fault code first.
• Low fuel pressure * Event code number
• Clogged fuel injector 241 may be indicated
• Sensor malfunction even if the system is
• Defective ECU normal.
• Defective fuel injec-
tion system
8-97
EVENT CODE TABLE ELEC

– +
No. Item Symptom Possible cause Remarks

244 Difficult/unable to start Engine starting difficult/ • Empty fuel tank • If a fault code is indi-
engine unable condition de- • Defective fuel injec- cated, perform the
tected 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-
• Improperly adjusted nance jobs for the
clutch cable fault code first.
• Defective fuel injec- * Event code number
tion system 245 may be indicated
• Dirty or worn spark even if the system is
plug normal.
• Defective battery
• Defective ECU
8-98
FUEL PUMP SYSTEM ELEC

– +
EAS20081
FUEL PUMP SYSTEM

EAS30513
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
R
5
8
MAIN
R R
15A
R R R
R
R R
R R/W
R/W
12
14
15
OFF
RUN
B START
B
39
B B/W
Br
B
23
R R
31
40 R
ON
OFF
R
Br Br
Y
Y Y R
Br
Br
Br
Br
B/W B
B/W B
R/W R/W
Br Br
69
Br Br Br Br/L Gy Gy 68 B B B/Y B R/W R/W R/W

Br Br Br Br Gy Gy B B/R B B/W R/W
Or Or
5. Fuse box
8. Main fuse
12.Battery
31.Fuel pump
39.Engine ground
40.Main switch
68.Junction 1
69. Junction 2
8-99
FUEL PUMP SYSTEM ELEC

– +
EAS30514
TROUBLESHOOTING
TIP
3. Fuel tank cover (left and right) and fuel tank top cover
4. Fuel tank
If the fuel pump fails to operate.
(Main fuse)
on page 8-142.
OK ↓
page 8-143.
OK ↓
OK ↓
OK ↓
5. Check the fuel pump operation. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
PRESSURE” on page 7-5.
OK ↓
6. Check the entire fuel pump system NG →
page 8-99.
OK ↓
Replace the ECU.
8-100
ABS (ANTI-LOCK BRAKE SYSTEM) ELEC

– +
EAS20085
ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30843
CIRCUIT DIAGRAM
R R Br
R R/L R Br/W Br
SPARE SPARE
Br R R
5
7 8 9 10
ABS-MOTOR
ABS-SOL
MAIN
R
ABS
30A
15A
2A
15A
Br/W R R R/L R
R R R
R R
R
R/W
Br/L R/W
12
14
15
B OFF
RUN
B START
B 18
39
B B/W Lg/W
Gy
Br Lg/L
B
B
B/W B 23
R R
40
ON
OFF
R
Br Br
W/B
Lg/L W
R Lg/W
Lg/W
35 Lg/L
Br L/B
R B
Br Br
R L/R Br
R Br Lg/L B
Br
R Lg/W
B/W B

34
B/W B
Gy
41
Br
R
43 Gy Br Br
Br Br B B/W
R/W R/W
67 Br Br Br Br/L
69
Gy
Gy Gy Gy
68 B B
B B B/Y B R/W R/W R/W
B B/R B B/W R/W
Br Br Br Br/L Gy Gy Or
Br Br Br Br Gy Gy
Or
ABS 54 B
W/L
W
70 W/B
R/L
R
Br/W
B/W
B G G 71
Gy W B
R R G R
Shield S
Br Br 72
W B
Y Y
Shield S Br Y
W/L 73
B/W B/W
L/B
L/R

8-101

– +
5. Fuse box
8. Main fuse
9. ABS motor fuse
10.ABS solenoid fuse
12.Battery
18.Front brake light switch
coupler
39.Engine ground
40.Main switch
41.Meter assembly
54.ABS warning indicator light
67.Rear brake light switch
68.Junction 1
69.Junction 2
72.Rear wheel sensor
73.Joint
8-102

– +
EAS30844
ABS COUPLER LOCATION CHART
Gy Or W/R Y/W Y/L P G Or/W W Br 1

W B
Gy

B
2
W B
3
Lg/L B
R Lg/W
1. Front wheel sensor coupler

2. Rear wheel sensor coupler
3. Yamaha diagnostic tool coupler / ABS test
coupler
4. ABS ECU coupler
5. Meter assembly coupler
8-103

– +
EAS30845
MAINTENANCE OF THE ABS ECU
Checking the ABS ECU

1. Check:
• Terminals “1” of the ABS ECU
Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off → Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
1
2
EAS30528
ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU (electronic control unit) has a self-diagnosis function. When failures occur in the system,
the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the YDT.
For information about using the YDT, refer to “[B-2] DIAGNOSIS USING THE FAULT CODES” on page
8-109. 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 8-136.
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 (6.3 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 (6.3 mi/h)). → ABS operation is normal.
3. The ABS warning light flashes → ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 8-105.
8-104

– +
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 YDT. When the service is finished,
check the normal operation of the vehicle, and then delete the fault code(s). For information about de-
leting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page 8-136. By deleting the
fault codes stored in the ABS ECU memory, it is possible to pursue the cause correctly if another mal-
function 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 inside of the right
air scoop, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the
lever and pedal, but these do not indicate a malfunction.
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 YDT when the ABS ECU has en-
tered 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 YDT 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.
8-105

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8-106

– +
EAS30530
BASIC PROCESS FOR TROUBLESHOOTING
Fails to
[A] Turn the main switch to “ON”, come on [A-1] Does only the ABS Yes • The ABS warning light (LED) is
and check the ABS warning warning light fail to defective.
Return to [A].
light. come on? • The wire harness is grounded
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.
No
Yes • The main switch is defective.
[A-2] Do all indicator lights • The battery voltage is low.
fail to come on? Return to [A].
• The main fuse is blown.
defective.
Cannot
[A-3] The ABS warning light communicate Yes • The ABS control unit fuse is
[A-4] Only the ABS ECU
comes on. blown. Return to [A].
fails to
Connect the YDT, and then • The ABS ECU coupler is
communicate.
execute functional diagnosis. disconnected.
Can the tool communicate • The wire harness is defective.
with the ABS ECU? • The hydraulic unit assembly is
defective.
Can communicate
[A-5] ABS ECU and FI ECU Yes

• The connection with the YDT is
fail to communicate. defective. Return to [A].
• The wire harness is defective.
Yes
[B-1] Check for ABS fault codes [B-2] Diagnose by the [B-3] Delete the fault codes. Return to [A].
in the screen for the YDT. fault code.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
No
The reaction force generated
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.
defective.
• The ABS warning light circuit
in the hydraulic unit
assembly is defective.
Finished.
8-107

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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 8-136.
EAS30531
[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS30532
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the white/blue terminal of the ABS ECU coupler and
white/blue terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS30964
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-139.
• 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 8-143.
• 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 8-142.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 8-101.
• If the meter assembly circuit is opened, replace the wire harness.
EAS31162
[A-3] THE ABS WARNING LIGHT COMES ON

Connect the YDT to the Yamaha diagnostic tool coupler / ABS test coupler and execute functional di-
agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that
is included with the tool.)
Check that communication with the ABS ECU is possible.
• Only the ABS ECU fails to communicate. [A-4]
• ABS ECU and FI ECU fail to communicate. [A-5]
• Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
8-108

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EAS31163
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE (The select unit screen does not appear.)
• Check the ABS control unit fuse for continuity.
• If the ABS control unit fuse is blown, replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-52.
3. Wire harness
• Open circuit between the main switch and the ABS ECU, or between the ABS ECU and the ground.
Check for continuity between brown terminal of the main switch coupler and brown/white terminal of
the ABS ECU coupler.
Check for continuity between black/white terminal of the ABS ECU coupler and the ground, and be-
tween the black terminal of the ABS ECU coupler and ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler / ABS test coupler.
Check for continuity between blue/red terminal of the ABS ECU coupler and blue/red terminal of the
Yamaha diagnostic tool coupler / ABS test coupler.
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the Yamaha diagnostic tool coupler / ABS test coupler.
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS31164
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE (Cannot connect due to a tool error.)
1. Yamaha diagnostic tool
Check that the Yamaha diagnostic tool is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler / ABS test coupler.
Check for continuity between blue/red terminal of the ABS ECU coupler and blue/red terminal of the
Yamaha diagnostic tool coupler / ABS test coupler.
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the Yamaha diagnostic tool coupler / ABS test coupler.
EAS31165
[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the Yamaha diagnostic tool is connected to the Yamaha diagnostic tool coupler / ABS test cou-
pler, 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.
8-109

– +

INS-18
(90890-03267)
Yamaha diagnostic tool (A/I)
INS-19
(90890-03264)

Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-32
Details about the displayed fault codes are shown in “SELF-DIAGNOSTIC FUNCTION TABLE (FOR
ABS (Anti-lock Brake System))” on page 8-112. Refer to this chart and check the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.
Operation of the Yamaha diagnostic tool (Fault diagnosis mode)

Malfunction results are displayed in the top part of the window area.
7 3 8 5 5 2
FI
ABS
4
1
6
13 12 11 10 9
1. Detected
The malfunction currently occurred are displayed.
2. Recovered
The malfunction detected in the past (already recovered) are displayed.
8-110

– +
3. The diagnosis codes related to the detected malfunction are displayed.
A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed. (e.g., FI, ABS)
5. Status of malfunction
The current conditions are displayed. (Malfunction/Recover)
6. Item
If a fault code is detected, the symptoms are displayed along with the item name.
7. Trouble list
The item list of the “detected malfunction” or “recover malfunction” are displayed.
8. Trouble Information
This appears to click on “detected malfunction (1)” for the details of the diagnosis are displayed.
Click [Service Manual/F10] to open the service manual and check the details of the fault.
9. Save
To save the result of diagnosis of malfunction, click [Save/F12].
TIP
Must save the result for future reference.
10.Update
To run the diagnosis of malfunction again, click [Update/F11].
11.Service Manual
To view the service manual, click [Service Manual/F10].
TIP
Service Manual of related model can be downloaded when system is connected with YMC server.
12.Erase all (Only recovered item can be Erased)
To delete all of the fault codes, click [Erase All/F2].
13.Delete selected items (Only recovered item can be Deleted)
To delete the selected fault codes, click [Delete selected items/F1].
8-111

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SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))

TIP
For details of the fault code, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page
8-105.
Fail-safe system
Diag-
Fault code Start- Driving
Item Symptom Check point nostic
No. ing the the ve- code
engine hicle
11* Front wheel sensor Front wheel sensor • Foreign material
25* (intermittent pulses signal is not re- adhered around
or no pulses) ceived properly. the front wheel
(Pulses are not re- sensor
ceived or are re- • Incorrect installa-
ceived intermittently tion of the front
while the vehicle is wheel
traveling.) • Defective sensor Able Able —
rotor or incorrect
installation of the
rotor
• Defective front
wheel sensor or in-
correct installation
of the sensor
12 Rear wheel sensor Rear wheel sensor • Foreign material
(intermittent pulses signal is not re- adhered around
or no pulses) ceived properly. the rear wheel
(Pulses are not re- sensor
ceived or are re- • Incorrect installa-
ceived intermittently tion of the rear
while the vehicle is wheel
traveling.) • Defective sensor Able Able —
rotor or incorrect
installation of the
rotor
• Defective rear
wheel sensor or in-
of the sensor
26* (abnormal pulse pe- signal is not re- adhered around
riod) ceived properly. the front wheel
(The pulse period is sensor
abnormal while the • Incorrect installa-
vehicle is traveling.) tion of the front
wheel
• Defective sensor Able Able —
rotor or incorrect
installation of the
rotor
• Defective front
wheel sensor or in-
of the sensor
8-112

– +
Fail-safe system
Diag-
engine hicle
14* Rear wheel sensor Rear wheel sensor • Foreign material
27* (abnormal pulse pe- signal is not re- adhered around
riod) ceived properly. the rear wheel
(The pulse period is sensor
abnormal while the • Incorrect installa-
vehicle is traveling.) tion of the rear
wheel
rotor or incorrect
installation of the
rotor
• Defective rear
wheel sensor or in-
of the sensor
15 Front wheel sensor Open or short cir- • Defective coupler
(open or short circuit is detected in between the front
cuit) the front wheel sen- wheel sensor and
sor. the hydraulic unit
assembly
cuit in the wire har-
ness between the Able Able —
front wheel sensor
and the hydraulic
unit assembly
• Defective front
wheel sensor or
hydraulic unit as-
sembly
16 Rear wheel sensor Open or short cir- • Defective coupler
(open or short circuit is detected in between the rear
cuit) the rear wheel sen- wheel sensor and
sor. the hydraulic unit
assembly
ness between the Able Able —
rear wheel sensor
and the hydraulic
unit assembly
• Defective rear
wheel sensor or
hydraulic unit as-
sembly
8-113

– +
Fail-safe system
Diag-
engine hicle
45* (missing pulses) signal is not re- adhered around
ceived properly. the front wheel
(Missing pulses are sensor
detected in the sig- • Incorrect installa-
nal while the vehicle tion of the front
is traveling.) wheel
rotor or incorrect
installation of the
rotor
• Defective front
wheel sensor or in-
of the sensor
18* Rear wheel sensor Rear wheel sensor • Foreign material
46* (missing pulses) signal is not re- adhered around
ceived properly. the rear wheel
nal while the vehicle tion of the rear
rotor or incorrect
installation of the
rotor
• Defective rear
wheel sensor or in-
of the sensor
21 Hydraulic unit as- Solenoid drive cir- • Defective hydrau-
sembly (defective cuit in the hydraulic lic unit assembly
solenoid drive cir- unit assembly is Able Able —
cuit) open or short-circuit-
ed.
8-114

– +
Fail-safe system
Diag-
engine hicle
24 Brake light switch or Brake light signal is • Defective signaling
tail/brake light not received proper- system (tail/brake
ly while the vehicle light or brake light
is traveling. (Brake switch)
light circuit, or front • Defective coupler
or rear brake light between the sig-
switch circuit) naling system (tail/
brake light or
brake light switch)
and the hydraulic
unit assembly Able Able —
ness between the
signaling system
(tail/brake light or
brake light switch)
and the hydraulic
unit assembly
• Defective hydrau-
lic unit assembly
31 Hydraulic unit as- Power is not sup- • Blown ABS sole-
sembly (abnormal plied to the solenoid noid fuse
ABS solenoid pow- circuit in the hydrau- • Defective coupler
er supply) lic unit assembly. between the bat-
tery and the hy-
draulic unit
assembly
• Open or short cir- Able Able —
ness between the
battery and the hy-
draulic unit assem-
bly
lic unit assembly
32 Hydraulic unit as- Short circuit is de- • Defective hydrau-
sembly (short circuit tected in the sole- lic unit assembly
in ABS solenoid noid power supply Able Able —
power supply circuit) circuit in the hydrau-
lic unit assembly.
8-115

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Fail-safe system
Diag-
engine hicle
33 Hydraulic unit as- Power is not sup- • Blown ABS motor
sembly (abnormal plied to the motor fuse
ABS motor power circuit in the hydrau- • Defective coupler
supply) lic unit assembly. between the bat-
tery and the hy-
draulic unit
assembly
• Open or short cir- Able Able —
ness between the
battery and the hy-
draulic unit assem-
bly
lic unit assembly
34 Hydraulic unit as- Short circuit is de- • Defective hydrau-
sembly (short circuit tected in the motor lic unit assembly
in ABS motor power power supply circuit Able Able —
supply circuit) in the hydraulic unit
assembly.
41 Front wheel ABS • Pulses from the • Incorrect installa-
(intermittent wheel front wheel sensor tion of the front
speed pulses or in- are received inter- wheel sensor
correct depressur- mittently while the • Incorrect rotation
ization) vehicle is traveling. of the front wheel
• Front wheel will • Front brake drag-
not recover from ging
Able Able —
the locking tenden- • Defective hydrau-
cy even though the lic unit assembly
signal is transmit-
ted from the ABS
ECU to reduce the
hydraulic pres-
sure.
42 Rear wheel ABS (in- • Pulses from the • Incorrect installa-
47 termittent wheel rear wheel sensor tion of the rear
speed pulses or in- are received inter- wheel sensor (for
correct depressur- mittently while the fault code No. 42)
ization) vehicle is traveling. • Incorrect rotation
(for fault code No. of the rear wheel
42) • Rear brake drag-
• Rear wheel will not ging
Able Able —
recover from the • Defective hydrau-
locking tendency lic unit assembly
even though the
signal is transmit-
ted from the ABS
ECU to reduce the
hydraulic pres-
sure.
8-116

– +
Fail-safe system
Diag-
engine hicle
43 Front wheel sensor Front wheel sensor • Foreign material
(missing pulses) signal is not re- adhered around
ceived properly. the front wheel
nal while the vehicle tion of the front
rotor or incorrect
installation of the
rotor
• Defective front
wheel sensor or in-
of the sensor
44 Rear wheel sensor Rear wheel sensor • Foreign material
(missing pulses) signal is not re- adhered around
ceived properly. the rear wheel
nal while the vehicle tion of the rear
rotor or incorrect
installation of the
rotor
• Defective rear
wheel sensor or in-
of the sensor
51 • Vehicle system • Power voltage • Defective battery
52 power supply (volt- supplied to the • Disconnected bat-
age of ABS ECU ABS ECU in the tery terminal
power supply is hydraulic unit as- • Defective charg-
high) (for fault sembly is too high. ing system
code No. 51) (for fault code No.
Able Able —
• Vehicle system 51)
power supply (volt- • Power voltage
age of wheel sen- supplied to the
sor power supply wheel sensor is
is high) (for fault too high. (for fault
code No. 52) code No. 52)
8-117

