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• Page 1
  OWNER’S MANUAL XT1200ZE Super Ténéré ABS MOTORCYCLE Read this manual carefully before oper- ating this vehicle. XT1200ZE BP9-28199-E0…
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  EAU69362 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. YAMAHA MOTOR ELECTRONICS CO., LTD. 1450-6, Mori, Mori-machi, Shuchi-gun, Shizuoka-ken, 437-0292 Japan DECLARATION of CONFORMITY Product: IMMOBILIZER Model: 2BS-00 Supplied by…
• Page 3
  If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! Yamaha continually seeks advancements in product design and quality. There-…

• Page 4: Important Manual Information

  *Product and specifications are subject to change without notice. EAU10201 XT1200ZE OWNER’S MANUAL ©2017 by Yamaha Motor Co., Ltd. 1st edition, January 2017 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

• Page 5: Table Of Contents

  Table of contents Safety information ……1-1 Engine break-in……. 5-4 Parking……….5-5 Description ……..2-1 Left view ……….2-1 Periodic maintenance and Right view……..2-2 adjustment ……..6-1 Controls and instruments….2-3 Owner’s tool kit……. 6-2 Periodic maintenance chart for the Instrument and control functions..3-1 emission control system….

• Page 6
  Table of contents Battery ………. 6-30 Replacing the fuses…… 6-32 Replacing a headlight bulb… 6-33 Replacing an auxiliary light bulb… 6-35 Turn signal light and brake/tail light ……….. 6-37 Replacing a license plate light bulb ……….. 6-38 Troubleshooting……6-39 Troubleshooting charts….6-40 Motorcycle care and storage..

• Page 7: Safety Information

  Safety information EAU1031C an accident or equipment damage. See page 4-1 for a list of pre-operation checks. Be a Responsible Owner  This motorcycle is designed to As the vehicle’s owner, you are re- carry the operator and a passen- sponsible for the safe and proper oper- ger.

• Page 8
  Safety information  Many accidents involve inexperi- • The passenger should always enced operators. In fact, many op- hold onto the operator, the seat erators who have been involved in strap or grab bar, if equipped, accidents do not even have a cur- with both hands and keep both rent motorcycle license.
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  Safety information Avoid Carbon Monoxide Poisoning extra care when riding a motorcycle All engine exhaust contains carbon that has added cargo or accessories. monoxide, a deadly gas. Breathing Here, along with the information about carbon monoxide can cause head- accessories below, are some general aches, dizziness, drowsiness, nausea, guidelines to follow if loading cargo to confusion, and eventually death.
• Page 10
  Genuine before using it to make sure that it Yamaha accessories, which are avail- does not in any way reduce able only from a Yamaha dealer, have ground clearance or cornering been designed, tested, and approved clearance, limit suspension travel, by Yamaha for use on your vehicle.
• Page 11
  Safety information operator and may limit control torcycle, such as the frame or up- ability, therefore, such accesso- per front fork triple clamp (and not, ries are not recommended. for example, to rubber-mounted  Use caution when adding electri- handlebars or turn signals, or cal accessories.

• Page 12: Description

  Description EAU63371 Left view 1. Fuel tank cap (page 3-30) 2. Seat lock (page 3-33) 3. Carrier (page 3-41) 4. Final gear oil filler bolt (page 6-14) 5. Final gear oil drain bolt (page 6-14) 6. Coolant reservoir (page 6-16) 7.

• Page 13: Right View

  Description EAU63391 Right view 1. Rear brake fluid reservoir (page 6-25) 2. Electronically adjustable suspension system (page 3-37) 3. Fuses (page 6-32) 4. Owner’s tool kit (page 6-2) 5. Battery (page 6-30) 6. Engine oil filler cap (page 6-10) 7. Engine oil level check window (page 6-10) 8.

• Page 14: Controls And Instruments

  Description EAU63401 Controls and instruments 1. Clutch lever (page 3-24) 2. Left handlebar switches (page 3-23) 3. Clutch fluid reservoir (page 6-25) 4. Multi-function meter unit (page 3-10) 5. Auxiliary DC jack (page 3-45) 6. Front brake fluid reservoir (page 6-25) 7.

• Page 15: Instrument And Control Functions

   Do not grind any key or alter its cess, take the vehicle along with all shape. three keys to a Yamaha dealer to have  Do not disassemble the plastic them re-registered. Do not use the key part of any key.

• Page 16: Main Switch/Steering Lock

  Instrument and control functions  Keep the standard keys as well EAU10474 Main switch/steering lock as keys of other immobilizer systems away from this vehi- cle’s code re-registering key.  Keep other immobilizer system keys away from the main switch as they may cause signal inter- ference.

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  Instrument and control functions To unlock the steering EWA10062 WARNING Never turn the key to “OFF” or “LOCK” while the vehicle is moving. Otherwise the electrical systems will be switched off, which may result in loss of control or an accident. EAU10696 LOCK The steering is locked and all electrical…

• Page 18: Indicator Lights And Warning Lights

  C.TEMP ˚C TIME TRIP 0:00 (page 6-10), have a Yamaha dealer check the vehicle.  Even if the oil level is sufficient, the 1. Left turn signal indicator light “ ” warning light may flicker when rid- 2.

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  If this occurs, braking. Have a Yamaha dealer have a Yamaha dealer check the on- check the brake system and electri- board diagnostic system. cal circuits as soon as possible.
• Page 20
  Immobilizer system indicator do not start the engine, take the light “ ” vehicle and all 3 keys to a Yamaha When the key is turned to “OFF” and dealer to have the standard keys 30 seconds have passed, the indicator re-registered.

• Page 21: Cruise Control System

  Instrument and control functions EAU59132 Cruise control system This model is equipped with a cruise control system designed to maintain a set cruising speed. The cruise control system operates only when riding in 3rd gear at speeds between about 50 km/h (31 mi/h) and 100 km/h (62 mi/h), 4th gear at speeds between about 50 km/h (31 mi/h) and 1.

• Page 22
  Instrument and control functions 2. Push the “SET–” side of the cruise you return the throttle grip, the vehicle control setting switch to activate will decelerate to the previously set the cruise control system. Your cruising speed. current traveling speed will be- come the set cruising speed.
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  Instrument and control functions When not traveling with a set cruising EWA16351 WARNING speed, if the start/engine stop switch is set to the “ ” position, the engine It is dangerous to use the resume stalls, or the sidestand is lowered, then function when the previously set the “…

• Page 24: Multi-Function Meter Unit

  Instrument and control functions  information display EAU80550 Multi-function meter unit  setting mode 5 6 7 The select switch “ ” and the menu switch “MENU” are located on GEAR the left handlebar. These switches al- A.TEMP ˚C C.TEMP ˚C low you to control or change the set- TIME TRIP…

• Page 25
  Tachometer If a problem is detected in the fuel me- ter circuit, all display segments of the fuel meter will start flashing. If this oc- curs, have a Yamaha dealer check the vehicle. Eco indicator 1. Tachometer 2. High-r/min zone The tachometer shows the engine speed.
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  Instrument and control functions Transmission gear indicator Traction control system indicator GEAR A.TEMP ˚C C.TEMP ˚C TIME TRIP 0:00 1. Neutral indicator light “ ” 1. Traction control system indicator 2. Transmission gear indicator This indicator shows the current trac- This indicator shows the current trans- tion control mode: “1”, “2”…
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  Instrument and control functions Push the menu switch “MENU” to ECA17931 NOTICE switch the display between the follow-  Be sure to wear gloves when ing functions. The display changes each time the switch is pushed. using the grip warmers. …
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  Instrument and control functions  average fuel consumption  instantaneous fuel consumption GEAR Odometer: TRIP-F The odometer shows the total distance traveled by the vehicle. In this case, push the select switch to rotate among the information display Tripmeters: pages in the following order; TRIP-1 TRIP-F →…
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  Instrument and control functions This timer shows the elapsed time This shows the temperature of the since the key was turned to “ON”. The coolant. The coolant temperature will maximum time that can be shown is vary with changes in the ambient tem- 99:59.
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  If there is a malfunction, “– –.–” will play flashes, and then push and hold be continuously displayed. Have a the “RESET” button for 2 seconds. Yamaha dealer check the vehicle. Setting mode After resetting the average fuel con- sumption, “_ _._” will be shown until the vehicle has traveled 1 km (0.6 mi).
• Page 31
  Instrument and control functions Push and hold the menu switch Adjusting the temperature levels of the “MENU” for 2 seconds to enter the set- grip warmer settings ting mode. To exit the setting mode 1. Use the select switch to highlight and return to the normal display, push “Grip Warmer”.
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  Instrument and control functions Grip Warmer MENU Grip Warmer Hi g h Maintenance Time Trip Middle Unit Display Brightness Clock 4. Use the select switch to highlight 2. Push the menu switch “MENU”, “Middle” or “Low”, and then chan- and then push the “RESET” but- ge the setting using the same pro- ton to select the item to reset.
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  Instrument and control functions MENU MENU Grip Warmer Grip Warmer Maintenance Maintenance Time Trip Time Trip Unit Unit Display Display Brightness Brightness Clock Clock 2. Push the menu switch “MENU” to 2. Push the menu switch “MENU”. display “TIME–2” and “TIME–3”. The unit setting display will be To reset a time trip, push the “RE- shown and “km or mile”…
• Page 34
  Instrument and control functions 2. Push the menu switch “MENU”, use the select switch to highlight When “km” is selected, “L/100km” or the page you want to adjust, and “km/L” can be set as the fuel con- then push the menu switch sumption units.
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  Instrument and control functions 5. Repeat the previous step to make other item changes, or if you are Brightness finished adjusting the information display page items, use the select switch to highlight “ ”, and then push the menu switch “MENU” to exit.

• Page 36: D-Mode (Drive Mode)

  Instrument and control functions 6. Push the menu switch “MENU” to EAU49433 D-mode (drive mode) return to the setting mode main D-mode is an electronically controlled screen. engine performance system with two mode selections (touring mode “T” and Resetting all of the display items sports mode “S”).

• Page 37: Handlebar Switches

  Instrument and control functions EAU1234M EAU12461 Handlebar switches Turn signal switch “ ” To signal a right-hand turn, push this Left switch to “ ”. To signal a left-hand turn, push this switch to “ ”. When released, the switch returns to the cen- ter position.

• Page 38: Clutch Lever

  Instrument and control functions EAU12781 EAU12832 Cruise control switches Clutch lever See page 3-7 for an explanation of the cruise control system. EAU54231 Menu switch “MENU” This switch is used to perform selec- tions in the function display and setting mode display of the multi-function me- ter unit.

• Page 39: Shift Pedal

  Instrument and control functions EAU12872 EAU49518 Shift pedal Brake lever The brake lever is located on the right side of the handlebar. To apply the front brake, pull the lever toward the throttle grip. This model is equipped with a unified brake system.

• Page 40: Brake Pedal

  Instrument and control functions When the vehicle starts moving, EAU49483 Brake pedal the unified brake system is re-en- abled.  The unified brake system does not function when the brake pedal is applied alone or before the brake lever is applied. The brake lever is equipped with a brake lever position adjusting dial.

• Page 41: Abs

  However, special tools are rear brakes independently. required, so please consult your Operate the brakes with ABS as you Yamaha dealer. would conventional brakes. If the ABS ECA16831 is activated, a pulsating sensation may NOTICE…

• Page 42: Traction Control System

  Instrument and control functions The traction control system indicator EAU58953 Traction control system light flashes when traction control has The traction control system helps engaged. You may notice slight chang- maintain traction when accelerating on es in engine and exhaust sounds when slippery surfaces, such as unpaved or the system has engaged.

• Page 43
  Instrument and control functions The traction control system mode can 4. Have a Yamaha dealer check the be changed only when the vehicle is vehicle and turn off the engine stopped. trouble warning light.  Push the “TCS” button to change between modes “1”…

• Page 44: Fuel Tank Cap

  Instrument and control functions EAU13075 EAU13222 Fuel tank cap Fuel Make sure there is sufficient gasoline in the tank. EWA10882 WARNING Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions.

• Page 45
  If the same identifier when fueling. gasoline spills on your skin, wash Your Yamaha engine has been de- with soap and water. If gasoline signed to use premium unleaded gas- spills on your clothing, change your oline with a research octane number of clothes.

• Page 46: Fuel Tank Overflow Hose

  Instrument and control functions EAU79161 EAU13434 Fuel tank overflow hose Catalytic converter This model is equipped with a catalytic converter in the exhaust system. EWA10863 WARNING The exhaust system is hot after op- eration. To prevent a fire hazard or burns: …

• Page 47: Rider Seat

  Instrument and control functions  The rider seat height can be ad- EAU49444 Rider seat justed to change the riding posi- tion. (See “Adjusting the rider seat To remove the rider seat height”.) 1. Insert the key into the seat lock, and then turn it counterclockwise.

• Page 48: Adjusting The Rider Seat Height

  Instrument and control functions EAU49475 Adjusting the rider seat height The rider seat height can be adjusted to one of two positions to suit the rid- er’s preference. The rider seat height was adjusted to the higher position at delivery. 1.

• Page 49
  Instrument and control functions Make sure that the rider seat is proper- ly secured before riding. 1. Rider seat height position adjuster 3. Install the rider seat height posi- tion adjuster so that the match mark is aligned with the “H” mark as shown.

• Page 50: Windshield

  Instrument and control functions EAU58982 Windshield  Make sure that the slide plate To suit the rider’s preference, the wind- holders are aligned with the match shield can be changed to one of four marks at the same height on both positions.

• Page 51: Adjusting The Front And Rear Suspension

  Yamaha dealer check the sus- Preload pension system. When riding with luggage or a passen- ger, use the preload adjusting function To adjust the preload to adjust the suspension system to 1. Turn the key to “ON”, start the en- match the load.

• Page 52
  Instrument and control functions GEAR GEAR 1. Menu switch “MENU” While the preload is being adjusted, 2. Select switch “ ” the information display may change as 3. Use the select switch to select the follows.  If the key is turned to “OFF” or the desired preload setting pictogram.
• Page 53
  Instrument and control functions GEAR GEAR GEAR HARD HARD 1. Damping force setting  If the preload is adjusted repeat- 2. Damping force setting level edly, the preload setting picto- gram will flash 4 times and the preload cannot be adjusted. Wait If the preload setting was not complet- approximately 6 minutes for the ed correctly:…
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  Instrument and control functions GEAR The damping force setting can be set to 7 levels (+3, +2, +1, 0, –1, –2 and –3). “+3” is the hardest level and “–3” is the softest level. 6. Push the menu switch “MENU”. If the vehicle moves while you are ad- justing the damping force, the informa- 1.

• Page 55: Carriers

  Take the shock ity of the standard carrier. absorber assembly to a Yamaha To use the additional carrier, consult a dealer for any service. Yamaha dealer. Standard carrier 1.

• Page 56: Luggage Strap Holders

  Instrument and control functions  Do not exceed the standard car- EAU49491 Luggage strap holders rier capacity of 5.0 kg (11 lb).  Do not exceed the additional carrier capacity of 5.0 kg (11 lb). ECA16822 NOTICE Do not lift the vehicle by either carri- 1.

• Page 57: Sidestand

  Therefore, check this system regularly and have a Yamaha dealer repair it if it does not function properly. 3-43…

• Page 58
  Does the engine start? The neutral switch may not be working correctly. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.

• Page 59: Auxiliary Dc Jack

  Instrument and control functions EAU49453 Auxiliary DC jack EWA14361 WARNING To prevent electrical shock or short- circuiting, make sure that the cap is installed when the auxiliary DC jack is not being used. ECA15432 NOTICE 1. Auxiliary DC jack The accessory connected to the 5.

• Page 60: For Your Safety — Pre-Operation Checks

  Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:…

• Page 61
  • Tighten if necessary. Instruments, lights, • Check operation. — • Correct if necessary. signals and switches • Check operation of ignition circuit cut-off system. Sidestand switch • If system is not working correctly, have Yamaha dealer 3-43 check vehicle.

• Page 62: Operation And Important Riding Points

  This model is equipped with: there is a control or function you do not  a lean angle sensor to stop the en- understand, ask your Yamaha dealer. gine in case of turnover. In this EWA10272 case, turn the key “OFF” and then WARNING to “ON”…

• Page 63: Starting The Engine

  The neutral indi- the clutch lever pulled and the cator light should come on. If not, sidestand up. ask a Yamaha dealer to check the See page 3-43 for more informa- electrical circuit. tion. 3. Start the engine by pushing 1.

• Page 64: Shifting

  Operation and important riding points EAU16673 and drive train, which are not Shifting designed withstand shock of forced shifting. 1. Shift pedal 2. Neutral position Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc.

• Page 65: Tips For Reducing Fuel Consumption

  Operation and important riding points EAU16811 EAU16842 Tips for reducing fuel con- Engine break-in sumption There is never a more important period in the life of your engine than the period Fuel consumption depends largely on between 0 and 1600 km (1000 mi). For your riding style.

• Page 66: Parking

  EAU17214 Parking cur during the engine break-in When parking, stop the engine, and period, immediately have a then remove the key from the main Yamaha dealer check the vehi- switch. cle. EWA10312 WARNING  Since the engine and exhaust system can become very hot,…

• Page 67: Periodic Maintenance And Adjustment

  If you are not familiar with vehicle ser- vice, have a Yamaha dealer perform service. EWA15123 WARNING Turn off the engine when performing…

• Page 68: Owner’s Tool Kit

  If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.

• Page 69: Periodic Maintenance Chart For The Emission Control System

   From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. EAU71071…

• Page 70: General Maintenance And Lubrication Chart

  • Perform dynamic inspection Diagnostic system √ √ √ √ √ √ using Yamaha diagnostic tool. check • Check the error codes. 2 * Air filter element • Replace. Every 40000 km (24000 mi) • Check operation, fluid level and √…

• Page 71
  Periodic maintenance and adjustment ODOMETER CHECK OR READINGS MAINTENANCE JOB ITEM X 1000 km X 1000 mi • Make sure that all nuts, bolts √ √ √ √ √ 13 * Chassis fasteners and screws are properly tight- ened. Brake lever pivot √…
• Page 72
  Periodic maintenance and adjustment ODOMETER CHECK OR READINGS MAINTENANCE JOB ITEM X 1000 km X 1000 mi • Check oil level and vehicle for √ √ √ √ √ oil leakage. 26 * Final gear oil √ √ √ • Change. Front and rear √…

• Page 73: Removing And Installing Cowlings

  Periodic maintenance and adjustment EAU18782 Removing and installing cowl- ings The cowlings shown need to be re- moved to perform some of the mainte- nance jobs described in this chapter. Refer to this section each time a cowl- ing needs to be removed and installed. 1.

• Page 74
  Periodic maintenance and adjustment 1. Cowling B 1. Cowling C 2. Bolt 2. Nut 3. Bolt 1. Quick fastener 1. Cowling C 2. Nut To install the cowling 3. Bolt 1. Place the cowling in the original position, and then install the bolts To install the cowling and the quick fasteners.

• Page 75: Checking The Spark Plugs

  The spark plugs are important engine components, which should checked periodically, preferably by a Yamaha dealer. Since heat and depos- its will cause any spark plug to slowly erode, they should be removed and checked in accordance with the peri- odic maintenance and lubrication 1.

• Page 76: Canister

  Periodic maintenance and adjustment EAU79401 EAU49506 Canister Engine oil and oil filter car- tridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter car- tridge replaced at the intervals speci- fied in the periodic maintenance and lubrication chart.

• Page 77
  Periodic maintenance and adjustment 4. If the engine oil is below the mini- mum level mark, add sufficient oil of the recommended type to raise it to the correct level. Check the O-ring for damage, and re- place it if necessary. 1.
• Page 78
  Tightening torque: Oil filter cartridge: 17 N·m (1.7 kgf·m, 13 lb·ft) An oil filter wrench is available at a Yamaha dealer. 11. Install the cowling. 12. Install the engine oil drain bolts 9. Apply a thin coat of clean engine…
• Page 79
  Do off and have a Yamaha dealer check not use oils with a diesel speci- the vehicle. fication of “CD” or oils of a high- 17.

• Page 80: Final Gear Oil

  Final gear oil The final gear case must be checked for oil leakage before each ride. If any leakage is found, have a Yamaha deal- er check and repair the vehicle. In ad- dition, the final gear oil level must be…

• Page 81
  5. Refill with the recommended final gear oil to the brim of the filler hole. Recommended final gear oil: Yamaha genuine shaft drive gear oil SAE 80W-90 API GL-5 or SAE 80 API GL-4 Hypoid gear oil Oil quantity: 0.20 L (0.21 US qt, 0.18 Imp.qt) 6.

• Page 82: Coolant

  If water has been added to the coolant, have a Yamaha dealer check the anti- freeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will 1.

• Page 83: Air Filter Element

  Have a maintenance and lubrication chart. Yamaha dealer change the coolant. Have a Yamaha dealer replace the air WARNING! Never attempt to remove filter element. the radiator cap when the engine is hot.

• Page 84: Checking The Engine Idling Speed

  Yamaha dealer. Engine idling speed: 1050–1150 r/min 1. Throttle grip free play Throttle grip free play: 3.0–5.0 mm (0.12–0.20 in) Periodically check the throttle grip free play and, if necessary, have a Yamaha dealer adjust it. 6-18…

• Page 85: Valve Clearance

  Therefore, it must be adjusted by a Yamaha dealer is essential to maintain the tires in good at the intervals specified in the periodic condition at all times and replace them maintenance and lubrication chart.

