Yamaha Yzf-R6 PDF

2017
SERVICE MANUAL
YZF-R6
YZFR6H
YZFR6HC
LIT-11616-30-60 BN6-28197-10
EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-10*) for basic instructions that
must be observed during servicing. Repair and maintenance work attempted by anyone without this
knowledge is likely to render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION

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

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

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
EAS20002
YZFR6H/YZFR6HC
SERVICE MANUAL
©2017 by Yamaha Motor Corporation, U.S.A.
First edition, March 2017
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-30-60
EAS20004
HOW TO USE THIS MANUAL

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

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

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

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

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

E
Silicone fluid
S
EAS10003
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
COOLING SYSTEM 6
FUEL SYSTEM 7
ELECTRICAL SYSTEM 8
TROUBLESHOOTING 9
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
INSTRUMENT FUNCTIONS ..................................................................... 1-2
SPECIAL TOOLS ............................................................................................ 1-8

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
on the right side of the steering head pipe.
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.
1-1
FEATURES
EAS20008
• The “ ”, “GPS”, and “QS” icons require ac-
FEATURES cessory parts to function.
EAS30682
INSTRUMENT FUNCTIONS Speedometer

The speedometer shows the vehicle’s traveling
Multi-function meter unit speed.
1 2 3 4
Tachometer
5
6
7 2
8
11 10 9
1. Tachometer
2. Shift light
3. TCS display 1. Tachometer
4. Coolant/air intake temperature display 2. Tachometer red zone
5. Drive mode display
6. Speedometer The electric tachometer shows the engine
7. Multi-function display speed, as measured by the rotational velocity of
8. Clock/lap timer the crankshaft, in revolutions per minute (r/min).
9. Transmission gear display When the vehicle is first powered on, the ta-
10. “RESET” button chometer needle will sweep once across the r/
11. “SELECT” button min range and then return to zero.
ECA19660
EWA17650
NOTICE
WARNING
Do not operate the engine in the tachometer
Be sure to stop the vehicle before making red zone.
any setting changes to the multi-function
meter unit. Changing settings while riding Red zone
can distract the operator and increase the 16500 r/min and above
risk of an accident.
The multi-function meter unit is equipped with Clock and lap timer
the following:
• speedometer
• tachometer
• clock
• lap timer
• coolant temperature display
• air intake temperature display
• transmission gear display
• drive mode display 1
• TCS display
• multi-function display 1. Clock
• display brightness and shift light control mode
TIP The clock uses a 12-hour time system.
• To switch the multi-function meter unit be-
tween miles and kilometers, push the “SE-
LECT” button for one second.
1-2
FEATURES
[To set the clock:] [To use the lap timer]

1. Turn the key to “ON”. 1. Push the “RESET” button for one second to
2. Push the “SELECT” button and the “RESET” set the lap timer to the counting-ready state
button for two seconds. The hour digits will (the colon “:” and period “.” will flash).
start flashing. 2. Push the pass switch “ ” to start the lap tim-
3. Push the “RESET” button to set the hours. er.
4. Push the “SELECT” button, and the minute 3. Push the pass switch “ ” to mark the start of
digits will start flashing. each new lap.
5. Push the “RESET” button to set the minutes. 4. Push the “SELECT” button to stop the lap
6. Push the “SELECT” button to confirm the set- timer.
tings and start the clock. 5. Push the “SELECT” button again to reset the
[To switch between the clock and lap timer] lap timer (or push the “RESET” button for one
Push and release the “SELECT” button and the second to reset the lap timer and set it to the
“RESET” button at the same time. counting-ready state).
[To view the lap time history]

1. Push the “SELECT” button for one second.
Lap order history is selected (indicated by “L-
20” in the lower part of the display), or push
the “SELECT” button again to select fast lap
history (indicated by “F-20”).
• “L-20” = lap order (most recent is L1)
1 • “F-20” = fastest order (fastest lap time is F1)
1. Lap timer
The lap timer records and stores up to 20 lap
times. The lap time history records are divided
into two groups, “L” for lap order and “F” for fast-
est order. For lap order, the most recent lap is
designated L1 (and L19 will become L20). In the
case of fast lap history, any new fast lap within 1
the top 20 will be inserted and the previous F20
will be pushed out of the history. 1. History type (L-20 or F-20)
2. Push the “RESET” button and the 1st lap time
of that history group (indicated by “L1” or
“F1”) is shown.
1. Lap number/Fastest rank

2. Lap time
1-3
FEATURES
3. Use the “SELECT” button to scroll the history This display indicates the temperature of the air
in ascending order, or use the “RESET” but- drawn into the air intake duct.
ton to scroll the history in descending order. Push the “RESET” button to switch the display
4. When you have finished viewing the lap re- between the coolant temperature and the air in-
cords you can: take temperature.
• push the “RESET” button for one second to TIP
delete that group of lap records. • When the coolant temperature display is se-
• push the “SELECT” button for one second to lected, “C” is displayed for one second, and
exit and return to the lap timer. then the coolant temperature is displayed.
• When the air intake temperature display is se-
Coolant temperature display lected, “A” is displayed for one second, and
then the air intake temperature is displayed.
1 • When the air temperature is below 16 °F, “16
°F” will be displayed.
Transmission gear display
1
1. Coolant temperature display
This display indicates the temperature of the
2
coolant from 105 °F to 255 °F in 1 °F increments.
If the coolant temperature is between 242 and
255 °F, the coolant temperature display flashes
and the coolant temperature warning light 1. Neutral indicator light “ ”
comes on. If this occurs, reduce the load on the 2. Transmission gear display
engine by riding at a moderate pace, at low rpm,
until the coolant temperature goes down. If the This display shows the selected gear. The neu-
temperature does not go down, or if the mes- tral position is indicated by “ ” and by the neutral
sage “HI” flashes, stop the engine and let it cool. indicator light.
TIP
Drive mode display
• When the vehicle is turned on, the coolant tem-
perature display is automatically selected.
• When the coolant temperature is below 105 °F,
“Lo” will be displayed. 1
Air intake temperature display
1. Drive mode display

This display indicates which drive mode has
been selected: “STD”, “A” or “B”.
1. Air intake temperature display
1-4
FEATURES
TCS display Odometer and tripmeters

The odometer shows the total distance traveled
by the vehicle.
The tripmeters show the distance traveled since
1
they were last reset. To reset a tripmeter, push
the “RESET” button for one second.
TIP
• The odometer will lock at 999999.
• The tripmeters will reset and continue counting
after 9999.9 is reached.
1. TCS display
This display indicates which traction control sys- Fuel reserve tripmeter
tem setting has been selected: “1” through “6” or If the fuel level warning light comes on, the dis-
“OFF”. play will automatically change to the fuel reserve
tripmeter “TRIP F” and start counting the dis-
Multi-function display tance traveled from that point. In this case, push
the “SELECT” button to switch the display in the
following order:
TRIP F → km/L, L/100 km or MPG → AVE _ _

_._ km/L, AVE _ _ _._ L/100 km or AVE _ _ _._
MPG → _ _._ → ODO → TRIP 1 → TRIP 2 →
1 TRIP F
TIP
If you do not reset the fuel reserve tripmeter
manually, after refueling and traveling 5 km (3
1. Multi-function display
mi), it will reset automatically and disappear from
The multi-function display is equipped with the the display.
following:
• odometer Instantaneous fuel consumption
• two tripmeters
• fuel reserve tripmeter
• instantaneous fuel consumption
• average fuel consumption
• total fuel used
Navigating the multi-function display

Push the “SELECT” button to change between 1
the odometer “ODO”, tripmeters “TRIP 1” and
“TRIP 2”, instantaneous fuel consumption “km/
L”, “L/100 km” or “MPG”, average fuel consump-
1. Instantaneous fuel consumption display
tion “AVE _ _ _._ km/L”, “AVE _ _ _._ L/100 km”
or “AVE _ _ _._ MPG”, and total fuel used “_ _._” This function calculates the fuel consumption
in the following order: under current riding conditions.
The instantaneous fuel consumption display is
ODO → TRIP 1 → TRIP 2 → km/L, L/100 km or set to “MPG”, or when using kilometers to “km/L”
MPG → AVE _ _ _._ km/L, AVE _ _ _._ L/100 or “L/100 km”. To switch between “km/L” and “L/
km or AVE _ _ _._ MPG → _ _._ → ODO 100 km”, push the “SELECT” button for one sec-
ond.
1-5
FEATURES
• “km/L”: The distance that can be traveled on Total fuel used

1.0 L of fuel under the current riding conditions
is shown.
• “L/100 km”: The amount of fuel necessary to
travel 100 km under the current riding condi-
tions is shown.
• “MPG”: The distance that can be traveled on
1.0 US gal of fuel under the current riding con- 1
ditions is shown.
TIP
If traveling at speeds under 20 km/h (12 mi/h), “_
_ _._” is displayed. 1. Total fuel used display
This display shows the total amount of fuel that
Average fuel consumption has been used since it was last reset.
When using miles, this figure is shown in gal-
lons. When using kilometers, this figure is shown
in liters.
To reset the total fuel used display, push the
“RESET” button for one second.
1 TIP
After the total fuel used display is reset, “_ _. _”
will be shown until the vehicle has traveled a suf-
ficient distance.
1. Average fuel consumption display

Display brightness and shift light control
This function calculates the average fuel con- mode
sumption since it was last reset.
The average fuel consumption display is set to 1
2
“AVE _ _ _._ MPG”, or when using kilometers to
“AVE _ _ _._ km/L” or “AVE _ _ _._ L/100 km”.
When using kilometers, push the “SELECT” but-
ton for one second to switch between “AVE _ _
_._ km/L” and “AVE _ _ _._ L/100 km”.
• “AVE _ _ _._ km/L”: The average distance that 3
can be traveled on 1.0 L of fuel is shown.
• “AVE _ _ _._ L/100 km”: The average amount
of fuel necessary to travel 100 km is shown. 1. Shift light
• “AVE _ _ _._ MPG”: The average distance that 2. Shift light activation range
can be traveled on 1.0 US gal of fuel is shown. 3. Brightness level display
TIP
This mode cycles through five control functions,
• To reset the average fuel consumption display, allowing you to make the following settings in the
push the “RESET” button for one second. order listed below.
• After resetting the average fuel consumption • Display brightness – adjust the brightness of
display, “_ _ _._” will be shown until the vehicle the displays and tachometer.
has traveled 1 km (0.6 mi). • Shift light activity function – set the shift light to
on, flash, or off.
• Shift light activation – set the engine speed at
which the shift light will be come on.
• Shift light deactivation – set the engine speed
at which the shift light will be go off.
1-6
FEATURES
• Shift light brightness – adjust the brightness of 1. Push the “RESET” button to set the activation
the shift light. point engine speed.
TIP 2. Push the “SELECT” button to confirm the set-
Refer to the brightness level display when ad- ting. The control mode changes to the shift
justing brightness levels. light deactivation point setting function.
[To set the shift light deactivation point]

[To adjust the display and tachometer bright- TIP
ness]
The deactivation range is the same as the acti-
1. Turn the key to “OFF”.
vation range. However, be sure to set the deac-
2. Push and hold the “SELECT” button.
tivation point to a higher engine speed than the
3. Turn the key to “ON”, and then release the
activation point, otherwise the shift light will not
“SELECT” button after five seconds.
come on.
4. Push the “RESET” button to set the bright-
ness level. 1. Push the “RESET” button to set the deactiva-
5. Push the “SELECT” button to confirm the set- tion point engine speed.
ting. The control mode changes to the shift 2. Push the “SELECT” button to confirm the set-
light activity function. ting. The control mode changes to the shift
light brightness function.
[To set the shift light activity function]
1. Push the “RESET” button to select one of the [To adjust the shift light brightness]
following shift light activity settings: 1. Push the “RESET” button to set the shift light
• On – the shift light will come on when activat- brightness level.
ed. (This setting is selected when the shift 2. Push the “SELECT” button to confirm the set-
light stays on.) ting and exit the display brightness and shift
• Flash – the shift light will flash when activat- light control mode.
ed. (This setting is selected when the shift
light flashes four times per second.)
• Off – the shift light is deactivated; in other
words, it will not come on or flash. (This set-
ting is selected when the shift light flashes
once every two seconds.)
2. Push the “SELECT” button to confirm the se-
lected shift light activity. The control mode
changes to the shift light activation point set-
ting function.
[To set the shift light activation point]

TIP
The shift light activation point can be set be-
tween 10000 r/min and 18000 r/min. From
10000 r/min to 13000 r/min, the shift light can be
set in increments of 500 r/min. From 13000 r/min
to 18000 r/min, the shift light can be set in incre-
ments of 200 r/min.
1-7
SPECIAL TOOLS
EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB (US) 3-4, 4-62, 4-63,
90890-03257 8-32, 8-130,
8-146, 8-151
Yamaha diagnostic tool (A/I) 3-4, 4-62, 4-63,

90890-03254 8-32, 8-130,
8-146, 8-151
Thickness gauge 3-6, 4-22, 4-32,

90890-03180 5-51
Feeler gauge set
YU-26900-9
Valve lapper 90890-04101

3-7
90890-04101
Valve lapping tool
YM-A8998
YM-A8998
Vacuum gauge 3-10

90890-03094
Vacuummate
YU-44456
YU-44456
1-8
SPECIAL TOOLS
Reference
pages
Steering nut wrench 3-20, 4-84
90890-01403
Exhaust flange nut wrench
YU-A9472
Oil filter wrench 3-26

90890-01426
Oil filter wrench
YU-38411
Oil pressure gauge set 3-28

90890-03120
Oil pressure adapter H 3-28

90890-03139
Hexagon wrench (41) 4-28, 4-29

41
90890-01525
Hexagon wrench (41) 41
YM-01525
Hydraulic unit holding tool 4-59, 4-60

90890-01594
Fork spring compressor 4-74, 4-80

90890-01441
Fork spring compressor
YM-01441
Rod holder 4-74, 4-80

90890-01434
Damper rod holder double ended
YM-01434
Damper rod holder (ø30) 4-75, 4-77

90890-01506
Damper rod holder
YM-01506
1-9
SPECIAL TOOLS
Reference
pages
Fork seal driver 4-77, 4-78, 4-78
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Rod puller 4-78, 4-80

90890-01437
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Rod puller attachment (M10) 4-78, 4-80

90890-01436
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Ring nut wrench 4-84

90890-01268
Spanner wrench
YU-01268
Ring nut wrench 4-92, 4-94

90890-01507
Ring nut wrench
YM-01507
1-10
SPECIAL TOOLS
Reference
pages
Damper rod holder (ø24) 4-92, 4-93
90890-01328
Damper rod holder
YM-01328
Drive chain cut & rivet tool 4-97

90890-01550
Drive chain cut & rivet tool
YM-01550
Compression gauge 90890-03081 5-8

90890-03081
Engine compression tester
YU-33223
YU-33223
Extension 5-8
90890-04136
Valve spring compressor 5-30, 5-35

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-30, 5-35

90890-04108
Valve spring compressor adapter 22 mm
YM-04108
Valve guide remover (ø4.5) 5-32

90890-04116
Valve guide remover (4.5 mm)
YM-04116
1-11
SPECIAL TOOLS
Reference
pages
Valve guide installer (ø4.5) 5-32
90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide reamer (ø4.5) 5-32

90890-04118
Valve guide reamer (4.5 mm)
YM-04118
Rotor holding tool 5-37, 5-38, 5-40,

90890-04166 5-40
Rotor holding tool
YM-04166
Flywheel puller 5-37

90890-01404
Flywheel puller
YM-01404
Yamaha bond No. 1215 5-38, 5-41, 5-66

90890-85505
(Three bond No.1215®)
Digital circuit tester (CD732) 5-44, 8-151,

90890-03243 8-152, 8-153,
Model 88 Multimeter with tachometer 8-154, 8-155,
YU-A1927 8-155, 8-156,
8-156, 8-157,
8-157, 8-158,
8-159, 8-160,
8-160, 8-161,
8-161, 8-162,
8-163
Universal clutch holder 5-50, 5-54
90890-04086
Universal clutch holder
YM-91042
1-12
SPECIAL TOOLS
Reference
pages
Piston pin puller set 5-70
90890-01304
Piston pin puller
YU-01304
YU-01304
Radiator cap tester 6-5, 6-6

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

90890-01352
Pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer 6-15

90890-04078
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driver 6-15

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
1-13
SPECIAL TOOLS
Reference
pages
Pressure gauge 7-15, 7-16
90890-03153
Pressure gauge
YU-03153
Fuel injector pressure adapter 7-15

90890-03210
Fuel injector pressure adapter
YU-03210
Fuel pressure adapter 7-16

90890-03176
Fuel pressure adapter
YM-03176
OBD/ GST Leadwire kit 8-32

90890-03249
Ignition checker 8-155

90890-06754
Oppama pet–4000 spark checker
YM-34487
Test harness– lean angle sensor (6P) 8-156

90890-03209
Test harness– lean angle sensor (6P)
YU-03209
Test harness– speed sensor (3P) 8-160

90890-03208
Test harness– speed sensor (3P)
YU-03208
1-14
SPECIAL TOOLS
1-15
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-7
ELECTRICAL SPECIFICATIONS .................................................................2-10
TIGHTENING TORQUES .............................................................................. 2-12

2
ENGINE TIGHTENING TORQUES......................................................... 2-12
CHASSIS TIGHTENING TORQUES.......................................................2-13
CABLE ROUTING ......................................................................................... 2-15

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model BN61 (YZFR6H_U49)
BN62 (YZFR6HC_CAL)
Dimensions
Overall length 2040 mm (80.3 in)
Overall width 695 mm (27.4 in)
Overall height 1150 mm (45.3 in)
Wheelbase 1375 mm (54.1 in)
Ground clearance 130 mm (5.12 in)
Minimum turning radius 3.6 m (11.81 ft)
Weight
Curb weight 190 kg (419 lb)
Loading
Maximum load 185 kg (408 lb)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 599 cm³
Cylinder arrangement Inline
Number of cylinders 4-cylinder
Bore × stroke 67.0 × 42.5 mm (2.64 × 1.67 in)
Compression ratio 13.1 : 1
Compression pressure 1392–1792 kPa/400 r/min (13.9–17.9 kgf/cm²/
400 r/min, 198.0–254.9 psi/400 r/min)
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline (Gasohol [E10]
acceptable)
Fuel tank capacity 17 L (4.5 US gal, 3.7 Imp.gal)
Fuel reserve amount 3.4 L (0.90 US gal, 0.75 Imp.gal)
Engine oil
Recommended brand YAMALUBE
SAE viscosity grades 10W-40, 10W-50, 15W-40, 20W-40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 2.40 L (2.54 US qt, 2.11 Imp.qt)
With oil filter removal 2.60 L (2.75 US qt, 2.29 Imp.qt)
Quantity (disassembled) 3.40 L (3.59 US qt, 2.99 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Inner-rotor-to-outer-rotor-tip clearance 0–0.120 mm (0–0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09–0.15 mm (0.0035–0.0059 in)
Limit 0.22 mm (0.0087 in)
Oil pressure 40.0 kPa/1300 r/min (0.40 kgf/cm²/1300 r/min,
5.8 psi/1300 r/min)
Relief valve operating pressure 700.0 kPa (7.00 kgf/cm², 101.5 psi)
Cooling system
Coolant quantity
Radiator (including all routes) 2.30 L (2.43 US qt, 2.02 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9
psi)
2-2
Thermostat
Valve opening temperature 69.0–73.0 °C (156.20–163.40 °F)
Valve full open temperature 85.0 °C (185.00 °F)
Valve lift (full open) 8.0 mm (0.31 in)
Water pump
Water pump type Single suction centrifugal pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug(s)
Manufacturer/model NGK/CR10EK
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Camshaft cap inside diameter 22.500–22.521 mm (0.8858–0.8867 in)
Camshaft journal diameter 22.459–22.472 mm (0.8842–0.8847 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) 33.750–33.850 mm (1.3287–1.3327 in)
Limit 33.675 mm (1.3258 in)
Lobe height (Exhaust) 32.950–33.050 mm (1.2972–1.3012 in)
Limit 32.875 mm (1.2943 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.12–0.19 mm (0.0047–0.0075 in)
Exhaust 0.16–0.23 mm (0.0063–0.0091 in)
Valve dimensions
Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) 1.10–1.30 mm (0.0433–0.0512 in)
Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in)
Limit 4.460 mm (0.1756 in)
Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in)
Limit 4.445 mm (0.1750 in)
Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance
(exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.095 mm (0.0037 in)
Valve stem runout 0.040 mm (0.0016 in)
Valve spring
Free length (intake) 37.47 mm (1.48 in)
Limit 35.60 mm (1.40 in)
Free length (exhaust) 37.67 mm (1.48 in)
2-3
Limit 35.79 mm (1.41 in)

Spring tilt (intake) 1.6 mm (0.06 in)
Spring tilt (exhaust) 1.6 mm (0.06 in)
Cylinder
Bore 67.000–67.010 mm (2.6378–2.6382 in)
Wear limit 67.060 mm (2.6402 in)
Piston
Diameter 66.975–66.990 mm (2.6368–2.6374 in)
Measuring point (from piston skirt bottom) 10.0 mm (0.39 in)
Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
Piston pin bore inside diameter 15.002–15.013 mm (0.5906–0.5911 in)
Limit 15.043 mm (0.5922 in)
Piston pin outside diameter 14.991–15.000 mm (0.5902–0.5906 in)
Limit 14.971 mm (0.5894 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
Piston ring
Top ring
Ring type Barrel
End gap limit 0.60 mm (0.0236 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
2nd ring
Ring type Taper
End gap limit 1.15 mm (0.0453 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Connecting rod
Oil clearance 0.037–0.061 mm (0.0015–0.0024 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.020–0.044 mm (0.0008–0.0017 in)
Bearing color code
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.80 mm (0.110 in)
Plate quantity 9 pcs
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
2-4
Plate quantity 8 pcs

Warpage limit 0.10 mm (0.004 in)
Clutch spring free length 55.00 mm (2.17 in)
Limit 54.00 mm (2.13 in)
Spring quantity 6 pcs
Drivetrain
Primary reduction ratio 2.073 (85/41)
Transmission type Constant mesh 6-speed
Gear ratio
1st 2.583 (31/12)
2nd 2.000 (32/16)
3rd 1.667 (30/18)
4th 1.444 (26/18)
5th 1.286 (27/21)
6th 1.150 (23/20)
Main axle runout limit 0.02 mm (0.0008 in)
Drive axle runout limit 0.02 mm (0.0008 in)
Secondary reduction ratio 2.813 (45/16)
Final drive Chain
Shifting mechanism
Installed shift rod length 267.2–269.2 mm (10.52–10.60 in)
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
Maximum consumption amperage 3.3 A
Throttle body
ID mark BN61 00 (YZFR6H_U49)
BN62 10 (YZFR6HC_CAL)
Fuel injector
Resistance 12.0 Ω
Accelerator position sensor

Resistance 1.26–2.34 kΩ
Throttle position sensor

Resistance 1.4–2.6 kΩ
Idling condition
Engine idling speed 1250–1350 r/min
AI system Active
O2 feedback control Inactive
Exhaust gas sampling point Sampling port on the exhaust pipe
Coolant temperature 95–105 °C (203–221 °F)
Difference in vacuum pressure between the
cylinders 0–1.3 kPa (10 mmHg, 0.4 inHg)
CO% 2.5–4.5 %
2-5
Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
Air induction system

Solenoid resistance 20–23 Ω
2-6
CHASSIS SPECIFICATIONS
EAS20015
Chassis
Frame type Diamond
Caster angle 24.0 °
Trail 97 mm (3.8 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/C × MT3.50
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C × MT5.50
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size 120/70ZR17M/C (58W)
Manufacturer/model DUNLOP/SPORTMAX D214F
Manufacturer/model BRIDGESTONE/BATTLAX S21F
Rear tire
Type Tubeless
Size 180/55ZR17M/C (73W)
Manufacturer/model DUNLOP/SPORTMAX D214
Manufacturer/model BRIDGESTONE/BATTLAX S21R
Tire air pressure (measured on cold tires)

Front 250 kPa (2.50 kgf/cm², 36 psi)
Rear 290 kPa (2.90 kgf/cm², 42 psi)
Front brake
Disc outside diameter × thickness 320.0 × 5.0 mm (12.60 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on wheel) 0.10 mm (0.0039 in)
Brake pad lining thickness 4.5 mm (0.18 in)
Master cylinder inside diameter 15.87 mm (0.62 in)
Caliper cylinder inside diameter (Left) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Caliper cylinder inside diameter (Right) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Specified brake fluid DOT 4
Rear brake
Disc outside diameter × thickness 220.0 × 5.0 mm (8.66 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
2-7
Brake pad lining thickness 4.5 mm (0.18 in)

Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 30.23 mm (1.1902 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Front fork travel 120.0 mm (4.72 in)
Wheel travel 120 mm (4.7 in)
Fork spring free length 219.5 mm (8.64 in)
Limit 215.1 mm (8.47 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil 01
Quantity (left) 390.0 cm³ (13.19 US oz, 13.73 Imp.oz)
Quantity (right) 390.0 cm³ (13.19 US oz, 13.73 Imp.oz)
Level (left) 80 mm (3.1 in)
Level (right) 80 mm (3.1 in)
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Turn
Adjustment value (Soft) 0
Adjustment value (STD) 6
Adjustment value (Hard) 15
Rebound damping
Unit for adjustment Click
Adjustment value from the start position (Soft) 14
Adjustment value from the start position (STD) 7
Adjustment value from the start position (Hard) 1
Compression damping
Unit for compression damping adjustment Click
Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Rear shock absorber assembly travel 60.0 mm (2.36 in)
Wheel travel 120 mm (4.7 in)
Spring preload
Adjustment value (Soft) 84.9 mm (3.34 in)
Adjustment value (STD) 89.9 mm (3.54 in)
Adjustment value (Hard) 92.9 mm (3.66 in)
Rebound damping
2-8

Compression damping
Fast compression damping
Unit for adjustment Turn
Adjustment value from the start position (Soft) 5.5
Slow compression damping
Drive chain
Size 525V11
Chain type Sealed type
Number of links 114
Drive chain slack (Maintenance stand) 30.0–45.0 mm (1.18–1.77 in)
Drive chain slack (Sidestand) 30.0–45.0 mm (1.18–1.77 in)
Limit 50.0 mm (1.97 in)
15-link length limit 239.3 mm (9.42 in)
2-9
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Engine control unit

Model/manufacturer TBDFY7/DENSO
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0 °/1300 r/min
Ignition coil
Primary coil resistance 1.19–1.61 Ω
Secondary coil resistance 9.35–12.65 kΩ
Charging system
Charging system AC magneto
Standard output 14.0 V, 30.2 A at 5000 r/min
Standard output 14.0 V, 420 W at 5000 r/min
Stator coil resistance 0.120–0.180 Ω
Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.3–14.7 V
Rectifier capacity (DC) 35.0 A
Battery
Model YTZ7S
Voltage, capacity 12 V, 6.0 Ah (10 HR)
Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal/position light LED
Rear turn signal light LED
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED
Indicator light
Neutral indicator light LED
High beam indicator light LED
Oil level warning light LED
Turn signal indicator light LED
Fuel level warning light LED
Coolant temperature warning light LED
Engine trouble warning light LED
ABS warning light LED
Shift timing indicator light LED
Traction control system indicator/warning light LED
2-10
Starter motor
Power output 0.60 kW
Armature coil resistance 0.0012–0.0022 Ω
Brush overall length 10.0 mm (0.39 in)
Limit 3.50 mm (0.14 in)
Brush spring force 7.16–9.52 N (730–971 gf, 25.77–34.27 oz)
Commutator diameter 28.0 mm (1.10 in)
Limit 27.0 mm (1.06 in)
Mica undercut (depth) 0.70 mm (0.03 in)
Oil level switch

Oil level switch resistance (maximum level
position) 484.0–536.0 Ω
Oil level switch resistance (minimum level
position) 114.0–126.0 Ω
Fuel sender unit

Sender unit resistance (empty) 137.0–185.0 Ω
Fuel injection sensor

Crankshaft position sensor resistance 248–372 Ω
Cylinder identification sensor output voltage (ON) 4.8 V or more
Cylinder identification sensor output voltage
(OFF) 0.8 V or less
Intake air temperature sensor resistance 5400–6600 Ω at 0 °C (5400–6600 Ω at 32 °F)
Intake air temperature sensor resistance 289–391 Ω at 80 °C (289–391 Ω at 176 °F)
Coolant temperature sensor resistance 2320–2590 Ω at 20 °C (2320–2590 Ω at 68 °F)
Lean angle sensor output voltage

Operating angle 65 °
Output voltage up to operating angle 0.4–1.4 V
Output voltage over operating angle 3.7–4.4 V
Fuse(s)
Main fuse 50.0 A
Headlight fuse 7.5 A
Signaling system fuse 10.0 A
Ignition fuse 15.0 A
Radiator fan motor fuse 15.0 A × 2
Turn signal light fuse 7.5 A
ABS ECU fuse 7.5 A
Fuel injection system fuse 15.0 A
ABS motor fuse 30.0 A
ABS solenoid fuse 10.0 A
Terminal fuse 1 2.0 A
Backup fuse 7.5 A
Electronic throttle valve fuse 7.5 A
2-11
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Spark plug M10 4 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Cylinder head cover bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Oil filter cartridge M20 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Oil filter cartridge bolt M20 1 70 N·m (7.0 kgf·m, 52 lb·ft) E
Engine oil drain bolt M14 1 43 N·m (4.3 kgf·m, 32 lb·ft)

Coolant drain bolt (water pump) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Muffler bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Muffler clamp bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Exhaust pipe assembly nut M8 8 20 N·m (2.0 kgf·m, 15 lb·ft)
Exhaust pipe assembly bolt M8 2 20 N·m (2.0 kgf·m, 15 lb·ft)
Exhaust pipe assembly bracket bolt
M8 2 30 N·m (3.0 kgf·m, 22 lb·ft) LT
(left upper side and right side)
Exhaust pipe assembly bracket bolt
M8 1 34 N·m (3.4 kgf·m, 25 lb·ft)
(left lower side)
Generator cover bolt M6 9 12 N·m (1.2 kgf·m, 8.9 lb·ft)
Generator rotor bolt M12 1 70 N·m (7.0 kgf·m, 52 lb·ft) E
Clutch cover bolt M6 7 12 N·m (1.2 kgf·m, 8.9 lb·ft)

Clutch cover bolt M6 2 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT
Stake
Drive sprocket nut M20 1 85 N·m (8.5 kgf·m, 63 lb·ft)
LT
2-12
TIGHTENING TORQUES
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Front wheel axle nut M24 1 115 N·m (11.5 kgf·m, 85 lb·ft) LS
Front wheel axle pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) See TIP.
Front brake caliper bolt M10 4 35 N·m (3.5 kgf·m, 26 lb·ft)
Brake caliper bleed screw (front and
M8 3 5 N·m (0.5 kgf·m, 3.7 lb·ft)
rear)
Rear wheel axle nut M24 1 110 N·m (11 kgf·m, 81 lb·ft) LS
Rear brake caliper bolt (M8) M8 1 12 N·m (1.2 kgf·m, 8.9 lb·ft) LT
Rear brake caliper bolt (M12) M12 1 27 N·m (2.7 kgf·m, 20 lb·ft) S
Handlebar bolt M6 2 13 N·m (1.3 kgf·m, 9.6 lb·ft)

Handlebar pinch bolt M8 2 32 N·m (3.2 kgf·m, 24 lb·ft)
Upper bracket pinch bolt M8 2 26 N·m (2.6 kgf·m, 19 lb·ft)
Lower bracket pinch bolt M8 4 23 N·m (2.3 kgf·m, 17 lb·ft) See TIP.
Steering stem nut M28 1 115 N·m (11.5 kgf·m, 85 lb·ft)
Lower ring nut (initial tightening
M30 1 52 N·m (5.2 kgf·m, 38 lb·ft) See TIP.
torque)
Lower ring nut (final tightening
M30 1 14 N·m (1.4 kgf·m, 10 lb·ft) See TIP.
torque)
TIP
Front wheel axle pinch bolt
1. Tighten the pinch bolt “2”, pinch bolt “1”, and pinch bolt “2” to 21 N·m (2.1 kgf·m, 15 lb·ft) in this order.
2. Check that the right end of the front axle is flush with the front fork. If necessary, manually push the
front axle or lightly tap it with a soft hammer until its end is flush with the front fork. However, if the
surface of the front axle end is not parallel to the surface of the front fork, align a point on the outer
edge of the axle with the fork, making sure that the axle does not protrude past the fork.
3. Tighten the pinch bolt “4”, pinch bolt “3”, and pinch bolt “4” to 21 N·m (2.1 kgf·m, 15 lb·ft) in this order.
4 3 2 1
TIP
Lower bracket pinch bolt
Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft) in the order pinch bolt “1” → pinch bolt “2” → pinch bolt
“1” → pinch bolt “2”.
2-13
TIGHTENING TORQUES
TIP
Lower ring nut
1. Tighten the ring nut to 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring
nut completely.
2. Tighten the lower ring nut to 14 N·m (1.4 kgf·m, 10 lb·ft).
2-14
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
9 A 1
8
2
F B
E 3 C
4
D 6
5
8 10
11
3 G
7
7 K
I L
H
2-15
CABLE ROUTING
1. Clutch cable
2. Main switch lead
3. Horn lead
4. Handlebar switch lead (left)
5. Horn
6. Handlebar switch lead (right)
7. Brake hose (front brake master cylinder to
hydraulic unit)
8. Throttle cable (decelerator cable)
9. Throttle cable (accelerator cable)
10. Lower bracket cover
11. Front fork
A. Route the left and right handlebar switch leads and
main switch lead to the inside of the front fork.
B. Fasten the left handlebar switch lead in front of the
front fork with a plastic locking tie. Point the end of
the plastic locking tie outward and cut off the
excess end of the tie to 1–5 mm (0.04–0.20 in).
C. Do not fasten the horn lead with the plastic locking
tie.
D. Route the right handlebar switch lead to the rear of
the throttle cables and under the clutch cable.
E. Route the clutch cable through the guide.
F. Route the right handlebar switch lead to the rear of
the brake hose (front brake master cylinder to
hydraulic unit).
G. Route the horn lead through the guide on the lower
bracket cover. Align the blue tape on the horn lead
with the guide.
H. Make sure that the plastic locking tie contacts the
lower bracket.
I. Fasten the brake hose (front brake master cylinder
to hydraulic unit) with a plastic locking tie, making
sure that the brake hose is positioned as shown in
the illustration.
J. Point the end of the plastic locking tie outward and
cut off the excess end of the tie to 1–5 mm (0.04–
0.20 in).
K. Inward
L. Outward
2-16
CABLE ROUTING
Clutch cable (right side view)
14
L 3
15
16
C
5
4 D
3 B
2
1
A
E
G
8 H
10
J
11 10
11
K
M
13 12 8 O N
17
18
12 13
P
Q
20 19
2-17
CABLE ROUTING
1. Heat protector P. Point the ends of the hose clamp to the left.
2. Handlebar switch coupler (right) Q. Face the yellow paint mark on the oil cooler outlet
3. Radiator fan motor lead (right) hose forward.
4. Front wheel sensor coupler
5. ABS ECU lead
6. Radiator cap
7. Coolant reservoir
8. Coolant reservoir breather hose
9. Radiator
10. Radiator outlet hose
11. Clutch cable
12. Water pump outlet pipe
13. Oil cooler outlet hose
14. Handlebar switch lead (right)
15. Front wheel sensor lead
16. Wire harness
17. Water jacket joint
18. Water jacket joint inlet hose
19. Oil cooler
20. Oil cooler inlet hose
A. Route the leads over the heat protector.
B. Route the right radiator fan motor lead to the inside
of the frame.
C. Route the right handlebar switch lead and front
wheel sensor lead to the inside of the ABS ECU
lead.
D. Route the right handlebar switch lead to the inside
of the brake hoses and under the clutch cable.
E. Route the right handlebar switch lead over the
radiator cap.
F. Insert the projection on the wire harness holder
completely into the hole in the hydraulic unit
bracket.
G. Fasten the clutch cable with the holder. Align the
bottom of the positioning guide on the clutch cable
with the top of the holder.
H. Route the coolant reservoir breather hose between
the radiator and the coolant reservoir and to the
outside of the damper attached to the radiator.
I. Align the paint mark on the radiator outlet hose
with the projection on the radiator pipe. Install the
radiator outlet hose onto the radiator pipe until the
end of the hose contacts the projection on the pipe.
J. Cross the clutch cable and coolant reservoir
breather hose, and then fasten them with the
holder. Align the holder with the lower edge of the
white paint mark on the coolant reservoir breather
hose. Face the holder opening to the inward.
K. Fasten the clutch cable to the radiator outlet hose
with the plastic band. Make sure that the plastic
band contacts the top of the radiator outlet hose
holder. Point the end of the plastic band inward,
angled rearward.
L. Route the right radiator fan motor lead over and to
the outside of the wire harness as shown in the
illustration, and then connect the right radiator fan
motor coupler so that the coupler is positioned to
the inside of the harness.
M. Forward
N. 60°
O. Position the clutch cable within the 20° angle
shown in the illustration.
2-18
CABLE ROUTING
Engine (right side view)
13 7 H
7 8 9
G
9 I
8 I
10
11
12
1 A 2
10 9
7
8
F E 6
3
5
D 5 C B 4
6
J
K
2-19
CABLE ROUTING
1. Crankshaft position sensor lead

2. Water pump breather hose
3. Coolant reservoir breather hose
4. Clutch cable
5. Water pump inlet hose
6. Water pump outlet hose
7. EXUP cable
8. O2 sensor lead
9. Rear brake light switch lead
10. Footrest bracket
11. Neutral switch connector
12. Rear wheel sensor lead
13. EXUP cable holder
A. Route the crankshaft position sensor lead to the
inside of the water pump breather hose.
B. Fasten the coolant reservoir breather hose with the
holder, making sure that the white paint mark on
the hose is positioned to the rear of the holder.
C. Route the coolant reservoir breather hose to the
inside of the clutch cable.
D. Point the ends of the hose clamp downward.
E. Align the paint mark on the water pump inlet hose
with the projection on the hose fitting of the water
pump. Install the water pump inlet hose onto the
hose fitting of the water pump until the end of the
hose contacts the projection on the hose fitting.
F. Route the clutch cable through the guide on the
engine.
G. Fasten the EXUP cables, rear brake light switch
lead, and O2 sensor lead with the holder. Do not
fasten the rear wheel sensor lead with the holder.
H. Temporally install the EXUP cables by aligning the
paint marks on the cables with the upper edge of
the EXUP cable holder. The paint marks may be
positioned anywhere after the EXUP cable holder
is installed to the footrest bracket.
I. The leads may be routed in any order.
J. Point the ends of the hose clamp downward as
K. 3–12 mm (0.12–0.47 in)
2-20
CABLE ROUTING
Rectifier/regulator bracket and coupler holder (left side view)
O 13 Q
N 12
14 5
M
2 3
P
15
1
2
3
L
A B
K
I 11
10
H
G 4 C
F 7 E 5
6
D
2-21
CABLE ROUTING
1. Main switch lead S. Align the edge of the screw clamp fastener with the
2. Handlebar switch lead (left) white paint mark on the thermostat outlet hose.
3. Radiator fan motor lead (left) Make sure that the white paint mark does not
protrude past the screw clamp fastener and the
4. AC magneto lead
fastener is not positioned within the 80° range
5. Thermostat outlet hose shown in the illustration.
6. AC magneto coupler
7. Radiator inlet pipe
8. Radiator inlet hose
9. Radiator
10. Radiator fan motor relay lead
11. Radiator fan motor relay
12. Coupler holder
13. Main switch coupler
14. Handlebar switch coupler (left)
15. Wire harness
A. Align the white paint mark on the thermostat outlet
hose with the black paint mark on the radiator inlet
pipe.
B. Route the thermostat outlet hose to the inside of
the frame.
C. Route the AC magneto lead between the frame
and the throttle body and under the thermostat
outlet hose.
D. Secure the plastic locking tie by inserting the
projection on the tie into the hole in the frame, and
then fasten the AC magneto lead at the blue tape
with the tie. Point the end of the plastic locking tie
downward, and then cut off the excess end of the
tie to 1–5 mm (0.04–0.20 in).
E. After connecting the AC magneto coupler, cover
the coupler with the coupler cover.
F. Align the paint mark on the radiator inlet hose with
the paint mark on the radiator inlet pipe.
G. Secure the plastic locking tie by inserting the
projection on the tie into the hole in the rectifier/
regulator bracket.
H. Fasten the radiator fan motor relay lead to the
rectifier/regulator bracket with a plastic locking tie.
I. Install the radiator fan motor relay completely onto
the tab on the rectifier/regulator bracket.
J. Align the paint mark on the radiator inlet hose with
the projection on the radiator pipe. Install the
radiator inlet hose onto the radiator pipe until the
end of the hose contacts the projection on the pipe.
K. 45–55 mm (1.77–2.17 in)
L. Fasten the left handlebar switch lead with the
plastic locking tie at the location shown in the
illustration.
M. Outward
N. Inward
O. Fasten the left handlebar switch lead with a plastic
locking tie, making sure that the lead is positioned
as shown in the illustration.
P. Position the end of the plastic locking tie within the
30° range shown in the illustration.
Q. Align the yellow paint mark on the thermostat
outlet hose with the projection on the thermostat
cover. Install the thermostat outlet hose onto the
thermostat cover until the end of the hose contacts
the projection on the cover.
R. 80°
2-22
CABLE ROUTING
Engine (left side view)
2 C
7 E
F
6 5 4
11 9
8 6
8
12 5
6
5 7
7 10
G G
10
2-23
CABLE ROUTING
1. Starter motor lead

2. Gear position sensor lead
3. Gear position sensor coupler
4. Sidestand bracket cover
5. Fuel tank overflow hose (hose joint to atmosphere)
6. Fuel tank breather hose (hose joint to atmosphere)
(except for California)
7. Sidestand switch lead
8. Crankcase
9. Oil filter cartridge
10. Oil level switch lead
11. Drive sprocket cover
12. Drive chain guide
A. Align the lower edge of the paint marks on the fuel
tank overflow hose (hose joint to atmosphere) and
fuel tank breather hose (hose joint to atmosphere)
with the upper edge of the holder. (except for
California)
Align the lower edge of the paint mark on the fuel
tank overflow hose (hose joint to atmosphere) with
the upper edge of the holder. (for California only)
B. Fasten the fuel tank overflow hose (hose joint to
atmosphere) and fuel tank breather hose (hose
joint to atmosphere) with the holder. Route the fuel
tank overflow hose (hose joint to atmosphere)
(white paint mark) to the inside of the fuel tank
breather hose (hose joint to atmosphere) (blue
paint mark). (except for California)
Fasten the fuel tank overflow hose (hose joint to
atmosphere) with the holder. (for California only)
C. Route the gear position sensor lead to the outside
of the other leads.
D. Fasten the fuel tank breather hose (hose joint to
atmosphere), sidestand switch lead, and oil level
switch lead with the holder. Make sure that the
holder contacts the bottom of the other holder.
Close the holder until two clicks or more are heard.
(Except for California)
Fasten the fuel tank overflow hose (hose joint to
atmosphere), sidestand switch lead, and oil level
switch lead with the holder. Make sure that the
holder contacts the bottom of the other holder.
Close the holder until two clicks or more are heard.
(for California only)
E. The cut angled ends of the fuel tank overflow hose
(hose joint atmosphere) and fuel tank breather
hose (hose joint to atmosphere) (except for
California) may be pointing in any direction.
F. Route the fuel tank overflow hose (hose joint to
atmosphere) and fuel tank breather hose (hose
joint to atmosphere) (except for California) through
the guide on the sidestand bracket cover. Route
the sidestand switch lead from between the guides
to the inside of the hose.
G. The leads may be routed in any order.
2-24
CABLE ROUTING
Frame (front top view)
5
3
F 6 7 8 9 10
J
E
C
4
3
B 1
15 I 14 13 12
H 11 G
M 17
14
K 16
18
17
12 L 11
19
20
2-25
CABLE ROUTING
1. Throttle cable (decelerator cable) M. Fasten the main switch lead and left handlebar
2. Throttle cable (accelerator cable) switch lead at the blue tape on each lead with the
3. Handlebar switch lead (right) plastic band. Route the main switch lead to the
inside of the left handlebar switch lead. Point the
4. Clutch cable
end of the plastic band inward and insert it
5. Front wheel sensor lead between the coupler holder and the frame.
6. Radiator fan motor coupler (right)
7. Radiator fan motor lead (right)
8. Throttle position sensor lead
9. Accelerator position sensor lead
10. Throttle servo motor lead
11. Handlebar switch coupler (left)
12. Handlebar switch lead (left)
13. Fuse box 2 lead
14. Main switch lead
15. Fuse box 2
16. Main switch coupler
17. Coupler holder
18. Radiator fan motor lead (left)
19. Wire harness
20. Radiator fan motor coupler (left)
A. Route the throttle cables to the right of the
projection on the plate on top of the radiator,
making sure not to twist them.
B. Make sure that the throttle cable (decelerator
cable) is not twisted or crossed.
C. Fasten the grommet on the front wheel sensor lead
with the holder on the radiator cover.
D. Secure the holder by inserting the projection on
the holder into the hole in the radiator cover, and
then fasten the clutch cable with the holder.
E. Fasten the right handlebar switch lead to the
hydraulic unit assembly bracket with a plastic
locking tie.
F. Fasten the right handlebar switch lead and front
wheel sensor lead with a plastic locking tie.
Position the plastic locking tie at the middle of the
protective tube on the right handlebar switch lead.
G. Secure the plastic band by inserting the projection
on the band into the hole in the coupler holder, and
then fasten the wire harness with the band. Point
the end of the plastic band inward and insert it
between the coupler holder and the frame.
H. Pass a plastic locking tie through the hole in the
rectifier/regulator bracket, and then fasten the wire
harness at the white tape with the tie. Point the end
of the plastic locking tie inward under the fuse box
2 lead and insert it into the hole in the coupler
holder. Route the wire harness above the rectifier/
regulator bracket.
I. Route the main switch lead to the inside of the left
handlebar switch lead. Make sure that the leads do
not cross.
J. Point the end of the plastic locking tie outward and
cut off the excess end of the tie to 1–5 mm (0.04–
0.20 in).
K. Fit the main switch couplers between the left
handlebar switch couplers and the coupler holder.
L. The couplers may be positioned in any order.
2-26
CABLE ROUTING
Frame (center top view)
21
A 1 2 B 3 C 10 22
N 9 23
4 5 N 12 24 M
6 7 8 D
9 E
10 E
11
12 F
13 D
14 D
15
16 H
18 17 I
O
19 25 P
26
L 20 K G J
27 Q
26
28 Q
22
3 20 27 S R
22
29
28
21
2-27
CABLE ROUTING
1. O2 sensor coupler K. Route the secondary injector sub-wire harness to

2. Fuel tank breather hose (hose joint to atmosphere) the outside of the intake air pressure sensor and
(except for California) under the fuel tank overflow hose (hose joint to
Fuel tank breather hose (hose joint to canister) (for atmosphere).
California only) L. Fasten the wire harness to the fuel rail with the
3. Intake funnel servo motor lead plastic band. Do not cut off the excess end of the
plastic band. Point the end of the plastic band
4. Fuel hose
downward.
5. Crankcase breather hose
M. Route the leads below the stay on the frame. The
6. Rear wheel sensor coupler leads may be routed in any order. Pass the plastic
7. Rear brake light switch coupler (black) locking tie through the hole in the stay on the frame
8. Oil level switch coupler from the top. Point the end of the plastic locking tie
9. Rear brake light switch lead inward.
10. O2 sensor lead N. Route the rear brake light switch lead and rear
wheel sensor lead to the inside of the wire
11. EXUP cable harness.
12. Rear wheel sensor lead O. Point the end of the plastic locking tie inward. Do
13. Sub-wire harness coupler (secondary injector) not cut off the excess end of the plastic locking tie.
14. Crankshaft position sensor coupler P. Route the sidestand switch lead between the wire
15. Fuel pump lead harness end caps.
16. Neutral switch lead Q. Route the starter motor lead and battery negative
17. Fuel tank overflow hose (hose joint to atmosphere) lead under the wire harness. The leads may be
18. Intake funnel servo motor coupler routed in any order.
19. Intake air pressure sensor lead R. Make sure that the engine ground lead terminal
and negative battery lead terminal contact the
20. Sub-wire harness (secondary injector) stopper on the crankcase as shown in the
21. Frame illustration. Either terminal may be installed on top.
22. Wire harness Install the terminals so that the crimped section of
23. Crankshaft position sensor lead each terminal that secures the lead is facing
24. Sub-wire harness (ignition) upward.
25. Sidestand switch lead S. Route the leads below the stay on the frame. The
leads may be routed in any order. Pass the plastic
26. Wire harness end cap locking tie through the hole in the stay on the frame
27. Starter motor lead from the top. Point the end of the plastic locking tie
28. Battery negative lead inward. Align the white tape on the wire harness
29. Engine ground lead with the plastic locking tie.
A. Fasten the wire harness at the white tape to the
fuel rail with the plastic band. Do not cut off the
excess end of the plastic band. Point the end of the
plastic band downward.
B. Route the fuel tank breather hose (hose joint to
atmosphere) under the fuel hose. (except for
California)
Route the fuel tank breather hose (hose joint to
canister) under the fuel hose. (for California only)
C. Route the intake funnel servo motor lead to the
front of the crankcase breather hose.
D. Position the coupler and lead to the front and
below the wire harness.
E. Route the lead to the outside of the EXUP cables.
F. Route the rear wheel sensor lead to the front of the
EXUP cables.
G. Secure the plastic locking tie by inserting the
projection on the tie into the hole in the frame, and
then fasten the wire harness with the tie.
H. Route the neutral switch lead to the rear of the wire
harness and between the crankcase and the
frame.
I. Route the fuel tank breather hose (hose joint to
atmosphere) to the rear of the fuel tank overflow
hose (hose joint to atmosphere). (except for
California)
J. Route the intake funnel servo motor lead to the
front of the intake air pressure sensor lead.
2-28
CABLE ROUTING
Headlight (top view)
A
3
5
2 8
1 9
4
2 B
5
10
3 C
3
F
15
5 15
14
13
12
5
16 2
E 7 14
11
2-29
CABLE ROUTING
1. Headlight assembly lead

2. Headlight control unit lead
3. Front turn signal/position light lead (right)
4. Atmospheric pressure sensor
5. Air duct
6. Meter assembly coupler
7. Front turn signal/position light lead (left)
8. Band
9. Headlight control unit
10. Front turn signal/position light coupler (right)
11. Front turn signal/position light coupler (left)
12. Intake air temperature sensor coupler
13. Auxiliary light lead (right)
14. Auxiliary light lead (left)
15. Sub-wire harness (auxiliary light)
16. Wire harness
A. Insert the projection on the left auxiliary light
coupler into the lower hole in the headlight cover.
Insert the projection on the right auxiliary light
coupler into the upper hole in the headlight cover.
When connecting the right auxiliary light coupler,
make sure that the leads for both sections of the
coupler have white tape.
B. Route the headlight control unit lead between the
band and the air duct, and to the outside of the
projection on the air duct.
C. After connecting the coupler, position the slack in
the right front turn signal/position light lead above
the air duct.
D. After connecting the right front turn signal/position
light coupler, fit the loop in the wire harness onto
the holder.
E. Align the lower edge of the blue tape on the wire
harness with the upper edge of the holder on the
air duct.
F. Position the portion of the right front turn signal/
position light lead with the coupler to the inside of
the holder.
2-30
CABLE ROUTING
Rear fender (top view)
H 18 I
15 4 I
14
13
15 1
14
G
I 4
13
I 3
2
2 A
3 H
4 15
F 14
17
12 I
12 16 I
15
5
15 12
I 3 E 5
I 4 11 11 J
10 6
N 2
14 K
M 14 6
15
15
D 9 H
15
14
9
7 B
C
L
8
2-31
CABLE ROUTING
1. EXUP servo motor

2. Battery
3. Relay unit lead
4. Battery negative lead
5. Fuse box 1
6. ECU (Engine Control Unit)
7. Tail/brake light lead
8. Tail/brake light assembly
9. License plate light lead
10. ECU coupler
11. ECU lead
12. Battery positive lead
13. Sidestand switch lead
14. Wire harness
15. Battery box
16. Starter relay lead
17. Main fuse lead
18. Starter motor lead
A. Position the white tape on the battery negative
lead and relay unit lead within the range shown in
the illustration.
B. Route the tail/brake light lead over the license
plate light lead and rear turn signal light leads.
C. Route the rear turn signal light lead to the front of
the tail/brake light coupler.
D. Route the license plate light lead under the tail/
brake light lead and rear turn signal light leads.
E. Route the ECU lead (small coupler) under the
ECU lead (large coupler).
F. White tape
G. Position the joint coupler so that its lead is routed
downward.
H. Insert the projection on the wire harness holder
into the hole in the battery box.
I. The leads may be routed in any order.
J. Route the ECU lead (small coupler) under the fuse
box 2.
K. Route the wire harness under the guide on the
battery box.
L. Fasten the rear turn signal light leads and license
plate light lead with the holder. The leads may be
routed in any order.
M. Route the wire harness under the guide on the
battery box.
N. Make sure that the battery negative lead and relay
unit lead are not pinched between the battery and
the holder on the battery box.
2-32
CABLE ROUTING
License plate light assembly (left side view)
1
2
B C
5 D
4 D
1 3 D
D 3 5 D 4 D
2-33
CABLE ROUTING
1. License plate light bracket

2. License plate light lead cover
3. License plate light lead
4. Rear turn signal light lead (right)
5. Rear turn signal light lead (left)
A. Route the right rear turn signal light lead, left rear
turn signal light lead, and license plate light lead
through the hole in the license plate light bracket.
B. Make sure that there is no slack in the right rear
turn signal light lead, left rear turn signal light lead,
or license plate light lead.
C. Fasten the right rear turn signal light lead, left rear
turn signal light lead, and license plate light lead
with the holder.
D. The leads may be routed in any order.
2-34
CABLE ROUTING
Front brake hose (front and left side view)
4 E 3 2
2
3 4
D 1
3
2-35
CABLE ROUTING
1. Hydraulic unit
2. Front wheel sensor lead
3. Brake hose (hydraulic unit to front brake calipers)
4. Brake hose (front brake master cylinder to
hydraulic unit)
5. Front brake caliper
A. Fasten the front wheel sensor lead to the brake
hose (hydraulic unit to front brake calipers) with the
holder. Align the holder with the white paint mark
on the brake hose (hydraulic unit to front brake
calipers). Route the front wheel sensor lead to the
rear of the brake hose (hydraulic unit to front brake
calipers).
B. Fasten the front wheel sensor lead to the brake
hose (hydraulic unit to front brake calipers) with the
holder. Make sure that the holder contacts the
grommet on the brake hose (hydraulic unit to front
brake calipers). Route the front wheel sensor lead
to the rear of the brake hose (hydraulic unit to front
brake calipers).
C. Fasten the front wheel sensor lead at the white
tape with the holder.
D. Point the open ends of the holder forward.
E. Fasten the brake hose (front brake master cylinder
to hydraulic unit) with the holder, making sure that
the white paint mark on the hose is visible through
the hole in the holder.
2-36
CABLE ROUTING
Rear brake hose (top and right side view)
2
1 3
2
A 5 B 4 C D
4 2
G 4 H 2
4
2
F
5
1
4 2
I
6
2-37
CABLE ROUTING
1. Rear brake caliper