– +
Fail-safe system
Diag-
engine hicle
53 Vehicle system pow- Power voltage sup- • Defective battery
er supply (voltage of plied to the ABS • Defective coupler
ABS ECU power ECU in the hydraulic between the bat-
supply is low) unit assembly is too tery and the hy-
low. draulic unit
assembly
Able Able —
ness between the
battery and the hy-
draulic unit assem-
bly
• Defective charg-
ing system
54 Hydraulic unit as- Abnormality is de- • Defective battery
sembly (defective tected in the sole- • Defective coupler
ABS solenoid and noid or motor power between the bat-
ABS motor power supply circuit in the tery and the hy-
supply circuits) hydraulic unit as- draulic unit
sembly. assembly
Able Able —
ness between the
battery and the hy-
draulic unit assem-
bly
• Defective charg-
ing system
lic unit assembly
55 Hydraulic unit as- Abnormal data is • Defective hydrau-
sembly (defective detected in the hy- lic unit assembly
Able Able —
ABS ECU) draulic unit assem-
bly.
56 Hydraulic unit as- Abnormality is de- • Defective hydrau-
sembly (abnormal tected in the power lic unit assembly
internal power sup- supply circuit in the Able Able —
ply) hydraulic unit as-
sembly.
63 Front wheel sensor Power voltage sup- • Short circuit in the
power supply (volt- plied from the ABS wire harness be-
age of power supply ECU to the front tween the front
is low) wheel sensor is too wheel sensor and
low. the hydraulic unit
Able Able —
assembly
• Defective front
wheel sensor
lic unit assembly
8-118

– +
Fail-safe system
Diag-
engine hicle
64 Rear wheel sensor Power voltage sup- • Short circuit in the
power supply (volt- plied from the ABS wire harness be-
age of power supply ECU to the rear tween the rear
is low) wheel sensor is too wheel sensor and
low. the hydraulic unit
Able Able —
assembly
• Defective rear
wheel sensor
lic unit assembly
* The fault code number varies according to the vehicle conditions.
8-119

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BASIC INSTRUCTIONS FOR TROUBLESHOOTING - ABS (Anti-lock brake system)
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
4-15.
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 WHEEL SENSOR
AND SENSOR ROTOR” on page 4-16.
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
4-22.
8-120

– +
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

4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed

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.
4-15.
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.
8-121

– +

TIP
• If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record-
ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re-
corded.
• Vehicle possibly ridden on uneven roads.
14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)
Rear wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

bends.
4-22.
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.
8-122

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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 red termi-
hydraulic unit assembly nal “2” and the red 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 red terminal “2” and between the
green terminal “4” and the red 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 red terminal
“5”.
1 2 3 4 5

G R 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 4-13 and “ABS (AN-
TI-LOCK BRAKE SYSTEM)” on page 8-101.
8-123

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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.
2 Open or short circuit in the wire harness • Check for continuity between the yellow terminal “1”
between the rear wheel sensor and the and the yellow terminal “4” and between the brown ter-
hydraulic unit assembly minal “2” and the brown terminal “5”.
• If there is no continuity, the wire harness is defective.
• Check that there is no short circuit between the yellow
terminal “1” and the brown terminal “2” and between
the yellow terminal “4” and the brown terminal “5”.
• Check that there is no short circuit between the black/
white terminal “3” and the yellow terminal “4” and be-
tween the black/white terminal “3” and the brown ter-
minal “5”.
2 1 3 5 4
Br Y W B
6 7
6. ABS ECU
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 4-20 and “ABS (AN-
TI-LOCK BRAKE SYSTEM)” on page 8-101.
8-124

– +

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.
4-15.

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
Symptom
bends.
4-22.
8-125

– +
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 opened or

Symptom
short-circuited.

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
8-101.
Fault code No. 24

Fault code No. 24
Item Brake light switch or tail/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 (tail/brake Check the brake light switches.
light or brake light switch) Refer to “CHECKING THE SWITCHES” on page 8-139.
2 Defective coupler between the signaling • Check the coupler for any pins that may be pulled out.
system (tail/brake light or brake light • Check the locking condition of the coupler.
switch) 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 ABS ECU coupler and front brake light
between the signaling system (tail/brake switch coupler.
light or brake light switch) and the hydrau- (gray–gray)
lic unit assembly • Between ABS ECU coupler and rear brake light switch
coupler.
(gray–gray)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
8-101.
8-126

– +
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.
Refer to “CHECKING THE SWITCHES” on page 8-139.
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)
8-101.
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

Symptom
hydraulic unit assembly.

8-101.
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.
8-127

– +
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)
8-101.
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.

8-101.
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.
4-15.
8-128

– +
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.
4-15 and “CHECKING THE FRONT BRAKE DISC” on
page 4-31.
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 4-31.
8-101.

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.
4-22.
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.
4-22.
3 Rear brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake pedal is operat-
ed and that the pressure decreases when the pedal is
released.
Refer to “CHECKING THE REAR BRAKE DISC” on
page 4-43.
8-129

– +
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.

8-101.
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

bends.
4-15.
Fault code No. 44

Fault code No. 44

Symptom

8-130

– +
Fault code No. 44

Symptom

bends.
4-22.

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 sup-
ply 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 BAT-
TERY” on page 8-143.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-9.
8-131

– +
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.

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.

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)
8-132

– +
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.

8-101.
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.

8-101.
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.

8-101.
8-133

– +
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
Symptom
is 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 red 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 R 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 R W B
3 4
3. ABS ECU
8-101.
8-134

– +
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
8-101.
8-135

– +
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.

INS-018
(90890-03267)
Yamaha diagnostic tool (A/I)
INS-019
(90890-03264)

Refer to “YAMAHA DIAGNOSTIC TOOL” on page 8-32.
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 brake master cylinder reservoir and brake fluid reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-18.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL” on page 4-18 and “INSTALLING THE REAR WHEEL”
on page 4-23.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-53.
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 8-136.
5. Checking the ABS warning light.
Check that the ABS warning light goes off.
If ABS warning light does not come on or if it does not goes off, refer to “CHECKING THE ABS
WARNING LIGHT” on page 4-56.
• 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.
8-136
ELECTRICAL COMPONENTS ELEC

– +
EAS20089
ELECTRICAL COMPONENTS
5 6 7 9
8 10
11
12,13,14,15
37 16
36
17
35
18
34
19
33 20
32
21
31 22
30 23
29
24
28
27 26 25
8-137

– +
1. Main switch
2. Front brake light switch
3. Clutch switch
4. Rectifier/regulator
5. Turn signal relay
6. Radiator fan motor relay
7. Hydraulic unit assembly
8. Spark plug
9. Ignition coil
10. Fuel sender
11. Fuel pump
12. FID (fast idle solenoid)
13. Intake air pressure sensor
14. Intake air temperature sensor
15. Throttle position sensor
16. ECU (engine control unit)
17.CCU (communication control unit)
19. Fuse box
20. Battery
21. Starter relay
22.Rear wheel sensor
23. Rear brake light switch
24. Starter motor
25.Sidestand switch
27. Gear position switch (Neutral switch)
28. AC magneto
30. Coolant temperature sensor
31. Fuel injector
32. O2 sensor
34. VVA (variable valve actuator) solenoid
35. Radiator fan motor
36. Horn 1
37.Horn 2
8-138

– +
EAS30549
CHECKING THE SWITCHES

Check each switch for continuity with the multimeter. If the continuity reading is incorrect, check the wir-
ing connections and if necessary, replace the switch.
13 1
R/B
2 Br/L
B/W
12
HI Ch Y/B
LO B/R Dg W/B
PASS Gy
11
OFF Br R/B P 3
ON OFF Gy B
RUN R/B
10 START Dg Ch
L
N 4
R TRIP
N Br/L L/W Br/W
INFO
9 5
L/G OFF P Y/W
ON
B
B 6 Br/L
B/W
8
B/W V
B R Gy
7 Sb W W Sb
Or P P Or
W/R Y/W Y/W W/R
Gy
1. Main switch 8. Quick shift switch

2. Front brake light switch 9. Sidestand switch
3. Engine stop / start switch 10.Turn signal light switch
4. Trip / information switch 11.Horn switch
5. Hazard switch 12.Dimmer / pass switch
6. Rear brake light switch 13.Clutch switch
7. Gear position switch
8-139