• Page 86
  If the center tread depth reaches the specified limit, if the tire has a nail or glass fragments in it, or if the side- wall is cracked, have a Yamaha dealer replace the tire immediately. 1. Tire air valve 2.
• Page 87
  After extensive tests, only the tires list- ed below have been approved for this model by Yamaha. Front tire: Size: 110/80R19M/C 59V Manufacturer/model: BRIDGESTONE/BW501…

• Page 88: Spoke Wheels

  If any damage is poor acceleration, there may be air in found, have a Yamaha dealer re- the clutch system. If there is air in the place the wheel. Do not attempt…

• Page 89: Checking The Brake Lever Free Play

  Since the brake light switches are components of the cruise control system, they must be adjusted by a Yamaha dealer, who has the nec- essary professional knowledge and ex- perience. 1. No brake lever free play There should be no free play at the brake lever end.

• Page 90: Checking The Front And Rear Brake Pads

  If a brake pad is damaged or if the lining thickness is less than 0.8 mm (0.03 in), have a Yamaha dealer replace the brake pads as a set. 1. Brake pad wear indicator Each front brake pad is provided with…

• Page 91: Checking The Brake Fluid Level

  Specified brake fluid: brake system for leakage. If the brake DOT 4 fluid level goes down suddenly, have a Yamaha dealer check the cause before EWA16011 WARNING further riding. Improper maintenance can result in loss of braking ability.

• Page 92: Changing The Brake And Clutch Fluids

  In addition, have ed by a Yamaha dealer at the intervals the oil seals of the brake and clutch specified in the periodic maintenance master cylinders and calipers as well chart.

• Page 93: Checking And Lubricating The Brake And Shift Pedals

  Periodic maintenance and adjustment EAU44276 EAU43602 Checking and lubricating the Checking and lubricating the brake and shift pedals brake and clutch levers The operation of the brake and shift The operation of the brake and clutch pedals should be checked before each levers should be checked before each ride, and the pedal pivots should be lu- ride, and the lever pivots should be lu-…

• Page 94: Checking And Lubricating The Centerstand And Sidestand

  The operation of the centerstand and The swingarm pivots must be lubricat- sidestand should be checked before ed by a Yamaha dealer at the intervals each ride, and the pivots and metal-to- specified in the periodic maintenance metal contact surfaces should be lubri- and lubrication chart.

• Page 95: Checking The Front Fork

  If any free there is no danger of it falling play can be felt, have a Yamaha over. dealer check or repair the steer- [EWA10752] 2.

• Page 96: Checking The Wheel Bearings

  A. (See page 6-7.) hub or if the wheel does not turn This model is equipped with a VRLA smoothly, have a Yamaha dealer (Valve Regulated Lead Acid) battery. check the wheel bearings. There is no need to check the electro- lyte or to add distilled water.

• Page 97
  ECA16531 NOTICE To charge the battery Always keep the battery charged. Have a Yamaha dealer charge the bat- Storing a discharged battery can tery as soon as possible if it seems to cause permanent battery damage. have discharged. Keep in mind that the…

• Page 98: Replacing The Fuses

  Periodic maintenance and adjustment EAU58963 Replacing the fuses The fuse boxes and the ABS motor fuse are located behind cowling A, and the main fuse, the cruise control fuse and the brake light fuse are located be- hind cowling B. (See page 6-7.) 1.

• Page 99: Replacing A Headlight Bulb

  4. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. 1. Do not touch the glass part of the bulb. 1. Remove the headlight bulb cover by turning it counterclockwise.

• Page 100
  Periodic maintenance and adjustment 6. Install the headlight bulb cover by turning it clockwise. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Headlight bulb cover 2. Disconnect the headlight coupler. 1. Headlight coupler 3. Unhook the headlight bulb holder, and then remove the burnt-out bulb.

• Page 101: Replacing An Auxiliary Light Bulb

  Periodic maintenance and adjustment EAU58971 Replacing an auxiliary light bulb This model is equipped with two auxil- iary lights. If an auxiliary light bulb burns out, replace it as follows. 1. Remove the windshield by remov- ing the screws. 1. Panel 2.

• Page 102
  Periodic maintenance and adjustment 1. Headlight unit 1. Auxiliary light bulb 2. Headlight unit bolt 8. Insert a new bulb into the socket. 9. Install the socket (together with the bulb) by pushing it in and turn- ing it clockwise. 10.

• Page 103: Turn Signal Light And Brake/Tail Light

  This model is equipped with LED-type turn signal lights and an LED-type Tightening torque: Windshield screw: brake/tail light. 0.5 N·m (0.05 kgf·m, 0.37 lb·ft) If a turn signal light or the brake/tail light does not come on, have a Yamaha dealer check it. 6-37…

• Page 104: Replacing A License Plate Light Bulb

  Periodic maintenance and adjustment EAU49722 Replacing a license plate light bulb 1. Remove the license plate light unit bolts. 1. License plate light bulb 4. Insert a new bulb into the socket. 5. Install the socket (together with the bulb) by pushing it in, and then turning it clockwise until it stops.

• Page 105: Troubleshooting

  The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self. However, should your motorcycle require any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the motorcycle properly.

• Page 106: Troubleshooting Charts

  Check the vehicle. compression. 4. Compression The engine does not start. There is compression. Have a Yamaha dealer check the vehicle. Operate the electric starter. There is no Have a Yamaha dealer check the vehicle. compression. 6-40…

• Page 107
  Start the engine. If the engine overheats again, The coolant level is have a Yamaha dealer check and repair the cooling system. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

• Page 108: Motorcycle Care And Storage

  Rust and corrosion can develop matte colored finished parts. Be even if high-quality components are sure to consult a Yamaha dealer for used. A rusty exhaust pipe may go un- advice on what products to use be- noticed on a car, however, it detracts fore cleaning the vehicle.

• Page 109
  Motorcycle care and storage structed. Also, thoroughly rinse compounds for plastic may the area off with water, immedi- leave scratches on the wind- ately dry it, and then apply a cor- shield. Test the product on a rosion protection spray. small hidden part of the wind- …
• Page 110
  3. To prevent corrosion, it is recom-  Consult a Yamaha dealer for ad- mended to apply a corrosion pro- vice on what products to use. tection spray metal, …

• Page 111: Storage

  Motorcycle care and storage der head so that the electrodes EAU49592 Storage are grounded. (This will limit sparking during the next step.) Short-term d. Turn the engine over several Always store your motorcycle in a cool, times with the starter. (This will dry place and, if necessary, protect it coat the cylinder walls with oil.) against dust with a porous cover.

• Page 112
  Motorcycle care and storage Make any necessary repairs before storing the motorcycle.

• Page 113: Specifications

  Final gear oil: 2250 mm (88.6 in) Overall width: Type: 980 mm (38.6 in) Yamaha genuine shaft drive gear oil SAE Overall height: 80W-90 API GL-5 or SAE 80 API GL-4 1410/1470 mm (55.5/57.9 in) Hypoid gear oil Seat height: Quantity: 845/870 mm (33.3/34.3 in)

• Page 114
  Specifications 2nd: Front wheel: 2.063 (33/16) Wheel type: 3rd: Spoke wheel 1.571 (33/21) Rim size: 4th: 19M/C x MT2.50 1.250 (30/24) Rear wheel: 5th: Wheel type: 1.042 (25/24) Spoke wheel 6th: Rim size: 0.929 (26/28) 17M/C x MT4.00 Chassis: Unified brake system: Frame type: Operation: Backbone…
• Page 115
  Specifications Battery: Terminal fuse 1: 3.0 A Model: Headlight fuse: YTZ12S 20.0 A Voltage, capacity: Brake light fuse: 12 V, 11.0 Ah (10 HR) 1.0 A Headlight: Signaling system fuse: Bulb type: 7.5 A Halogen bulb Ignition fuse: Bulb wattage: 20.0 A Headlight: Parking lighting fuse:…

• Page 116: Consumer Information

  Yamaha dealer. area. VEHICLE IDENTIFICATION NUMBER: EAU26442 Engine serial number…

• Page 117: Diagnostic Connector

  Consumer information the space provided. This information EAU69910 Diagnostic connector will be needed when ordering spare parts from a Yamaha dealer. 1. Diagnostic connector The diagnostic connector is located as shown.

• Page 118: Vehicle Data Recording

   Vehicle status and engine perfor- mance data  Fuel-injection and emission-relat- ed data Yamaha will not disclose this data to a third party except:  With the consent of the vehicle owner  Where obligated by law …

• Page 119: Index

  Index Fuel tank cap ……..3-30 Fuel tank overflow hose……3-32 ABS …………3-27 Fuses, replacing……..6-32 ABS warning light……..3-5 Air filter element ……..6-17 Auxiliary DC jack ……..3-45 Handlebar switches ……3-23 Auxiliary light bulb, replacing ….6-35 Hazard switch ……..

• Page 120
  Index Suspension, adjusting the front and rear ………….3-37 Swingarm pivots, lubricating ….6-28 Throttle grip and cable, checking and lubricating………..6-26 Throttle grip free play, checking …6-18 Tires …………6-19 Tool kit …………6-2 Traction control system ……3-28 Traction control system indicator light …3-5 Troubleshooting……..6-39 Troubleshooting charts……6-40 Turn signal indicator lights……3-4…
• Page 122
  Original instructions PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2017.02-0.3×1 CR…

Yamaha XT1200Z Super Tenere
Эксплуатационный мануал, 2010 г.в., PDF 3 Мб — скачать
Сервис мануал, 2010 г.в., PDF 35 Мб — скачать
Каталог запчастей, 2010 г.в., PDF 2 Мб — скачать

---

Для просмотра рекомендуется программа Foxit Reader

Записан

Держите переведённую мной схему электропроводки с описанием на русском Yamaha XT1200Z. Распечатайте на одном листе с обеих сторон, положите в файл и уберите в бумажник. «Пусть будет на всякий».
https://cloud.mail.ru/public/59dB/doNpc5hp3

Записан

А что это значит, «девка хоть куда»?

Отлично!
Большое спасибо 

Записан

Принимаются (в личку) любые пожелания по неточностям перевода и опечаткам, а также благодарности. =)

Нифига, здесь напишу.
Огромное, человеческое, спасибо!!!

Записан

Руководство по обслуживанию xt1200z на русском http://file.sampo.ru/46fjkn/

файл не найден
можно перезалить или на почту
Greco-roman(cобака)точкаru

Записан

Всем добрый день. Купил XT1200ZE 2016 г.в. Подскажите где скачать Сервис мануал ? Заранее благодарен.

Записан

Первое сообщение Хан Соло

Yamaha XT1200Z Super Tenere
Эксплуатационный мануал, 2010 г.в., PDF 3 Мб — скачать
Сервис мануал, 2010 г.в., PDF 35 Мб — скачать
Каталог запчастей, 2010 г.в., PDF 2 Мб — скачать
Для просмотра рекомендуется программа Foxit Reader

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мануал на русском ссылка не активна

Записан

Руководство по обслуживанию, которое на русском — это не тоже самое, что и сервис-мануал. Это книжечка, описывающая вкратце куда вставлять ключ, в какую дырку сколько бензину заливать, какой кнопкой дудеть, первая — вниз, и прочие секреты. Себе я ее не сохранял.

Записан

Формат файла: PDF

Доступность: Бесплатно как и все руководства на сайте. Без регистрации и SMS.

Дополнительно: Чтение инструкции онлайн

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1. Manuals
2. Brands
3. Yamaha Manuals
4. Motorcycle
5. XT1200Z(Z) 2010
6. Service manual

• Page 1
  2010 SERVICE MANUAL XT1200Z(Z) 23P-28197-E0…
• Page 2
  EAS20040 XT1200Z(Z) 2010 SERVICE MANUAL ©2010 by Yamaha Motor Co., Ltd. First edition, March 2010 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
• Page 3
  EAS20071 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

• Page 4: How To Use This Manual

  EAS20091 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. •…

• Page 5: Symbols

  EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque…

• Page 7: Table Of Contents

  EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING…

• Page 9: General Information

  MODEL LABEL………………1-1 FEATURES…………………. 1-2 OUTLINE OF THE FI SYSTEM…………..1-2 FI SYSTEM………………..1-3 YCC-T (Yamaha Chip Controlled Throttle)……….1-4 OUTLINE OF THE UBS …………….1-6 OUTLINE OF THE ABS…………….1-10 ABS COMPONENT FUNCTIONS …………1-15 UBS AND ABS OPERATION …………..1-20 ABS SELF-DIAGNOSIS FUNCTION…………

• Page 10: Identification

  IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the rider seat. This information will be needed to order spare parts.

• Page 11: Features

  FEATURES EAS20170 FEATURES EAS30340 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.

• Page 12: Fi System

  FEATURES EAS23P1100 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at 324 kPa (3.24 kgf/cm², 47.0 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.

• Page 13: Ycc-T (Yamaha Chip Controlled Throttle)

  Yamaha developed the YCC-T system employing the most advanced electronic control technologies. Electronic control throttle systems have been used on automobiles, but Yamaha has developed a fast- er, more compact system specifically for the needs of a sports motorcycle. The Yamaha-developed system has a high-speed calculating capacity that produces computations of running conditions every 1/1000th of a second.

• Page 14
  FEATURES YCC-T system outline 1. Throttle position sensor 2. Throttle servo motor 3. Accelerator position sensor 4. ECU (engine control unit) 5. YCC-T CPU 6. FI CPU 7. Sensor input 8. Neutral switch 9. Crankshaft position sensor 10. Rear wheel sensor 11.

• Page 15: Outline Of The Ubs

  FEATURES EAS23P1060 OUTLINE OF THE UBS This model is equipped with a unified brake system (UBS) that operates the rear brake when the brake lever is squeezed. When the brake lever is squeezed, the rear brake force is controlled electronically according to the brake lever input (hydraulic pressure) and vehicle speed (deceleration).

• Page 16
  FEATURES • Brake lever input and brake pedal input: Front braking and rear braking (with and without UBS oper- ation) Brake lever and brake pedal both operated A. Brake lever is operated before brake pedal B. Brake pedal is operated before brake lever a.
• Page 17
  FEATURES When the brake lever is squeezed, the front brake master cylinder pressure sensor in the hydraulic unit detects the hydraulic pressure. The ABS ECU calculates the appropriate rear brake force according to the detected hydraulic pressure and sends a signal to the rear brake hydraulic pump. The hydraulic pump pressurizes the rear brake caliper using electronic control to operate the rear brake.
• Page 18
  FEATURES a. Hydraulic pressure distribution b. Rear brake output (bars) c. Front brake input (bars) d. Rider only e. When carrying the maximum load f. Vehicle speed coefficient g. Coefficient (%) h. Speed (km/h)

• Page 19: Outline Of The Abs

  FEATURES EAS23P1061 OUTLINE OF THE ABS 1. This model is equipped with the latest, advanced type of ABS, which has improved feeling during operation and smoother braking than previous ABS brakes. The ABS ECU detects the hydraulic pressure using the pressure sensors and controls the pressure linearly using continuously variable adjustments to obtain the appropriate pressure when the wheels have a tendency to lock or accord- ing to the operation input (hydraulic pressure) from the brake lever or brake pedal.

• Page 20
  FEATURES 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. •…
• Page 21
  FEATURES 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 (%) 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.
• Page 22
  FEATURES 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.
• Page 23
  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 also includes a highly developed self-diagnosis function. The ABS has been designed to op- erate as a conventional brake system if the ABS malfunctions.

• Page 24: Abs Component Functions

  FEATURES ABS block diagram 1. Front brake master cylinder 10. Front brake master cylinder pressure sensor 2. Rear brake master cylinder 11. Check valve 3. Hydraulic unit assembly 12. Buffer chamber 4. Rear brake master cylinder pressure sensor 13. Inlet solenoid valve 5.

• Page 25
  FEATURES 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 set to “ON”, the ABS warning light comes on for 2 seconds, then goes off, so that the rider can check if the ABS warning light is disconnected and check if the ABS is operating prop- erly.
• Page 26
  FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (outlet solenoid valves, inlet solenoid valves, a shuttle solenoid valve, and a separation solenoid valve), buffer chambers, damping chambers, hydraulic pumps, an ABS motor, hydraulic pressure sensors (front brake master cylinder pressure sensor, rear brake master cylinder pressure sensor, and rear brake caliper pressure sensor), and an ABS ECU.
• Page 27
  FEATURES 4 5 6 18 19 20 21 1. Battery 18. Rear brake inlet solenoid 2. AC magneto 19. Rear brake outlet solenoid 3. Rectifier/regulator 20. Separation solenoid valve 4. Main fuse 21. Shuttle solenoid valve 5. Main switch 22. ABS motor 6.
• Page 28
  FEATURES • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was set to “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.

• Page 29: Ubs And Abs Operation

  FEATURES EAS23P1063 UBS AND ABS OPERATION The ABS hydraulic circuit consists of two systems: one for the front wheel and one for the rear wheel. Normal braking (ABS not activated and UBS not activated) Front brakes: When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU.

• Page 30
  FEATURES Emergency braking (ABS activated and UBS not activated) Depressurizing phase: When the front wheel (or the rear 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 closes the brake line from the brake master cylinder.
• Page 31
  FEATURES UBS (ABS not activated and UBS activated) Brake lever input only Front brakes: When the ABS is not activated, the inlet solenoid valve is open and the outlet solenoid valve is closed because a control signal has not been transmitted from the ABS ECU. Therefore, when the brake lever is squeezed, the hydraulic pressure in the front brake master cylinder increases and the brake fluid is sent to the front brake calipers.
• Page 32
  FEATURES UBS (ABS activated and UBS activated) Brake lever input only Front brakes: Refer to “Emergency braking (ABS activated and UBS not activated)”. Rear brake: When the rear wheel is about to lock, the outlet solenoid valve is opened by the “depressurization” sig- nal transmitted from the ABS ECU.

• Page 33: Abs Self-Diagnosis Function

  FEATURES EAS23P1064 ABS SELF-DIAGNOSIS FUNCTION ABS warning light The ABS warning light “1” comes on when a malfunction is detected by the ABS self-diagnosis. The ABS warning light is located on the meter assembly. Instances when the ABS warning light comes on 1.

• Page 34
  FEATURES 3. The ABS warning light comes on while riding. If the ABS warning light comes on while riding, a malfunction has been detected in the ABS or UBS. The ABS hydraulic control will not be performed. The ABS will have recourse to manual braking if this occurs.

• Page 35: Abs Warning Light And Operation

  FEATURES The ABS warning light comes on or flashes if the vehicle is ridden with the test coupler adapter con- nected to the ABS test coupler. EAS23P1065 ABS WARNING LIGHT AND OPERATION ABS warning light • When the main switch is set to “ON”, the ABS warning light comes on for 2 seconds, then goes off. •…

• Page 36
  FEATURES ABS and UBS function EWA23P1038 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.

• Page 37: Outline Of The Tcs (Traction Control System)

  FEATURES EAS23P1099 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.

• Page 38
  FEATURES 1. Front wheel sensor D. Actuator control 2. Rear wheel sensor E. Fuel cut-off 3. ABS ECU (electronic control unit) F. Ignition timing (retarded) 4. Traction control system switch G. Traction control system indicator light (flashes) 5. ECU (engine control unit) H.
• Page 39
  FEATURES • “TCS” “Off”: The traction control system is turned off. The system may also be automatically disabled in some riding conditions (Refer to “Resetting”). When the key is turned to “ON”, the traction control system is enabled and “TCS” “1” displays in the multi-function meter.

• Page 40: Instrument Functions

  FEATURES • a traction control system mode display (which EAS23P1106 INSTRUMENT FUNCTIONS shows the selected traction control system mode) Multi-function meter unit • a self-diagnosis device EWA23P1041 • an LCD and tachometer brightness control WARNING mode Be sure to stop the vehicle before making The left and right set buttons, located under the any setting changes to the multi-function display, allow you to control or change the set-…

• Page 41
  FEATURES Odometer and tripmeter modes Clock 1. Odometer/tripmeter/fuel reserve tripmeter 1. Clock 2. Left set button 2. Right set button 3. Left set button Pushing the left button switches the display be- tween the odometer mode “ODO” and the trip- The clock displays when the key is turned to meter modes “TRIP 1”…
• Page 42
  FEATURES Air intake temperature mode This fuel meter is equipped with a self-diagnosis system. If a problem is detected in the electrical circuit, all display segments start flashing. If this occurs, check the electrical circuit. Refer to “SIGNALING SYSTEM” on page 8-21. Air intake temperature, coolant temperature, instantaneous fuel consumption and aver- age fuel consumption modes…
• Page 43
  FEATURES Instantaneous fuel consumption mode • The “AVE_ _._ km/L” display shows the aver- age distance that can be traveled on 1.0 L of fuel. • The “AVE_ _._ L/100 km” display shows the average amount of fuel necessary to travel 100 •…
• Page 44
  FEATURES This display indicates which traction control sys- EWA23P1042 NOTICE tem mode has been selected: “1”, “2” or “Off”. If the display indicates a fault code, the vehi- For more details on the modes and on how to cle should be checked as soon as possible select them, refer to “TCS (Traction Control Sys- in order to avoid engine damage.
• Page 45
  FEATURES 1. Drive mode switch “MODE” Before using D-mode, make sure you under- stand its operation along with the operation of the drive mode switch. Touring mode “T” The touring mode “T” is suitable for various riding conditions. This mode allows the rider to enjoy smooth driv- ability from the low-speed range to the high- speed range.

• Page 46: Important Information

  5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

• Page 47: Bearings And Oil Seals

  IMPORTANT INFORMATION EAS20231 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

• Page 48: Basic Service Information

  BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.