2. Brake hose (rear brake master cylinder to
hydraulic unit)
3. Hydraulic unit
4. Brake hose (hydraulic unit to rear brake caliper)
5. Rear wheel sensor lead
6. Rear brake master cylinder
A. Fasten the rear wheel sensor lead to the brake
hose (hydraulic unit to rear brake caliper) with the
holder. Install the holder on the shrink-tubing
portion of the brake hose and make sure that the
holder contacts the edge of the metal section of the
brake hose. Route the rear wheel sensor lead to
the outside of the brake hose (hydraulic unit to rear
brake caliper).
B. Fasten the rear wheel sensor lead at the white
tape to the brake hose (hydraulic unit to rear brake
caliper) with the holder. Align the rear edge of the
holder with the front end of the shrink-tubing
portion of the brake hose. Route the rear wheel
sensor lead to the outside of the brake hose
(hydraulic unit to rear brake caliper).
C. Fasten the rear wheel sensor lead at the white
tape to the brake hose (hydraulic unit to rear brake
caliper) with the holder. Route the rear wheel
sensor lead over the brake hose (hydraulic unit to
rear brake caliper).
D. Fasten the rear wheel sensor lead to the brake
holder. Install the holder on the shrink-tubing
portion of the brake hose and align the rear edge
of the holder with the rear end of the shrink-tubing
portion of the brake hose. Route the rear wheel
sensor lead over the brake hose (hydraulic unit to
rear brake caliper).
E. Install the holder completely onto the projection on
the frame.
F. Fasten the brake hose (hydraulic unit to rear brake
caliper) with the holder. Face the catch of the
holder outward.
G. Fasten the rear wheel sensor lead to the brake
holder. Face the catch of the holder downward.
Route the rear wheel sensor lead to the outside of
the brake hose (hydraulic unit to rear brake
caliper).
H. Fasten the grommet on the brake hose (hydraulic
unit to rear brake caliper) with the holder. Face the
catch of the holder outward.
I. Install the holder completely onto the projection on
the bracket.
2-38
CABLE ROUTING
Fuel tank and canister (front view)
B
B
A
C
1
2
3
5
4
E
6
F
7
F
7
5
6
5
2-39
CABLE ROUTING
1. Fuel tank breather hose (fuel tank to hose joint)

2. Fuel tank overflow hose (fuel tank to hose joint)
3. Fuel tank overflow hose (hose joint to atmosphere)
4. Fuel hose
5. Fuel tank breather hose (hose joint to atmosphere)
(except for California)
Fuel tank breather hose (hose joint to canister) (for
California only)
6. Canister
7. Canister purge hose
A. Face the yellow paint mark on the fuel tank
breather hose (fuel tank to hose joint) downward.
B. The ends of the hose clamp may be pointing in any
direction. Make sure not to install the hose clamp
on the raised portion of the hose fitting.
C. Face the white paint mark on the fuel tank overflow
hose (fuel tank to hose joint) downward.
D. Point the ends of the hose clamp inward.
E. For California only
F. To the throttle body
G. Point the ends of the hose clamp in the direction
2-40
CABLE ROUTING
Air cut-off valve (right side view)
E 4
4
6 F
7 F 5
6
7
D
2
2
C
G
3
4
3
B
5
2-41
CABLE ROUTING
1. Air filter case

2. Air induction system hose (air filter case to air cut-
off valve)
3. Air cut-off valve
4. Air induction system hose (air cut-off valve to reed
valve cover)
5. Reed valve cover
6. Cylinder identification sensor lead
7. Wire harness (to ignition coil and air cut-off valve)
A. Point the ends of the hose clamp forward.
B. Install the air induction system hose (air cut-off
valve to reed valve cover) completely onto the hose
fitting of the reed valve cover.
Perform this procedure for both the left and right
sides.
C. Point the ends of the hose clamp rearward.
Perform this procedure for both the left and right
sides.
D. Point the ends of the hose clamp outward.
E. The catch of the holder may be facing in any
direction.
F. The leads may be routed in any order.
G. Face the paint mark on the air induction system
hose (air filter case to air cut-off valve) forward.
2-42
CABLE ROUTING
2-43
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 .......................3-2
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL ........................................................................................................ 3-4
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUGS ............................................................. 3-5
ADJUSTING THE VALVE CLEARANCE .................................................. 3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-8
CHECKING THE CRANKCASE BREATHER HOSE ................................3-9
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-9
CHECKING THE EXHAUST SYSTEM....................................................3-11
CHECKING THE CANISTER (for California only)................................... 3-12
CHECKING THE AIR INDUCTION SYSTEM..........................................3-12
3
REPLACING THE AIR FILTER ELEMENT ............................................. 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY................................... 3-13
CHECKING THE BRAKE OPERATION .................................................. 3-13
CHECKING THE BRAKE FLUID LEVEL................................................. 3-13
ADJUSTING THE FRONT DISC BRAKE................................................ 3-14
CHECKING THE FRONT BRAKE PADS ................................................ 3-15
ADJUSTING THE REAR DISC BRAKE .................................................. 3-15
CHECKING THE REAR BRAKE PADS .................................................. 3-15
CHECKING THE FRONT BRAKE HOSES ............................................. 3-15
CHECKING THE REAR BRAKE HOSES................................................ 3-16
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)......................... 3-16
CHECKING THE WHEELS ..................................................................... 3-17
CHECKING THE TIRES..........................................................................3-17
CHECKING THE WHEEL BEARINGS ....................................................3-18
CHECKING THE SWINGARM OPERATION ..........................................3-19
LUBRICATING THE SWINGARM PIVOT ............................................... 3-19
DRIVE CHAIN SLACK............................................................................. 3-19
LUBRICATING THE DRIVE CHAIN ........................................................ 3-20
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-20
LUBRICATING THE STEERING HEAD.................................................. 3-21
CHECKING THE CHASSIS FASTENERS .............................................. 3-21
LUBRICATING THE LEVERS .................................................................3-21
LUBRICATING THE PEDALS .................................................................3-21
CHECKING THE SIDESTAND................................................................3-21
LUBRICATING THE SIDESTAND........................................................... 3-21
CHECKING THE SIDESTAND SWITCH................................................. 3-21
CHECKING THE FRONT FORK ............................................................. 3-21
ADJUSTING THE FRONT FORK LEGS ................................................. 3-22
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-23
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-23
CHECKING THE CONNECTING ARM AND RELAY ARM.....................3-25
CHECKING THE ENGINE OIL LEVEL....................................................3-25
CHANGING THE ENGINE OIL ...............................................................3-26
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-27
CHECKING THE COOLANT LEVEL.......................................................3-28
CHECKING THE COOLING SYSTEM ....................................................3-29
CHANGING THE COOLANT................................................................... 3-29
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-31
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-31
CHECKING AND LUBRICATING THE CABLES .................................... 3-31
ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-32
CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......................... 3-32
CHECKING AND CHARGING THE BATTERY....................................... 3-32
CHECKING THE FUSES ........................................................................3-32
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-32
PERIODIC MAINTENANCE
EAS20022
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.
ROUTINE INITIAL ODOMETER READINGS
× 1000 mi 0.6 4 8 12 16 20
No. ITEM
× 1000 km 1 7 13 19 25 31
month 1 6 12 18 24 30
• Check fuel hoses for cracks or
1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition.
√ √ √
2 * Spark plugs • Adjust gap and clean.
• Replace. √ √
• Check and adjust valve clear-
3 * Valve clearance Every 26600 mi (42000 km)
ance when engine is cold.
• Check breather hose for cracks
4 * Crankcase breath- or damage. √ √ √ √ √
er system
5 * Fuel injection • Adjust synchronization. √ √ √ √ √
• Check for leakage.
6 * Exhaust system • Tighten if necessary. √ √ √ √ √
• Replace gasket(s) if necessary.
Evaporative emis- • Check control system for dam-
7 * sion control system age. √ √
(for California only) • Replace if necessary.
Air induction sys- • Check the air cut-off valve, reed

8 * valve, and hose for damage. √ √
tem • Replace any damaged parts.
3-1
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.
× 1000 mi 0.6 4 8 12 16 20
No. ITEM
× 1000 km 1 7 13 19 25 31
month 1 6 12 18 24 30
• Perform dynamic inspection us-
Diagnostic system
1 * check ing Yamaha diagnostic tool. √ √ √ √ √ √
• Check the fault codes.
2 * Air filter element • Replace. Every 24000 mi (37000 km)
3 * Clutch • Check operation. √ √ √ √ √ √

• Adjust or replace cable.
• Check operation, fluid level,
4 * Front brake and for fluid leakage. √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check operation, fluid level,
and for fluid leakage.
5 * Rear brake • Replace brake pads if neces- √ √ √ √ √ √
sary.
• Check for cracks or damage.
• Check for correct routing and √ √ √ √ √
6 * Brake hoses clamping.
• Replace. Every 4 years
7 * Brake fluid • Change. Every 2 years
8 * Wheels • Check runout and for damage. √ √ √ √ √

• Check tread depth and for dam-
age.
9 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearings for smooth op-
10 * Wheel bearings eration. √ √ √ √ √
• Check bearing assemblies for
√
looseness.
11 * Swingarm pivot
bearings • Moderately repack with lithium-
soap-based grease. √
• Check chain slack, alignment

and condition.
12 Drive chain • Adjust and lubricate chain with Every 600 mi (1000 km) and after washing the motorcycle, riding in
the rain or riding in wet areas
a special O-ring chain lubricant
thoroughly.
• Check bearing assemblies for
√ √ √ √ √ √
looseness.
13 * Steering bearings
• Moderately repack with lithium-
soap-based grease. Every 16000 mi (25000 km)
• Check all chassis fitting and

14 * Chassis fasteners fasteners. √ √ √ √ √
• Correct if necessary.
15 Brake lever pivot • Apply silicone grease lightly. √ √ √ √ √

shaft
Brake pedal pivot • Apply lithium-soap-based
16 √ √ √ √ √
shaft grease lightly.
3-2
× 1000 mi 0.6 4 8 12 16 20
No. ITEM
× 1000 km 1 7 13 19 25 31
month 1 6 12 18 24 30
17 Clutch lever pivot • Apply lithium-soap-based √ √ √ √ √

Shift pedal pivot • Apply lithium-soap-based
18 √ √ √ √ √
• Check operation.
19 Sidestand pivot • Apply lithium-soap-based √ √ √ √ √
grease lightly.
• Check operation and replace if
20 * Sidestand switch necessary. √ √ √ √ √ √
• Check operation and for oil

21 * Front fork leakage. √ √ √ √ √
Shock absorber as- • Check operation and for oil

22 * leakage. √ √ √ √ √
sembly • Replace if necessary.
23 * Rear suspension • Check operation. √ √

link pivots • Correct if necessary.
• Change (warm engine before
24 Engine oil √ √ √ √ √ √
draining).
Engine oil filter car-
25 * tridge • Replace. √ √ √
• Check hoses for cracks or dam-

age. √ √ √ √ √
26 * Cooling system • Replace if necessary.
• Change coolant. √
Front and rear
27 * • Check operation. √ √ √ √ √ √
brake switches
• Apply Yamaha cable lubricant
28 * Control cables or other suitable cable lubricant √ √ √ √ √ √
thoroughly.
• Check operation.
• Check throttle grip free play,
29 * Throttle grip and adjust if necessary. √ √ √ √ √
• Lubricate cable and grip hous-
ing.
30 * Lights, signals and • Check operation. √ √ √ √ √ √

switches • Adjust headlight beam.
TIP
• Air filter
• This model’s air filter uses a disposable oil-coated paper element. This element cannot be cleaned
with compressed air, doing so will only damage it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• Hydraulic brake service
• Regularly check the front and rear brake fluid levels. Replenish if necessary.
• Every two years replace the rear brake master cylinder, the internal components of the front brake
master cylinder, the brake calipers, and change the brake fluid.
• Replace the brake hoses every four years or sooner if cracked or damaged.
3-3
EAS32024 EAS30057
CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE

YAMAHA DIAGNOSTIC TOOL 1. Remove:
Use the Yamaha diagnostic tool and check the • Rider seat
vehicle according to the following procedure. Refer to “GENERAL CHASSIS (1)” on page
1. Remove: 4-1.
• Rider seat • Fuel tank cover (left)
Refer to “GENERAL CHASSIS (1)” on page • Fuel tank cover (right)
4-1. Refer to “FUEL TANK” on page 7-1.
2. Remove the protective cap, and then connect 2. Remove:
the Yamaha diagnostic tool to the coupler “1”. • Fuel tank bolts “1”
TIP
Yamaha diagnostic tool USB (US)
90890-03257 After removing the fuel tank bolts, lift up the front
Yamaha diagnostic tool (A/I) of the fuel tank.
90890-03254 ECA20070
NOTICE
1 When lifting up the fuel tank, be careful not

to pull the fuel tank overflow hose and fuel
tank breather hose.
1
1
1
3. Check:
• Fault codes
TIP
Use the “Diagnosis of malfunction” function of 3. Check:
the Yamaha diagnostic tool to check the fault • Fuel hoses “1”
codes. For information about using the Yamaha • Fuel tank overflow hose “2”
diagnostic tool, refer to the operation manual • Fuel tank breather hose “3”
that is included with the tool. Cracks/damage → Replace.
Fault code number is displayed → Check and Loose connection → Connect properly.
repair the probable cause of the malfunction.
Refer to “TROUBLESHOOTING DETAILS 2 1
(FAULT CODE)” on page 8-33.
4. Perform:
• Dynamic inspection
TIP
Use the “Dynamic inspection” function of the 3
Yamaha diagnostic tool version 3.0 and after to
perform the dynamic inspection. For information 1
about using the Yamaha diagnostic tool, refer to
the operation manual that is included with the 4. Install:
tool. • Fuel tank bolts
5. Install: Fuel tank bolt (left and right)

• Rider seat 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Refer to “GENERAL CHASSIS (1)” on page Fuel tank bolt (front)

4-1. 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
3-4
5. Install:
• Fuel tank cover (left) Spark plug gap
• Fuel tank cover (right) 0.6–0.7 mm (0.024–0.028 in)
Refer to “FUEL TANK” on page 7-1.
• Rider seat
Refer to “GENERAL CHASSIS (1)” on page
4-1.
EAS30035
CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Remove:
• Rider seat
Refer to “GENERAL CHASSIS (1)” on page 7. Install:
4-1. • Spark plugs
• Fuel tank • Ignition coils
• Air filter case Spark plug
Refer to “AIR FILTER CASE” on page 7-5. 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
• Air induction system solenoid
Refer to “AIR INDUCTION SYSTEM” on TIP
page 7-19. Before installing the spark plug, clean the spark
2. Remove: plug and gasket surface.
• Ignition coils
8. Install:
• Spark plugs
ECA13320 • Air induction system solenoid
NOTICE Refer to “AIR INDUCTION SYSTEM” on
Before removing the spark plugs, blow away page 7-19.
any dirt accumulated in the spark plug wells • Air filter case
with compressed air to prevent it from falling Refer to “AIR FILTER CASE” on page 7-5.
into the cylinders. • Fuel tank
3. Check: • Rider seat
• Spark plug type Refer to “GENERAL CHASSIS (1)” on page
Incorrect → Change. 4-1.
Manufacturer/model EAS30023
NGK/CR10EK ADJUSTING THE VALVE CLEARANCE

4. Check: valves.
• Electrode “1” TIP
Damage/wear → Replace the spark plug. • Valve clearance adjustment should be made
• Insulator “2” on a cold engine, at room temperature.
Abnormal color → Replace the spark plug. • When the valve clearance is to be measured or
Normal color is medium-to-light tan. adjusted, the piston must be at top dead center
5. Clean: (TDC) on the compression stroke.
• Spark plug
(with a spark plug cleaner or wire brush) 1. Remove:
6. Measure: • Front side cowling assembly
• Spark plug gap “a” Refer to “GENERAL CHASSIS (5)” on page
(with a wire thickness gauge) 4-8.
Out of specification → Regap. • Fuel tank
3-5
• Air filter case TIP

Refer to “AIR FILTER CASE” on page 7-5. TDC on the compression stroke can be found
• Throttle body when the camshaft lobes are turned away from
Refer to “THROTTLE BODIES” on page each other.
7-10.
• Air cut-off valve
Refer to “AIR INDUCTION SYSTEM” on
page 7-19.
• Radiator
Refer to “RADIATOR” on page 6-3.
2. Remove:
• Ignition coils
• Spark plugs b
a
• Cylinder head cover
Refer to “CAMSHAFTS” on page 5-18.
3. Remove: IN EX
• Pickup rotor cover “1”
1
c. Measure the valve clearance with a thick-
ness gauge “1”.
4. Measure:
• Valve clearance Thickness gauge
90890-03180
Out of specification → Adjust.
Feeler gauge set
Valve clearance (cold) YU-26900-9
Intake
0.12–0.19 mm (0.0047–0.0075 in) TIP
Exhaust • If the valve clearance is incorrect, note the
0.16–0.23 mm (0.0063–0.0091 in) measured reading.
• Measure the valve clearance in the following
a. Turn the crankshaft clockwise. sequence.
Valve clearance measuring sequence

Cylinder #1 → #2 → #4 → #3
b. When piston #1 is at TDC on the compres-

sion stroke, align the TDC mark “a” on the
pickup rotor with the crankcase mating
surface “b”.
3-6
TIP
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
• Make a note of the position of each valve lifter
“1” and valve pad “2” so that they can be in-
stalled in the correct place.
A. Front
d. To measure the valve clearances of the
other cylinders, starting with cylinder #1 at
TDC, turn the crankshaft clockwise as
specified in the following table.
A. Degrees that the crankshaft is turned

clockwise
B. Cylinder b. Calculate the difference between the
C. Combustion cycle specified valve clearance and the mea-
sured valve clearance.
Cylinder #2 180°
Example:
Cylinder #4 360° Specified valve clearance = 0.11–0.20
Cylinder #3 540° mm (0.004–0.008 in)
Measured valve clearance = 0.23 mm
5. Remove: (0.009 in)
• Camshafts 0.23 mm (0.009 in) – 0.20 mm (0.008 in) =
TIP 0.03 mm (0.001 in)
• Refer to “CAMSHAFTS” on page 5-18. c. Check the thickness of the current valve
• When removing the timing chain and cam- pad.
shafts, fasten the timing chain with a wire to re- TIP
trieve it if it falls into the crankcase. The thickness “a” of each valve pad is marked in
6. Adjust: hundredths of millimeters on the side that touch-
• Valve clearance es the valve lifter.
a. Remove the valve lifter “1” and the valve Example:
pad “2” with a valve lapper “3”. If the valve pad is marked “155”, the pad
Valve lapper thickness is 1.55 mm (0.061 in).
90890-04101
Valve lapping tool
YM-A8998
3-7
d. Calculate the sum of the values obtained g. Install the exhaust and intake camshafts,
in steps (b) and (c) to determine the re- timing chain and camshaft caps.
quired valve pad thickness and the valve
pad number. Camshaft cap bolt (intake and ex-
Example: haust)
T.
R.
1.55 mm (0.061 in) + 0.03 mm (0.001 in) = 10 N·m (1.0 kgf·m, 7.4 lb·ft)
1.58 mm (0.062 in)
The valve pad number is 158. TIP
e. Round off the valve pad number according • Refer to “CAMSHAFTS” on page 5-18.
to the following table, and then select the • Lubricate the camshaft bearings, camshaft
suitable valve pad. lobes and camshaft journals.
• First, install the exhaust camshaft.
Last digit Rounded value
• Align the camshaft marks with the camshaft
0, 1, 2 0 cap marks.
3, 4, 5, 6 5 • Turn the crankshaft clockwise several full turns
7, 8, 9 10
to seat the parts.
h. Measure the valve clearance again.
TIP i. If the valve clearance is still out of specifi-
Refer to the following table for the available cation, repeat all of the valve clearance
valve pads. adjustment steps until the specified clear-
ance is obtained.
Valve pad range Nos. 150–240
7. Install:
1.50–2.40 mm • All removed parts
Valve pad thickness
(0.0591–0.0945 in)
TIP
25 thicknesses in 0.05
Available valve pads mm (0.002 in) incre-
For installation, reverse the removal procedure.
ments
EAS31017
Example: CHECKING THE ENGINE IDLING SPEED

Valve pad number = 158 TIP
Rounded value = 160 Prior to checking the engine idling speed, the
New valve pad number = 160 throttle body synchronization should be adjusted
f. Install the new valve pad “1” and the valve properly, the air filter element should be clean,
lifter “2”. and the engine should have adequate compres-
TIP sion.
• Lubricate the valve lifter with engine oil. 1. Start the engine and let it warm up for several
• The valve lifter must turn smoothly when rotat- minutes.
ed by hand. 2. Check:
• Install the valve lifter and the valve pad in the • Engine idling speed
correct place. Out of specification → Go to next step.
Engine idling speed

1250–1350 r/min
3-8
3. Check:
• ISC (idle speed control) learning value 1
“00” or “01” → Check the intake system.
“02” → Clean the throttle bodies.
Refer to “CHECKING AND CLEANING THE
THROTTLE BODIES” on page 7-13.
a. Connect the Yamaha diagnostic tool.
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNC-
TION AND DIAGNOSTIC CODE TABLE”
on page 9-1. 4. Install:
b. Check the ISC (idle speed control) leaning • Fuel tank bolts
value.
Fuel tank bolt (left and right)
EAS30061
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
CHECKING THE CRANKCASE BREATHER
R.
Fuel tank bolt (front)
HOSE 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
1. Remove:
• Rider seat 5. Install:
Refer to “GENERAL CHASSIS (1)” on page • Fuel tank cover (left)
4-1. • Fuel tank cover (right)
• Fuel tank cover (left) Refer to “FUEL TANK” on page 7-1.
• Fuel tank cover (right) • Rider seat
Refer to “FUEL TANK” on page 7-1. Refer to “GENERAL CHASSIS (1)” on page
2. Remove: 4-1.
• Fuel tank bolts “1”
EAS30027
TIP SYNCHRONIZING THE THROTTLE BODIES
After removing the fuel tank bolts, lift up the front TIP
of the fuel tank. Prior to synchronizing the throttle bodies, the
ECA20070
valve clearance and the engine idling speed
NOTICE should be properly adjusted.
When lifting up the fuel tank, be careful not
1. Stand the vehicle on a level surface.
to pull the fuel tank overflow hose and fuel
tank breather hose. TIP
Place the vehicle on a suitable stand.
1 2. Remove:
1
1 • Rider seat
4-1.
• Fuel tank
• Canister (for California only)
3. Remove:
3. Check: • Caps “1”
• Crankcase breather hose “1”
Cracks/damage → Replace.
Loose connection → Connect properly.
3-9
1
1
1 1
4. Install: c. Using the throttle body that has the bypass

• Vacuum gauge “1” air screw with a white paint mark as the
• Digital tachometer standard, turn the bypass air screws with-
out white paint marks in or out to the adjust
Vacuum gauge the other throttle bodies.
90890-03094
TIP
Vacuummate
YU-44456 • If more than one throttle body has a bypass air
screw with a white paint mark, use the one with
the lowest vacuum pressure as the standard.
1 • After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
• If an air screw was removed, turn the screw 3/
4 turn in and be sure to synchronize the throttle
body.
Difference in vacuum pressure

between the cylinders
5. Install: 0–1.3 kPa (10 mmHg, 0.4 inHg)
Refer to “FUEL TANK” on page 7-1. TIP
• Fuel tank • The difference in vacuum pressure between
Refer to “FUEL TANK” on page 7-1. two throttle bodies should not exceed 1.3 kPa
6. Adjust: (10 mmHg).
• Throttle body synchronization • If you are unable to adjust the throttle body
synchronization using this procedure, use the
Basic procedure following procedure instead.
a. Start the engine, warm it up for several
minutes, and then let it run at the specified
engine idling speed. Alternate procedure
TIP
Engine idling speed Use this alternate procedure if you are unable to
1250–1350 r/min adjust the throttle body synchronization using
the basic procedure.
b. Turn the bypass air screw “1” with a white
paint mark out a little, and then turn it in ful- a. Start the engine, warm it up for several
ly. minutes, and then let it run at the specified
engine idling speed.
Engine idling speed

1250–1350 r/min
b. Turn all of the bypass air screws in fully.
3-10
c. Using the throttle body with the lowest • Bottom cowling

vacuum pressure as the standard, turn out Refer to “GENERAL CHASSIS (5)” on page
the bypass air screws of the other throttle 4-8.
bodies to adjust them. 2. Check:
TIP • Exhaust pipe assembly “1”
• Do not turn out the bypass air screw of the • Muffler “2”
throttle body with the lowest vacuum pressure. Cracks/damage → Replace.
• After each step, rev the engine two or three • Gaskets “3”
times, each time for less than a second, and Exhaust gas leaks → Replace.
check the synchronization again. 3. Check:
• If an air screw was removed, turn the screw 3/ Tightening torque
4 turn in and be sure to synchronize the throttle • Exhaust pipe assembly nuts “4”
body. • Exhaust pipe assembly bracket bolts (left up-
per side and right side) “5”
• Exhaust pipe assembly bracket bolt (left low-
Difference in vacuum pressure
er side) “6”
between the cylinders
0–1.3 kPa (10 mmHg, 0.4 inHg) • Exhaust pipe assembly bolts “7”
• Muffler clamp bolt “8”
TIP
• Muffler bolt “9”
The difference in vacuum pressure between two Exhaust pipe assembly nut
throttle bodies should not exceed 1.3 kPa (10 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
mmHg). R. Exhaust pipe assembly bracket
bolt (left upper side and right
7. Stop the engine and remove the measuring side)
equipment. 30 N·m (3.0 kgf·m, 22 lb·ft)
8. Allow the engine to cool, and then start the LOCTITE®
engine and check that the engine speed does Exhaust pipe assembly bracket
not rise abnormally high. bolt (left lower side)
9. Adjust: 34 N·m (3.4 kgf·m, 25 lb·ft)
• Throttle cable free play Exhaust pipe assembly bolt
Refer to “ADJUSTING THE THROTTLE CA- 20 N·m (2.0 kgf·m, 15 lb·ft)
BLE FREE PLAY” on page 3-32. Muffler clamp bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
Throttle grip free play Muffler bolt
3.0–5.0 mm (0.12–0.20 in) 20 N·m (2.0 kgf·m, 15 lb·ft)
10.Install:
• Caps
• Fuel tank
• Rider seat
4-1.
EAS30062
CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the ex-
haust pipe assembly and gaskets.
1. Remove:
• Front side cowling assembly
3-11
• Upper air filter case

Refer to “AIR FILTER CASE” on page 7-5.
2. Remove:
• Air filter element “1”
3 5
7 5
6
9
7
3. Check:
1 • Air filter element
8 Damage → Replace.
(8)
2 TIP
4
• Replace the air filter element every 37000 km
3 (24000 mi) of operation.
• The air filter needs more frequent service if you
4. Install: are riding in unusually wet or dusty areas.
• Bottom cowling
• Front side cowling assembly 4. Install:
Refer to “GENERAL CHASSIS (5)” on page • Air filter element
ECA20710
4-8.
NOTICE
EAS30626
Never operate the engine without the air filter
CHECKING THE CANISTER (for California
element installed. Unfiltered air will cause
only)
rapid wear of engine parts and may damage
1. Remove:
the engine. Operating the engine without the
• Fuel tank
air filter element will also affect throttle body
synchronization, leading to poor engine per-
2. Check:
formance and possible overheating.
• Canister
• Canister purge hoses TIP
• Fuel tank breather hoses When installing the air filter element into the low-
Cracks/damage→ Replace. er air filter case, make sure that the sealing sur-
3. Install: faces are aligned to prevent any air leaks.
• Fuel tank
Refer to “FUEL TANK” on page 7-1. a. Insert the air filter projections “1” “2” into
the part of the air filter case “3”.
EAS30627
CHECKING THE AIR INDUCTION SYSTEM

Refer to “CHECKING THE AIR INDUCTION 1
SYSTEM” on page 7-22.
EAS30051
REPLACING THE AIR FILTER ELEMENT

1. Remove:
• Rider seat
Refer to “GENERAL CHASSIS (1)” on page 3
2
4-1.
• Fuel tank b. Fold the air filter “1” forward and then fit
Refer to “FUEL TANK” on page 7-1. into the air filter case.
3-12
1 TIP
If the specified clutch lever free play cannot be
obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
a. Remove the front side cowling assembly.
Refer to “GENERAL CHASSIS (5)” on
page 4-8.
5. Install: b. Loosen the locknut “1”.
• Upper air filter case c. Turn the adjusting nut “2” until the speci-
Refer to “AIR FILTER CASE” on page 7-5. fied clutch lever free play is obtained.
• Fuel tank d. Tighten the locknut “1”.
Clutch cable locknut
• Rider seat 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
4-1.
EAS31089
ADJUSTING THE CLUTCH LEVER FREE

PLAY
1. Check:
• Clutch lever free play “a”
Out of specification → Adjust. 1
2
Clutch lever free play
10.0–15.0 mm (0.39–0.59 in)
e. Install the front side cowling assembly.
Refer to “GENERAL CHASSIS (5)” on
page 4-8.
a
EAS30801
CHECKING THE BRAKE OPERATION

1. Check:
• Brake operation
Brake not working properly → Check the
brake system.
Refer to “FRONT BRAKE” on page 4-33 and
2. Adjust: “REAR BRAKE” on page 4-46.
• Clutch lever free play TIP
Drive on the dry road, operate the front and rear
Handlebar side brakes separately and check to see if the brakes
a. Turn the adjusting bolt “1” until the speci- are operating properly.
fied clutch lever free play is obtained.
EAS30074
CHECKING THE BRAKE FLUID LEVEL

1 1. Stand the vehicle on a level surface.
TIP
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
3-13
2. Check: ECA13540
• Brake fluid level NOTICE

Below the minimum level mark “a” → Add the Brake fluid may damage painted surfaces
specified brake fluid to the proper level. and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
Front brake
Specified brake fluid TIP
DOT 4 In order to ensure a correct reading of the brake
Rear brake fluid level, make sure the top of the brake fluid
Specified brake fluid reservoir is horizontal.
DOT 4
EAS30070
A ADJUSTING THE FRONT DISC BRAKE

1. Adjust:
• Brake lever position
(distance “a” from the throttle grip to the brake
a lever)
a
B
a
a. Push the brake lever forward.
b. Turn the adjusting dial “1” until the brake
lever is in the desired position.
c. Align the appropriate setting on the adjust-
ing dial with the mark “a” on the brake le-
A. Front brake ver.
B. Rear brake
EWA13090
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to 1 a
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, EWA13050
leading to poor brake performance. WARNING

• When refilling, be careful that water does A soft or spongy feeling in the brake lever
not enter the brake fluid reservoir. Water can indicate the presence of air in the brake
will significantly lower the boiling point of system. Before the vehicle is operated, the
the brake fluid and could cause vapor lock. air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance.
3-14
ECA13490 EWA17030
NOTICE WARNING
After adjusting the brake lever position, A soft or spongy feeling in the brake pedal
make sure there is no brake drag. can indicate the presence of air in the brake
system. Before the vehicle is operated, the
EAS30075 air must be removed by bleeding the brake
CHECKING THE FRONT BRAKE PADS system. Air in the brake system will consid-
The following procedure applies to all of the erably reduce braking performance.
brake pads. ECA13510
1. Operate the brake. NOTICE
2. Check:
After adjusting the brake pedal position,
• Front brake pad
make sure there is no brake drag.
Wear indicators “a” almost touch the brake
disc → Replace the brake pads as a set. 2. Adjust:
Refer to “FRONT BRAKE” on page 4-33. • Rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-31.
EAS30076
CHECKING THE REAR BRAKE PADS

a a
brake pads.
1. Operate the brake.
2. Check:
• Rear brake pad
Wear indicator groove “a” almost appears →
EAS30072
Replace the brake pads as a set.
ADJUSTING THE REAR DISC BRAKE Refer to “REAR BRAKE” on page 4-46.
1. Adjust:
• Brake pedal position
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the speci- a a
fied brake pedal position is obtained.
EWA18830
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt “a” is
visible through the hole “b”.
EAS30077
CHECKING THE FRONT BRAKE HOSES

brake hoses and brake hose holders.
1. Check:
1 • Brake hoses “1”
Cracks/damage/wear → Replace.
2 2. Check:
b a • Brake hose holders “2”
Loose → Tighten the holder bolt.
c. Tighten the locknut “1” to specification.
Rear brake pedal adjusting lock-

nut
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft)
3-15
EAS30893
1 BLEEDING THE HYDRAULIC BRAKE

SYSTEM (ABS)
2 EWA14000
WARNING
Always bleed the brake system when the
1
brake related parts are removed.
ECA22640
1 2 NOTICE
• Bleed the brake system in the following or-
3. Hold the vehicle upright and apply the brake der.
several times. • 1st step: Front brake master cylinder
4. Check: • 2nd step: Front brake calipers
• Brake hoses • 3rd step: Rear brake caliper
Brake fluid leakage → Replace the damaged EWA16530
hose. WARNING
Refer to “FRONT BRAKE” on page 4-33 and Bleed the ABS whenever:
“ABS (Anti-lock Brake System)” on page • the system is disassembled.
4-57. • a brake hose is loosened, disconnected or
replaced.
EAS30078
CHECKING THE REAR BRAKE HOSES • the brake fluid level is very low.
1. Check: • brake operation is faulty.
• Brake hoses “1” TIP
Cracks/damage/wear → Replace. • Be careful not to spill any brake fluid or allow
2. Check: the brake fluid reservoir to overflow.
• Brake hose holders “2” • When bleeding the ABS, make sure that there
Loose connection → Connect. is always enough brake fluid before applying
the brake. Ignoring this precaution could allow
1 air to enter the ABS, considerably lengthening
the bleeding procedure.
2 • If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.
• Repeat the bleeding procedure when the tiny
2 bubbles in the hose have disappeared.
2
1 1. Bleed:
2 • ABS
3. Hold the vehicle upright and apply the brake a. Fill the brake fluid reservoir to the proper
several times. level with the specified brake fluid.
4. Check: b. Install the diaphragm (brake fluid reser-
• Brake hoses voir).
Brake fluid leakage → Replace the damaged c. Connect a clear plastic hose “1” tightly to
hose. the bleed screw “2”.
Refer to “REAR BRAKE” on page 4-46 and A
“ABS (Anti-lock Brake System)” on page
4-57.
2
1
3-16
B Front brake master cylinder

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

1 level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13.
C 2
EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
EAS30105
CHECKING THE WHEELS

The following procedure applies to both of the
1
wheels.
1. Check:
A. Front brake master cylinder • Wheel
B. Front brake caliper (left/right) Damage/out-of-round → Replace.
C. Rear brake caliper EWA13260
WARNING
d. Place the other end of the hose into a con-
Never attempt to make any repairs to the
tainer.
wheel.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully de- TIP
press the brake pedal and hold it in posi- After a tire or wheel has been changed or re-
tion. placed, always balance the wheel.
g. Loosen the bleed screw.
TIP EAS30104
Loosening the bleed screw will release the pres- CHECKING THE TIRES
sure and cause the brake lever to contact the The following procedure applies to both of the
throttle grip or the brake pedal to fully extend. tires.
1. Check:
h. Tighten the bleed screw and then release • Tire pressure
the brake lever or brake pedal. Out of specification → Regulate.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Check the operation of the hydraulic unit.
Refer to “HYDRAULIC UNIT OPERA-
TION TEST” on page 4-61.
ECA17061
NOTICE
Make sure that the main switch is turned to
“OFF” before checking the operation of the
hydraulic unit. EWA13181
k. After operating the ABS, repeat steps (e) WARNING

to (i), and then fill the brake fluid reservoir • The tire pressure should only be checked
to the proper level with the specified brake and regulated when the tire temperature
fluid. equals the ambient air temperature.
l. Tighten the bleed screw to specification.
3-17
• The tire pressure and the suspension must and of the same design. No guarantee con-
be adjusted according to the total weight cerning handling characteristics can be giv-
(including cargo, rider, passenger and ac- en if a tire combination other than one
cessories) and the anticipated riding approved by Yamaha is used on this vehicle.
speed.
• Operation of an overloaded vehicle could Front tire
cause tire damage, an accident or an injury. Size
NEVER OVERLOAD THE VEHICLE. 120/70ZR17M/C (58W)
Manufacturer/model
Tire air pressure (measured on DUNLOP/SPORTMAX D214F
cold tires) Manufacturer/model
Front BRIDGESTONE/BATTLAX S21F
250 kPa (2.50 kgf/cm², 36 psi)
Rear
Rear tire
290 kPa (2.90 kgf/cm², 42 psi)
Size
Maximum load
180/55ZR17M/C (73W)
185 kg (408 lb)
Manufacturer/model
* Total weight of rider, passenger, cargo DUNLOP/SPORTMAX D214
and accessories Manufacturer/model
EWA13190
BRIDGESTONE/BATTLAX S21R
WARNING EWA13210
It is dangerous to ride with a worn-out tire. WARNING

When the tire tread reaches the wear limit, re- New tires have a relatively low grip on the
place the tire immediately. road surface until they have been slightly
2. Check: worn. Therefore, approximately 100 km
• Tire surfaces should be traveled at normal speed before
Damage/wear → Replace the tire. any high-speed riding is done.
TIP
Wear limit (front)
1.0 mm (0.04 in) For tires with a direction of rotation mark “1”:
Wear limit (rear) • Install the tire with the mark pointing in the di-
1.0 mm (0.04 in) rection of wheel rotation.
• Align the mark “2” with the valve installation
point.
1. Tire tread depth

2. Side wall
EAS30641
3. Wear indicator CHECKING THE WHEEL BEARINGS
EWA14090 The following procedure applies to all of the
WARNING wheel bearings.
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
3-18
1. Check: 2. Shift the transmission into the neutral posi-

• Wheel bearings tion.
Refer to “CHECKING THE FRONT WHEEL” 3. Check:
on page 4-18 and “CHECKING THE REAR Drive chain slack “a”
WHEEL” on page 4-28. Out of specification → Adjust.
EAS30802
Drive chain slack (Maintenance
CHECKING THE SWINGARM OPERATION stand)
1. Check: 30.0–45.0 mm (1.18–1.77 in)
• Swingarm operation Drive chain slack (Sidestand)
Swingarm not working properly → Check the 30.0–45.0 mm (1.18–1.77 in)
swingarm. Limit
Refer to “SWINGARM” on page 4-90. 50.0 mm (1.97 in)
2. Check:
• Swingarm excessive play
Refer to “SWINGARM” on page 4-90.
EAS30643
LUBRICATING THE SWINGARM PIVOT

1. Lubricate:
• Bearings a
• Dust covers
• Pivot shaft
• Pivot shaft ring nut
Recommended lubricant Adjusting the drive chain slack

Lithium-soap-based grease EWA13120
WARNING
Refer to “INSTALLING THE SWINGARM” on Securely support the vehicle so that there is
page 4-93. no danger of it falling over.
EAS31923
1. Loosen:
DRIVE CHAIN SLACK
• Wheel axle nut “1”
Checking the drive chain slack
EWA13120
WARNING
Securely support the vehicle so that there is 1
no danger of it falling over.
ECA13550
NOTICE
A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing- 2. Adjust:
arm or cause an accident. Therefore, keep • Drive chain slack
the drive chain slack within the specified lim- a. Loosen both of the drive chain puller lock-
its. nuts “1”.
1. Stand the vehicle on a level surface. b. Turn both of the drive chain puller adjust-
TIP ing bolts “2” until the specified drive chain
Place the vehicle on a suitable stand so that the slack is obtained.
rear wheel is elevated. TIP
• To maintain the proper wheel alignment, adjust
both sides evenly.
3-19
• There should be no clearance between the ad- TIP

justing block and the adjusting bolts. Place the vehicle on a suitable stand so that the
front wheel is elevated.
2 1
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
• Upper bracket
Refer to “HANDLEBARS” on page 4-66.
c. Tighten the wheel axle nut to specification. 4. Adjust:
• Steering head
Wheel axle nut
110 N·m (11 kgf·m, 81 lb·ft) a. Remove the lock washer “1”, upper ring
T.
nut “2”, and rubber washer “3”.

R.
d. Tighten the drive chain puller locknuts to

specification.
Drive chain puller locknut

16 N·m (1.6 kgf·m, 12 lb·ft)
T.
R.
EAS30091
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive b. Loosen the lower ring nut “4” and then
chain should be serviced, especially when the tighten it to specification with a steering
vehicle is used in dusty areas. nut wrench “5”.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean- Steering nut wrench
ing, high-pressure washing, certain solvents, 90890-01403
and the use of a coarse brush can damage Exhaust flange nut wrench
these O-rings. Therefore, use only kerosene to YU-A9472
clean the drive chain. Wipe the drive chain dry
and thoroughly lubricate it with engine oil or
Lower ring nut (initial tightening
chain lubricant that is suitable for O-ring chains.
torque)
T.
Do not use any other lubricants on the drive

R.
52 N·m (5.2 kgf·m, 38 lb·ft)

chain since they may contain solvents that could
damage the O-rings. TIP
Recommended lubricant Set the torque wrench at a right angle to the
Engine oil or chain lubricant steering nut wrench.
suitable for O-ring chains
EAS30096
CHECKING AND ADJUSTING THE

STEERING HEAD
EWA13120
WARNING
Securely support the vehicle so that there is
3-20
c. Loosen the lower ring nut completely, then EAS31186
CHECKING THE CHASSIS FASTENERS

tighten it to specification.
EWA13140 Make sure that all nuts, bolts, and screws are
WARNING properly tightened.
Do not overtighten the lower ring nut. Refer to “CHASSIS TIGHTENING TORQUES”
on page 2-13.
Lower ring nut (final tightening EAS30720
torque) LUBRICATING THE LEVERS

T.
R.
14 N·m (1.4 kgf·m, 10 lb·ft) Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
d. Check the steering head for looseness or
binding by turning the front fork all the way Recommended lubricant
in both directions. If any binding is felt, re- Lithium-soap-based grease
move the lower bracket and check the up-
EAS30721
per and lower bearings.
LUBRICATING THE PEDALS
Refer to “STEERING HEAD” on page
Lubricate the pivoting point and metal-to-metal
4-82.
moving parts of the pedals.
e. Install the rubber washer “3”.
f. Install the upper ring nut “2”. Recommended lubricant
g. Finger tighten the upper ring nut “2”, then Lithium-soap-based grease
align the slots of both ring nuts. If neces-
sary, hold the lower ring nut and tighten EAS30650
the upper ring nut until their slots are CHECKING THE SIDESTAND
aligned. 1. Check:
h. Install the lock washer “1”. • Sidestand operation
TIP Check that the sidestand moves smoothly.
Rough movement → Repair or replace.
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”. EAS30117
LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.
Recommended lubricant
Lithium-soap-based grease
EAS30652
CHECKING THE SIDESTAND SWITCH

Refer to “CHECKING THE SWITCHES” on
page 8-150.
5. Install: EAS30099
• Upper bracket CHECKING THE FRONT FORK
Refer to “HANDLEBARS” on page 4-66. 1. Stand the vehicle on a level surface.
EWA13120
EAS30646
WARNING
LUBRICATING THE STEERING HEAD
1. Lubricate: Securely support the vehicle so that there is
• Upper bearing no danger of it falling over.
• Lower bearing 2. Check:
• Bearing cover • Inner tube “1”
• Lower bearing dust seal Damage/scratches → Replace.
• Oil seal “2”
Recommended lubricant Oil leakage → Replace.
3-21
2
Direction “a”
Spring preload is increased (suspen-
1
sion is harder).
Direction “b”
Spring preload is decreased (suspen-
sion is softer).
Spring preload
Minimum (soft)
3. Hold the vehicle upright and apply the front 0 turn(s) in direction “a”*
brake. Standard
4. Check: 6 turn(s) in direction “a”*
• Front fork operation Maximum (hard)
Push down hard on the handlebar several
15 turn(s) in direction “a”*
times and check if the front fork rebounds
smoothly. * With the adjusting nut fully turned in di-
Rough movement → Repair. rection “b”
Refer to “FRONT FORK” on page 4-71.
1
a b
EAS30101 Rebound damping

ADJUSTING THE FRONT FORK LEGS ECA13590
The following procedure applies to both of the NOTICE

front fork legs. Never go beyond the maximum or minimum
EWA13120
adjustment positions.
WARNING
1. Adjust:
• Rebound damping
a. Turn the adjusting bolt “1” in direction “a”
or “b”.
Spring preload
EWA17040
Direction “a”
WARNING Rebound damping is increased (sus-
Always adjust both front fork legs evenly. pension is harder).
Uneven adjustment can result in poor han- Direction “b”
dling and loss of stability. Rebound damping is decreased (sus-
ECA13590
pension is softer).
NOTICE
Never go beyond the maximum or minimum
1. Adjust:
• Spring preload
a. Turn the adjusting nut “1” in direction “a” or
“b”.
3-22
Rebound damping Compression damping

Minimum (soft) Minimum (soft)
14 click(s) in direction “b”* 23 click(s) in direction “b”*
Standard Standard
Maximum (hard) Maximum (hard)
* With the adjusting bolt fully turned in di- * With the adjusting bolt fully turned in di-
rection “a” rection “a”
TIP TIP
Although the total number of clicks of a damping Although the total number of clicks of a damping
force adjusting mechanism may not exactly force adjusting mechanism may not exactly
match the above specifications due to small dif- match the above specifications due to small dif-
ferences in production, the actual number of ferences in production, the actual number of
clicks always represents the entire adjusting clicks always represents the entire adjusting
range. To obtain a precise adjustment, it would range. To obtain a precise adjustment, it would
be advisable to check the number of clicks of be advisable to check the number of clicks of
each damping force adjusting mechanism and each damping force adjusting mechanism and
to modify the specifications as necessary. to modify the specifications as necessary.
a b b a
1
EAS30808
Compression damping CHECKING THE REAR SHOCK ABSORBER
ECA13590
NOTICE ASSEMBLY
Refer to “CHECKING THE REAR SHOCK AB-
SORBER ASSEMBLY” on page 4-87.
EAS30103
1. Adjust: ADJUSTING THE REAR SHOCK ABSORBER
• Compression damping ASSEMBLY
a. Turn the adjusting bolt “1” in direction “a” EWA13120
or “b”. WARNING
Direction “a”
Compression damping is increased
(suspension is harder).
Direction “b” Spring preload
Compression damping is decreased ECA13590
(suspension is softer). NOTICE

1. Adjust:
• Spring preload
3-23
b. Adjust the spring preload with the special Rebound damping

wrench included in the owner’s tool kit. ECA13590
c. Turn the adjusting ring “2” in direction “a” NOTICE

or “b”. Never go beyond the maximum or minimum
Direction “a”
1. Adjust:
Spring preload is increased (suspen-
sion is harder). • Rebound damping
Direction “b” a. Turn the adjusting bolt “1” in direction “a”
Spring preload is decreased (suspen- or “b”.
sion is softer).
Direction “a”
Rebound damping is increased (sus-
pension is harder).
Direction “b”
Rebound damping is decreased (sus-
1 pension is softer).
2
b Rebound damping
a
Minimum (soft)
23 click(s) in direction “b”*
Standard
TIP 12 click(s) in direction “b”*
The spring preload setting is determined by Maximum (hard)
measuring distance “c”. The longer distance “c” 1 click(s) in direction “b”*
is, the higher the spring preload; the shorter dis- * With the adjusting screw fully turned in
tance “c” is, the lower the spring preload. direction “a”
TIP
To obtain a precise adjustment, it is advisable to
check the actual total number of clicks of the
c damping force adjusting mechanism. This ad-
justment range may not exactly match the spec-
ifications listed due to small differences in
production.
1
Spring preload
Minimum (soft) a b
84.9 mm (3.34 in)
Standard
89.9 mm (3.54 in)
Maximum (hard)
92.9 mm (3.66 in)
d. Tighten the locknut to the specified torque.

Compression damping (for fast compres-
Spring preload adjusting ring sion damping)
ECA13590
locknut
T.
NOTICE
R.
28 N·m (2.8 kgf·m, 21 lb·ft)

3-24
1. Adjust:
• Compression damping (for fast compression Direction “a”
damping) Compression damping is increased
a. Turn the adjusting bolt “1” in direction “a” (suspension is harder).
or “b”. Direction “b”
Compression damping is decreased
Direction “a” (suspension is softer).
Compression damping is increased
(suspension is harder).
Direction “b” Slow compression damping
Compression damping is decreased Minimum (soft)
(suspension is softer). 18 click(s) in direction “b”*
Standard
14 click(s) in direction “b”*
Fast compression damping Maximum (hard)
Minimum (soft) 1 click(s) in direction “b”*
5.5 turn(s) in direction “b”* * With the adjusting screw fully turned in
Standard direction “a”
3 turn(s) in direction “b”*
Maximum (hard) TIP
0 turn(s) in direction “b”* To obtain a precise adjustment, it is advisable to
* With the adjusting bolt fully turned in di- check the actual total number of clicks of the
rection “a” damping force adjusting mechanism. This ad-
TIP ifications listed due to small differences in
To obtain a precise adjustment, it is advisable to production.
check the actual total number of turns of the
damping force adjusting mechanism. This ad-
1
ifications listed due to small differences in
a b
production.
a b
EAS30809
CHECKING THE CONNECTING ARM AND

RELAY ARM
Refer to “CHECKING THE CONNECTING ARM
AND RELAY ARM” on page 4-88.
Compression damping (for slow compres- EAS30038
sion damping) CHECKING THE ENGINE OIL LEVEL

ECA13590 1. Stand the vehicle on a level surface.
NOTICE TIP
Never go beyond the maximum or minimum • Place the vehicle on a suitable stand.
adjustment positions. • Make sure the vehicle is upright.
1. Adjust: 2. Start the engine, warm it up for several min-
• Compression damping (for slow compression utes, and then turn it off.
damping) 3. Remove:
a. Turn the adjusting bolt “1” in direction “a” • Dipstick “1”
or “b”.
3-25
4. Check: EAS30039
CHANGING THE ENGINE OIL

• Engine oil level
1. Start the engine, warm it up for several min-
The engine oil level should be between the
utes, and then turn it off.
minimum level mark “a” and maximum level
2. Remove:
mark “b”.
• Bottom cowling
Below the minimum level mark → Add the
recommended engine oil to the proper level.
4-8.
TIP 3. Place a container under the engine oil drain
• Before checking the engine oil level, wait a few bolt.
minutes until the oil has settled. 4. Remove:
• Do not screw the dipstick in when inspecting • Engine oil filler cap “1”
the oil level.
1
1
1
b
a
5. Remove:
• Engine oil drain bolt “1”
Recommended brand (along with the gasket “2”)
YAMALUBE
SAE viscosity grades
10W-40, 10W-50, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade
API service SG type or higher, 2
JASO standard MA
ECA13361
NOTICE 1
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause 6. Drain:
clutch slippage. Therefore, do not add any • Engine oil
chemical additives or use engine oils with a (completely from the crankcase)
grade of “CD” or higher and do not use oils 7. If the oil filter cartridge is also to be replaced,
labeled “ENERGY CONSERVING II”. perform the following procedure.
• Do not allow foreign materials to enter the a. Remove the shift arm “1”.
crankcase. b. Pull the fuel tank breather hose “2” (except
for California) and fuel tank over flow hose
5. Start the engine, warm it up for several min- “3” upward to remove them from the guide
utes, and then turn it off. “4”.
6. Check the engine oil level again. c. Remove the oil filter cartridge “5” with an
TIP oil filter wrench “6”.
Before checking the engine oil level, wait a few
minutes until the oil has settled. Oil filter wrench
90890-01426
7. Install: Oil filter wrench
• Dipstick YU-38411
3-26
1
8
5 b 9
4
2
3
8. Check:
• Engine oil drain bolt gasket
Damage → Replace.
9. Install:
• Engine oil drain bolt
(along with the gasket)
Engine oil drain bolt

6 43 N·m (4.3 kgf·m, 32 lb·ft)
T.
R.
10.Fill:
d. Lubricate the O-ring “7” of the new oil filter • Crankcase
cartridge with a thin coat of engine oil. (with the specified amount of the recom-
ECA23090
NOTICE mended engine oil)

Make sure the O-ring “7” is positioned cor- Engine oil quantity
rectly in the groove of the oil filter cartridge. Quantity (disassembled)
3.40 L (3.59 US qt, 2.99 Imp.qt)
Oil change
2.40 L (2.54 US qt, 2.11 Imp.qt)
7 With oil filter removal
2.60 L (2.75 US qt, 2.29 Imp.qt)
11.Install:
• Engine oil filler cap
12.Start the engine, warm it up for several min-
utes, and then turn it off.
13.Check:
e. Tighten the new oil filter cartridge to spec- • Engine
ification with an oil filter wrench. (for engine oil leaks)
14.Check:
Oil filter cartridge
• Engine oil level
17 N·m (1.7 kgf·m, 13 lb·ft)
T.
Refer to “CHECKING THE ENGINE OIL

R.
f. Insert the fuel tank breather hose and fuel LEVEL” on page 3-25.
tank overflow hose into the guide and EAS30040
place them in their original position. MEASURING THE ENGINE OIL PRESSURE
g. Install the shift arm “8” by aligning the slot 1. Check:
“a” in the shift arm with the notch “b” in the • Engine oil level
shift shaft “9”. Below the minimum level mark → Add the
recommended engine oil to the proper level.
Shift arm bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
3-27

utes, and then turn it off. Oil pressure
ECA13410 40.0 kPa/1300 r/min (0.40 kgf/
NOTICE cm²/1300 r/min, 5.8 psi/1300 r/
When the engine is cold, the engine oil will min)
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after Engine oil pressure Possible causes
warming up the engine. • Faulty oil pump
3. Remove: • Clogged oil filter
Below specification • Leaking oil passage
• Front side cowling assembly • Broken or damaged
Refer to “GENERAL CHASSIS (5)” on page oil seal
4-8.
• Leaking oil passage
4. Remove: Above specification • Faulty oil filter
• Main gallery bolt “1” • Oil viscosity too high
EWA12980
WARNING 7. Install:
The engine, muffler and engine oil are ex- • Main gallery bolt
tremely hot.
Main gallery bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
8. Install:R.