– +
ECA14371
NOTICE
Never insert the multimeter probes into the coupler terminal slots. Always insert the probes
from the opposite end “a” of the coupler, taking care not to loosen or damage the leads.
Multimeter
INS-003
(90890-03189)
TIP
When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red and brown when the switch is turned to “ON”.
8-140

– +
EAS30550
CHECKING THE BULBS AND BULB Multimeter

SOCKETS INS-003
TIP (90890-03189)
Do not check any of the lights that use LEDs.
a. Connect the positive tester probe to termi-
Check each bulb and bulb socket for damage or nal “1” and the negative tester probe to ter-
wear, proper connections, and also for continuity minal “2”, and check the continuity.
between the terminals. b. Connect the positive tester probe to termi-
Damage/wear → Repair or replace the bulb, nal “1” and the negative tester probe to ter-
bulb socket or both. minal “3”, and check the continuity.
Improperly connected → Properly connect. c. If either of the readings indicate no conti-
No continuity → Repair or replace the bulb, bulb nuity, replace the bulb.
socket or both.
Types of bulbs
The bulbs used on this vehicle are shown in the
illustration.
• Bulbs “a” are used for turn signal and can be
removed from the socket by pushing and turn-
ing the bulb counterclockwise. 3
• Bulbs “b” are used for license plate lights and 2
can be removed from their respective sockets 1
by carefully pulling them out.
Checking the condition of the bulb sockets

a b The following procedure applies to all of the bulb
sockets.
1. Check:
• Bulb socket (for continuity)
(with the multimeter)
No continuity → Replace.
Multimeter
INS-003
(90890-03189)
Checking the condition of the bulbs
The following procedure applies to all of the TIP
bulbs. Check each bulb socket for continuity in the
1. Remove: same manner as described in the bulb section;
• Bulb however, note the following.
ECA22810
NOTICE a. Install a good bulb into the bulb socket.

Be sure to hold the socket firmly when re- b. Connect the multimeter probes to the re-
moving the bulb. Never pull the lead, other- spective leads of the bulb socket.
wise it may be pulled out of the terminal in c. Check the bulb socket for continuity. If any
the coupler. of the readings indicate no continuity, re-
place the bulb socket.
2. Check:
• Bulb (for continuity)
(with the multimeter)
No continuity → Replace.
8-141

– +
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:
• Passenger seat
• Passenger seat
• Rider seat
• Rider seat
4-1.
4-1.
2. Check:
• Fuse EAS31005
a. Connect the multimeter to the fuse and REPLACING THE ECU (engine control unit)
check the continuity. 1. Turn the main switch to “OFF”.
TIP
2. Replace the ECU (engine control unit).
Refer to “REMOVING THE ECU (engine con-
Set the multimeter selector to “Ω × 1”.
trol unit)” on page 8-142.
Refer to “INSTALLING THE ECU (engine
Multimeter control unit)” on page 8-143.
INS-003 3. Check:
(90890-03189) • Engine idling speed
Start the engine, warm it up, and then mea-
b. If the multimeter indicates “∞”, replace the
sure the engine idling speed.
fuse.
3. Replace: Engine idling speed
• Blown fuse 1300–1500 r/min
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct amperage EAS31319
rating. REMOVING THE ECU (engine control unit)

c. Set on the switches to verify if the electri- 1. Remove:
cal circuit is operational. • Rider seat
d. If the fuse immediately blows again, check Refer to “GENERAL CHASSIS (1)” on page
the electrical circuit. 4-1.
2. Disconnect:
Amperage
Fuses Q’ty • ECU coupler “1”
rating
TIP
Main 15 A 1
Accessories fuse 2A 1 Push the lock lever “a” of the ECU coupler in the
direction of the arrow shown, and then discon-
ABS solenoid 15 A 1
nect the coupler by puling it backward.
ABS motor 30 A 1
ABS control unit 2A 1
Spare 30 A 1
Spare 15 A 1
Spare 2A 1 1
8-142

– +
INSTALLING THE ECU (engine control unit) 1. Remove:

1. Connect: • Rider seat
• ECU coupler “1” Refer to “GENERAL CHASSIS (1)” on page
TIP 4-1.
2. Disconnect:
Make sure that the ECU coupler is connected in
• Battery leads
the correct position, and then push the ECU cou-
(from the battery terminals)
pler in the direction of the arrow shown until a ECA13640
distinct “click” is heard. WARNING

First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
1
3
2
2. Install: 1
• Rider seat
Refer to “GENERAL CHASSIS (1)” on page 3. Check:
4-1. • Battery charge
EAS30552
a. Connect a multimeter “3” to the battery ter-
CHECKING AND CHARGING THE BATTERY minals.
• Positive multimeter probe →
ECA20530
NOTICE Positive battery terminal

• This is a VRLA (Valve Regulated Lead Acid) • Negative multimeter →
battery. Never remove the sealing caps be- Negative battery terminal
cause the balance between cells will not be TIP
maintained and battery performance will
deteriorate. • The charge state of a VRLA (Valve Regulated
• Charging time, charging amperage and Lead Acid) battery can be checked by measur-
charging voltage for a VRLA (Valve Regu- ing its open-circuit voltage (i.e., the voltage
lated Lead Acid) battery are different from when the positive battery terminal is discon-
those of conventional batteries. The VRLA nected).
(Valve Regulated Lead Acid) battery should • No charging is necessary when the open-cir-
be charged according to the appropriate cuit voltage equals or exceeds 12.8 V.
charging method. If the battery is over- b. Check the charge of the battery, as shown
charged, the electrolyte level will drop con- in the charts and the following example.
siderably. Therefore, take special care Example
when charging the battery. Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
TIP
Charge of the battery = 20–30%
Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check the
charge state of the battery by measuring the
specific gravity of the electrolyte. Therefore, the
charge of the battery has to be checked by mea-
suring the voltage at the battery terminals.
8-143

– +
• When charging a battery, be sure to remove

it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
cle, disconnect the negative battery lead
from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
A. Open-circuit voltage (V)
• Make sure the battery charger lead clips are
B. Charging time (hours)
in full contact with the battery terminal and
C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
that they are not shorted. A corroded bat-
D. These values vary with the temperature, the
tery charger lead clip may generate heat in
condition of the battery plates, and the the contact area and a weak clip spring may
electrolyte level. cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
charging is completed before measuring
A. Open-circuit voltage (V) the open-circuit voltage.
B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
4. Remove:
• Battery band
• Battery
5. Charge:
• Battery
(refer to the appropriate charging method)
EWA13300
WARNING
A. Open-circuit voltage (V)
Do not quick charge a battery.
B. Time (minutes)
ECA13671 C. Charging
NOTICE D. Ambient temperature 20 °C (68 °F)
• Do not use a high-rate battery charger E. Check the open-circuit voltage
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
8-144

– +
Charging method using a variable-current (volt- TIP

age) charger
Voltage should be measured 30 minutes after
a. Measure the open-circuit voltage prior to
the engine is stopped.
charging.
TIP b. Connect a charger and ammeter to the
Voltage should be measured 30 minutes after battery and start charging.
the engine is stopped. c. Make sure that the current is higher than
the standard charging current written on
b. Connect a charger and ammeter to the the battery.
battery and start charging. TIP
TIP
If the current is lower than the standard charging
Set the charging voltage to 16–17 V. If the set- current written on the battery, this type of battery
ting is lower, charging will be insufficient. If too charger cannot charge the VRLA (Valve Regu-
high, the battery will be over-charged. lated Lead Acid) battery. A variable voltage
charger is recommended.
c. Make sure that the current is higher than
the standard charging current written on d. Charge the battery until the battery’s
the battery. charging voltage is 15 V.
TIP TIP
If the current is lower than the standard charging Set the charging time at 20 hours (maximum).
current written on the battery, set the charging
voltage adjust dial at 20–24 V and monitor the e. Measure the battery open-circuit voltage
amperage for 3–5 minutes to check the battery. after leaving the battery unused for more
than 30 minutes.
• Standard charging current is reached. 12.8 V or more --- Charging is completed.
Battery is good. 12.7 V or less --- Recharging is required.
• Standard charging current is not reached. Under 12.0 V --- Replace the battery.
Replace the battery.
6. Install:
d. Adjust the voltage so that the current is at • Battery
the standard charging level. • Battery band
e. Set the time according to the charging TIP
time suitable for the open-circuit voltage.
Ensure leads under the band routed properly.
f. If charging requires more than 5 hours, it is
advisable to check the charging current af-
ter a lapse of 5 hours. If there is any 7. Connect:
change in the amperage, adjust the volt- • Battery leads
age to obtain the standard charging cur- (to the battery terminals)
rent.
ECA13630
g. Measure the battery open-circuit voltage
NOTICE
after leaving the battery unused for more
than 30 minutes. First, connect the positive battery lead “1”,
and then the negative battery lead “2”.
12.8 V or more --- Charging is completed.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery. 1
Charging method using a constant voltage