• Page 49: Electrical System

  BASIC SERVICE INFORMATION ECA16760 EAS30402 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;…

• Page 50
  BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE…
• Page 51
  BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •…
• Page 52
  BASIC SERVICE INFORMATION • As a quick remedy, use a contact revitalizer available at most part stores. 4. Connect: • Lead • Coupler • Connector • When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely.

• Page 53: Special Tools

  SPECIAL TOOLS EAS20260 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.

• Page 54
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Steering nut wrench 3-20, 4-94 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-25, 5-87 90890-01426 YU-38411 Oil pressure gauge set 3-26 90890-03120 Oil pressure adapter B 3-26 90890-03124 Fork spring compressor 4-85, 4-90 90890-01441 YM-01441…
• Page 55
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rod puller attachment (M10) 4-89 90890-01436 Universal damping rod bleeding tool set YM-A8703 YM-A8703 Ring gear fix bolt (M14) 4-110 90890-01548 YM-01548 Final gear backlash band 4-110 90890-01511 Middle drive gear lash tool YM-01230 Coupling gear holding tool 4-112, 4-116…
• Page 56
  Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485 Rotor holding tool 5-17, 5-20 90890-01235 Universal magneto & rotor holder YU-01235 Yamaha bond No. 1215 5-23, 5-47, 90890-85505 5-88 (Three Bond No.1215®) Valve spring compressor 5-30, 5-35 90890-04019 YM-04019 Valve spring compressor attachment…
• Page 57
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover & installer set (ø5.5) 5-32 90890-04016 Valve guide remover (5.5 mm) YM-01122 Valve guide installer (ø5.5) 5-32 90890-04015 Valve guide installer (5.5 mm) YM-04015 Valve guide reamer (5.5 mm) 5-32 90890-01196 YM-01196…
• Page 58
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-60, 5-63 90890-04086 YM-91042 Slide hammer bolt 5-109 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-109 90890-01084 YU-01083-3 YU-01083-3 Universal joint holder 5-117, 5-119 90890-04160 90890-04160 Damper spring compressor 5-117, 5-119 90890-04090 1-49…
• Page 59
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle drive shaft nut wrench (55 mm) 5-118 90890-04054 Offset wrench 55 mm YM-04054 YM-04054 Middle gear backlash tool 5-121 90890-04080 Middle drive gear holder YM-33222 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter…
• Page 60
  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Pressure gauge 7-11 90890-03153 YU-03153 Fuel injector pressure adapter 7-11 90890-03210 YU-03210 Fuel pressure adapter 7-11 90890-03176 YM-03176 Pocket tester 8-130, 8-131,…

• Page 61: Specifications

  SPECIFICATIONS GENERAL SPECIFICATIONS ……………. 2-1 ENGINE SPECIFICATIONS …………….2-2 CHASSIS SPECIFICATIONS ……………. 2-10 ELECTRICAL SPECIFICATIONS …………..2-13 TIGHTENING TORQUES …………….2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS……2-16 ENGINE TIGHTENING TORQUES…………2-17 CHASSIS TIGHTENING TORQUES…………2-22 LUBRICATION POINTS AND LUBRICANT TYPES ……..2-28 ENGINE………………..

• Page 62: General Specifications

  GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 23P1 (Europe except (B) and (F)) (ZA) 23P2 (B) (F) 23P3 (AUS) Dimensions Overall length 2255 mm (88.8 in) Overall width 980 mm (38.6 in) Overall height 1410 mm (55.5 in) Seat height 845 mm (33.3 in) (low position) 870 mm (34.3 in) (high position) Wheelbase…

• Page 63: Engine Specifications

  9.4 psi/1100 r/min) at oil temperature of 65.0– 75.0 °C (149.00–167.00 °F) Final gear oil Type Yamaha genuine shaft drive gear oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil Quantity 0.20 L (0.21 US qt, 0.18 Imp.qt)

• Page 64
  ENGINE SPECIFICATIONS Oil-pump-housing-to-inner-and-outer-rotor clearance (scavenging pump) 0.06–0.13 mm (0.0024–0.0051 in) Limit 0.20 mm (0.0079 in) Relief valve operating pressure 540.0–660.0 kPa (5.40–6.60 kgf/cm², 78.3–95.7 psi) Cooling system Radiator capacity (including all routes) 1.83 L (1.93 US qt, 1.61 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.26 L (0.27 US qt, 0.23 Imp.qt) Radiator cap opening pressure…
• Page 65
  ENGINE SPECIFICATIONS Limit 29.850 mm (1.1752 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.10–0.16 mm (0.0039–0.0063 in) Exhaust 0.22–0.28 mm (0.0087–0.0110 in) Valve dimensions Valve head diameter A (intake) 36.90–37.10 mm (1.4528–1.4606 in) Valve head diameter A (exhaust) 30.90–31.10 mm (1.2165–1.2244 in)
• Page 66
  ENGINE SPECIFICATIONS Valve stem diameter (exhaust) 5.460–5.475 mm (0.2150–0.2156 in) Limit 5.430 mm (0.2138 in) Valve guide inside diameter (intake) 5.500–5.512 mm (0.2165–0.2170 in) Limit 5.550 mm (0.2185 in) Valve guide inside diameter (exhaust) 5.500–5.512 mm (0.2165–0.2170 in) Limit 5.550 mm (0.2185 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit…
• Page 67
  ENGINE SPECIFICATIONS Diameter D 97.965–97.980 mm (3.8569–3.8575 in) Height H 8.0 mm (0.31 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 22.004–22.015 mm (0.8663–0.8667 in) Limit 22.045 mm (0.8679 in) Piston pin outside diameter 21.991–22.000 mm (0.8658–0.8661 in) Limit 21.971 mm (0.8650 in)
• Page 68
  ENGINE SPECIFICATIONS Crankshaft Width A 165.60–166.40 mm (6.520–6.551 in) Width B 67.75–68.25 mm (2.67–2.69 in) Runout limit C 0.020 mm (0.0008 in) Big end side clearance D 0.160–0.262 mm (0.0063–0.0103 in) Journal oil clearance 0.020–0.044 mm (0.0008–0.0017 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow Balancer Balancer drive method…
• Page 69
  ENGINE SPECIFICATIONS 25/24 (1.042) 26/28 (0.929) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork guide bar bending limit 0.100 mm (0.0039 in) Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in) Air filter…
• Page 70
  ENGINE SPECIFICATIONS Final gear backlash 0.20–0.40 mm (0.008–0.016 in)

• Page 71: Chassis Specifications

  CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Steel tube backbone Caster angle 28.00° Trail 126.0 mm (4.96 in) Front wheel Wheel type Spoke wheel 19M/C × MT2.50 Rim size Rim material Aluminum Wheel travel 190.0 mm (7.48 in) Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in)

• Page 72
  CHASSIS SPECIFICATIONS Brake disc thickness limit 4.0 mm (0.16 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter…
• Page 73
  CHASSIS SPECIFICATIONS Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions *With the adjusting screw fully turned in Minimum 10 click(s) out* Standard 8 click(s) out* Maximum 1 click(s) out* Compression damping adjusting positions *With the adjusting screw fully turned in Minimum 13 click(s) out* Standard…

• Page 74: Electrical Specifications

  ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 5.0°/1100 r/min Engine control unit Model/manufacturer TBDF77/DENSO (Europe except (B) and (F)) (ZA) (AUS) TBDFD2/DENSO (B) (F) Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω…

• Page 75
  ELECTRICAL SPECIFICATIONS Engine trouble warning light ABS warning light Immobilizer system indicator light Traction control system indicator light Electric starting system System type Constant mesh Starter motor Power output 0.75 kW 0.0100–0.0200 Ω Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force…
• Page 76
  ELECTRICAL SPECIFICATIONS ABS solenoid fuse 20.0 A Backup fuse 7.5 A Electronic throttle valve fuse 7.5 A Accessory light fuse (OPTION) 20.0 A Spare fuse 30.0 A Spare fuse 20.0 A Spare fuse 10.0 A Spare fuse 7.5 A Spare fuse 3.0 A 2-15…

• Page 77: Tightening Torques

  TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20331 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.

• Page 78: Engine Tightening Torques

  TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe protector screw 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Exhaust pipe joint bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) sensor…

• Page 79
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Coolant drain bolt (water pump) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) l=55 mm (2.17 in) Generator cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) l=25 mm Generator cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) (0.99 in) Generator rotor bolt 130 Nm (13 m·kgf, 94 ft·lbf)
• Page 80
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear balancer holder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) l=130 mm (5.12 in) Crankcase bolt See TIP. l=78 mm (3.07 in) Crankcase bolt 24 Nm (2.4 m·kgf, 17 ft·lbf) l=80 mm (3.15 in) Crankcase bolt 24 Nm (2.4 m·kgf, 17 ft·lbf)
• Page 81
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pipe bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil pump assembly bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Oil pump housing cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Oil strainer (oil pump) bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Main axle assembly bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
• Page 82
  TIGHTENING TORQUES Crankcase bolt Tighten the crankcase bolts “1”–“6” to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence. Then, retighten the bolts one at a time as follows: • Tighten the crankcase bolts “1”–“6” to 20 Nm (2.0 m·kgf, 14 ft·lbf). •…

• Page 83: Chassis Tightening Torques

  TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front right 75 Nm (7.5 m·kgf, 54 ft·lbf) side) Engine mounting bolt (front left 75 Nm (7.5 m·kgf, 54 ft·lbf) side) Engine mounting bolt (rear right 68 Nm (6.8 m·kgf, 49 ft·lbf) lower side) Engine mounting bolt (rear left…

• Page 84
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine guard bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Right side panel bolt 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Right side inner panel bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Left side cowling bolt 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Left side panel bolt…
• Page 85
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake master cylinder hold- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) er bolt Brake master cylinder reservoir 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) cap bolt Brake lever pivot bolt 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf) Brake lever pivot nut 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Clutch master cylinder holder bolt…
• Page 86
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear wheel sensor bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Rear wheel sensor rotor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) Spoke 6 Nm (0.6 m·kgf, 4.3 ft·lbf) Front brake caliper bolt…
• Page 87
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Swingarm pivot shaft end plate 6 Nm (0.6 m·kgf, 4.3 ft·lbf) bolt Rubber boot cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Rubber boot joint bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Final drive assembly nut 42 Nm (4.2 m·kgf, 30 ft·lbf) Final gear oil drain bolt…
• Page 88
  TIGHTENING TORQUES 2-27…

• Page 89: Lubrication Points And Lubricant Types

  LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Camshaft lobes and camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Crankshaft big ends Piston surfaces Piston pins Connecting rod bolts…

• Page 90
  Lubrication point Lubricant Shift forks and shift fork guide bars Shift drum assembly Shift shaft washer Universal joint inner surface Yamaha genuine shaft drive oil SAE 80 Ring gear thrust washer API GL-5 or SAE 80 API GL-4 Hypoid gear oil…

• Page 91: Chassis

  LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings Steering bearing oil seal lips Steering shaft and nut thread Front wheel oil seal lips (right and left) Rear wheel oil seal lip Rear wheel drive hub mating surface Rear brake pedal pivoting point and metal-to-metal moving parts Passenger footrest pivoting point and ball Shift pedal pivoting point and metal-to-metal moving parts…

• Page 92: Lubrication System Chart And Diagrams

  LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31…

• Page 93
  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pan (oil tank) 2. Oil strainer (oil pan) 3. Oil pump assembly 4. Oil pump (scavenging) 5. Oil pump (feed) 6. Relief valve 7. Oil filter cartridge 8. Front balancer shaft 9. Main gallery 10.

• Page 94: Lubrication Diagrams

  LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS Cylinder (right side view) and crankshaft (rear view) 2-33…

• Page 95
  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil check bolt 2. Cylinder head 3. Cylinder 4. Upper crankcase 5. Timing chain tensioner 6. Intake camshaft 7. Exhaust camshaft 8. Exhaust camshaft cap 9. Oil nozzle 1 10. Crankshaft 11. Main gallery bolt 12.
• Page 96
  LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase (top view) and transmission (front view) 2-35…
• Page 97
  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil delivery passage cover 3. Front balancer shaft 4. Crankshaft 5. Drive axle 6. Middle driven pinion gear 7. Lower crankcase 8. Oil pan 9. Main axle 2-36…
• Page 98
  LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (right side view) 2-37…
• Page 99
  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Shift fork-C 2. Shift fork-R 3. Shift fork-L 4. Oil pump assembly 5. Oil pan 6. Oil strainer (oil pump) 7. Shift fork upper guide bar 2-38…
• Page 100
  LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (left side view) 2-39…
• Page 101
  LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump assembly 2. Oil filter cartridge 3. Oil strainer cover 4. Oil strainer (oil pan) 5. Oil pan 6. Lower crankcase 7. Upper crankcase 8. Rear balancer shaft 2-40…

• Page 102: Cooling System Diagrams

  COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-41…

• Page 103
  COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator inlet hose 3. Radiator outlet hose 4. Radiator 5. Thermostat 6. Radiator outlet pipe 7. Water pump inlet hose 8. Water pump 2-42…

• Page 104: Cable Routing

  CABLE ROUTING EAS20430 CABLE ROUTING Headlight assembly (front and rear view) 2-43…

• Page 105
  CABLE ROUTING 1. Meter assembly lead 2. Front left turn signal light lead 3. Auxiliary DC jack 4. Front right turn signal light lead 5. Auxiliary DC jack lead 6. Headlight sub-wire harness 7. Meter assembly 8. Left auxiliary light 9.
• Page 106
  CABLE ROUTING Handlebar (front view) 2-45…
• Page 107
  CABLE ROUTING 1. Right handlebar switch lead 2. Throttle cable (accelerator cable) 3. Throttle cable (decelerator cable) 4. Clutch hose 5. Left handlebar switch lead 6. Main switch lead 7. Horn lead 8. Front wheel sensor lead 9. Brake hose (hydraulic unit to left front brake caliper) 10.
• Page 108
  CABLE ROUTING Front brake hose (left side view) 2-47…
• Page 109
  CABLE ROUTING 1. Clutch hose Q. Route the front wheel sensor lead, brake hose (hydraulic unit to left front brake caliper), and horn 2. Throttle cable (decelerator cable) lead in the order shown in the illustration. 3. Throttle cable (accelerator cable) R.
• Page 110
  CABLE ROUTING Front brake hose (left side view) 2-49…
• Page 111
  CABLE ROUTING AA.Route the immobilizer unit lead to the inside of the throttle cables. AB.Position the immobilizer unit coupler below the brake hose (front brake master cylinder to hydraulic unit). AC.Upward AD.Route the throttle cables between the brake hose (front brake master cylinder to hydraulic unit) and the clutch hose.
• Page 112
  CABLE ROUTING Fuel tank and throttle bodies (left side view) 2-51…
• Page 113
  CABLE ROUTING 1. Fuel tank overflow hose and fuel tank breather hose 2. Fuel tank 3. Fuel hose 4. Fuel pump 5. Air filter case 6. Cylinder head breather hose A. Align the hose clamps with the white paint marks on the fuel tank overflow hose and fuel tank breather hose.
• Page 114
  CABLE ROUTING Coolant reservoir (rear and left side view) 2-53…
• Page 115
  CABLE ROUTING 1. Coolant reservoir hose 2. Coolant reservoir breather hose 3. Neutral switch lead 4. Coolant reservoir cap 5. Radiator 6. Radiator inlet hose 7. Clutch pipe 8. Brake hose (front brake master cylinder to hydraulic unit) A. Point the ends of the hose clamp to the left. B.
• Page 116
  CABLE ROUTING Engine (left side view) 2-55…
• Page 117
  CABLE ROUTING 1. Stator coil lead Q. Route the fuel tank overflow hose and fuel tank breather hose so that the hoses cross no more 2. Clutch hose than once between the fuel tank and the holder. 3. Brake hose (front brake master cylinder to hydraulic unit) 4.
• Page 118
  CABLE ROUTING Front brake hose (right side view) 2-57…
• Page 119
  CABLE ROUTING 1. Brake hose (front brake master cylinder to hydraulic unit) 2. Stator coil lead 3. Wire harness 4. Intake air temperature sensor lead 5. Negative battery lead 6. Starter motor lead 7. Right handlebar switch lead 8. Immobilizer unit lead 9.
• Page 120
  CABLE ROUTING Electrical components tray (right side view) 2-59…
• Page 121
  CABLE ROUTING 1. Headlight relay J. Install the positive battery lead terminal and negative battery lead terminal to the starter relay 2. Turn signal/hazard relay so that the terminals are parallel to the relay as 3. Radiator fan motor relay shown in the illustration.
• Page 122
  CABLE ROUTING Electrical components tray (right side view) 2-61…
• Page 123
  CABLE ROUTING AA.Route the stator coil lead over the wire harness. AB.Fasten the stator coil lead, wire harness, wire harness (starting circuit cut-off relay lead and starter relay lead), and wire harness (rectifier/regulator lead and stator coil lead) with the plastic band. Route the leads in the order shown in the illustration.
• Page 124
  CABLE ROUTING Engine (right side view) 2-63…
• Page 125
  CABLE ROUTING 1. Brake hose (hydraulic unit to rear brake caliper) 2. Rear wheel sensor lead 3. O sensor #1 lead 4. O sensor #2 lead 5. Crankshaft position sensor lead 6. Rear brake light switch lead 7. Footrest plate A.
• Page 126
  CABLE ROUTING Rear brake hose (right side view) 2-65…
• Page 127
  CABLE ROUTING 1. Brake fluid reservoir hose 2. Brake hose (rear brake master cylinder to hydraulic unit) 3. Rear brake light switch lead 4. Brake hose (hydraulic unit to rear brake caliper) 5. Rear wheel sensor lead A. Install the brake fluid reservoir hose onto the hose fitting of the brake fluid reservoir, making sure that the hose contacts the reservoir.
• Page 128
  CABLE ROUTING Throttle bodies (top view) 2-67…
• Page 129
  CABLE ROUTING 1. Immobilizer unit lead 2. Cylinder-#1 left ignition coil lead 3. Accelerator position sensor lead 4. Cylinder-#1 right ignition coil lead (white tape) 5. Cylinder-#2 left ignition coil lead 6. Cylinder-#2 right ignition coil lead (white tape) 7. Throttle servo motor lead (yellow tape) 8.
• Page 130
  CABLE ROUTING Hydraulic unit assembly (top view) 13 12 2-69…
• Page 131
  CABLE ROUTING 1. Engine ground lead 2. Wire harness 3. ABS ECU lead 4. ABS test coupler 5. ABS test coupler lead 6. Hydraulic unit assembly 7. Coolant reservoir hose 8. Oil level switch lead 9. Sidestand switch lead 10. Fuel hose 11.
• Page 132
  CABLE ROUTING Rear fender (top view) 2-71…
• Page 133
  CABLE ROUTING 1. License plate light lead 2. Rear right turn signal light lead 3. Tail/brake light lead 4. Rear left turn signal light lead 5. Frame ground lead 6. Lean angle sensor sub-wire harness 7. ABS test coupler lead A.
• Page 134
  CABLE ROUTING 2-73…

• Page 135: Periodic Checks And Adjustments

  PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE …………….3-1 INTRODUCTION ………………3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ………………..3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ……. 3-1 CHECKING THE FUEL LINE …………..3-4 CHECKING THE SPARK PLUGS …………. 3-4 ADJUSTING THE VALVE CLEARANCE ……….

• Page 136
  CHECKING THE BRAKE LIGHT SWITCHES……… 3-30 ADJUSTING THE REAR BRAKE LIGHT SWITCH ……… 3-30 CHECKING AND LUBRICATING THE CABLES ……..3-31 CHECKING THE THROTTLE GRIP OPERATION ……… 3-31 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ……3-32 ADJUSTING THE HEADLIGHT BEAMS……….3-32 REPLACING THE HEADLIGHT BULBS ……….

• Page 138: Periodic Maintenance

  UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.

• Page 139
  PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM 1000 km 10000 km 20000 km 30000 km 40000 km CHECK (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check tread depth and for damage. √ √ √ √…
• Page 140
  PERIODIC MAINTENANCE • The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas. • Hydraulic brake and clutch service • Regularly check and, if necessary, correct the brake fluid and clutch fluid levels. •…

• Page 141: Checking The Fuel Line

  PERIODIC MAINTENANCE EAS21030 CHECKING THE FUEL LINE 1. Remove: • Rider seat • Left side cowling • Right side panel Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • Fuel tank bolts “1” After removing the fuel tank bolts, lift up the front 4.

• Page 142: Adjusting The Valve Clearance

  PERIODIC MAINTENANCE 6. Clean: • Throttle bodies • Spark plug Refer to “THROTTLE BODIES” on page 7-5. (with a spark plug cleaner or wire brush) • Clutch cover 7. Measure: Refer to “CLUTCH” on page 5-52. • Spark plug gap “a” •…

• Page 143
  PERIODIC MAINTENANCE d. Turn the crankshaft clockwise 270 degrees so that the pickup rotor T mark “e” is pointing up as shown in the illustration. e. Measure the valve clearance #2 with a thick- ness gauge. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 L LLL L LLL…
• Page 144
  PERIODIC MAINTENANCE d. Calculate the sum of the values obtained in steps (b) and (c) to determine the required valve pad thickness and the valve pad num- ber. Example: 1.48 mm (0.058 in) + 0.04 mm (0.002 in) = 1.52 mm (0.060 in) The valve pad number is 152.