4-8.
EAS30066
1 CHECKING THE COOLANT LEVEL

TIP
5. Install:
• Oil pressure gauge set “1” • Place the vehicle on a suitable stand.
• Oil pressure adapter H “2” • Make sure the vehicle is upright.
2. Check:
Oil pressure gauge set • Coolant level
90890-03120
The coolant level should be between the min-
Oil pressure adapter H
90890-03139 imum level mark “a” and maximum level mark
“b”.
Below the minimum level mark → Remove
the coolant reservoir cap, add the recom-
mended coolant to the proper level.
TIP
2 To access the coolant reservoir cap, remove the
1 right front upper panel. Refer to “GENERAL
CHASSIS (5)” on page 4-8.
ECA13470
NOTICE
• Adding water instead of coolant lowers the
6. Measure: antifreeze content of the coolant. If water is
• Engine oil pressure used instead of coolant check, and if nec-
(at the following conditions) essary, correct the antifreeze concentra-
tion of the coolant.
3-28
• Use only distilled water. However, if dis-

tilled water is not available, soft water may 4
be used.
b 1 3
2
a
6
utes, and then turn it off. 7
4. Check:
• Coolant level
TIP
Before checking the coolant level, wait a few
minutes until it settles.
EAS30067 13 9
CHECKING THE COOLING SYSTEM
1. Remove: 12
4-8. 11
10
• Exhaust pipe assembly 8
Refer to “ENGINE REMOVAL” on page 5-9.
2. Check:
• Radiator “1”
• Radiator inlet hose “2”
• Radiator inlet pipe “3” 16
• Radiator outlet hose “4”
• Radiator outlet pipe “5” 14
• Thermostat “6” 15
• Thermostat outlet hose “7”
• Oil cooler “8”
• Oil cooler outlet hose “9”
• Oil cooler inlet hose “10”
• Water pump outlet pipe “11” 3. Install:
• Water jacket joint inlet hose “12” • Exhaust pipe assembly
• Water jacket joint “13” Refer to “ENGINE REMOVAL” on page 5-9.
• Water pump “14” • Front side cowling assembly
• Water pump inlet hose “15” Refer to “GENERAL CHASSIS (5)” on page
• Water pump outlet hose “16” 4-8.
EAS30068
CHANGING THE COOLANT
Refer to and “OIL COOLER” on page 6-7.
1. Remove:
Refer to “THERMOSTAT” on page 6-10.
• Front upper panel
Refer to “WATER PUMP” on page 6-12.
3-29
• Bottom cowling
4-8. 2
2. Remove:
• Radiator cap “1”
EWA13030
WARNING
1
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in- 7. Drain:
jury. When the engine has cooled, open the • Coolant
radiator cap as follows: (from the coolant reservoir)
Place a thick rag or a towel over the radiator 8. Install:
cap and slowly turn the radiator cap counter- • Coolant reservoir
clockwise toward the detent to allow any re- 9. Connect:
sidual pressure to escape. When the hissing • Water pump inlet hose
sound has stopped, press down on the radi- 10.Install:
ator cap and turn it counterclockwise to re- • Coolant drain bolt (water pump)
move. (along with the copper washer New )
Coolant drain bolt (water pump)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
1
R.
11.Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Mixing ratio
1:1 (antifreeze:water)
3. Remove: Radiator (including all routes)
• Coolant drain bolt (water pump) “1” 2.30 L (2.43 US qt, 2.02 Imp.qt)
(along with the copper washer “2”) Coolant reservoir (up to the maxi-
4. Disconnect: mum level mark)
• Water pump inlet hose “3” 0.25 L (0.26 US qt, 0.22 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
1 2 EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
3 • If coolant splashes on your clothes, quickly
wash it away with water and then with soap
5. Drain:
and water.
• Coolant
• If coolant is swallowed, induce vomiting
(from the engine and radiator)
and get immediate medical attention.
6. Remove:
• Coolant reservoir “1”
• Coolant reservoir cap “2”
3-30
ECA13481
• Rear brake light switch operation
NOTICE When operating the brake lever and brake
• Adding water instead of coolant lowers the pedal, confirm that the brake light turns on.
antifreeze content of the coolant. If water is Faulty → Refer to “CHECKING THE
used instead of coolant, check, and if nec- SWITCHES” on page 8-150.
essary, correct the antifreeze concentra-
EAS30083
tion of the coolant.
ADJUSTING THE REAR BRAKE LIGHT
• Use only distilled water. However, if dis-
SWITCH
tilled water is not available, soft water may
TIP
be used.
• If coolant comes into contact with painted The rear brake light switch is operated by move-
surfaces, immediately wash them with wa- ment of the brake pedal. The rear brake light
ter. switch is properly adjusted when the brake light
• Do not mix different types of antifreeze. comes on just before the braking effect starts.
12.Install: 1. Check:
• Radiator cap • Rear brake light operation timing
13.Fill: Incorrect → Adjust.
• Coolant reservoir 2. Adjust:
(with the recommended coolant to the maxi- • Rear brake light operation timing
mum level mark “a”) a. Hold the main body “1” of the rear brake
light switch so that it does not rotate and
turn the adjusting nut “2” until the rear
brake light comes on at the proper time.
1
2
14.Install:
• Coolant reservoir cap
15.Start the engine, warm it up for several min-
utes, and then stop it. EAS30114
16.Check: CHECKING AND LUBRICATING THE

• Coolant level CABLES
Refer to “CHECKING THE COOLANT LEV- The following procedure applies to all of the in-
EL” on page 3-28. ner and outer cables.
EWA13270
TIP WARNING
Before checking the coolant level, wait a few Damaged outer cable may cause the cable to
minutes until the coolant has settled. corrode and interfere with its movement. Re-
17.Install: place damaged outer cable and inner cables
• Bottom cowling as soon as possible.
• Front side cowling assembly 1. Check:
• Front upper panel • Outer cable
Refer to “GENERAL CHASSIS (5)” on page Damage → Replace.
4-8. 2. Check:
EAS30658
• Cable operation
CHECKING THE BRAKE LIGHT SWITCHES Rough movement → Lubricate.
1. Check:
• Front brake light switch operation
3-31
EWA12910
Recommended lubricant WARNING

Engine oil or a suitable cable lu- After adjusting the throttle cable free play,
bricant start the engine and turn the handlebar to the
right and to the left to ensure that this does
TIP not cause the engine idling speed to change.
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit- EAS30663
able lubricating device. CHECKING THE SWITCHES, LIGHTS AND

SIGNALS
EAS30707 1. Check that all switches operate and that all
ADJUSTING THE THROTTLE CABLE FREE lights come on.
PLAY Refer to “Instrument and control functions” in
TIP OWNER’S MANUAL.
Prior to adjusting the throttle cable free play, the Faulty → Refer to “CHECKING THE
engine idling speed and throttle body synchroni- SWITCHES” on page 8-150 and “CHECK-
zation should be adjusted properly. ING THE BULBS AND BULB SOCKETS” in
“BASIC INFORMATION” (separate volume).
1. Check:
• Throttle cable free play “a” EAS30120
CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
Throttle grip free play BATTERY” on page 8-152.
3.0–5.0 mm (0.12–0.20 in) EAS30121
CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page
8-151.
EAS30124
ADJUSTING THE HEADLIGHT BEAMS

1. Adjust:
a • Headlight beam (vertically)
TIP
To adjust the headlight beam (vertically), insert
a crosshead screwdriver into holes “a” in the
2. Adjust: headlight cover and turn the adjusting screw.
• Throttle cable free play
b. Turn the adjusting nut “2” until the speci-
fied throttle cable free play is obtained.
c. Tighten the locknut “1”.
Throttle cable locknut

4.3 N·m (0.43 kgf·m, 3.2 lb·ft)
T.
R.
3-32
a a
a. Turn the adjusting screw “1”. a. Turn the adjusting screw “1”.
1 1
1 1
2. Adjust:
• Headlight beam (horizontally)
TIP
To adjust the headlight beam (horizontally), in-
sert a crosshead screwdriver into holes “a” in the
headlight cover and turn the adjusting screw.
3-33
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1
GENERAL CHASSIS (2) ................................................................................. 4-2

REMOVING THE REAR CENTER COVER ..............................................4-3
INSTALLING THE REAR CENTER COVER.............................................4-3
REMOVING THE REAR SIDE COWLING ................................................ 4-3
INSTALLING THE REAR SIDE COWLING............................................... 4-3
GENERAL CHASSIS (3) ................................................................................. 4-5
GENERAL CHASSIS (4) ................................................................................. 4-6

REMOVING THE FRONT UPPER COWLING.......................................... 4-7
INSTALLING THE FRONT UPPER COWLING ........................................ 4-7
GENERAL CHASSIS (5) ................................................................................. 4-8

REMOVING THE FRONT UPPER PANEL ............................................... 4-9
REMOVING THE FRONT SIDE COWLING UPPER INNER PANEL ....... 4-9
REMOVING THE FRONT SIDE COWLING LOWER INNER PANEL....... 4-9
REMOVING THE FRONT SIDE COWLING ASSEMBLY .........................4-9
4
REMOVING THE FRONT LOWER PANEL ............................................4-10
INSTALLING THE FRONT LOWER PANEL ...........................................4-10
INSTALLING THE BOTTOM COWLING
AND FRONT SIDE COWLING ASSEMBLY...........................................4-10
INSTALLING THE FRONT SIDE COWLING LOWER INNER PANEL ... 4-11
INSTALLING THE FRONT SIDE COWLING UPPER INNER PANEL .... 4-12
INSTALLING THE FRONT UPPER PANEL............................................4-12
GENERAL CHASSIS (6) ............................................................................... 4-13

REMOVING THE HEADLIGHT ASSEMBLY...........................................4-15
INSTALLING THE HEADLIGHT ASSEMBLY .........................................4-15
REMOVING THE AIR DUCT................................................................... 4-15
INSTALLING THE AIR DUCT .................................................................4-15
FRONT WHEEL............................................................................................. 4-16

REMOVING THE FRONT WHEEL.......................................................... 4-18
DISASSEMBLING THE FRONT WHEEL................................................ 4-18
CHECKING THE FRONT WHEEL .......................................................... 4-18
ASSEMBLING THE FRONT WHEEL......................................................4-19
MAINTENANCE OF THE FRONT WHEEL SENSOR
AND SENSOR ROTOR ..........................................................................4-20
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-21
INSTALLING THE FRONT WHEEL (DISC BRAKE) ...............................4-21
REAR WHEEL ...............................................................................................4-24
REMOVING THE REAR WHEEL ............................................................ 4-27
DISASSEMBLING THE REAR WHEEL .................................................. 4-27
CHECKING THE REAR WHEEL............................................................. 4-28
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-28
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .........4-28
ASSEMBLING THE REAR WHEEL ........................................................ 4-29
MAINTENANCE OF THE REAR WHEEL SENSOR
AND SENSOR ROTOR ..........................................................................4-30
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-30
INSTALLING THE REAR WHEEL (DISC BRAKE) .................................4-30
FRONT BRAKE ............................................................................................. 4-33

INTRODUCTION .....................................................................................4-39
CHECKING THE FRONT BRAKE DISCS............................................... 4-39
REPLACING THE FRONT BRAKE PADS .............................................. 4-40
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-41
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-41
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-42
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-42
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-42
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-43
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-44
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-44
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-44
REAR BRAKE ...............................................................................................4-46

INTRODUCTION .....................................................................................4-50
CHECKING THE REAR BRAKE DISC....................................................4-50
REPLACING THE REAR BRAKE PADS................................................. 4-50
REMOVING THE REAR BRAKE CALIPER ............................................4-52
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-52
CHECKING THE REAR BRAKE CALIPER............................................. 4-52
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-53
INSTALLING THE REAR BRAKE CALIPER...........................................4-53
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-54
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-54
THE REAR BRAKE MASTER CYLINDER .............................................. 4-55
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-55
ABS (Anti-lock Brake System) .................................................................... 4-57

REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-59
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-60
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-60
HYDRAULIC UNIT OPERATION TEST .................................................. 4-61
CHECKING THE ABS WARNING LIGHT ............................................... 4-65
HANDLEBARS ..............................................................................................4-66
REMOVING THE HANDLEBARS ........................................................... 4-68
CHECKING THE HANDLEBARS ............................................................ 4-68
INSTALLING THE HANDLEBARS .......................................................... 4-68
FRONT FORK................................................................................................4-71
REMOVING THE FRONT FORK LEGS.................................................. 4-74
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-74
CHECKING THE FRONT FORK LEGS .................................................. 4-75
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-76
INSTALLING THE FRONT FORK LEGS ................................................ 4-80
STEERING HEAD.......................................................................................... 4-82

REMOVING THE LOWER BRACKET.....................................................4-84
CHECKING THE STEERING HEAD .......................................................4-84
INSTALLING THE STEERING HEAD .....................................................4-84
REAR SHOCK ABSORBER ASSEMBLY ....................................................4-86

HANDLING THE REAR SHOCK ABSORBER ........................................ 4-87
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-87
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-87
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-87
CHECKING THE CONNECTING ARM AND RELAY ARM.....................4-88
INSTALLING THE RELAY ARM..............................................................4-88
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-88
SWINGARM................................................................................................... 4-90
REMOVING THE SWINGARM................................................................4-92
CHECKING THE SWINGARM ................................................................4-92
INSTALLING THE SWINGARM ..............................................................4-93
CHAIN DRIVE................................................................................................4-95
REMOVING THE DRIVE CHAIN............................................................. 4-96
CHECKING THE DRIVE CHAIN ............................................................. 4-96
CHECKING THE DRIVE SPROCKET.....................................................4-97
CHECKING THE REAR WHEEL SPROCKET........................................ 4-97
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-97
INSTALLING THE DRIVE CHAIN ........................................................... 4-97
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the seat and battery
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1 2
5 4
6 7
Order Job/Parts to remove Q’ty Remarks

1 Rider seat 1
2 Passenger seat 1
3 Negative battery lead 1 Disconnect.
4 Positive battery lead 1 Disconnect.
5 Battery band 1
6 Battery 1
7 Damper 1
4-1
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the rear side cowlings
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
5 2
3
7 N•m (0.7 kgf•m, 5.2 lb•ft)

(4)
T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
LT 1
1
28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.
LT

Rider seat/Passenger seat 4-1.
1 Owner’s tool kit 1
2 Rear center cover 1
3 Rider seat bracket 1
4 Passenger footrest 2
5 Rear side cowling 2
4-2
GENERAL CHASSIS (2)
EAS32351
REMOVING THE REAR CENTER COVER c

1. Remove: a 1
d
• Rear center cover “1”
1 a
b
2
b
EAS32386
REMOVING THE REAR SIDE COWLING

rear side cowlings.
a. Remove the quick fasteners. 1. Remove:
b. Unhook the holes “a” in the rear center • Rear side cowling “1”
cover from the projections “b” on the rear
lower cover “2”, and unhook the projec-
1
tions “c” on the rear center cover from the
holes “d” in the rear lower cover, and then
remove the rear center cover.
a
c 1
b
c
d a. Remove the bolts and quick fastener.
2 b. Unhook the projection “a” on the rear side
d cowling from the hole “b” in the rear lower
cover “2”, and then remove the rear side
cowling.
EAS32352
INSTALLING THE REAR CENTER COVER b 2 a

1. Install:
• Rear center cover “1”
1
1
EAS32387
INSTALLING THE REAR SIDE COWLING

rear side cowlings.
a. Fit the projections “a” on the rear center 1. Install:
cover into the holes “b” in the rear lower • Rear side cowling “1”
cover “2”, and fit the holes “c” in the rear
center cover onto the projections “d” on
the rear lower cover, and then install the
quick fasteners.
4-3
GENERAL CHASSIS (2)
a. Fit the projection “a” on the rear side cowl-

ing into the hole “b” in the rear lower cover
“2”, and then tighten the rear side cowling
bolts.
Rear side cowling bolt

9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.
R.
b 2 a
4-4
GENERAL CHASSIS (3)
EAS20156
GENERAL CHASSIS (3)

Removing the tail/brake light assembly
8
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7
3 9
(4)
1 6
(4) (3)
LT
LT
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Rear side cowling 4-2.
1 Passenger seat bracket 1
2 License plate light connector 2 Disconnect.
3 Rear turn signal light coupler 2 Disconnect.
4 Coupler holder 1
5 Tail/brake light coupler 1 Disconnect.
6 License plate light assembly 1
7 Rear lower cover assembly 1
8 Tail/brake light assembly 1
9 Rear lower cover 1
4-5
GENERAL CHASSIS (4)
EAS20157
GENERAL CHASSIS (4)

Removing the front upper cowling
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2
0.4 N•m (0.04 kgf•m, 0.30 lb•ft)
T.R
.
1
(4)
1
3
(4)
(4)
(4)
4

1 Front turn signal/position light coupler 2 Disconnect.
2 Rearview mirror 2
3 Front upper cowling 1
4 Windshield 1
4-6
GENERAL CHASSIS (4)
EAS31362
REMOVING THE FRONT UPPER COWLING

2
1. Remove:
1
• Front upper cowling “1” c d
1
a b
a b
a. Remove the bolts.

b. Unhook the projections “a” on the front up-
per cowling from the holes “b” in the head-
light assembly “2”, and remove the
projections “c” on the front upper cowling
from the grommets “d”, and then remove
the front upper cowling.
2
1
c d
a b
a b
EAS31363
INSTALLING THE FRONT UPPER COWLING

1. Install:
• Front upper cowling “1”
1
a. Fit the projections “a” on the front upper

cowling into the holes “b” in the headlight
assembly “2”, and insert the projections “c”
on the front upper cowling into the grom-
mets “d”.
b. Install the bolts.
Front center cowling bolt

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
4-7
GENERAL CHASSIS (5)
EAS20158
GENERAL CHASSIS (5)

Removing the front side cowlings
3.8 N•m (0.38 kgf•m, 2.8 lb•ft) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
T.R
.
.
4
6
8
(4)
1
7 5 1
5 (3)
8
(4)
4 6
(4)
2
4.5 N•m (0.45 kgf•m, 3.3 lb•ft)
(3)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
(4)
T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft) (4)
T.R
.
2 7
3
3.8 N•m (0.38 kgf•m, 2.8 lb•ft) 4.5 N•m (0.45 kgf•m, 3.3 lb•ft)
T.R
T.R
.
.

Front upper cowling 4-6.
1 Front upper panel 2
2 Front side cowling upper inner panel 2
3 Front side cowling lower inner panel 1
4 Front side cowling assembly 2
5 Front lower panel 2
6 Upper front side cowling 2
7 Lower front side cowling 2
8 Bottom cowling 2
4-8
GENERAL CHASSIS (5)
EAS31266
a. Remove the quick fasteners.
REMOVING THE FRONT UPPER PANEL
b. Unhook the holes “a” in the front side cowl-
ing upper inner panel from the projections
front upper panels.
“b” on the side cowling assembly “2”, and
1. Remove:
then remove the front side cowling upper
• Front upper panel “1”
inner panel.
1
2
b
a. Remove the quick fasteners.
EAS32391
b. Remove the projection “a” on the front up- REMOVING THE FRONT SIDE COWLING
per panel from the grommet “b”, and un- LOWER INNER PANEL
hook the projection “c” on the front upper 1. Remove:
panel from the hole “d” in the front lower • Front side cowling lower inner panel “1”
panel “2”.
c. Slide the front upper panel rearward and
remove the projections “e” on the front up-
per panel from the holes “f” in the front low-
er panel.
e
1
a
1
a. Remove the bolts.
c b. Slide the front side cowling lower inner
b panel in the direction of the arrow shown in
the illustration to remove the holes “a” in
f 2 d
the front side cowling lower inner panel
EAS32390 from the projections “b” on the front side
REMOVING THE FRONT SIDE COWLING cowling assemblies “2”.
UPPER INNER PANEL
front side cowling upper inner panels. a 1
1. Remove:
• Front side cowling upper inner panel “1”
2
b
a
a b
1 b
EAS31360
REMOVING THE FRONT SIDE COWLING

ASSEMBLY
front side cowling assemblies.
4-9
GENERAL CHASSIS (5)
1. Remove:
• Front side cowling assembly “1” a 1
2
b
1
EAS31275
INSTALLING THE FRONT LOWER PANEL

a. Remove the bolts and quick fastener. The following procedure applies to both of the
b. Unhook the hole “a” in the front side cowl- front lower panels.
ing assembly from the projection “b” on the 1. Install:
headlight cover “2”, and unhook the pro- • Front lower panel “1”
jection “c” on the front side cowling assem- a. Fit the projections “a” on the upper front
bly from the hole “d” in the headlight cover. side cowling “2” into the holes “b” in the
c. Slide the front side cowling assembly rear- front lower panel, and then insert the pro-
ward to remove the hole “e” in the front jection “c” on the upper front side cowling
side cowling assembly from the projection into the hole “d” in the front lower panel.
“f” on the bottom cowling “3”. (right side
only) d 1
a b
d. Remove the front side cowling assembly.
2
2 c
b
a
d
a
EAS32392
c INSTALLING THE BOTTOM COWLING AND
1
FRONT SIDE COWLING ASSEMBLY
bottom cowlings and front side cowling assem-
blies.
3 1. Install:
f
e • Bottom cowling “1”
• Bottom cowling bolt
(temporarily tighten)
• Front side cowling assembly “2”
• Front side cowling assembly bolt
EAS31274
REMOVING THE FRONT LOWER PANEL

front lower panels.
1. Remove: 2
• Front lower panel “1”
a. Unhook the hole “a” in the front lower pan-
el from the projection “b” on the upper front
side cowling “2”.
1
4-10
GENERAL CHASSIS (5)
a. Install the bottom cowling temporarily. • Front side cowling assembly bolt (M6 × 12)
b. Fit the projection “a” on the bottom cowling “5”
into the hole “b” in the front side cowling • Front side cowling assembly bolt (M6 × 30)
assembly, and then slide the front side “6”
cowling forward. (right side only) • Front side cowling assembly bolt (M5 × 9) “7”
• Front side cowling assembly bolt (M6 × 20)
(left side only) “8”
a Bottom cowling bolt (M6 × 20)

b 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
T.
R.
Bottom cowling bolt (M5 × 9)
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Front lower panel bolt (M5 × 9)
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Front lower panel bolt (M6 × 12)
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
c. Fit the projection “c” on the front side cowl-
Front side cowling assembly bolt
ing assembly into the hole “d” in the head-
(M6 × 12)
light cover “3”, and then insert the 7 N·m (0.7 kgf·m, 5.2 lb·ft)
projection “e” on the front side cowling as- Front side cowling assembly bolt
sembly into the hole “f” in the headlight (M6 × 30)
cover. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
d. Fit the hole “g” in the front side cowling as- Front side cowling assembly bolt
sembly onto the projection “h” on the (M5 × 9)
headlight cover, and then install the front 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
side cowling assembly bolts temporarily. Front side cowling assembly bolt
(M6 × 20) (left side only)
3 4.5 N·m (0.45 kgf·m, 3.3 lb·ft)
h
f 5
d 6
g 4
3
c e
2
2. Install:
• Quick fastener “1”
7 1 7 8 1 2
EAS32393
INSTALLING THE FRONT SIDE COWLING

LOWER INNER PANEL
1. Install:
• Front side cowling lower inner panel “1”
3. Tighten:
• Bottom cowling bolt (M6 × 20) “1”
• Bottom cowling bolt (M5 × 9) “2”
• Front lower panel bolt (M5 × 9) “3”
• Front lower panel bolt (M6 × 12) “4”
1
4-11
GENERAL CHASSIS (5)
a. Fit the projection “a” on the front side cowl-

ing assembly “2” into the holes “b” in the
2
front side cowling lower inner panel, and
then slide the front side cowling lower in- 1
ner panel in the direction of the arrow d
a
b. Install the front side cowling lower inner
panel bolts. d
a c
c b
Front side cowling lower inner b
panel bolt b. Install the quick fasteners.
T.
R.
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

EAS31267
INSTALLING THE FRONT UPPER PANEL

b 1 front upper panels.
1. Install:
• Front upper panel “1”
1
a 2
b
a
a b
EAS32394
INSTALLING THE FRONT SIDE COWLING

UPPER INNER PANEL
front side cowling upper inner panels.
1. Install: a. Fit the projections “a” on the front upper
• Front side cowling upper inner panel “1” panel into the holes “b” in the front lower
panel “2”, and then slide the front upper
panel forward.
b. Fit the projections “c” on the front upper
panel into the holes “d” in the front lower
1 panel.
c. Fit the projection “e” on the front upper
panel into the hole “f” in the front lower
panel, and then insert the projection “g” on
the front upper panel into the grommet “h”.
a
a. Fit the portions “a” of the front side cowling 1
upper inner panel into the slots “b” in the
front side cowling assembly “2”, and then g
fit the projections “c” on the front side cowl-
ing assembly into the holes “d” in the front
c e c
side cowling upper inner panel. h
b 2 d f d
d. Install the quick fasteners.
4-12
GENERAL CHASSIS (6)
EAS20159
GENERAL CHASSIS (6)

Removing the headlight assembly
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)

T.R
.
2 8
3 6
5
1
(4)
(3) (4)
4
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
1.3 N•m (0.13 kgf•m, 0.95 lb•ft)

T.R
.

Front side cowling assembly 4-8.
1 Auxiliary light coupler 1 Disconnect.
2 Atmospheric pressure sensor coupler 1 Disconnect.
3 Intake air temperature sensor coupler 1 Disconnect.
4 Headlight coupler 2 Disconnect.
5 Headlight assembly 1
6 Meter coupler 1 Disconnect.
7 Meter 1
8 Headlight bracket 1
4-13
GENERAL CHASSIS (6)
Disassembling the headlight assembly
1
8 2
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.
7
(3)
3
4
7 6 (4) New
5
(3)
4.3 N•m (0.43 kgf•m, 3.2 lb•ft)

T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.

1 Air duct assembly 1
2 Headlight control unit 1
3 Intake air temperature sensor 1
4 Atmospheric pressure sensor 1
5 Air duct 1
6 Headlight assembly 1
7 Auxiliary light 2
8 Headlight cover 1
4-14
GENERAL CHASSIS (6)
EAS32395
REMOVING THE HEADLIGHT ASSEMBLY b

2
1. Remove: 1
• Headlight assembly “1”
a. Remove the screws. a
b. Unhook the projections “a” on the air duct
“2” from the holes “b” in the headlight
bracket “3”, and then remove the headlight
assembly.
a
2 a 3
1 EAS31797
INSTALLING THE AIR DUCT

1. Install:
b • Air duct “1”
a. Fit the portions “a” of the air duct into the
slots “b” in the headlight cover “2”, and
b
then fit the projections “c” on the air duct
into the holes “d” in the headlight cover.
b. Install the quick fastener.
EAS31128
INSTALLING THE HEADLIGHT ASSEMBLY d b d

b 2
1. Install: 1
• Headlight assembly “1” d
a. Insert the projections “a” on the headlight a
assembly into the grommet “b”, and fit the c
projections “c” on the air duct “2” into the a
holes “d” in the headlight bracket “3”. a
b c
b. Install the screws. b
c a
Headlight assembly screw
1.3 N·m (0.13 kgf·m, 0.95 lb·ft)
T.
R.
1 c a 3
2
b
a b
d
a b
EAS32396
REMOVING THE AIR DUCT

1. Remove:
• Air duct “1”
a. Remove the quick fastener.
b. Unhook the projections “a” on the air duct
from the holes “b” in the headlight cover
“2”.
4-15
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake discs
2 3 6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft) 1 35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
.
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
5
3
21 N•m (2.1 kgf•m, 15 lb•ft)
T.R
.
10
11
6 1
2
7
4 5
115 N•m (11.5 kgf•m, 85 lb•ft)

LT
T.R
.
LT
9
11
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
7 N•m (0.7 kgf•m, 5.2 lb•ft)

.
10
T.R
.

1 Reflector bracket 2
2 Front reflector 2
3 Front brake hose holder 2
4 Front wheel sensor 1
5 Front brake caliper 2
6 Wheel axle pinch bolt 4 Loosen.
7 Front wheel axle nut 1
8 Front wheel axle 1
9 Front wheel 1
10 Collar 2
11 Front brake disc 2
4-16
FRONT WHEEL
Disassembling the front wheel
2
3
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
LT
3
2
1

1 Front wheel sensor rotor 1
2 Oil seal 2
3 Wheel bearing 2
4 Spacer 1
4-17
FRONT WHEEL
EAS30145
• If any solvent gets on the wheel sensor ro-
REMOVING THE FRONT WHEEL
ECA21380
tor, wipe it off immediately.
NOTICE 1. Remove:
Keep magnets (including magnetic pick-up • Oil seals
tools, magnetic screwdrivers, etc.) away • Wheel bearings
from the front wheel sensor “1”, otherwise a. Clean the surface of the front wheel hub.
the wheel sensor may be damaged, resulting b. Remove the oil seals “1” with a flat-head
in improper performance of the ABS. screwdriver.
TIP
To prevent damaging the wheel, place a rag “2”
between the screwdriver and the wheel surface.

EWA13120
WARNING
no danger of it falling over. c. Remove the wheel bearings “3” with a
general bearing puller.
2. Remove:
• Front brake caliper (left)
• Front brake caliper (right)
• Front wheel sensor
ECA21440
NOTICE
• Do not apply the brake lever when remov-
ing the brake calipers.
• Be sure not to contact the sensor electrode
to any metal part when removing the front
wheel sensor from the sensor housing.
EAS30147
3. Elevate: CHECKING THE FRONT WHEEL
• Front wheel 1. Check:
TIP • Wheel axle
Place the vehicle on a maintenance stand so Roll the wheel axle on a flat surface.
that the front wheel is elevated. Bends → Replace.
EWA13460
4. Loosen: WARNING
• Wheel axle pinch bolt Do not attempt to straighten a bent wheel ax-
5. Remove: le.
• Front wheel axle nut
• Front wheel axle
• Front wheel
EAS30146
DISASSEMBLING THE FRONT WHEEL

ECA21340
NOTICE
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
4-18
FRONT WHEEL
EAS30151
ASSEMBLING THE FRONT WHEEL

ECA21340
NOTICE
ject it to shocks.
1. Install:
• Wheel bearings New
2. Check: • Oil seals New
• Tire a. Install the new wheel bearing (left side).
ECA18110
• Front wheel
NOTICE
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page Do not contact the wheel bearing inner race
3-17 and “CHECKING THE WHEELS” on “1” or balls “2”. Contact should be made
page 3-17. only with the outer race “3”.
3. Measure: TIP
• Radial wheel runout “1”
Use a socket “4” that matches the diameter of
• Lateral wheel runout “2”
the wheel bearing outer race.
Over the specified limits → Replace.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
b. Install the spacer.

c. Install the new wheel bearing (right side).
TIP
Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
4. Check: “3” and outer race “4” are pressed at the same
• Wheel bearings time, and then press the bearing until the inner
Front wheel turns roughly or is loose → Re- race makes contact with the spacer “5”.
place the wheel bearings.
• Oil seals
d. Install the new oil seals.
4-19
FRONT WHEEL
2. Install: • Do not drop or shock the wheel sensor or

• Front wheel sensor rotor the wheel sensor rotor.
Wheel sensor rotor bolt 1. Check:

8 N·m (0.8 kgf·m, 5.9 lb·ft) • Front wheel sensor
T.
Cracks/bends/distortion → Replace.
R.
LOCTITE®
Iron powder/dust → Clean.
ECA17200
2. Check:
NOTICE • Front wheel sensor rotor “1”
Replace the wheel sensor rotor bolts with Cracks/damage/scratches → Replace the
new ones. front wheel sensor rotor.
Iron powder/dust/solvent → Clean.
TIP
TIP
Install the wheel sensor rotor with the stamped
mark “1” facing outward. • The wheel sensor rotor is installed on the inner
side of the wheel hub.
• When cleaning the wheel sensor rotor, be
careful not to damage the surface of the sensor
1 rotor.
B 1
3. Measure:
• Wheel sensor rotor runout
Out of specification → Correct the wheel sen-
sor rotor runout or replace the wheel sensor
rotor. 3. Measure:
Refer to “MAINTENANCE OF THE FRONT • Wheel sensor rotor runout
WHEEL SENSOR AND SENSOR ROTOR” Out of specification → Clean the installation
on page 4-20. surface of the wheel sensor rotor and correct
the wheel sensor rotor runout, or replace the
Wheel sensor rotor runout limit wheel sensor rotor.
0.25 mm (0.01 in)
Wheel sensor rotor runout limit
EAS30155 0.25 mm (0.01 in)
MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR a. Hold the dial gauge at a right angle against
ECA21070 the wheel sensor rotor surface.
NOTICE b. Measure the wheel sensor rotor runout.
• Handle the ABS components with care
since they have been accurately adjusted.
Keep them away from dirt and do not sub-
ject them to shocks.
• The front wheel sensor cannot be disas-
sembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or
front wheel sensor rotor.
4-20
FRONT WHEEL
EAS30154
INSTALLING THE FRONT WHEEL (DISC

BRAKE)
1. Install:
• Front brake discs
Front brake disc bolt

17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
LOCTITE®
ECA19150
NOTICE
Replace the brake disc bolts with new ones.
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
c. If the runout is above specification, re-

move the sensor rotor from the wheel, ro-
tate it by two bolt holes, and then install it.
Wheel sensor rotor bolt LT

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
LOCTITE®
2. Check:
ECA17200 • Front brake discs
NOTICE Refer to “CHECKING THE FRONT BRAKE
Replace the wheel sensor rotor bolts with DISCS” on page 4-39.
new ones. 3. Lubricate:
• Oil seal lips
d. If the runout is still above specification, re-
place the wheel sensor rotor. Recommended lubricant
EAS30152
ADJUSTING THE FRONT WHEEL STATIC
BALANCE 4. Install:
TIP
• Collars
• Front wheel
• After replacing the tire, wheel or both, the front
• Front wheel axle
wheel static balance should be adjusted.
• Front wheel axle nut
• Adjust the front wheel static balance with the
TIP
brake disc installed.
Apply lithium soap-based grease onto the mat-
1. Remove: ing surface of the front wheel axle nut.
• Balancing weight(s)
2. Find: 5. Tighten:
• Front wheel’s heavy spot • Front wheel axle nut
3. Adjust:
Front wheel axle nut
• Front wheel static balance 115 N·m (11.5 kgf·m, 85 lb·ft)
T.
4. Check:
R.
• Front wheel static balance
4-21
FRONT WHEEL
ECA14140
7. Install:
NOTICE • Front wheel sensor
Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times Front wheel sensor bolt
and check if the front fork rebounds smooth- 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
ly. ECA21020
6. Tighten: NOTICE
• Front wheel axle pinch bolt Make sure there are no foreign materials in
a. Tighten the pinch bolt “2”, pinch bolt “1”, the front wheel sensor rotor and front wheel
and pinch bolt “2” to the specified torque in sensor. Foreign materials cause damage to
this order. the front wheel sensor rotor and front wheel
sensor.
Front wheel axle pinch bolt
21 N·m (2.1 kgf·m, 15 lb·ft) TIP
T.
R.
• When installing the front wheel sensor, check

b. Check that the right end “a” of the front the front wheel sensor lead for twists.
axle is flush with the front fork “b”. If nec- • To route the front wheel sensor lead, refer to
essary, manually push the front axle or “CABLE ROUTING” on page 2-15.
lightly tap it with a soft hammer until its end
is flush with the front fork. However, if the 8. Measure:
surface of the front axle end is not parallel • Distance “a”
to the surface of the front fork, align a point (between the wheel sensor rotor “1” and front
on the outer edge of the axle with the fork, wheel sensor “2”)
making sure that the axle does not pro- Out of specification → Check the wheel bear-
trude past the fork. ing for looseness, and the front wheel sensor
and sensor rotor installation conditions
b (warpage caused by overtorque, wrong in-
a stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
vice and caught foreign materials). If there is
any defective part, repair or replace the de-
fective part.
Distance “a” (between the front

wheel sensor rotor and front
c. Tighten the pinch bolt “4”, pinch bolt “3”, wheel sensor)
and pinch bolt “4” to the specified torque in 0.9–1.7 mm (0.035–0.067 in)
this order.
TIP
Front wheel axle pinch bolt Measure the distance between the front wheel
21 N·m (2.1 kgf·m, 15 lb·ft) sensor rotor and front wheel sensor in several
T.
R.
places in one rotation of the front wheel. Do not

turn the front wheel while the thickness gauge is
installed. This may damage the front wheel sen-
sor rotor and the front wheel sensor.
Thickness gauge
90890-03180
Feeler gauge set
4 3 2 1 YU-26900-9
4-22
FRONT WHEEL
a 1
2
1
9. Install:
• Front brake calipers
• Front brake hose holder
Front brake caliper bolt

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

6 N·m (0.6 kgf·m, 4.4 lb·ft)
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-23
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel
110 N•m (11 kgf•m, 81 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
.
9
1
10
LS
4
5
8
7
LS
3 2 2 3
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.

Rear brake caliper Refer to “REAR BRAKE” on page 4-46.
1 Rear wheel sensor 1
2 Locknut 2 Loosen.
3 Adjusting bolt 2 Loosen.
4 Rear wheel axle nut 1
5 Washer 1
6 Rear wheel axle 1
7 Adjusting block (left) 1
8 Adjusting block (right) 1
9 Rear wheel 1
10 Brake caliper bracket 1
4-24
REAR WHEEL
Removing the brake disc and rear wheel sprocket

8 N•m (0.8 kgf•m, 5.9 lb•ft)
(5)
T.R
.
(5) New 30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
.
New
LT
3
LT
1
4
100 N•m (10 kgf•m, 74 lb•ft)
T.R
.
10
9
11
6
8
LS 7
New 2 (6)

1 Collar 1
2 Collar 1
3 Rear wheel sensor rotor 1
4 Rear brake disc 1
5 Rear wheel sprocket 1
6 Rear wheel drive hub 1
7 Oil seal 1
8 Bearing 1
9 Rear wheel drive hub damper 6
10 Collar 1
11 Rear wheel 1
4-25
REAR WHEEL
Disassembling the rear wheel
80 N•m (8.0 kgf•m, 59 lb•ft)
T.R
.
LT
3
4
5
New
New
LS
LT
New 1

1 Wheel bearing 1
2 Spacer 1
3 Oil seal 1
4 Wheel bearing ring nut 1
5 Wheel bearing 1
4-26
REAR WHEEL
EAS30910
REMOVING THE REAR WHEEL

ECA21390
1
NOTICE
Keep magnets (including magnetic pick-up
tools, magnetic screwdrivers, etc.) away 2
from the rear wheel sensor “1”, otherwise
the wheel sensor may be damaged, resulting
in improper performance of the ABS.
3. Remove:
• Rear wheel axle nut “1”
1 • Washer
• Rear wheel axle “2”
• Rear wheel
• Brake caliper bracket
ECA21400
NOTICE
Be sure to remove the rear wheel sensor be-
1. Stand the vehicle on a level surface. fore removing the brake caliper bracket, oth-
EWA13120
erwise the sensor could be damaged.
WARNING
Securely support the vehicle so that there is TIP
no danger of it falling over. Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
TIP
Place the vehicle on a maintenance stand so
that the rear wheel is elevated. 1
EAS30158
DISASSEMBLING THE REAR WHEEL

ECA21340
2. Remove: NOTICE
• Rear brake caliper “1” • Do not drop the wheel sensor rotor or sub-
• Rear wheel sensor “2” ject it to shocks.
ECA21040
NOTICE tor, wipe it off immediately.
• Do not depress the brake pedal when re-
1. Remove:
moving the brake caliper.
• Wheel bearing ring nut “1”
• Be sure not to contact the sensor electrode
to any metal part when removing the rear TIP
wheel sensor from the rear brake caliper Use the hexagon wrench (41) “2” to remove the
bracket. wheel bearing ring nut by turning it clockwise “a”.
4-27
REAR WHEEL
EAS30160
Hexagon wrench (41) CHECKING THE REAR WHEEL DRIVE HUB

90890-01525 1. Check:
Hexagon wrench (41) • Rear wheel drive hub “1”
YM-01525 Cracks/damage → Replace.
• Rear wheel drive hub dampers “2”
1
1 2
2 2
a EAS30161
CHECKING AND REPLACING THE REAR

2 WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth “a” wear → Replace the
drive sprocket, the rear wheel sprocket and
the drive chain as a set.
Bent teeth → Replace the drive sprocket, the
2. Remove: rear wheel sprocket and the drive chain as a
• Wheel bearings set.
Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-18.
EAS30159
CHECKING THE REAR WHEEL

1. Check:
• Wheel axle
• Wheel bearings
• Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-18.
2. Check:
b. Correct
• Tire
1. Drive chain roller
• Rear wheel
2. Rear wheel sprocket
Refer to “CHECKING THE TIRES” on page 2. Replace:
3-17 and “CHECKING THE WHEELS” on • Rear wheel sprocket
page 3-17. a. Remove the rear wheel sprocket nuts and
3. Measure: the rear wheel sprocket.
• Radial wheel runout b. Clean the rear wheel drive hub with a
• Lateral wheel runout clean cloth, especially the surfaces that
Refer to “CHECKING THE FRONT WHEEL” contact the sprocket.
on page 4-18. c. Install the new rear wheel sprocket.
Rear wheel sprocket nut

100 N·m (10 kgf·m, 74 lb·ft)
T.
R.
4-28
REAR WHEEL
TIP 2
Tighten the rear wheel sprocket nuts in stages
and in a crisscross pattern.
3
1
2. Install:
• Wheel bearing ring nut
TIP
Apply locking agent (LOCTITE®) onto the two
EAS30163
ASSEMBLING THE REAR WHEEL symmetric places on the circumference of the

ECA21340 threads of the wheel bearing ring nut.
NOTICE
ject it to shocks. b
tor, wipe it off immediately. a
1. Install:
• Wheel bearings New
a. Install the new wheel bearing (right side).
ECA18110
NOTICE
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made
only with the outer race “3”.
TIP
Use a socket “4” that matches the diameter of
the wheel bearing outer race.
LT LT
a. Width: two grooves of the threaded portion

b. Length: more than 40 mm (1.57 in)
3. Tighten:
• Wheel bearing ring nut “1”
TIP
Use the hexagon wrench (41) “2” to tighten the
wheel bearing ring nut by turning it counterclock-
b. Install the new wheel bearing (left side). wise “a”.
TIP
Place a suitable washer “1” between the socket Hexagon wrench (41)
“2” and the bearing “3” outside diameter. 90890-01525
Hexagon wrench (41)
Install depth “a” YM-01525
4.5–5.5 mm (0.18–0.22 in)
4-29
REAR WHEEL
3. Measure:
Wheel bearing ring nut • Wheel sensor rotor runout
T.
R.
80 N·m (8.0 kgf·m, 59 lb·ft) Refer to “MAINTENANCE OF THE FRONT
LOCTITE® WHEEL SENSOR AND SENSOR ROTOR”
on page 4-20.
EAS30164
1 ADJUSTING THE REAR WHEEL STATIC
BALANCE
TIP
• After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
• Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-21.
2
a EAS30165
INSTALLING THE REAR WHEEL (DISC

BRAKE)
1. Install:
• Rear brake disc
• Rear wheel sensor rotor
EAS30167
Rear brake disc bolt
MAINTENANCE OF THE REAR WHEEL
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
SENSOR AND SENSOR ROTOR

R.
ECA21060
LOCTITE®
NOTICE Rear wheel sensor rotor bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
• Handle the ABS components with care
since they have been accurately adjusted. ECA19150
Keep them away from dirt and do not sub- NOTICE

ject them to shocks. Replace the brake disc bolts with new ones.
• The rear wheel sensor cannot be disassem-
bled. Do not attempt to disassemble it. If TIP
faulty, replace with a new one. • Install the brake disc so that the recessed por-
• Keep any type of magnets (including mag- tions of the bolt holes “a” face away from the
netic pick-up tools, magnetic screwdrivers, hub.
etc.) away from the rear wheel sensor or • Tighten the brake disc bolts in stages and in a
rear wheel sensor rotor. crisscross pattern.
• Do not drop or shock the wheel sensor or
the wheel sensor rotor.
1. Check: a
• Rear wheel sensor
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR”
on page 4-20.
2. Check:
LT
• Rear wheel sensor rotor
Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR”
on page 4-20.
4-30
REAR WHEEL
• Washer
• Rear wheel axle nut
LT
TIP
• Do not install the brake caliper.
• Align the slot “a” in the swingarm with the pro-
jection “b” of the brake caliper bracket.
• Install the adjusting block (left side) so that pro-
jections “c” is facing outward.
• Install the adjusting block (right side) so that
sharp-edged corner “d” is facing outward.
ECA21011
NOTICE
• Do not drop the wheel sensor rotor or sub- a
ject it to shocks.
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones. b
TIP
Install the wheel sensor rotor with the stamped
mark “b” facing outward.
2. Install:
• Rear wheel sprocket
Refer to “CHECKING AND REPLACING d
THE REAR WHEEL SPROCKET” on page
4-28.
3. Check:
• Rear brake disc
Refer to “CHECKING THE REAR BRAKE
DISC” on page 4-50. d
4. Lubricate: 6. Install:
• Oil seal lips • Rear brake caliper
• Rear brake caliper bolts
Recommended lubricant 7. Adjust:
Lithium-soap-based grease • Drive chain slack
Refer to “Adjusting the drive chain slack” on
5. Install:
page 3-19.
• Collars
• Brake caliper bracket
• Rear wheel
• Adjusting blocks
• Rear wheel axle
4-31
REAR WHEEL
TIP
stand) When installing the rear wheel sensor, check the
30.0–45.0 mm (1.18–1.77 in) rear wheel sensor lead for twists.
Drive chain slack (Sidestand) 10.Measure:
30.0–45.0 mm (1.18–1.77 in) • Distance “a”
(between the wheel sensor rotor “1” and rear
8. Tighten:
wheel sensor “2”)
• Rear wheel axle nut
Out of specification → Check the wheel bear-
ing for looseness, and the rear wheel sensor
Rear wheel axle nut and sensor rotor installation conditions
110 N·m (11 kgf·m, 81 lb·ft) (warpage caused by overtorque, wrong in-
T.
R.
Rear brake caliper bolt (front) stallation direction, rotor decentering, LOC-
27 N·m (2.7 kgf·m, 20 lb·ft) TITE® on the mounting surface of the rotor,
Rear brake caliper bolt (rear) deformation caused by an impact during ser-
12 N·m (1.2 kgf·m, 8.9 lb·ft) vice and caught foreign materials). If there is
LOCTITE® any defective part, repair or replace the de-
EWA13500
fective part.
WARNING
Distance “a” (between the rear
Make sure the brake hose is routed properly. wheel sensor rotor and rear
wheel sensor)
TIP
1.1–1.7 mm (0.043–0.067 in)
When tightening the wheel axle nut, there
should be no clearance “a” between the adjust- TIP
ing block “1” and adjusting bolt “2”.
Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
A B
a places in one rotation of the rear wheel. Do not
a turn the rear wheel while the thickness gauge is
installed. This may damage the rear wheel sen-
sor rotor and the rear wheel sensor.
Thickness gauge
90890-03180
2 1 Feeler gauge set
2
1 YU-26900-9
A. Left side
B. Right side
9. Install:
• Rear wheel sensor
Rear wheel sensor bolt 1

7 N·m (0.7 kgf·m, 5.2 lb·ft) 2
T.
R.
ECA21080
NOTICE
1 2 a
Make sure there are no foreign materials in
the rear wheel sensor rotor and rear wheel
sensor. Foreign materials cause damage to
the rear wheel sensor rotor and rear wheel
sensor.
4-32
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
6 5 N•m (0.5 kgf•m, 3.7 lb•ft)
5
T.R
.
8
9
New
3
7 4
2 1
FW
D
35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
.

The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Front reflector 1
8 Bleed screw 1
9 Bleed screw 1 Right brake caliper side.
4-33
FRONT BRAKE
Removing the front brake master cylinder

3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
2 D
1.2 N•m (0.12 kgf•m, 0.88 lb•ft) FW
T.R
.
3 6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
1
32 N•m (3.2 kgf•m, 24 lb•ft)
4
T.R
.
7 1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.
5
10
S
New
6
LT
9
8
16 N•m (1.6 kgf•m, 12 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
T.R
.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
1 Brake fluid reservoir cap stopper 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir bracket 1
7 Brake fluid reservoir hose 1
8 Brake lever 1
9 Front brake light switch lead connector 2 Disconnect.
10 Brake hose union bolt 1
4-34
FRONT BRAKE
Removing the front brake master cylinder

3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
D
1.2 N•m (0.12 kgf•m, 0.88 lb•ft) FW
T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.
S
11 New
LT
12
14
15
13
16 N•m (1.6 kgf•m, 12 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
T.R
.

11 Brake hose gasket 2
12 Brake hose 1
13 Front brake master cylinder holder 1
14 Front brake master cylinder 1
15 Front brake light switch 1
4-35
FRONT BRAKE
Disassembling the front brake master cylinder
5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
2
3
BF
4
1 New
BF
1 New

1 Brake master cylinder kit 1
2 Bleed screw 1
3 Cap 1
4 Brake master cylinder body 1
4-36
FRONT BRAKE
Removing the front brake calipers

6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
1 2
3 4 New
6
32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
FW 35 N•m (3.5 kgf•m, 26 lb•ft)

D
T.R
.

Drain.
1 Front reflector 1
5 Brake hose 1
4-37
FRONT BRAKE
Disassembling the front brake calipers

5 N•m (0.5 kgf•m, 3.7 lb•ft) LS
T.R
.
8
FW 9
D
5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
New
2 New 4
1 S
6
New 5 7 New
6
S
BF
6 7 New
7
New 5 New
7
BF New 6 New S

1 Brake pad clip 2
2 Brake pad pin 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Bleed screw 1
9 Bleed screw 1 Right brake caliper side.
4-38
FRONT BRAKE
EAS30168
e. Measure the runout 1.5 mm (0.06 in) be-
INTRODUCTION
EWA14101
low the edge of the brake disc.
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly. 4. Measure:
• Never use solvents on internal brake com- • Brake disc thickness
ponents. Measure the brake disc thickness at a few dif-
• Use only clean or new brake fluid for clean- ferent locations.
ing brake components. Out of specification → Replace.
• Brake fluid may damage painted surfaces Brake disc thickness limit
and plastic parts. Therefore, always clean 4.5 mm (0.18 in)
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS30169
CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake
discs. 5. Adjust:
1. Remove: • Brake disc runout
• Front wheel a. Remove the brake disc.
Refer to “FRONT WHEEL” on page 4-16. b. Rotate the brake disc by two bolt holes.
2. Check: c. Install the brake disc.
• Front brake disc
Damage/galling → Replace. Front brake disc bolt
3. Measure: 17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
• Brake disc runout LOCTITE®

Out of specification → Correct the brake disc
ECA19150
runout or replace the brake disc.
NOTICE
Brake disc runout limit (as mea- Replace the brake disc bolts with new ones.
sured on wheel)
0.10 mm (0.0039 in) TIP
Tighten the brake disc bolts in stages and in a
a. Place the vehicle on a maintenance stand crisscross pattern.
so that the front wheel is elevated.
b. Before measuring the brake disc runout,
turn the handlebar to the left or right to en-
sure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
4-39
FRONT BRAKE
1
LT
d. Measure the brake disc runout. 3. Measure:

e. If out of specification, repeat the adjust- • Brake pad wear limit “a”
ment steps until the brake disc runout is Out of specification → Replace the brake
within specification. pads as a set.
f. If the brake disc runout cannot be brought
within specification, replace the brake Brake pad lining thickness
disc. 4.5 mm (0.18 in)
6. Install: Limit
0.5 mm (0.02 in)
• Front wheel
Refer to “FRONT WHEEL” on page 4-16.
EAS30170
REPLACING THE FRONT BRAKE PADS

The following procedure applies to both brake
calipers. a
TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Remove: 4. Remove:
• Brake pad clips “1” • Brake caliper
• Brake pad pin “2” 5. Install:
• Brake pad spring “3” • Brake pads
3 • Brake pad spring
TIP
Always install new brake pads and new brake
pad spring as a set.
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
1 b. Loosen the bleed screw and push the
2 brake caliper pistons into the brake caliper
2. Remove: with your finger.
• Brake pads “1”
4-40
FRONT BRAKE
1
2
c. Tighten the bleed screw. 8. Check:

• Brake lever operation
Brake caliper bleed screw Soft or spongy feeling → Bleed the brake sys-
5 N·m (0.5 kgf·m, 3.7 lb·ft) tem.
T.
R.
Refer to “BLEEDING THE HYDRAULIC

d. Install the brake pads and brake pad
spring.
TIP EAS30171
REMOVING THE FRONT BRAKE CALIPERS

The arrow mark “a” on the brake pad spring
must point in the direction of disc rotation.
brake calipers.
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
• Brake hose gaskets “2”
• Brake hose “3”
TIP
Put the end of the brake hose into a container
6. Install: and pump out the brake fluid carefully.
• Brake pad pin
• Brake pad clips 3
• Front brake caliper
1
Front brake caliper bolt
35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
7. Check: 2
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID EAS30172
LEVEL” on page 3-13. DISASSEMBLING THE FRONT BRAKE

CALIPERS
brake calipers.
1. Remove:
• Brake caliper pistons “1”
• Brake caliper piston dust seals “2”
• Brake caliper piston seals “3”
4-41
FRONT BRAKE
1 1 • Brake caliper cylinders “2”

Scratches/wear → Replace the brake caliper
assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
2 • Brake fluid delivery passages
2
(brake caliper body)
Obstruction → Blow out with compressed air.
3 3 EWA13611
WARNING
a. Secure the right side brake caliper pistons
with a piece of wood “a”. Whenever a brake caliper is disassembled,
b. Blow compressed air into the brake hose replace the brake caliper piston dust seals
joint opening “b” to force out the left side and brake caliper piston seals.
pistons from the brake caliper.
EWA17060
WARNING 3
• Never try to pry out the brake caliper pis-
tons.
• Do not loosen the bolts “4”. 2
1 1
4
EAS30174
ASSEMBLING THE FRONT BRAKE

CALIPERS
EWA16560
a b
WARNING
• Before installation, all internal brake com-
c. Remove the brake caliper piston dust ponents should be cleaned and lubricated
seals and brake caliper piston seals. with clean or new brake fluid.
d. Repeat the previous steps to force out the • Never use solvents on internal brake com-
right side pistons from the brake caliper. ponents as they will cause the brake caliper
piston dust seals and brake caliper piston
EAS30173
seals to swell and distort.
CHECKING THE FRONT BRAKE CALIPERS • Whenever a brake caliper is disassembled,
The following procedure applies to both of the replace the brake caliper piston dust seals
brake calipers. and brake caliper piston seals.
Recommended brake component
replacement schedule
Specified brake fluid
Brake pads If necessary DOT 4
Piston seals Every two years
EAS30175
Piston dust seals Every two years INSTALLING THE FRONT BRAKE CALIPERS
Brake hoses Every four years The following procedure applies to both of the
Every two years and brake calipers.
Brake fluid whenever the brake is 1. Install:
disassembled • Front brake caliper “1”
(temporarily)
1. Check:
• Brake caliper pistons “1” • Brake hose gaskets New
Rust/scratches/wear → Replace the brake • Brake hose “2”
caliper pistons. • Brake hose union bolt “3”
4-42
FRONT BRAKE

Front brake hose union bolt is already in the system. Mixing brake fluids
T.
R.
32 N·m (3.2 kgf·m, 24 lb·ft) may result in a harmful chemical reaction,
EWA13531
leading to poor brake performance.
WARNING • When refilling, be careful that water does
Proper brake hose routing is essential to in- not enter the brake fluid reservoir. Water
sure safe vehicle operation. will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA14170
ECA13540
NOTICE
NOTICE
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe Brake fluid may damage painted surfaces
“a” touches the projection “b” on the brake and plastic parts. Therefore, always clean up
caliper. any spilt brake fluid immediately.
5. Bleed:
2 • Brake system
a BRAKE SYSTEM (ABS)” on page 3-16.
6. Check:
3 b • Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
1
LEVEL” on page 3-13.
2. Remove:
3. Install:
• Brake pads a
• Brake pad spring
• Brake pad pin
• Brake pad clips
Front brake caliper bolt 7. Check:

35 N·m (3.5 kgf·m, 26 lb·ft)
T.

R.
Refer to “REPLACING THE FRONT BRAKE Soft or spongy feeling → Bleed the brake sys-
PADS” on page 4-40. tem.
4. Fill: Refer to “BLEEDING THE HYDRAULIC
• Brake master cylinder reservoir BRAKE SYSTEM (ABS)” on page 3-16.
(with the specified amount of the specified EAS30179
brake fluid) REMOVING THE FRONT BRAKE MASTER

CYLINDER
Specified brake fluid TIP
DOT 4
Before removing the front brake master cylinder,
EWA13090 drain the brake fluid from the entire brake sys-
WARNING tem.
• Use only the designated brake fluid. Other 1. Remove:
brake fluids may cause the rubber seals to • Brake hose union bolt “1”
deteriorate, causing leakage and poor • Brake hose gaskets “2”
brake performance. • Brake hose “3”
4-43
FRONT BRAKE
EAS30181
TIP ASSEMBLING THE FRONT BRAKE MASTER
To collect any remaining brake fluid, place a CYLINDER
container under the master cylinder and the end EWA13520
of the brake hose. WARNING

ponents should be cleaned and lubricated
with clean or new brake fluid.
1 • Never use solvents on internal brake com-
ponents.