charger
a. Measure the open-circuit voltage prior to
charging.
8-145

– +
8. Check: Radiator fan motor relay

• Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• Battery terminals
Dielectric grease
10.Install:
• Rider seat
Refer to “GENERAL CHASSIS (1)” on page 1. Positive battery terminal
4-1 2. Negative battery terminal
EAS30553 3. Positive tester probe
CHECKING THE RELAYS 4. Negative tester probe
Check each switch for continuity with the multi-
meter. If the continuity reading is incorrect, re-
Result
place the relay.
Continuity
Multimeter (between “3” and “4”)
INS-003
(90890-03189) Turn signal relay
1. Check:
1. Disconnect the relay from the wire harness. • Turn signal relay input voltage
2. Connect the multimeter (Ω × 1) and battery Out of specification → The wiring circuit from
(12 V) to the relay terminal as shown. the main switch to the turn signal relay cou-
Check the relay operation. pler is faulty and must be repaired.
Turn signal relay input voltage
Starter relay
DC 12 V
1 2
a. Connect the multimeter (DC 20 V) to the
turn signal relay terminal as shown.
Multimeter
3 4 INS-003
+ R R/W (90890-03189)
R/W L/W
• Positive tester probe →
brown “1”
• Negative tester probe →
1. Positive battery terminal ground
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
Result
Continuity
(between “3” and “4”) Br/W
Br
1
8-146

– +
b. Set the main switch to “ON”.

c. Measure the turn signal relay input volt- For diode 1:
age. Continuity
2. Check: Positive tester probe → sky/
blue “1”
• Turn signal relay output voltage
Negative tester probe → red/
Out of specification → Replace. black “2”
No continuity
Turn signal relay output voltage
Positive tester probe → red/
DC 12 V
black “2”
Negative tester probe → sky
a. Connect the multimeter (DC 20 V) to the
blue “1”
turn signal relay terminal as shown. For diode 2:
Continuity
Multimeter
Positive tester probe → sky/
INS-003
blue “1”
(90890-03189)
Negative tester probe → blue/
green “2”
• Positive tester probe → No continuity
brown/white “1” Positive tester probe → blue/
ground
green “2”
Negative tester probe → sky
blue “1”
Br/W
Br 1
2
b. Set the main switch to “ON”.
c. Measure the turn signal relay output volt-
age. a. Disconnect the diode from the wire har-
ness.
EAS30555 b. Connect the multimeter (Ω × 1) to the di-
CHECKING THE DIODES ode terminals as shown.
1. Check: c. Check the diode for continuity.
• Diode d. Check the diode for no continuity.
EAS30557
Multimeter CHECKING THE SPARK PLUG CAP

INS-003 1. Check:
(90890-03189) • Spark plug cap resistance
TIP
The multimeter or the analog multimeter Resistance
4.00–6.00 kΩ
readings are shown in the following table.
a. Remove the spark plug cap from the spark
plug lead.
b. Connect the multimeter (Ω × 1k) to the
spark plug cap as shown.
8-147

– +
2. Check:
Multimeter • Secondary coil resistance
INS-003 Out of specification → Replace.
(90890-03189)
Secondary coil resistance
9.45–11.55 kΩ
a. Disconnect the spark plug cap from the ig-

nition coil.
b. Connect the multimeter (Ω × 1k) to the ig-
nition coil as shown.
Multimeter
INS-003
(90890-03189)
c. Measure the spark plug cap resistance. • Positive tester probe →

EAS30558
terminal “1”
CHECKING THE IGNITION COIL • Negative tester probe →
ignition coil lead “2”
1. Check:
• Primary coil resistance
Primary coil resistance

2.34–2.86 Ω
a. Disconnect the ignition coil connectors

from the ignition coil terminals.
b. Connect the multimeter (Ω × 1) to the igni-
tion coil as shown.
Multimeter c. Measure the secondary coil resistance.

INS-003
(90890-03189) EAS30556
CHECKING THE IGNITION SPARK GAP

• Positive tester probe → 1. Check:
terminal “1” • Ignition spark gap
• Negative tester probe → Out of specification → Perform the ignition
terminal “2” system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page
8-3.
Minimum ignition spark gap

6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
a. Disconnect the spark plug cap from the
spark plug.
c. Measure the primary coil resistance.
b. Connect the ignition checker “1” as
shown.
8-148

– +
Ignition checker
INS-007 2
(90890-06754)
W
b. Measure the crankshaft position sensor

resistance.
EAS30561
CHECKING THE LEAN ANGLE SENSOR

2. Spark plug cap 1. Remove:
• Lean angle sensor
c. Set the main switch to “ON” and the 2. Check:
engine stop/start switch to “ ”. • Lean angle sensor output voltage
d. Measure the ignition spark gap “a”. Out of specification → Replace.
e. Crank the engine by pushing the start
switch “ ” and gradually increase the Lean angle sensor output voltage
spark gap until a misfire occurs. Operating angle
50 °
EAS30560
Output voltage up to operating
CHECKING THE CRANKSHAFT POSITION angle
SENSOR 0.4–1.4 V
1. Disconnect: Output voltage over operating
• Crankshaft position sensor coupler angle
(from the wire harness) 3.7–4.4 V
2. Check:
• Crankshaft position sensor resistance Connecting the Yamaha diagnostic tool.
Out of specification → Replace the crank- Refer to “FUEL INJECTION SYSTEM” on
shaft position sensor/stator assembly. page 8-28.
EAS30562
Crankshaft position sensor resis-
CHECKING THE STARTER MOTOR
tance
228–342 Ω OPERATION
1. Check:
a. Connect the multimeter (Ω × 100) to the • Starter motor operation
crankshaft position sensor coupler as Does not operate → Perform the electric
shown. starting system troubleshooting, starting with
step 4.
Multimeter Refer to “TROUBLESHOOTING” on page
INS-003 8-7.
(90890-03189) a. Connect the positive battery terminal “1”
and starter motor lead “2” with a jumper
• Positive tester probe → lead “3”.
red “1”
white “2”
8-149

– +
EWA13810
WARNING
• A wire that is used as a jumper lead must 1
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may W
burn.
W
• This check is likely to produce sparks,
therefore, make sure no flammable gas or 2
fluid is in the vicinity.
b. Measure the stator coil resistance.

EAS30680
CHECKING THE RECTIFIER/REGULATOR

1. Check:
• Rectifier/regulator output voltage (Charging
voltage)
Out of specification → Replace the rectifier/
regulator.
b. Check the starter motor operation. Rectifier/regulator output voltage

14.0–14.8 V at 5000 r/min
EAS30566
CHECKING THE STATOR COIL a. Connect the multimeter (DC 20 V) to the

1. Disconnect: rectifier/regulator coupler as shown.
• Stator coil coupler
(from the wire harness) Multimeter
2. Check: INS-003
• Stator coil resistance (90890-03189)
shaft position sensor/stator assembly. • Positive tester probe →
positive battery terminal “1”
Stator coil resistance • Negative tester probe →
0.360–0.540 Ω negative battery terminal “2”
a. Connect the multimeter (Ω × 1) to the sta-

tor coil coupler as shown. 1
Multimeter
INS-003
(90890-03189)

white “1”
2
white “2”
b. Start the engine and let it run at approxi-
mately 5000 r/min.
c. Measure the charging voltage.
8-150

– +
CHECKING THE HORN a. Connect the multimeter (Ω × 10) to the fuel

1. Check: sender coupler as shown.
• Horn resistance
Out of specification → Replace. Multimeter
INS-003
Coil resistance (90890-03189)
1.35–1.75 Ω
a. Disconnect the horn connectors from the terminal “1”
horn terminals. • Negative tester probe →
b. Connect the multimeter (Ω × 1) to the horn terminal “2”
terminals.
1 2
Multimeter
INS-003
(90890-03189)

horn terminal “1”
horn terminal “2”
1 b. Move the fuel sender float to the minimum

“3” and maximum “4” level positions.
c. Measure the horn resistance.