• Page 145: Synchronizing The Throttle Bodies

  PERIODIC MAINTENANCE g. Install the exhaust and intake camshafts, tim- ing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Refer to “CAMSHAFTS” on page 5-11. • Lubricate the camshaft lobes and camshaft journals with molybdenum disulfide oil. •…

• Page 146
  PERIODIC MAINTENANCE ECA23P1079 NOTICE Do not turn the bypass air screw of the throt- tle body that is the standard. Otherwise, the engine may run roughly at idle and the throttle bodies may not operate properly. • Turn the cylinder #1 air screw or cylinder #2 air screw using the carburetor angle driver.

• Page 147: Checking The Exhaust System

  PERIODIC MAINTENANCE 2. Stop the engine and remove the measuring equipment. 3. Install: • Cap • Intake air pressure sensor hose 4. Adjust: • Throttle cable free play Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-31. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) EAS21081 CHECKING THE EXHAUST SYSTEM…

• Page 148: Checking The Cylinder Head Breather Hose

  PERIODIC MAINTENANCE 3. Press the left set button to select the CO ad- justment mode “Co” “1” or the diagnostic The CO adjustment volume appears on the mode “dIAG”. odometer LCD. • To decrease the CO adjustment volume, press the right set button. •…

• Page 149: Adjusting The Clutch Lever

  PERIODIC MAINTENANCE 6. Install: • Air filter case cover After removing the fuel tank bolts, lift up the front • Cap of the fuel tank. Air filter case cover screw ECA23P1003 NOTICE 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf) When lifting up the fuel tank, be careful not ECA23P1035 to pull the fuel tank overflow hose and fuel NOTICE…

• Page 150: Checking The Clutch Fluid Level

  PERIODIC MAINTENANCE • When refilling, be careful that water does not enter the clutch master cylinder reser- voir. Water will significantly lower the boil- ing point of the clutch fluid and could cause vapor lock. ECA13420 NOTICE Clutch fluid may damage painted surfaces or plastic parts.

• Page 151: Adjusting The Front Disc Brake

  PERIODIC MAINTENANCE b. Install the clutch master cylinder reservoir di- aphragm. Be sure to align the setting on the adjusting dial c. Connect a clear plastic hose “1” tightly to the with the arrow mark “2” on the brake lever. bleed screw “2”.

• Page 152: Bleeding The Hydraulic Brake System (Abs)

  PERIODIC MAINTENANCE EAS23P1020 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. ECA23P1037 NOTICE • Bleed the brake system in the following or- der. • 1st step: Right front brake caliper •…

• Page 153: Checking The Front Brake Pads

  PERIODIC MAINTENANCE Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-71. ECA23P1038 NOTICE Make sure that the main switch is turned to “OFF” before checking the operation of the hydraulic unit. k. After operating the ABS, repeat steps (e) to (i), and then fill the brake master cylinder res- ervoir or brake fluid reservoir to the proper level with the recommended brake fluid.

• Page 154: Checking The Brake Hoses

  PERIODIC MAINTENANCE 1. Operate the brake. EWA13260 WARNING 2. Check: Never attempt to make any repairs to the • Rear brake pad wear limit “a” Out of specification → Replace the brake wheel. pads as a set. Refer to “REAR BRAKE” on page 4-52. After a tire or wheel has been changed or re- placed, always balance the wheel.

• Page 155: Checking The Tires

  PERIODIC MAINTENANCE Tire air pressure (measured on cold tires) Loading condition 0–90 kg (0–198 lb) Front 225 kPa (2.25 kgf/cm², 33 psi) Rear 250 kPa (2.50 kgf/cm², 36 psi) Loading condition 90–209 kg (198–461 lb) Front EAS21650 225 kPa (2.25 kgf/cm², 33 psi) CHECKING THE TIRES Rear The following procedure applies to both of the…

• Page 156: Checking The Wheel Bearings

  1. Measure: en if a tire combination other than one • Swingarm side play approved by Yamaha is used on this vehicle. • Swingarm vertical movement Refer to “REMOVING THE SWINGARM” on Front tire page 4-102.

• Page 157: Checking And Adjusting The Steering Head

  PERIODIC MAINTENANCE EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the front wheel is elevated.

• Page 158: Lubricating The Steering Head

  PERIODIC MAINTENANCE EAS23P1026 EAS21730 LUBRICATING THE STEERING HEAD LUBRICATING THE CENTERSTAND 1. Lubricate: Lubricate the pivoting point and metal-to-metal • Upper bearing moving parts of the centerstand. • Lower bearing Recommended lubricant • Bearing races Lithium-soap-based grease • Ring nut threads Recommended lubricant EAS23P1075 CHECKING THE SIDESTAND SWITCH…

• Page 159
  PERIODIC MAINTENANCE • Securely support the vehicle so that there is no danger of it falling over. Spring preload ECA13570 NOTICE • Grooves are provided to indicate the ad- justment position. • Never go beyond the maximum or mini- mum adjustment positions. 2.

• Page 160: Checking The Rear Suspension

  PERIODIC MAINTENANCE Compression damping 3. Check: ECA13590 • Rear shock absorber assembly operation NOTICE • Rear suspension link pivots Never go beyond the maximum or minimum Push down seat on the vehicle several times adjustment positions. and check if the rear shock absorber assem- bly rebounds smoothly.

• Page 161: Checking The Engine Oil Level

  PERIODIC MAINTENANCE EAS20731 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. SO FT • Place the vehicle on the centerstand. H A RD • Make sure the vehicle is upright. 2. Start the engine and warm it up for ten min- utes until the engine oil has reached a normal temperature of 60 °C (140 °F), and then turn the engine off.

• Page 162: Changing The Engine Oil

  PERIODIC MAINTENANCE ECA23P1072 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 la- beled “ENERGY CONSERVING II”.

• Page 163: Measuring The Engine Oil Pressure

  PERIODIC MAINTENANCE d. Tighten the new oil filter cartridge to specifi- 10.Start the engine, warm it up for several min- cation with an oil filter wrench. utes, and then turn it off. 11.Check: Oil filter cartridge • Engine 17 Nm (1.7 m·kgf, 12 ft·lbf) (for engine oil leaks) 12.Check: e.

• Page 164: Checking The Coolant Level

  PERIODIC MAINTENANCE 6. Measure: ECA13470 NOTICE • Engine oil pressure • Adding water instead of coolant lowers the Oil pressure antifreeze content of the coolant. If water is 65.0 kPa/1100 r/min (0.65 used instead of coolant check, and if nec- kgf/cm²/1100 r/min, 9.4 psi/1100 essary, correct the antifreeze concentra- r/min) at oil temperature of…

• Page 165: Changing The Coolant

  PERIODIC MAINTENANCE sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move. 3. Remove: • Coolant drain bolt (water pump) “1” (along with the copper washer “2”) 4.

• Page 166: Checking The Final Gear Oil Level

  10.Install: • Radiator cap Type 11.Fill: Yamaha genuine shaft drive • Coolant reservoir gear oil SAE 80 API GL-5 or SAE (with the recommended coolant to the maxi- 80 API GL-4 Hypoid gear oil mum level mark “a”)

• Page 167: Changing The Final Gear Oil

  PERIODIC MAINTENANCE ECA23P1039 NOTICE Take care not to allow foreign material to en- ter the final gear case. 6. Check: • Oil level Refer to “CHECKING THE FINAL GEAR OIL LEVEL” on page 3-29. 7. Install: • Final gear oil filler bolt 4.

• Page 168: Checking And Lubricating The Cables

  PERIODIC MAINTENANCE 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. 3.

• Page 169: Checking The Switches, Lights And Signals

  PERIODIC MAINTENANCE d. Tighten the locknut. e. Slide the rubber cover to its original position. Make sure that the adjusting nut is covered com- pletely by the rubber cover. L LLL L LLL L LLL L LLL L LLL EAS23P1074 CHECKING THE SWITCHES, LIGHTS AND SIGNALS 1.

• Page 170: Replacing The Auxiliary Light Bulbs

  PERIODIC MAINTENANCE EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: • Headlight bulb Secure the new headlight bulb with the head- light bulb holder. ECA13690 4.

• Page 171: Chassis

  CHASSIS GENERAL CHASSIS………………4-1 INSTALLING THE SEATS…………….. 4-2 INSTALLING THE CARRIERS…………..4-2 REMOVING THE ABS UNIT COVER …………4-7 INSTALLING THE ABS UNIT COVER …………4-7 REMOVING THE SIDE COWLINGS…………4-9 INSTALLING THE SIDE COWLINGS …………4-9 INSTALLING THE ELECTRICAL COMPONENTS TRAY……. 4-14 ASSEMBLING THE HEADLIGHT …………

• Page 172
  REAR BRAKE ………………..4-52 INTRODUCTION ………………4-59 CHECKING THE REAR BRAKE DISC………… 4-59 REPLACING THE REAR BRAKE PADS……….4-59 REMOVING THE REAR BRAKE CALIPER ……….4-60 DISASSEMBLING THE REAR BRAKE CALIPER ……..4-60 CHECKING THE REAR BRAKE CALIPER……….4-61 ASSEMBLING THE REAR BRAKE CALIPER ……..4-61 INSTALLING THE REAR BRAKE CALIPER………..
• Page 173
  SWINGARM………………..4-100 REMOVING THE SWINGARM…………..4-102 CHECKING THE SWINGARM …………..4-102 INSTALLING THE SWINGARM …………4-102 SHAFT DRIVE …………………4-104 TROUBLESHOOTING …………….4-108 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS……..4-109 MEASURING THE FINAL GEAR BACKLASH ……..4-109 ADJUSTING THE FINAL GEAR BACKLASH ……..4-110 MEASURING THE RING-GEAR-TO-STOPPER-BOLT CLEARANCE………………4-111 ADJUSTING THE RING-GEAR-TO-STOPPER-BOLT…

• Page 174: General Chassis

  GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and carriers 20 Nm (2.0 m kgf, 14 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) 7 Nm (0.7 m 7 Nm (0.7 m kgf, 5.1 ft kgf, 5.1 ft Ibf) Ibf) •…

• Page 175: Installing The Seats

  GENERAL CHASSIS EAS23P1003 INSTALLING THE SEATS 1. Install: • Passenger seat “1” Insert the projection “a” on the rear of the pas- senger seat into the seat holder “b” in the addi- tional carrier. L LLL L LLL L LLL L LLL L LLL M MMM…

• Page 176
  GENERAL CHASSIS Standard carrier 3. Tighten: Additional carrier • Seat bracket bolts “1” • Additional carrier bolts “2” Seat bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Additional carrier bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Before tightening the bolts, make sure to align the bolt holes “a”…
• Page 177
  GENERAL CHASSIS Align the slots “a” in the washer with the projec- tions “b” on the grab bar. 5. Remove: • Rubber plug “1” 6. Install: • Standard carrier “1” Standard carrier bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Use the two standard carrier bracket bolts “2” and the standard carrier bolt (45 mm) “3”.
• Page 178
  GENERAL CHASSIS Removing the tail/brake light assembly 15 Nm (1.5 m kgf, 11 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •…
• Page 179
  GENERAL CHASSIS Removing the tail/brake light assembly 15 Nm (1.5 m kgf, 11 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •…

• Page 180: Removing The Abs Unit Cover

  GENERAL CHASSIS EAS23P1103 REMOVING THE ABS UNIT COVER 1. Remove: • ABS unit cover “1” Remove the quick fastener screw “2”, and then pull the ABS unit cover off as shown in the illus- tration. 3. Install: • ABS unit cover “1” Insert the projections “a”…

• Page 181
  GENERAL CHASSIS Removing the side cowlings, side panel, and engine guard 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • •…

• Page 182: Removing The Side Cowlings

  GENERAL CHASSIS b. Install the left side cowling bolts and quick EAS23P1104 REMOVING THE SIDE COWLINGS fastener screws, and then tighten the bolts to 1. Remove: specification. • Left side cowling “1” M MMM M MMM M MMM M MMM M MMM Left side cowling bolt a.

• Page 183
  GENERAL CHASSIS Removing the electrical components tray 1/2 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the side cowlings, side Right side panel panel, and engine guard”. Negative battery lead Disconnect.
• Page 184
  GENERAL CHASSIS Removing the electrical components tray 1/2 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Turn signal/hazard relay Radiator fan motor relay Stator coil coupler Disconnect. For installation, reverse the removal proce- dure.
• Page 185
  GENERAL CHASSIS Removing the electrical components tray 2/2 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuse box 1…
• Page 186
  GENERAL CHASSIS Removing the electrical components tray 2/2 7 Nm (0.7 m kgf, 5.1 ft Ibf) 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rectifier/regulator…

• Page 187: Installing The Electrical Components Tray

  GENERAL CHASSIS EAS23P1069 INSTALLING THE ELECTRICAL COMPONENTS TRAY 1. Install: • Electrical components tray “1” Electrical components tray bolt “2” 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Electrical components tray bolt “3” and “4” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) M MMM M MMM M MMM M MMM…

• Page 188
  GENERAL CHASSIS Removing the headlight assembly 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 0.7 Nm (0.07 m kgf, 0.51 ft Ibf) •…
• Page 189
  GENERAL CHASSIS Disassembling the headlight Order Job/Parts to remove Q’ty Remarks Auxiliary light socket Auxiliary light bulb Headlight bulb cover Headlight coupler Disconnect. Headlight solenoid coupler Disconnect. Headlight bulb Headlight sub-wire harness For assembly, reverse the disassembly pro- cedure. 4-16…

• Page 190: Assembling The Headlight

  GENERAL CHASSIS EAS23P1012 ASSEMBLING THE HEADLIGHT 1. Install: • Headlight sub-wire harness “1” Route the headlight sub-wire harness through the hole in the headlight, and then connect the headlight solenoid couplers “2” and headlight couplers “3”. EAS23P1105 INSTALLING THE HEADLIGHT ASSEMBLY AND WINDSHIELD 1.

• Page 191
  GENERAL CHASSIS Removing the air filter case 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.6 Nm (0.16 m kgf, 1.2 ft Ibf) • • 1.2 Nm (0.12 m kgf, 0.87 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) 1.6 Nm (0.16 m…

• Page 192: Removing The Air Filter Case

  GENERAL CHASSIS EAS23P1013 REMOVING THE AIR FILTER CASE 1. Remove: • Fuel tank bolts “1” • Air filter case After removing the fuel tank bolts, lift up the front of the fuel tank. ECA23P1003 NOTICE When lifting up the fuel tank, be careful not to pull the fuel tank overflow hose and fuel tank breather hose.

• Page 193: Front Wheel

  FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel sensor, front wheel and brake discs 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 72 Nm (7.2 m kgf, 52 ft Ibf) •…

• Page 194
  FRONT WHEEL Removing the front wheel sensor, front wheel and brake discs 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 72 Nm (7.2 m kgf, 52 ft Ibf) •…
• Page 195
  FRONT WHEEL Disassembling the front wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil seal Front wheel sensor rotor Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-22…

• Page 196: Removing The Front Wheel

  FRONT WHEEL b. Remove the oil seals “1” with a flat-head EAS21900 REMOVING THE FRONT WHEEL screwdriver. ECA23P1004 NOTICE To prevent damaging the wheel, place a rag “2” Keep magnets (including magnetic pick-up between the screwdriver and the surface of the tools, magnetic screwdrivers, etc.) away wheel.

• Page 197: Maintenance Of The Front Wheel Sensor And Sensor Rotor

  FRONT WHEEL • Front wheel EAS22010 MAINTENANCE OF THE FRONT WHEEL Damage/wear → Replace. SENSOR AND SENSOR ROTOR Refer to “CHECKING THE TIRES” on page ECA23P1006 3-18 and “CHECKING THE WHEELS” on NOTICE page 3-17. • Handle the ABS components with care 3.

• Page 198: Assembling The Front Wheel

  FRONT WHEEL 3. Measure: d. If the deflection is still above specification, re- • Wheel sensor rotor deflection place the wheel sensor rotor. Out of specification → Clean the installation L LLL L LLL L LLL L LLL L LLL surface of the wheel sensor rotor and correct EAS21960 the wheel sensor rotor deflection, or replace…

• Page 199: Adjusting The Front Wheel Static Balance

  FRONT WHEEL b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. L LLL L LLL L LLL L LLL L LLL 2. Install: c. Turn the front wheel 90° so that the “X ”…

• Page 200: Installing The Front Wheel (Front Brake Discs)

  FRONT WHEEL c. If the heavy spot does not stay in that posi- 2. Check: tion, install a heavier weight. • Front brake discs d. Repeat steps (b) and (c) until the front wheel Refer to “CHECKING THE FRONT BRAKE is balanced.

• Page 201
  FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Insert the front wheel axle from the right side Front brake caliper bolt 40 Nm (4.0 m·kgf, 29 ft·lbf) and tighten it to 72 Nm (7.2 m·kgf, 52 ft·lbf). b.

• Page 202: Rear Wheel

  REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel sensor, rear wheel and brake disc 25 Nm (2.5 m kgf, 18 ft Ibf) 125 Nm (12.5 m kgf, 90 ft lbf) • • • • 23 Nm (2.3 m kgf, 17 ft Ibf) •…

• Page 203
  REAR WHEEL Removing the rear wheel sensor, rear wheel and brake disc 25 Nm (2.5 m kgf, 18 ft Ibf) 125 Nm (12.5 m kgf, 90 ft lbf) • • • • 23 Nm (2.3 m kgf, 17 ft Ibf) •…
• Page 204
  REAR WHEEL Disassembling the rear wheel 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Dust seal Rear wheel drive hub Wheel bearing Collar Rear wheel drive hub damper Bearing Spacer Rear wheel sensor rotor Oil seal Wheel bearing For assembly, reverse the disassembly pro-…

• Page 205: Removing The Rear Wheel

  REAR WHEEL EAS22050 EAS22080 REMOVING THE REAR WHEEL DISASSEMBLING THE REAR WHEEL ECA23P1013 ECA23P1015 NOTICE NOTICE Keep magnets (including magnetic pick-up • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away tools, magnetic screwdrivers, etc.) away from the rear wheel hub “1”, otherwise the from the wheel sensor rotor.

• Page 206: Maintenance Of The Rear Wheel Sensor And Sensor Rotor

  REAR WHEEL • Oil seal 3. Measure: Refer to “CHECKING THE FRONT WHEEL” • Wheel sensor rotor deflection on page 4-23. Refer to “MAINTENANCE OF THE FRONT 2. Check: WHEEL SENSOR AND SENSOR ROTOR” • Tire on page 4-24. • Rear wheel Damage/wear →…

• Page 207: Adjusting The Rear Wheel Static Balance

  REAR WHEEL Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) LOCTITE® Tighten the brake disc bolts in stages and in a crisscross pattern. L LLL L LLL L LLL L LLL L LLL 2. Install: • Rear wheel sensor rotor Rear wheel sensor rotor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LOCTITE®…

• Page 208
  REAR WHEEL ECA23P1017 NOTICE To route the rear wheel sensor lead, refer to “CABLE ROUTING” on page 2-43. When installing the rear wheel sensor, check the rear wheel sensor lead for twists and the sensor electrode for foreign materials. 8. Check: •…

• Page 209: Front Brake

  FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty…

• Page 210
  FRONT BRAKE Removing the front brake pads 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Bleed screw…
• Page 211
  FRONT BRAKE Removing the front brake master cylinder 17 Nm (1.7 m kgf, 12 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) •…
• Page 212
  FRONT BRAKE Removing the front brake master cylinder 17 Nm (1.7 m kgf, 12 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) •…
• Page 213
  FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-40…
• Page 214
  FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of…
• Page 215
  FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake hose (hydraulic unit to left front brake cal-…
• Page 216
  FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.

• Page 217: Introduction

  FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22221 INTRODUCTION low the edge of the brake disc. EWA14101 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

• Page 218: Replacing The Front Brake Pads

  FRONT BRAKE d. Measure the brake disc deflection. 3. Measure: e. If out of specification, repeat the adjustment • Brake pad wear limit “a” Out of specification → Replace the brake steps until the brake disc deflection is within specification. pads as a set.

• Page 219: Removing The Front Brake Calipers

  FRONT BRAKE c. Tighten the bleed screw. 8. Check: • Brake lever operation Front brake caliper bleed screw Soft or spongy feeling → Bleed the brake sys- 5 Nm (0.5 m·kgf, 3.6 ft·lbf) tem. Refer to “BLEEDING THE HYDRAULIC d. Install the brake pads and brake pad spring. BRAKE SYSTEM (ABS)”…

• Page 220: Checking The Front Brake Calipers

  FRONT BRAKE Recommended brake component replace- ment schedule Brake pads If necessary Piston seals Every two years Piston dust seals Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake is disassembled M MMM M MMM M MMM M MMM…

• Page 221: Installing The Front Brake Calipers

  FRONT BRAKE • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and brake caliper piston seals. Recommended fluid DOT 4 EAS22440 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. 1.

• Page 222: Removing The Front Brake Master Cylinder

  FRONT BRAKE • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids To collect any remaining brake fluid, place a may result in a harmful chemical reaction, container under the master cylinder and the end leading to poor brake performance.

• Page 223: Installing The Front Brake Master Cylinder

  FRONT BRAKE • Turn the handlebar to the left and right to make EAS22530 INSTALLING THE FRONT BRAKE MASTER sure the brake hose does not touch other parts CYLINDER (e.g., wire harness, cables, leads). Correct if 1. Install: necessary. • Brake master cylinder “1” •…

• Page 224
  FRONT BRAKE 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-15. 4-51…
• Page 225
  REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Rear brake pad Brake pad shim…
• Page 226
  REAR BRAKE Removing the rear brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •…
• Page 227
  REAR BRAKE Removing the rear brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) •…
• Page 228
  REAR BRAKE Disassembling the rear brake master cylinder 17 Nm (1.7 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake master cylinder joint Brake master cylinder kit Circlip Brake hose joint Filter plate Filter Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
• Page 229
  REAR BRAKE Removing the rear brake caliper 125 Nm (12.5 m kgf, 90 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) •…
• Page 230
  REAR BRAKE Removing the rear brake caliper 125 Nm (12.5 m kgf, 90 ft lbf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 25 Nm (2.5 m kgf, 18 ft Ibf) •…
• Page 231
  REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.