2 DOT 4
3
1. Install:
Brake master cylinder kit “1”
EAS30725
(to the brake master cylinder body “2”)
CHECKING THE FRONT BRAKE MASTER
CYLINDER TIP
1. Check: Align the projection “a” on the brake master cyl-
• Brake master cylinder inder kit with the hole “b” in the brake master cyl-
Damage/scratches/wear → Replace. inder body.
• Brake fluid delivery passages
(brake master cylinder body)
2. Check: 1 b
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake fluid reservoir “1” a
• Brake fluid reservoir diaphragm holder “2”
Cracks/damage → Replace. 2
• Brake fluid reservoir diaphragm “3” EAS30182
Damage/wear → Replace. INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Front brake master cylinder
2 • Front brake master cylinder holder
3 Front brake master cylinder hold-
er bolt
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft)

1
TIP
4. Check: • Install the front brake master cylinder holder

• Brake hoses with the “UP” mark “a” facing up.
Cracks/damage/wear → Replace. • Align the end of the front brake master cylinder
with the punch mark “b” on the handlebar.
• First, tighten the upper bolt, then the lower bolt.
4-44
FRONT BRAKE
EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
b
brake performance.
a
may result in a harmful chemical reaction,
2. Install: • When refilling, be careful that water does
• Brake hose gaskets New not enter the brake master cylinder reser-
• Brake hose voir. Water will significantly lower the boil-
• Brake hose union bolt ing point of the brake fluid and could cause
vapor lock.
Front brake hose union bolt ECA13540
32 N·m (3.2 kgf·m, 24 lb·ft) NOTICE

T.
R.
EWA13531
Brake fluid may damage painted surfaces
WARNING and plastic parts. Therefore, always clean up
Proper brake hose routing is essential to in-
sure safe vehicle operation. 4. Bleed:
• Brake system
TIP Refer to “BLEEDING THE HYDRAULIC
• When installing the brake hose onto the master BRAKE SYSTEM (ABS)” on page 3-16.
cylinder, make sure the projection “a” on the 5. Check:
brake hose touches the projection “b” on the • Brake fluid level
master cylinder. Below the minimum level mark “a” → Add the
• While holding the brake hose, tighten the union specified brake fluid to the proper level.
bolt as shown. Refer to “CHECKING THE BRAKE FLUID
• Turn the handlebars to the left and right to LEVEL” on page 3-13.
make sure the brake hose does not touch other
parts (e.g., wire harness, cables, leads). Cor-
rect if necessary.
a
b
6. Check:
Soft or spongy feeling → Bleed the brake sys-
3. Fill: tem.
• Brake master cylinder reservoir Refer to “BLEEDING THE HYDRAULIC
(with the specified amount of the specified BRAKE SYSTEM (ABS)” on page 3-16.
brake fluid)

DOT 4
4-45
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads
D
FW
5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
8 3
S
7 2
1
LT
5 17 N•m (1.7 kgf•m, 13 lb•ft)

T.R
.
6 2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
4 12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
6
5
1 Screw plug 1
2 Brake pad retaining bolt 1
3 Rear brake caliper 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad insulator 2
8 Bleed screw 1
4-46
REAR BRAKE
Removing the rear brake master cylinder

26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
2
3
12 6 4
New
1
7 N•m (0.7 kgf•m, 5.2 lb•ft) 7
New
T.R
.
New
11 5
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)

LT
LT
T.R
.
9 13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
LT 10 8
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.

Drain.
1 Brake fluid reservoir 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir hose 1
6 Rear brake hose 1
7 Rear brake hose joint 1
8 Footrest assembly (right) 1
9 Rear brake light switch 1
10 Footrest plate 1
Do not disassemble the rear brake master
11 Rear brake master cylinder 1 cylinder.
12 Brake fluid reservoir bracket 1
4-47
REAR BRAKE
Removing the rear brake caliper
D
FW
32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
1
New 2
3
4
LT
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.

Drain.
3 Brake hose 1
4 Rear brake caliper 1
4-48
REAR BRAKE
Disassembling the rear brake caliper
7 D
FW
8 New
9 New 5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
10
BF
2
1
4
5
11
3
17 N•m (1.7 kgf•m, 13 lb•ft)

5
T.R
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

4
T.R
.

1 Screw plug 1
2 Brake pad retaining bolt 1
3 Brake pad 2
4 Brake pad shim 2
5 Brake pad insulator 2
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Bleed screw 1
11 Caliper bolt boot 1
4-49
REAR BRAKE
EAS30183
INTRODUCTION Brake disc thickness limit

EWA14101
4.5 mm (0.18 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc runout
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISCS” on page 4-39.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
sembly. 6. Install:
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-24.
• Use only clean or new brake fluid for clean- EAS30185
ing brake components. REPLACING THE REAR BRAKE PADS

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

EAS30184
CHECKING THE REAR BRAKE DISC 4.5 mm (0.18 in)

Limit
1. Remove:
1.0 mm (0.04 in)
• Rear wheel
Refer to “REAR WHEEL” on page 4-24.
2. Check:
• Rear brake disc
Damage/galling → Replace.
3. Measure: a
• Brake disc runout
Out of specification → Correct the brake disc
runout or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-39.
Brake disc runout limit (as mea- 2. Install:

sured on wheel) • Brake pad insulators
0.15 mm (0.0059 in) • Brake pad shims
(onto the brake pads)
4. Measure: • Brake pad spring
• Brake disc thickness (into the rear brake caliper)
Measure the brake disc thickness at a few dif- • Brake pads
ferent locations.
Out of specification → Replace.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-39.
4-50
REAR BRAKE
TIP
Always install new brake pads, brake pad insu- a
lators, brake pad shims, and brake pad spring as
a set.
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
b. Loosen the bleed screw and push the
brake caliper piston into the brake caliper
with your finger.
3. Lubricate:
Silicone grease
1
ECA14150
2 NOTICE
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.
c. Tighten the bleed screw. 4. Install:
• Rear brake caliper
Brake caliper bleed screw • Brake pad retaining bolts
5 N·m (0.5 kgf·m, 3.7 lb·ft) • Screw plug
T.
R.
d. Install the brake pad insulators and brake Rear brake caliper bolt (front)
pad shims onto each brake pads. 27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
TIP Rear brake caliper bolt (rear)

Apply silicone grease between the brake pad in- 12 N·m (1.2 kgf·m, 8.9 lb·ft)
sulator and brake pad shim. LOCTITE®
Rear brake pad retaining bolt
ECA14150
17 N·m (1.7 kgf·m, 13 lb·ft)
NOTICE Rear brake caliper screw plug
• Do not allow grease to contact the brake 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
pads.
• Remove any excess grease. 5. Check:
• Brake fluid level
e. Install the brake pads and brake pad Below the minimum level mark “a” → Add the
spring. specified brake fluid to the proper level.
TIP Refer to “CHECKING THE BRAKE FLUID
The longer tangs “a” of the brake pad spring LEVEL” on page 3-13.
must point in the direction of the brake caliper
piston.
4-51
REAR BRAKE
6. Check: EWA13550
• Brake pedal operation WARNING

Soft or spongy feeling → Bleed the brake sys- • Cover the brake caliper piston with a rag.
tem. Be careful not to get injured when the pis-
Refer to “BLEEDING THE HYDRAULIC ton is expelled from the brake caliper.
BRAKE SYSTEM (ABS)” on page 3-16. • Never try to pry out the brake caliper pis-
ton.
EAS30186
REMOVING THE REAR BRAKE CALIPER

TIP
a
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
• Brake hose gaskets “2”
• Brake hose “3”
TIP
Put the end of the brake hose into a container b. Remove the brake caliper piston dust seal
and pump out the brake fluid carefully. and brake caliper piston seal.
3 EAS30188
1 CHECKING THE REAR BRAKE CALIPER
Recommended brake component
2 replacement schedule
Brake pads If necessary
Piston seal Every two years
Piston dust seal Every two years
Brake hoses Every four years
Every two years and
EAS30187
Brake fluid whenever the brake is
DISASSEMBLING THE REAR BRAKE disassembled
CALIPER
1. Remove: 1. Check:
• Brake caliper piston “1” • Brake caliper piston “1”
• Brake caliper piston dust seal “2” Rust/scratches/wear → Replace the brake
• Brake caliper piston seal “3” caliper piston.
• Brake caliper cylinder “2”
Scratches/wear → Replace the brake caliper
1 assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
2
assembly.
• Brake fluid delivery passages
(brake caliper body)
3 Obstruction → Blow out with compressed air.
EWA13601
WARNING
a. Blow compressed air into the brake hose
Whenever a brake caliper is disassembled,
joint opening “a” to force out the piston
replace the brake caliper piston dust seal
from the brake caliper.
and brake caliper piston seal.
4-52
REAR BRAKE
2
1 3
2
1
3
EWA13531
2. Check: WARNING
• Rear brake caliper bracket
Proper brake hose routing is essential to in-
sure safe vehicle operation.
Refer to “REAR WHEEL” on page 4-24.
ECA19080
EAS30189 NOTICE
ASSEMBLING THE REAR BRAKE CALIPER When installing the brake hose onto the
EWA17080
WARNING brake caliper “1”, make sure the brake pipe

“a” passes between the projections “b” on
the brake caliper.
ponents should be cleaned and lubricated
with clean or new brake fluid. ba
• Never use solvents on internal brake com- 1
ponents as they will cause the brake caliper
piston dust seal and brake caliper piston
seal to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.

DOT 4 2. Remove:
• Rear brake caliper
EAS30190 3. Install:
INSTALLING THE REAR BRAKE CALIPER • Brake pad insulators
1. Install: • Brake pad shims
• Rear brake caliper “1” (onto the brake pads)
(temporarily) • Brake pad spring
• Brake hose gaskets New (into the rear brake caliper)
• Brake hose “2” • Brake pads
• Brake hose union bolt “3” • Rear brake caliper
Refer to “REPLACING THE REAR BRAKE
Rear brake hose union bolt PADS” on page 4-50.
32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
Rear brake caliper bolt (front)

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

12 N·m (1.2 kgf·m, 8.9 lb·ft)
LOCTITE®
Rear brake pad retaining bolt
17 N·m (1.7 kgf·m, 13 lb·ft)
Rear brake caliper screw plug
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
4-53
REAR BRAKE
4. Fill: EAS30193
REMOVING THE REAR BRAKE MASTER

• Brake fluid reservoir
CYLINDER
(with the specified amount of the specified
brake fluid) TIP
Before removing the rear brake master cylinder,
Specified brake fluid drain the brake fluid from the entire brake sys-
DOT 4 tem.
EWA13090 1. Remove:
WARNING • Rear brake hose union bolt “1”
• Use only the designated brake fluid. Other • Brake hose gaskets “2”
brake fluids may cause the rubber seals to • Rear brake hose “3”
deteriorate, causing leakage and poor TIP
brake performance. To collect any remaining brake fluid, place a
• Refill with the same type of brake fluid that container under the master cylinder and the end
is already in the system. Mixing brake fluids of the brake hose.
1
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock. 2 3
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
EAS30194
5. Bleed: CHECKING THE REAR BRAKE MASTER

• Brake system CYLINDER
Refer to “BLEEDING THE HYDRAULIC 1. Check:
BRAKE SYSTEM (ABS)” on page 3-16. • Brake master cylinder
6. Check: Damage/scratches/wear → Replace.
• Brake fluid level • Brake fluid delivery passages
Below the minimum level mark “a” → Add the (brake master cylinder body)
specified brake fluid to the proper level. Obstruction → Blow out with compressed air.
Refer to “CHECKING THE BRAKE FLUID 2. Check:
LEVEL” on page 3-13. • Brake fluid reservoir
• Brake fluid reservoir diaphragm
a 3. Check:
• Rear brake hose
• Rear brake hose joint
• Brake fluid reservoir hose
7. Check:
• Brake pedal operation
tem.
4-54
REAR BRAKE
EAS31743
THE REAR BRAKE MASTER CYLINDER 3 a

ECA23000
NOTICE
Do not disassemble the rear brake master
cylinder. If the master cylinder malfunctions, New 2 1
replace the rear brake master cylinder as-
sembly.
EAS30196
INSTALLING THE REAR BRAKE MASTER

CYLINDER 3. Fill:
1. Install: • Brake fluid reservoir
• Rear brake hose joint “1” (with the specified amount of the specified
brake fluid)
Rear brake hose joint union bolt
32 N·m (3.2 kgf·m, 24 lb·ft) Specified brake fluid
T.
R.
DOT 4
TIP
EWA13090
Make sure that the side “a” of the rear brake WARNING
hose joint contacts the projection “b” on the rear • Use only the designated brake fluid. Other
brake master cylinder.
brake fluids may cause the rubber seals to
b brake performance.
1 a • Refill with the same type of brake fluid that
1 may result in a harmful chemical reaction,
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
2. Install: ECA13540
• Rear brake hose “1” NOTICE

• Brake hose gaskets “2” New Brake fluid may damage painted surfaces
• Rear brake hose union bolt “3” and plastic parts. Therefore, always clean up
Rear brake hose union bolt
26 N·m (2.6 kgf·m, 19 lb·ft) 4. Bleed:
T.
R.
• Brake system
EWA13531 Refer to “BLEEDING THE HYDRAULIC
WARNING BRAKE SYSTEM (ABS)” on page 3-16.
Proper brake hose routing is essential to in- 5. Check:
sure safe vehicle operation. • Brake fluid level
Refer to “CABLE ROUTING” on page 2-15. Below the minimum level mark “a” → Add the
ECA14160 specified brake fluid to the proper level.
NOTICE Refer to “CHECKING THE BRAKE FLUID
When installing the brake hose onto the LEVEL” on page 3-13.
brake master cylinder, make sure the brake
pipe touches the projection “a” as shown.
4-55
REAR BRAKE
6. Check:
• Brake pedal operation
tem.
7. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-15.
8. Adjust:
• Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-31.
4-56
ABS (Anti-lock Brake System)
EAS20032

Removing the hydraulic unit assembly
27 N•m (2.7 kgf•m, 20 lb•ft)

T.R
.
2 27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
3 New 2
BF
BF
7
3 New 3 New
2 4
New
3 2
BF
3
3 New
6 5 4
3 BF
3
New
5
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Drain.
1 ABS ECU coupler 1 Disconnect.
3 Gasket 8
Front brake hose (hydraulic unit to front brake
4 1
calipers)
Front brake hose (front brake master cylinder to
5 1
hydraulic unit)
Rear brake hose (rear brake master cylinder to
6 1
hydraulic unit)
Rear brake hose (hydraulic unit to rear brake
7 1
caliper)
4-57
Removing the hydraulic unit assembly
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
27 N•m (2.7 kgf•m, 20 lb•ft)
T.R
.
BF New
BF
New New
New
BF New
BF
New
8
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

8 Hydraulic unit 1
9 Hydraulic unit bracket 1
4-58
EAS30197
REMOVING THE HYDRAULIC UNIT

ASSEMBLY 1
ECA18230
NOTICE
Unless necessary, avoid removing and in-
stalling the brake pipes of the hydraulic unit
assembly.
EWA13930
WARNING a
Refill with the same type of brake fluid that is
already in the system. Mixing fluids may re- 2. Remove:
sult in a harmful chemical reaction, leading • Brake hose union bolt “1”
to poor braking performance. TIP
ECA19790 Hold the hydraulic unit holding tool “2” with one
NOTICE hand to secure the hydraulic unit, and then loos-
• Handle the ABS components with care en the brake hose union bolt.
since they have been accurately adjusted.
Keep them away from dirt and do not sub- Hydraulic unit holding tool
ject them to shocks. 90890-01594
• Do not set the main switch to “ON” when
removing the hydraulic unit assembly.
• Do not clean with compressed air. 1
• Do not reuse the brake fluid.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. 2
• Do not allow any brake fluid to contact the 1
couplers. Brake fluid may damage the cou- 1
plers and cause bad contacts.
• If the brake pipe flare nuts for the hydraulic
unit assembly have been removed, be sure 3. Remove:
to tighten them to the specified torque and • Brake hoses
bleed the brake system. TIP
1. Disconnect: Do not operate the brake lever and brake pedal
• ABS ECU coupler “1” while removing the brake hoses.
ECA18251
TIP
NOTICE
While pushing the portion “a” of the ABS ECU
coupler, pull the lock lever up to release the lock. When removing the brake hoses, cover the
area around the hydraulic unit assembly to
ECA20080
NOTICE
catch any spilt brake fluid. Do not allow the
brake fluid to contact other parts.
Do not use a tool to disconnect the ABS ECU
coupler. 4. Remove:
• Hydraulic unit assembly “1”
TIP
• To avoid brake fluid leakage and to prevent for-
eign materials from entering the hydraulic unit
assembly, insert a rubber plug “a” or a bolt
(M10 × 1.0) into each brake hose union bolt
hole.
4-59
• When using a bolt, do not tighten the bolt until ECA21121
the bolt head touches the hydraulic unit. Other- NOTICE

wise, the brake hose union bolt seating surface If the brake hose union bolt does not turn
could be deformed. easily, replace the hydraulic unit assembly,
brake hoses, and related parts as a set.
TIP
• Apply brake fluid to the threads of the brake
a hose union bolts.
• Temporarily tighten the brake hose union bolts.
• To route the brake hose, refer to “CABLE
ROUTING” on page 2-15.
1
4
2
EAS30198
CHECKING THE HYDRAULIC UNIT

ASSEMBLY 3
1. Check:
• Hydraulic unit assembly
Cracks/damage → Replace the hydraulic unit 1
assembly and the brake hoses that are con-
nected to the assembly as a set. 4. Tighten:
EAS30200
• Brake hose union bolt
INSTALLING THE HYDRAULIC UNIT
Brake hose union bolt
ASSEMBLY
27 N·m (2.7 kgf·m, 20 lb·ft)
T.
1. Install:
R.
• Hydraulic unit assembly a. Set the hydraulic unit holding tool “1” on
ECA21371
the hydraulic unit “2”.
NOTICE
Do not remove the rubber plugs or bolts Hydraulic unit holding tool
(M10 × 1.0) installed in the brake hose union 90890-01594
bolt holes before installing the hydraulic unit
b. Insert a plate “3” that has a thickness of
assembly.
approximately 6 mm (0.24 in) between the
TIP hydraulic unit “2” and the hydraulic unit
Do not allow any foreign materials to enter the bracket bolt.
hydraulic unit assembly or the brake hoses c. Tighten the union bolt “4” for the rear
when installing the hydraulic unit assembly. brake hose (hydraulic unit to rear brake
caliper).
2. Remove:
TIP
• Rubber plugs or bolts (M10 × 1.0)
3. Install: Make sure that the pipe section “a” of the rear
• Rear brake hose (hydraulic unit to rear brake brake hose contacts the projection “b” on the hy-
caliper) “1” draulic unit holding tool.
• Rear brake hose (rear brake master cylinder
to hydraulic unit) “2” b
a
• Front brake hose (front brake master cylinder
to hydraulic unit) “3”
3
• Front brake hose (hydraulic unit to front brake
calipers) “4” 1
• Gasket New
• Brake hose union bolts
(temporarily)
4 2
4-60
d. Tighten the union bolts “5” for the rear EWA13090
brake hose (rear brake master cylinder to WARNING

hydraulic unit) and front brake hose (front • Use only the designated brake fluid. Other
brake master cylinder to hydraulic unit). brake fluids may cause the rubber seals to
TIP deteriorate, causing leakage and poor
brake performance.
Make sure that the projection “c” on the rear
brake hose and the projection “d” on the front
brake hose contact the other brake hoses as
e. Tighten the union bolt “6” for the front • When refilling, be careful that water does
brake hose (hydraulic unit to front brake not enter the brake fluid reservoir. Water
calipers). will significantly lower the boiling point of
TIP the brake fluid and could cause vapor lock.
Make sure that the pipe section “e” of the front ECA13540
brake hose contacts the projection “f” on the hy- NOTICE

draulic unit bracket. Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
6 e any spilt brake fluid immediately.
f 7. Bleed:
• Brake system
5 Refer to “BLEEDING THE HYDRAULIC
d 8. Check the operation of the hydraulic unit ac-
5 cording to the brake lever and the brake ped-
c al response. (Refer to “HYDRAULIC UNIT
OPERATION TEST” on page 4-61.)
ECA14770
5. Connect:
NOTICE
• ABS ECU coupler “1”
TIP
Always check the operation of the hydraulic
unit according to the brake lever and the
Connect the ABS ECU coupler, and then push
brake pedal response.
the lock lever of the coupler in the direction of the
arrow shown. 9. Delete the fault codes. (Refer to “[B-3] DE-
LETING THE FAULT CODES” on page
8-146.)
1 10.Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-65.)
EAS30201
HYDRAULIC UNIT OPERATION TEST

The reaction-force pulsating action generated in
the brake lever and brake pedal when the ABS
is activated can be tested when the vehicle is
stopped.
The hydraulic unit operation can be tested using
6. Fill: the following two methods.
• Brake master cylinder reservoir • Brake line routing confirmation: this test
• Brake fluid reservoir checks the function of the ABS after the sys-
(with the specified amount of the specified tem was disassembled, adjusted, or serviced.
brake fluid) • ABS reaction-force confirmation: this test gen-
erates the same reaction-force pulsating action
that is generated in the brake lever and brake
DOT 4
pedal when the ABS is activated.
4-61
Brake line routing confirmation

EWA13120 1
WARNING
TIP
• For the brake line routing confirmation, use the
diagnosis of function of the Yamaha diagnostic
tool.
• Before performing the brake line routing confir- 6. Start the Yamaha diagnostic tool and display
mation, make sure that no malfunctions have the diagnosis of function screen.
been detected in the ABS ECU and that the 7. Select code No. 2, “Brake line routing confir-
wheels are not rotating. mation”.
1. Place the vehicle on a maintenance stand. 8. Click “Actuator Check” “1”, and then operate
2. Turn the main switch to “OFF”. the brake lever “2” and brake pedal “3” simul-
3. Remove: taneously.
• Rider seat TIP
Refer to “GENERAL CHASSIS (1)” on page • The hydraulic unit operates 1 second after the
4-1. brake lever and brake pedal are operated si-
4. Check: multaneously and continues for approximately
• Battery voltage 5 seconds.
Lower than 12.8 V → Charge or replace the • The operation of the hydraulic unit can be con-
battery. firmed using the indicator.
On: The hydraulic unit is operating.
Battery voltage
Flashing: The conditions for operating the hy-
Higher than 12.8 V
draulic unit have not been met.
Off: The brake lever and brake pedal are not
TIP
being operated.
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform brake line routing
confirmation.
5. Removing the protective cap “1”, and then

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

90890-03257
Yamaha diagnostic tool (A/I) 2 3
90890-03254
4-62
9. Check: 1. Place the vehicle on a maintenance stand.

• Hydraulic unit operation 2. Turn the main switch to “OFF”.
Click “Actuator Check”, a single pulse will be 3. Remove:
generated in the brake lever “1”, brake pedal • Rider seat
“2”, and again in the brake lever “1”, in this or- Refer to “GENERAL CHASSIS (1)” on page
der. 4-1.
4. Check:
• Battery voltage
Lower than 12.8 V → Charge or replace the
battery.
Battery voltage
Higher than 12.8 V
1 2 TIP
If the battery voltage is lower than 12.8 V, charge
TIP the battery, and then perform ABS reaction-
force confirmation.
“ON” and “OFF” on the tool screen indicate
when the brakes are being applied and released
respectively.
ECA17371
NOTICE
• Check that the pulse is felt in the brake le-
ver, brake pedal, and again in the brake le-
ver, in this order.
• If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
correctly to the hydraulic unit assembly. 5. Removing the protective cap “1”, and then
• If the pulse is hardly felt in either the brake connect the Yamaha diagnostic tool to the
lever or brake pedal, check that the brake Yamaha diagnostic tool coupler (4P).
hoses and brake pipes are connected cor- Yamaha diagnostic tool USB (US)
rectly to the hydraulic unit assembly. 90890-03257
10.If the operation of the hydraulic unit is normal, Yamaha diagnostic tool (A/I)
delete all of the fault codes. 90890-03254
ABS reaction-force confirmation 1

EWA13120
WARNING
TIP
• For the ABS reaction-force confirmation, use
the diagnosis of function of the Yamaha diag-
nostic tool. For more information, refer to the
operation manual of the Yamaha diagnostic
tool.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
4-63
6. Start the Yamaha diagnostic tool and display

the diagnosis of function screen.
7. Select code No. 1, “ABS reaction-force con-
firmation”.
8. Click “Actuator Check” “1”, and then operate
the brake lever “2” and brake pedal “3” simul-
taneously.
TIP
• The hydraulic unit operates 1 second after the 1
brake lever and brake pedal are operated si-
multaneously and continues for approximately 10.After the pulsating action has stopped in the
5 seconds. brake lever, it is generated in the brake pedal
• The operation of the hydraulic unit can be con- “1” and continues for a few seconds.
firmed using the indicator. TIP
On: The hydraulic unit is operating. • The reaction-force pulsating action consists of
Flashing: The conditions for operating the hy- quick pulses.
draulic unit have not been met. • Be sure to continue operating the brake lever
Off: The brake lever and brake pedal are not and brake pedal even after the pulsating action
being operated. has stopped.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
11.After the pulsating action has stopped in the

brake pedal, it is generated in the brake lever
and continues for a few seconds.
TIP
• The reaction-force pulsating action consists of
2 3 quick pulses.
• “ON” and “OFF” on the tool screen indicate
9. A reaction-force pulsating action is generated when the brakes are being applied and re-
in the brake lever “1” and continues for a few leased respectively.
seconds. ECA17371
TIP NOTICE
• The reaction-force pulsating action consists of • Check that the pulse is felt in the brake le-
quick pulses. ver, brake pedal, and again in the brake le-
• Be sure to continue operating the brake lever ver, in this order.
and brake pedal even after the pulsating action • If the pulse is felt in the brake pedal before
has stopped. it is felt in the brake lever, check that the
• “ON” and “OFF” on the tool screen indicate brake hoses and brake pipes are connected
when the brakes are being applied and re- correctly to the hydraulic unit assembly.
leased respectively.
4-64
• If the pulse is hardly felt in either the brake

lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
12.Turn the main switch to “OFF”.
13.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
stall the protective cap.
14.Turn the main switch to “ON”.
15.Set the engine stop switch to “ ”.
16.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage → Replace the hydraulic
unit, brake pipes, and related parts as a set.
17.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
EAS30202
CHECKING THE ABS WARNING LIGHT

After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 5 km/h
(3.1 mi/h) or performing a trial run.
4-65
HANDLEBARS
EAS20033
HANDLEBARS
Removing the handlebars
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
115 N•m (11.5 kgf•m, 85 lb•ft)
T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.
10 LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
LS
11
8
7
LS
3
LS 4
32 N•m (3.2 kgf•m, 24 lb•ft) 9 5
T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft) 2

T.R
.
LT 1
4.3 N•m (0.43 kgf•m, 3.2 lb•ft)
T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

6
T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.
4.5 N•m (0.45 kgf•m, 3.3 lb•ft)

T.R
.

Headlight assembly 4-13.
1 Grip end (left) 1
2 Handlebar grip 1
3 Clutch switch connector 2 Disconnect.
4 Horn connector 2 Disconnect.
5 Handlebar switch coupler (left) 2 Disconnect.
6 Handlebar switch (left) 1
7 Clutch cable 1 Disconnect.
8 Clutch lever assembly 1
9 Clutch switch 1
10 Grip end (right) 1
11 Throttle cable housing 1
4-66
HANDLEBARS
Removing the handlebars
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
115 N•m (11.5 kgf•m, 85 lb•ft)
T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft) 20

T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.
LS 18 25
19
13
12
17 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
22 11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
14 LS
16 24 23
21
LS
15 LS
32 N•m (3.2 kgf•m, 24 lb•ft)

T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

T.R
.
LT
4.3 N•m (0.43 kgf•m, 3.2 lb•ft)
T.R
.
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.
4.5 N•m (0.45 kgf•m, 3.3 lb•ft)

T.R
.

12 Throttle cable 2 Disconnect.
13 Throttle grip 1
14 Front brake light switch connector 2 Disconnect.
15 Handlebar switch coupler (right) 2 Disconnect.
16 Handlebar switch (right) 1
17 Front brake master cylinder holder 1
18 Front brake master cylinder assembly 1
19 Main switch coupler 2 Disconnect.
20 Upper bracket 1
21 Handlebar (left) 1
22 Handlebar (right) 1
23 Rectifier/regulator bracket 1
24 Rectifier/regulator 1
25 Coupler holder (left) 1
4-67
HANDLEBARS
EAS30203
• Align the mating surfaces of the brake master
REMOVING THE HANDLEBARS
cylinder holder with the punch mark “b” on the
EWA13120
handlebar.
WARNING
2. Remove: 1
• Handlebar grip “1”
TIP
Blow compressed air between the handlebar b
and the handlebar grip, and gradually push the a
grip off the handlebar. 2
3. Install:
• Handlebar switch (right) “1”
Handlebar switch screw

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
TIP
Align the projection “a” on the right handlebar
switch with the hole “b” on the right handlebar.
EAS30204 1
CHECKING THE HANDLEBARS
1. Check:
• Handlebar (left) a
• Handlebar (right) b
Bends/cracks/damage → Replace.
EWA13690
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it. 4. Install:
• Throttle grip
EAS30205
INSTALLING THE HANDLEBARS • Throttle cables

1. Stand the vehicle on a level surface. • Throttle cable housing “1”
EWA13120
WARNING Throttle cable housing bolt

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.

R.

TIP
2. Install: Align the projection “a” on the throttle cable
• Front brake master cylinder “1” housing with the hole “b” in the right handlebar.
• Front brake master cylinder holder “2”
Front brake master cylinder bolt

16 N·m (1.6 kgf·m, 12 lb·ft)
T.
R.
TIP
• Install the brake master cylinder holder with the
“UP” mark “a” facing up.
4-68
HANDLEBARS
TIP
1 Align the projection “a” on the left handlebar
switch with the hole “b” in the left handlebar.
a
1
1
b b
5. Install: a
• Grip end (right) “1”
TIP
There should be 1–3 mm (0.04–0.12 in) of clear-
8. Install:
ance “a” between the throttle grip and the right
• Handlebar grip “1”
grip end.
• Grip end (left) “2”
Grip end bolt

a 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
a. Apply a thin coat of rubber adhesive onto
the end of the left handlebar.
b. Slide the handlebar grip over the end of
the left handlebar.
c. Wipe off any excess rubber adhesive with
1
a clean rag.
EWA13700
6. Install: WARNING
• Clutch lever assembly “1” Do not touch the handlebar grip until the rub-
Clutch lever assembly bolt ber adhesive has fully dried.
11 N·m (1.1 kgf·m, 8.1 lb·ft) TIP
T.
R.
There should be 1–3 mm (0.04–0.12 in) of clear-

TIP
ance “a” between the handlebar grip and the grip
Align the mating surfaces of the clutch lever as- end.
sembly with the punch mark “a” on the left han-
dlebar.
a
9. Check:
• Cable routing
7. Install:
TIP
• Handlebar switch (left) “1”
Make sure the main switch lead, brake hoses,
Handlebar switch screw throttle cables, clutch cable, and handlebar
3.5 N·m (0.35 kgf·m, 2.6 lb·ft) switch leads are routed properly. Refer to “CA-
T.
R.
BLE ROUTING” on page 2-15.
4-69
HANDLEBARS
10.Adjust:
• Clutch cable free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-13.
Clutch lever free play

10.0–15.0 mm (0.39–0.59 in)
11.Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-32.
Throttle grip free play

3.0–5.0 mm (0.12–0.20 in)
4-70
FRONT FORK
EAS20034
FRONT FORK
Removing the front fork legs
32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
T.R
.
4 3 26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
5
23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.
6
7
6
1
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.

the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-16.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Handlebar pinch bolt 1 Loosen.
4 Handlebar bolt 1 Loosen.
5 Cap bolt 1 Loosen.
6 Lower bracket pinch bolt 2 Loosen.
7 Front fork leg 1
4-71
FRONT FORK
Disassembling the front fork legs

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
11
10
9
21 N•m (2.1 kgf•m, 15 lb•ft)

T.R
.

the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Guide 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Damper adjusting rod 1 1
8 Damper adjusting rod 2 1
9 Dust seal 1
10 Oil seal clip 1
11 Outer tube 1
4-72
FRONT FORK
Disassembling the front fork legs

23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
15 N•m (1.5 kgf•m, 11 lb•ft) 15
T.R
.
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
17
16
14
13
12
21 N•m (2.1 kgf•m, 15 lb•ft)

T.R
.

12 Oil seal 1
13 Washer 1
14 Outer tube bushing 1
15 Inner tube bushing 1
16 Damper rod assembly 1
17 Inner tube 1
4-73
FRONT FORK
EAS30206 EAS30207
REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the The following procedure applies to both of the
front fork legs. front fork legs.
1. Stand the vehicle on a level surface. 1. Turn the spring preload adjusting nut “1”
EWA13120
counterclockwise until it stops.
WARNING
no danger of it falling over. 1
TIP
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Remove:
Refer to “FRONT BRAKE” on page 4-33.
• Front wheel 2. Remove:
Refer to “FRONT WHEEL” on page 4-16. • Cap bolt “1”
3. Loosen: (from the damper rod assembly)
• Handlebar pinch bolt “1” • Guide “2”
• Upper bracket pinch bolt “2” • Spacer “3”
• Handlebar bolt “3” • Locknut “4”
• Cap bolt “4” a. Press down on the spacer with the fork
• Lower bracket pinch bolts “5” spring compressor “5”.
EWA13640
WARNING b. Install the rod holder “6” between the lock-

nut “4” and the guide “2”.
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg. Fork spring compressor
90890-01441
4 YM-01441
Rod holder
90890-01434
3 Damper rod holder double ended
YM-01434
TIP
2 1
Use the side of the rod holder that is marked “B”.
6
4
2
5 3
5
4. Remove: c. Hold the cap bolt “1” and loosen the lock-
• Front fork leg nut “4”.
4-74
FRONT FORK
ECA17390
5. Remove:
NOTICE • Outer tube
When loosening the nut, be sure not to break a. Hold the front fork leg horizontally.
the projections on the cap bolt collar of the b. Securely clamp the brake caliper bracket
cap bolt. in a vise with soft jaws.
c. Separate the outer tube from the inner
1 tube by pulling the outer tube forcefully but
carefully.
ECA19880
NOTICE
4 Excessive force will damage the bushings.
Damaged bushings must be replaced.
d. Remove the cap bolt and guide.

e. Remove the rod holder and fork spring
compressor.
f. Remove the spacer and locknut.
3. Drain:
• Fork oil
TIP
Stroke the damper rod assembly “1” several 6. Remove:
times while draining the fork oil. • Damper rod assembly
TIP
Remove the damper rod assembly with the
damper rod holder “1”.
Damper rod holder (ø30)

90890-01506
Damper rod holder
YM-01506
4. Remove: 1
• Dust seal “1”
• Oil seal clip “2”
(with a flat-head screwdriver)
ECA19100
NOTICE
Do not scratch the outer tube.
EAS30208
1 CHECKING THE FRONT FORK LEGS
front fork legs.
1. Check:
• Inner tube “1”
• Outer tube “2”
2 Bends/damage/scratches → Replace.
4-75
FRONT FORK
EWA13650
WARNING
Do not attempt to straighten a bent inner 1
tube as this may dangerously weaken it.
4. Check:
• Cap bolt “1”
• Cap bolt collar projection “2”
2. Measure: 1
• Spring free length “a”
Fork spring free length

219.5 mm (8.64 in)
Limit
215.1 mm (8.47 in)
2
EAS30209
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
EWA18360
WARNING
If both front fork legs are not filled with the
specified amount of the fork oil, it may cause
poor handling and a loss of stability.
3. Check: TIP
• Damper rod “1” • When assembling the front fork leg, be sure to
Damage/wear → Replace. replace the following parts:
Obstruction → Blow out all of the oil passag- –Inner tube bushing
es with compressed air. –Outer tube bushing
ECA19110
NOTICE –Oil seal

–Oil seal clip
• The front fork leg has a very sophisticated
–Dust seal
internal construction, which are particular-
–O-ring
ly sensitive to foreign material.
• Before assembling the front fork leg, make
• When disassembling and assembling the
sure all of the components are clean.
front fork leg, do not allow any foreign ma-
terial to enter the front fork. 1. Install:
• Damper rod assembly “1”
ECA22560
NOTICE
Allow the damper rod assembly to slide
slowly down the inner tube. Be careful not to
damage the inner tube.
4-76
FRONT FORK
TIP
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
1 • Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
2. Tighten:
3
• Damper rod assembly 4
5
Front fork damper rod assembly
40 N·m (4.0 kgf·m, 30 lb·ft) 6
T.
R.
TIP 1
Tighten the damper rod assembly with the 2
damper rod holder “1”.

90890-01506
Damper rod holder
YM-01506
5. Install:
• Outer tube
(to the inner tube)
6. Install:
• Outer tube bushing “1”
• Washer “2”
3. Lubricate: (with the fork seal driver “3”)
• Inner tube’s outer surface
Fork seal driver
Recommended oil 90890-01442
Yamaha Suspension Oil 01 Adjustable fork seal driver (36–46
mm)
4. Install: YM-01442
• Dust seal “1” New
• Oil seal clip “2” New
• Oil seal “3” New
• Washer “4”
• Outer tube bushing “5” New 3
• Inner tube bushing “6” New 2
ECA19170
NOTICE 1
Make sure the numbered side of the oil seal
faces bottom side.
4-77
FRONT FORK
7. Install:
• Oil seal “1”
(with the fork seal driver “2”)
2
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 1
mm)
YM-01442
10.Install:
• Rod puller “1”
• Rod puller attachment (M10) “2”
(onto the damper rod “3”)
Rod puller
90890-01437
Universal damping rod bleeding
tool set
YM-A8703
8. Install: Rod puller attachment (M10)
90890-01436
• Oil seal clip “1”
TIP tool set
Adjust the oil seal clip so that it fits into the outer YM-A8703
tube’s groove.
11.Fill:
9. Install: • Front fork leg
• Dust seal “1” (with the specified amount of the recom-
(with the fork seal driver “2”) mended fork oil)
Fork seal driver Recommended oil
90890-01442 Yamaha Suspension Oil 01
Adjustable fork seal driver (36–46 Quantity (left)
mm) 390.0 cm³ (13.19 US oz, 13.73
YM-01442 Imp.oz)
Quantity (right)
390.0 cm³ (13.19 US oz, 13.73
Imp.oz)
ECA14230
NOTICE
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
4-78
FRONT FORK
• When disassembling and assembling the • Damper adjusting rod 2 “4”

front fork leg, do not allow any foreign ma- • Damper adjusting rod 1 “5”
terial to enter the front fork. • Guide “6”
12.After filling the front fork leg, slowly stroke the • Cap bolt “7”
damper rod “1” up and down (at least ten (along with the O-ring New )
times) to distribute the fork oil.
TIP
Be sure to stroke the damper rod slowly be-
cause the fork oil may spurt out.
a. Remove the rod puller and rod puller at-

tachment.
b. Install the fork spring.
TIP
Install the fork spring with the smaller diameter
13.Before measuring the fork oil level, wait ten “a” facing up “A”.
minutes until the oil has settled and the air
bubbles have dispersed.
TIP
Be sure to bleed the front fork leg of any residual
air.
14.Measure:
• Front fork leg oil level “a”
(from the top of the outer tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification → Correct. c. Install the locknut all the way onto the
damper rod assembly.
Level (left) d. Install the rod puller and rod puller attach-
80 mm (3.1 in) ment.
Level (right)
e. Install the spacer and guide.
80 mm (3.1 in)
f. Install the fork spring compressor.
g. Press down on the spacer with the fork
spring compressor “1”.
h. Pull up the rod puller and install the rod
holder “2” between the locknut “3” and the
guide “4”.
15.Install:
• Fork spring “1”
• Spacer “2”
• Locknut “3”
4-79
FRONT FORK
Rod puller 5
90890-01437
tool set
YM-A8703 3
Rod puller attachment (M10)
90890-01436
tool set
YM-A8703
l. Remove the rod holder and fork spring
90890-01441
Fork spring compressor compressor.
YM-01441 16.Install:
Rod holder • Cap bolt
90890-01434 (to the outer tube)
Damper rod holder double ended TIP
YM-01434 • Temporarily tighten the cap bolt.
• When to tighten the cap bolt to the specified
TIP torque is after installing the front fork leg to the
Use the side of the rod holder that is marked “B”. vehicle and tightening the lower bracket pinch
bolts.
EAS30210
3
INSTALLING THE FRONT FORK LEGS
4 The following procedure applies to both of the
2 front fork legs.
1. Install:
1 • Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
EWA13680
i. Remove the rod puller and rod puller at- WARNING

tachment. Make sure the brake hoses are routed prop-
j. Install the damper adjusting rods and cap erly.
bolt, and then finger tighten the cap bolt.
EWA13670
TIP
WARNING Align the outer tube with the position “a” as
Always use a new cap bolt O-ring. shown in the illustration.
k. Hold the cap bolt “5” and tighten the lock-

nut “3” to specification.
ECA17390
NOTICE a
When loosening the nut, be sure not to break
the projections on the cap bolt collar of the
a
cap bolt.
Front fork cap bolt locknut

15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
2. Tighten:
• Lower bracket pinch bolts “1” and “2”
4-80
FRONT FORK
Lower bracket pinch bolt

T.
R.
23 N·m (2.3 kgf·m, 17 lb·ft) 55–65° 55–65°
TIP
Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft)
in the order pinch bolt “1” → pinch bolt “2” →
pinch bolt “1” → pinch bolt “2”.
4. Check:
1 • Cable routing
TIP
Make sure the brake hose, throttle cables, clutch
cable, and handlebar switch leads are routed
2 properly. Refer to “CABLE ROUTING” on page
2-15.
5. Adjust:
3. Tighten:
• Spring preload
• Cap bolt “1”
• Rebound damping
Front fork cap bolt • Compression damping
23 N·m (2.3 kgf·m, 17 lb·ft) Refer to “ADJUSTING THE FRONT FORK
T.
R.
LEGS” on page 3-22.

• Handlebar bolt “2”
Handlebar bolt
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
• Handlebar pinch bolt “3”
Handlebar pinch bolt

32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
• Upper bracket pinch bolt “4”
Upper bracket pinch bolt

26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
4 3
TIP
When installing the front fork legs, make sure
that the spring preload adjusting nuts are posi-
tioned at the angles shown in the illustration.
4-81
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
1st 52 N•m (5.2 kgf•m, 38 lb•ft)
T.R
2nd 14 N•m (1.4 kgf•m, 10 lb•ft)
.
6
LS
LS
LS LS
5
LS
2 3
7 N•m (0.7 kgf•m, 5.2 lb•ft)

1
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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

Headlight bracket 4-13.
Front fork legs Refer to “FRONT FORK” on page 4-71.
Handlebars Refer to “HANDLEBARS” on page 4-66.
1 Horn 1
3 Front brake hose holder bracket 1
4 Lower bracket cover 1
5 Throttle cable guide 1
6 Lock washer 1
4-82
STEERING HEAD
Removing the lower bracket

1st 52 N•m (5.2 kgf•m, 38 lb•ft)
T.R
2nd 14 N•m (1.4 kgf•m, 10 lb•ft)
.
18
14
LS
7
15 8
LS
16 9
LS LS
11
12
LS 13
17
10
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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

7 Upper ring nut 1
8 Rubber washer 1
9 Lower ring nut 1
10 Lower bracket 1
11 Upper bearing cover 1
12 Upper bearing inner race 1
13 Upper bearing 1
14 Lower bearing 1
15 Lower bearing inner race 1
16 Lower bearing dust seal 1
17 Upper bearing outer race 1
18 Lower bearing outer race 1
4-83
STEERING HEAD
EAS30213
3. Replace:
REMOVING THE LOWER BRACKET
• Bearings
EWA13120
• Bearing races
WARNING a. Remove the bearing race from the steer-
Securely support the vehicle so that there is ing head pipe “1” with a long rod “2” and
no danger of it falling over. hammer.
b. Remove the bearing race from the lower
2. Remove: bracket “3” with a floor chisel “4” and ham-
• Upper ring nut “1” mer.
• Rubber washer c. Install new bearing races.
• Lower ring nut “2” ECA14270
• Lower bracket NOTICE

EWA13730
If the bearing race is not installed properly,
WARNING
the steering head pipe could be damaged.
Securely support the lower bracket so that
there is no danger of it falling. TIP
Always replace the bearings and bearing races
TIP as a set.
Hold the lower ring nut with the ring nut wrench
“3”, and then remove the upper ring nut with the
steering nut wrench “4”.
Ring nut wrench

90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
4 3
2 4. Check:
• Upper bracket
EAS30214
Refer to “HANDLEBARS” on page 4-66.
CHECKING THE STEERING HEAD
• Lower bracket
1. Wash:
(along with the steering stem)
• Bearings
• Bearing races
EAS30216
Recommended cleaning solvent INSTALLING THE STEERING HEAD

Kerosene 1. Lubricate:
• Upper bearing
2. Check: • Lower bearing
• Bearings • Bearing races
• Bearing races
Damage/pitting → Replace.
4-84
STEERING HEAD
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Upper ring nut “3”
• Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-20.
4-85
REAR SHOCK ABSORBER ASSEMBLY
EAS20036

Removing the rear shock absorber assembly
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
44 N•m (4.4 kgf•m, 32 lb•ft)
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
T.R
.
52 N•m (5.2 kgf•m, 38 lb•ft)

T.R
.
10
11
40 N•m (4.0 kgf•m, 30 lb•ft)

T.R
.

Exhaust pipe assembly brackets Refer to “ENGINE REMOVAL” on page 5-9.
Rear wheel Refer to “REAR WHEEL” on page 4-24.
Fuel tank Refer to “FUEL TANK” on page 7-1.
1 Connecting arm 2
2 Relay arm collar 1
3 Relay arm 1
4 Collar 1
5 Collar 1
6 Oil seal 6
7 Bearing 2
8 Bearing 2
9 Rear shock absorber assembly 1
10 Washer 1
11 Rear shock absorber assembly bracket 1
4-86
EAS30826
HANDLING THE REAR SHOCK ABSORBER TIP

EWA13740 Place the vehicle on a suitable stand so that the
WARNING rear wheel is elevated.
This rear shock absorber contains highly 2. Remove:
compressed nitrogen gas. Before handling • Connecting arm bolts “1”
the rear shock absorber, read and make sure • Connecting arms “2”
you understand the following information. • Rear shock absorber assembly lower bolt “3”
The manufacturer cannot be held responsi-
TIP
ble for property damage or personal injury
that may result from improper handling of While removing the connecting arm bolts, hold
the rear shock absorber. the swingarm so that it does not drop down.
• Do not tamper or attempt to open the rear
shock absorber. 1
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure. 2
• Do not deform or damage the rear shock
3
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
3. Remove:
EAS30729
• Rear shock absorber assembly bracket nut
DISPOSING OF A REAR SHOCK ABSORBER
“1”
1. Gas pressure must be released before dis-
• Rear shock absorber assembly upper bolt “2”
posing of a rear shock absorber. To release
• Washer “3”
the gas pressure, drill a 2–3 mm (0.08–0.12
• Rear shock absorber assembly bracket “4”
in) hole through the rear shock absorber as
• Rear shock absorber assembly
shown.
EWA13760 TIP
WARNING Lower the swingarm, and then remove the rear
Wear eye protection to prevent eye damage shock absorber assembly from between the
from released gas or metal chips. swingarm and frame.
3
1
UP
4
2
EAS30219 EAS30220
REMOVING THE REAR SHOCK ABSORBER CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY ASSEMBLY
1. Stand the vehicle on a level surface. 1. Check:
EWA13120
• Rear shock absorber rod
WARNING Bends/damage → Replace the rear shock
Securely support the vehicle so that there is absorber assembly.
no danger of it falling over. • Rear shock absorber
Gas leaks/oil leaks → Replace the rear shock
absorber assembly.
4-87
• Spring
4 5
Damage/wear → Replace the rear shock ab-
sorber assembly. 1
• Bushing
• Collar 3 3
Damage/scratches → Replace.
• Bolts 6 6
Bends/damage/wear → Replace.
a
EAS30221
CHECKING THE CONNECTING ARM AND A b b B

RELAY ARM 2 2
1. Check: 3
3
• Connecting arms
• Relay arm
2. Check:
• Bearings
• Oil seals 3 3
Damage/pitting → Replace. a 1
3. Check:
• Collars 4. Rear shock absorber
Damage/scratches → Replace. 5. Relay arm
6. Connecting arms
EAS30222
A. Left side
INSTALLING THE RELAY ARM
B. Right side
1. Lubricate:
• Collars EAS30225
• Bearings INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
Recommended lubricant 1. Lubricate:
Lithium-soap-based grease • Collar
• Bearings
2. Install:
• Bearings “1”, “2” Recommended lubricant
(to the relay arm) Lithium-soap-based grease
• Oil seals “3”
2. Tighten:
Installed depth of bearing “a” • Relay arm nut
4.5 mm (0.18 in)
Installed depth of bearing “b” Relay arm and frame nut
3.5 mm (0.14 in) 40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
TIP 3. Install:
When installing the oil seals to the relay arm, • Rear shock absorber assembly bracket “1”
face the character stamp of the oil seals outside. (onto the rear shock absorber assembly)
• Washer “2”
(onto the rear shock absorber assembly)
TIP
• Temporarily tighten the rear shock absorber
assembly bracket nut.
• Install the washer with the brim pointing back of
the vehicle and the “UP” punch mark facing up.
4-88
UP
1
4. Tighten:
• Rear shock absorber assembly lower nut
Rear shock absorber assembly

lower nut
T.
R.
40 N·m (4.0 kgf·m, 30 lb·ft)
• Rear shock absorber assembly upper nut

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

bracket nut
T.
R.
52 N·m (5.2 kgf·m, 38 lb·ft)
5. Install:
• Connecting arms
TIP
When installing the connecting arms, lift up the
swingarm.
6. Tighten:
• Connecting arm nuts
Connecting arm and relay arm

nut
T.
R.
40 N·m (4.0 kgf·m, 30 lb·ft)

Connecting arm and swingarm
nut
40 N·m (4.0 kgf·m, 30 lb·ft)
4-89
SWINGARM
EAS20037
SWINGARM
Removing the swingarm
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
95 N•m (9.5 kgf•m, 70 lb•ft)
T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
LS 1
LS 2
1
LS 2
New
New
LS
LS
6 5
7
LS
70 N•m (7.0 kgf•m, 52 lb•ft) LS

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
4
.
28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.

Rear wheel Refer to “REAR WHEEL” on page 4-24.
Refer to “REAR SHOCK ABSORBER AS-
Rear shock absorber SEMBLY” on page 4-86.
Drive chain guide (drive sprocket side) Refer to “CHAIN DRIVE” on page 4-95.
1 Drive chain adjusting bolt 2
2 Drive chain adjusting locknut 2
3 Rear fender 1
4 Footrest assembly (left) 1
5 Drive chain guard 1
6 Drive chain 1
7 Swingarm pivot shaft nut 1
4-90
SWINGARM
Removing the swingarm
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
95 N•m (9.5 kgf•m, 70 lb•ft)
T.R
.
9 16 N•m (1.6 kgf•m, 12 lb•ft)

10 T.R
.
LS
LS
11 18
LS
20
New
19 15 New
14 LS
12
LS 20
19
13
8
17
LS 14
16
70 N•m (7.0 kgf•m, 52 lb•ft) LS
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
.