EAS30573
CHECKING THE FUEL SENDER

1. Disconnect: c. Measure the fuel sender resistance.
• Fuel pump coupler EAS31372
(from the wire harness) CHECKING THE FUEL METER

• Fuel sender coupler This model is equipped with a self-diagnosis de-
(from the wire harness) vice for the fuel level detection circuit.
2. Remove: 1. Check:
• Fuel pump • Fuel meter “1”
(from the fuel tank) (Turn the main switch to “ON”)
3. Check: Fuel meter comes on for a few seconds, then
• Fuel sender resistance goes off → Fuel meter is OK.
Out of specification → Replace the fuel send- Fuel meter does not come on → Replace the
er. fuel pump sender or meter assembly.
All the fuel meter display segments flash re-
Sender unit resistance (full) peatedly → Check entire fuel pump circuit.
10.0–14.0 Ω Refer to “TROUBLESHOOTING” on page
Sender unit resistance (empty) 8-100.
267.0–273.0 Ω
8-151

– +
EAS30578
CHECKING THE COOLANT TEMPERATURE

SENSOR
1. Remove:
• Coolant temperature sensor
EWA14130
WARNING
• Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature sen-
sor to strong shocks. If the coolant temper-
EAS30576 ature sensor is dropped, replace it.
CHECKING THE SPEED SENSOR
2. Check:
1. Check:
• Coolant temperature sensor resistance
• Speed sensor output voltage
Coolant temperature sensor re-
Front wheel speed pulse (in ro- sistance
tate) 2513–2777 Ω at 20 °C (2513–
0–999 2777 Ω at 68 °F)
Coolant temperature sensor re-
Connecting the Yamaha diagnostic tool. sistance
Refer to “YAMAHA DIAGNOSTIC TOOL” on 210–221 Ω at 100 °C (210–221 Ω
page 8-32. at 212 °F)
EAS30577
CHECKING THE RADIATOR FAN MOTOR a. Connect the multimeter (Ω × 100) to the
1. Check: coolant temperature sensor terminals as
• Radiator fan motor shown.
Faulty/rough movement → Replace.
Multimeter
a. Disconnect the radiator fan motor coupler
INS-003
from the wire harness. (90890-03189)
b. Connect the battery (DC 12 V) as shown.
• Positive tester probe → b. Immerse the coolant temperature sensor
blue “1” “1” in a container filled with coolant “2”.
black “2” TIP
Make sure the coolant temperature sensor ter-
minals do not get wet.
c. Place a thermometer “3” in the coolant.
1
L
3
B 1
2
c. Measure the radiator fan motor move- 2

ment.
d. Slowly heat the coolant, and then let it cool
down to the specified temperature.
e. Check the coolant temperature sensor re-
sistance.
8-152

– +
3. Install: EAS30597
CHECKING THE FID (FAST IDLE SOLENOID)

• Coolant temperature sensor
1. Remove:
Coolant temperature sensor • Throttle body from vehicle
15 N·m (1.5 kgf·m, 11 lb·ft) Refer to “THROTTLE BODY” on page 7-7.
T.
R.
2. Check:
EAS30596 • FID (fast idle solenoid) resistance
CHECKING THE THROTTLE BODY SENSOR a. Connect the multimeter (Ω × 10) to the ter-
ASSEMBLY minals of the FID (fast idle solenoid).
EWA20700
WARNING • Positive tester probe →

FID terminal “1”
• Do not remove the throttle body sensor as- • Negative tester probe →
sembly. FID terminal “2”
• Handle the throttle body sensor assembly
with special care.
Multimeter
• Never subject the throttle body sensor as- INS-003
sembly to strong shocks. If the throttle (90890-03189)
body sensor assembly is dropped, replace
it. b. Measure the FID (fast idle solenoid) resis-
tance.
Throttle position sensor Out of specification → Replace the throttle
1. Check: body assembly.
• Throttle position sensor with Yamaha diag-
FID (fast idle solenoid) resistance
nostic tool
31.5–38.5 Ω
Connecting the Yamaha diagnostic tool.
page 8-32.
Throttle position sensor signal 2 1

fully close condition
13–21
Throttle position sensor signal
fully open condition
92–107
Intake air pressure sensor

1. Check: EAS31612
• Intake air pressure sensor CHECKING THE VVA SOLENOID

Out of specification → Replace the throttle 1. Check:
body. • VVA solenoid resistance
Connecting the Yamaha diagnostic tool. Out of specification → Replace.
page 8-32. Resistance
1.8–2.2 Ω at 20 °C (12.0 Ω at
Intake air temperature sensor 68 °F)
1. Check:
a. Disconnect the VVA solenoid coupler from
• Intake air temperature sensor
the VVA solenoid.
Out of specification → Replace the throttle
b. Connect the multimeter to the VVA sole-
body.
noid terminal as shown.
Connecting the Yamaha diagnostic tool.
page 8-32.
8-153

– +
Multimeter
INS-003
(90890-03189)

solenoid terminal “1” 1
solenoid terminal “2”
2
1 2 c. Measure the fuel injector resistance.
c. Measure the VVA solenoid resistance.

EAS30681
CHECKING THE FUEL INJECTOR

1. Remove:
• Fuel injector
Refer to “THROTTLE BODY” on page 7-7.
2. Check:
• Fuel injector resistance
Out of specification → Replace the fuel injec-
tor.
Resistance
12.2 Ω
a. Disconnect the fuel injector coupler from

the fuel injector.
b. Connect the multimeter to the fuel injector
coupler as shown.
Multimeter
INS-003
(90890-03189)

fuel injector terminal “1”
fuel injector terminal “2”
8-154

– +
8-155
TROUBLESHOOTING
TROUBLESHOOTING ....................................................................................9-1
GENERAL INFORMATION ......................................................................9-1
STARTING FAILURES .............................................................................9-1
INCORRECT ENGINE IDLING SPEED ...................................................9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ..........................9-2
FAULTY GEAR SHIFTING .......................................................................9-2
SHIFT PEDAL DOES NOT MOVE ...........................................................9-2
JUMPS OUT OF GEAR ............................................................................9-2
FAULTY CLUTCH ....................................................................................9-2
OVERHEATING .......................................................................................9-3
OVERCOOLING .......................................................................................9-3
POOR BRAKING PERFORMANCE .........................................................9-3
FAULTY FRONT FORK LEGS .................................................................9-3
FAULTY LIGHTING OR SIGNALING SYSTEM .......................................9-4
TROUBLESHOOTING AT THE ABS WARNING LIGHT .........................9-4
9
TRBL
TROUBLESHOOTING SHTG
EAS28450
4. Canister
TROUBLESHOOTING • Hose clogged
EAS28460
• Hose band / twisted
GENERAL INFORMATION
TIP
Electrical system
1. Battery
The following guide for troubleshooting does not • Discharged battery
cover all the possible causes of trouble. It should • Faulty battery
be helpful, however, as a guide to basic trouble- 2. Fuse(s)
shooting. Refer to the relative procedure in this • Blown, damaged or incorrect fuse
manual for checks, adjustments, and replace- • Improperly installed fuse
ment of parts. 3. Spark plug
• Incorrect spark plug gap
EAS28470
• Incorrect spark plug heat range
STARTING FAILURES
• Fouled spark plug
Engine • Worn or damaged electrode
• Worn or damaged insulator
1. Cylinder and cylinder head • Faulty spark plug cap
• Loose spark plug
4. Ignition coil
• Loose cylinder head or cylinder
• Damaged cylinder head gasket • Cracked or broken ignition coil body
• Damaged cylinder gasket • Broken or shorted primary or secondary coils
• Worn or damaged cylinder • Faulty spark plug lead
• Incorrect valve clearance 5. Ignition system
• Improperly sealed valve • Faulty ECU
• Incorrect valve-to-valve-seat contact • Faulty crankshaft position sensor
• Incorrect valve timing • Broken AC magneto rotor woodruff key
• Faulty valve spring 6. Switches and wiring
• Seized valve • Faulty main switch
2. Piston and piston ring(s) • Faulty engine stop switch
• Improperly installed piston ring • Broken or shorted wiring
• Damaged, worn or fatigued piston ring • Faulty gear position switch
• Seized piston ring • Faulty front, rear or both brake light switches
• Seized or damaged piston • Faulty sidestand switch
• Faulty start switch
3. Air filter • Faulty clutch switch
• Improperly installed air filter • Improperly grounded circuit
• Clogged air filter element • Loose connections
4. Crankcase and crankshaft 7. Starting system
• Improperly assembled crankcase • Faulty sidestand switch
• Seized crankshaft • Faulty starter motor
• Faulty starter relay
Fuel system • Faulty starter clutch
1. Fuel tank • Faulty diode
• Empty fuel tank EAS28490
• Deteriorated or contaminated fuel INCORRECT ENGINE IDLING SPEED
2. Fuel pump
• Faulty fuel pump Engine
• Clogged fuel pump filter 1. Cylinder and cylinder head
• Clogged fuel tank cap breather hole • Incorrect valve clearance
• Clogged or damaged fuel hose • Damaged valve train components
3. Throttle body 2. Air filter
• Deteriorated or contaminated fuel • Clogged air filter element
• Sucked-in air
9-1
TRBL
Fuel system Transmission
1. Throttle body • Seized transmission gear
• Damaged or loose throttle body joint • Foreign object between transmission gears
• Improperly adjusted engine idling speed (idle • Improperly assembled transmission
adjusting screw)
EAS28550
• Improper throttle cable free play JUMPS OUT OF GEAR
• Flooded throttle body
Shift shaft
Electrical system
• Incorrect shift pedal position
1. Battery • Improperly returned stopper lever
• Discharged battery
• Faulty battery Shift forks
2. Spark plug • Worn shift fork
• Incorrect spark plug gap
• Incorrect spark plug heat range Shift drum
• Fouled spark plug • Incorrect axial play
• Worn or damaged electrode • Worn shift drum groove
• Worn or damaged insulator
Transmission
• Faulty spark plug cap
• Worn gear dog
3. Ignition coil
• Broken or shorted primary or secondary coils EAS28560
• Faulty spark plug lead FAULTY CLUTCH