• Page 232: Rear Brake

  REAR BRAKE EAS22561 INTRODUCTION Brake disc thickness limit EWA14101 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •…

• Page 233: Removing The Rear Brake Caliper

  REAR BRAKE • Brake pads Always install new brake pads, brake pad shims and brake pad supports as a set. M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.

• Page 234: Checking The Rear Brake Caliper

  REAR BRAKE • Brake caliper cylinder “2” Scratches/wear → Replace the brake caliper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA23P1005 WARNING M MMM…

• Page 235
  REAR BRAKE Brake hose union bolt Align the slot “a” of the rear wheel sensor hous- 30 Nm (3.0 m·kgf, 22 ft·lbf) ing “1” with the projection “b” of the rear brake caliper bracket “2”, and then assemble them. EWA13530 WARNING ECA14470 Proper brake hose routing is essential to in-…

• Page 236: Removing The Rear Brake Master Cylinder

  REAR BRAKE 6. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)” on page 3-15. 7. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”…

• Page 237: Assembling The Rear Brake Master Cylinder

  REAR BRAKE • Install the rear brake light switch spring “2” as EAS22730 ASSEMBLING THE REAR BRAKE MASTER shown in the illustration. CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •…

• Page 238
  REAR BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

• Page 239: Abs (Anti-Lock Brake System)

  ABS (Anti-Lock Brake System) EAS22760 ABS (Anti-Lock Brake System) Removing the rear fender assembly and brake hoses 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •…

• Page 240
  ABS (Anti-Lock Brake System) Removing the rear fender assembly and brake hoses 30 Nm (3.0 m kgf, 22 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •…
• Page 241
  ABS (Anti-Lock Brake System) Removing the hydraulic unit assembly 16 Nm (1.6 m kgf, 12 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •…

• Page 242: Removing The Hydraulic Unit Assembly

  ABS (Anti-Lock Brake System) EAS23P1014 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA23P1023 NOTICE Unless necessary, avoid removing and in- stalling the brake pipes of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is 2. Remove: already in the system.

• Page 243: Checking The Hydraulic Unit Assembly

  ABS (Anti-Lock Brake System) ECA23P1027 NOTICE Do not remove the rubber plugs or bolts (M10 × 1.00) installed in the flare nut holes before installing the hydraulic unit assem- bly. M MMM M MMM M MMM M MMM M MMM a.

• Page 244: Hydraulic Unit Operation Tests

  ABS (Anti-Lock Brake System) EWA23P1007 WARNING Brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to ECA23P1029 deteriorate, causing leakage and poor NOTICE brake performance. When installing each brake hose onto the hy- •…

• Page 245
  ABS (Anti-Lock Brake System) • Hydraulic unit operation test 2: this test gener- ates the same reaction-force pulsating action that is generated in the brake lever and brake pedal when the ABS is activated. Hydraulic unit operation test 1 EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over.
• Page 246
  ABS (Anti-Lock Brake System) • If the pulse is hardly felt in either the brake 5. Remove the protective cap and then connect lever or brake pedal, check that the brake the test coupler adapter “1” to the ABS test hoses and brake pipes are connected cor- coupler “2”.
• Page 247
  ABS (Anti-Lock Brake System) 9. After releasing the start switch, operate the brake lever and the brake pedal simulta- neously. 12.After the pulsating action has stopped in the brake pedal, it is generated in the brake lever 0.5 second later and continues for approxi- 10.A reaction-force pulsating action is generated mately 2.5 seconds.

• Page 248: Trial Run

  ABS (Anti-Lock Brake System) EAS22820 TRIAL RUN After all checks and servicing are completed, al- ways ensure the vehicle has no problems by performing a trial run at a speed of faster than 30 km/h. 4-75…

• Page 249: Handlebar

  HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •…

• Page 250
  HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •…
• Page 251
  HANDLEBAR Removing the handlebar 17 Nm (1.7 m kgf, 12 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •…

• Page 252: Removing The Handlebar

  HANDLEBAR EAS22860 REMOVING THE HANDLEBAR • The upper handlebar holders should be in- 1. Stand the vehicle on a level surface. stalled with the punch marks “a” facing for- EWA13120 WARNING ward. • Align the punch mark “b” on the handlebar with Securely support the vehicle so that there is the upper surface of the lower handlebar hold- no danger of it falling over.

• Page 253
  HANDLEBAR 4. Install: Right grip end bolt • Right handlebar switch “1” 27 Nm (2.7 m·kgf, 20 ft·lbf) Right upper hand shield bolt Right handlebar switch screw 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Right lower hand shield bolt 4.5 Nm (0.45 m·kgf, 3.3 ft·lbf) LOCTITE®…
• Page 254
  HANDLEBAR • Align the mating surfaces of the clutch master cylinder holder with the punch mark “b” on the There should be 1–3 mm (0.04–0.12 in) of clear- handlebar. ance “b” between the handlebar grip and the grip • First, tighten the front bolt, then the rear bolt. end.

• Page 255: Front Fork

  FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 26 Nm (2.6 m kgf, 19 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)

• Page 256
  FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs.
• Page 257
  FRONT FORK Disassembling the front fork legs 15 Nm (1.5 m kgf, 11 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Damper rod assembly Dust seal Oil seal clip Outer tube Oil seal Washer…

• Page 258: Removing The Front Fork Legs

  FRONT FORK • Nut “4” EAS22960 REMOVING THE FRONT FORK LEGS • Collar “5” The following procedure applies to both of the M MMM M MMM M MMM M MMM M MMM front fork legs. a. Press down on the spacer with the fork spring 1.

• Page 259: Checking The Front Fork Legs

  FRONT FORK Damper rod holder 90890-01423 Damping rod holder YM-01423 L LLL L LLL L LLL L LLL L LLL EAS23011 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: 4. Remove: •…

• Page 260: Assembling The Front Fork Legs

  FRONT FORK ECA14200 NOTICE • Before installing the oil seal, lubricate its lips • The front fork leg has a built-in damper ad- with lithium-soap-based grease. justing rod and a very sophisticated inter- • Lubricate the outer surface of the inner tube nal construction, which are particularly with fork oil.

• Page 261
  FRONT FORK 5. Install: • Oil seal “1” (with the fork seal driver “2”) Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 YM-01442 8. Install: • Damper rod assembly “1” • Inner tube ECA23P1063 NOTICE Allow the damper rod assembly to slide slowly down the inner tube until it contacts the bottom of the inner tube.
• Page 262
  FRONT FORK • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork. 13.After filling the front fork leg, slowly stroke the damper rod “1” up and down (at least ten times) to distribute the fork oil.
• Page 263
  FRONT FORK • Collar “6” • Nut “7” • Cap bolt “8” g. Press down on the spacer with the fork spring compressor “9” and then secure the com- pressor with a suitable tool “10”. M MMM M MMM M MMM M MMM M MMM a.

• Page 264: Installing The Front Fork Legs

  FRONT FORK EWA13680 WARNING Make sure the brake hoses are routed prop- erly. k. Install the damper adjusting rod and cap bolt, and then finger tighten the cap bolt. EWA23P1008 WARNING Always use a new cap bolt O-ring. l. Hold the cap bolt and tighten the nut to spec- ification.

• Page 265: Steering Head

  STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 130 Nm (13 m kgf, 94 ft lbf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •…

• Page 266
  STEERING HEAD Removing the lower bracket 130 Nm (13 m kgf, 94 ft lbf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •…

• Page 267: Removing The Lower Bracket

  STEERING HEAD M MMM M MMM M MMM M MMM M MMM EAS23110 REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe “1” with a long rod “2” and hammer. EWA13120 b.

• Page 268
  STEERING HEAD • Lower bracket cap Be sure to fit the hexagonal portion of the steer- Face the hole “a” in the lower bracket cap rear- ing stem nut “2” into the hexagonal recess in the ward. steering stem nut cap and push the cap down until it contacts the nut flange.

• Page 269: Rear Shock Absorber Assembly

  REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 59 Nm (5.9 m kgf, 43 ft Ibf) •…

• Page 270
  REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • 59 Nm (5.9 m kgf, 43 ft Ibf) • • 49 Nm (4.9 m kgf, 35 ft Ibf)

• Page 271: Handling The Rear Shock Absorber

  REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly lower bolt “1” the rear shock absorber, read and make sure •…

• Page 272: Checking The Connecting Arm And Relay Arm

  REAR SHOCK ABSORBER ASSEMBLY • Spacer Damage/scratches → Replace. • Bolts Bends/damage/wear → Replace. EAS23261 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: • Connecting arms • Relay arm Damage/wear → Replace. 2. Check: • Bearings • Oil seals È…

• Page 273: Swingarm

  SWINGARM EAS23330 SWINGARM Removing the swingarm 120 Nm (12 m kgf, 87 ft lbf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 274
  SWINGARM Removing the swingarm 120 Nm (12 m kgf, 87 ft lbf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 275: Removing The Swingarm

  SWINGARM EAS23350 ECA23P1064 REMOVING THE SWINGARM NOTICE 1. Stand the vehicle on a level surface. Before loosening the pivot shaft, be sure to EWA13120 remove the pivot shaft end plate. WARNING Securely support the vehicle so that there is no danger of it falling over. Slide the rubber boot “2”…

• Page 276
  SWINGARM Make sure that the four projections “a” on the plate are securely fitted onto the frame. 3. Install: • Rubber boot “1” • Align the “ ” mark “a” on the rubber boot with the “ ” mark “b” on the middle driven pinion gear bearing housing “2”.

• Page 277: Shaft Drive

  SHAFT DRIVE EAS23551 SHAFT DRIVE Removing the final drive assembly and drive shaft 42 Nm (4.2 m kgf, 30 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Final gear oil Refer to “CHANGING THE FINAL GEAR OIL”…

• Page 278
  Refer to “ADJUSTING THE FINAL GEAR BACKLASH” on page 4-110 and “ALIGNING Thrust washer THE FINAL DRIVE PINION GEAR AND RING GEAR” on page 4-114. * Yamaha genuine shaft drive oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil 4-105…
• Page 279
  Final drive pinion gear shim PINION GEAR AND RING GEAR” on page 4-114. Bearing holder Dowel pin Final drive pinion gear bearing * Yamaha genuine shaft drive oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil 4-106…
• Page 280
  Job/Parts to remove Q’ty Remarks Ring gear bearing Oil seal Collar Final gear case For assembly, reverse the disassembly pro- cedure. * Yamaha genuine shaft drive oil SAE 80 API GL-5 or SAE 80 API GL-4 Hypoid gear oil 4-107…

• Page 281: Troubleshooting

  SHAFT DRIVE EAS23560 TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sus- B. Improper gear backlash tained speeds (not to be confused with en- C. Damaged gear teeth gine surging or transmission-related D.

• Page 282: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks

  SHAFT DRIVE NO → 2. Place the vehicle on the center- Rear wheel bearings and shaft drive bear- stand so that the rear wheel is ele- ings are probably not damaged. Repeat vated and then spin the rear wheel. the test or remove and check the compo- Is the wheel bearing damaged? nents.

• Page 283: Adjusting The Final Gear Backlash

  SHAFT DRIVE h. Reinstall the ring gear fix bolt, final gear back- Final gear backlash lash band, and dial gauge. 0.20–0.40 mm (0.008–0.016 in) i. Repeat steps (d) to (h) three more times (for a total of four measurements). M MMM M MMM M MMM M MMM…

• Page 284: Measuring The Ring-Gear-To-Stopper-Bolt Clearance

  SHAFT DRIVE b. If it is necessary to increase the final gear backlash by more than 0.2 mm (0.008 in), re- duce the ring gear shim thickness by 0.2 mm (0.008 in) for every 0.2 mm (0.008 in) in- crease of thrust washer thickness. c.

• Page 285: Disassembling The Final Drive Assembly

  SHAFT DRIVE ECA14320 NOTICE • The stopper bolt has left-hand threads. To tighten the stopper bolt, turn it counter- clockwise. • Apply LOCTITE® onto the stopper bolt. 3. Remove: • Coupling gear nut • Washer • Coupling gear “1” (with the coupling gear holding tool “2”) Coupling gear holding tool 4.

• Page 286: Removing And Installing The Bearings

  SHAFT DRIVE ECA14340 NOTICE The final drive pinion gear should only be re- moved if ring gear replacement is necessary. M MMM M MMM M MMM M MMM M MMM a. Install the coupling gear nut “1”. b. Install the general puller “2”. Fit the jaws of the general puller onto the cou- pling gear nut.

• Page 287: Assembling The Final Drive Assembly

  (with an appropriate press tool “4” and press) replaced: • Final gear case The bearing can be reused, but Yamaha recom- • Ring gear bearing housing mends installing a new one. • Any bearing 1.

• Page 288
  SHAFT DRIVE b. To find final drive pinion gear shim thickness Where: “A”, use the following formula: c = a numeral on the final gear case, to be di- vided by 100 and added to “52”. Final drive pinion gear shim thickness d = a numeral indicated by the punch mark on A = a — b — 0.2 the ring gear bearing housing, to be divided…
• Page 289
  SHAFT DRIVE In the example above, the calculated ring gear Install the washer with its “OUT” mark “a” facing shim thickness is 0.52 mm (0.0205 in). The chart outward. instructs you to round off the 2 to 0. Thus, you should use a 0.50 mm (0.0197 in) ring gear shim.

• Page 290: Checking The Drive Shaft

  SHAFT DRIVE e. Measure the width of the flattened Plasti- gauge® “1”. 7. Install: • Ring gear bearing housing (along with the ring gear) Ring-gear-to-thrust-washer clear- 8. Adjust: ance • Final gear backlash 0.10–0.20 mm (0.004–0.008 in) Refer to “MEASURING THE FINAL GEAR BACKLASH”…

• Page 291
  SHAFT DRIVE Recommended lubricant Molybdenum disulfide grease 2. Lubricate: • Drive shaft spline (universal joint side) Recommended lubricant Lithium-soap-based grease 3. Install: • Oil seal “1” • Washer “2” (to the drive shaft with the fork seal driver weight “3” and fork seal driver attachment (ø 30) “4”) Fork seal driver weight 90890-01367…
• Page 292
  SHAFT DRIVE 4-119…

• Page 293: Engine

  ENGINE ENGINE INSPECTION ………………5-1 MEASURING THE COMPRESSION PRESSURE……..5-1 ENGINE REMOVAL ………………5-3 REMOVING THE ENGINE ……………. 5-9 INSTALLING THE ENGINE…………… 5-9 INSTALLING THE EXHAUST PIPE AND MUFFLER……5-10 CAMSHAFTS………………..5-11 REMOVING THE CYLINDER HEAD COVER……… 5-15 REMOVING THE CAMSHAFTS………….. 5-16 CHECKING THE CAMSHAFTS …………..

• Page 294
  ELECTRIC STARTER ………………. 5-48 CHECKING THE STARTER MOTOR …………. 5-50 ASSEMBLING THE STARTER MOTOR……….5-51 CLUTCH ………………….5-52 REMOVING THE CLUTCH …………..5-60 CHECKING THE FRICTION PLATES…………. 5-61 CHECKING THE CLUTCH PLATES …………5-61 CHECKING THE CLUTCH SPRING PLATE……….. 5-61 CHECKING THE CLUTCH HOUSING …………
• Page 295
  CRANKCASE ………………..5-82 REMOVING THE REAR BALANCER …………. 5-87 DISASSEMBLING THE CRANKCASE………… 5-87 CHECKING THE CRANKCASE ………….. 5-88 CHECKING THE REAR BALANCER …………5-88 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE (INTAKE SIDE) ………………5-88 CHECKING THE OIL NOZZLES …………. 5-88 ASSEMBLING THE CRANKCASE…………

• Page 296: Engine Inspection

  ENGINE INSPECTION EAS23P1087 ENGINE INSPECTION EAS20710 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 8. Measure: 1. Measure: • Compression pressure • Valve clearance Out of specification →…

• Page 297
  ENGINE INSPECTION Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Repair. Pistons, valves, cylin- der head gasket or Same as without oil piston ring(s) possi- bly defective → Re- pair.

• Page 298: Engine Removal

  ENGINE REMOVAL EAS23711 ENGINE REMOVAL Removing the exhaust pipe 28 Nm (2.8 m kgf, 20 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 47 Nm (4.7 m kgf, 34 ft Ibf) •…

• Page 299
  ENGINE REMOVAL Removing the exhaust pipe 28 Nm (2.8 m kgf, 20 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 47 Nm (4.7 m kgf, 34 ft Ibf) •…
• Page 300
  ENGINE REMOVAL Disconnecting the leads 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 63 Nm (6.3 m kgf, 46 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.
• Page 301
  ENGINE REMOVAL Disconnecting the leads 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 63 Nm (6.3 m kgf, 46 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Stator coil coupler Disconnect.
• Page 302
  ENGINE REMOVAL Removing the engine 75 Nm (7.5 m kgf, 54 ft Ibf) 68 Nm (6.8 m kgf, 49 ft Ibf) • • • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 75 Nm (7.5 m kgf, 54 ft Ibf) •…
• Page 303
  ENGINE REMOVAL Removing the engine 75 Nm (7.5 m kgf, 54 ft Ibf) 68 Nm (6.8 m kgf, 49 ft Ibf) • • • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 75 Nm (7.5 m kgf, 54 ft Ibf) •…

• Page 304: Removing The Engine

  ENGINE REMOVAL EAS23P1029 REMOVING THE ENGINE Pivot shaft wrench 1. Loosen: 90890-01485 • Engine positioning bolt Frame mount insert wrench YM-01485 Loosen the engine positioning bolt with the pivot shaft wrench “1”. • Tighten the engine positioning bolt with a pivot shaft wrench.

• Page 305: Installing The Exhaust Pipe And Muffler

  ENGINE REMOVAL Install the rubber damper to the frame so that the “O” mark “a” on the damper is facing inward. 3. Install: • Rubber cover “1” • Muffler cover “2” Muffler cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Muffler cover nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) EAS23P1030…

• Page 306: Camshafts

  CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 307
  CAMSHAFTS Removing the cylinder head cover 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…
• Page 308
  CAMSHAFTS Removing the camshafts 24 Nm (2.4 m kgf, 17 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 24 Nm (2.4 m kgf, 17 ft Ibf) •…
• Page 309
  CAMSHAFTS Removing the camshafts 24 Nm (2.4 m kgf, 17 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) 24 Nm (2.4 m kgf, 17 ft Ibf) •…

• Page 310: Removing The Cylinder Head Cover

  CAMSHAFTS EAS23P1089 REMOVING THE CYLINDER HEAD COVER 1. Remove: • Plastic band “1” • Wire harness holder “2” 5. Remove: • Brake hose joint bolt (hydraulic unit to left front brake caliper) “1” To remove the wire harness holder, push in the tab “a”…

• Page 311: Removing The Camshafts

  CAMSHAFTS • Brake pipe (hydraulic unit to left front brake caliper) “3” 9. Remove: • Cylinder head cover “1” • Cylinder head cover gasket Lift up the wire harness, brake pipes, clutch pipe, and clutch hose, and then pull the cylinder head cover rearward to remove it.

• Page 312: Checking The Camshafts

  CAMSHAFTS ECA13720 NOTICE To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 4. Remove: • Intake camshaft “1” • Exhaust camshaft “2” To prevent the timing chain from falling into the EAS23850 CHECKING THE CAMSHAFTS…

• Page 313: Checking The Camshaft Sprocket

  CAMSHAFTS • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the Plastigauge®. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 3.

• Page 314: Checking The Timing Chain Tensioners

  CAMSHAFTS L LLL L LLL L LLL L LLL L LLL a. 1/4 tooth b. Correct EAS23980 CHECKING THE DECOMPRESSION SYSTEM 1. Timing chain roller 1. Check: 2. Camshaft sprocket • Decompression system EAS23960 CHECKING THE TIMING CHAIN • Check that the decompression pins “1” TENSIONERS projects from the camshaft.

• Page 315
  CAMSHAFTS ECA23P1077 NOTICE Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. • Install the cam lobe #1 “a” at the position shown in the illustration. •…
• Page 316
  CAMSHAFTS ECA23P1073 NOTICE Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing. • When installing the timing chain, start with the exhaust camshaft and be sure to keep the tim- ing chain as tight as possible on the exhaust side.
• Page 317
  CAMSHAFTS d. Tighten the intake camshaft cap bolts. c. Install the timing chain tensioner in the cylin- der block. To prevent the timing chain from skipping a tooth Timing chain tensioner bolt on the intake camshaft sprocket, do not remove 10 Nm (1.0 m·kgf, 7.2 ft·lbf) the plastic locking tie before installing the timing chain tensioner.

• Page 318: Installing The Cylinder Head Cover

  CAMSHAFTS Refer to the installation steps above. • Apply Yamaha bond No.1215 “4” onto the mat- • Intake camshaft hole ing surfaces of the cylinder head cover gasket Make sure the hole “e” in the intake camshaft and cylinder head.