8 Washer 1
9 Swingarm pivot shaft ring nut 1
10 Washer 1
11 Swingarm pivot shaft 1
12 Swingarm 1
13 Drive chain guide (swingarm side) 1
14 Dust cover 2
15 Bearing 1
16 Bearing 1
17 Collar 1
18 Collar 1
19 Oil seal 2
20 Bearing 2
4-91
SWINGARM
EAS30226
4. Remove:
REMOVING THE SWINGARM
• Swingarm pivot shaft ring nut “1”
EWA13120 TIP
WARNING Loosen the swingarm pivot shaft ring nut with
Securely support the vehicle so that there is the ring nut wrench “2”.
Ring nut wrench
TIP
90890-01507
Place the vehicle on a suitable stand so that the Ring nut wrench
rear wheel is elevated. YM-01507
2. Measure:
• Swingarm side play
• Swingarm vertical movement
1
a. Measure the tightening torque of the pivot
shaft nut, pivot shaft ring nut, and pivot
shaft.
Swingarm pivot shaft nut

70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
Swingarm pivot shaft ring nut 2

95 N·m (9.5 kgf·m, 70 lb·ft)
Swingarm pivot shaft 5. Remove:
16 N·m (1.6 kgf·m, 12 lb·ft) • Swingarm pivot shaft “1”
TIP
b. Measure the swingarm side play “A” by
moving the swingarm from side to side. Loosen the swingarm pivot shaft with the damp-
c. If the swingarm side play is out of specifi- er rod holder (24 mm) “2”.
cation, check the collars, bearings, wash-
ers, and dust covers. Damper rod holder (ø24)
90890-01328
Swingarm side play (at the end of Damper rod holder
the swingarm) YM-01328
1.0 mm (0.04 in)
d. Check the swingarm vertical movement

“B” by moving the swingarm up and down. 2
If swingarm vertical movement is not 1
smooth or if there is binding, check the col-
lars, bearings, washers, and dust covers.
EAS30227
CHECKING THE SWINGARM

B 1. Check:
A • Swingarm
2. Check:
3. Remove: • Pivot shaft
• Drive chain Roll the pivot shaft on a flat surface.
Refer to “REMOVING THE DRIVE CHAIN” Bends → Replace.
on page 4-96.
4-92
SWINGARM
EWA13770
WARNING
Do not attempt to straighten a bent pivot 1 2
shaft.
A B
a 5 6 a
5
7
3. Wash: A B
• Pivot shaft
• Dust covers 4 4
• Collars 3
• Washers b b
• Bearings
Recommended cleaning solvent 5. Swingarm

Kerosene 6. Swingarm pivot shaft
7. Bolt
4. Check: A. Left side
• Dust covers B. Right side
• Collars
• Oil seals 3. Install:
Damage/wear → Replace. • Swingarm pivot shaft “1”
• Bearings
Swingarm pivot shaft
Damage/pitting → Replace. 16 N·m (1.6 kgf·m, 12 lb·ft)
T.
R.
EAS30228
INSTALLING THE SWINGARM TIP

1. Lubricate: Tighten the swingarm pivot shaft with the damp-
• Bearings er rod holder (24 mm) “2”.
• Collars
• Dust covers
• Pivot shaft 90890-01328
Damper rod holder
YM-01328
2. Install:
• Bearing “1”
• Bearing “2” 2
1
• Bearings “3”
• Oil seals “4”
Installed depth of bearing “a”

0–1.0 mm (0–0.04 in)
Installed depth of bearing “b”
4.0 mm (0.16 in)
4. Install:
• Swingarm pivot shaft ring nut “1”
4-93
SWINGARM
Swingarm pivot shaft ring nut

T.
R.
95 N·m (9.5 kgf·m, 70 lb·ft)
TIP
• Lubricate the swingarm pivot ring nut threads
and mating surfaces with lithium-soap-based
grease.
• Tighten the swingarm pivot shaft ring nut with
the ring nut wrench “2”.
Ring nut wrench

90890-01507
Ring nut wrench
YM-01507
5. Install:
• Swingarm pivot shaft nut
Swingarm pivot shaft nut

70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
TIP
Lubricate the swingarm pivot shaft nut threads
and mating surfaces with lithium-soap-based
grease.
6. Adjust:
• Drive chain slack
Refer to “Adjusting the drive chain slack” on
page 3-19.

stand)
30.0–45.0 mm (1.18–1.77 in)
Drive chain slack (Sidestand)
30.0–45.0 mm (1.18–1.77 in)
4-94
CHAIN DRIVE
EAS20038
CHAIN DRIVE
Removing the drive sprocket and drive chain
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
1
LT
4
3
New 2 LT
6 85 N•m (8.5 kgf•m, 63 lb•ft) LT LT
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Front side cowling assembly/Bottom cowling 4-8.
Shift rod Refer to “ENGINE REMOVAL” on page 5-9.
1 Drive sprocket cover 1
2 Drive sprocket nut 1
3 Washer 1
4 Drive sprocket 1
5 Drive chain 1
6 Drive chain guide (drive sprocket side) 1
4-95
CHAIN DRIVE
EAS30229
• Perform this procedure 2–3 times, at a different
REMOVING THE DRIVE CHAIN
location each time.
EWA13120
WARNING
TIP
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
2. Remove:
• Drive chain
(with the drive chain cutter) 2. Check:
TIP • Drive chain
Stiffness → Clean and lubricate or replace.
Only cut the drive chain if it or the swingarm is to
be replaced.
EAS30230
CHECKING THE DRIVE CHAIN

1. Measure:
• 15-link section “a” of the drive chain
Out of specification → Replace the drive
chain.
15-link length limit

239.3 mm (9.42 in) 3. Clean:
• Drive chain
a. Measure the length “a” between the inner a. Wipe the drive chain with a clean cloth.
sides of the pins and the length “b” be- b. Put the drive chain in kerosene and re-
tween the outer sides of the pins on a 15- move any remaining dirt.
link section of the drive chain as shown in c. Remove the drive chain from the kerosene
the illustration. and completely dry it.
ECA14290
NOTICE
• This motorcycle has a drive chain with
small rubber O-rings “1” between the drive
chain side plates. Never use high-pressure
water or air, steam, gasoline, certain sol-
vents (e.g., benzine), or a coarse brush to
clean the drive chain. High-pressure meth-
ods could force dirt or water into the drive
chain’s internals, and solvents will deterio-
b. Calculate the length “c” of the 15-link sec- rate the O-rings. A coarse brush can also
tion of the drive chain using the following damage the O-rings. Therefore, use only
formula. kerosene to clean the drive chain.
Drive chain 15-link section length “c” = • Do not soak the drive chain in kerosene for
(length “a” between pin inner sides + more than ten minutes, otherwise the O-
length “b” between pin outer sides)/2 rings can be damaged.
TIP
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
4-96
CHAIN DRIVE
b. Correct
1. Drive chain roller
2. Drive sprocket
EAS30232
CHECKING THE REAR WHEEL SPROCKET

Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-28.
EAS30233
CHECKING THE REAR WHEEL DRIVE HUB

Refer to “CHECKING THE REAR WHEEL
4. Check:
DRIVE HUB” on page 4-28.
• O-rings “1”
Damage → Replace the drive chain. EAS30234
• Drive chain rollers “2” INSTALLING THE DRIVE CHAIN

Damage/wear → Replace the drive chain. 1. Install:
• Drive chain side plates “3” • Drive chain
Damage/wear/cracks → Replace the drive
ECA17410
NOTICE
chain.
Be sure to put on safety goggles when work-
ing.
TIP
• Install the drive chain joint with the drive chain
cut & rivet tool.
• After riveting, make sure the diameter between
the edges “a” of the connecting pin “1” is 5.5–
5.8 mm (0.22–0.23 in).
5. Lubricate: Drive chain cut & rivet tool

• Drive chain 90890-01550
Drive chain cut & rivet tool
Recommended lubricant YM-01550
Engine oil or chain lubricant
EAS30231
1
CHECKING THE DRIVE SPROCKET
1. Check:
• Drive sprocket
More than 1/4 tooth “a” wear → Replace the
drive sprockets as a set.
Bent teeth → Replace the drive sprockets as a
a set.
4-97
CHAIN DRIVE
2. Lubricate:
• Drive chain
Engine oil or chain lubricant
3. Install:
• Drive sprocket “1”
• Washer “2”
• Drive sprocket nut “3” New
TIP
• While applying the rear brake, tighten the drive
sprocket nut.
• Stake the drive sprocket nut “3” at a cutout “a”
in the drive axle.
Drive sprocket nut

85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.
LOCTITE®
1
a 2
a
New 3
4-98
CHAIN DRIVE
4-99
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

ENGINE OIL LUBRICATION CHART .......................................................5-1
LUBRICATION DIAGRAMS ...................................................................... 5-2
ENGINE INSPECTION .................................................................................... 5-8

MEASURE THE COMPRESSION PRESSURE........................................ 5-8
ENGINE REMOVAL ........................................................................................5-9

INSTALLING THE ENGINE..................................................................... 5-15
ADJUSTING THE SHIFT PEDAL............................................................ 5-15
ADJUSTING THE EXUP CABLES .......................................................... 5-16
CAMSHAFTS.................................................................................................5-18
REMOVING THE CAMSHAFTS..............................................................5-20
CHECKING THE CAMSHAFTS ..............................................................5-20
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,
AND TIMING CHAIN GUIDES ...............................................................5-21
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-22
INSTALLING THE CAMSHAFTS ............................................................ 5-23
CYLINDER HEAD.......................................................................................... 5-26

REMOVING THE CYLINDER HEAD.......................................................5-27
CHECKING THE CYLINDER HEAD .......................................................5-27
INSTALLING THE CYLINDER HEAD .....................................................5-27
5
VALVES AND VALVE SPRINGS.................................................................. 5-29
REMOVING THE VALVES...................................................................... 5-30
CHECKING THE VALVES AND VALVE GUIDES ..................................5-30
CHECKING THE VALVE SEATS ............................................................ 5-32
CHECKING THE VALVE SPRINGS........................................................ 5-33
CHECKING THE VALVE LIFTERS ......................................................... 5-34
INSTALLING THE VALVES .................................................................... 5-34
GENERATOR AND STARTER CLUTCH......................................................5-36

REMOVING THE GENERATOR ............................................................. 5-37
CHECKING THE STARTER CLUTCH ....................................................5-37
INSTALLING THE STARTER CLUTCH .................................................. 5-37
INSTALLING THE GENERATOR............................................................ 5-38
PICKUP ROTOR............................................................................................ 5-39

REMOVING THE PICKUP ROTOR ........................................................ 5-40
INSTALLING THE PICKUP ROTOR .......................................................5-40
ELECTRIC STARTER ...................................................................................5-42

CHECKING THE STARTER MOTOR .....................................................5-44
ASSEMBLING THE STARTER MOTOR................................................. 5-45
CLUTCH ........................................................................................................5-46
REMOVING THE CLUTCH ..................................................................... 5-50
CHECKING THE FRICTION PLATES.....................................................5-50
CHECKING THE CLUTCH PLATES .......................................................5-50
CHECKING THE CLUTCH SPRINGS.....................................................5-51
CHECKING THE CLUTCH HOUSING ....................................................5-52
CHECKING THE CLUTCH BOSS........................................................... 5-52
CHECKING THE PRESSURE PLATE ....................................................5-52
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-52
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-52
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-53
CHECKING THE OIL PUMP DRIVE SPROCKET
AND OIL PUMP DRIVE CHAIN..............................................................5-53
INSTALLING THE CLUTCH.................................................................... 5-53
SHIFT SHAFT................................................................................................5-56
CHECKING THE SHIFT SHAFT ............................................................. 5-58
CHECKING THE STOPPER LEVER ......................................................5-58
INSTALLING THE SHIFT SHAFT ........................................................... 5-58
OIL PUMP...................................................................................................... 5-59

REMOVING THE OIL PAN...................................................................... 5-62
CHECKING THE OIL PUMP ................................................................... 5-62
CHECKING THE RELIEF VALVE ........................................................... 5-62
CHECKING THE OIL PIPES ................................................................... 5-62
CHECKING THE OIL STRAINER ........................................................... 5-62
ASSEMBLING THE OIL PUMP...............................................................5-62
INSTALLING THE OIL PAN .................................................................... 5-63
CRANKCASE ................................................................................................5-64
DISASSEMBLING THE CRANKCASE....................................................5-66
CHECKING THE CRANKCASE ..............................................................5-66
CHECKING THE OIL PIPE ..................................................................... 5-66
CHECKING THE TIMING CHAIN............................................................ 5-66
ASSEMBLING THE CRANKCASE.......................................................... 5-66
INSTALLING THE GEAR POSITION SENSOR...................................... 5-67
CONNECTING RODS AND PISTONS .......................................................... 5-69

REMOVING THE CONNECTING RODS AND PISTONS.......................5-70
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-70
CHECKING THE PISTON RINGS........................................................... 5-71
CHECKING THE PISTON PINS..............................................................5-72
CHECKING THE CONNECTING RODS................................................. 5-72
INSTALLING THE CONNECTING RODS AND PISTONS .....................5-74
CRANKSHAFT ..............................................................................................5-77
REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......................5-78
CHECKING THE OIL NOZZLES ............................................................. 5-78
CHECKING THE CRANKSHAFT AND CONNECTING RODS............... 5-78
INSTALLING THE CRANKSHAFT .......................................................... 5-80
TRANSMISSION............................................................................................ 5-81
REMOVING THE TRANSMISSION ........................................................ 5-86
CHECKING THE SHIFT FORKS............................................................. 5-86
CHECKING THE SHIFT DRUM ASSEMBLY..........................................5-86
CHECKING THE TRANSMISSION ......................................................... 5-87
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..............................5-87
INSTALLING THE TRANSMISSION .......................................................5-88
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20298

EAS32362
ENGINE OIL LUBRICATION CHART
10
7 8
11
5
12
2 4 13
1 3 14
1. Oil strainer
2. Oil pump
3. Relief valve
4. Oil filter
5. Oil cooler
6. Main gallery
7. Oil nozzle
8. Timing chain tensioner
9. Intake camshaft
10. Exhaust camshaft
11. Oil pipe
12. Main axle
13. Shift fork
14. Drive axle
5-1
EAS32363
LUBRICATION DIAGRAMS
4
3
1. Ventilation chamber cover
2. Relief valve
3. Ventilation chamber oil drain pipe
4. Oil cooler
5-2
2
3
7
6
5
1. Timing chain tensioner
2. Intake camshaft
3. Exhaust camshaft
4. Oil check bolt
5. Oil strainer
7. Oil pipe
8. Oil pump
5-3
2
1
4
1. Oil cooler
2. Oil filter
3. Oil pipe
4. Oil pump
5. Oil strainer
5-4
5 3
4
1. Main axle
2. Oil pump
3. Oil pipe
5. Relief valve
5-5
1. Cylinder head
2. Intake camshaft
3. Exhaust camshaft
4. Crankshaft
5. Oil nozzle
5-6
1. Oil pipe
2. Main axle
3. Drive axle
5-7
ENGINE INSPECTION
EAS20041
ENGINE INSPECTION Compression pressure

1392–1792 kPa/400 r/min (13.9–
EAS30249
17.9 kgf/cm²/400 r/min, 198.0–
MEASURE THE COMPRESSION PRESSURE 254.9 psi/400 r/min)
The following procedure applies to all of the cyl-
inders. a. Set the main switch to “ON”.
TIP b. With the throttle wide open, crank the en-
Insufficient compression pressure will result in a gine until the reading on the compression
loss of performance. gauge stabilizes.
EWA12940
1. Measure: WARNING
• Valve clearance To prevent sparking, ground all spark plug
Out of specification → Adjust. leads before cranking the engine.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5. TIP
2. Start the engine, warm it up for several min- The difference in compression pressure be-
utes, and then turn it off. tween cylinders should not exceed 100 kPa (1
3. Remove: kg/cm², 14 psi).
• Radiator
c. If the compression pressure is above the
maximum specification, check the cylinder
4. Remove:
head, valve surfaces and piston crown for
• Ignition coils
carbon deposits.
• Spark plugs
ECA13340
Carbon deposits → Eliminate.
NOTICE d. If the compression pressure is below the
Before removing the spark plugs, use com- minimum specification, pour a teaspoonful
pressed air to blow away any dirt accumulat- of engine oil into the spark plug bore and
ed in the spark plug wells to prevent it from measure again.
falling into the cylinders. Refer to the following table.
Compression pressure (with oil applied into the
5. Install: cylinder)
• Compression gauge “1”
Reading Diagnosis
• Extension “2”
Piston ring(s) wear or
Higher than without oil
Compression gauge damage → Repair.
90890-03081 Pistons, valves, cylinder
Engine compression tester head gasket or piston
Same as without oil
YU-33223 ring(s) possibly defec-
Extension tive → Repair.
90890-04136
7. Install:
• Spark plugs
• Ignition coils
2 Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
8. Install:
• Radiator
1 Refer to “RADIATOR” on page 6-3.
6. Measure:
• Compression pressure
Out of specification → Refer to steps (c) and
(d).
5-8
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the exhaust pipe assembly
7
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft) 2

T.R
.
45 N•m (4.5 kgf•m, 33 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
LT
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
LT
LT
LS
New
LT
1
2
5
LT
LT
4
3
6 New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
20 N•m (2.0 kgf•m, 15 lb•ft) 30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.
T.R
.
(8) 20 N•m (2.0 kgf•m, 15 lb•ft) 34 N•m (3.4 kgf•m, 25 lb•ft)

T.R
.
T.R
.

Radiator bracket Refer to “RADIATOR” on page 6-3.
1 EXUP valve pulley cover 1
2 EXUP cable 1 Black adjusting bolt
3 EXUP cable 1
4 Clamp 1
5 Muffler 1
6 Gasket 1
7 O2 sensor coupler 1 Disconnect.
5-9
ENGINE REMOVAL
Removing the exhaust pipe assembly

15
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft) 16

T.R
.
45 N•m (4.5 kgf•m, 33 lb•ft)

T.R
.
14
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
LT
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.
LT
LT
LS
10 New
LT
8
LT
LT
13
12 New
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
9 6 N•m (0.6 kgf•m, 4.4 lb•ft)

11
T.R
.
20 N•m (2.0 kgf•m, 15 lb•ft) 30 N•m (3.0 kgf•m, 22 lb•ft)

T.R
.
T.R
.
(8) 20 N•m (2.0 kgf•m, 15 lb•ft) 34 N•m (3.4 kgf•m, 25 lb•ft)

T.R
.
T.R
.

Remove the O2 sensor only when neces-
8 O2 sensor 1
sary.
9 Exhaust pipe assembly 1
10 Gasket 4
11 Exhaust pipe assembly bracket (left lower side) 1
12 Exhaust pipe assembly bracket (left upper side) 1
13 Exhaust pipe assembly bracket (right side) 1
14 EXUP servo motor coupler 1 Disconnect.
15 EXUP servo motor cover 1
16 EXUP servo motor 1
5-10
ENGINE REMOVAL
Disconnecting the leads and hoses

10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
70 N•m (7.0 kgf•m, 52 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
E
LS
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
New
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.

Air filter case Refer to “AIR FILTER CASE” on page 7-5.
Refer to “THROTTLE BODIES” on page
Throttle body 7-10.
Air cut-off valve page 7-19.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-42.
Thermostat Refer to “THERMOSTAT” on page 6-10.
Radiator Refer to “RADIATOR” on page 6-3.
Oil cooler Refer to “OIL COOLER” on page 6-7.
Water pump Refer to “WATER PUMP” on page 6-12.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-95.
1 Shift rod 1
2 Shift arm 1
5-11
ENGINE REMOVAL
Disconnecting the leads and hoses

10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
6
5 7
10 8
11 9
15
12
70 N•m (7.0 kgf•m, 52 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
E
14
16 4
LS
16 13
10 N•m (1.0 kgf•m, 7.4 lb•ft) 3
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
.
New
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.

3 Oil filter cartridge 1
4 Oil filter cartridge bolt 1
5 Crankcase breather hose 1
6 Negative battery terminal 1 Disconnect.
7 Engine ground terminal 1 Disconnect.
8 Oil level switch coupler 1 Disconnect.
9 Crankshaft position sensor coupler 1 Disconnect.
10 Neutral switch connector 1 Disconnect.
11 Coolant temperature sensor coupler 1 Disconnect.
12 Gear position sensor coupler 1 Disconnect.
13 Stator coil assembly coupler 1 Disconnect.
15 Cylinder identification sensor coupler 1 Disconnect.
16 Ignition coil coupler 4 Disconnect.
5-12
ENGINE REMOVAL
Removing the engine
LS 10 40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
64 N•m (6.4 kgf•m, 47 lb•ft)
T.R
.
5
9
7 8
6 5
LS
1
2 3 4
3 4
1 2
40 N•m (4.0 kgf•m, 30 lb•ft)

T.R
.
64 N•m (6.4 kgf•m, 47 lb•ft)

T.R
.
40 N•m (4.0 kgf•m, 30 lb•ft)

T.R
.

1 Engine mounting bolt (front right side) 2
2 Engine mounting collar (outside) 2
3 Engine mounting collar (center) 2
4 Engine mounting collar (inside) 2
5 Engine mounting bolt (front left side) 2
6 Engine mounting nut (rear upper side) 1
10 Engine mounting bolt (rear upper side) 1
5-13
ENGINE REMOVAL
Removing the engine
LS 40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
64 N•m (6.4 kgf•m, 47 lb•ft)
T.R
.
15
LS
12 14
13
11
40 N•m (4.0 kgf•m, 30 lb•ft)

T.R
.
64 N•m (6.4 kgf•m, 47 lb•ft)

T.R
.
40 N•m (4.0 kgf•m, 30 lb•ft)

T.R
.
16

11 Engine mounting nut (rear lower side) 1
15 Engine mounting bolt (rear lower side) 1
16 Engine 1
5-14
ENGINE REMOVAL
EAS30251
INSTALLING THE ENGINE

1. Install:
• Engine “1” 3
54
• Engine mounting bolt (rear lower side) “2” 8 6 9
• Engine mounting bolt (rear upper side) “3”
• Engine mounting collars (inside) “4” 2
9
• Engine mounting collar (center) “5”
• Engine mounting collars (outside) “6” 13
• Engine mounting nut (rear lower side) “7” 10
12 11
• Engine mounting nut (rear upper side) “8”
54
(temporarily tighten) 76
• Engine mounting bolts (front left side) “9”
(temporarily tighten) 11 10
• Engine mounting collars (inside) “10” 13 12
• Engine mounting collar (center) “11”
• Engine mounting collars (outside) “12” 1
• Engine mounting bolts (front right side) “13”
TIP
3. Install:
• Be sure to pass the drive axle through the drive • Shift arm “1”
chain when installing the engine “1”.
• Do not fully tighten the bolts and nuts. Shift arm bolt
2. Tighten: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• Engine mounting nut (rear lower side) “7”

TIP
• Engine mounting nut (rear upper side) “8”
• Engine mounting bolts (front left side) “9” Install the shift arm “1” with its slot “a” aligned
• Engine mounting bolts (front right side) “13” with the notch “b” in end of the shift shaft.
Engine mounting nut (rear lower

side) 1
T.
R.
64 N·m (6.4 kgf·m, 47 lb·ft)

Engine mounting nut (rear upper
side)
64 N·m (6.4 kgf·m, 47 lb·ft) a
Engine mounting bolt (front left
side)
40 N·m (4.0 kgf·m, 30 lb·ft)
Engine mounting bolt (front right b
side) EAS31590
40 N·m (4.0 kgf·m, 30 lb·ft) ADJUSTING THE SHIFT PEDAL
TIP
The shift pedal position is determined by the in-
stalled shift rod length “a”.
1. Remove:
• Side cowling assembly
4-1.
2. Measure:
• Installed shift rod length “a”
Incorrect → Adjust.
5-15
ENGINE REMOVAL
Installed shift rod length

267.2–269.2 mm (10.52–10.60 in)
a 1
2. Check:
• EXUP system operation
a. Activate the diagnostic mode and select
the diagnostic code number “53”.
3. Adjust:
Refer to “FUEL INJECTION SYSTEM” on
• Installed shift rod length
page 8-29.
a. Loosen both locknuts “1”.
b. Set the engine stop switch to “ ”.
b. Turn the shift rod “2” until the specified in-
c. Check that the EXUP valve operates prop-
stalled shift rod length is obtained.
erly.
TIP
2 Check that the projection “a” on the EXUP valve
pulley contacts the stopper “b” (fully open posi-
tion). If the projection does not contact the stop-
per, adjust the EXUP cable free play.
1
b a
c. Tighten both locknuts to specification.
Locknut (shift rod upper side)

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Locknut (shift rod lower side)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
d. Make sure the installed shift rod length is 3. Adjust:

within specification. • EXUP cable free play
4. Install: a. Turn the main switch to “ON”.
• Side cowling assembly b. Loosen the locknut “1”.
Refer to “GENERAL CHASSIS (1)” on page c. Turn the adjusting nut “2” until the projec-
4-1. tion “a” on the EXUP valve pulley slightly
contacts the stopper “b” and make sure
EAS31788
the EXUP cable (black metal) “3” is not
ADJUSTING THE EXUP CABLES
slack.
1. Remove:
d. Tighten the locknut “1” to specification.
• EXUP valve pulley cover “1”
Locknut (EXUP cable adjusting
nut)
T.
R.
6 N·m (0.6 kgf·m, 4.4 lb·ft)
e. Loosen the locknut “4”.
5-16
ENGINE REMOVAL
f. Turn the adjusting nut “5” until the tension

of the EXUP cable (white metal) “6” is the
same as that of the EXUP cable (black
metal) “3”.
g. Tighten the locknut “4” to specification.
Locknut (EXUP cable adjusting

nut)
T.
R.
6 N·m (0.6 kgf·m, 4.4 lb·ft)
6 4 5
3 1 2
4. Install:
• EXUP valve pulley cover
EXUP valve pulley cover bolt

(front side)
T.
R.
8 N·m (0.8 kgf·m, 5.9 lb·ft)

LOCTITE®
EXUP valve pulley cover bolt
(rear side)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
LOCTITE®
5-17
CAMSHAFTS
EAS20043
CAMSHAFTS
Removing the cylinder head cover
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
1
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
2
4 LT
LT
3
6
LS
New
5 New

Radiator Refer to “RADIATOR” on page 6-3.
Refer to “THROTTLE BODIES” on page
Throttle body 7-10.
Air cut-off valve/Reed valve assembly page 7-19.
1 Ignition coil 4
2 Spark plug 4
3 Cylinder identification sensor 1
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (upper side) 1
5-18
CAMSHAFTS
Removing the camshafts
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
4
4
4
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
1 6 7
5
5
5
M
2
6 8
24 N•m (2.4 kgf•m, 18 lb•ft)
1
T.R
New 3
.
10
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
9
11

Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-39.
1 Camshaft sprocket bolt 4 Loosen.
2 Timing chain tensioner 1
3 Timing chain tensioner gasket 1
4 Intake camshaft cap 3
5 Exhaust camshaft cap 3
6 Camshaft sprocket 2
7 Intake camshaft 1
8 Exhaust camshaft 1
9 Pin 2
10 Timing chain guide (intake side) 1
11 Timing chain guide (exhaust side) 1
5-19
CAMSHAFTS
EAS30256 ECA13720
REMOVING THE CAMSHAFTS NOTICE

1. Remove: To prevent damage to the cylinder head,
• Pickup rotor cover camshafts or camshaft caps, loosen the
Refer to “PICKUP ROTOR” on page 5-39. camshaft cap bolts in stages and in a criss-
2. Align: cross pattern, working from the outside in.
• TDC mark on the pickup rotor
(with the crankcase mating surface)
a. Turn the crankshaft clockwise.
4. Remove:
• Intake camshaft
b. When piston #1 is at TDC on the compres- • Exhaust camshaft
sion stroke, align the TDC mark “a” on the TIP
pickup rotor with the crankcase mating To prevent the timing chain from falling into the
surface “b”. crankcase, fasten it with a wire “1”.
b
a
1
TIP
EAS30257
TDC on the compression stroke can be found
CHECKING THE CAMSHAFTS
when the camshaft lobes are turned away from
1. Check:
each other.
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
IN EX
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions

Lobe height (Intake)
33.750–33.850 mm (1.3287–
1.3327 in)
Limit
3. Remove: 33.675 mm (1.3258 in)
• Camshaft caps “1” Lobe height (Exhaust)
32.950–33.050 mm (1.2972–
1.3012 in)
Limit
32.875 mm (1.2943 in)
5-20
CAMSHAFTS
TIP
• 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 (intake and ex-

haust)
T.
3. Measure:
R.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
• Camshaft runout
Out of specification → Replace. d. Remove the camshaft caps and then mea-
sure the width of the Plastigauge® “1”.
Camshaft runout limit
0.030 mm (0.0012 in)
5. Measure:
• Camshaft journal diameter “a”
4. Measure: Out of specification → Replace the camshaft.
• Camshaft-journal-to-camshaft-cap clearance Within specification → Replace the cylinder
Out of specification → Measure the camshaft head and the camshaft caps as a set.
journal diameter.
Camshaft journal diameter
Camshaft-journal-to-camshaft- 22.459–22.472 mm (0.8842–
cap clearance 0.8847 in)
0.028–0.062 mm (0.0011–0.0024
in)
Limit
0.080 mm (0.0032 in)
a. Install the camshaft into the cylinder head

(without the camshaft caps).
b. Position a strip of Plastigauge® “1” onto
the camshaft journal as shown.
EAS31784
CHECKING THE TIMING CHAIN, CAMSHAFT

SPROCKETS, AND TIMING CHAIN GUIDES
1. Check:
• Timing chain “1”
Damage/stiffness → Replace the timing
chain and camshaft and camshaft sprocket
as a set.
c. Install the camshaft caps.
5-21
CAMSHAFTS
2. Check: • Timing chain tensioner rod

• Camshaft sprocket TIP
More than 1/4 tooth wear “a” → Replace the Prior to installing the timing chain tensioner rod,
camshaft sprocket and the timing chain as a drain the engine oil from the timing chain ten-
set. sioner housing.
a. Install the timing chain tensioner springs,
timing chain tensioner spring seat, and
timing chain tensioner rod “1”.
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
3. Check:
• Timing chain guide (exhaust side) b. Squeeze the timing chain tensioner clip
• Timing chain guide (intake side) “2”, and then push the timing chain ten-
• Timing chain guide (upper side) sioner rod “3” into the timing chain tension-
Damage/wear → Replace the defective er housing.
part(s).
TIP
EAS30266 Do not release the timing chain tensioner clip
CHECKING THE TIMING CHAIN TENSIONER while pushing the rod into the housing, other-
1. Remove: wise the rod may be ejected.
• Timing chain tensioner rod “1”
• Timing chain tensioner spring seat “2”
• Timing chain tensioner inner spring “3”
• Timing chain tensioner outer spring “5”
• Timing chain tensioner housing “6”
TIP
Squeeze the timing chain tensioner clip “4”, and
then remove the timing chain tensioner springs
and timing chain tensioner rod.
6
c. Hook the clip “4” to the timing chain ten-
1 2 3 4 5
sioner rod “3”.
TIP
Hook the timing chain tensioner rod pin “5” to the
center of the clip “4”. After the installation, check
that the clip “4” can come off by its own weight
2. Check: by pushing the timing chain tensioner rod “3” at
• Timing chain tensioner housing the position of installation.
• Timing chain tensioner rod
• Timing chain tensioner spring seat
• Timing chain tensioner springs
Damage/wear → Replace the as a set.
3. Assemble:
• Timing chain tensioner springs
• Timing chain tensioner spring seat
5-22
CAMSHAFTS
• Intake camshaft “3”

(with the camshaft sprockets temporarily
tightened)
TIP
• Make sure the match marks “a” on the cam-
shaft sprockets are aligned with the cylinder
head edge “b”.
• Be sure to install the timing chain so that the
exhaust side of the chain is taut and the intake
side is slack.
EAS30269
INSTALLING THE CAMSHAFTS 3. Install:

1. Align: • Intake camshaft caps
• TDC mark on the pickup rotor • Exhaust camshaft caps
(with the crankcase mating surface) TIP
a. Turn the crankshaft clockwise. • Make sure each camshaft cap is installed in its
original place. Refer to the identification marks
as follows:
“I1”, “I2”: Intake
“E1”, “E2”: Exhaust
• Make sure the arrow mark “a” on each cam-
shaft points towards the right side of the en-
gine.
E2 E1
E1
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark “a” on the
pickup rotor with the crankcase mating
surface “b”.
I1
I2 I1
a a
b
a a
2. Install:
• Timing chain “1”
• Exhaust camshaft “2”
a a
5-23
CAMSHAFTS
4. Install: TIP
• Camshaft cap bolts If the engine is not disassembled, set the engine
stop switch to “ ”, and then crank the engine a
Camshaft cap bolt (intake and ex-
haust) few times by pressing the start switch for approx-
T.
imately 0.5–1.0 second each time.

R.
10 N·m (1.0 kgf·m, 7.4 lb·ft)

ECA13730
7. Check that the timing chain is taut. If the
NOTICE chain is slack, reinstall the timing chain ten-
sioner.
The camshaft cap bolts must be tightened
TIP
evenly or damage to the cylinder head, cam-
shaft caps, and camshafts will result. If the engine is not disassembled, start the en-
gine and check for any abnormal noise. If any
TIP abnormal noise is heard, reinstall the timing
Tighten the camshaft cap bolts in stages and in chain tensioner.
a crisscross pattern, working from the inner caps
8. Check:
out.
• TDC mark “a”
5. Install: Make sure the TDC mark on the pickup rotor
• Timing chain tensioner gasket “1” New is aligned with the crankcase mating surface
• Timing chain tensioner “2” “b”.
Timing chain tensioner bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
• Be sure to install the timing chain tensioner
gasket so that its section with the “L” mark “a”
is protruding from the lower left side of the tim- b
a
ing chain tensioner.
• The punch mark “b” on the timing chain ten-
sioner should face up. • Camshaft sprocket match mark “c”
Make sure the marks on the camshaft
b sprockets are aligned with the edge of the cyl-
inder head “d”.
a Out of alignment → Adjust.
L
2 Refer to the installation steps above.
New 1
6. Rotate the crankshaft a few times to release

the timing chain tensioner rod.
9. Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
10.Install:
• Cylinder head cover gasket New
5-24
CAMSHAFTS
• Cylinder head cover
Cylinder head cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Apply bond TB1541C “1” onto the mating sur-
faces of the cylinder head cover and cylinder
head cover gasket.
• Apply bond TB1215B “2” onto the mating sur-
faces of the cylinder head cover gasket and
cylinder head.
• Tighten the cylinder head cover bolts stages
and in a crisscross pattern.
1 1
5-25
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
1st 25 N•m (2.5 kgf•m, 18 lb•ft) 1st 30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
T.R
2nd 42 N•m (4.2 kgf•m, 31 lb•ft) 2nd 60 N•m (6.0 kgf•m, 44 lb•ft)
.
.
18 N•m (1.8 kgf•m, 13 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft) 15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-9.
Camshafts Refer to “CAMSHAFTS” on page 5-18.
1 Coolant temperature sensor 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5-26
CYLINDER HEAD
EAS30276
3. Measure:
REMOVING THE CYLINDER HEAD
• Cylinder head warpage
1. Remove:
Out of specification → Resurface the cylinder
• Cylinder head bolts
head.
• Cylinder head nuts
TIP Warpage limit
• Loosen the nuts, cap nuts, and bolts in de- 0.05 mm (0.0020 in)
creasing numerical order (refer to the numbers
in the illustration).
• Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
6 2 4 10
8 12
a. Place a straightedge “1” and a thickness

9 11 gauge “2” across the cylinder head.
3 1 5 7
EAS30277
CHECKING THE CYLINDER HEAD

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

• Cylinder head 1. Install:
Damage/scratches → Replace. • Cylinder head
TIP
TIP
Replace the titanium valves with the cylinder Pass the timing chain through the timing chain
head. cavity.
Refer to “CHECKING THE VALVE SEATS” 2. Tighten:

on page 5-32. • Cylinder head nuts “1”–“7”, “10”
• Cylinder head water jacket
Mineral deposits/rust → Eliminate.
5-27
CYLINDER HEAD
Cylinder head nut (1st)

T.
R.
25 N·m (2.5 kgf·m, 18 lb·ft)
Cylinder head nut (final)
42 N·m (4.2 kgf·m, 31 lb·ft)
• Cylinder head cap nuts “8”, “9”
Cylinder head cap nut (1st)

30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
Cylinder head cap nut (final)

60 N·m (6.0 kgf·m, 44 lb·ft)
• Cylinder head bolts “11”, “12”
Cylinder head bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
• Lubricate the bolt threads and the bearing sur-
faces with engine oil.
• Tighten the cylinder head nuts, cap nuts, and
bolts in the proper tightening sequence as
shown and torque them in two stages.
6 2 4 10
8 12
9 11
3 1 5 7
5-28
VALVES AND VALVE SPRINGS
EAS20045

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

Cylinder head Refer to “CYLINDER HEAD” on page 5-26.
1 Valve lifter 16
2 Valve pad 16
3 Valve cotter 32
4 Upper spring seat 16
5 Intake valve spring 8
6 Exhaust valve spring 8
7 Intake valve 8
8 Exhaust valve 8
9 Valve stem seal 16
10 Lower spring seat 16
11 Intake valve guide 8
12 Exhaust valve guide 8
5-29
EAS30283
REMOVING THE VALVES TIP

The following procedure applies to all of the Remove the valve cotters by compressing the
valves and related components. valve spring with the valve spring compressor
TIP
“1” and the valve spring compressor attachment
“2”.
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal. Valve spring compressor
90890-04019
1. Remove: Valve spring compressor
• Valve lifter “1” YM-04019
• Valve pad “2” Valve spring compressor attach-
TIP ment
90890-04108
Make a note of the position of each valve lifter Valve spring compressor adapt-
and valve pad so that they can be reinstalled in er 22 mm
their original place. YM-04108
2. Check:
• Valve sealing 4. Remove:
Leakage at the valve seat → Check the valve • Upper spring seat “1”
face, valve seat, and valve seat width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-32. • Valve stem seal “4”
a. Pour a clean solvent “a” into the intake and • Lower spring seat “5”
exhaust ports. TIP
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
EAS30284
CHECKING THE VALVES AND VALVE

3. Remove:
GUIDES
• Valve cotters
valves and valve guides.
5-30
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)
0.010–0.037 mm (0.0004–0.0015 b. Install the new valve guide with the valve
in) guide installer “2” and valve guide remov-
Limit er “1”.
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.095 mm (0.0037 in)
a. Valve guide position

c. After installing the valve guide, bore the
valve guide with the valve guide reamer
“3” to obtain the proper valve-stem-to-
valve-guide clearance.
TIP
After replacing the valve guide, reface the valve
2. Replace: seat.
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
a. Remove the valve guide with the valve
guide remover “1”.
5-31
2. Check:
Valve guide remover (ø4.5) • Valve seat
90890-04116 Pitting/wear → Replace the cylinder head.
Valve guide remover (4.5 mm) 3. Measure:
YM-04116
• Valve seat width C “a”
Valve guide installer (ø4.5)
90890-04117 Out of specification → Replace the cylinder
Valve guide installer (4.5 mm) head.
YM-04117
Valve guide reamer (ø4.5) Valve seat contact width (intake)
90890-04118 0.90–1.10 mm (0.0354–0.0433 in)
Valve guide reamer (4.5 mm) Limit
YM-04118 1.6 mm (0.06 in)
Valve seat contact width (ex-
3. Eliminate: haust)
1.10–1.30 mm (0.0433–0.0512 in)
• Carbon deposits
Limit
(from the valve face and valve seat) 1.8 mm (0.07 in)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5. Measure:
• Valve stem runout
Out of specification → Replace the valve.
TIP
• When installing a new valve, always replace
the valve guide. a. Apply blue layout fluid “b” onto the valve
• If the valve is removed or replaced, always reface.
place the valve stem seal.
Valve stem runout

0.040 mm (0.0016 in)
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
d. Measure the valve seat width.
EAS30285 TIP
CHECKING THE VALVE SEATS Where the valve seat and valve face contacted
The following procedure applies to all of the one another, the blueing will have been re-
valves and valve seats. moved.
1. Eliminate:
• Carbon deposits 4. Lap:
(from the valve face and valve seat) • Valve face
• Valve seat
5-32
ECA23100
e. Apply a fine lapping compound to the
NOTICE valve face and repeat the above steps.
This model uses titanium intake and exhaust f. After every lapping procedure, be sure to
valves. clean off all of the lapping compound from
Titanium valves that have been used to lap the valve face and valve seat.
the valve seats must not be used. Always re- g. Apply blue layout fluid “b” onto the valve
place lapped valves with new valves. face.
TIP
• When replacing the cylinder head, replace the
valves without lapping the valve seats and
valve faces.
• When replacing the valves or valve guides, use
new valves to lap the valve seats, and then re-
place them with new valves.
a. Apply a coarse lapping compound “a” to
the valve face.
ECA13790
h. Install the valve into the cylinder head.
NOTICE i. Press the valve through the valve guide
Do not let the lapping compound enter the and onto the valve seat to make a clear
gap between the valve stem and the valve impression.
guide. j. Measure the valve seat width “c” again. If
the valve seat width is out of specification,
reface and lap the valve seat.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head. EAS30286
CHECKING THE VALVE SPRINGS

d. Turn the valve until the valve face and
valve seat are evenly polished, then clean
valve springs.
off all of the lapping compound.
1. Measure:
TIP
• Valve spring free length “a”
For the best lapping results, lightly tap the valve Out of specification → Replace the valve
seat while rotating the valve back and forth be- spring.
tween your hands.
Free length (intake)
37.47 mm (1.48 in)
Limit
35.60 mm (1.40 in)
Free length (exhaust)
37.67 mm (1.48 in)
Limit
35.79 mm (1.41 in)
5-33
2. Measure: 2. Lubricate:
• Valve spring tilt “a” • Valve stem “1”
Out of specification → Replace the valve • Valve stem seal “2”
spring. (with the recommended lubricant)
Spring tilt (intake) Recommended lubricant

1.6 mm (0.06 in) Molybdenum disulfide oil
Spring tilt (exhaust)
1.6 mm (0.06 in)
3. Install:
• Lower spring seat “1”
EAS30287 • Valve stem seal “2”
CHECKING THE VALVE LIFTERS • Valve “3”
The following procedure applies to all of the • Valve spring “4”
valve lifters. • Upper spring seat “5”
1. Check: (into the cylinder head)
• Valve lifter TIP
Damage/scratches → Replace the valve lift-
• Make sure each valve is installed in its original
ers and cylinder head.
place.
EAS30288 • Install the valve springs with the larger pitch “a”
INSTALLING THE VALVES facing up.
valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
5-34
b. Smaller pitch 6. Lubricate:

• Valve lifter
4. Install: (with the recommended lubricant)
• Valve cotters
TIP Recommended lubricant
Engine oil
Install the valve cotters by compressing the
valve spring with the valve spring compressor 7. Install:
“1” and the valve spring compressor attachment • Valve pad
“2”. • Valve lifter
TIP
Valve spring compressor
• The valve lifter must move smoothly when ro-
90890-04019
Valve spring compressor tated with a finger.
YM-04019 • Each valve lifter and valve pad must be rein-
Valve spring compressor attach- stalled in its original position.
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-35
GENERATOR AND STARTER CLUTCH
EAS20047

Removing the generator and starter clutch
New
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
E
LT
LT
New
New E
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
70 N•m (7.0 kgf•m, 52 lb•ft)

T.R
.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-26.
1 Stator coil assembly coupler 1 Disconnect.
2 Generator cover 1
3 Generator cover gasket 1
4 Dowel pin 2
5 Stator coil assembly lead holder 1
6 Stator coil assembly 1
7 Starter clutch idle gear shaft 1
8 Starter clutch idle gear 1
9 Generator rotor 1
10 Starter clutch 1
11 Starter clutch gear 1
5-36
EAS30295 EAS30299
REMOVING THE GENERATOR CHECKING THE STARTER CLUTCH

• Generator rotor bolt “1” • Starter clutch rollers
• Washer Damage/wear → Replace.
TIP 2. Check:
While holding the generator rotor “2” with the ro- • Starter clutch idle gear
tor holding tool “3”, loosen the generator rotor • Starter clutch gear
bolt. Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
Rotor holding tool
• Starter clutch gear’s contacting surfaces
90890-04166
Rotor holding tool Damage/pitting/wear → Replace the starter
YM-04166 clutch gear.
4. Check:
• Starter clutch operation
3 a. Install the starter clutch gear “1” onto the
generator 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
1 starter clutch is faulty and must be re-
placed.
2 c. When turning the starter clutch gear coun-
2. Remove: terclockwise “B”, it should turn freely, oth-
• Generator rotor “1” erwise the starter clutch is faulty and must
(with the flywheel puller “2”) be replaced.
ECA13880
NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller set center bolt and the crank-
shaft.
Flywheel puller
90890-01404
Flywheel puller
YM-01404 EAS30300
INSTALLING THE STARTER CLUTCH

1. Install:
• Starter clutch “1”
TIP
1 Be sure to install the starter clutch so that its side
with the arrow mark “a” is facing inward, away
2 from the rotor.
5-37
a Yamaha bond No. 1215

1
90890-85505
EAS30302
INSTALLING THE GENERATOR

1. Install:
• Generator rotor
• Washer New
• Generator rotor bolt
TIP
• Clean the tapered portion of the crankshaft and
the generator rotor hub.
• Lubricate the generator rotor bolt threads and
washer mating surfaces with engine oil.
2. Tighten:
• Generator rotor bolt “1”
Generator rotor bolt

70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
TIP
While holding the generator rotor “2” with the ro-
tor holding tool “3”, tighten the generator rotor
bolt.
Rotor holding tool

90890-04166
Rotor holding tool
YM-04166
2
3. Apply:
• Sealant
(onto the stator coil assembly lead grommet)
5-38
PICKUP ROTOR
EAS20147
PICKUP ROTOR
Removing the pickup rotor
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
6
15 N•m (1.5 kgf•m, 11 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
New 4
5
New 3
New LT
LT
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
LS
1
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Refer to “GENERATOR AND STARTER
Generator cover CLUTCH” on page 5-36.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Pickup rotor cover 1
4 Pickup rotor cover gasket 1
5 Crankshaft position sensor 1
6 Pickup rotor 1
5-39
PICKUP ROTOR
EAS30873
REMOVING THE PICKUP ROTOR

1. Remove:
b a
• Pickup rotor bolt “1”
• Washer
• Pickup rotor
TIP
While holding the generator rotor “2” with the ro- 1
tor holding tool “3”, loosen the pickup rotor bolt.
Rotor holding tool 2. Tighten:

90890-04166 • Pickup rotor bolt “1”
Rotor holding tool
YM-04166 Pickup rotor bolt
35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
TIP
While holding the generator rotor “2” with the ro-
tor holding tool “3”, tighten the pickup rotor bolt.
Rotor holding tool

1 90890-04166
Rotor holding tool
YM-04166
2
EAS30874
INSTALLING THE PICKUP ROTOR 3

1. Install:
• Pickup rotor “1”
• Washer
• Pickup rotor bolt
TIP
When installing the pickup rotor, align the
groove “a” in the crankshaft with the projection 2
“b” on the pickup rotor.
5-40
PICKUP ROTOR
3. Apply:
• Sealant
(onto the crankshaft position sensor lead
grommet)
Yamaha bond No. 1215

90890-85505
5-41
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor
10 N•m (1.0 kgf•m, 7.4 lb •ft)
T.
R.
LT
LT

Rider seat 4-1.
Thermostat Refer to “THERMOSTAT” on page 6-10.
1 Starter motor lead 1
2 Starter motor assembly 1
5-42
ELECTRIC STARTER
Disassembling the starter motor
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
New
12
11
New
9
New
7
10
8
6
3 4 New
5
2
LS
New 1 New

1 O-ring 1
2 Starter motor front cover 1
3 Lock washer 1
4 Oil seal 1
5 Bearing 1
6 Washer set 1
7 Starter motor yoke 1
8 Armature assembly 1
9 Gasket 2
10 Washer set 2
11 Brush holder (along with the brushes) 1
12 Starter motor rear cover 1
5-43
ELECTRIC STARTER
EAS30325
CHECKING THE STARTER MOTOR Digital circuit tester (CD732)

1. Check: 90890-03243
• Commutator Model 88 Multimeter with ta-
Dirt → Clean with 600 grit sandpaper. chometer
2. Measure: YU-A1927
• Commutator diameter “1”
Out of specification → Replace the starter
Armature coil resistance
motor.
0.0012–0.0022 Ω
Limit
27.0 mm (1.06 in) b. If the resistance is out of specification, re-
place the starter motor.
3. Measure: 5. Measure:
• Mica undercut “a” • Brush length “a”
Out of specification → Scrape the mica to the Out of specification → Replace the brushes
proper measurement with a hacksaw blade as a set.
that has been grounded to fit the commutator.
Limit
Mica undercut (depth) 3.50 mm (0.14 in)
0.70 mm (0.03 in)
TIP
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
6. Measure:
• Brush spring force
Out of specification → Replace the brush
springs as a set.
4. Measure: Brush spring force

• Armature assembly resistance 7.16–9.52 N (730–971 gf, 25.77–
34.27 oz)
Out of specification → Replace the starter
motor.
a. Measure the armature assembly resis-
tance with the digital circuit tester.
5-44
ELECTRIC STARTER
7. Check:
• Gear teeth
Damage/wear → Replace the gear.
8. Check:
• Bearing
• Oil seal
Damage/wear → Replace the defective
part(s).
EAS30326
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor yoke “1”
TIP
Align the tab “a” on the brush holder with the slot
“b” in the starter motor yoke.
2. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
TIP
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front and
starter motor rear covers.
5-45
CLUTCH
EAS20055
CLUTCH
Removing the clutch cover
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
1
6 New
LS
5 New
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
7
LT
LT
4
7 N•m (0.7 kgf•m, 5.2 lb•ft) 3
T.R
New
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Drain.
page 3-26.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-29.
1 Water pump breather hose 1 Disconnect.
3 Pull lever 1
4 Pull lever spring 1
5 Clutch cover 1
6 Clutch cover gasket 1
7 Dowel pin 2
5-46
CLUTCH
Removing the pull lever shaft
LS
New
5
4
3 New
LS
E

1 Circlip 1
2 Pull lever shaft 1
3 Oil seal 1
4 Bearing 1
5 Bearing 1
5-47
CLUTCH
Removing the clutch

115 N•m (11.5 kgf•m, 85 lb•ft)
T.R
.
E
LT
LT
LT
12 E
12 N•m (1.2 kgf•m, 8.9 lb•ft)
9
T.R
.
11
LT
10
New
25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
3 2
8
1
7
6
5 4
LS
E
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.

Oil strainer Refer to “OIL PUMP” on page 5-59.
1 Clutch spring 6
2 Pressure plate 1
3 Pull rod 1
4 Friction plate 1 1 brown painting
5 Clutch plate 1 1
6 Friction plate 2 7 black painting
7 Clutch plate 2 1
8 Clutch plate 3 6
9 Friction plate 3 1 purple painting
10 Clutch boss nut 1
11 Spring 3
12 Clutch boss 1
5-48
CLUTCH
Removing the clutch

115 N•m (11.5 kgf•m, 85 lb•ft)
T.R
.
21 20 19 18
E
17 16
15
22 LT
LT 14
LT
13
E
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
LT
New
25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
LS
E
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.

13 Clutch boss plate 1
14 Washer 1
15 Thrust washer 1 1
16 Spacer 1
17 Bearing 1
18 Clutch housing 1
19 Oil pump drive chain 1
22 Oil pump drive chain guide 1
5-49
CLUTCH
EAS30346
REMOVING THE CLUTCH TIP

1. Remove: Remove the spacer and bearing from the main
• Oil strainer axle, then remove the oil pump drive chain from
Refer to “OIL PUMP” on page 5-59. the oil pump driven sprocket, and then remove
• Water pump the clutch housing and oil pump drive chain from
Refer to “WATER PUMP” on page 6-12. the main axle.
• Friction plates
• Clutch plates
TIP 1
Be sure to mark the friction plates and clutch 2
plates or note the position of each part so that
they are installed in their original positions.
2. Straighten the clutch boss nut rib “a”.
EAS30348
CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-
tion plates.
1. Check:
• Friction plate
Damage/wear → Replace the friction plates
as a set.
3. Loosen: 2. Measure:
• Clutch boss nut “1” • Friction plate thickness
TIP Out of specification → Replace the friction
While holding the clutch boss “2” with the univer- plates as a set.
sal clutch holder “3”, loosen the clutch boss nut. TIP
Measure the friction plate at four places.
90890-04086
Friction plate thickness
2.92–3.08 mm (0.115–0.121 in)
YM-91042
Wear limit
2.80 mm (0.110 in)
3 1
4. Remove:
• Spacer “1”
EAS30349
• Bearing CHECKING THE CLUTCH PLATES
• Clutch housing “2” The following procedure applies to all of the
• Oil pump drive chain clutch plates.
5-50
CLUTCH
1. Check: a
• Clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch
plates as a set.
Thickness gauge a. Adjust the assembly width by replacing

90890-03180 the clutch plate “1” and, if necessary,
Feeler gauge set clutch plate “2”.
YU-26900-9
b. Select the clutch plate from the following
table.
Clutch plate thickness Clutch plate “1”
1.90–2.10 mm (0.075–0.083 in)
Warpage limit Part No. Thickness
0.10 mm (0.004 in) 168-16325-00 1.6 mm (0.063 in)
3J2-16324-00 2.0 mm (0.079 in) STD
TIP
The clutch plate thickness specification listed 168-16324-00 2.3 mm (0.091 in)
above is for the plates with the standard thick-
ness only. If a clutch plate with one of the other Clutch plate “2”
two plate thicknesses is installed, use 1.50–1.70 Part No. Thickness
mm (0.059–0.067 in) or 2.20–2.40 mm (0.086–
3J2-16324-00 2.0 mm (0.079 in) STD
0.094 in) for the specification according to the
plate. 168-16324-00 2.3 mm (0.091 in)
TIP
When adjusting the clutch assembly width (by
replacing the clutch plate(s)), be sure to replace
the clutch plate “1” first. After replacing the clutch
plate “1”, if specifications cannot be met, replace
the clutch plate “2”.
2 1
3. Measure:
• Assembly width “a” of the friction plates and
clutch plates
Assembly width
42.4–43.0 mm (1.67–1.69 in)
EAS30351
CHECKING THE CLUTCH SPRINGS

clutch springs.
1. Check:
• Clutch spring
Damage → Replace the clutch springs as a
set.
5-51
CLUTCH
2. Measure:
• Clutch spring free length “a”
Out of specification → Replace the clutch
springs as a set.
Clutch spring free length

55.00 mm (2.17 in)
Limit
54.00 mm (2.13 in)
EAS30354
CHECKING THE PRESSURE PLATE

1. Check:
• Pressure plate “1”
• Bearing “2”
1
EAS30352
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
2
TIP
Pitting on the clutch housing dogs will cause er- EAS30356
ratic clutch operation. CHECKING THE PRIMARY DRIVE GEAR
1. Check:
• Primary drive gear
Damage/wear → Replace the clutch housing
and crankshaft as a set.
Excessive noise during operation → Replace
the clutch housing and crankshaft as a set.
EAS30357
CHECKING THE PRIMARY DRIVEN GEAR

1. Check:
• Primary driven gear “1”
2. Check: Damage/wear → Replace the clutch housing
• Bearing and crankshaft as a set.
Damage/wear → Replace the bearing and Excessive noise during operation → Replace
clutch housing. the clutch housing and crankshaft as a set.
EAS30353
CHECKING THE CLUTCH BOSS

1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
TIP
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
5-52
CLUTCH
EAS30358
CHECKING THE PULL LEVER SHAFT AND

PULL ROD
1. Check: 2
• Pull lever shaft pinion gear teeth “1”
• Pull rod teeth “2”
Damage/wear → Replace the pull rod and
pull lever shaft pinion gear as a set.
1
2. Install:
• Clutch boss plate “1”
• Clutch boss “2”
TIP
Fit the projections “a” on the clutch boss into the
grooves “b” in the clutch boss plate.
2. Check: b a
• Bearing
1
EAS31601
2
CHECKING THE OIL PUMP DRIVE
SPROCKET AND OIL PUMP DRIVE CHAIN
1. Check:
• Oil pump drive sprocket a
Cracks/damage/wear → Replace the clutch b
housing, oil pump drive chain, and oil pump 3. Install:
driven sprocket as a set. • Springs “1”
2. Check: TIP
• Oil pump drive chain • Stack the springs on top of each other, making
Damage/stiffness → Replace the clutch sure that the tab “a” on each spring is in a dif-
housing, oil pump drive chain, and oil pump ferent position.
driven sprocket as a set. • Fit the tabs “a” on the springs into the grooves
EAS30363
“b” in the clutch boss plate.
INSTALLING THE CLUTCH
1. Install: 1
• Oil pump drive chain “1”
• Clutch housing “2”
TIP
• Install the oil pump drive chain onto the clutch
housing, and then install the chain onto the oil a
pump driven sprocket while installing the clutch
housing onto the main axle. a
• Make sure that the oil pump drive chain passes a
through the oil pump drive chain guide.
5-53
CLUTCH
• Install the last friction plate “1” offset from the

b other friction plates “2”, making sure to align a
1 projection on the friction plate with the punch
mark “a” on the clutch housing.
b 1
a 2
4. Tighten:
• Clutch boss nut “1” New a
Clutch boss nut
115 N·m (11.5 kgf·m, 85 lb·ft) 7. Install:
T.
R.
• Pressure plate “1”

TIP
TIP
• While holding the clutch boss “2” with the uni-
Align the punch marks “a” in the pressure plate
versal clutch holder “3”, tighten the clutch boss
with one of the three punch marks “b” in the
nut.
clutch boss.
• Stake the clutch boss nut at a cutout “a” in the
main axle.
1
90890-04086
YM-91042
a a
3 b
8. Install:
1 New • Seat plate
• Clutch springs
• Clutch spring bolts
2 Clutch spring bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
5. Lubricate:
• Friction plates TIP
• Clutch plates Tighten the clutch spring bolts in stages and in a
(with the recommended lubricant) crisscross pattern.
Engine oil
6. Install:
• Friction plates
• Clutch plates
TIP
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
5-54
CLUTCH
9. Install: 11.Adjust:
• Dowel pins • Clutch cable free play
• Clutch cover gasket New Refer to “ADJUSTING THE CLUTCH LEVER
• Clutch cover “1” FREE PLAY” on page 3-13.
Clutch cover bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
• Position the pull rod so that the teeth “a” face
towards the rear of the vehicle. Then, install the
clutch cover.
• Apply locking agent (LOCTITE®) to the
threads of only the clutch cover bolts “a” shown
in the illustration.
• Tighten the clutch cover bolts in stages and in
a crisscross pattern.
10.Install:
• Pull lever spring “1”
• Pull lever “2”
• Washer
• Circlip New
TIP
• Make sure that the mark “a” on the pull lever is
facing up.
• When installing the pull lever, push it and
check that its punch mark “b” aligns with the
mark “c” on the clutch cover. Make sure that
the pull rod teeth and pull lever shaft pinion
gear are engaged.
c
1
2
a b
5-55
SHIFT SHAFT
EAS20057
SHIFT SHAFT
Removing the shift shaft and stopper lever
New
4
5
6
7
9
10 New
E New
3 LS
8
1
2
22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.
LT

Shift arm Refer to “ENGINE REMOVAL” on page 5-9.
Clutch housing Refer to “CLUTCH” on page 5-46.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Circlip 1
6 Washer 1
7 Stopper lever 1
8 Stopper lever spring 1
9 Spacer 1
10 Shift shaft spring 1
5-56
SHIFT SHAFT
Removing the shift shaft and stopper lever
New 13
New
E New
LS
12
13
E
22 N•m (2.2 kgf•m, 16 lb•ft)

T.R
.
11
LT

11 Shift shaft spring stopper 1
12 Oil seal 1
13 Bearing 2
5-57
SHIFT SHAFT
EAS30377
CHECKING THE SHIFT SHAFT

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

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

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

22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.
LOCTITE®
TIP
• Lubricate the oil seal lips with lithium-soap-
based grease.
• Hook the end of the shift shaft spring onto the
shift shaft spring stopper.
• Hook the ends of the stopper lever spring “3”
onto the stopper lever “4” and the crankcase
boss “5”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
4 2
5-58
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pan and oil pump
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
LS New
New LS New
New
LS
New
LT
LT New
12 N•m (1.2 kgf•m, 8.9 lb•ft) LS
T.R
.
5 4 4 2 5
New
1
4
2
3
4
3
New
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
43 N•m (4.3 kgf•m, 32 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
T.R
.
.

Drain.
page 3-26.
Drain.
page 3-29.
Exhaust pipe assembly Refer to “ENGINE REMOVAL” on page 5-9.
Clutch housing Refer to “CLUTCH” on page 5-46.
1 Oil level switch coupler 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4 Bottom cowling bracket 2
5 Oil pan 1
5-59
OIL PUMP
Removing the oil pan and oil pump

12
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
11 LS New
10
New LS New
New
8
LS
7 6 13
New 9
LT
LT New
12 N•m (1.2 kgf•m, 8.9 lb•ft) LS
T.R
.
7
New
10
11
New
9 12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
43 N•m (4.3 kgf•m, 32 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
T.R
.
.

6 Oil pan gasket 1
7 Oil strainer 1
8 Oil strainer gasket 1
9 Oil pipe 1
10 Ventilation chamber oil drain pipe 1
11 Oil pump assembly 1
12 Dowel pin 2
13 Relief valve assembly 1
5-60
OIL PUMP
Disassembling the oil pump
E
8
7
2
6
3
LS 4
1
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.