• Cracked or broken ignition coil
Clutch slips
4. Ignition system
1. Clutch
• Faulty ECU
• Faulty crankshaft position sensor • Improperly assembled clutch
• Broken AC magneto rotor woodruff key • Improperly adjusted clutch cable
• Loose or fatigued clutch spring
EAS28510 • Worn friction plate
POOR MEDIUM-AND-HIGH-SPEED • Worn clutch plate
PERFORMANCE 2. Engine oil
Refer to “STARTING FAILURES” on page 9-1. • Incorrect oil level
• Incorrect oil viscosity (low)
Engine • Deteriorated oil
1. Air filter
• Clogged air filter element Clutch drags
1. Clutch
Fuel system
• Unevenly tensioned clutch springs
1. Fuel pump • Warped pressure plate
• Faulty fuel pump • Bent clutch plate
EAS28530
• Swollen friction plate
FAULTY GEAR SHIFTING • Bent clutch push rod
• Broken clutch boss
Shifting is difficult • Burnt primary driven gear bushing
Refer to “Clutch drags”. • Clutch push lever match marks not aligned
2. Engine oil
EAS28540
SHIFT PEDAL DOES NOT MOVE • Incorrect oil level

• Incorrect oil viscosity (high)
Shift shaft • Deteriorated oil
• Bent shift shaft
Shift drum and shift forks

• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
9-2
TRBL
EAS28600 EAS28610
OVERHEATING OVERCOOLING
Engine Cooling system

1. Engine clogged 1. Thermostat
• Clogged coolant passages • Thermostat stays opened
• Clogged engine oil passages • Faulty coolant temperature sensor
• Heavy carbon buildup on piston top & valves
EAS28640
head. POOR BRAKING PERFORMANCE
2. Engine oil • Worn brake pad
• Incorrect oil level • Worn brake disc
• Incorrect oil viscosity • Air in hydraulic brake system
• Inferior oil quality • Leaking brake fluid
3. Ignition system • Faulty brake caliper kit
• Improper spark plug gap • Faulty brake caliper seal
• Improper spark plug heat range • Loose union bolt
4. Compression system • Damaged brake hose
• More carbon deposition • Oil or grease on the brake disc
• Improperly adjusted valve timing • Oil or grease on the brake pad
• Improperly adjusted valve clearance • Incorrect brake fluid level
EAS28650
Cooling system FAULTY FRONT FORK LEGS
1. Coolant
• Low coolant level Leaking oil
2. Radiator • Bent, damaged or rusty inner tube
• Damaged or leaking radiator • Cracked or damaged outer tube
• Faulty radiator cap • Improperly installed oil seal
• Bent or damaged radiator fin • Damaged oil seal lip
3. Water pump • Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged or faulty water pump
• Damaged damper rod assembly bolt copper
4. Thermostat washer
• Thermostat stays closed • Cracked or damaged front fork cap O-ring
5. Hose(s) and pipe(s)
• Damaged hose Malfunction
• Improperly connected hose • Bent or damaged inner tube
• Damaged pipe • Bent or damaged outer tube
• Improperly connected pipe • Damaged fork spring
• Air in cooling system • Worn or damaged outer tube bushing
• Bent or damaged damper rod
Fuel system • Incorrect oil viscosity
1. Throttle body • Incorrect oil level
• Damaged or loose throttle body joint EAS28670
2. Air filter UNSTABLE HANDLING

• Clogged air filter element
Handlebar
Chassis • Bent or improperly installed right handlebar
1. Brake(s) • Bent or improperly installed left handlebar
• Dragging brake 1. Steering head components
• Improperly installed upper bracket
Electrical system • Improperly installed lower bracket
1. Spark plug (improperly tightened ring nut)
• Incorrect spark plug gap • Bent steering stem
• Incorrect spark plug heat range • Damaged ball bearing or bearing race
2. Ignition system
• Faulty ECU
9-3
TRBL
2. Front fork leg(s) Tail/brake light bulb burnt out
• Unevenly oil levels (both front fork legs) • Wrong tail/brake light bulb (LED)
• Unevenly tensioned fork spring (both front • Faulty battery
fork legs) • Incorrectly adjusted rear brake light switch
• Broken fork spring • Tail/brake light bulb life expired
• Bent or damaged inner tube
• Bent or damaged outer tube Turn signal does not come on
3. Swingarm • Faulty turn signal switch
• Worn bearing • Faulty turn signal relay
• Bent or damaged swingarm • Burnt-out turn signal bulb
• Incorrect connection
Rear shock absorber assembly • Damaged or faulty wire harness
• Faulty rear shock absorber spring • Improperly grounded circuit
• Leaking oil • Faulty battery
Tire(s) • Blown, damaged or incorrect fuse
• Unevenly tire pressures (front and rear)
Turn signal blinks slowly
• Incorrect tire pressure • Faulty turn signal relay
• Unevenly tire wear • Faulty main switch
Wheel(s) • Faulty turn signal switch
• Incorrect wheel balance • Incorrect turn signal bulb
• Deformed cast wheel
Turn signal remains lit
• Damaged wheel bearing • Faulty turn signal relay
• Bent or loose wheel axle • Burnt-out turn signal bulb
• Excessive wheel runout
Turn signal blinks quickly
Frame • Incorrect turn signal bulb
• Bent frame • Faulty turn signal relay
• Damaged steering head pipe • Burnt-out turn signal bulb
• Improperly installed bearing race
EAS28710
Horn does not sound
FAULTY LIGHTING OR SIGNALING SYSTEM • Damaged or faulty horn
• Faulty main switch
Headlight does not come on • Faulty horn switch
• Wrong headlight (LED) bulb • Faulty battery
• Too many electrical accessories • Blown, damaged or incorrect fuse
• Hard charging • Faulty wire harness
EAS30848
• Improperly grounded circuit TROUBLESHOOTING AT THE ABS
• Poor contacts (main switch) WARNING LIGHT
• Burnt-out headlight (LED) bulb Refer to “BASIC PROCESS FOR TROUBLE-
Headlight bulb burnt out SHOOTING” on page 8-107.
• Wrong headlight (LED) bulb
• Faulty battery
• Faulty rectifier/regulator
• Improperly grounded circuit
• Faulty main switch
Tail/brake light does not come on

• Too many electrical accessories
• Burnt-out tail/brake light
9-4
EAS20091
51. Turn signal indicator light EAS30613
WIRING DIAGRAM (Right) COLOR CODE