• Page 319
  CAMSHAFTS c. Check that the cylinder head cover gasket “2” 7. Install: is installed properly between the cylinder • Clutch hose holder bolt “1” head cover and the cylinder head. Clutch hose holder bolt 9 Nm (0.9 m·kgf, 6.5 ft·lbf) Insert the tab “a”…
• Page 320
  CAMSHAFTS 9. Install: • Stator coil lead • Starter motor lead • Plastic bands • Wire harness holder 5-25…

• Page 321: Cylinder Head

  CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 20 Nm (2.0 m kgf, 14 ft Ibf) • • 75 Nm (7.5 m kgf, 54 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 322: Removing The Cylinder Head

  CYLINDER HEAD • Cylinder head water jacket EAS24120 REMOVING THE CYLINDER HEAD Mineral deposits/rust → Eliminate. 1. Remove: 3. Measure: • Cylinder head bolts • Cylinder head warpage Out of specification → Resurface the cylinder • Loosen the bolts in the proper sequence as head.

• Page 323
  CYLINDER HEAD 2. Tighten: • Cylinder head bolts EWA23P1013 WARNING Replace the bolts with new ones. Tighten the bolts using the following procedure. ×2 ×6 M MMM M MMM M MMM M MMM M MMM a. Lubricate the cylinder head bolts with engine oil.
• Page 324
  VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-26. Valve lifter Valve pad Valve cotter Valve spring retainer Valve spring Exhaust valve Intake valve Valve stem seal…

• Page 325: Valves And Valve Springs

  VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “1” and the valve spring compressor attachment “2”.

• Page 326
  VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” — Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”…

• Page 327: Checking The Valve Seats

  VALVES AND VALVE SPRINGS Valve guide remover & installer Valve stem runout set (ø5.5) 0.010 mm (0.0004 in) 90890-04016 Valve guide remover (5.5 mm) YM-01122 Valve guide installer (ø5.5) 90890-04015 Valve guide installer (5.5 mm) YM-04015 Valve guide reamer (5.5 mm) 90890-01196 YM-01196 L LLL…

• Page 328
  VALVES AND VALVE SPRINGS For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.

• Page 329: Checking The Valve Springs

  VALVES AND VALVE SPRINGS EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. Free length (intake) 40.22 mm (1.58 in) Limit b.

• Page 330
  VALVES AND VALVE SPRINGS 2. Lubricate: b. Smaller pitch • Valve stem “1” 4. Install: • Valve stem end • Valve cotters • Valve stem seal “2” (with the recommended lubricant) Install the valve cotters by compressing the Recommended lubricant valve spring with the valve spring compressor Molybdenum disulfide oil “1”…
• Page 331
  VALVES AND VALVE SPRINGS 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil • Valve lifter (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: • Valve pad • Valve lifter • The valve lifter must move smoothly when ro- tated with a finger.
• Page 332
  CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-26. Water jacket cover Cylinder Cylinder gasket Dowel pin…

• Page 333: Cylinder And Pistons

  CYLINDER AND PISTONS • Oil ring EAS24380 REMOVING THE PISTONS The following procedure applies to both of the When removing a piston ring, open the end gap pistons. with your fingers and lift the other side of the ring 1. Remove: over the piston crown.

• Page 334: Checking The Piston Rings

  CYLINDER AND PISTONS EAS24430 CHECKING THE PISTON RINGS The following procedure applies to both of the piston rings. 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston b.

• Page 335: Checking The Piston Pins

  CYLINDER AND PISTONS Piston pin outside diameter 21.991–22.000 mm (0.8658– 0.8661 in) Limit 21.971 mm (0.8650 in) a. 40.0 mm (1.57 in) 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. 3. Measure: The oil ring expander spacer’s end gap cannot •…

• Page 336
  CYLINDER AND PISTONS 1. Install: • Oil ring expander “1” • Lower oil ring rail “2” • Upper oil ring rail “3” • 2nd ring “4” • Top ring “5” • Install the oil ring expander as shown in the il- lustration.
• Page 337
  CYLINDER AND PISTONS 5-42…

• Page 338: Generator And Starter Clutch

  GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 339
  GENERATOR AND STARTER CLUTCH Removing the stator coil, generator rotor and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 340: Removing The Generator

  GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. Sheave holder EAS24560 REMOVING THE STARTER CLUTCH 90890-01701 1.

• Page 341: Checking The Torque Limiter

  GENERATOR AND STARTER CLUTCH M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch gear “1” onto the gen- erator rotor “2” and hold the generator rotor. b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.

• Page 342
  GENERATOR AND STARTER CLUTCH 3. Apply: • Sealant (onto the stator coil lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 4. Install: • Generator cover gasket • Generator cover Generator cover bolt (M6 × 55) 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE®…

• Page 343: Electric Starter

  ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 7-1. Starter motor lead Disconnect.

• Page 344
  ELECTRIC STARTER Disassembling the starter motor 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover Starter motor rear cover Brush holder set Armature assembly Starter motor yoke…

• Page 345: Checking The Starter Motor

  ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Cut the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut (depth) L LLL L LLL…

• Page 346: Assembling The Starter Motor

  ELECTRIC STARTER 7. Check: • Bearing • Oil seal Damage/wear → Replace the starter motor front cover. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a”…

• Page 347: Clutch

  CLUTCH EAS25061 CLUTCH Removing the clutch cover 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • (14) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) •…

• Page 348
  CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 9,11 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “Removing the clutch release cylin- Clutch release cylinder der”.
• Page 349
  CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch boss nut Conical spring washer Wire circlip Clutch plate Friction plate 3 Inside diameter: 135 mm (5.31 in) Clutch damper spring…
• Page 350
  CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Spacer Thrust plate For installation, reverse the removal proce- dure. 5-55…
• Page 351
  CLUTCH Removing the clutch master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •…
• Page 352
  CLUTCH Removing the clutch master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 1.0 Nm (0.10 m kgf, 0.72 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •…
• Page 353
  CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. 5-58…
• Page 354
  CLUTCH Removing the clutch release cylinder 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.

• Page 355: Removing The Clutch

  CLUTCH 4. Remove: EAS25070 REMOVING THE CLUTCH • Long clutch push rod “1” 1. Remove: • Clutch cover “1” Push the long clutch push rod into the clutch re- lease cylinder side of the engine, and remove it Loosen each bolt 1/4 of a turn at a time, in stag- from the clutch side of the engine.

• Page 356: Checking The Friction Plates

  CLUTCH There is a built-in damper between the clutch boss and the clutch plate. It is not necessary to remove the wire circlip “4” and disassemble the built-in damper unless there is serious clutch chattering. A. Friction plate 1, 2 B.

• Page 357: Checking The Clutch Housing

  CLUTCH 2. Check: • Clutch spring plate seat Pitting on the clutch boss splines will cause er- Damage → Replace. ratic clutch operation. 3. Measure: • Clutch spring free height Out of specification → Replace the clutch spring plate. Clutch spring height 6.78 mm (0.27 in) Minimum height 6.44 mm (0.25 in)

• Page 358: Installing The Clutch

  CLUTCH Excessive noise during operation → Replace • Clutch boss nut “3” the clutch housing and crankshaft as a set. Clutch boss nut 125 Nm (12.5 m·kgf, 90 ft·lbf) • Lubricate the conical spring washer and clutch boss nut threads with engine oil. •…

• Page 359: Disassembling The Clutch Master Cylinder

  CLUTCH 8. Install: • Clutch cover “1” Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE® Tighten the clutch cover bolts in the proper tight- ening sequence as shown. 6. Install: • Clutch spring plate “1” • Clutch spring plate retainer “2” 1,9,25 Clutch spring plate retainer bolt 10,26…

• Page 360: Checking The Clutch Master Cylinder

  CLUTCH • Clutch fluid may damage painted surfaces 2. Check: and plastic parts. Therefore, always clean • Clutch master cylinder kit Rust/scratches/wear → Replace. up any spilt fluid immediately. • Avoid clutch fluid coming into contact with 3. Check: the eyes as it can cause serious injury. •…

• Page 361: Removing The Clutch Release Cylinder

  CLUTCH EWA13370 WARNING • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • Refill with the same type of clutch fluid that is already in the system. Mixing clutch flu- ids may result in a harmful chemical reac- tion, leading to poor clutch performance.

• Page 362: Assembling The Clutch Release Cylinder

  CLUTCH 2. Install: • Clutch release cylinder plate “1” Put the end of the clutch hose into a container • Dowel pins and pump out the clutch fluid carefully. • Clutch release cylinder Clutch release cylinder bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE®…

• Page 363
  CLUTCH 4. Fill: 7. Check: • Clutch master cylinder reservoir • Clutch lever operation Soft or spongy feeling → Bleed the clutch (with the specified amount of the recom- mended clutch fluid) system. Refer to “BLEEDING THE HYDRAULIC Recommended fluid CLUTCH SYSTEM”…

• Page 364: Pickup Rotor

  PICKUP ROTOR EAS24520 PICKUP ROTOR Removing the pickup rotor 65 Nm (6.5 m kgf, 47 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-25.

• Page 365: Removing The Pickup Rotor

  PICKUP ROTOR EAS24530 REMOVING THE PICKUP ROTOR 1. Remove: • Pickup rotor bolt “1” • Washer “2” • Pickup rotor “3” While holding the generator rotor “4” with the sheave holder “5”, loosen the pickup rotor bolt. Sheave holder 2. Tighten: 90890-01701 •…

• Page 366
  PICKUP ROTOR Crankshaft position sensor hold- er bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® 4. Measure: • Gap (between the crankshaft position sensor “1” and pickup rotor “2”) “a” Out of specification → Reinstall or replace. Gap (between the crankshaft po- sition sensor and pickup rotor) 1.0 mm (0.04 in) 5-71…

• Page 367: Shift Shaft

  SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) •…

• Page 368
  SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks…

• Page 369: Checking The Shift Shaft

  SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever 3. Install: Bends/damage → Replace. • Shift arm “1” Roller turns roughly →…

• Page 370
  SHIFT SHAFT 2. Adjust: • Installed shift rod length M MMM M MMM M MMM M MMM M MMM a. Loosen both locknuts “1”. ECA23P1088 NOTICE The shift rod locknut (shift pedal side) has left-hand threads. b. Turn the shift rod “2” in direction “a” or “b” until the specified installed shift rod length is ob- tained.

• Page 371: Oil Pump

  OIL PUMP EAS24921 OIL PUMP Removing the oil pan and oil pump assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (17) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 372
  OIL PUMP Removing the oil pan and oil pump assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (17) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •…
• Page 373
  OIL PUMP Disassembling the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil strainer (oil pump) Spring Relief valve Oil pump inner rotor 1 Oil pump outer rotor 1 Oil pump housing cover Oil pump driven gear…
• Page 374
  OIL PUMP Disassembling the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump inner rotor 2 Oil pump outer rotor 2 Oil pump housing For assembly, reverse the disassembly pro- cedure.

• Page 375: Removing The Oil Pan And Oil Strainer Cover

  OIL PUMP EAS24930 3. Oil pump housing REMOVING THE OIL PAN AND OIL STRAINER COVER Inner-rotor-to-outer-rotor-tip 1. Remove: clearance • Oil strainer cover Less than 0.120 mm (0.0047 in) • Oil strainer (oil pan) Limit • Oil pan 0.20 mm (0.0079 in) •…

• Page 376: Checking The Oil Strainer

  OIL PUMP EAS24990 CHECKING THE OIL STRAINER Apply Three Bond No.1541C® “1” onto the mat- 1. Check: ing surfaces of the oil strainer cover and oil • Oil strainer (oil pan) strainer cover gasket. Damage → Replace. Contaminants → Clean with solvent. •…

• Page 377: Crankcase

  CRANKCASE EAS25540 CRANKCASE Removing the rear balancer 12 Nm (1.2 m kgf, 8.7 ft Ibf) (10) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •…

• Page 378
  CRANKCASE Removing the rear balancer 12 Nm (1.2 m kgf, 8.7 ft Ibf) (10) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •…
• Page 379
  CRANKCASE Separating the crankcase 24 Nm (2.4 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) •…
• Page 380
  CRANKCASE Separating the crankcase 24 Nm (2.4 m kgf, 17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) •…
• Page 381
  CRANKCASE Removing the oil nozzle 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 0.5 Nm (0.05 m kgf, 0.36 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) •…

• Page 382: Removing The Rear Balancer

  CRANKCASE • M10 × 130 mm bolts: “1”–“6” EAS23P1092 REMOVING THE REAR BALANCER • M8 × 78 mm bolts: “7”–“12” 1. Remove: • M8 × 80 mm bolts: “13”–“19” • Rear balancer “1” • M8 × 60 mm bolts: “20”, “21”, “30”–“32” ECA23P1075 •…

• Page 383: Checking The Crankcase

  2. Apply: and make sure the crankcase halves sepa- • Sealant rate evenly. (onto the crankcase mating surfaces) EAS25580 Yamaha bond No. 1215 CHECKING THE CRANKCASE 90890-85505 1. Thoroughly wash the crankcase halves in a (Three Bond No.1215®) mild solvent.

• Page 384
  CRANKCASE • Before installing the crankcase bolts “7”–“12”, install the O-rings onto the bolts, making sure that each O-ring contacts the bolt flange. • Lubricate the bolts “1”–“6” threads and wash- ers with engine oil. • Lubricate the bolts “7”–“32” threads and mating surfaces with engine oil.
• Page 385
  CRANKCASE EWA23P1016 WARNING If the bolt is tightened more than the speci- fied angle, do not loosen the bolt and then re- tighten it. Instead, replace the bolt with a new ×3 one and perform the procedure again. ECA23P1045 NOTICE •…
• Page 386
  CRANKCASE Crankcase bolt “7”–“21”, “30”– “32” 24 Nm (2.4 m·kgf, 17 ft·lbf) Crankcase bolt “22”–“29” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Tighten the crankcase bolts in the proper tight- ening sequence as shown. A. Lower crankcase B. Upper crankcase 11.Install: •…

• Page 387: Installing The Rear Balancer

  CRANKCASE Rear balancer shaft retainer bolt Apply Three Bond No.1541C® “2” onto the mat- 12 Nm (1.2 m·kgf, 8.7 ft·lbf) ing surfaces of the oil delivery passage cover LOCTITE® and oil delivery passage cover O-ring. L LLL L LLL L LLL L LLL L LLL EAS23P1095…

• Page 388: Crankshaft And Balancer

  CRANKSHAFT AND BALANCER EAS25950 CRANKSHAFT AND BALANCER Removing the crankshaft, connecting rods and front balancer 1st 20 Nm (2.0 m kgf, 14 ft Ibf) • • 2nd Specified angle 145–155˚ Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-82. ECA23P1076 NOTICE Front balancer shaft…

• Page 389
  CRANKSHAFT AND BALANCER Removing the crankshaft, connecting rods and front balancer 1st 20 Nm (2.0 m kgf, 14 ft Ibf) • • 2nd Specified angle 145–155˚ Order Job/Parts to remove Q’ty Remarks Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce- dure.

• Page 390: Removing The Front Balancer Shaft

  CRANKSHAFT AND BALANCER EAS23P1096 REMOVING THE FRONT BALANCER SHAFT Identify the position of each connecting rod cap, 1. Remove: connecting rod, and big end bearing so that it • Front balancer shaft “1” can be reinstalled in its original place. ECA23P1076 NOTICE The front balancer shaft should not be disas-…

• Page 391
  CRANKSHAFT AND BALANCER b. Install the crankshaft journal lower bearings “1” and the crankshaft into the lower crank- case. Align the projections “a” on the crankshaft jour- nal lower bearings with the notches “b” in the lower crankcase. f. Oil groove e.

• Page 392: Checking The Connecting Rods

  CRANKSHAFT AND BALANCER M MMM M MMM M MMM M MMM M MMM The following procedure applies to all of the connecting rods. ECA13930 NOTICE Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clear- ance and prevent engine damage, the big end bearings must be installed in their origi- nal positions.

• Page 393: Checking The Front Balancer

  CRANKSHAFT AND BALANCER • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. • Make sure that the projection “e” on the con- necting rod cap faces the same direction as the “Y”…

• Page 394
  CRANKSHAFT AND BALANCER 2. Measure: • Balancer shaft-journal-to-balancer shaft-jour- nal-bearing clearance Out of specification → Replace the balancer shaft journal bearings. Balancer shaft-journal-to-balanc- er shaft-journal-bearing clear- ance 0.016–0.040 mm (0.0006–0.0016 d. Install the front balancer shaft journal upper bearings “3” into the upper crankcase and as- ECA23P1048 NOTICE semble the crankcase halves.

• Page 395: Installing The Connecting Rods

  CRANKSHAFT AND BALANCER 3. Select: Bearing color code • Front balancer shaft journal bearings (J –J 1.Blue 2.Black 3.Brown 4.Green • The numbers “A” stamped into the lower crank- EAS26150 INSTALLING THE CONNECTING RODS case and the numbers “B” stamped into the 1.

• Page 396: Installing The Crankshaft

  CRANKSHAFT AND BALANCER 30˚ 30˚ 145–155˚ 4. Tighten: EWA13400 WARNING • Connecting rod nuts M MMM M MMM M MMM M MMM M MMM If the connecting rod nut is tightened more EWA13390 than the specified angle, do not loosen the WARNING nut and then retighten it.

• Page 397: Installing The Front Balancer Shaft

  CRANKSHAFT AND BALANCER c. Oil groove EAS26220 INSTALLING THE FRONT BALANCER SHAFT 1. Install: • Front balancer shaft journal upper bearings (into the upper crankcase) • Front balancer shaft journal lower bearings (into the lower crankcase) • Align the projections “a” on the front balancer shaft journal bearings “1”…

• Page 398: Transmission

  TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE”…

• Page 399
  TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Main axle assembly Bearing For installation, reverse the removal proce- dure.
• Page 400
  TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd/4th pinion gear Circlip Toothed washer 5th pinion gear 5-105…
• Page 401
  TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks Collar Bearing housing Spacer Bearing Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure. 5-106…
• Page 402
  TRANSMISSION Disassembling the drive axle/middle drive pinion gear Order Job/Parts to remove Q’ty Remarks Middle drive pinion gear assembly Refer to “MIDDLE GEAR” on page 5-113. Bearing Washer 1st wheel gear Collar 5th wheel gear Circlip Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer…
• Page 403
  TRANSMISSION Disassembling the drive axle/middle drive pinion gear Order Job/Parts to remove Q’ty Remarks 4th wheel gear Collar Toothed washer Circlip 6th wheel gear Circlip Toothed washer 2nd wheel gear Collar Drive axle For assembly, reverse the disassembly pro- cedure. 5-108…

• Page 404: Removing The Transmission

  TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: • Main axle assembly “1” Remove the main axle assembly with the slide hammer bolts “2” and weight. Slide hammer bolt 90890-01083 3. Check: Slide hammer bolt 6 mm • Shift fork movement YU-01083-1 (along the shift fork guide bar) Weight…

• Page 405: Assembling The Main Axle And Drive Axle

  TRANSMISSION Out of specification → Replace the main axle. Incorrect → Reassemble the transmission axle assemblies. Main axle runout limit 5. Check: 0.08 mm (0.0032 in) • Transmission gear movement Rough movement → Replace the defective part(s). EAS23P1046 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1.

• Page 406: Installing The Transmission

  TRANSMISSION 2. Install: • Main axle assembly “1” • Main axle bearing housing bolts Main axle bearing housing bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LOCTITE® When installing the main axle assembly, use a pin “2” to align the bearing housing hole with the A.

• Page 407
  TRANSMISSION • Install each shift drum retainer with its “OUT” mark “a” facing outward. • Align the projection “b” on the shift fork upper guide bar with the slot “c” in the shift drum up- per retainer. 5. Check: • Transmission Rough movement →…

• Page 408: Middle Gear

  MIDDLE GEAR EAS25711 MIDDLE GEAR Removing the middle driven pinion gear 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • •…

• Page 409
  MIDDLE GEAR Removing the middle driven pinion gear 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 33 Nm (3.3 m kgf, 24 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • Order Job/Parts to remove Q’ty Remarks Universal joint yoke nut…
• Page 410
  MIDDLE GEAR Removing the middle drive pinion gear 110 Nm (11 m kgf, 80 ft lbf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-82. Middle drive pinion gear bearing retainer Refer to “ALIGNING THE MIDDLE GEAR”…
• Page 411
  MIDDLE GEAR Removing the middle drive pinion gear 110 Nm (11 m kgf, 80 ft lbf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Middle drive pinion gear nut Middle drive pinion gear Bearing Middle drive pinion gear bearing housing For installation, reverse the removal proce-…

• Page 412: Removing The Middle Driven Pinion Gear Assembly

  MIDDLE GEAR • While holding the universal joint yoke “2” with EAS23P1033 REMOVING THE MIDDLE DRIVEN PINION the universal joint holder “3” and the 20 mm GEAR ASSEMBLY (0.79 in) diameter attachment, loosen the uni- 1. Remove: versal joint yoke nut. Place a rag between the •…

• Page 413: Checking The Middle Driven Pinion Gear Assembly

  MIDDLE GEAR b. Attach the middle drive shaft nut wrench (55 3. Check: mm) “1”. • Spring Cracks/damage → Replace. Middle drive shaft nut wrench (55 4. Check: • Bearings 90890-04054 Damage/pitting → Replace. Offset wrench 55 mm YM-04054 EAS23P1039 ASSEMBLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1.