1 Oil pump housing cover 1
2 Pin 2
3 Oil pump inner rotor 1
4 Oil pump outer rotor 1
5 Pin 1
6 Washer 1
7 Oil pump housing 1
8 Oil pump driven sprocket 1
5-61
OIL PUMP
EAS30333
REMOVING THE OIL PAN

1. Remove:
• Oil level switch lead holder
• Bottom cowling brackets
• Oil pan
• Oil pan gasket
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them. EAS30338
CHECKING THE RELIEF VALVE

EAS30337 1. Check:
CHECKING THE OIL PUMP • Relief valve body “1”
1. Check: • Relief valve “2”
• Oil pump driven sprocket • Spring “3”
• Oil pump housing • O-ring “4”
• Oil pump housing cover Damage/wear → Replace the defective
Cracks/damage/wear → Replace the defec- part(s).
tive part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
EAS30742
CHECKING THE OIL PIPES

The following procedure applies to all of the oil
delivery pipes.
1. Check:
1. Inner rotor • Ventilation chamber oil drain pipe
2. Outer rotor • Oil pipe
Damage → Replace.
Inner-rotor-to-outer-rotor-tip Obstruction → Wash and blow out with com-
clearance pressed air.
0–0.120 mm (0–0.0047 in)
EAS30340
Limit CHECKING THE OIL STRAINER
0.20 mm (0.0079 in)
1. Check:
Outer-rotor-to-oil-pump-housing
clearance • Oil strainer
0.09–0.15 mm (0.0035–0.0059 in) Damage → Replace.
Limit Contaminants → Clean with solvent.
0.22 mm (0.0087 in) EAS30342
ASSEMBLING THE OIL PUMP

3. Check: 1. Lubricate:
• Oil pump operation • Inner rotor
Rough movement → Repeat steps (1) and • Outer rotor
(2) or replace the defective part(s). • Oil pump shaft
(with the recommended lubricant)
5-62
OIL PUMP
Engine oil and lithium-soap-
based grease
2. Install:
• Oil pump driven sprocket
• Oil pump housing “1”
• Washer “2”
• Pin “3”
• Oil pump inner rotor “4”
• Oil pump outer rotor
TIP
When installing the inner rotor, align the pin “3”
in the oil pump shaft with the groove “a” in the in-
ner rotor “4”.
4
a
1
3
2
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-62.
EAS30345
INSTALLING THE OIL PAN

1. Install:
• Oil pan gasket New
• Oil pan
• Bottom cowling brackets
• Oil level switch lead holder
Oil pan bolt

12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
TIP
Tighten the oil pan bolts in stages and in a criss-
cross pattern.
5-63
CRANKCASE
EAS20059
CRANKCASE
Separating the crankcase
LS
LS
New
2
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
LS
New New
LS
New
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
LT
.
LT
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
New
LT 3
4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 4
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft) New

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
New
1
LT
LT
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-9.
Cylinder head Refer to “CYLINDER HEAD” on page 5-26.
Refer to “GENERATOR AND STARTER
Starter clutch CLUTCH” on page 5-36.
Shift shaft Refer to “SHIFT SHAFT” on page 5-56.
Pickup rotor Refer to “PICKUP ROTOR” on page 5-39.
Oil pump drive chain guide Refer to “CLUTCH” on page 5-46.
Oil pump assembly Refer to “OIL PUMP” on page 5-59.
1 Timing chain 1
2 Dipstick 1
3 Neutral switch lead 1
4 Neutral switch 1
5-64
CRANKCASE
Separating the crankcase

LS
11 LS
New
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
LS
New New
LS
New
8
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
LT
.
LT
5 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
New 12
LT
12
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft) New

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

7
T.R
.
10
New
9
6
LT
LT
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

5 Gear position sensor 1
6 Ventilation chamber cover 1
7 Ventilation chamber cover gasket 1
8 Oil pipe 1
9 Oil baffle plate 1 1
10 Oil baffle plate 2 1
11 Lower crankcase 1
12 Dowel pin 3
5-65
CRANKCASE
EAS30389 EAS30743
DISASSEMBLING THE CRANKCASE CHECKING THE OIL PIPE

1. Place the engine upside down. 1. Check:
2. Remove: • Oil pipe
• Crankcase bolts Damage → Replace.
TIP Obstruction → Wash and blow out with com-
• Loosen each bolt 1/4 of a turn at a time. After pressed air.
all of the bolts are fully loosened, remove them. EAS31445
• Loosen the bolts in decreasing numerical order CHECKING THE TIMING CHAIN
(refer to the numbers in the illustration). Refer to “CAMSHAFTS” on page 5-18.
• The numbers embossed on the crankcase in-
EAS30397
dicate the crankcase tightening sequence. ASSEMBLING THE CRANKCASE
• M8 × 115 mm bolts: “8”, “9” 1. Lubricate:
• M8 × 85 mm bolts: “1”–“7”, “10” • Crankshaft journal bearings
• M8 × 65 mm bolts: “11”, “12” (with the recommended lubricant)
• M6 × 80 mm bolt: “29”
• M6 × 65 mm shoulder bolts: “13”, “14” Recommended lubricant
Engine oil
• M6 × 65 mm bolts: “16”, “20”, “21”
• M6 × 55 mm bolts: “15”, “22”–“27” 2. Apply:
• M6 × 45 mm bolts: “17”–“19” • Sealant
• M6 × 30 mm bolt: “28” (onto the crankcase mating surfaces)
13 26 25 24 23 22
21 Yamaha bond No. 1215
7 5 1 3 9 90890-85505
27 10 4 2 6 8
15 20 14 TIP
29 12 Do not allow any sealant to come into contact
16 with the oil gallery or crankshaft journal bear-
11 ings. Do not apply sealant to within 2–3 mm
28 17 18 19 (0.08–0.12 in) of the crankshaft journal bearings.
3. Remove:
• Lower crankcase
ECA13900
NOTICE
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase 1
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
EAS30390
1. Three Bond No.1215®
CHECKING THE CRANKCASE
3. Install:
1. Thoroughly wash the crankcase halves in a
• Dowel pins
mild solvent.
4. Set the shift drum assembly and transmission
2. Thoroughly clean all the gasket surfaces and
gears in the neutral position.
crankcase mating surfaces.
5. Install:
3. Check:
• Lower crankcase “1”
• Crankcase
(onto the upper crankcase “2”)
• Oil delivery passages
5-66
CRANKCASE
ECA13980
*Loosen all bolts following the tightening or-
NOTICE der and then tighten to specification torque.
Before tightening the crankcase bolts, make TIP
sure the transmission gears shift correctly
when the shift drum assembly is turned by
hand.
• Tighten the bolts in the tightening sequence
cast on the crankcase.
1
7 5 1 3 9
10 4 2 6 8
2
6. Install:
• Crankcase bolts
8. Tighten:
TIP • Crankcase bolts “11”–“29”
• Lubricate the bolts “1”–“10” thread part and
washers with engine oil. Crankcase bolt (M8 × 65 mm)
• Lubricate the bolts “11”–“29” thread part and T.
R. 24 N·m (2.4 kgf·m, 18 lb·ft)
mating surfaces with engine oil. Crankcase bolt (M6)
• Finger tighten the crankcase bolts. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
• M8 × 115 mm bolts: “8”, “9” TIP
• M8 × 85 mm bolts: “1”–“7”, “10”
• M8 × 65 mm bolts: “11”, “12”
• M6 × 80 mm bolt: “29”
• Tighten the bolts in the tightening sequence
• M6 × 65 mm shoulder bolts: “13”, “14”
cast on the crankcase.
• M6 × 65 mm bolts: “16”, “20”, “21”
• M6 × 55 mm bolts: “15”, “22”–“27”
13 26 25 24 23 22
• M6 × 45 mm bolts: “17”–“19” 21
• M6 × 30 mm bolt: “28”
13 26 25 24 23 22 27
21 15 20 14
7 5 1 3 9
29 12
27 10 4 2 6 8
16
15 20 14 11
29 12 28 17 18 19
16 EAS31658
11 INSTALLING THE GEAR POSITION SENSOR
28 17 18 19 ECA22630
NOTICE
7. Tighten:
• Crankcase bolts “1”–“10” To prevent damage to the gear position sen-
sor, keep magnets (including any pickup tool
Crankcase bolt (M8 × 115 mm, M8 with a magnet, magnetized screwdrivers,
× 85 mm) etc.) away from the gear position sensor.
T.
R.
1st: 20 N·m (2.0 kgf·m, 15 lb·ft)

1. Install:
*2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
3rd: Bolt “1”–“7”, “10” +50° Bolt • O-ring New
“8”, “9” +75° • Gear position sensor “1”
5-67
CRANKCASE
Gear position sensor bolt

T.
R.
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
LOCTITE®
TIP
• Lubricate the O-ring with lithium-soap-based
grease.
• Fit the end “a” of the shift drum assembly into
the opening “b” in the gear position sensor “1”.
a
1
5-68
CONNECTING RODS AND PISTONS
EAS20132

Removing the connecting rods and pistons
1st 15 N•m (1.5 kgf•m, 11 lb •ft)
T.
2nd Specified angle 175 -185
R.
M New
M
E New 1
7 2
E
M M
New New
6
5
New 3
4
E 3 New
10
9 E

Separate.
Crankcase Refer to “CRANKCASE” on page 5-64.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Piston pin clip 8
4 Piston pin 4
5 Piston 4
6 Connecting rod 4
7 Big end upper bearing 4
8 Top ring 4
9 2nd ring 4
10 Oil ring 4
5-69
EAS30745
REMOVING THE CONNECTING RODS AND 1

PISTONS 4
The following procedure applies to all of the con-
necting rods and pistons. 3
1. Remove:
• Connecting rod cap “1” 2
TIP 1
Identify the position of each connecting rod so
that it can be reinstalled in its original place.
2. Remove: 4. Remove:
• Big end bearings • Top ring
(from the connecting rods and connecting rod • 2nd ring
caps) • Oil ring
TIP TIP
Identify the position of each big end bearing so When removing a piston ring, open the end gap
that it can be reinstalled in its original place. with your fingers and lift the other side of the ring
over the piston crown.
3. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
• Connecting rod “4”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• For reference during installation, put an identi- EAS30747
fication mark on each piston crown. CHECKING THE CYLINDERS AND PISTONS
• Before removing the piston pin, deburr the pis- The following procedure applies to all of the cyl-
ton pin clip’s groove and the piston’s pin bore inders and pistons.
area. If both areas are deburred and the piston 1. Check:
pin is still difficult to remove, remove it with the • Piston wall
piston pin puller set “5”. • Cylinder wall
Vertical scratches → Rebore or replace the
Piston pin puller set cylinder, and replace the piston and piston
90890-01304 rings as a set.
Piston pin puller 2. Measure:
YU-01304 • Piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylin-
der bore gauge.
5-70
TIP
Piston-to-cylinder clearance
Measure cylinder bore “C” by taking side-to-side 0.010–0.035 mm (0.0004–0.0014
and front-to-back measurements of the cylinder. in)
Bore f. If out of specification, rebore or replace the

67.000–67.010 mm (2.6378– cylinder, and replace the piston and piston
2.6382 in) rings as a set.
Wear limit
67.060 mm (2.6402 in) EAS30748
CHECKING THE PISTON RINGS

1. Measure:
“C” = maximum of D1, D2, D3, D4, D5, D6
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
Piston ring
Top ring
Ring side clearance
b. If out of specification, rebore or replace the 0.030–0.065 mm (0.0012–
cylinder, and replace the piston and piston 0.0026 in)
rings as a set. 2nd ring
c. Measure piston skirt diameter “P” with the Ring side clearance
micrometer. 0.020–0.055 mm (0.0008–
0.0022 in)
Piston
Diameter
66.975–66.990 mm (2.6368–
2.6374 in)
P
2. Install:
• Piston ring
(into the cylinder)
TIP
a. 10 mm (0.39 in) from the bottom edge of the Use the piston crown to level the piston ring near
piston
bottom of cylinder “a”, where cylinder wear is
d. If out of specification, replace the piston lowest.
and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
• Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “P”
5-71
b. Upper of cylinder 3. Measure:

• Piston pin bore diameter “b”
3. Measure: Out of specification → Replace the piston.
• Piston ring end gap
Out of specification → Replace the piston Piston pin bore inside diameter
ring. 15.002–15.013 mm (0.5906–
TIP 0.5911 in)
The oil ring expander spacer’s end gap cannot Limit
15.043 mm (0.5922 in)
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring
Top ring
End gap limit
0.60 mm (0.0236 in)
2nd ring
End gap limit
1.15 mm (0.0453 in)
EAS30749
CHECKING THE PISTON PINS 4. Calculate:

The following procedure applies to all of the pis- • Piston-pin-to-piston-pin-bore clearance
ton pins. Out of specification → Replace the piston pin
1. Check: and piston as a set.
• Piston pin • Piston-pin-to-piston-pin-bore clearance =
Blue discoloration/grooves → Replace the Piston pin bore diameter “b” -
piston pin and then check the lubrication sys- Piston pin outside diameter “a”
tem.
2. Measure: Piston-pin-to-piston-pin-bore
• Piston pin outside diameter “a” clearance
Out of specification → Replace the piston pin. 0.002–0.022 mm (0.0001–0.0009
in)
Piston pin outside diameter
14.991–15.000 mm (0.5902– EAS30750
0.5906 in) CHECKING THE CONNECTING RODS

Limit 1. Measure:
14.971 mm (0.5894 in) • Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.
Oil clearance
0.037–0.061 mm (0.0015–0.0024
in)
5-72
The following procedure applies to all of the • Make sure the “Y” mark “c” on the connecting
connecting rods. rod faces towards the left side of the crank-
ECA13930
shaft.
NOTICE • Make sure the characters “d” on both the con-
Do not interchange the big end bearings and necting rod and connecting rod cap are
connecting rods. To obtain the correct aligned.
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
end bearings must be installed in their origi- d
nal positions.
a. Clean the big end bearings, crankshaft
pins, and the inside of the connecting rods
halves. c
b. Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
TIP e. Tighten the connecting rod nuts.
Align the projections “a” on the big end bearings Refer to “INSTALLING THE CONNECT-
with the notches “b” in the connecting rod and ING RODS AND PISTONS” on page 5-74.
connecting rod cap. f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECT-
ING RODS AND PISTONS” on page 5-70.
g. Measure the compressed Plastigauge®
width “e” on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select re-
placement big end bearings.
c. Put a piece of Plastigauge® “1” on the

crankshaft pin.
1 e
2. Select:
• Big end bearings (P1–P4)
TIP
• The numbers stamped into the crankshaft web
d. Assemble the connecting rod halves. and the numbers on the connecting rods are
TIP used to determine the replacement big end
bearing sizes.
• Do not move the connecting rod or crankshaft
• P1–P4 refer to the bearings shown in the crank-
until the clearance measurement has been
completed. shaft illustration.
• Lubricate the bolt threads and nut seats with
molybdenum disulfide grease.
5-73
1. Install:
• Top ring “1”
• 2nd ring “2”
• Upper oil ring rail “3”
P2 P3 • Oil ring expander “4”
• Lower oil ring rail “5”
P1 P4
TIP
Be sure to install the piston rings so that the
manufacturer’s marks or numbers “a” face up.
P1 P2 P3 P4
211221111
2. Install:
• Piston “1”
(onto the respective connecting rod “2”)
• Piston pin “3”
• Piston pin clips “4” New
TIP
5F • Apply engine oil onto the piston pin.
• Make sure that the “Y” mark “a” on the connect-
ing rod left when the punch mark “b” on the pis-
ton is pointing up. Refer to the illustration.
For example, if the connecting rod P1 and the • Install the piston pin clips, so that the clip ends
crankshaft web P1 numbers are 5 and 1 re- are 3 mm (0.12 in) “c” or more from the cutout
in the piston.
spectively, then the bearing size for P1 is:
• Reinstall each piston into its original cylinder
P1 (connecting rod) - P1 (crankshaft) (numbering order starting from the left: #1 to
= #4).
5 - 1 = 4 (green)
a 4 New
Bearing color code
Code 1 2
Blue 1
Code 2
Black 3
Code 3 b
Brown New 4
Code 4
Green
EAS30751
INSTALLING THE CONNECTING RODS AND

PISTONS
The following procedure applies to all of the pis-
tons and connecting rods.
5-74
7. Install:
• Big end bearings
• Connecting rod and piston assembly
• Connecting rod cap
TIP
• Align the projections on the big end bearings
c with the notches in the connecting rods and
connecting rod caps.
4 New • Be sure to reinstall each big end bearing in its
original place.
3. Offset: • While compressing the piston rings one hand,
• Piston ring end gaps install the connecting rod assembly into the cyl-
A inder with the other hand.
90˚ • Make sure the “Y” marks “a” on the connecting
d.e b rods face towards the left side of the crank-
shaft.
• Make sure the characters “b” on both the con-
90˚ necting rod and connecting rod cap are
aligned.
a.c b 5F
45˚ a
a. Top ring
b. Upper oil ring rail
c. Oil ring expander
d. 2nd ring
e. Lower oil ring rail
A. Exhaust side
4. Lubricate:
• Piston 8. Tighten:
• Piston rings • Connecting rod nuts “1”
• Cylinder
Engine oil
5. Lubricate:
• Bolt threads
• Nut seats
EWA13390
Recommended lubricant WARNING
Molybdenum disulfide oil
• Replace the connecting rod bolts and nuts
6. Lubricate: with new ones.
• Crankshaft pins • Clean the connecting rod bolts and nuts.
• Connecting rod big end bearing inner surface TIP
Tighten the connecting rod nuts using the follow-
Recommended lubricant ing procedure.
Engine oil a. Tighten the connecting rod nuts with a
torque wrench.
5-75
Connecting rod nut (1st)

T.
R.
15 N·m (1.5 kgf·m, 11 lb·ft)
b. Put a mark “1” on the corner of the con-

necting rod nut “2” and the connecting rod
“3”.
c. Tighten the connecting rod nuts further to

reach the specified angle 175°–185°.
Connecting rod nut (final)

Specified angle 175°–185°
T.
R.
EWA13400
WARNING
If the connecting rod nut is tightened more
than the specified angle, do not loosen the
nut and then retighten it. Instead, replace the
connecting rod bolt and nut with a new one
and perform the procedure again.
ECA13950
NOTICE
Do not use a torque wrench to tighten the
connecting rod nut to the specified angle.
TIP
On a hexagonal nut, note that the angle from
one corner to another is 60°.
5-76
CRANKSHAFT
EAS20061
CRANKSHAFT
Removing the crankshaft
1
E
4
LS
New

Separate.
Refer to “CONNECTING RODS AND PIS-
Connecting rod caps TONS” on page 5-69.
1 Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5
4 Oil nozzle 4
5-77
CRANKSHAFT
EAS30419
3. Measure:
REMOVING THE CRANKSHAFT JOURNAL
• Crankshaft-journal-to-crankshaft-journal-
BEARINGS
bearing clearance
1. Remove:
Out of specification → Replace the crank-
• Crankshaft journal lower bearings
shaft journal bearings.
(from the lower crankcase)
• Crankshaft journal upper bearings Journal oil clearance
(from the upper crankcase) 0.020–0.044 mm (0.0008–0.0017
TIP in)
Identify the position of each crankshaft journal ECA13920
bearing so that it can be reinstalled in its original NOTICE
place.
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
EAS30837
CHECKING THE OIL NOZZLES journal-to-crankshaft-journal-bearing clear-

The following procedure applies to all of the oil ance and prevent engine damage, the crank-
nozzles. shaft journal bearings must be installed in
1. Check: their original positions.
• Oil nozzle a. Clean the crankshaft journal bearings,
Damage/wear → Replace the oil nozzle. crankshaft journals, and bearing portions
• O-ring of the crankcase.
Damage/wear → Replace. b. Place the upper crankcase upside down
• Oil passage on a bench.
Obstruction → Blow out with compressed air. c. Install the crankshaft journal upper bear-
EAS30423
ings “1” and the crankshaft into the upper
CHECKING THE CRANKSHAFT AND crankcase.
CONNECTING RODS TIP
1. Measure: Align the projections “a” on the crankshaft jour-
• Crankshaft runout nal upper bearings with the notches “b” in the up-
Out of specification → Replace the crank- per crankcase.
shaft.
Runout limit
0.030 mm (0.0012 in)
d. Put a piece of Plastigauge® “1” on each

crankshaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
2. Check: the crankshaft journal.
• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear → Replace the crankshaft.
5-78
CRANKSHAFT
4. Select:
• Crankshaft journal bearings (J1–J5)
TIP
• The numbers “A” stamped into the crankshaft
web and the numbers “B” stamped into the
lower crankcase are used to determine the re-
placement crankshaft journal bearing sizes.
• J1–J5 refer to the bearings shown in the crank-
shaft illustration.
e. Install the crankshaft journal lower bear- • If J1–J5 of crankcase are the same, only J1 is
ings “1” into the lower crankcase and as- stamped.
semble the crankcase halves.
TIP
• Align the projections “a” of the crankshaft jour-
nal lower bearings with the notches “b” in the
lower crankcase.
• Do not move the crankshaft until the clearance J1 J2 J3 J4 J5
measurement has been completed.
A J1 J2 J3 J4 J5
211221111
f. Tighten the bolts to specification in the

tightening sequence cast on the crank-
case.
Refer to “CRANKCASE” on page 5-64.
g. Remove the lower crankcase and the
crankshaft journal lower bearings.
h. Measure the compressed Plastigauge®
width “a” on each crankshaft journal. 555 54
If the crankshaft-journal-to-crankshaft-
journal-bearing clearance is out of specifi-
cation, select replacement crankshaft
journal bearings.
B J1 J2 J3 J4 J5
For example, if the crankcase J1 and crank-
shaft web J1 numbers are 6 and 2 respective-
ly, then the bearing size for J1 is:
J1 (crankcase) - J1 (crankshaft web) - 1
=
6 - 2 - 1 = 3 (brown)
5-79
CRANKSHAFT
Bearing color code

Code 0
White
Code 1
Blue
Code 2
Black
Code 3
Brown
Code 4
Green
EAS30791
INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft journal upper bearings
(into the upper crankcase)
• Crankshaft journal lower bearings
(into the lower crankcase)
TIP
• Align the projections “a” on the crankshaft jour-
nal bearings “1” with the notches “b” in the
crankcases.
• Be sure to install each crankshaft journal bear-
ing in its original place.
5-80
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
LS
1 3
New
E
8
LT
E 4 9
E
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
E
New
7
LS 6
5 E
10
E
5 7
LT LT 6
E 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.

Separate.
1 Drive axle assembly 1
2 Circlip 1
3 Oil seal 1
4 Bearing 1
5 Shift drum retainer 2
6 Spring 2
7 Shift fork guide bar 2
8 Shift fork-L 1
9 Shift fork-R 1
10 Shift drum assembly 1
5-81
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks

LS
12
New
E
11
LT
E
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
E
14
E
New
15
LS
E
E
13
LT LT
E 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

11 Shift fork-C 1
12 Main axle assembly 1
13 Oil pipe 1
14 Bearing 1
15 Bearing 1
5-82
TRANSMISSION
Disassembling the main axle assembly
13
14
15
8
12
11
7 New
6
10 New
5 M 9
4
3
M
2
1 M

1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Collar 1
6 Washer 1
7 Circlip 1
8 3rd/4th pinion gear 1
9 Circlip 1
10 Washer 1
11 5th pinion gear 1
12 Collar 1
13 Bearing housing 1
14 Bearing 1
15 Main axle/1st pinion gear 1
5-83
TRANSMISSION
Disassembling the drive axle assembly
1 2
M
New
5
8 3
6
9
10 4
7
12 M
M
13
11
New
14
M New
M
E
M

1 Washer 1
2 1st wheel gear 1
3 Collar 1
4 5th wheel gear 1
5 Circlip 1
6 Washer 1
7 3rd wheel gear 1
8 Collar 1
9 Toothed lock washer 1
10 Toothed lock washer retainer 1
11 4th wheel gear 1
12 Collar 1
13 Washer 1
14 Circlip 1
5-84
TRANSMISSION
Disassembling the drive axle assembly
New
M M
New
M 16 New 18
M
15 19
21 17
20
E
M

15 6th wheel gear 1
16 Circlip 1
17 Washer 1
18 2nd wheel gear 1
19 Collar 1
20 Bearing 1
21 Drive axle 1
5-85
TRANSMISSION
EAS30430
2. Check:
REMOVING THE TRANSMISSION
• Shift fork guide bar
1. Remove:
Roll the shift fork guide bar on a flat surface.
• Main axle assembly “1”
Bends → Replace.
a. Remove the main axle assembly bearing EWA12840
housing bolts “2” WARNING

Do not attempt to straighten a bent shift fork
2 guide bar.
2
1
b. Insert two bolts “3” of the proper size, as

shown in the illustration, into the main axle
assembly bearing housing.
3. Check:
1 mm 6 mm
• Shift fork movement
(along the shift fork guide bar)
30 mm Rough movement → Replace the shift forks
and shift fork guide bar as a set.
c. Tighten the bolts until they contact the

crankcase surface.
d. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
4. Check:
EAS30431
• Shift fork guide bar (for the shift fork-C) oil
CHECKING THE SHIFT FORKS
passage
The following procedure applies to all of the shift
Clogging/damage → Replace the shift fork
forks.
guide bar (for the shift fork-C).
1. Check:
• Shift fork cam follower “1” EAS30432
• Shift fork pawl “2” CHECKING THE SHIFT DRUM ASSEMBLY

Bends/damage/scoring/wear → Replace the 1. Check:
shift fork. • Shift drum groove
Damage/scratches/wear → Replace the shift
drum assembly.
• Shift drum segment “1”
Damage/wear → Replace the shift drum as-
sembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly.
5-86
TRANSMISSION
• Transmission gear dogs

Cracks/damage/rounded edges → Replace
the defective gear(s).
EAS30433
CHECKING THE TRANSMISSION

1. Measure:
• Main axle runout
4. Check:
(with a centering device and dial gauge “1”)
• Transmission gear engagement
Out of specification → Replace the main axle.
(each pinion gear to its respective wheel
Main axle runout limit gear)
0.02 mm (0.0008 in) Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• Circlips
Bends/damage/looseness → Replace.
EAS30435
ASSEMBLING THE MAIN AXLE AND DRIVE

AXLE
2. Measure: 1. Install:
• Drive axle runout • Toothed washer “1”
(with a centering device and dial gauge “1”)
• Circlip “2” New
Out of specification → Replace the drive axle.
TIP
Drive axle runout limit • Be sure the circlip sharp-edged corner “a” is
0.02 mm (0.0008 in) positioned opposite side to the toothed washer
and gear.
• Install the circlip so that both ends “b” rest on
the sides of a spline “c” with both axles aligned.
3. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
5-87
TRANSMISSION
2 New 1 2 New 1
2. Install:
b • Main axle assembly “1”
TIP
Stake the main axle assembly bearing housing
bolts “2” at a cutout “a” in the main axle assem-
bly bearing housing “3”.
2 a
c
a 2
2. Install:
• Toothed lock washer retainer “1” 1
• Toothed lock washer “2” 3
TIP a
2
• With the toothed lock washer retainer “1” in the
groove “a” in the axle, align the projection “c”
on the retainer with an axle spline “b”, and then 3. Install:
install the toothed lock washer “2”. • Shift fork-C “1”
• Be sure to align the projection on the toothed • Shift drum assembly “2”
lock washer that is between the alignment • Shift fork guide bar “3”
marks “e” with the alignment mark “d” on the TIP
retainer. • The embossed marks on the shift forks should
face towards the right side of the engine and be
1 d b e in the following sequence: “R”, “C”, “L”.
2 • Carefully position the shift forks so that they
c
b are installed correctly into the transmission
gears.
a • Install shift fork-C into the groove “a” in the 3rd
c and 4th pinion gear on the main axle.
2 • Install the shift fork guide bar “3” in the crank-
case with the plug “4” facing in the direction
1 e shown in the illustration.
EAS30438
INSTALLING THE TRANSMISSION

1. Install:
• Bearing “1”
TIP
a
Face the seal side of the bearing to the outside
and install it close to the right side end of the 3
crankcase.
2 1
5-88
TRANSMISSION
6 a b 5
4
1 d
1 2
3 c
3
4 3
c
6. Main axle assembly

4. Install:
• Shift fork-R “1”
• Shift fork-L “2”
• Shift fork guide bar
• Springs
• Shift drum retainers “3”
• Bearing
• Oil seal
• Circlip “4”
• Drive axle assembly “5”
Shift drum retainer bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
TIP
• Install shift fork-R into the groove “a” in the 5th
wheel gear and shift fork-L into the groove “b”
in the 6th wheel gear on the drive axle.
• Install the shift drum retainer with its “OUT”
mark “c” facing outward.
• Make sure that the drive axle bearing circlip “4”
is inserted into the grooves “d” in the upper
crankcase.
5-89
COOLING SYSTEM
COOLING SYSTEM DIAGRAMS .................................................................... 6-1
RADIATOR ...................................................................................................... 6-3

REMOVING THE RADIATOR ...................................................................6-5
CHECKING THE RADIATOR.................................................................... 6-5
INSTALLING THE RADIATOR..................................................................6-6
OIL COOLER...................................................................................................6-7
REMOVING THE OIL COOLER................................................................6-9
CHECKING THE OIL COOLER ................................................................6-9
INSTALLING THE OIL COOLER .............................................................. 6-9
THERMOSTAT ..............................................................................................6-10
REMOVING THE THERMOSTAT ........................................................... 6-11
CHECKING THE THERMOSTAT............................................................ 6-11
INSTALLING THE THERMOSTAT.......................................................... 6-11
WATER PUMP...............................................................................................6-12
REMOVING THE WATER PUMP ........................................................... 6-14
DISASSEMBLING THE WATER PUMP.................................................. 6-14
CHECKING THE WATER PUMP ............................................................ 6-14
ASSEMBLING THE WATER PUMP........................................................ 6-14
INSTALLING THE WATER PUMP .......................................................... 6-15
6
COOLING SYSTEM DIAGRAMS
EAS20299
1. Radiator inlet hose

2. Radiator inlet pipe
3. Thermostat outlet hose
4. Radiator
6-1
1
3
6 13
5
6
8
7 9
12 8
11 9
10 15
14
1. Water pump breather hose
2. Coolant reservoir hose
3. Coolant reservoir
4. Radiator
5. Radiator outlet hose
6. Oil cooler outlet hose
7. Radiator outlet pipe
8. Water jacket joint inlet hose
9. Water pump outlet pipe
10. Water pump inlet hose
11. Water pump outlet hose
12. Water pump
13. Water jacket joint
14. Oil cooler
15. Oil cooler inlet hose
6-2
RADIATOR
EAS20063
RADIATOR
Removing the radiator
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
2 4
5 4
(6)
3
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

4.5 N•m (0.45 kgf•m, 3.3 lb•ft)
T.R
.
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Front side cowling assembly/Bottom cowlings 4-8.
Drain.
page 3-29.
Rectifier/regulator bracket Refer to “HANDLEBARS” on page 4-66.
Refer to “ABS (Anti-lock Brake System)” on
Front brake hose joint page 4-57.
1 Coolant reservoir breather hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir 1
4 Radiator fan motor coupler 2 Disconnect.
5 Radiator cap 1
6 Radiator 1
6-3
RADIATOR
Removing the radiator
13 N•m (1.3 kgf•m, 9.6 lb•ft)
T.R
.
12
11
13
8
(6)
8
10
7 8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
9
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
4.5 N•m (0.45 kgf•m, 3.3 lb•ft) T.R
.
14
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

7 Front brake hose joint bracket 1
8 Radiator fan 2
9 Radiator inlet hose 1
10 Radiator inlet pipe 1
11 Radiator outlet hose holder 1
12 Radiator outlet hose 1
13 Radiator outlet pipe 1
14 Radiator bracket 1
6-4
RADIATOR
EAS31659
REMOVING THE RADIATOR

1. Remove:
• Hose clamp (Clic-R) “1”
TIP
• Remove the hose clamp using the hose clamp
pliers “2”.
• When removing the hose clamp, make sure
that the thick tip “a” of the hose clamp pliers is
directed as shown in the illustration.
2. Check:
• Radiator hoses
a • Radiator pipes
3. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
1 2 Radiator cap valve opening pres-

sure
107.9–137.3 kPa (1.08–1.37 kgf/
cm², 15.6–19.9 psi)
a. Install the radiator cap tester “1” and radi-

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

90890-01325
YU-24460-A
Radiator cap tester adapter
A. Hose clamp pliers 90890-01352
EAS30439
Pressure tester adapter
CHECKING THE RADIATOR YU-33984
1. Check:
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-head
screwdriver.
b. Apply the specified pressure for ten sec-

onds and make sure there is no drop in
pressure.
4. Check:
• Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-25.
6-5
RADIATOR
EAS30440
3. Fill:
INSTALLING THE RADIATOR
• Cooling system
1. Install:
• Radiator bracket “1”
mended coolant)
TIP Refer to “CHANGING THE COOLANT” on
Make sure the projection “a” on the radiator page 3-29.
bracket touches the projection “b” on the crank- 4. Check:
case. • Cooling system
Leaks → Repair or replace any faulty part.
a. Attach the radiator cap tester “1” and radi-
ator cap tester adapter “2” to the radiator.
a
Radiator cap tester
90890-01325
1 YU-24460-A
b
2. Install: 2
• Hose clamp (Clic-R) “1” New
TIP 1
• Install the hose clamp using the hose clamp pli-
ers “2”.
• When installing the hose clamp, make sure
that the thin tip “a” of the hose clamp pliers is
directed as shown in the illustration.
b. Apply 100 kPa (14.50 psi) (1.0 kg/cm²) of
• For more information about installing the hose,
pressure.
refer to “CABLE ROUTING” on page 2-15.
c. Measure the indicated pressure with the
gauge.
a
1 2
A. Hose clamp pliers
6-6
OIL COOLER
EAS20064
OIL COOLER
Removing the oil cooler

T.R
T.R
.
.

Drain.
page 3-26.
Drain.
page 3-29.
Exhaust pipe assembly Refer to “ENGINE REMOVAL” on page 5-9.
1 Oil cooler outlet hose 1
2 Oil cooler inlet hose 1
3 Water jacket joint 1
4 O-ring 1
5 Water jacket joint inlet hose 1
6 Water pump outlet pipe 1
7 Oil cooler union bolt 1
8 Gasket 1
6-7
OIL COOLER
Removing the oil cooler

T.R
T.R
.
.

9 Oil cooler 1
10 O-ring 1
6-8
OIL COOLER
EAS32365
3. Install:
REMOVING THE OIL COOLER
• Hose clamp (Clic-R)
1. Remove:
4. Fill:
• Cooling system
EAS30441 (with the specified amount of the recom-
CHECKING THE OIL COOLER mended coolant)
1. Check: Refer to “CHANGING THE COOLANT” on
• Oil cooler page 3-29.
Cracks/damage → Replace. • Crankcase
2. Check: (with the specified amount of the recom-
• Oil cooler inlet hose mended engine oil)
• Oil cooler outlet hose Refer to “CHANGING THE ENGINE OIL” on
• Water jacket joint inlet hose page 3-26.
Cracks/damage/wear → Replace. 5. Check:
3. Check: • Cooling system
• Water pump outlet pipe Leaks → Repair or replace any faulty part.
Damage → Replace.
Obstruction → Wash and blow out with com-
pressed air.
EAS30442
INSTALLING THE OIL COOLER

1. Clean:
• Mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
• O-ring New
• Oil cooler “1”
• Gasket “2” New
• Oil cooler union bolt “3”
Oil cooler union bolt

63 N·m (6.3 kgf·m, 47 lb·ft)
T.
R.
TIP
• Before installing the oil cooler, lubricate the its
union bolt with a thin coat of engine oil.
• Make sure the O-ring is positioned properly.
• Make sure the projection “a” on the oil cooler
touches the projection “b” on the crankcase.
New
6-9
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.

Drain.
page 3-29.
2 Thermostat outlet hose 1
3 Thermostat cover 1
4 Thermostat 1
6-10
THERMOSTAT
EAS32366
REMOVING THE THERMOSTAT TIP

1. Remove: If the accuracy of the thermostat is in doubt, re-
• Hose clamp (Clic-R) place it. A faulty thermostat could cause serious
Refer to “RADIATOR” on page 6-3. overheating or overcooling.
EAS30443
2. Check:
CHECKING THE THERMOSTAT • Thermostat cover
1. Check: Cracks/damage → Replace.
• Thermostat EAS30939
Does not open at 71–85 °C (159.8–185.0 °F) INSTALLING THE THERMOSTAT
→ Replace. 1. Install:
• Thermostat
TIP
Install the thermostat with its breather hole “a”
facing up.
a. Suspend the thermostat “1” in a container

“2” filled with water.
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water.
d. While stirring the water, observe the ther-
mostat and thermometer’s indicated tem- 2. Install:
perature. • Hose clamp (Clic-R)
3. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-29.
4. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
A. Fully closed
B. Fully open
6-11
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.
12 N•m (1.2 kgf•m, 8.9 lb•ft)

T.R
.

It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.
Front side cowling/Bottom cowling 4-8.
Drain.
page 3-29.
2 Water pump inlet hose 1
3 Water pump outlet hose 1
4 Water pump breather hose 1
5 Water pump assembly 1
6-12
WATER PUMP
Disassembling the water pump

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

T.R
.

1 Water pump housing cover 1
2 Gasket 1
3 Circlip 1
4 Impeller shaft (along with the impeller) 1
5 Mechanical seal 1
6 Bearing 1
7 Oil seal 1
8 O-ring 1
6-13
WATER PUMP
EAS32367
REMOVING THE WATER PUMP

1. Remove:
EAS30446
DISASSEMBLING THE WATER PUMP

1. Remove:
• Circlip 5. Remove:
• Impeller shaft • Mechanical seal (impeller side) “1”
2. Remove: (from the impeller, with a thin, flat-head
• Mechanical seal (housing side) “1” screwdriver)
TIP TIP
Remove the mechanical seal (housing side) Do not scratch the impeller shaft.
from the outside of the water pump housing.
EAS30447
2. Water pump housing CHECKING THE WATER PUMP
• Oil seal “1” • Water pump housing cover
(with a thin, flat-head screwdriver) • Water pump housing
• Impeller shaft
TIP
Remove the oil seal from the outside of the water 2. Check:
pump housing. • Bearing
Rough movement → Replace.
3. Check:
• Water pump inlet pipe
• Water pump outlet hose
• Water pump breather hose
EAS30448
ASSEMBLING THE WATER PUMP

4. Remove: 1. Install:
• Bearing “1” • Oil seal “1” New
TIP (into the water pump housing “2”)
Remove the bearing from inside of the water TIP
pump housing. • Before installing the oil seal, apply tap water or
coolant onto its out surface.
• Install the oil seal with a socket that matches its
outside diameter.
6-14
WATER PUMP
2. Install:
4. Measure:
• Mechanical seal (housing side) “1” New
• Impeller shaft tilt
(into the water pump housing “2”)
ECA20330
Out of specification → Repeat steps (3) and
NOTICE (4).
ECA20340
Never lubricate the mechanical seal (hous- NOTICE
ing side) surface with oil or grease.
Make sure the mechanical seal (impeller
TIP side) is flush with the impeller.
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it Impeller shaft tilt limit
touches the water pump housing. 0.15 mm (0.006 in)
Mechanical seal installer

90890-04078
Water pump seal installer
YM-33221-A
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058
1. Straightedge
2. Impeller
4 EAS30449
INSTALLING THE WATER PUMP

3
1. Install:
• Water pump assembly “1”
• O-ring “2” New
2
Water pump assembly bolt
12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
A. Push down LOCTITE®

3. Mechanical seal installer
4. Middle driven shaft bearing driver TIP
• Align the slit “a” on the impeller shaft with the
3. Install:
projection “b” on the oil pump shaft.
• Mechanical seal (impeller side) “1” New • Lubricate the O-ring with a thin coat of lithium-
TIP soap-based grease.
Before installing the mechanical seal (impeller
side), apply tap water or coolant onto its outer
surface.
6-15
WATER PUMP
2. Install:
3. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-29.
4. Check:
• Cooling system
Leaks → Repair or replace the faulty part.
6-16
WATER PUMP
6-17
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-4
REMOVING THE FUEL PUMP .................................................................7-4
CHECKING THE FUEL PUMP BODY.......................................................7-4
INSTALLING THE FUEL PUMP................................................................7-4
INSTALLING THE FUEL TANK.................................................................7-4
AIR FILTER CASE .......................................................................................... 7-5

REMOVING THE FUEL HOSE (PRIMARY INJECTOR FUEL RAIL
SIDE AND SECONDARY INJECTOR FUEL RAIL SIDE) ........................7-7
REMOVING THE AIR FILTER CASE........................................................7-7
CHECKING THE SECONDARY INJECTORS (BEFORE REMOVING) ...7-7
CHECKING THE SECONDARY INJECTORS .......................................... 7-7
REMOVING THE INTAKE FUNNEL .........................................................7-7
CHECKING THE INTAKE FUNNEL .......................................................... 7-7
INSTALLING THE INTAKE FUNNEL ........................................................7-8
CHECKING THE INTAKE FUNNEL OPERATION....................................7-8
INSTALLING THE AIR FILTER CASE ......................................................7-8
INSTALLING THE FUEL HOSE (PRIMARY INJECTOR FUEL RAIL
SIDE AND SECONDARY INJECTOR FUEL RAIL SIDE) ........................7-8
THROTTLE BODIES .....................................................................................7-10

CHECKING THE PRIMARY INJECTORS (BEFORE REMOVING)........ 7-13
CHECKING THE THROTTLE BODY JOINTS ........................................ 7-13
CHECKING THE PRIMARY INJECTORS............................................... 7-13
CHECKING AND CLEANING THE THROTTLE BODIES.......................7-13
REPLACING THE THROTTLE BODIES ................................................. 7-15
INSTALLING THE INJECTORS ..............................................................7-15
CHECKING THE INJECTOR PRESSURE.............................................. 7-15
CHECKING THE FUEL PRESSURE ......................................................7-16
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-17
ADJUSTING THE ACCELERATOR POSITION SENSOR......................7-17
AIR INDUCTION SYSTEM ............................................................................7-19

CHECKING THE AIR INDUCTION SYSTEM..........................................7-22
7
INSTALLING THE AIR INDUCTION SYSTEM........................................ 7-22
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank and fuel pump
5 N•m (0.5 kgf•m, 3.7 lb•ft) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
1
.
T.R
.
(4)
4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 8
T.R
.
3 2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
7
New
5
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft) 6

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

Rider seat 4-1.
1 Fuel tank cover (right) 1
2 Fuel tank cover (left) 1
Fuel tank breather hose (hose joint to atmo- Disconnect.
3 1
sphere) Except for California
Disconnect.
4 Fuel tank breather hose (hose joint to canister) 1 For California only
Fuel tank overflow hose (hose joint to atmo-
5 1 Disconnect.
sphere)
6 Fuel pump coupler 1 Disconnect.
7 Fuel hose (fuel tank side) 1 Disconnect.
8 Fuel tank 1
7-1
FUEL TANK
Removing the fuel tank and fuel pump

5 N•m (0.5 kgf•m, 3.7 lb•ft) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
T.R
.
(4)
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
13
10
7 N•m (0.7 kgf•m, 5.2 lb•ft)

9
T.R
.
11
New
12
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

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

9 Fuel tank cover (top) 1
10 Fuel tank breather hose (fuel tank to hose joint) 1
11 Fuel tank overflow hose (fuel tank to hose joint) 1
12 Fuel pump 1
13 Fuel tank bracket 1
7-2
FUEL TANK
Removing the canister (for California only)
4
3
1 5
2
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
LT

1 Canister purge hose (throttle body-#4 to 3-way 1

joint)
Canister purge hose (throttle body-#2 to 3-way
2 1
joint)
3 3-way joint 1
4 Canister purge hose (3-way joint to canister) 1
5 Canister holder 1
6 Canister 1
7 Canister bracket 1
7-3
FUEL TANK
EAS30450
• Do not touch the base section of the fuel
REMOVING THE FUEL TANK
sender.
1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump. EAS30454
2. Remove: CHECKING THE FUEL PUMP BODY
• Fuel pump coupler 1. Check:
• Fuel hose (fuel tank side) • Fuel pump body
• Fuel tank breather hose (hose joint to atmo- Obstruction → Clean.
sphere) (except for California) Cracks/damage → Replace fuel pump as-
• Fuel tank breather hose (hose joint to canis- sembly.
ter) (for California only)
EAS30456
• Fuel tank overflow hose (hose joint to atmo-
INSTALLING THE FUEL PUMP
sphere)
EWA17610
1. Tighten:
WARNING • Fuel pump
Cover fuel hose connections with a cloth Fuel pump bolt
when disconnecting them. Residual pres- 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
sure in the fuel lines could cause fuel to
R.
spurt out when removing the hoses. TIP
TIP • Do not damage the installation surfaces of the
• To remove the fuel hose from the fuel pump, fuel tank when installing the fuel pump.
press the two buttons “1” on the sides of the • Always use a new fuel pump gasket.
connector, and then remove the hose. • Install the fuel pump as shown in the illustra-
• Remove the fuel hose manually without using tion.
any tools. • Install the fuel pump bracket “1” with the
• Before removing the hose, place a few rags in stamped mark “a” facing outward.
the area under where it will be removed. • Align the projection “b” on the fuel pump with
the slot in the fuel pump bracket.
b 1
FWD
3. Remove:
• Fuel tank EAS30457
INSTALLING THE FUEL TANK

TIP
1. Connect:
• Place the fuel tank on a level surface. • Fuel hose (fuel tank side)
• Make sure that the fuel pipe does not contact
TIP
the ground; otherwise, the fuel pump could be
damaged. Install the fuel hose securely onto the fuel pump
until a distinct “click” is heard.
EAS30451
REMOVING THE FUEL PUMP

1. Remove:
• Fuel pump
ECA14721
NOTICE
• Do not drop the fuel pump or give it a
strong shock.
7-4
AIR FILTER CASE
EAS20068
AIR FILTER CASE

Removing the air filter case and secondary injectors
4.2 N•m (0.42 kgf•m, 3.1 lb•ft) 5 N•m (0.5 kgf•m, 3.7 lb•ft) 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
T.R
T.R
.
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 9 (4)
T.R
.
8
7
(10)
4.2 N•m (0.42 kgf•m, 3.1 lb•ft)

T.R
.
5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
4
6
1

1 Crankcase breather hose 1 Disconnect.
2 Sub-wire harness coupler 1 Disconnect.
3 Intake funnel servo motor coupler 1
4 Fuel hose (secondary injector fuel rail side) 1 Disconnect.
5 Upper air filter case 1
6 Secondary injector holder 1
7 Cylinder-#1 secondary injector coupler 1 Disconnect.
7-5
AIR FILTER CASE
Removing the air filter case and secondary injectors

4.2 N•m (0.42 kgf•m, 3.1 lb•ft) 5 N•m (0.5 kgf•m, 3.7 lb•ft) 2.0 N•m (0.20 kgf•m, 1.5 lb•ft)
T.R
T.R
T.R
.
.
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 10

(4)
T.R
14
.
(10)
11
15
18
16
12
19
4.2 N•m (0.42 kgf•m, 3.1 lb•ft)
T.R
.
5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
17
13

11 Sub-wire harness 1
12 Secondary injector fuel rail 1
13 Secondary injector 4
14 Air filter element 1
15 Intake funnel assembly 1
16 Intake funnel servo motor rod assembly 1
Air induction system hose (air filter case to air
17 1 Disconnect.
cut-off valve)
18 Lower air filter case 1
19 Intake funnel servo motor 1
7-6
AIR FILTER CASE
EAS30459 EAS30458
REMOVING THE FUEL HOSE (PRIMARY CHECKING THE SECONDARY INJECTORS

INJECTOR FUEL RAIL SIDE AND (BEFORE REMOVING)
SECONDARY INJECTOR FUEL RAIL SIDE) 1. Check:
1. Remove: • Injectors
• Fuel hose (primary injector fuel rail side and Use the diagnostic code numbers “40”–“43”.
secondary injector fuel rail side) Refer to “SELF-DIAGNOSTIC FUNCTION
EWA17610
AND DIAGNOSTIC CODE TABLE” on page
WARNING 9-1.
Cover fuel hose connections with a cloth
EAS30462
when disconnecting them. Residual pres-
CHECKING THE SECONDARY INJECTORS
1. Check:
spurt out when removing the hoses.
• Injectors
TIP Damage → Replace.
• To remove the fuel hose from the secondary EAS30461
injector fuel rail, slide the fuel hose connector REMOVING THE INTAKE FUNNEL
cover “1” on the end of the hose in the direction 1. Remove:
of the arrow shown, press the two buttons “2” • Intake funnel joint bolts
on the sides of the connector, and then remove • Intake funnel assembly
the hose. • Intake funnel servo motor rod assembly
• Remove the fuel hose manually without using TIP
any tools. Loosen the intake funnel joint bolts in proper se-
• Before removing the hose, place a few rags in quence as shown.
the area under where it will be removed.
1 2
EAS30463
CHECKING THE INTAKE FUNNEL

EAS31663
REMOVING THE AIR FILTER CASE 1. Check:

1. Remove: • Intake funnel servo motor rod assembly
• Upper air filter case Damage/scratches → Replace.
• Intake funnel assembly
TIP
Loosen the upper air filter case bolts in proper 2. Check:
sequence as shown. • Intake funnel movement
Sticks → Replace the intake funnel assem-
bly.
ECA17550
NOTICE
• Make sure that the intake funnel smoothly
moves to the contacting surface between
upper stopper and lower seating position
when it is moved by hand.
• Make sure that the intake funnel smoothly
strokes from the upper position to the seat-
ing position by its own weight.
7-7
AIR FILTER CASE
EAS31618
INSTALLING THE AIR FILTER CASE

1. Install:
• Upper air filter case
Upper air filter case to lower air

filter case bolt
T.
R.
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
Air filter bolt
2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
A. Upper
B. Lower TIP
EAS30464 Tighten the upper air filter case to lower air filter
INSTALLING THE INTAKE FUNNEL case bolts and air filter bolt in proper sequence
1. Install: as shown.
• Intake funnel servo motor rod assembly
• Intake funnel assembly
2. Tighten:
• Intake funnel joint bolts “1”
Intake funnel joint bolt 1

4.2 N·m (0.42 kgf·m, 3.1 lb·ft)
T.
R.
• Intake funnel joint bolts “2”
Intake funnel joint bolt 2

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.
EAS30468
INSTALLING THE FUEL HOSE (PRIMARY

INJECTOR FUEL RAIL SIDE AND
SECONDARY INJECTOR FUEL RAIL SIDE)
1. Connect:
• Fuel hose (primary injector fuel rail side and
secondary injector fuel rail side)
ECA17500
NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
EAS30465
hose connector cover on the fuel hose is in
CHECKING THE INTAKE FUNNEL
the correct position, otherwise the fuel hose
OPERATION
will not be properly installed.
1. Check:
• Intake funnel operation TIP
a. Activate the diagnostic mode and select • Install the fuel hose securely onto the second-
the diagnostic code number “34”. ary injector fuel rail until a distinct “click” is
Refer to “SELF-DIAGNOSTIC FUNC- heard.
TION AND DIAGNOSTIC CODE TABLE” • To install the fuel hose onto the secondary in-
on page 9-1. jector fuel rail, slide the fuel hose connector
b. Set the engine stop switch to “ ”. cover “1” on the end of the hose in the direction
c. Check that the intake funnel operate of the arrow shown.
smoothly strokes from the upper position
to the lower seating position.
7-8
AIR FILTER CASE
7-9
THROTTLE BODIES
EAS20070
THROTTLE BODIES
Removing the throttle body assembly
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
8
7
6
4
2
3

Canister For California only
Air induction system cover page 7-19.
1 Fuel hose 1
2 Throttle servo motor coupler 1 Disconnect.
3 Accelerator position sensor 1 Disconnect.
4 Throttle position sensor 1 Disconnect.
5 Intake air pressure sensor coupler 1 Disconnect.
6 Cylinder-#1 primary injector coupler 1 Disconnect.
7-10
THROTTLE BODIES
Removing the throttle body assembly
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) 15
14
10
16
13
11
12

11 Throttle cable (decelerator cable) 1
12 Throttle cable (accelerator cable) 1
13 Throttle body assembly 1
14 Throttle body joint clamp 4
15 Heat protector 1
16 Throttle body joint 4
7-11
THROTTLE BODIES
Removing the primary injectors

3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
5 N•m (0.5 kgf•m, 3.7 lb•ft)
1
T.R
.
1
1 1
1 2
3.5 N•m (0.35 kgf•m, 2.6 lb•ft) 3
1
T.R
.
4
4
4
7
6
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
1 Intake air pressure sensor hose 7

2 Intake air pressure sensor 1
3 Primary injector fuel rail 1
4 Primary injector 4
5 Throttle position sensor 1
6 Accelerator position sensor 1
7 Throttle bodies 1
7-12
THROTTLE BODIES
EAS31666 EAS30769
CHECKING THE PRIMARY INJECTORS CHECKING AND CLEANING THE THROTTLE

(BEFORE REMOVING) BODIES
1. Check: TIP
• Injectors Before cleaning the throttle bodies, check the
Use the diagnostic code numbers “36”–“39”. following items:
Refer to “SELF-DIAGNOSTIC FUNCTION • Valve clearance
AND DIAGNOSTIC CODE TABLE” on page • Spark plugs
9-1. • Air filter element
EAS30792 • Throttle body joints
CHECKING THE THROTTLE BODY JOINTS • Fuel hoses
The following procedure applies to all of the • Air induction system
throttle body joints. • Exhaust system
1. Remove: • Crankcase breather hose
• Rider seat • Vacuum hose
Refer to “GENERAL CHASSIS (1)” on page EWA17340
4-1. WARNING
• Fuel tank If the throttle bodies are subjected to strong
Refer to “FUEL TANK” on page 7-1. shocks or dropped during cleaning, replace
• Air filter case them as a set.
• Throttle body 1. Check:
Refer to “THROTTLE BODIES” on page • Throttle bodies
7-10. Cracks/damage → Replace the throttle bod-
2. Check: ies as a set.
• Throttle body joints “1” 2. Clean:
Cracks/damage → Replace. • Throttle bodies
ECA21540
NOTICE
• Observe the following precautions; other-
wise, the throttle bodies may not operate
properly.
• Do not subject the throttle bodies to exces-
sive force.
• Clean the throttle bodies in the recom-
1 mended cleaning solvent.
• Do not use any caustic carburetor cleaning
3. Install: solution.
• Throttle body • Do not apply cleaning solvent directly to
Refer to “THROTTLE BODIES” on page any plastic parts, sensors, or seals.
7-10. • Be careful not to remove the white paint
• Air filter case mark that identifies the standard throttle
Refer to “AIR FILTER CASE” on page 7-5. body.
• Fuel tank • Do not turn the bypass air screws “a”; oth-
Refer to “FUEL TANK” on page 7-1. erwise, the throttle body synchronization
• Rider seat will be affected.
4-1. Recommended cleaning solvent
Yamaha Oil & Brake Cleaner
EAS31668
CHECKING THE PRIMARY INJECTORS

1. Check:
• Injectors
Damage → Replace.
7-13
THROTTLE BODIES
TIP
• Do not allow any cleaning solvent to enter the
opening for the injectors.
• Do not apply any cleaning solvent to the por-
tions of the throttle valve shafts between the
throttle bodies.
a e. Remove the carbon deposits from the in-
side of each throttle body in a downward
a direction, from the air filter case side of the
a. Place the throttle bodies on a flat surface throttle body to the engine side.
ECA17590
with the air filter case side facing up.
NOTICE
b. Install the suitable caps onto the hose fit-
tings “a”. • Do not use a tool, such as a wire brush, to
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
aged.
• Do not allow carbon deposits or other for-
eign materials to enter any of the passages
in each throttle body or in the space be-
tween the throttle valve shaft and the throt-
tle body.
a
a f. After removing the carbon deposits, clean
the inside of the throttle bodies with the
c. Hold the throttle valves in the open posi- recommended cleaning solvent, and then
tion. dry the throttle bodies using compressed
EWA15940
air.
WARNING
g. Make sure that there are no carbon de-
When cleaning the throttle bodies, be careful posits or other foreign materials in any of
not to injure yourself on the throttle valves or the passages “a” in each throttle body or in
other components of the throttle bodies. the space “b” between the throttle valve
ECA20380 shaft and the throttle body.
NOTICE
a
• Do not open the throttle valves by supply-
ing electrical power to the throttle bodies.
• Do not use tools to open the throttle valves
or to keep them in the open position.
• Do not open the throttle valves quickly.
3. Install the throttle bodies.