YZF155D-A 2022 52. Turn signal indicator light (Left) B Black
1. AC magneto assembly 53. Fuel meter Br Brown
2. Crankshaft position sensor 54. ABS warning indicator light Ch Chocolate
3. AC magneto 55. Gear position indicator Dg Dark green
4. Rectifier/regulator 56. Gear position switch G Green
5. Fuse box 57. Radiator fan motor Gy Gray
58. Radiator fan motor relay L Blue
6. Accessories fuse
59. Horn 1 Or Orange
P Pink
8. Main fuse 60. Handlebar switch (left)
R Red
9. ABS motor fuse 61. Dimmer / pass switch
Sb Sky blue
10. ABS solenoid fuse 62. Horn 2
V Violet
11. Accessories socket 63. Horn switch W White
12. Battery 64. Turn signal switch Y Yellow
13. Starter relay 65. Clutch switch B/L Black/Blue
14. Handlebar switch (right) 66. Turn signal relay B/R Black/Red
15. Engine stop / start switch 67. Rear brake light switch B/Y Black/Yellow
16. Trip / information switch 68. Junction 1 B/W Black/White
17. Hazard switch 69. Junction 2 Br/L Brown/Blue
18. Front brake light switch 70. ABS ECU (Hydraulic control Br/W Brown/White
19. Throttle body sensor assembly unit) G/R Green/Red
20. Intake air pressure assembly 71. Front wheel sensor Gy/G Gray/Green
21. Intake air temperature sensor 72. Rear wheel sensor L/B Blue/Black
22. Throttle position sensor 73. Joint L/G Blue/Green
23. ECU (Engine Control Unit) 74. Brake/Taillight assembly L/R Blue/Red
24. Ignition coil 75. Brake light L/W Blue/White
25. Spark plug 76. Taillight Lg/W Light green/White
26. O2 sensor 77. Rear turn signal light (Right) Lg/L Light green/Blue
78. Rear turn signal light (Left) Or/B Orange/Black
27. FID (fast idle solenoid) Or/W Orange/White
28. Coolant temperature sensor 79. Front turn signal light (Right)
80. Front turn signal light (Left) P/B Pink/Black
29. VVA (variable valve actuation) P/W Pink/White
solenoid 81. Sidestand switch
R/B Red/Black
30. Lean angle sensor 82. Diode 2
R/L Red/Blue
31. Fuel pump 83. Headlight assembly
R/W Red/White
32. Fuel sender 84. Headlight (High beam) Y/B Yellow/Black
33. Fuel injector 85. Headlight (Low beam) Y/G Yellow/Green
34. Yamaha diagnostic tool cou- 86. License plate light Y/L Yellow/Blue
pler/ABS test coupler 87. Auxiliary light (Right) Y/R Yellow/Red
35. CCU (Communication control 88. Auxiliary light (Left) Y/W Yellow/White
unit) W/B White/Black
36. Quick shift switch W/L White/Blue
37. Diode 1 W/R White/Red
38. Starter motor W/Y White/Yellow
39. Engine ground
40. Main switch
41. Meter assembly
42. Neutral indicator light
43. Multi-function display
44. Traction control indicator light
45. Engine trouble warning light
46. Coolant temperature warning
light
47. Shift indicator light
48. Incoming notification indicator
light 1
49. Incoming notification indicator
light 2
50. High beam indicator light
BCW-F8197-E0
1Y245(SM-01)1578-10-21-E
R R Br
R R/L R Br/W Br
YZF155D-A 2022
SPARE SPARE
WIRING DIAGRAM
Br R R
5
6 7 8 9 10
1 R R
2A
2A
30A
15A
ABS
R
MAIN
15A
ABS-SOL
ABS-MOTOR
2
R W/R
Br Br/W R R R/L R
W B/L
W W Ch Y/B B/R R/W L/G R/B V P/W Or/B W/Y B/L W/R Y
W W
3 B/Y L Lg/W W/B B/L B/W Br/W Gy/G Y/W B/L B/L P/B Or
R/W
11 R R R 24
W R Br
4 13 Or Or
W 26
R R
B/L Y/W L P/W Br/W Y/L P/B Br
R R/W R/W 25 B B
R W/R Gy/G B/L
B L B/L W L
B R/W R/W
19 B
B L/W L/W Br/L L/W Br/W P/W Y/W Br/L R/W
12 L/W P/B P/B Br
20 L L Gy/G Gy/G
P/W P/W B/L
R/W 14
15 Br/L L/W Br/W P Y/W B/L
21 B/L
B/L
TRIP Br/W Br/W
B B B/W Gy Gy B OFF OFF
RUN N Y/W Y/W 27
R/B R/B ON Br
B START INFO
B Ch Dg Dg Ch
B B 18
B B
16 17 22
39 Y/R L
B B B
B B B B B/W Lg/W Or/W G
B Y/W B/W P/W Br/W Dg Ch Gy
R/B Br Lg/L
B/W B B/W B G/R
B/W R/W R/W R/B
B B 28 32
B/W B 23
B R/B R/B R/B B/L G
B/W R R CONNECTED
29 31
38 Sb G
40 37 R
R/B L/G Ch
ON
OFF 30
Y/G Or/W
Sb Sb
R B/L
Br Br L
Y
B/W V V Y Y R
Sb W/B
Sb
36 Lg/L W
Sb R Lg/W Y/B
B R B/R
Lg/W 33
35 B/Y
Lg/L
Br V B/W L/B Or/B Or/B R/W
R R B
Br Br Br
R L/R Br
W/Y
R R Br Br Br Br Lg/L B
Br R/W
R Lg/W
B/W B

34
B/W B
Gy
41
42
Br Sb
Br
R
Gy Br Br
43 Y/W
P/W Br/W 66
R Br Br B B/W
Y/L
44 58 Br
TCS 59 Br R/W R/W R/W R/W
67 Br Br Br Br Br Br Br Br/L
EG_ALARM 45 Br/W
P 69
46 Br/W
WATER Gy
Br/W
Y/B Y/B Br P R/B
SHIFT 47
L
48 60 62 63
W/Y 61 64 65 R/B
L Gy Gy Gy Gy
49 68 B B B B B/R B/Y B B/W
INCOMING_NOTIFICATION_2 HI OFF L
LO N B B B/Y B R/W R/W R/W
ON
PASS R B B/R B B/W R/W
HI_BEAM 50 L L 57
Y/R B B Br Br Br Br/L Gy Gy Or
Ch Y/B
Br R/B P B/W Br Br Br Br Gy Gy
51 B/R Dg W/B
TURN_R Or
B
Dg Y Br R/B P B Ch Dg B/W
52 B/W Dg Y/B
TURN_L
Ch Ch Y/B
G B
Or/W 53 CONNECTED
ABS 54 Sb
B 82
L/G
Sb L/G B/W
L/G L/G L/G
W/L Ch
Ch Ch
Ch
81 L/G W
55 Ch 70 W/B
L/G B
Br
W P Y/W W/R Or Gy L B
Sb W W Sb B/W R/L
L Dg Dg Dg
Or P P Or L R
Dg B/W
W/R Y/W Y/W W/R
1 Dg Br/W
W 83 Br Y Br Gy B/W
N Br 74 B G G 71
2 86 W B
P Gy
3 R R G R
Y/W Ch Dg Ch Dg Shield S
4 L
W/R Br L
5 84 80 79 78 77
Or B B Br Br 72
6
12V 5W
Gy B W B
75 Y Y
Gy Ch Dg Ch Dg Shield S Br Y
56
B
12V 10W
12V 10W
12V 10W
12V 10W
Sb B B B B
85 W/L 73
B/W B/W
L L Y/R
88 87 G Y B R B B B B B 76
L/B
B Y/B L/R
B L L B L B B L Y/R Y Y/B B Br B
B
B B
B B

Y/B
Y/B
B Y/B Y/B
B B

Service Manual: YZF155D-A YZF155-A

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Service Manual: YZF155D-A YZF155-A

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BCWF8197E0.

book Page 1 Thursday, November 18, 2021 9:18 AM

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.

YZF155D-A & YZF155-A

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Molybdenum disulfide oil

Filling fluid Brake fluid

Lubricant B Wheel bearing grease

Special tool LS Lithium-soap-based grease

Tightening torque M Molybdenum disulfide grease

Wear limit, clearance S Silicone grease

Engine speed Apply locking agent (LOCTITE®).

Electrical data New Replace the part with a new one.

IMPORTANT INFORMATION ...................................................................... 1-34

BASIC SERVICE INFORMATION ................................................................ 1-36

SPECIAL TOOLS ......................................................................................... 1-42

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

OUTLINE OF THE TCS (Traction Control System)

1. Traction control system indicator light

1. Front wheel sensor

Quick shift system

1. Engine trouble warning light

1. Fuel pump 11.Throttle body

OUTLINE OF THE ABS

1. Yamaha diagnostic tool coupler/ ABS test

Brake force and vehicle stability

a. Chassis speed d. Depressurizing phase

ABS operation and vehicle control

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

Electronic ABS features

1. Rear brake master cylinder 9. Buffer chamber

ABS COMPONENT FUNCTIONS

Wheel sensors and wheel sensor rotors

3. At low speed 7. Voltage

ABS warning light

Hydraulic unit assembly

Hydraulic control valve

3. Brake master cylinder

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

1. Battery 14. ABS ECU

ABS control operation

1. Software operation flow

Normal braking (ABS not activated)

1. Brake master cylinder

1. Brake master cylinder

ABS WARNING LIGHT AND OPERATION

ABS warning light

• At facilities nearby that are emitting strong

plants, broadcasting stations, airports,

HANDLEBAR SWITCHES Stop/Run/Start switch “ / / ”

Dimmer/Pass switch “ / /PASS”

INDICATOR LIGHTS AND WARNING LIGHTS NOTICE

Engine trouble warning light “ ”