• Page 414: Installing The Middle Drive Pinion Gear Assembly

  MIDDLE GEAR EAS23P1040 INSTALLING THE MIDDLE DRIVE PINION GEAR ASSEMBLY 1. Install: • Washer • Spring retainers “1” While compressing the spring with the damper spring compressor “2”, install the washer and spring retainers. 3. Install: Damper spring compressor • Universal joint yoke nut “1” 90890-04090 M MMM M MMM…

• Page 415: Installing The Middle Driven Pinion Gear Assembly

  MIDDLE GEAR EAS23P1042 INSTALLING THE MIDDLE DRIVEN PINION GEAR ASSEMBLY 1. Install: • Middle driven pinion gear shim(s) “1” • Middle driven pinion gear assembly Middle driven pinion gear bearing housing bolt 33 Nm (3.3 m·kgf, 24 ft·lbf) LOCTITE® b. Remove the universal joint holder, and then turn the nut with a torque wrench to check the starting torque.

• Page 416: Measuring The Middle Gear Backlash

  MIDDLE GEAR 2. Measure: • Middle gear backlash Out of specification → Refer to “ADJUSTING THE MIDDLE GEAR BACKLASH” on page 5-121. Middle gear backlash 0.045–0.090 mm (0.002–0.004 in) M MMM M MMM M MMM M MMM M MMM a. Hold the middle drive pinion gear “1” with the d.

• Page 417
  MIDDLE GEAR Middle driven pinion gear bearing housing bolt 33 Nm (3.3 m·kgf, 24 ft·lbf) ECA23P1047 NOTICE Do not overtighten the middle driven pinion gear bearing housing bolts or you may ob- tain too little middle gear backlash and dam- age the middle gears.

• Page 418: Aligning The Middle Gear

  MIDDLE GEAR 11.Measure: M MMM M MMM M MMM M MMM M MMM a. Position the middle gears with the appropri- • Middle gear backlash ate shim(s) that has had its respective thick- Out of specification → Refer to “MEASUR- ness calculated from information marked on ING THE MIDDLE GEAR BACKLASH”…

• Page 419
  MIDDLE GEAR Hundredths Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness- Middle drive pinion gear shim Thickness (mm) “g”= a numeral on the upper crankcase, to be 0.10 0.15 0.20 0.30 0.40 0.50 divided by 100 and added to “98.00”…
• Page 420
  MIDDLE GEAR Hundredths Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thickness- Middle driven pinion gear shim Thickness (mm) 0.10 0.15 0.20 0.30 0.40 0.50 L LLL L LLL L LLL L LLL L LLL 5-125…

• Page 421: Cooling System

  COOLING SYSTEM RADIATOR …………………. 6-1 CHECKING THE RADIATOR…………..6-3 INSTALLING THE RADIATOR…………..6-3 THERMOSTAT ………………..6-4 CHECKING THE THERMOSTAT………….. 6-5 INSTALLING THE THERMOSTAT…………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 …………

• Page 422
  RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •…

• Page 423: Radiator

  RADIATOR Removing the radiator 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) •…

• Page 424: Checking The Radiator

  RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the inner side of the radiator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

• Page 425: Thermostat

  THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 18 Nm (1.8 m kgf, 13 ft Ibf) •…

• Page 426: Checking The Thermostat

  THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 69–73 °C (156.2–163.4 °F) EAS26480 INSTALLING THE THERMOSTAT → Replace. 1. Install: • Thermostat Install the thermostat with its breather hole “a” facing forward.

• Page 427: Water Pump

  WATER PUMP EAS26500 WATER PUMP Removing the water pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 428
  WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover Gasket Circlip Impeller shaft Water pump seal Bearing Oil seal Water pump housing Rubber damper holder Rubber damper Water pump seal assembly For assembly, reverse the disassembly pro-…

• Page 429: Disassembling The Water Pump

  WATER PUMP EAS26510 EAS26541 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Water pump seal “1” • Water pump housing cover • Water pump housing • Impeller shaft Remove the water pump seal from the inside of •…

• Page 430
  WATER PUMP Mechanical seal installer 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 1. Straightedge 2. Impeller 3. Install: • Oil seal “1” (into the water pump housing “2”) Install the oil seal with a socket “3”…

• Page 431: Installing The Water Pump

  WATER PUMP EAS26590 INSTALLING THE WATER PUMP 1. Install: • Water pump assembly Align the projection “a” on the impeller shaft “1” with the slot “b” in the front balancer shaft “2”. 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”…

• Page 432
  WATER PUMP 6-11…

• Page 433: Fuel System

  FUEL SYSTEM FUEL TANK………………… 7-1 REMOVING THE FUEL TANK …………..7-3 REMOVING THE FUEL PUMP …………..7-3 CHECKING THE FUEL PUMP BODY…………7-3 INSTALLING THE FUEL PUMP…………..7-3 INSTALLING THE FUEL TANK…………..7-4 THROTTLE BODIES ………………7-5 CHECKING THE INJECTORS (BEFORE REMOVING) ……7-8 REMOVING THE INJECTORS …………..

• Page 434: Fuel Tank

  FUEL TANK EAS26620 FUEL TANK Removing the fuel tank and fuel pump 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) •…

• Page 435
  FUEL TANK Removing the fuel tank and fuel pump 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •…

• Page 436: Removing The Fuel Tank

  FUEL TANK EAS26630 ECA14720 REMOVING THE FUEL TANK NOTICE 1. Extract the fuel in the fuel tank through the • Do not drop the fuel pump or give it a fuel tank cap with a pump. strong shock. 2. Remove: •…

• Page 437: Installing The Fuel Tank

  FUEL TANK • Install the fuel hose connector securely onto the fuel tank until a distinct “click” is heard, and then make sure that it does not come loose. • After installing the fuel hose holder “1”, make sure that the sections “a”, “b”, and “c” of the holder are installed securely.

• Page 438
  THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) •…

• Page 439: Throttle Bodies

  THROTTLE BODIES Removing the throttle bodies 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 4.5 Nm (0.45 m kgf, 3.3 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 3.0 Nm (0.30 m kgf, 2.2 ft Ibf) •…

• Page 440
  THROTTLE BODIES Removing the injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) •…

• Page 441: Checking The Injectors (Before Removing)

  THROTTLE BODIES EAS23P1077 EAS23P1080 CHECKING THE INJECTORS (BEFORE CHECKING AND CLEANING THE THROTTLE REMOVING) BODIES 1. Check: • Injectors Clean the throttle bodies only if they cannot be Use the diagnostic code number “d:36–d:37”. synchronized using the bypass air screws. Be- Refer to “DIAGNOSTIC MODE”…

• Page 442
  THROTTLE BODIES • Do not apply cleaning solvent directly to any plastic parts, sensors, or seals. • Do not directly push the throttle valves to open them. • Be careful not to remove the white paint mark that identifies the standard throttle body.

• Page 443: Checking The Throttle Body Joints

  THROTTLE BODIES • If an injector is subject to strong shocks or excessive force, replace it. • If installing the original fuel rail and screws, remove the white paint marks using a cleaning solvent. Otherwise, paint chips on the screw seats could prevent the screws from being tightened to the specified torque.

• Page 444: Checking The Fuel Pressure

  THROTTLE BODIES ECA23P1003 NOTICE Pressure gauge 90890-03153 When lifting up the fuel tank, be careful not YU-03153 to pull the fuel tank overflow hose and fuel Fuel injector pressure adapter tank breather hose. 90890-03210 YU-03210 b. Remove the fuel hose holder “2” and then disconnect the fuel hose “3”…

• Page 445: Adjusting The Throttle Position Sensor

  THROTTLE BODIES d. Start the engine. e. Measure the fuel pressure. “dIAG” appears on the odometer LCD. Output pressure f. Diagnostic code number “d:01” is selected. 324.0 kPa (3.24 kgf/cm², 47.0 g. Adjust the position of the throttle position sen- psi) sor angle so that 9–20 can appear in the meter.

• Page 446: Installing The Throttle Body Joints

  THROTTLE BODIES M MMM M MMM M MMM M MMM M MMM l. Check the meter display value. If the meter a. Temporary tighten the accelerator position display value is not 97–113, adjust the accel- sensor. erator position sensor angle. b.

• Page 447: Electrical System

  ELECTRICAL SYSTEM IGNITION SYSTEM ………………8-1 CIRCUIT DIAGRAM ……………… 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION……. 8-3 TROUBLESHOOTING …………….8-4 ELECTRIC STARTING SYSTEM …………..8-7 CIRCUIT DIAGRAM ……………… 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ……8-9 TROUBLESHOOTING …………….8-10 CHARGING SYSTEM………………8-13 CIRCUIT DIAGRAM …………….

• Page 448
  ABS (ANTI-LOCK BRAKE SYSTEM)…………8-89 CIRCUIT DIAGRAM …………….8-89 ABS COMPONENTS CHART …………..8-91 ABS COUPLER LOCATION CHART …………8-93 MAINTENANCE OF THE ABS ECU …………8-95 ABS TROUBLESHOOTING OUTLINE………… 8-95 BASIC INSTRUCTIONS FOR TROUBLESHOOTING ……8-96 BASIC PROCESS FOR TROUBLESHOOTING ……..8-97 [A] CHECKING THE ABS WARNING LIGHT……….

• Page 450: Ignition System

  IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM…

• Page 451
  IGNITION SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 18.Ignition fuse 21.Relay unit 24.Neutral switch 25.Sidestand switch 28.Crankshaft position sensor 34.Lean angle sensor 39.ECU (engine control unit) 40.Cylinder-#1 left ignition coil 41.Cylinder-#1 right ignition coil 42.Cylinder-#2 left ignition coil 43.Cylinder-#2 right ignition coil 44.Spark plug 54.Frame ground…

• Page 452: Engine Stopping Due To Sidestand Operation

  IGNITION SYSTEM EAS23P1071 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ECU does not flow to the ignition coils or injectors when the neutral switch circuit or sidestand switch circuit is open.

• Page 453: Troubleshooting

  IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel 3. Air filter case NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).

• Page 454
  IGNITION SYSTEM NG → 9. Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch. SWITCHES” on page 8-137. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch. SWITCHES” on page 8-137. OK ↓…
• Page 455
  IGNITION SYSTEM…

• Page 456: Electric Starting System

  ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM…

• Page 457
  ELECTRIC STARTING SYSTEM 3. Main fuse 4. Battery 5. Engine ground 7. Starter relay 8. Starter motor 9. Main switch 18.Ignition fuse 21.Relay unit 22.Starting circuit cut-off relay 24.Neutral switch 25.Sidestand switch 54.Frame ground 72.Clutch switch 99.Engine stop switch 100.Start switch…

• Page 458: Starting Circuit Cut-Off System Operation

  ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop 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: •…

• Page 459: Troubleshooting

  ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel 3. Fuel tank NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

• Page 460
  ELECTRIC STARTING SYSTEM NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 8-137. OK ↓ NG → 10.Check the neutral switch. Refer to “CHECKING THE Replace the neutral switch.
• Page 461
  ELECTRIC STARTING SYSTEM 8-12…

• Page 462: Charging System

  CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-13…

• Page 463
  CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Main fuse 4. Battery 8-14…

• Page 464: Troubleshooting

  CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”…

• Page 465
  CHARGING SYSTEM 8-16…

• Page 466: Lighting System

  LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17…

• Page 467
  LIGHTING SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 13.Headlight fuse 18.Ignition fuse 39.ECU (engine control unit) 54.Frame ground 60.Multi-function meter 63.High beam indicator light 67.Meter light 70.Headlight relay 73.Pass switch 74.Dimmer switch 84.Headlight 87.License plate light 89.Tail/brake light 93.Taillight fuse 8-18…

• Page 468: Troubleshooting

  LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light or meter light. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel NG → 1.

• Page 469
  LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-17. OK ↓ Replace the ECU, meter assembly, head light assembly, or tail/brake light. 8-20…

• Page 470: Signaling System

  SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21…

• Page 471
  SIGNALING SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 17.ABS ECU fuse 18.Ignition fuse 21.Relay unit 24.Neutral switch 27.Fuel sender 32.Coolant temperature sensor 39.ECU (engine control unit) 49.Rear wheel sensor 51.Rear wheel sensor lead shield 52.ABS ECU (electronic control unit) 54.Frame ground 57.Oil level warning light 58.Neutral indicator light…

• Page 472: Troubleshooting

  SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •…

• Page 473
  SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-21. OK ↓ Replace the horn. The tail/brake light fails to come on. NG → 1.
• Page 474
  SIGNALING SYSTEM NG → 5. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-21. OK ↓ Replace the meter assembly. The neutral indicator light fails to come on. NG →…
• Page 475
  SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-21. OK ↓ Replace the meter assembly. The coolant temperature meter, coolant temperature warning light, or both fail to come on. NG →…

• Page 476: Cooling System

  COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27…

• Page 477
  COOLING SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 16.Radiator fan motor fuse 18.Ignition fuse 32.Coolant temperature sensor 39.ECU (engine control unit) 54.Frame ground 90.Radiator fan motor 91.Radiator fan motor relay 8-28…

• Page 478: Troubleshooting

  COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel 3. Fuel tank 4. Left side cowling 5. Air filter case NG → 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s).

• Page 479
  COOLING SYSTEM NG → 7. Check the entire cooling system wiring. Properly connect or repair the cooling sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-27. OK ↓ Replace the ECU. 8-30…

• Page 480: Fuel Injection System

  FUEL INJECTION SYSTEM EAS27331 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31…

• Page 481
  FUEL INJECTION SYSTEM 3. Main fuse 4. Battery 5. Engine ground 7. Starter relay 9. Main switch 10.Fuel injection system fuse 11.Electric throttle valve fuse 13.Headlight fuse 17.ABS ECU fuse 18.Ignition fuse 21.Relay unit 22.Starting circuit cut-off relay 23.Fuel pump relay 24.Neutral switch 25.Sidestand switch 26.Fuel pump…

• Page 482: Ecu Self-Diagnostic Function

  FUEL INJECTION SYSTEM EAS27351 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.

• Page 483: Troubleshooting Method

  FUEL INJECTION SYSTEM 4. Set the main switch to “OFF”, then to “ON” EAS30580 TROUBLESHOOTING METHOD again, and then check that no fault code num- ber is displayed. The engine operation is not normal and the engine trouble warning light comes on. If another fault code number is displayed, repeat 1.

• Page 484
  FUEL INJECTION SYSTEM • All displays on the meter disappear except the odometer displays. • “dIAG” appears on the odometer LCD. If “Co” appears on the odometer LCD, press the left set button to select “dIAG”. 4. Simultaneously press the right set button and left set button for 2 seconds or more to set the diag- nostic mode.

• Page 485: Troubleshooting Details

  FUEL INJECTION SYSTEM • If a diagnostic code No. does not have a corresponding fault code number, the information is shown in “DIAGNOSTIC CODE TABLE”. (Refer to “DIAGNOSTIC CODE TABLE” on page 8-73.) 8. Connect the wire harness coupler to the fuel pump. EAS27462 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter.

• Page 486
  FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Installed condition of crank- Improperly installed sensor Crank the engine. → Reinstall or replace the shaft position sensor. Fault code number is not dis- played →…
• Page 487
  FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Set the main switch to “ON”. place the wire harness. Fault code number is not dis- played →…
• Page 488
  FUEL INJECTION SYSTEM Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Set the engine stop switch to “ ”, and then operate the throttle Procedure while pushing the start switch “ ”. (If the display value changes, the performance is OK.) Probable cause of mal- Confirmation of service…
• Page 489
  FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor signal 2 Meter display • 7–23 (fully closed position) d:13 Procedure • Check with throttle valves fully closed. Probable cause of mal- Confirmation of service Item Maintenance job…
• Page 490
  FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Throttle position sensor out- Check for disconnected lead Set the main switch to “ON”. put voltage in the throttle position sensor Fault code number is not dis- played →…
• Page 491
  FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the black/red Item lead of the ECU is detected. Improperly connected → Connection of wire harness Set the main switch to “ON”, ECU coupler. Connect the coupler secure- and then extend and retract Check the locking condition ly or repair/replace the wire…
• Page 492
  FUEL INJECTION SYSTEM Fault code No. Item Coolant temperature sensor: open or short circuit detected. Improperly connected → Connection of coolant tem- Set the main switch to “ON”. perature sensor coupler. Connect the coupler secure- Fault code number is not dis- played →…
• Page 493
  FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Connection of intake air tem- Set the main switch to “ON”. perature sensor coupler. Connect the coupler secure- Fault code number is not dis- played →…
• Page 494
  FUEL INJECTION SYSTEM Fault code No. sensor #1: no normal signals are received from the O sen- Item sor #1. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Installed condition of O sen- Improperly installed sensor Start the engine, warm it up, →…
• Page 495
  FUEL INJECTION SYSTEM Fault code No. sensor #1: no normal signals are received from the O sen- Item sor #1. Defective O sensor. Replace the O sensor. Start the engine, warm it up, and then race it. Refer to “ENGINE REMOV- Execute the diagnostic AL”…
• Page 496
  FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 left ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#1 left ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
• Page 497
  FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 left ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#1 left ignition coil. Malfunction in ECU. Replace the ECU. Fault code No. Cylinder-#1 right ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#1 right ignition coil.
• Page 498
  FUEL INJECTION SYSTEM Fault code No. Cylinder-#1 right ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#1 right ignition coil. Defective cylinder-#1 right ig- Execute the diagnostic Start the engine and let it idle nition coil.
• Page 499
  FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 left ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#2 left ignition coil. Open or short circuit → Re- Wire harness continuity. Start the engine and let it idle place the wire harness.
• Page 500
  FUEL INJECTION SYSTEM Fault code No. Cylinder-#2 right ignition coil: open or short circuit detected in Item the primary lead of the cylinder-#2 right ignition coil. Improperly connected → Connection of wire harness Start the engine and let it idle ECU coupler.
• Page 501
  FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Identify the malfunctioning Execute the diagnostic mode — injector (Code No. d:36, 37). Identify the injector that does not produce an operating sound.
• Page 502
  FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No. d:08 Lean angle sensor output voltage Meter display • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Remove the lean angle sensor and incline it more than 65 de- Procedure grees.
• Page 503
  FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Malfunction in ECU. Replace the ECU. Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected.
• Page 504
  FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected → Connection of ABS ECU Execute the diagnostic coupler.
• Page 505
  FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction in ECU. Replace the ECU.
• Page 506
  FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected → Connection of neutral switch Start the engine, and input coupler.
• Page 507
  FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
• Page 508
  FUEL INJECTION SYSTEM Fault code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Defective clutch switch. Check the clutch switch.
• Page 509
  FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: the ECU is unable to monitor the battery Item voltage (an open or short circuit in the wire harness to the ECU). Improperly connected → Connection of wire harness Set the main switch to “ON”. ECU coupler.
• Page 510
  FUEL INJECTION SYSTEM Fault code No. EEPROM cylinder fault code number: an error is detected Item while reading or writing on EEPROM (CO adjustment value). EEPROM fault code display • 00 (no history) • 01–04: Cylinder fault code number (history exists) Meter display If more than one cylinder is defective, the display switches every two seconds to show the cylinder fault code numbers of all defec-…
• Page 511
  FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Meter display — Procedure — Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Malfunction in charging sys- Check the charging system. Start the engine and let it idle tem.
• Page 512
  FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Accelerator position sensor signal 2 Meter display • 9–25 (fully closed position) • 97–113 (fully open position) d:15 • Check with throttle grip in fully closed position. Procedure •…
• Page 513
  FUEL INJECTION SYSTEM Fault code No. Item Accelerator position sensor: open or short circuit detected. Accelerator position sensor Check for disconnected lead Set the main switch to “ON”. output voltage in the accelerator position Fault code number is not dis- played →…
• Page 514
  FUEL INJECTION SYSTEM Fault code No. Item YCC-T drive system: malfunction detected. Abnormality → Replace the Check the ETV (Electronic Set the main switch to “ON”. Throttle Valve) fuse. ETV (Electronic Throttle Fault code number is not dis- played → Service is finished. Valve) fuse.
• Page 515
  FUEL INJECTION SYSTEM Fault code No. sensor #2: no normal signals are received from the O sen- Item sor #2. Improperly connected → Connection of O sensor Start the engine, warm it up, Connect the coupler secure- and then race it. coupler.
• Page 516
  FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item rear wheel sensor. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. d:16 Front wheel speed pulse Meter display 0–999 Check that the number increases when the front wheel is rotated.
• Page 517
  FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item rear wheel sensor. Improperly connected → Connection of ABS ECU Execute the diagnostic coupler. Connect the coupler secure- mode. (Code No. d:16) Check the locking condition ly or repair/replace the wire Rotate the front wheel by of the coupler.
• Page 518
  FUEL INJECTION SYSTEM Fault code No. Front wheel sensor: no normal signals are received from the Item rear wheel sensor. Defective rear wheel sensor. Improperly installed sensor Execute the diagnostic → Reinstall or repair the sen- mode. (Code No. d:16) sor.
• Page 519
  FUEL INJECTION SYSTEM Fault code No. Er-1 ECU internal malfunction (output signal error): no signals are Item received from the ECU. Improperly connected → Connection of multi-function Set the main switch to “ON”. meter coupler. Connect the coupler secure- Fault code number is not dis- played →…
• Page 520
  FUEL INJECTION SYSTEM Fault code No. Er-2 ECU internal malfunction (output signal error): no signals are Item received from the ECU within the specified duration. Improperly connected → Connection of multi-function Set the main switch to “ON”. meter coupler. Connect the coupler secure- Fault code number is not dis- played →…
• Page 521
  FUEL INJECTION SYSTEM Fault code No. Er-3 ECU internal malfunction (output signal error): data from the Item ECU cannot be received correctly. Improperly connected → Connection of multi-function Set the main switch to “ON”. meter coupler. Connect the coupler secure- Fault code number is not dis- played →…

• Page 522: Diagnostic Code Table

  FUEL INJECTION SYSTEM Fault code No. Er-4 ECU internal malfunction (input signal error): non-registered Item data has been received from the meter. Improperly connected → Connection of multi-function Set the main switch to “ON”. meter coupler. Connect the coupler secure- Fault code number is not dis- played →…

• Page 523
  FUEL INJECTION SYSTEM Diag- nostic Item Meter display/Actuation Procedure code d:57 Grip warmer relay Illuminates the engine trou- — ble warning light. d:61 Malfunction history code — display • No history • History exists 11–70: Fault code number • If more than one malfunc- tion is detected, the display switches every two seconds to show the fault code num-…

• Page 524: Fuel Pump System

  FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-75…

• Page 525
  FUEL PUMP SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 10.Fuel injection system fuse 18.Ignition fuse 21.Relay unit 23.Fuel pump relay 26.Fuel pump 39.ECU (engine control unit) 54.Frame ground 99.Engine stop switch 8-76…

• Page 526: Troubleshooting

  FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Right side cowling 2. Right side panel 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).