4. Reset:
• ISC (Idle Speed Control) learning values
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
d. Apply the recommended cleaning solvent 9-1.
to the throttle valves and the inside of the 5. Reset:
throttle bodies to remove any carbon de- • A/F control learning value
posits. Use the diagnostic code number “87”.
7-14
THROTTLE BODIES
Refer to “SELF-DIAGNOSTIC FUNCTION • If installing the original fuel rail and bolts,
AND DIAGNOSTIC CODE TABLE” on page remove the white paint marks using a
9-1. cleaning solvent. Otherwise, paint chips on
6. Adjust: the bolt seats could prevent the bolts from
• Throttle bodies synchronizing being tightened to the specified torque.
Out of specification → Replace the throttle 1. Install a new seal onto the end of each injec-
bodies. tor.
Refer to “SYNCHRONIZING THE THROT- 2. Install the injectors “1” to the fuel rail “2”.
TLE BODIES” on page 3-9. 3. Install the injector assemblies to the throttle
EAS31160 bodies.
REPLACING THE THROTTLE BODIES
1. Remove the throttle bodies from the vehicle. Fuel rail screw (throttle body)
2. Install a new throttle bodies to the vehicle. 5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.
R.
3. Reset:
• ISC (Idle Speed Control) learning values
Use the diagnostic code number “67”. 1
2
AND DIAGNOSTIC CODE TABLE” on page 1
9-1. 1
4. Reset:
• A/F control learning value
Use the diagnostic code number “87”. 1
9-1. 4. Check the injector pressure after the injectors
5. Adjust: are installed.
• Throttle bodies synchronizing Refer to “CHECKING THE INJECTOR
Refer to “SYNCHRONIZING THE THROT- PRESSURE” on page 7-15.
TLE BODIES” on page 3-9. EAS30481
6. Place the vehicle on a maintenance stand so CHECKING THE INJECTOR PRESSURE

that the rear wheel is elevated. TIP
7. Check: • After installing the injectors, perform the follow-
• Engine idling speed ing steps to check the injector pressure.
Start the engine, warm it up, and then mea- • Do not allow any foreign materials to enter the
sure the engine idling speed. fuel lines.
Engine idling speed 1. Check:
1250–1350 r/min • Injector pressure
a. Connect the fuel injector pressure adapter
EAS30480 “1” to the injector joint “2”, and then con-
INSTALLING THE INJECTORS nect an air compressor “3” to the adapter.
ECA21550
NOTICE b. Connect the pressure gauge “4” to the fuel

injector pressure adapter “1”.
• Always use new O-rings.
• When installing the injectors, do not allow Pressure gauge
any foreign material to enter or adhere to 90890-03153
the injectors, fuel rails, or O-rings. Pressure gauge
• Be careful not to twist or pinch the O-rings YU-03153
when installing the injectors. Fuel injector pressure adapter
• When installing the injector, install it at the 90890-03210
same position as the removed cylinder. Fuel injector pressure adapter
• If an injector is subject to strong shocks or YU-03210
excessive force, replace it.
7-15
THROTTLE BODIES
EWA17320
WARNING
Cover fuel hose connections with a cloth
when disconnecting them. Residual pres-
spurt out when removing the hose.
ECA17490
NOTICE
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with
c. Close the valve on the injector pressure tools.
adapter.
d. Apply air pressure with the air compres-
sor.
e. Open the valve on the injector pressure
adapter until the specified pressure is
reached.
Specified air pressure

490 kPa (5.0 kgf/cm², 71.1 psi)
1
ECA17600
NOTICE c. Connect the pressure gauge “2” and fuel

Never exceed the specified air pressure or pressure adapter “3” to the fuel hose.
damage could occur.
Pressure gauge
f. Close the valve on the injector pressure 90890-03153
adapter. Pressure gauge
g. Check that the specified air pressure is YU-03153
held at least one minute. Fuel pressure adapter
Pressure drops → Check the pressure 90890-03176
gauge and adapter. Fuel pressure adapter
YM-03176
Check the seals and O-rings and then re-
install.
Out of specification → Replace the fuel in-
jectors.
EAS30482
CHECKING THE FUEL PRESSURE

1. Remove:
• Rider seat
4-1.
2. Check:
• Fuel pressure
d. Start the engine.
a. Remove the fuel tank bolts and hold up the
e. Measure the fuel pressure.
fuel tank.
Faulty → Replace the fuel pump.
b. Disconnect the fuel hose “1” from the fuel
pump. Fuel line pressure (at idle)
Refer to “FUEL TANK” on page 7-1. 300–390 kPa (3.0–3.9 kgf/cm²,
43.5–56.6 psi)
3. Install:
• Fuel tank
7-16
THROTTLE BODIES
• Rider seat g. After adjusting the throttle position sensor

Refer to “GENERAL CHASSIS (1)” on page angle, tighten the throttle position sensor
4-1. bolts “1”.
EAS30485
Throttle position sensor bolt
ADJUSTING THE THROTTLE POSITION 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
SENSOR
R.
ECA17540
NOTICE
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
• Throttle position sensor
Refer to “DIAGNOSTIC CODE: SENSOR
OPERATION TABLE” on page 9-11. EAS30486
2. Adjust: ADJUSTING THE ACCELERATOR POSITION

• Throttle position sensor angle SENSOR
EWA15960
TIP WARNING
Before adjusting the throttle position sensor, the • Handle the accelerator position sensor with
throttle bodies must be removed. special care.
a. Temporary tighten the throttle position • Never subject the accelerator position sen-
sensor bolts. sor to strong shocks. If the accelerator po-
b. Check that the throttle valves are fully sition sensor is dropped, replace it.
closed. 1. Check:
c. Connect the throttle position sensor to the • Accelerator position sensor
wire harness. Refer to “DIAGNOSTIC CODE: SENSOR
d. Remove the protective cap “1”, and then OPERATION TABLE” on page 9-11.
connect the Yamaha diagnostic tool to 2. Adjust:
coupler. • Accelerator position sensor angle
TIP TIP
For information about using the Yamaha diag- Before adjusting the accelerator position sensor,
nostic tool, refer to the operation manual that is the throttle bodies must be removed.
included with the tool.
a. Temporary tighten the accelerator position
1 sensor bolts.
b. Check that the throttle valves are fully
closed.
c. Connect the accelerator position sensor to
the wire harness.
d. Connect the throttle cables to the throttle
bodies.
e. Remove the protective cap “1”, and then
connect the Yamaha diagnostic tool to
coupler.
e. Diagnostic code number “01” is selected.
TIP
f. Adjust the position of the throttle position
sensor angle so that 11–21 can appear in For information about using the Yamaha diag-
the Yamaha diagnostic tool screen. nostic tool, refer to the operation manual that is
included with the tool.
7-17
THROTTLE BODIES
q. Repeat steps (f) to (p) until the Yamaha di-

1 agnostic tool screen values are within the
specified ranges.
r. If the Yamaha diagnostic tool screen val-
ues are not within the specified ranges af-
ter repeating steps (f) to (p) several times,
replace the accelerator position sensor.
f. Diagnostic code number “14” is selected.

g. Turn the throttle grip to the fully closed po-
sition.
h. Adjust the position of the accelerator posi-
tion sensor angle so that 11–21 can ap-
pear in the Yamaha diagnostic tool
screen.
i. After adjusting the accelerator position
sensor angle, tighten the accelerator posi-
tion sensor bolts “1”.
Accelerator position sensor bolt

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
j. Turn the throttle grip to the fully open posi-

tion.
k. Check the Yamaha diagnostic tool screen
value. If the Yamaha diagnostic tool
screen value is not 96–106, adjust the ac-
celerator position sensor angle.
l. Select the diagnostic code number “15”.
m. Turn the throttle grip to the fully closed po-
sition.
n. Check the Yamaha diagnostic tool screen
screen value is not 9–23, adjust the accel-
erator position sensor angle.
o. Turn the throttle grip to the fully open posi-
tion.
p. Check the Yamaha diagnostic tool screen
screen value is not 93–109, adjust the ac-
celerator position sensor angle.
7-18
AIR INDUCTION SYSTEM
EAS20071
1 4
2 3
2
4
3
5
1. Lower air filter case

2. Air induction system hose (air filter case to air
cut-off valve)
3. Air cut-off valve
4. Air induction system hose (air cut-off valve to
cylinder head cover)
5. Reed valve assembly
6. Exhaust port
7-19
Removing the air cut-off valve

1 Air induction system cover 1
2 Air induction system solenoid coupler 1 Disconnect.
Air induction system hose (air filter case to air
3 1
cut-off valve)
Air induction system hose (air cut-off valve to
4 2
cylinder head cover)
5 Air cut-off valve 1
7-20
Removing the reed valves

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

1 Reed valve cover 2
2 Reed valve assembly 2
3 Reed valve plate 4
7-21
EAS30488
2. Check:
• Reed valve
• Reed valve stopper
Air injection
• Reed valve seat
The air induction system burns unburned ex-
Cracks/damage → Replace the reed valve
haust gases by injecting fresh air (secondary air)
assembly.
into the exhaust port, reducing the emission of
There is a gap “a” between the reed valve
hydrocarbons. When there is negative pressure
and the reed valve seat → Replace the reed
at the exhaust port, the reed valve opens, allow-
valve assembly.
ing secondary air to flow into the exhaust port.
The required temperature for burning the un-
burned exhaust gases is approximately 600 to
700 °C (1112 to 1292 °F).
Air cut-off valve

The air cut-off valve is controlled by the signals
from the ECU in accordance with the combus-
tion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the vehicle is be-
ing driven. However, if the coolant temperature 3. Check:
is below the specified value, the air cut-off valve • Air cut-off valve
remains open and allows the air to flow into the Cracks/damage → Replace.
exhaust pipe assembly until the temperature be- 4. Check:
comes higher than the specified value. • Air induction system solenoid
Refer to “CHECKING THE AIR INDUCTION
SYSTEM SOLENOID” on page 8-159.
EAS30489
INSTALLING THE AIR INDUCTION SYSTEM

1. Install:
A • Reed valve plate
TIP
Align the projection “a” on the cylinder head cov-
B B er “1” with the hole “b” in the reed valve plate.
B B
2. Install:
A. From the air filter case • Reed valve assembly
B. To the cylinder head TIP
1. Check: Install the reed valve assembly so that the open
• Hoses side turns to the exhaust side of the engine.
Loose connections → Connect properly.
7-22
A. Exhaust side
3. Install:
• Reed valve cover
Reed valve cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
7-23
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 ............................................................................8-11
CHARGING SYSTEM....................................................................................8-13
CIRCUIT DIAGRAM ................................................................................ 8-13
LIGHTING SYSTEM ......................................................................................8-15

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

CIRCUIT DIAGRAM ................................................................................ 8-19
COOLING SYSTEM....................................................................................... 8-25

CIRCUIT DIAGRAM ................................................................................ 8-25
FUEL INJECTION SYSTEM..........................................................................8-29

CIRCUIT DIAGRAM ................................................................................ 8-29
ECU SELF-DIAGNOSTIC FUNCTION....................................................8-31
TROUBLESHOOTING METHOD............................................................ 8-31
YAMAHA DIAGNOSTIC TOOL ...............................................................8-32
TROUBLESHOOTING DETAILS (FAULT CODE) ..................................8-33
TROUBLESHOOTING DETAILS (EVENT CODE)................................8-117
FUEL PUMP SYSTEM.................................................................................8-119

CIRCUIT DIAGRAM ..............................................................................8-119
TROUBLESHOOTING ..........................................................................8-121
8
ABS (Anti-lock Brake System) ..................................................................8-123
CIRCUIT DIAGRAM ..............................................................................8-123
ABS COUPLER LOCATION CHART ....................................................8-125
MAINTENANCE OF THE ABS ECU .....................................................8-126
ABS TROUBLESHOOTING OUTLINE..................................................8-126
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ..........................8-127
BASIC PROCESS FOR TROUBLESHOOTING ...................................8-128
[A] CHECKING THE ABS WARNING LIGHT........................................8-129
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON...........8-129
[A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR
LIGHTS FAIL TO COME ON ................................................................8-129
[A-3] THE ABS WARNING LIGHT COMES ON ....................................8-129
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE ......................8-130
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE ......................8-130
[B-1] MALFUNCTION ARE CURRENTLY DETECTED ........................8-130
[B-2] DIAGNOSIS USING THE FAULT CODES ...................................8-130
[B-3] DELETING THE FAULT CODES..................................................8-146
[C-1] FINAL CHECK ..............................................................................8-147
ELECTRICAL COMPONENTS....................................................................8-148
CHECKING THE SWITCHES ...............................................................8-150
CHECKING THE FUSES ......................................................................8-151
REPLACING THE ECU (engine control unit) ........................................8-151
CHECKING AND CHARGING THE BATTERY.....................................8-152
CHECKING THE RELAYS ....................................................................8-152
CHECKING THE RELAY UNIT (DIODE) ..............................................8-153
CHECKING THE IGNITION COILS.......................................................8-154
CHECKING THE CRANKSHAFT POSITION SENSOR........................8-155
CHECKING THE LEAN ANGLE SENSOR............................................8-155
CHECKING THE STARTER MOTOR OPERATION .............................8-156
CHECKING THE STATOR COIL ..........................................................8-156
CHECKING THE RECTIFIER/REGULATOR ........................................8-157
CHECKING THE OIL LEVEL SWITCH .................................................8-157
CHECKING THE FUEL SENDER .........................................................8-158
CHECKING THE FUEL LEVEL WARNING LIGHT ...............................8-158
CHECKING THE OIL LEVEL WARNING LIGHT ..................................8-158
CHECKING THE RADIATOR FAN MOTORS.......................................8-159
CHECKING THE COOLANT TEMPERATURE SENSOR.....................8-159
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ....................8-159
CHECKING THE CYLINDER IDENTIFICATION SENSOR ..................8-160
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................8-160
CHECKING THE THROTTLE POSITION SENSOR .............................8-161
CHECKING THE ACCELERATOR POSITION SENSOR .....................8-161
CHECKING THE THROTTLE SERVO MOTOR ...................................8-162
CHECKING THE FUEL INJECTORS....................................................8-162
EAS30490
EAS20072
46
28 45
5
3
ON 47
OFF L/Y L/B L/B L/Y
Br/R Br/R
CIRCUIT DIAGRAM
45
48
IGNITION SYSTEM
31 45
6 33
49
A
A
A
32 A 45
A
24
25 36
FREE
PUSH
11
44
15
8-1
41
A B
IGNITION SYSTEM
IGNITION SYSTEM
3. Main switch
4. Main fuse
5. Battery
6. Engine ground
11.Backup fuse
15.Ignition fuse
24.Handlebar switch (right)
25.Engine stop switch
28.Relay unit
31.Joint coupler
32.Neutral switch
33.Sidestand switch
36.Lean angle sensor
41.Crankshaft position sensor
44.ECU (Engine Control Unit)
45.Spark plug
46.Ignition coil #1
47.Ignition coil #2
48.Ignition coil #3
49.Ignition coil #4
A. Wire harness
B. Sub-wire harness (ignition)
8-2
IGNITION SYSTEM
EAS30491
ENGINE STOPPING DUE TO SIDESTAND OPERATION

When the engine is running and the transmission is in gear, the engine will stop if the sidestand is
moved down. This is because the electric current from the ignition coils does not flow to the ECU when
both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from
producing a spark. However, the engine continues to run under the following conditions:
• The transmission is in gear (the neutral switch circuit is open) and the sidestand is up (the sidestand
switch circuit is closed).
• The transmission is in neutral (the neutral switch circuit is closed) and the sidestand is down (the side-
stand switch circuit is open).
9
5
8
6
10 11
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Ignition coil
7. Spark plug
9. Relay unit (diode)
10. Sidestand switch
11. Neutral switch
8-3
IGNITION SYSTEM
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Fuel tank
3. Air filter case
4. Front side cowling assemblies
5. Rear center cover
6. Air induction system solenoid
1. Check the fuses. NG →

(Main, backup, and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-151.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-152.
OK ↓
3. Check the spark plugs. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug(s).
PLUGS” on page 3-5.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION COILS” on page 8-154.
NG ↓
5. Check the ignition coils. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil(s).
TION COILS” on page 8-154.
OK ↓
6. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on
page 8-155.
OK ↓
7. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-150.
OK ↓
8-4
IGNITION SYSTEM
8. Check the engine stop switch. NG →

• The engine stop switch is faulty.
Refer to “CHECKING THE
• Replace the right handlebar switch.
OK ↓
9. Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
10.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
11.Check the relay unit (diode). NG →
Refer to “CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)” on page 8-153.
OK ↓
12.Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 8-155.
OK ↓
13.Check the entire ignition system NG →
wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-1.
OK ↓
Replace the ECU.
Refer to “REPLACING THE ECU (en-
gine control unit)” on page 8-151.
8-5
IGNITION SYSTEM
8-6
ELECTRIC STARTING SYSTEM
EAS20073

EAS30493
CIRCUIT DIAGRAM
33
31
31
32
29
PUSH
FREE
28
90
26
25
24
DOWN
UP
(N)
20
21
5
4
15
3
OFF
ON
8-7
3. Main switch
4. Main fuse
5. Battery
6. Engine ground
15.Ignition fuse
20.Starter relay
21.Starter motor
26.Start switch
28.Relay unit
29.Starting circuit cut-off relay
31.Joint coupler
32.Neutral switch
33.Sidestand switch
90.Clutch switch
8-8
EAS30494
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:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the
sidestand switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay
is closed and the engine can be started by pressing the start switch.
8-9
a. WHEN THE TRANSMISSION IS IN 1. Battery

NEUTRAL 2. Main fuse
b. WHEN THE SIDESTAND IS UP AND THE 3. Main switch
CLUTCH LEVER IS PULLED TO THE 4. Ignition fuse
HANDLEBAR
6. Relay unit (starting circuit cut-off relay)
7. Relay unit (diode)
8. Clutch switch
9. Sidestand switch
10. Neutral switch
11. Start switch
12. Starter relay
13. Starter motor
8-10
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Rider seat
2. Fuel tank bracket
4. Thermostat

(Main and ignition)
OK ↓
page 8-152.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
8-156.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-44.
OK ↓
5. Check the relay unit (starting circuit NG →
cut-off relay).
Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 8-152.
OK ↓
6. Check the relay unit (diode). NG →
OK ↓
7. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
8-11

OK ↓
OK ↓
10.Check the neutral switch. NG →
OK ↓
11.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
12.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
13.Check the start switch. NG →
• The start switch is faulty.
OK ↓
14.Check the entire starting system NG →
page 8-7.
OK ↓
The starting system circuit is OK.
8-12
CHARGING SYSTEM
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
5
4
6
2
1
1. AC magneto
2. Rectifier/regulator
4. Main fuse
5. Battery
6. Engine ground
8-13
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Rider seat
2. Front side cowling assembly (left)
3. Fuel tank
1. Check the fuse. NG →

(Main)
Replace the fuse.
OK ↓
page 8-152.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR • Replace the stator coil assembly.
COIL” on page 8-156.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
8-157.
OK ↓
5. Check the entire charging system NG →
page 8-13.
OK ↓
The charging system circuit is OK.
8-14
LIGHTING SYSTEM
EAS20075
LIGHTING SYSTEM
EAS30498
CIRCUIT DIAGRAM
44
79
81
75
70
31
94
95
87
96
86
31
22
DOWN
UP
(N)
84
98
99
5
4
11
14
15
16
3
OFF
ON
8-15
LIGHTING SYSTEM
3. Main switch
4. Main fuse
5. Battery
6. Engine ground
11.Backup fuse
14.Headlight fuse
15.Ignition fuse
16.Signaling system fuse
22.Auxiliary light
31.Joint coupler
70.Meter assembly
75.Multi-function meter
79.High beam indicator light
81.Meter light
84.Handlebar switch (left)
86.Pass switch
87.Dimmer switch
94.Front turn signal/position light (right)
95.Front turn signal/position light (left)
96.Headlight assembly
98.Tail/brake light assembly
99.License plate light
8-16
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight (high beam), headlight (low beam), auxiliary light, high beam
indicator light, taillight, position light, license plate light or meter light.
TIP
1. Rider seat
2. Fuel tank
3. Front side cowling assembly (left)
1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb and bulb socket.
AND BULB SOCKETS” in “BASIC
INFORMATION” (separate volume).
OK ↓
(Main, backup, headlight, ignition,
and signaling system) Replace the fuse(s).
OK ↓
page 8-152.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
• The dimmer switch is faulty.
• Replace the left handlebar switch.
OK ↓
6. Check the entire lighting system NG →
page 8-15.
OK ↓
Replace the ECU, meter assembly,
headlight assembly, front turn signal/
position light, license plate light, tail/
brake light or auxiliary light.
8-17
LIGHTING SYSTEM
8-18
EAS30500
EAS20076
28
5
3
ON
OFF L/Y L/B L/B L/Y
Br/R Br/R
CIRCUIT DIAGRAM
35
6
SIGNALING SYSTEM
23 32
8
FREE
PUSH
69
11 83
13
70
84 71 44
15 88 89 72
UP
16 (N) 73
DOWN
8-19
74
91
75
42
97
77
31
98
31
80
63
95 94 93 92
65
SIGNALING SYSTEM
SIGNALING SYSTEM
3. Main switch
4. Main fuse
5. Battery
6. Engine ground
8. ABS ECU fuse
11.Backup fuse
13.Turn signal light fuse
15.Ignition fuse
23.Front brake light switch
28.Relay unit
31.Joint coupler
32.Neutral switch
35.Gear position sensor
42.Coolant temperature sensor
63.ABS ECU
65.Rear wheel sensor
69.Fuel sender
70.Meter assembly
71.Fuel level warning light
72.Oil level warning light
73.Neutral indicator light
74.Shift light
77.Coolant temperature warning light
80.Turn signal indicator light
83.Oil level switch
84.Handlebar switch (left)
88.Horn switch
89.Turn signal switch
91.Horn
92.Rear turn signal light (right)
93.Rear turn signal light (left)
94.Front turn signal/position light (right)
95.Front turn signal/position light (left)
97.Rear brake light switch
98.Tail/brake light assembly
8-20
SIGNALING SYSTEM
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or indicator light.
• The horn fails to sound.
• The speedometer fail to operate
TIP
1. Rider seat
2. Fuel tank
4. Bottom cowlings

(Main, ABS ECU, backup, turn sig-
nal light, ignition and signaling sys-
tem)
OK ↓
page 8-152.
OK ↓
OK ↓
4. Check the entire signaling system NG →
page 8-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
• The horn switch is faulty.
OK ↓
8-21
SIGNALING SYSTEM

page 8-19.
OK ↓
Replace the horn.
The tail/brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
page 8-19.
OK ↓
Replace the tail/brake light.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal switch. NG →
• The turn signal switch is faulty.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly, front turn
signal/position light, or rear turn signal
light.
The neutral indicator light fails to come on.

1. Check the neutral switch. NG →
OK ↓
8-22
SIGNALING SYSTEM
2. Check the relay unit (diode). NG →

OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The oil level warning light fails to come on.

1. Check the oil level switch. NG →
Refer to “CHECKING THE OIL Replace the oil level switch.
LEVEL SWITCH” on page 8-157.
OK ↓
page 8-19.
OK ↓
The fuel level warning light fails to come on.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 8-158.
OK ↓
page 8-19.
OK ↓
The coolant temperature warning light fails to come on.

1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-159.
OK ↓
8-23
SIGNALING SYSTEM

page 8-19.
OK ↓
Replace the ECU or meter assembly.
The speedometer fails to operate.

1. Check the rear wheel sensor. NG →
Refer to “MAINTENANCE OF THE
Replace the rear wheel sensor.
REAR WHEEL SENSOR AND
SENSOR ROTOR” on page 4-30.
OK ↓
2. Check the entire rear wheel sensor NG →
Properly connect or replace the wire har-
wiring.
ness.
Refer to TIP.
OK ↓
Replace the hydraulic unit assembly,
ECU or meter assembly.
TIP
Replace the wire harness if there is an open or short circuit.
• Between rear wheel sensor coupler and ABS ECU coupler.
(white–white)
(black–black)
• Between ABS ECU coupler and ECU coupler.
(gray/black–gray/black)
(white/yellow–white/yellow)
• Between ECU coupler and meter assembly coupler.
(light green/blue–light green/blue)
(light green/white–light green/white)
The shift light fails to come on.

1. Check that the shift light activation NG →
function is set correctly.
Set the shift light activation function.
Refer to “INSTRUMENT FUNC-
TIONS” on page 1-2.
OK ↓
8-24
COOLING SYSTEM
EAS20077
COOLING SYSTEM
EAS30502
CIRCUIT DIAGRAM
44
42
5
4
100
6
11
15
17
18
3
101
OFF
ON
103
8-25
COOLING SYSTEM
3. Main switch
4. Main fuse
5. Battery
6. Engine ground
11.Backup fuse
15.Ignition fuse
17.Radiator fan motor fuse (right)
18.Radiator fan motor fuse (left)
100.Radiator fan motor (right)
101.Radiator fan motor (left)
103.Radiator fan motor relay
8-26
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
TIP
1. Rider seat
2. Fuel tank

(Main, backup, ignition and radiator
fan motor) Replace the fuse(s).
OK ↓
page 8-152.
OK ↓
OK ↓
4. Check the radiator fan motors. NG →
Refer to “CHECKING THE RADIA-
Replace the radiator fan motor(s).
TOR FAN MOTORS” on page
8-159.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK ↓
6. Check the coolant temperature. NG →
Refer to “CHECKING THE COOL-
Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-159.
OK ↓
7. Check the entire cooling system NG →
page 8-25.
OK ↓
Replace the ECU.
8-27
COOLING SYSTEM
8-28
EAS30504
EAS20078
46
28 45
5
29
3 30
ON 47
OFF L/Y L/B L/B L/Y
CIRCUIT DIAGRAM
Br/R Br/R
31 45
48
31 35 45
6 33
49
A
A
34 A
32 A 45
A
A
A
A
7 24
50
A A
8 25 36
FREE
PUSH
FUEL INJECTION SYSTEM
51
10 37
68 52
11
38 53
54
103 70 39 55
14 84 44 B B
B
B
B
15 40
87 56
UP
(N) 57
DOWN
8-29
58
90
31 41
75
42 59
31
43 60
31 61
78
62
31
67
96
63
66 64
65
A B
B
A C
3. Main switch 70.Meter assembly

4. Main fuse 75.Multi-function meter
5. Battery 78.Engine trouble warning light
6. Engine ground 84.Handlebar switch (left)
7. Fuel injection system fuse 87.Dimmer switch
8. ABS ECU fuse 90.Clutch switch
10.Electronic throttle valve fuse 96.Headlight assembly
11.Backup fuse 103.Radiator fan motor relay
14.Headlight fuse
A. Wire harness
15.Ignition fuse
B. Sub-wire harness (ignition)
C. Sub-wire harness (secondary injector)
28.Relay unit
29.Starting circuit cut-off relay
30.Fuel pump relay
31.Joint coupler
32.Neutral switch
33.Sidestand switch
34.Cylinder identification sensor
35.Gear position sensor
36.Lean angle sensor
37.Intake air pressure sensor
38.Atmospheric pressure sensor
39.Intake air temperature sensor
40.O2 sensor
41.Crankshaft position sensor
43.EXUP servo motor
45.Spark plug
46.Ignition coil #1
47.Ignition coil #2
48.Ignition coil #3
49.Ignition coil #4
50.Air induction system solenoid
51.Primary injector #1
55.Secondary injector #1
59.Accelerator position sensor
60.Throttle position sensor
61.Intake funnel servo motor
62.Throttle servo motor
63.ABS ECU
64.Front wheel sensor
66.Yamaha diagnostic tool coupler
67.Shift switch (OPTION)
68.Fuel pump
8-30
EAS30505
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code
number is stored in the memory of the ECU.
Checking the engine trouble warning light

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

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS30506
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
a. Check the fault code numbers that have a condition of “Malfunction” using the Yamaha diagnostic
tool.
b. Identify the faulty system with the fault code number.
c. Identify the probable cause of the malfunction.
2. Check and repair the probable cause of the malfunction.
Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOTING Check and repair.
DETAILS (FAULT CODE)” on page 8-33.
Monitor the operation of the sensors and actuators in
the diagnostic mode. Refer to “TROUBLESHOOT-
ING DETAILS (FAULT CODE)” on page 8-33 and
“SELF-DIAGNOSTIC FUNCTION AND DIAGNOS-
TIC CODE TABLE” on page 9-1.
3. Perform the reinstatement action for the fuel injection system.

Refer to “Confirmation of service completion” in the appropriate table in “TROUBLESHOOTING DE-
TAILS (FAULT CODE)” on page 8-33.
TIP
• If another fault code number is displayed, repeat steps (1) to (3) until no fault code number is dis-
played.
• Turning the main switch to “OFF” will not erase the malfunction history.
8-31
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “DIAG-
NOSTIC CODE: SENSOR OPERATION TABLE” on page 9-11 and “DIAGNOSTIC CODE: ACTU-
ATOR OPERATION TABLE” on page 9-14.
01: Throttle position sensor signal 1 (throttle angle)
13: Throttle position sensor signal 2 (throttle angle)
14: Accelerator position sensor signal 1 (throttle angle)
15: Accelerator position sensor signal 2 (throttle angle)
30: Cylinder-#1 ignition coil
36: Primary injector #1
40: Secondary injector #1
48: Air induction system solenoid
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
EAS30951
YAMAHA DIAGNOSTIC TOOL

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.

90890-03257
Yamaha diagnostic tool (A/I)
90890-03254
TIP
A generic scan tool can also be used to identify malfunctions.
OBD/ GST Leadwire kit

90890-03249
Connecting the Yamaha diagnostic tool

Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
1
8-32
EAS31791
TROUBLESHOOTING DETAILS (FAULT CODE)

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given.
After the check and service of the malfunctioning part have been completed, delete the fault codes dis-
played on the Yamaha diagnostic tool according to the reinstatement method.
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-1.
Parts connected to the ECU

The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Throttle servo motor
• Primary injector #1 • Handlebar switch (left and right)
• Primary injector #2 • Gear position sensor
• Primary injector #3 • Headlight assembly
• Primary injector #4 • Relay unit
• Accelerator position sensor • Radiator fan motor relay
• Throttle position sensor • Meter assembly
• Intake air pressure sensor • Starter relay
• Atmospheric pressure sensor • EXUP servo motor
• Coolant temperature sensor • Intake funnel servo motor
• Intake air temperature sensor • Sub-wire harness (ignition)
• O2 sensor • Sub-wire harness (secondary injector)
• Lean angle sensor • Shift switch (OPTION)
• ABS ECU
8-33
Fault code No. P0030

TIP
• If fault code numbers “P0030” and “P0112” are both indicated, take the actions specified for fault code
number “P0112” first.
Item O2 sensor heater: defective heater controller detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. —
Tool display —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of O2 sensor cou- Improperly connected → Con- Turn the main switch to “ON”,
pler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is “Recover” → Go to
terminals and locking condition item 6 and finish the service.
of the pins). Condition is “Malfunction” →
Start the engine, and then
check the condition of the fault
code.
Condition is “Recover” → Go to
item 6 and finish the service.
Condition is “Malfunction” → Go
to item 2.
TIP
For this check, also set the en-
gine stop switch to “ON”.
8-34

2 Connection of ECU coupler. Improperly connected → Con- Turn the main switch to “ON”,
Check the locking condition of nect the coupler securely or re- and then check the condition of
the coupler. place the wire harness. the fault code using the mal-
Disconnect the coupler and function mode of the Yamaha di-
check the pins (bent or broken agnostic tool.
terminals and locking condition Condition is “Recover” → Go to
of the pins). item 6 and finish the service.
Condition is “Malfunction” →
code.
to item 3.
TIP
3 Wire harness continuity. Open or short circuit → Properly Turn the main switch to “ON”,
connect or replace the wire har- and then check the condition of
ness. the fault code using the mal-
Between O2 sensor coupler and function mode of the Yamaha di-
ECU coupler. agnostic tool.
pink/black–pink/black Condition is “Recover” → Go to
Between O2 sensor coupler and item 6 and finish the service.
relay unit coupler. Condition is “Malfunction” →
red/blue–red/blue Start the engine, and then
code.
to item 4.
TIP
4 Defective O2 sensor heater. Replace the O2 sensor. Turn the main switch to “ON”,
and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
code.
to item 5.
TIP
8-35

5 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-151.
6 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of “Recover” using
light goes off. the Yamaha diagnostic tool, and
then delete the fault code.

Intake air pressure sensor or atmospheric pressure sensor: when

Item the main switch is turned to “ON”, the intake air pressure sensor
voltage and atmospheric pressure sensor voltage differ greatly.
Fail-safe system
Diagnostic code No. 03, 02
Tool display Displays the intake air pressure.
03 Operate the throttle while pushing the start switch “ ”. (If the display val-
Procedure
ue changes, the performance is OK.)
Tool display Displays the atmospheric pressure.
02 Compare the actually measured atmospheric pressure with the tool dis-
Procedure
play value.
1 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”,
sensor. (Code No. 03) and then check the condition of
When engine is stopped: the fault code using the mal-
Atmospheric pressure at the function mode of the Yamaha
current altitude and weather diagnostic tool.
conditions is indicated. Condition is “Recover” → Go to
0 m above sea level: Approx. item 4 and finish the service.
101 kPa (757.6 mmHg, 29.8 Condition is “Malfunction” → Go
inHg) to item 2.
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20.7 inHg)
Displayed value is incorrect →
Replace the intake air pressure
sensor.
8-36
Intake air pressure sensor or atmospheric pressure sensor: when

Item the main switch is turned to “ON”, the intake air pressure sensor
voltage and atmospheric pressure sensor voltage differ greatly.
2 Defective atmospheric pres- Execute the diagnostic mode. Turn the main switch to “ON”,
sure sensor. (Code No. 02) and then check the condition of
Atmospheric pressure at the function mode of the Yamaha
current altitude and weather diagnostic tool.
0 m above sea level: Approx. item 4 and finish the service.
101 kPa (757.6 mmHg, 29.8 Condition is “Malfunction” → Go
inHg) to item 3.
mmHg, 20.7 inHg)
Replace the atmospheric pres-
sure sensor.
3 Malfunction in ECU. Replace the ECU.
page 8-151.
Fault code No. P0107, P0108

[P0107] Intake air pressure sensor: ground short circuit detected.

Item [P0108] Intake air pressure sensor: open or power short circuit de-
tected.
Fail-safe system
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Operate the throttle while pushing the start switch “ ”. (If the display val-
Procedure
ue changes, the performance is OK.)
1 Connection of intake air pres- Improperly connected → Con- Turn the main switch to “ON”,
sure sensor coupler. nect the coupler securely or re- and then check the condition of
of the pins). Condition is “Malfunction” → Go
to item 2.
8-37

tected.
to item 3.
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”,
the wire harness. and then check the condition of
agnostic tool.
to item 4.
3-1
2
1 5V 5V
L
3 L
P/W
4 P/W
B/L
5 B/L
1. Intake air pressure sensor

2. ECU
3. Sensor input lead
4. Sensor output lead
5. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the intake air pressure sensor coupler from the intake air pressure sensor.
3-3 [For P0107] Ground short circuit
Between intake air pressure sensor coupler and ground: pink/white–ground
If there is continuity, replace the wire harness.
B/L P/W L
8-38

tected.
3-4 [For P0108] Open circuit
Between intake air pressure sensor coupler and ECU coupler: blue–blue
If there is no continuity, replace the wire harness.
Y/R R/W R/G Gy B/G G P/W Y/G W/G Lg/W

B/L P/W L Lg/R W W/B L/R B/R P G/W P/L B/Y Lg/L
R/L B/W B/L L Gy/B W/Y W/R Br/W Gy/G Y/W L/W L/Y V

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


Between intake air pressure sensor coupler and ECU coupler: black/blue–black/blue

3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-33.
8-39

tected.
3-8 [For P0107, P0108] Short circuit
Between intake air pressure sensor output terminal (pink/white) “a” of ECU coupler and any other
ECU coupler terminal “b”.
b a

Lg/R W W/B L/R B/R P G/W P/L B/Y Lg/L
4 Installed condition of intake air Check for looseness or pinch- Turn the main switch to “ON”,
pressure sensor. ing. and then check the condition of
Improperly installed sensor → the fault code using the mal-
Reinstall or replace the sensor. function mode of the Yamaha di-
agnostic tool.
to item 5.
5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”,
Atmospheric pressure at the function mode of the Yamaha di-
current altitude and weather agnostic tool.
At sea level: Approx. 101 kPa item 7 and finish the service.
(757.6 mmHg, 29.8 inHg) Condition is “Malfunction” → Go
1000 m (3300 ft) above sea lev- to item 6.
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. → Re-
place the intake air pressure
sensor.
page 8-151.
8-40

tected.

TIP
Perform this procedure when the engine is cold.
[P0112] Intake air temperature sensor: ground short circuit detected.

Item [P0113] Intake air temperature sensor: open or power short circuit
detected.
Fail-safe system
Tool display Displays the air temperature.
Compare the actually measured air temperature with the tool display val-
Procedure
ue.
1 Connection of intake air tem- Improperly connected → Con- Turn the main switch to “ON”,
perature sensor coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
agnostic tool.
to item 4.
8-41

detected.
3-1
2
5V
1
Br/W
3 Br/W
B/L B/L
4
1. Intake air temperature sensor

2. ECU
Disconnect the intake air temperature sensor coupler from the intake air temperature sensor.
Between intake air temperature sensor coupler and ground: brown/white–ground
Br/W B/L

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

Br/W B/L
8-42

detected.
Between intake air temperature sensor coupler and ECU coupler: black/blue–black/blue

Br/W B/L
Between intake air temperature sensor output terminal (brown/white) “a” of ECU coupler and any
other ECU coupler terminal “b”.

b a
4 Installed condition of intake air Check for looseness or pinch- Turn the main switch to “ON”,
temperature sensor. ing. and then check the condition of
agnostic tool.
to item 5.
5 Defective intake air tempera- Execute the diagnostic mode. Turn the main switch to “ON”,
ture sensor. (Code No. 05) and then check the condition of
When engine is cold: the fault code using the mal-
Displayed temperature is close function mode of the Yamaha di-
to the ambient temperature. agnostic tool.
The displayed temperature is Condition is “Recover” → Go to
not close to the ambient tem- item 7 and finish the service.
perature. → Replace the intake Condition is “Malfunction” → Go
air temperature sensor. to item 6.
page 8-151.
8-43

detected.

TIP
Perform this procedure when the engine is cold.
[P0117] Coolant temperature sensor: ground short circuit detected.

Item [P0118] Coolant temperature sensor: open or power short circuit de-
tected.
Fail-safe system
When engine is cold: Displays temperature closer to air temperature.
Tool display
When engine is hot: Displays current coolant temperature.
Compare the actually measured coolant temperature with the tool display
Procedure
value.
1 Connection of coolant tempera- Improperly connected → Con- Turn the main switch to “ON”,
ture sensor coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
agnostic tool.
to item 4.
8-44

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

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

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

G/W B/L Lg/R W W/B L/R B/R P G/W P/L B/Y Lg/L
8-45

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

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

4 Installed condition of coolant Check for looseness or pinch- Turn the main switch to “ON”,
temperature sensor. ing. and then check the condition of
agnostic tool.
to item 5.
5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to “ON”,
When engine is cold: the fault code using the mal-
Displayed temperature is close function mode of the Yamaha di-
to the ambient temperature. agnostic tool.
The displayed temperature is Condition is “Recover” → Go to
not close to the ambient tem- item 7 and finish the service.
perature → Replace the coolant Condition is “Malfunction” → Go
temperature sensor. to item 6.
page 8-151.
8-46

tected.
Fault code No. P0122, P0123, P0222, P0223, P2135

TIP
If a fault code number (“P0122”, “P0123”, “P0222”, or “P0223”) other than “P2135” is indicated, take the
actions specified for that fault code number first.
[P0122, P0222] Throttle position sensor: ground short circuit detect-

ed.
Item [P0123, P0223] Throttle position sensor: open or power short circuit
detected.
[P2135] Deviation error
Able/Unable to start engine
Fail-safe system
Able/Unable to drive vehicle
Throttle position sensor signal 1
Tool display • 11–21 (fully closed position)
01 • 96–106 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
Throttle position sensor signal 2
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
1 Connection of throttle position Improperly connected → Con- Turn the main switch to “ON”,
sensor coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
8-47

ed.
detected.
agnostic tool.
to item 4.
3-1
2
1 5V 5V 5V
L
3 L
W
4 W
B
4 B
B/L
5 B/L
1. Throttle position sensor

2. ECU
Disconnect the throttle position sensor coupler from the throttle position sensor.
[For P2135] Deviation error
Between throttle position sensor coupler and ground: white–ground
B/L W L B
8-48

ed.
detected.
Between throttle position sensor coupler and ground: black–ground
B/L W L B

Between throttle position sensor coupler and ECU coupler: white–white
Gy/G O/G Gy/R O P/B L L

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

Between throttle position sensor coupler and ECU coupler: black–black

B/L W L B
8-49

ed.
detected.
3-7 [For P0123, P0223] Open circuit
Between throttle position sensor coupler and ECU coupler: black/blue–black/blue

B/L W L B
Between throttle position sensor output terminal (white) “a” of ECU coupler and any other ECU cou-
pler terminal “b”


Between throttle position sensor output terminal (black) “a” of ECU coupler and any other ECU cou-
pler terminal “b”

a
b
8-50

ed.
detected.
4 Installed condition of throttle po- Check for looseness or pinch- Turn the main switch to “ON”,
sition sensor. ing. and then check the condition of
Reinstall or adjust the sensor. function mode of the Yamaha di-
Refer to “ADJUSTING THE agnostic tool.
THROTTLE POSITION SEN- Condition is “Recover” → Go to
SOR” on page 7-17. item 8 and finish the service.
to item 5.
5 Throttle position sensor resis- Measure the throttle position Turn the main switch to “ON”,
tance. sensor resistance. and then check the condition of
black/blue–blue the fault code using the mal-
Refer to “CHECKING THE function mode of the Yamaha di-
THROTTLE POSITION SEN- agnostic tool.
SOR” on page 8-161. Condition is “Recover” → Go to
to item 6.
6 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ON”,
sor. signal 1. and then check the condition of
Execute the diagnostic mode. the fault code using the mal-
(Code No. 01) function mode of the Yamaha di-
When the throttle valves are ful- agnostic tool.
ly closed: Condition is “Recover” → Go to
A value of 11–21 is indicated. item 8 and finish the service.
When throttle valves are fully Condition is “Malfunction” → Go
open: to item 7.
A value of 96–106 is indicated.
Check throttle position sensor
signal 2.
Execute the diagnostic mode.
(Code No. 13)
When the throttle valves are ful-
ly closed:
ly open:
An indicated value is out of the
specified range → Replace the
throttle position sensor.
page 8-151.
8-51

Item O2 sensor: short circuit detected (power short circuit).

Fail-safe system
Tool display —
Procedure —
1 Installed condition of O2 sensor. Check for looseness or pinch- Turn the main switch to “ON”,
ing. and then check the condition of
agnostic tool.
to item 2.
2 Connection of O2 sensor cou- Improperly connected → Con- Turn the main switch to “ON”,
to item 3.
to item 4.
4 Wire harness continuity. Open or short circuit → Properly Turn the main switch to “ON”,
connect or replace the wire har- and then check the condition of
ness. the fault code using the mal-
Between O2 sensor coupler and function mode of the Yamaha di-
ECU coupler. agnostic tool.
black/blue–black/blue Condition is “Recover” → Go to
gray/green–gray/green item 7 and finish the service.
to item 5.
5 Defective O2 sensor. Check the O2 sensor. Turn the main switch to “ON”,
Defective → Replace the O2 and then check the condition of
sensor. the fault code using the mal-
Refer to “ENGINE REMOVAL” function mode of the Yamaha di-
on page 5-9. agnostic tool.
to item 6.
8-52
Item O2 sensor: short circuit detected (power short circuit).

page 8-151.

Item Primary injector #1: malfunction in primary injector #1.

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)
Actuates primary injector #1 five times at one-second intervals.
Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on
each time the primary injector is actuated.
Disconnect the fuel pump coupler. Check that primary injector #1 is actu-
Procedure
ated five times by listening for the operating sound.
1 Connection of primary injector Improperly connected → Con- Execute the diagnostic mode.
#1 coupler. nect the coupler securely or re- (Code No. 36)
Check the locking condition of place the wire harness. Operating sound → Go to item
the coupler. 6.
Disconnect the coupler and No operating sound → Go to
check the pins (bent or broken item 2.
terminals and locking condition
of the pins).
2 Defective primary injector #1. Measure the primary injector re- Execute the diagnostic mode.
sistance. (Code No. 36)
Replace if out of specification. Operating sound → Go to item
Refer to “CHECKING THE 6.
FUEL INJECTORS” on page No operating sound → Go to
8-162. item 3.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 36)
the coupler. place the wire harness. Operating sound → Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound → Go to
terminals and locking condition item 4.
of the pins).
4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 36)
Between primary injector cou- Operating sound → Go to item
pler and ECU coupler. 6.
red/black–red/black No operating sound → Go to
Between primary injector cou- item 5.
pler and relay unit coupler.
red/blue–red/blue
8-53

page 8-151.
6 Delete the fault code and check Start the engine and let it idle for
that the engine trouble warning approximately 5 seconds.
light goes off. Confirm that the fault code has
a condition of “Recover” using
the malfunction mode of the
Yamaha diagnostic tool, and


Fail-safe system
Procedure
the coupler. 6.
of the pins).
8-162. item 3.
of the pins).
8-54

green/black–green/black No operating sound → Go to
red/blue–red/blue
page 8-151.


Fail-safe system
Procedure
the coupler. 6.
of the pins).
8-162. item 3.
8-55

of the pins).
blue/black–blue/black No operating sound → Go to
red/blue–red/blue
page 8-151.


Fail-safe system
Procedure
the coupler. 6.
of the pins).
8-56

8-162. item 3.
of the pins).
orange/black–orange/black No operating sound → Go to
red/blue–red/blue
page 8-151.

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Tool display —
Procedure —
8-57
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
1 Connection of crankshaft posi- Improperly connected → Con- Crank the engine, and then
tion sensor coupler. nect the coupler securely or re- check the condition of the fault
Check the locking condition of place the wire harness. code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler and tool.
to item 2.
2 Connection of ECU coupler. Improperly connected → Con- Crank the engine, and then
Check the locking condition of nect the coupler securely or re- check the condition of the fault
the coupler. place the wire harness. code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
to item 3.
3 Wire harness continuity. Open or short circuit → Replace Crank the engine, and then
the wire harness. check the condition of the fault
Between crankshaft position code using the malfunction
sensor coupler and ECU cou- mode of the Yamaha diagnostic
pler. tool.
gray–gray Condition is “Recover” → Go to
black/blue–black/blue item 7 and finish the service.
to item 4.
4 Installed condition of crankshaft Improperly installed sensor → Crank the engine, and then
position sensor. Reinstall or replace the sensor. check the condition of the fault
Check for looseness or pinch- Refer to “PICKUP ROTOR” on code using the malfunction
ing. page 5-39. mode of the Yamaha diagnostic
tool.
to item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine, and then
sensor. sensor. check the condition of the fault
Refer to “CHECKING THE code using the malfunction
CRANKSHAFT POSITION mode of the Yamaha diagnostic
SENSOR” on page 8-155. tool.
Replace if defective. Condition is “Recover” → Go to
to item 6.
page 8-151.
8-58

Cylinder identification sensor: no normal signals are received from

Item
the cylinder identification sensor.
Fail-safe system
Tool display —
Procedure —
1 Connection of cylinder identifi- Improperly connected → Con- Crank the engine, and then
cation sensor coupler. nect the coupler securely or re- check the condition of the fault
Check the locking condition of place the sub-wire harness. code using the malfunction
to item 2.
2 Connection of ECU coupler. Improperly connected → Con- Crank the engine, and then
Check the locking condition of nect the coupler securely or re- check the condition of the fault
the coupler. place the wire harness. code using the malfunction
to item 3.
3 Connection of sub-wire har- Improperly connected → Con- Crank the engine, and then
ness coupler. nect the coupler securely or re- check the condition of the fault
Check the locking condition of place the sub-wire harness. code using the malfunction
to item 4.
4 Wire harness and/or sub-wire Open or short circuit → Replace Crank the engine, and then
harness continuity. the wire harness and/or sub- check the condition of the fault
wire harness. code using the malfunction
Between cylinder identification mode of the Yamaha diagnostic
sensor coupler and sub-wire tool.
harness coupler. Condition is “Recover” → Go to
blue–blue item 8 and finish the service.
white/black–white/black Condition is “Malfunction” → Go
black/blue–black/blue to item 5.
Between sub-wire harness cou-
pler and ECU coupler.
blue–blue
white/black–white/black
black/blue–black/blue
8-59
Cylinder identification sensor: no normal signals are received from

Item
the cylinder identification sensor.
5 Installed condition of cylinder Improperly installed sensor → Crank the engine, and then
identification sensor. Reinstall or replace the sensor. check the condition of the fault
Check for looseness or pinch- code using the malfunction
ing. mode of the Yamaha diagnostic
tool.
to item 6.
6 Defective cylinder identification Check the cylinder identification Crank the engine, and then
sensor. sensor. check the condition of the fault
Refer to “CHECKING THE CYL- code using the malfunction
INDER IDENTIFICATION SEN- mode of the Yamaha diagnostic
SOR” on page 8-160. tool.
to item 7.
page 8-151.

Cylinder-#1 ignition coil: open or short circuit detected in the prima-

Item
ry lead of the cylinder-#1 ignition coil.
Fail-safe system
Actuates the cylinder-#1 ignition coil five times at one-second intervals.
each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
1 Connection of cylinder-#1 igni- Improperly connected → Con- Start the engine and let it idle for
tion coil coupler. nect the coupler securely or re- approximately 5 seconds.
Check the locking condition of place the sub-wire harness. Check the condition of the fault
the coupler. code using the malfunction
to item 2.
8-60

Item
2 Connection of ECU coupler. Improperly connected → Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
the coupler. place the wire harness. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is “Recover” → Go to
to item 3.
3 Connection of sub-wire har- Improperly connected → Con- Start the engine and let it idle for
ness coupler. nect the coupler securely or re- approximately 5 seconds.
to item 4.
4 Wire harness and/or sub-wire Open or short circuit → Replace Start the engine and let it idle for
harness continuity. the wire harness and/or sub- approximately 5 seconds.
wire harness. Check the condition of the fault
Between cylinder-#1 ignition coil code using the malfunction
coupler and sub-wire harness mode of the Yamaha diagnostic
coupler. tool.
orange–orange Condition is “Recover” → Go to
Between sub-wire harness cou- item 8 and finish the service.
pler and ECU coupler. Condition is “Malfunction” → Go
orange–orange to item 5
5 Installed condition of cylinder-#1 Check for looseness or pinch- Start the engine and let it idle for
ignition coil. ing. approximately 5 seconds.
Improperly installed ignition coil Check the condition of the fault
→ Reinstall or replace the igni- code using the malfunction
tion coil. mode of the Yamaha diagnostic
tool.
to item 6.
6 Defective cylinder-#1 ignition Measure the primary coil resis- Start the engine and let it idle for
coil. tance of the cylinder-#1 ignition approximately 5 seconds.
coil. Check the condition of the fault
Replace if out of specification. code using the malfunction
Refer to “CHECKING THE IG- mode of the Yamaha diagnostic
NITION COILS” on page 8-154. tool.
to item 7.
8-61

Item
7 Malfunction in ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark → Replace the ECU.
page 8-151.


Item
Fail-safe system
Procedure
to item 2.
to item 3.
8-62

Item
to item 4.
4 Wire harness and/or sub-wire Open or short circuit → Replace Start the engine and let it idle for
harness continuity. the wire harness and/or sub- approximately 5 seconds.
wire harness. Check the condition of the fault
Between cylinder-#2 ignition coil code using the malfunction
coupler and sub-wire harness mode of the Yamaha diagnostic
coupler. tool.
gray/red–gray/red Condition is “Recover” → Go to
Between sub-wire harness cou- item 8 and finish the service.
pler and ECU coupler. Condition is “Malfunction” → Go
gray/red–gray/red to item 5.
tool.
to item 6.
to item 7.
(Code No. 31)
page 8-151.
8-63


Item
Fail-safe system
Procedure
to item 2.
to item 3.
to item 4.
4 Wire harness continuity. Open or short circuit → Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between cylinder-#3 ignition coil Check the condition of the fault
coupler and sub-wire harness code using the malfunction
coupler. mode of the Yamaha diagnostic
orange/green–orange/green tool.
Between sub-wire harness cou- Condition is “Recover” → Go to
pler and ECU coupler. item 8 and finish the service.
orange/green–orange/green Condition is “Malfunction” → Go
to item 5.
8-64

Item
tool.
to item 6.
to item 7.
(Code No. 32)
page 8-151.


Item
Fail-safe system
Procedure
8-65

Item
to item 2.
to item 3.
to item 4.
Between cylinder-#4 ignition coil Check the condition of the fault
coupler and sub-wire harness code using the malfunction
coupler. mode of the Yamaha diagnostic
gray/green–gray/green tool.
pler and ECU coupler. item 8 and finish the service.
gray/green–gray/green Condition is “Malfunction” → Go
to item 5.
tool.
to item 6.
8-66

Item
to item 7.
(Code No. 33)
page 8-151.

TIP
If fault code numbers “P048D/P048E” and “P0476” are both indicated, take the actions specified for
fault code number “P048D/P048E” first.
Item EXUP servo motor: stuck EXUP servo motor is detected.

Fail-safe system
After the EXUP is fully closed, it stops at the opening base position (inter-
mediate position).
Actuation
This operation takes approximately 3 seconds during which the “check”
indicator is displayed on the Yamaha diagnostic tool.
Procedure Check the operating sound.
Probable cause of Confirmation of service com-
malfunction and check pletion
1 Connection of EXUP servo mo- Improperly connected → Con- Turn the main switch to “ON”,
tor coupler. nect the coupler securely or re- and then check the condition of
to item 2.
8-67
Item EXUP servo motor: stuck EXUP servo motor is detected.

to item 3.
Between EXUP servo motor the fault code using the mal-
coupler and ECU coupler. function mode of the Yamaha di-
black/green–black/green agnostic tool.
black/red–black/red Condition is “Recover” → Go to
to item 4.
4 Defective EXUP servo motor. Disconnect the cables and exe- Turn the main switch to “ON”,
cute the diagnostic code. and then check the condition of
(Code No. 53) the fault code using the mal-
Check the operating sound of function mode of the Yamaha di-
the motor. agnostic tool.
to item 5.
5 Defective EXUP valve, pulley, Turn the EXUP valve manually Turn the main switch to “ON”,
and cables. with the cables disconnected. and then check the condition of
Replace the muffler or EXUP the fault code using the mal-
cable if defective. function mode of the Yamaha di-
agnostic tool.
to item 6.
page 8-151.
8-68

Item Radiator fan motor relay: open or short circuit is detected.

Fail-safe system
Radiator fan motor relay five times at one-second intervals. The “check”
Actuation indicator on the Yamaha diagnostic tool screen comes on each time the
Radiator fan motor relay is actuated.
Check that Radiator fan motor relay is actuated five times by listening for
Procedure
the operating sound.
1 Connection of radiator fan motor Improperly connected → Con- Turn the main switch to “ON”,
relay coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
Between radiator fan motor re- the fault code using the mal-
lay coupler and ECU coupler. function mode of the Yamaha di-
green/yellow–green/yellow agnostic tool.
Between radiator fan motor re- Condition is “Recover” → Go to
lay coupler and ignition fuse. item 6 and finish the service.
red/white–red/white Condition is “Malfunction” → Go
to item 4.
4 Defective radiator fan motor re- Check the radiator fan motor re- Turn the main switch to “ON”,
lay. lay. and then check the condition of
Refer to “CHECKING THE RE- the fault code using the mal-
LAYS” on page 8-152. function mode of the Yamaha di-
Replace if defective. agnostic tool.
to item 5.
page 8-151.
8-69
Item Radiator fan motor relay: open or short circuit is detected.