• Page 527
  FUEL PUMP SYSTEM 8-78…

• Page 528: Immobilizer System

  IMMOBILIZER SYSTEM EAS27640 IMMOBILIZER SYSTEM EAS27650 CIRCUIT DIAGRAM 8-79…

• Page 529
  IMMOBILIZER SYSTEM 3. Main fuse 4. Battery 5. Engine ground 9. Main switch 12.Backup fuse (odometer, clock, and immobilizer system) 18.Ignition fuse 20.Immobilizer unit 39.ECU (engine control unit) 54.Frame ground 56.Immobilizer system indicator light 60.Multi-function meter 8-80…

• Page 530: General Information

  IMMOBILIZER SYSTEM EAS27671 GENERAL INFORMATION This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the standard keys. This system consists of the following: • a code re-registering key (with a red bow) • two standard keys (with a black bow) that can be re-registered with new codes •…

• Page 531
  IMMOBILIZER SYSTEM Parts to be replaced Main switch/immo- Key registration re- Accesso- bilizer unit Standard quirement ry lock* Main Immobiliz- and key switch er unit √ Standard key is lost New standard key All keys have been Code re-registering √ √…
• Page 532
  IMMOBILIZER SYSTEM Standby mode a. Main switch “ON” e. Standby mode on b. Main switch “OFF” f. Standby mode off c. LED on d. LED off Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
• Page 533
  IMMOBILIZER SYSTEM Standard key registration a. Main switch “ON” B. Immobilizer system indicator light stops flashing when the registration of the second b. Main switch “OFF” standard key is complete. c. LED on d. LED off e. Less than 5.0 s f.

• Page 534: Troubleshooting

  IMMOBILIZER SYSTEM EAS27701 TROUBLESHOOTING When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor flashes. NG → 1. Check the fuses. (Main, ignition, and backup) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

• Page 535
  IMMOBILIZER SYSTEM Fault Part Symptom Cause Action code IMMOBILIZER Codes between the 1. Signal received from 1. Place the immo- UNIT key and immobilizer other transponder bilizer unit at unit do not match. (failed to recognize least 50 mm code after ten con- away from the secutive attempts).
• Page 536
  IMMOBILIZER SYSTEM a. Light on b. Light off 8-87…
• Page 537
  IMMOBILIZER SYSTEM 8-88…

• Page 538: Abs (Anti-Lock Brake System)

  ABS (ANTI-LOCK BRAKE SYSTEM) EAS28790 ABS (ANTI-LOCK BRAKE SYSTEM) EAS27730 CIRCUIT DIAGRAM 8-89…

• Page 539
  ABS (ANTI-LOCK BRAKE SYSTEM) 3. Main fuse 4. Battery 5. Engine ground 6. ABS motor fuse 7. Starter relay 9. Main switch 14.ABS solenoid fuse 17.ABS ECU fuse 18.Ignition fuse 21.Relay unit 22.Starting circuit cut-off relay 39.ECU (engine control unit) 48.Front wheel sensor 49.Rear wheel sensor 50.Front wheel sensor lead shield…

• Page 540: Abs Components Chart

  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27740 ABS COMPONENTS CHART 12 13 1. ABS warning light 2. Front wheel sensor rotor 3. Front wheel sensor 4. Right front brake caliper 5. Left front brake caliper 6. ABS ECU fuse 7. ABS solenoid fuse 8.

• Page 541
  ABS (ANTI-LOCK BRAKE SYSTEM) 8-92…

• Page 542: Abs Coupler Location Chart

  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27750 ABS COUPLER LOCATION CHART Lg R/W G Dg Sb/W (GRAY) Y W/L R/W B Br L/B Dg Br/W 8-93…

• Page 543
  ABS (ANTI-LOCK BRAKE SYSTEM) 1. Right handlebar switch coupler 2. Starter relay coupler 3. Main fuse coupler 4. ABS ECU coupler 5. ABS test coupler 6. Rear wheel sensor coupler 7. Front wheel sensor coupler 8. Meter assembly coupler 8-94…

• Page 544: Maintenance Of The Abs Ecu

  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27770 MAINTENANCE OF THE ABS ECU If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air. Checking the ABS ECU 1. Check: • Terminals “1” of the ABS ECU Cracks/damage → Replace the hydraulic unit assembly and the brake pipes that are con- nected to the assembly as a set.

• Page 545: Basic Instructions For Troubleshooting

  ABS (ANTI-LOCK BRAKE SYSTEM) The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was set to “ON”. During this test, a “clicking” noise can be heard from under the rider seat, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.

• Page 546: Basic Process For Troubleshooting

  ABS (ANTI-LOCK BRAKE SYSTEM) EAS27810 BASIC PROCESS FOR TROUBLESHOOTING [A] Set the main switch to “ON” and check the ABS warning light. The ABS warning light (LED) is defective. • The wire harness is grounded between the • [B-1] Does the ABS warning [C-1] Does only the ABS warning ABS ECU and the meter assembly.

• Page 547: [A] Checking The Abs Warning Light

  ABS (ANTI-LOCK BRAKE SYSTEM) EWA23P1019 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. (Refer to “[D-3] FINAL CHECK” on page 8-131.) EAS27830 [A] CHECKING THE ABS WARNING LIGHT Set the main switch to “ON”.

• Page 548: [B-5] Malfunctions Are Currently Detected

  ABS (ANTI-LOCK BRAKE SYSTEM) a. Light on e. Fault code 21 b. Light off f. 1 cycle c. Time (second) g. Repeats d. Fault code 12 2. The ABS warning light flashes every 0.5 second for more than 6 seconds. The ABS warning light flashes every 0.5 second if no fault code for a past malfunction is stored in the memory of the ABS ECU.

• Page 549: [C-3] The Abs Warning Light Remains On

  ABS (ANTI-LOCK BRAKE SYSTEM) 2. Battery • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-142. • If the battery is defective, clean the battery terminals and recharge it, or replace the battery. 3.

• Page 550: [C-4] The Abs Warning Light Flashes

  ABS (ANTI-LOCK BRAKE SYSTEM) • Set the main switch to “ON”, and then check the ABS warning light. • If the ABS warning light is on, the internal circuit of the meter assembly is defective. Replace the meter assembly. • If the ABS warning light does not come on, the ABS ECU is defective. Replace the hydraulic unit assembly.

• Page 551
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. • Rear wheel sensor circuit • Wire harness (ABS circuit) Rear wheel sensor circuit is short-cir- • Connection of the rear wheel sensor cou- cuited. pler and ABS ECU coupler •…
• Page 552
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault Symptom Check point code No. Solenoid valve data is abnormal. • Hydraulic unit assembly Hydraulic pressure sensor power is ab- • Hydraulic unit assembly normal. Front brake master cylinder pressure • Hydraulic unit assembly sensor is defective. Rear brake master cylinder pressure •…
• Page 553
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel sensor signal is not received prop- erly. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or • Set the main replace the wheel sensor if nec- switch to “ON”…
• Page 554
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear wheel sensor signal is not received proper- Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or • Set the main replace the wheel sensor if nec- switch to “ON”…
• Page 555
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Incorrect signal from the front wheel sensor is detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or • Set the main replace the wheel sensor if nec- switch to “ON”…
• Page 556
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Incorrect signal from the rear wheel sensor is detected. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel sensor. Check for looseness. Repair or • Set the main replace the wheel sensor if nec- switch to “ON”…
• Page 557
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Connections • Check the coupler for any pins • Set the main • Front wheel sensor coupler that may be pulled out.
• Page 558
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Wire harness continuity. • Check for continuity between the white terminal “1” and the white terminal “3”…
• Page 559
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and front wheel sensor coupler, and then delete the fault…
• Page 560
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Wire harness continuity. • Check for continuity between the white terminal “1” and the white terminal “3”…
• Page 561
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear wheel sensor circuit is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective wheel sensor. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and rear wheel sensor coupler, and then delete the fault…
• Page 562
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Missing pulses detected in the rear wheel sen- sor signal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Installed condition of wheel bearings, Check the components for loose- •…
• Page 563
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Start switch signal is not received properly (start switch circuit or start switch monitor cir- cuit). Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Engine startability. Check the electric starting sys- •…
• Page 564
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom ABS motor is defective. Power is not supplied to the ABS motor. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Recharge or replace the battery. • Set the main Refer to “CHECKING AND switch to “ON”…
• Page 565
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Hydraulic unit ABS motor is short-circuited. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Short circuit in ABS motor relay. Replace the hydraulic unit as- • Set the main sembly.
• Page 566
  Brake lines • Check the brake lines for kinks and deterioration. EWA23P1020 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake…
• Page 567
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Front wheel will not recover from the locking tendency even though the signal is continuous- ly transmitted from the ABS ECU to release the hydraulic pressure (when the battery voltage is normal). Order Item/components and probable Check or maintenance job Reinstatement…
• Page 568
  (particularly between the hydraulic unit and the rear brake caliper). EWA23P1020 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
• Page 569
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear wheel will not recover from the locking ten- dency even though the signal is continuously transmitted from the ABS ECU to release the hy- draulic pressure (when the battery voltage is normal).
• Page 570
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Power voltage is too high. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Battery voltage Replace the battery. • Set the main Refer to “CHECKING AND switch to “ON” CHARGING THE BATTERY”…
• Page 571
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom ABS ECU has internal malfunction. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Hydraulic unit assembly internal mal- Replace the hydraulic unit as- • Set the main function. sembly.
• Page 572
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Hydraulic pressure sensor power is abnormal. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Defective internal monitor circuit (hy- Replace the hydraulic unit as- • Set the main draulic pressure sensor power).
• Page 573
  ABS (ANTI-LOCK BRAKE SYSTEM) Fault code No. Symptom Rear brake master cylinder pressure sensor is defective. Order Item/components and probable Check or maintenance job Reinstatement cause confirmation method Rear brake master cylinder pressure Replace the hydraulic unit as- • Set the main sensor malfunction.
• Page 574
  (particularly between the hydraulic unit and the rear brake caliper). EWA23P1020 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
• Page 575
  ABS (ANTI-LOCK BRAKE SYSTEM) EWA23P1022 WARNING The rear brake will not function properly if the connections are reversed. • Brake hose (rear brake master cylinder to hydraulic unit brake pipe joint) “1” inlet: from the rear brake master cylinder • Brake hose (hydraulic unit brake pipe joint to rear brake caliper) “2” outlet: to the rear brake caliper •…
• Page 576
  (particularly between the hydraulic unit and the rear brake caliper). EWA23P1020 WARNING Only use genuine Yamaha parts. Using other brake pipes, hoses and union bolts may close the brake lines. • Check that the connections of the brake lines from the brake master cylinder to the hydraulic unit are correct.
• Page 577
  ABS (ANTI-LOCK BRAKE SYSTEM) EWA23P1022 WARNING The rear brake will not function properly if the connections are reversed. • Brake hose (rear brake master cylinder to hydraulic unit brake pipe joint) “1” inlet: from the rear brake master cylinder • Brake hose (hydraulic unit brake pipe joint to rear brake caliper) “2” outlet: to the rear brake caliper •…

• Page 578: [D-1] Deleting The Fault Codes

  ABS (ANTI-LOCK BRAKE SYSTEM) 8. Set the main switch to “OFF”. EAS23P1056 [D-1] DELETING THE FAULT CODES 9. Disconnect the test coupler adapter from the 1. Remove the protective cap, and then connect ABS test coupler, and then install the protec- the test coupler adapter “1”…

• Page 579
  ABS (ANTI-LOCK BRAKE SYSTEM) L/B Dg Br/W b. Measure the ABS ECU voltage. 4. Connect the ABS ECU coupler (without cou- pler cover) “1”. L LLL L LLL L LLL L LLL L LLL 9. Check: • ABS-ECU-to-start-switch-lead continuity Push both lock plates “2” down simultaneously No continuity →…

• Page 580: [D-3] Final Check

  ABS (ANTI-LOCK BRAKE SYSTEM) M MMM M MMM M MMM M MMM M MMM 11.If the above-mentioned checks are within a. Connect the pocket tester (DC 20 V) to the specification, replace the hydraulic unit as- ABS ECU coupler. sembly. 12.Install the coupler cover “1”…

• Page 581
  ABS (ANTI-LOCK BRAKE SYSTEM) 8-132…

• Page 582: Electrical Components

  ELECTRICAL COMPONENTS EAS27973 ELECTRICAL COMPONENTS 8-133…

• Page 583
  ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Clutch switch 4. Intake air temperature sensor 5. Throttle servo motor 6. Throttle position sensor 7. Accelerator position sensor 8. Intake air pressure sensor 9. Fuel pump 10. Rear brake light switch 11.
• Page 584
  ELECTRICAL COMPONENTS 8-135…
• Page 585
  ELECTRICAL COMPONENTS 1. Rectifier/regulator 2. Relay unit 3. Main fuse 4. Radiator fan motor relay 5. Turn signal/hazard relay 6. Headlight relay 7. ECU (engine control unit) 8. Starter relay 9. ABS motor fuse 10. Hydraulic unit assembly 11. Lean angle sensor 12.

• Page 586: Checking The Switches

  ELECTRICAL COMPONENTS EAS27981 CHECKING THE SWITCHES R/Y W/Y Br/W Br/W R Br/L Br/R R/Y Br/W W/Y Br/R Br B/W Br B/Y L/Y Ch (BLACK) ( BLACK ) Br/L R/W R/B L/W B W/G B/W MODE (BLACK) (BLACK) G/Y Br (GRAY) (BROWN) 8-137…

• Page 587
  ELECTRICAL COMPONENTS 1. Pass switch 2. Dimmer switch 3. Hazard switch 4. Turn signal switch 5. Horn switch 6. Engine stop switch 7. Start switch 8. D-mode switch 9. Front brake light switch 10. Rear brake light switch 11. Neutral switch 12.
• Page 588
  ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

• Page 589: Checking The Bulbs And Bulb Sockets

  ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB WARNING SOCKETS Since the headlight bulb gets extremely hot, keep flammable products and your hands Do not check any of the lights that use LEDs. away from the bulb until it has cooled down. ECA14380 Check each bulb and bulb socket for damage or NOTICE…

• Page 590: Checking The Fuses

  ELECTRICAL COMPONENTS Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace the The following procedure applies to all of the bulb fuse. sockets. L LLL L LLL L LLL L LLL L LLL 1. Check: 3.

• Page 591: Checking And Charging The Battery

  ELECTRICAL COMPONENTS cal system, cause the lighting and ignition be charged according to the appropriate systems to malfunction and could possibly charging method. If the battery is over- cause a fire. charged, the electrolyte level will drop con- siderably. Therefore, take special care L LLL L LLL L LLL…

• Page 592
  ELECTRICAL COMPONENTS • No charging is necessary when the open-cir- • If it is impossible to regulate the charging cuit voltage equals or exceeds 12.8 V. current on the battery charger, be careful not to overcharge the battery. b. Check the charge of the battery, as shown in •…
• Page 593
  ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.

• Page 594: Checking The Relays

  ELECTRICAL COMPONENTS 10.Install: 3. Positive tester probe • Right side cowling 4. Negative tester probe Refer to “GENERAL CHASSIS” on page 4-1. Result EAS28040 Continuity CHECKING THE RELAYS (between “3”and “4”) Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay.

• Page 595: Checking The Turn Signal/Hazard Relay

  ELECTRICAL COMPONENTS Radiator fan motor relay Br/L b. Turn the main switch to “ON”. 1. Positive battery terminal c. Measure the turn signal/hazard relay input 2. Negative battery terminal voltage. 3. Positive tester probe L LLL L LLL L LLL L LLL L LLL 4.

• Page 596: Checking The Relay Unit (Diode)

  ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C M MMM M MMM M MMM M MMM M MMM a. Disconnect the relay unit from the wire har- The pocket tester and the analog pocket tester ness.

• Page 597: Checking The Ignition Spark Gap

  ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. M MMM M MMM M MMM M MMM M MMM a. Remove the ignition coil from the spark plug. b.

• Page 598: Checking The Lean Angle Sensor

  ELECTRICAL COMPONENTS • Positive tester probe → Pocket tester yellow/green “1” 90890-03112 • Negative tester probe → Analog pocket tester black/blue “2” YU-03112-C • Positive tester probe → black “1” • Negative tester probe → gray “2” c. Turn the main switch to “ON”. d.

• Page 599: Checking The Stator Coil

  ELECTRICAL COMPONENTS b. Check the starter motor operation. EAS28170 CHECKING THE RECTIFIER/REGULATOR L LLL L LLL L LLL L LLL L LLL 1. Check: • Charging voltage EAS28150 CHECKING THE STATOR COIL Out of specification → Replace the rectifi- 1. Disconnect: er/regulator.

• Page 600: Checking The Fuel Sender

  ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM • Positive tester probe → a. Connect the pocket tester (Ω × 100) to the en- green “1” gine oil level gauge terminal as shown. • Negative tester probe → black “2”…

• Page 601: Checking The Oil Level Warning Light

  ELECTRICAL COMPONENTS c. Measure the radiator fan motor movement. EAS29050 CHECKING THE OIL LEVEL WARNING L LLL L LLL L LLL L LLL L LLL LIGHT EAS28261 CHECKING THE COOLANT TEMPERATURE This model is equipped with a self-diagnosis de- vice for the oil level detection circuit. SENSOR 1.

• Page 602: Checking The Throttle Position Sensor

  ELECTRICAL COMPONENTS • Positive tester probe → blue “1” • Negative tester probe → black/blue “2” d. Heat the coolant or let it cool down to the specified temperatures. e. Measure the coolant temperature sensor re- sistance. L LLL L LLL L LLL L LLL L LLL…

• Page 603: Checking The Intake Air Pressure Sensor

  ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM Pocket tester a. Connect the test harness S-pressure sensor 90890-03112 (3P) between the intake air pressure sensor Analog pocket tester and wire harness. YU-03112-C ECA23P1082 NOTICE • Positive tester probe → Pay attention to the installing direction of the blue “1”…

• Page 604: Checking The Intake Air Temperature Sensor

  ELECTRICAL COMPONENTS 3. Install: EAS28421 CHECKING THE INTAKE AIR • Intake air temperature sensor TEMPERATURE SENSOR 1. Remove: Intake air temperature sensor • Intake air temperature sensor screw (from the air filter case.) 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf) EWA14110 WARNING EAS23P1072 CHECKING THE FUEL INJECTORS…

• Page 605
  ELECTRICAL COMPONENTS 2. Disconnect: • Throttle servo motor coupler 3. Check: • Throttle servo motor resistance Out of specification → Replace the throttle bodies. Resistance 0–100 Ω ECA23P1083 NOTICE Do not disassemble the throttle servo motor. M MMM M MMM M MMM M MMM M MMM…
• Page 606
  ELECTRICAL COMPONENTS 8-157…

• Page 607: Troubleshooting

  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 ………………

• Page 608: Troubleshooting

  TROUBLESHOOTING Electrical system EAS28451 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.

• Page 609: Poor Medium-And-High-Speed Performance

  TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •…

• Page 610: Overheating

  TROUBLESHOOTING EAS30480 EAS28620 OVERHEATING POOR BRAKING PERFORMANCE • Worn brake pad Engine • Worn brake disc 1. Clogged coolant passages • Air in hydraulic brake system • Cylinder head and piston(s) • Leaking brake fluid • Heavy carbon buildup • Faulty brake caliper kit 2.

• Page 611: Faulty Lighting Or Signaling System

  TROUBLESHOOTING 4. Swingarm Turn signal does not come on • Worn bearing or bushing • Faulty turn signal switch • Bent or damaged swingarm • Faulty turn signal/hazard relay 5. Rear shock absorber assembly(-ies) • Burnt-out turn signal bulb • Faulty rear shock absorber spring •…

• Page 612: Wiring Diagram

  EAS28740 54. Frame ground EAS28750 WIRING DIAGRAM COLOR CODE 55. Meter assembly Black 56. Immobilizer system indicator XT1200Z(Z) 2010 Brown light 1. AC magneto Chocolate 57. Oil level warning light 2. Rectifier/regulator Dark green 58. Neutral indicator light 3. Main fuse Green 59.

• Page 614
  YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN…

• Page 615: Wiring Diagram

  XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO Br/G W3 W2 (BLACK) (GRAY) R/W2 LEAN ANGLE SENSOR NEUTRAL SWITCH WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS SUB-WIRE HARNESS Br/W…

• Page 616
  XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 XT1200Z(Z) 2010 WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO (BLACK) (GRAY) LEAN ANGLE SENSOR NEUTRAL SWITCH WIRE HARNESS WIRE HARNESS SUB-WIRE HARNESS SUB-WIRE HARNESS (BLACK) (BLACK) (BLACK) (BLACK) ( DARK BLUE )