Fault code No. P048D, P048E

TIP
If fault code numbers “P048D/P048E” and “P0476” are both indicated, take the actions specified for
fault code number “P048D/P048E” first.
[P048D] EXUP servo motor: open or ground short circuit detected.

Item
[P048E] EXUP servo motor: power short circuit detected.
Fail-safe system
After the EXUP is fully closed, it stops at the opening base position (inter-
mediate position).
Actuation
This operation takes approximately 3 seconds during which the “check”
indicator is displayed on the Yamaha diagnostic tool.
Procedure Check the operating sound.
1 Connection of EXUP servo mo- Improperly connected → Con- Turn the main switch to “ON”,
to item 2.
to item 3.
agnostic tool.
to item 4.
8-70

Item
3-1
2
1 5V
L
3 L
W/R 4 W/R
B/L
5 B/L
1. EXUP servo motor

2. ECU
Disconnect the EXUP servo motor coupler from the EXUP servo motor.
3-3 [For P048D] Ground short circuit
Between EXUP servo motor coupler and ground: white/red–ground
L W/R B/L
B/G B/R
3-4 [For P048D] Open circuit

Between EXUP servo motor coupler and ECU coupler: blue–blue

L W/R B/L
B/G B/R Lg/R W W/B L/R B/R P G/W P/L B/Y Lg/L
8-71

Item
Between EXUP servo motor coupler and ECU coupler: white/red–white/red

L W/R B/L

Between EXUP servo motor coupler and ECU coupler: black/blue–black/blue

L W/R B/L
3-8 [For P048D/P048E] Short circuit
Between EXUP servo motor output terminal (white/red) “a” of ECU coupler and any other ECU cou-
pler terminal “b”.

4 Defective EXUP servo motor. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 53) and then check the condition of
Check the operating sound of the fault code using the mal-
the motor. function mode of the Yamaha di-
Replace if defective. agnostic tool.
to item 5.
8-72

Item
page 8-151.

TIP
In case “P0500” is detected, or both “P0500” and “P1500” are detected, proceed from item A-1.
[P0500, P1500] Rear wheel sensor: no normal signals are re-

A
ceived from the rear wheel sensor.
Item
B [P1500] Neutral switch: open or short circuit is detected.
C [P1500] Clutch switch: open or short circuit is detected.

Fail-safe system
Rear wheel speed pulse
Tool display
0–999
Check that the number increases when the rear wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
A-1 Locate the malfunction. Fault code No. P0500 or P0500 Value does not increase → Go
and P1500 detected. to item A-2.
(Code No. 07)
Rotate the rear wheel by hand
and check that the indicated val-
ue increases.
Fault code No. P1500 detected. Incorrect indication → Go to
Execute the diagnostic mode. item B-2 for the neutral switch.
(Code No. 21)
When the transmission is in
neutral: “ON”
gear with the clutch lever re-
leased: “OFF”
When the transmission is in Incorrect indication → Go to
gear with the clutch lever item C-2 for the clutch switch.
squeezed and the sidestand re-
tracted: “ON”
8-73

A
Item

A-2 Connection of rear wheel sen- Improperly connected → Con- Execute the diagnostic mode.
sor coupler. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate the rear wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue increases.
check the pins (bent or broken Value increases → Go to item
terminals and locking condition A-8.
of the pins). Value does not increase → Go
to item A-3.
A-3 Connection of ABS ECU cou- Improperly connected → Con- Execute the diagnostic mode.
pler. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate the rear wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue increases.
check the pins (bent or broken Value increases → Go to item
terminals and locking condition A-8.
to item A-4.
A-4 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
the coupler. place the wire harness. Rotate the rear wheel by hand
Disconnect the coupler and and check that the indicated val-
check the pins (bent or broken ue increases.
terminals and locking condition Value increases → Go to item
of the pins). A-8.
Value does not increase → Go
to item A-5.
A-5 Rear wheel sensor lead continu- Open or short circuit, or defec- Execute the diagnostic mode.
ity, or defective rear wheel sen- tive sensor → Replace the rear (Code No. 07)
sor. wheel sensor. Rotate the rear wheel by hand
Between rear wheel sensor cou- and check that the indicated val-
pler and ABS ECU coupler. ue increases.
black–black Value increases → Go to item
white–white A-8.
Between ABS ECU coupler and Value does not increase → Go
ECU coupler. to item A-6.
white/yellow–white/yellow
A-6 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
Refer to “REPLACING THE (Code No. 07)
ECU (engine control unit)” on Rotate the rear wheel by hand
page 8-151. and check that the indicated val-
ue increases.
Value increases → Go to item
A-8.
to item A-7.
A-7 Malfunction in ABS ECU. Replace the Hydraulic unit as- Go to item A-8.
sembly.
8-74

A
Item

A-8 Delete the fault code and check Turn the main switch to “ON”,
that the engine trouble warning and then rotate the rear wheel
light goes off. by hand.
Start the engine, and input the
vehicle speed signals by operat-
ing the vehicle at 20 to 30 km/h
(12 to 19 mph).
Confirm that the fault code has
Delete this fault code even if it
has a condition of “Malfunction”.

A
Item

Fail-safe system
Neutral switch
Tool display • “ON” (when the transmission is in neutral)
• “OFF” (when the transmission is in gear with the clutch lever released)
Procedure Operate the transmission and clutch lever.
8-75

A
Item

B-1 Locate the malfunction. Fault code No. P0500 or P0500 Value does not increase → Go
and P1500 detected. to item A-2 for the rear wheel
Execute the diagnostic mode. sensor.
(Code No. 07)
ue increases.
Execute the diagnostic mode. item B-2.
(Code No. 21)
neutral: “ON”
leased: “OFF”
gear with the clutch lever item C-2 for the clutch switch.
squeezed and the sidestand is
retracted: “ON”
B-2 Connection of neutral switch Improperly connected → Con- Execute the diagnostic mode.
coupler. nect the coupler securely or re- (Code No. 21)
Check the locking condition of place the wire harness. When the transmission is in
the coupler. neutral: “ON”
Disconnect the coupler and When the transmission is in
check the pins (bent or broken gear with the clutch lever re-
terminals and locking condition leased: “OFF”
of the pins). Correct indication → Go to item
B-8.
Incorrect indication → Go to
item B-3.
B-3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
the coupler. place the wire harness. When the transmission is in
Disconnect the coupler and neutral: “ON”
check the pins (bent or broken When the transmission is in
terminals and locking condition gear with the clutch lever re-
of the pins). leased: “OFF”
Correct indication → Go to item
B-8.
item B-4.
B-4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
Between relay unit coupler and When the transmission is in
joint coupler. neutral: “ON”
black/yellow–black/yellow When the transmission is in
Between joint coupler and ECU gear with the clutch lever re-
coupler. leased: “OFF”
black/yellow–black/yellow Correct indication → Go to item
Between relay unit coupler and B-8.
neutral switch connector. Incorrect indication → Go to
sky blue–sky blue item B-5.
8-76

A
Item

B-5 Defective neutral switch. Check the neutral switch. Execute the diagnostic mode.
Replace if defective. (Code No. 21)
Refer to “CHECKING THE When the transmission is in
SWITCHES” on page 8-150. neutral: “ON”
leased: “OFF”
B-8.
item B-6.
B-6 Faulty shift drum (neutral detec- Malfunction → Replace the shift Execute the diagnostic mode.
tion area). drum. (Code No. 21)
Refer to “TRANSMISSION” on When the transmission is in
page 5-81. neutral: “ON”
leased: “OFF”
B-8.
item B-7.
B-7 Malfunction in ECU. Replace the ECU. Service is finished.
page 8-151.
B-8 Delete the fault code and check Turn the main switch to “ON”,
(12 to 19 mph).
8-77

A
Item

Fail-safe system
Clutch switch
• “ON” (when the clutch lever is squeezed with the transmission in gear
Tool display and when the sidestand is retracted)
• “OFF” (when the clutch lever is squeezed with the transmission in gear
and when the sidestand is extended)
Procedure Operate the transmission, clutch lever, and sidestand.
C-1 Locate the malfunction. Fault code No. P0500 or P0500 Value does not increase → Go
and P1500 detected. to item A-2 for the rear wheel
Execute the diagnostic mode. sensor.
(Code No. 07)
ue increases.
Execute the diagnostic mode. item B-2 for the neutral switch.
(Code No. 21)
neutral: “ON”
leased: “OFF”
gear with the clutch lever item C-2.
squeezed and the sidestand re-
tracted: “ON”
C-2 Clutch lever adjustment. Refer to “ADJUSTING THE Execute the diagnostic mode.
CLUTCH LEVER FREE PLAY” (Code No. 21)
on page 3-13. When the clutch lever is re-
leased with the transmission in
gear and when the sidestand is
retracted: “OFF”
When the clutch lever is
squeezed with the transmission
in gear and when the sidestand
is retracted: “ON”
Correct indication→ Go to item
C-8.
item C-3.
8-78

A
Item

C-3 Connection of clutch switch cou- Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of place the wire harness. When the clutch lever is re-
the coupler. leased with the transmission in
Disconnect the coupler and gear and when the sidestand is
check the pins (bent or broken retracted: “OFF”
terminals and locking condition When the clutch lever is
of the pins). squeezed with the transmission
C-8.
item C-4.
C-4 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
the coupler. place the wire harness. When the clutch lever is re-
Disconnect the coupler and leased with the transmission in
check the pins (bent or broken gear and when the sidestand is
terminals and locking condition retracted: “OFF”
of the pins). When the clutch lever is
C-8.
item C-5.
C-5 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness or left handle- (Code No. 21)
bar switch. When the clutch lever is re-
Between ECU coupler and joint leased with the transmission in
coupler. gear and when the sidestand is
black/yellow–black/yellow retracted: “OFF”
Between joint coupler and relay When the clutch lever is
unit coupler. squeezed with the transmission
black/yellow–black/yellow in gear and when the sidestand
Between joint coupler and left is retracted: “ON”
handlebar switch coupler. Correct indication→ Go to item
black/yellow–black/yellow C-8.
Between relay unit coupler and Incorrect indication → Go to
left handlebar switch coupler. item C-6.
blue/yellow–blue/yellow
Between left handlebar switch
coupler and clutch switch con-
nector.
black/yellow–black/yellow
black/yellow–black/yellow
8-79

A
Item

C-6 Defective clutch switch. Check the clutch switch. Execute the diagnostic mode.
Replace if defective. (Code No. 21)
Refer to “CHECKING THE When the clutch lever is re-
SWITCHES” on page 8-150. leased with the transmission in
gear and when the sidestand is
retracted: “OFF”
When the clutch lever is
C-8.
item C-7.
C-7 Malfunction in ECU. Replace the ECU. Service is finished.
page 8-151.
C-8 Delete the fault code and check Turn the main switch to “ON”,
(12 to 19 mph).
8-80

Item Charging voltage is abnormal.

Fail-safe system
Tool display —
Procedure —
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle for
Refer to “CHARGING SYSTEM” approximately 5 seconds.
on page 8-13. Check the condition of the fault
Defective rectifier/regulator or code using the malfunction
AC magneto → Replace. mode of the Yamaha diagnostic
Defective connection in the tool.
charging system circuit → Prop- Condition is “Recover” → Go to
erly connect or replace the wire item 2 and finish the service.
harness. Condition is “Malfunction” →
Repeat item 1.

Faulty ECU memory. (When this malfunction is detected in the ECU,

Item
the fault code number might not appear on the tool display.)
Fail-safe system
Tool display —
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ON”.
Refer to “REPLACING THE Check that the engine trouble
ECU (engine control unit)” on warning light does not come on.
page 8-151.

ECU internal malfunction. (When this malfunction is detected in the

Item
ECU, the fault code number might not appear on the tool display.)
Fail-safe system
8-81
ECU internal malfunction. (When this malfunction is detected in the

Item
ECU, the fault code number might not appear on the tool display.)
Tool display —
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ON”.
Refer to “REPLACING THE Check that the engine trouble
ECU (engine control unit)” on warning light does not come on.
page 8-151.
Fault code No. P062F

Fault code No. P062F
EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
Fail-safe system
00
• No malfunctions detected (If the self-diagnosis fault code P062F is indi-
cated, the ECU is defective.)
01–04 (CO adjustment value)
• (If more than one cylinder is defective, the display alternates every two
Tool display seconds to show all the detected cylinder numbers. When all cylinder
numbers are shown, the display repeats the same process.)
11 (Data error for ISC (idle speed control) learning values)
12 (O2 feedback learning value)
13 (OBD memory value)
Procedure —
1 Locate the malfunction Execute the diagnostic mode.
(Code No. 60)
page 8-151.
8-82

Item YCC-T drive system: malfunction detected.

Fail-safe system
Tool display —
Procedure —
1 Connection of throttle servo mo- Improperly connected → Con- Turn the main switch to “ON”,
the coupler. function mode of the Yamaha
Disconnect the coupler and diagnostic tool.
to item 2.
Disconnect the coupler and function mode of the Yamaha
check the pins (bent or broken diagnostic tool.
to item 3.
3 Check the electronic throttle Blown fuse → Replace the fuse. Turn the main switch to “ON”,
valve fuse. and then check the condition of
function mode of the Yamaha
diagnostic tool.
to item 4.
Between electronic throttle the fault code using the mal-
valve fuse and ECU coupler. function mode of the Yamaha
red/blue–red/blue diagnostic tool.
Between throttle servo motor Condition is “Recover” → Go to
coupler and ECU coupler. item 7 and finish the service.
light green/red–light green/red Condition is “Malfunction” → Go
yellow/red–yellow/red to item 5.
5 Defective throttle bodies. Check the throttle bodies. Turn the main switch to “ON”,
Replace if defective. and then check the condition of
Refer to “CHECKING THE the fault code using the mal-
THROTTLE SERVO MOTOR” function mode of the Yamaha
on page 8-162. diagnostic tool.
to item 6.
8-83
Item YCC-T drive system: malfunction detected.

page 8-151.

Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
Fail-safe system
Fuel system voltage (battery voltage)
Tool display
Approximately 12.0
09 Set the engine stop switch to “ ”, and then compare the actually mea-
Procedure sured battery voltage with the tool display value. (If the actually mea-
sured battery voltage is low, recharge the battery.)
Actuates the relay unit five times at one-second intervals.
Actuation The “check” indicator on the Yamaha diagnostic tool screen come on
50 each time the relay is actuated.
Check that the relay unit is actuated five times by listening for the operat-
Procedure
ing sound.
1 Connection of relay unit coupler. Improperly connected → Con- Start the engine and let it idle for
to item 2.
to item 3.
8-84
Fuel system voltage: incorrect voltage supplied to the fuel injector

Item
and fuel pump.
Between fuel injection system Check the condition of the fault
fuse and relay unit coupler. code using the malfunction
brown/white–brown/white mode of the Yamaha diagnostic
Between ignition fuse and right tool.
handlebar switch coupler. Condition is “Recover” → Go to
red/white–red/white item 7 and finish the service.
Between right handlebar switch Condition is “Malfunction” → Go
coupler and relay unit coupler. to item 4.
red/black–red/black
Between relay unit coupler and
ECU coupler.
red/blue–red/blue
blue/white–blue/white
4 Defective relay unit. Execute the diagnostic mode. Start the engine and let it idle for
(Code No. 50) approximately 5 seconds.
No operating sound → Replace Check the condition of the fault
the relay unit. code using the malfunction
mode of the Yamaha diagnostic
tool.
to item 5.
5 Defective relay unit. Execute the diagnostic mode. Start the engine and let it idle for
(Code No. 09) approximately 5 seconds.
Fuel system voltage is below Check the condition of the fault
3 V → Replace the relay unit. code using the malfunction
tool.
to item 6.
page 8-151.

[P0916] Gear position sensor: open or ground short circuit detected.

Item
[P0917] Gear position sensor: power short circuit detected.
Fail-safe system Able to drive vehicle
However, the vehicle cannot start off again after stopping without chang-
ing gears.
8-85

Item
Tool display —
Procedure —
1 Connection of gear position Improperly connected → Con- Turn the main switch to “ON”,
sensor coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
agnostic tool.
Condition is ”Recover” → Go to
to item 4.
3-1
2
1 5V
L/R
3 L/R
G
4 G
W
5 W
1. Gear position sensor

2. ECU
Disconnect the gear position sensor coupler from the gear position sensor.
8-86

Item
Between gear position sensor coupler and ground: green–ground
L/R G W

Between gear position sensor coupler and ECU coupler: blue/red–blue/red

L/R G W Lg/R W W/B L/R B/R P G/W P/L B/Y Lg/L

Between gear position sensor coupler and ECU coupler: green–green

8-87

Item
Between gear position sensor coupler and ECU coupler: white–white

3-8 [For P0916/P0917] Short circuit
Between gear position sensor output terminal (green) “a” of ECU coupler and any other ECU coupler
terminal “b”.

4 Installed condition of gear posi- Improperly installed sensor → Turn the main switch to “ON”,
tion sensor. Reinstall or adjust the sensor. and then check the condition of
Check for looseness or pinch- Refer to “INSTALLING THE the fault code using the mal-
ing. GEAR POSITION SENSOR” on function mode of the Yamaha di-
page 5-67. agnostic tool.
to item 5.
5 Defective gear position sensor. Make sure that the position of Turn the main switch to “ON”,
each gear is correctly displayed and then check the condition of
on the meter. the fault code using the mal-
If incorrect → Replace the gear function mode of the Yamaha di-
position sensor. agnostic tool.
to item 6.
page 8-151.
8-88

Item

Item Air induction system solenoid: open or short circuit is detected.

Fail-safe system
Actuates air induction system solenoid five times at one-second inter-
Actuation vals. The “check” indicator on the Yamaha diagnostic tool screen comes
on each time the air induction system solenoid is actuated.
Check that air induction system solenoid is actuated five times by listen-
Procedure
ing for the operating sound.
1 Connection of air induction sys- Improperly connected → Con- Turn the main switch to “ON”,
tem solenoid coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the sub-wire harness. the fault code using the mal-
code.
to item 2.
code.
to item 3.
8-89
Item Air induction system solenoid: open or short circuit is detected.

3 Connection of sub-wire har- Improperly connected → Con- Turn the main switch to “ON”,
ness coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the sub-wire harness. the fault code using the mal-
code.
to item 4.
Between ECU coupler and sub- the fault code using the mal-
wire harness coupler. function mode of the Yamaha di-
brown/red–brown/red agnostic tool.
pler and air induction system item 7 and finish the service.
solenoid coupler. Condition is “Malfunction” →
brown/red–brown/red Start the engine, and then
Between air induction system check the condition of the fault
solenoid coupler and sub-wire code.
harness coupler. Condition is “Recover” → Go to
red/white–red/white item 7 and finish the service.
Between sub-wire harness cou- Condition is “Malfunction” → Go
pler and ignition fuse. to item 5.
red/white–red/white
5 Defective air induction system Check the air induction system Turn the main switch to “ON”,
solenoid. solenoid. and then check the condition of
Refer to “CHECKING THE AIR the fault code using the mal-
INDUCTION SYSTEM SOLE- function mode of the Yamaha di-
NOID” on page 8-159. agnostic tool.
code.
to item 6.
page 8-151.
8-90

Malfunction in ECU internal circuit (malfunction of ECU power cut-

Item
off function).
Fail-safe system
Tool display —
Procedure —
1 Installed condition of battery Improperly installed battery or Turn the main switch to “ON”,
leads. battery leads → Reinstall or re- and then check the condition of
Check the installed condition of place the battery leads. the fault code using the mal-
the battery and battery leads function mode of the Yamaha di-
(loose bolts). agnostic tool.
to item 2.
2 Connection of starter relay cou- Improperly connected → Con- Turn the main switch to “ON”,
to item 3.
3 Check the backup fuse. Blown fuse → Replace the fuse Turn the main switch to “ON”,
or wire harness. and then check the condition of
agnostic tool.
to item 4.
4 Wire harness continuity be- Open or short circuit → Replace Turn the main switch to “ON”,
tween battery and ECU coupler. the wire harness. and then check the condition of
Between battery terminal and the fault code using the mal-
main fuse coupler. function mode of the Yamaha di-
red–red agnostic tool.
Between main fuse coupler and Condition is “Recover” → Go to
backup fuse. item 7 and finish the service.
red–red Condition is “Malfunction” → Go
Between backup fuse and ECU to item 5.
coupler.
red/green–red/green
8-91
Malfunction in ECU internal circuit (malfunction of ECU power cut-

Item
off function).
5 Wire harness continuity be- Open or short circuit → Replace Turn the main switch to “ON”,
tween main switch and ECU the wire harness. and then check the condition of
coupler. Between main switch coupler the fault code using the mal-
and ignition fuse. function mode of the Yamaha di-
brown/blue–brown/blue agnostic tool.
Between ignition fuse and ECU Condition is “Recover” → Go to
coupler. item 7 and finish the service.
red/white–red/white Condition is “Malfunction” → Go
to item 6.
page 8-151.

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

Item
[P1605] Lean angle sensor: open or power short circuit.
Fail-safe system
Tool display • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
1 Connection of lean angle sensor Improperly connected → Con- Turn the main switch to “ON”,
coupler. nect the coupler securely or re- then to “OFF”, and then back to
Check the locking condition of place the wire harness. “ON”.
the coupler. Check the condition of the fault
to item 2.
8-92

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

2. ECU
Disconnect the lean angle sensor coupler from the lean angle sensor.
Between lean angle sensor coupler and ground: yellow/green–ground
G
L Y/G B/L
8-93

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

G
L Y/G B/L Lg/R W W/B L/R B/R P G/W P/L B/Y Lg/L

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

G

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

G
8-94

Item
Between lean angle sensor output terminal (yellow/green) “a” of ECU coupler and any other ECU
coupler terminal “b”.

4 Defective lean angle sensor. Refer to “CHECKING THE Turn the main switch to “ON”,
LEAN ANGLE SENSOR” on then to “OFF”, and then back to
page 8-155. “ON”.
Check the condition of the fault
tool.
to item 5.
page 8-151.

TIP
If a fault code number (“P2122”, “P2123”, “P2127”, or “P2128”) other than “P2138” is indicated, take the
actions specified for that fault code number first.
[P2122] Accelerator position sensor: open or ground short circuit

detected.
[P2123] Accelerator position sensor: power short circuit detected.
Item [P2127] Accelerator position sensor: ground short circuit detected.
[P2128] Accelerator position sensor: open or power short circuit de-
tected.
Able/unable to start engine
Fail-safe system
Able/unable to drive vehicle
8-95

detected.
tected.
Accelerator position sensor signal 1
• Check with throttle grip fully closed position.
Procedure
• Check with throttle grip fully open position.
Accelerator position sensor signal 2
• Check with throttle grip fully closed position.
Procedure
• Check with throttle grip fully open position.
1 Connection of accelerator posi- Improperly connected → Con- Turn the main switch to “ON”,
tion sensor coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
agnostic tool.
to item 4.
8-96

detected.
tected.
3-1
2
1 5V 5V
L
3 L
W
4 W
B
4 B
B/L
5 B/L
1. Accelerator position sensor

2. ECU
Disconnect the accelerator position sensor coupler from the accelerator position sensor.
Between accelerator position sensor coupler and ground: white–ground
W B/L L B

Between accelerator position sensor coupler and ground: black–ground
W B/L L B
8-97

detected.
tected.
Between accelerator position sensor coupler and ECU coupler: blue–blue

W B/L L B

Between accelerator position sensor coupler and ECU coupler: white–white

W B/L L B

Between accelerator position sensor coupler and ECU coupler: black–black

W B/L L B
8-98

detected.
tected.
3-8 [For P2122, P2128] Open circuit
Between accelerator position sensor coupler and ECU coupler: black/blue–black/blue

W B/L L B
Between accelerator position sensor output terminal (white) “a” of ECU coupler and any other ECU
a

Between accelerator position sensor output terminal (black) “a” of ECU coupler and any other ECU

a
b
8-99

detected.
tected.
4 Installed condition of accelera- Check for looseness or pinch- Turn the main switch to “ON”,
tor position sensor. ing. and then check the condition of
Reinstall or adjust the sensor. function mode of the Yamaha di-
Refer to “ADJUSTING THE AC- agnostic tool.
CELERATOR POSITION SEN- Condition is “Recover” → Go to
SOR” on page 7-17. item 8 and finish the service.
to item 5.
5 Accelerator position sensor re- Measure the accelerator posi- Turn the main switch to “ON”,
sistance. tion sensor resistance. and then check the condition of
black/blue–blue the fault code using the mal-
Refer to “CHECKING THE AC- function mode of the Yamaha di-
CELERATOR POSITION SEN- agnostic tool.
SOR” on page 8-161. Condition is “Recover” → Go to
to item 6.
6 Defective accelerator position Check accelerator position sen- Turn the main switch to “ON”,
sensor. sor signal 1. and then check the condition of
Execute the diagnostic mode. the fault code using the mal-
(Code No. 14) function mode of the Yamaha di-
When the throttle valves are ful- agnostic tool.
ly closed: Condition is “Recover” → Go to
A value of 11–21 is indicated. item 8 and finish the service.
When throttle valves are fully Condition is “Malfunction” → Go
open: to item 7.
Check accelerator position sen-
sor signal 2.
(Code No. 15)
ly closed:
ly open:
An indicated value is out of the
specified range → Replace the
accelerator position sensor.
page 8-151.
8-100

Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
Fail-safe system
Front wheel speed pulse
Tool display
0–999
Check that the number increases when the front wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
1 Connection of front wheel sen- Improperly connected → Con- Execute the diagnostic mode.
sor coupler. nect the coupler securely or re- (Code No. 16)
Check the locking condition of place the wire harness. Rotate the front wheel by hand
the coupler. and check that the indicated
Disconnect the coupler and value increases.
check the pins (bent or broken Value increases → Go to item 8
terminals and locking condition and delete the fault code.
to item 2.
2 Connection of ABS ECU cou- Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of place the wire harness. Rotate the front wheel by hand
the coupler. and check that the indicated
Disconnect the coupler and value increases.
check the pins (bent or broken Value increases → Go to item 8
terminals and locking condition and delete the fault code.
to item 3.
the coupler. place the wire harness. Rotate the front wheel by hand
Disconnect the coupler and and check that the indicated
check the pins (bent or broken value increases.
terminals and locking condition Value increases → Go to item 8
of the pins). and delete the fault code.
to item 4.
Between front wheel sensor Rotate the front wheel by hand
coupler and ABS ECU coupler. and check that the indicated
black–black value increases.
white–white Value increases → Go to item 8
Between ABS ECU coupler and and delete the fault code.
ECU coupler. Value does not increase → Go
gray/black–gray/black to item 5.
8-101
Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
5 Defective front wheel sensor. Improperly installed sensor → Execute the diagnostic mode.
Reinstall or replace the sensor. (Code No. 16)
Rotate the front wheel by hand
and check that the indicated
value increases.
Value increases → Go to item 8
and delete the fault code.
to item 6.
6 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
Refer to “REPLACING THE (Code No. 16)
ECU (engine control unit)” on Rotate the front wheel by hand
page 8-151. and check that the indicated
value increases.
Value increases → Go to item 8
and delete the fault code.
to item 7.
7 Malfunction in ABS ECU. Replace the Hydraulic unit as- Go to item 8.
sembly.
8 Delete the fault code and check Turn the main switch to “ON”,
that the engine trouble warning and then rotate the front wheel
ing the vehicle at 20 to 30 km/
h(12 to 19 mph).
8-102

TIP
If fault code numbers “P2195” and “P0030” are both indicated, take the actions specified for fault code
Item O2 sensor: Open circuit detected.

Fail-safe system
Tool display —
Procedure —
1 Installed condition of O2 sensor. Check for looseness or pinch- Start the engine and let it idle for
ing. approximately 10 seconds.
Improperly installed sensor → Check the condition of the fault
Reinstall or replace the sensor. code using the malfunction
tool.
to item 2.
Also, delete this fault code,
which has a condition of “Mal-
function”.
2 Connection of O2 sensor cou- Improperly connected → Con- Start the engine and let it idle for
pler. nect the coupler securely or re- approximately 10 seconds.
Check the locking condition of place the wire harness. Check the condition of the fault
to item 3.
function”.
to item 4.
function”.
8-103
Item O2 sensor: Open circuit detected.

Between O2 sensor coupler and Check the condition of the fault
ECU coupler. code using the malfunction
black/blue–black/blue mode of the Yamaha diagnostic
gray/green–gray/green tool.
pink/black–pink/black Condition is “Recover” → Go to
Between O2 sensor coupler and item 8 and finish the service.
relay unit. Condition is “Malfunction” → Go
red/blue–red/blue to item 5.
function”.
5 Check fuel pressure. Refer to “CHECKING THE Start the engine and let it idle for
FUEL PRESSURE” on page approximately 10 seconds.
7-16. Check the condition of the fault
tool.
to item 6.
function”.
6 Defective O2 sensor. Check the O2 sensor. Start the engine and let it idle for
Replace if defective. approximately 10 seconds.
Refer to “ENGINE REMOVAL” Check the condition of the fault
on page 5-9. code using the malfunction
tool.
to item 7.
function”.
page 8-151.
8-104
Fault code No. P21CF

Item Secondary injector #1: malfunction in secondary injector #1.

Fail-safe system
Actuates secondary injector #1 five times at one-second intervals.
each time the secondary injector is actuated.
Disconnect the fuel pump coupler. Check that secondary injector #1 is
Procedure
actuated five times by listening for the operating sound.
1 Connection of secondary injec- Improperly connected → Con- Execute the diagnostic mode.
tor #1 coupler. nect the coupler securely or re- (Code No. 40)
Check the locking condition of place the sub-wire harness. Operating sound → Go to item
the coupler. 7.
of the pins).
2 Defective secondary injector #1. Measure the secondary injector Execute the diagnostic mode.
resistance. (Code No. 40)
8-162. item 3.
of the pins).
4 Connection of sub-wire har- Improperly connected → Con- Execute the diagnostic mode.
ness coupler. nect the coupler securely or re- (Code No. 40)
the coupler. 7.
of the pins).
8-105

Between secondary injector Operating sound → Go to item
coupler and sub-wire harness 7.
coupler. No operating sound → Go to
white/blue–white/blue item 6.
white/blue–white/blue
Between secondary injector
coupler and sub-wire harness
coupler.
red/blue–red/blue
red/blue–red/blue
page 8-151.
Fault code No. P21D0


Fail-safe system
Procedure
the coupler. 7.
of the pins).
8-106

8-162. item 3.
of the pins).
the coupler. 7.
of the pins).
sky blue/white–sky blue/white item 6.
Between sub-wire harness and
ECU coupler.
sky blue/white–sky blue/white
coupler.
red/blue–red/blue
red/blue–red/blue
page 8-151.
8-107


Fail-safe system
Procedure
the coupler. 7.
of the pins).
8-162. item 3.
of the pins).
the coupler. 7.
of the pins).
8-108

brown/yellow–brown/yellow item 6.
brown/yellow–brown/yellow
coupler.
red/blue–red/blue
red/blue–red/blue
page 8-151.


Fail-safe system
Procedure
the coupler. 7.
of the pins).
8-109

8-162. item 3.
of the pins).
the coupler. 7.
of the pins).
brown/black–brown/black item 6.
brown/black–brown/black
coupler.
red/blue–red/blue
red/blue–red/blue
page 8-151.
8-110

[P2228] Atmospheric pressure sensor: ground short circuit detect-

ed.
Item
[P2229] Atmospheric pressure sensor: open or power short circuit
detected.
Fail-safe system
Tool display Displays the atmospheric pressure.
Compare the actually measured atmospheric pressure with the tool dis-
Procedure
play value.
1 Connection of atmospheric Improperly connected → Con- Turn the main switch to “ON”,
pressure sensor coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
agnostic tool.
to item 4.
8-111

ed.
Item
detected.
3-1
2
1 5V 5V
L
3 L
P
4 P
B/L
5 B/L

2. ECU
Disconnect the atmospheric pressure sensor coupler from the atmospheric pressure sensor.
Between atmospheric pressure sensor coupler and ground: pink–ground
B/L P L

Between atmospheric pressure sensor coupler and ECU coupler: blue–blue

B/L P L Lg/R W W/B L/R B/R P G/W P/L B/Y Lg/L
8-112

ed.
Item
detected.
Between atmospheric pressure sensor coupler and ECU coupler: pink–pink


Between atmospheric pressure sensor coupler and ECU coupler: black/blue–black/blue

Between atmospheric pressure sensor output terminal (pink) “a” of ECU coupler and any other ECU

8-113

ed.
Item
detected.
4 Installed condition of atmo- Check for looseness or pinch- Turn the main switch to “ON”,
spheric pressure sensor. ing. and then check the condition of
agnostic tool.
to item 5.
5 Defective atmospheric pressure Execute the diagnostic mode. Turn the main switch to “ON”,
Atmospheric pressure at the function mode of the Yamaha di-
current altitude and weather agnostic tool.
At sea level: Approx. 101 kPa item 7 and finish the service.
(757.6 mmHg, 29.8 inHg) Condition is “Malfunction” → Go
1000 m (3300 ft) above sea lev- to item 6.
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
Replace the atmospheric pres-
sure sensor.
page 8-151.
8-114
Fault code No. U0155 or “Err”

TIP
“Err” is displayed on the clock display of the multi-function meter, but the engine trouble warning light
does not come on.
Event code No. U0155 or “Err”
CAN communication error (with the meter): communication be-
Item
tween the ECU and the meter is not possible.
Fail-safe system
Tool display —
Procedure —
1 Connection of meter assembly Improperly connected → Con- Turn the main switch to “ON”,
coupler. nect the coupler securely or re- and then check the condition of
to item 2.
to item 3.
Between meter assembly cou- the fault code using the mal-
pler and joint coupler. function mode of the Yamaha di-
light green/blue–light green/blue agnostic tool.
light green/white–light green/ Condition is “Recover” → Go to
white item 6 and finish the service.
Between joint coupler and ECU Condition is “Malfunction” → Go
coupler. to item 4.
light green/blue–light green/blue
light green/white–light green/
white
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”,
and then check the condition of
agnostic tool.
to item 5.
8-115

page 8-151.
8-116
EAS31790
TROUBLESHOOTING DETAILS (EVENT CODE)
Event code No. 30

Event code No. 30
Item Latch up detected.
Fail-safe system
Tool display • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
1 The vehicle has overturned. Raise the vehicle upright. Turn the main switch to “ON”,
then to “OFF”, and then back to
“ON”.
Engine trouble warning light
does not come on → Service is
finished.
comes on → Go to item 2.
2 Installed condition of lean angle Check the installed direction Turn the main switch to “ON”,
sensor. and condition of the sensor. then to “OFF”, and then back to
“ON”.
finished.
3 Defective lean angle sensor. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 08) then to “OFF”, and then back to
Incorrect indication → Replace “ON”.
the lean angle sensor. Engine trouble warning light
finished.
page 8-151.
Event code No. 70

TIP
If a fault code is indicated, perform the checks and maintenance jobs for the fault code first.
Event code No. 70
Engine idling stop: engine is forcefully stopped because it was left
Item
idling for a long time.
Fail-safe system
8-117
Tool display —
Procedure —
1 Engine has been left idling for a Turn the main switch “OFF”. Start the engine.
long time. Able to start engine → Service
is finished.
Unable to start engine → Go to
item 2.
page 8-151.
8-118
FUEL PUMP SYSTEM
EAS20081
FUEL PUMP SYSTEM

EAS30513
CIRCUIT DIAGRAM
44
68
30
PUSH
FREE
28
25
24
5
4
11
15
7
3
OFF
ON
8-119
FUEL PUMP SYSTEM
3. Main switch
4. Main fuse
5. Battery
6. Engine ground
7. Fuel injection system fuse
11.Backup fuse
15.Ignition fuse
28.Relay unit
30.Fuel pump relay
68.Fuel pump
8-120
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Rider seat
2. Fuel tank

(Main, fuel injection, backup, and
ignition) Replace the fuse(s).
OK ↓
page 8-152.
OK ↓
OK ↓
OK ↓
5. Check the relay unit (fuel pump re- NG →
lay).
Replace the relay unit.
Refer to “CHECKING THE RE-
OK ↓
6. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PUMP BODY” on page 7-4.
OK ↓
7. Check the entire fuel pump system NG →
page 8-119.
OK ↓
Replace the ECU.
8-121
FUEL PUMP SYSTEM
8-122
EAS20085

EAS30843
CIRCUIT DIAGRAM
64
65
63
44
66
31
31
75
82
70
PUSH
FREE
23
19
97
5
4
11
12
15
16
8
3
OFF
ON
8-123
3. Main switch
4. Main fuse
5. Battery
6. Engine ground
8. ABS ECU fuse
11.Backup fuse
12.ABS solenoid fuse
15.Ignition fuse
19.ABS motor fuse
23.Front brake light switch
31.Joint coupler
63.ABS ECU
64.Front wheel sensor
66.Yamaha diagnostic tool coupler
70.Meter assembly
82.ABS warning light
97.Rear brake light switch
8-124
EAS30844
ABS COUPLER LOCATION CHART
B/W R/W G Br/R Dg Ch W/B W/Y

2
Lg/L Lg/WG/WR/G R/GSb/W G/L G/O Y
L/W Gy/B G Y L R/B B Lg/L B/W
R G/O W/Y L B W W Lg/W B
3
W B B W
4
W B B W
5
Lg/L Lg/W
R/G B/W
1. Meter assembly coupler

2. ABS ECU coupler
3. Front wheel sensor coupler
4. Rear wheel sensor coupler
5. Yamaha diagnostic tool coupler
8-125
EAS30845
MAINTENANCE OF THE ABS ECU
Checking the ABS ECU

1. Check:
• Terminals “1” of the ABS ECU
Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off → Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
1
EAS30528
ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU (Electronic Control Unit) has a self-diagnosis function. When failures occur in the sys-
tem, the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the
Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG-
NOSIS USING THE FAULT CODES” on page 8-130. For troubleshooting items other than the following
items, follow the normal service method.
EWA16710
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-147.
ABS operation when the ABS warning light comes on

1. The ABS warning light remains on → ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 5 km/h (3 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 5 km/h (3 mi/h)) → ABS operation is normal.
3. The ABS warning light flashes → ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 8-127.
8-126
Self-diagnosis and servicing

The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page
8-146. By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause
correctly if another malfunction occurs.
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned to “ON”. During this test, a “clicking” noise can be heard from inside of the right
side cowling, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at
the lever and pedal, but these do not indicate a malfunction.
Self-diagnosis using the ABS ECU
The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”. It also
checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are detect-
ed, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the
ABS ECU has entered the self-diagnosis mode.
Special precautions for handling and servicing a vehicle equipped with ABS
ECA17620
NOTICE
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction
occurs.)
EAS30529
BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420
WARNING
• Perform the troubleshooting [A]→[B]→[C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.
8-127
EAS30530
BASIC PROCESS FOR TROUBLESHOOTING
[A] Turn the main switch to “ON”, Fails to

come on [A-1] Does only the ABS • The wire harness is grounded
and check the ABS warning Yes between the ABS ECU and the
warning light fail to Return to [A].
light. meter assembly.
come on?
Comes on • The meter assembly is defective.
• The hydraulic unit assembly is
defective.
No
• The main switch is defective.
[A-2] Do all indicator lights Yes • The battery voltage is low. Return to [A].
fail to come on? • The main fuse is blown.
• The meter assembly is defective.
Cannot
[A-3] The ABS warning light comes communicate [A-4] Only the ABS ECU Yes
• The ABS ECU fuse is blown.
on. • The ABS solenoid fuse is blown. Return to [A].
fails to communicate.
Connect the Yamaha • The ABS ECU coupler is
diagnostic tool, and then
disconnected.
execute functional diagnosis.
Can the tool communicate with • The wire harness is defective.
the ABS ECU? • The hydraulic unit assembly
is defective.
Can communicate
No
[A-5] ABS ECU and FI ECU Yes • The connection with the Yamaha
Return to [A].
fail to communicate. diagnostic tool is defective.
• The battery voltage is low.
[B-1] Check for ABS fault Yes [B-2] Diagnose by the fault [B-3] Delete the fault codes.
Return to [A].
codes in the screen for the code.
Yamaha diagnostic tool.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect. Refer to
“[C-1] FINAL CHECK”.
[C-1] Perform the final checks. No • The brake hoses and brake
Were all of the final checks pipes are not connected Return to [A].
completed normally? correctly.
Yes The ABS warning light does
(The ABS warning light not go off when the light is
goes off when the light is checked. Refer to “[C-1]
checked.) FINAL CHECK”.
• The malfunction is not
corrected.
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The meter assembly is defective.
• The hydraulic unit assembly

is defective.
Finished.
8-128
EWA16710
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-147.
EAS30531
[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS30532
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the green/orange terminal of the ABS ECU coupler
and green/orange terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS30533
[A-2] THE ABS WARNING LIGHT AND OTHER INDICATOR LIGHTS FAIL TO COME ON
1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-150.
• If there is no continuity, replace the main switch.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-152.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-151.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 8-123.
• If the meter assembly circuit is open, replace the wire harness.
EAS31162
[A-3] THE ABS WARNING LIGHT COMES ON

Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di-
agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that
is included with the tool.)
Check that communication with the ABS ECU is possible.
• Only the ABS ECU fails to communicate. [A-4]
• ABS ECU and FI ECU fail to communicate. [A-5]
• Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
8-129
EAS31163
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE

1. ABS ECU fuse
• Check the ABS ECU fuse for continuity.
• If the ABS ECU fuse is blown, replace the fuse.
2. ABS ECU coupler
• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-60.
3. Wire harness
• Open circuit between the main switch and the ABS ECU, or between the ABS ECU and the ground.
Check for continuity between brown/blue terminal of the main switch coupler and red/black terminal
of the ABS ECU coupler.
Check for continuity between black terminal of the ABS ECU coupler and the ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler.
Check for continuity between light green/blue terminal of the ABS ECU coupler and light green/blue
terminal of the Yamaha diagnostic tool coupler. (CANH)
Check for continuity between light green/white terminal of the ABS ECU coupler and light green/
white terminal of the Yamaha diagnostic tool coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS31164
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE

1. Yamaha diagnostic tool
Check that the Yamaha diagnostic tool is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the Yamaha diagnostic tool cou-
pler.
Check for continuity between light green/blue terminal of the ABS ECU coupler and light green/blue
terminal of the Yamaha diagnostic tool coupler. (CANH)
Check for continuity between light green/white terminal of the ABS ECU coupler and light green/
white terminal of the Yamaha diagnostic tool coupler. (CANL)
EAS31165
[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the Yamaha diagnostic tool is connected to the Yamaha diagnostic tool coupler, the fault codes
will be displayed on the computer screen.
• A fault code is displayed. [B-2]
• A fault code is not displayed. [C-1]
EAS31166
[B-2] DIAGNOSIS USING THE FAULT CODES

This model uses the Yamaha diagnostic tool to identify malfunctions.
For information about using the Yamaha diagnostic tool, refer to the operation manual that is included
with the tool.

90890-03257
90890-03254
8-130

Removing the rider seat. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
1
Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.
Fault code table

TIP
Record all of the fault codes displayed and inspect the check points.
Fault code
Item Symptom Check point
No.
11 Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the front wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
12 Rear wheel sensor (intermit- Rear wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the rear wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) rear wheel
rotor
• Defective rear wheel sen-
of the sensor
8-131
Fault code
No.
13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
front wheel
rotor
of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered
27* mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
rear wheel
rotor
of the sensor
15 Front wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the front wheel sen- the front wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
sor or hydraulic unit as-
sembly
16 Rear wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the rear wheel sen- the rear wheel sensor and
sor. the hydraulic unit assembly
rear wheel sensor and the
hydraulic unit assembly
sor or hydraulic unit as-
sembly
21 Hydraulic unit assembly (de- Solenoid drive circuit in the • Defective hydraulic unit as-
fective solenoid drive circuit) hydraulic unit assembly is sembly
open or short-circuited.
31 Hydraulic unit assembly (de- Power is not supplied to the • Blown ABS solenoid fuse
fective ABS solenoid power solenoid circuit in the hy- • Defective coupler between
circuit) draulic unit assembly. the battery and the hydrau-
lic unit assembly
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
8-132
Fault code
No.
33 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS motor fuse
normal ABS motor power motor circuit in the hydraulic • Defective coupler between
supply) unit assembly. the battery and the hydrau-
lic unit assembly
unit assembly
• Defective hydraulic unit as-
sembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS motor the motor power supply cir- sembly
power supply circuit) cuit in the hydraulic unit as-
sembly.
41 Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- front wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. front wheel
• Front wheel will not recover • Front brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
42 Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- rear wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. rear wheel
• Rear wheel will not recover • Rear brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
43* Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
45* pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) front wheel
rotor
of the sensor
44* Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
46* pulses) not received properly. (Miss- around the rear wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) rear wheel
rotor
of the sensor
8-133
Fault code
No.
51 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Disconnected battery ter-
supply is high) lic unit assembly is too high. minal
• Defective charging system
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lic unit assembly is too low. the battery and the hydrau-
lic unit assembly
unit assembly
55 Hydraulic unit assembly (de- Abnormal data is detected in • Defective hydraulic unit as-
fective ABS ECU) the hydraulic unit assembly. sembly
56 Hydraulic unit assembly (ab- Abnormality detected in in- • Defective hydraulic unit as-
normal internal circuit) ternal circuit of hydraulic unit sembly
assembly.
57 Vehicle CAN communication Short-circuit in CAN commu- • Short-circuit in CAN com-
line or power source of vehi- nication line or the voltage munication line
cle system that supplies the hydraulic • Defective battery
unit assembly is too low. • Defective coupler between
battery and hydraulic unit
assembly
• Wire harness between bat-
tery and hydraulic unit is in-
terrupted or has short-
circuited
62 Power supply voltage failure Abnormality detected in • Defective hydraulic unit as-
in pressure sensor pressure sensor power sup- sembly
ply circuit of hydraulic unit
assembly.
68 Hydraulic unit assembly (de- Abnormality detected in • Defective front brake line
fective front pressure sensor) pressure sensor circuit at • Defective hydraulic unit as-
front caliper side of hydrau- sembly
lic unit assembly.
* The fault code number varies according to the vehicle conditions.
8-134
Fault code No. 11

TIP
If the rear wheel continues to turn for more than 20 seconds after the front wheel has stopped, this will
be recorded.
Fault code No. 11
Item Front wheel sensor (intermittent pulses or no pulses)
Front wheel sensor signal is not received properly. (Pulses are not
Symptom
received or are received intermittently while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-18.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-20.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Fault code No. 12

Fault code No. 12
Item Rear wheel sensor (intermittent pulses or no pulses)
Rear wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-28.
Refer to “MAINTENANCE OF THE REAR WHEEL
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
8-135
Fault code No. 13, 26

TIP
• If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record-
ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re-
corded.
• Vehicle possibly ridden on uneven roads.
13
Fault code No.
26
Item Front wheel sensor (abnormal pulse period)
Front wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

bends.
4-18.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage. Re-
lation of the rotor place the sensor rotor if there is visible damage.

TIP
• If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record-
ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re-
corded.
• Vehicle possibly ridden on uneven roads.
14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)
Rear wheel sensor signal is not received properly. (The pulse period
Symptom

bends.
4-28.
8-136
14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)
Rear wheel sensor signal is not received properly. (The pulse period
Symptom

Fault code No. 15

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

1 Defective coupler between the front wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
TIP
Turn the main switch to “OFF” before disconnecting or
connecting a coupler.
8-137
Fault code No. 15
Item Front wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the front wheel sensor.

2 Open or short circuit in the wire harness • Check for continuity between the white terminal “1”
between the front wheel sensor and the and the white terminal “4” and between the black ter-
hydraulic unit assembly minal “2” and the black terminal “5”.
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the white
terminal “1” and the black terminal “2” and between
the white terminal “4” and the black terminal “5”.
• If there is short circuit, the wire harness is defective.
• Check that there is no short circuit between the black/
white terminal “3” and the white terminal “4” and be-
tween the black/white terminal “3” and the black termi-
nal “5”.
3 5 4

B W W B
1 2
7
6
6. ABS ECU
7. Wheel sensor
3 Defective front wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “FRONT WHEEL” on page 4-16 and “ABS (An-
ti-lock Brake System)” on page 4-57.
Fault code No. 16

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

1 Defective coupler between the rear wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
pler securely.
TIP
8-138
Fault code No. 16
Item Rear wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the rear wheel sensor.

2 Open or short circuit in the wire harness • Check for continuity between the white terminal “1”
between the rear wheel sensor and the and the white terminal “4” and between the black ter-
hydraulic unit assembly minal “2” and the black terminal “5”.
• If there is no continuity, the wire harness is defective.
• Check that there is no short circuit between the white
terminal “1” and the black terminal “2” and between
the white terminal “4” and the black terminal “5”.
• Check that there is no short circuit between the black/
white terminal “3” and the white terminal “4” and be-
tween the black/white terminal “3” and the black termi-
nal “5”.
3 5 4

B W W B
2 1
7
6
6. ABS ECU
7. Wheel sensor
3 Defective rear wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “REAR WHEEL” on page 4-24 and “ABS (Anti-
lock Brake System)” on page 4-57.
Fault code No. 21

Fault code No. 21
Item Hydraulic unit assembly (defective solenoid drive circuit)
Solenoid drive circuit in the hydraulic unit assembly is open or

Symptom
short-circuited.

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-57.
8-139
Fault code No. 31

Fault code No. 31
Item Hydraulic unit assembly (defective ABS solenoid power circuit)
Power is not supplied to the solenoid circuit in the hydraulic unit as-
Symptom
sembly.

1 Blown ABS solenoid fuse Check the ABS solenoid fuse. If the ABS solenoid fuse
is blown, replace the fuse and check the wire harness.
2 Defective coupler between the battery • Check the locking condition of the coupler.
and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
TIP
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS solenoid fuse.
assembly (blue/white–blue/white)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
Fault code No. 33

Fault code No. 33
Item Hydraulic unit assembly (abnormal ABS motor power supply)
Power is not supplied to the motor circuit in the hydraulic unit as-
Symptom
sembly.

1 Blown ABS motor fuse Check the ABS motor fuse. If the ABS motor fuse is
blown, replace the fuse and check the wire harness.
2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
pler securely.
TIP
between the battery and the hydraulic unit • Between ABS ECU coupler and starter relay coupler
assembly (ABS motor fuse).
(red–red)
• Between ABS ECU coupler and ground.
(black–black)
8-140
Fault code No. 34

Fault code No. 34
Hydraulic unit assembly (short circuit in ABS motor power supply

Item
circuit)
Short circuit is detected in the motor power supply circuit in the hy-
Symptom
draulic unit assembly.

Fault code No. 41

Fault code No. 41
Front wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)
• Pulses from the front wheel sensor are received intermittently

while the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

sensor bends.
4-18.
2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel
and make sure that it rotates smoothly.
4-18 and “CHECKING THE FRONT BRAKE DISCS” on
page 4-39.
3 Front brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake lever is operated
and that the pressure decreases when the lever is re-
leased.
Refer to “CHECKING THE FRONT BRAKE DISCS” on
page 4-39.
8-141
Fault code No. 42

Fault code No. 42
Rear wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)
• Pulses from the rear wheel sensor are received intermittently while
the vehicle is traveling.
Symptom • Rear wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

sensor bends.
4-28.
2 Incorrect rotation of the rear wheel Check that there is no brake disc drag on the wheel and
make sure that it rotates smoothly.
4-28 and “CHECKING THE REAR BRAKE DISC” on
page 4-50.
3 Rear brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake pedal is operat-
ed and that the pressure decreases when the pedal is
released.
Refer to “CHECKING THE REAR BRAKE DISC” on
page 4-50.

TIP
After the fault code No. 45 is recorded, fault code No. 43 will be recorded if a certain speed and time
are exceeded.
43
Fault code No.
45
Item Front wheel sensor (missing pulses)
Front wheel sensor signal is not received properly. (Missing pulses

Symptom
are detected in the signal while the vehicle is traveling.)

bends.
4-18.
8-142
43
Fault code No.
45
Item Front wheel sensor (missing pulses)
Front wheel sensor signal is not received properly. (Missing pulses

Symptom


TIP
After the fault code No. 46 is recorded, fault code No. 44 will be recorded if a certain speed and time
are exceeded.
44
Fault code No.
46
Item Rear wheel sensor (missing pulses)
Rear wheel sensor signal is not received properly. (Missing pulses

Symptom

bends.
4-28.
8-143
Fault code No. 51

Fault code No. 51
Vehicle system power supply (voltage of ABS ECU power supply is

Item
high)
Power voltage supplied to the ABS ECU in the hydraulic unit assem-
Symptom
bly is too high.

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-152.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-13.
Fault code No. 53

Fault code No. 53
Vehicle system power supply (voltage of ABS ECU power supply is

Item
low)
Power voltage supplied to the ABS ECU in the hydraulic unit assem-
Symptom
bly is too low.

on page 8-152.
pler securely.
TIP
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS ECU fuse.
assembly (red/black–red/black)
Fault code No. 55

Fault code No. 55
Item Hydraulic unit assembly (defective ABS ECU)
Symptom Abnormal data is detected in the hydraulic unit assembly.

8-144
Fault code No. 56

Fault code No. 56
Item Hydraulic unit assembly (abnormal internal circuit)
Symptom Abnormality detected in internal circuit of hydraulic unit assembly.

Fault code No. 57

Fault code No. 57
Item Vehicle CAN communication line or power source of vehicle system
Short-circuit in CAN communication line or the voltage that supplies

Symptom
the hydraulic unit assembly is too low.

1 Short-circuit in CAN communication line Replace if there is an open or short circuit.
• Between ABS ECU coupler and joint coupler.
• Between joint coupler and ECU coupler.
on page 8-152.
pler securely.
TIP
4 Open or short circuit in the wire harness Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and starter relay coupler
assembly (ABS motor fuse).
(red–red)
• Between ABS ECU coupler and ABS solenoid fuse.
(blue/white–blue/white)
8-145
Fault code No. 62

Fault code No. 62
Item Power supply voltage failure in pressure sensor
Abnormality detected in pressure sensor power supply circuit of hy-

Symptom
draulic unit assembly.

Fault code No. 68

Fault code No. 68
Item Hydraulic unit assembly (defective front pressure sensor)
Abnormality detected in pressure sensor circuit at front caliper side

Symptom
of hydraulic unit assembly.

1 Defective front brake line Check the front brake line and if there is bending or
blocking, replace the front brake line.
EAS31167
[B-3] DELETING THE FAULT CODES

To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault
codes, refer to the operation manual of the Yamaha diagnostic tool.
Check that all the displayed fault codes are deleted.

90890-03257
90890-03254

Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
1
8-146
EAS31168
[C-1] FINAL CHECK

Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.
Checking procedures
1. Check the brake fluid level in the brake master cylinder reservoir and brake fluid reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-13.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (DISC BRAKE)” on page 4-21 and “INSTALLING THE
REAR WHEEL (DISC BRAKE)” on page 4-30.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TEST” on page 4-61.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 8-146.
5. Checking the ABS warning light.
Refer to “CHECKING THE ABS WARNING LIGHT” on page 4-65.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between green/orange terminal of the ABS ECU coupler and green/orange ter-
minal of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.
8-147
ELECTRICAL COMPONENTS
EAS20089
2 3 4 5
1 6
20
10
19
11
12
18
13
17
15 14
16
1. Main switch 19. Rectifier/regulator

2. Front brake light switch 20. Horn
3. Clutch switch
4. Fuse box 2
5. EXUP servo motor
6. Main fuse
7. Battery
8. Fuse box 1
9. ABS motor fuse
10. Starter relay
11. Neutral switch
12. Rear brake light switch
13. O2 sensor
14. Sidestand switch
15. Gear position sensor
16. Oil level switch
17. Ignition coil
18. Radiator fan motor
8-148
7 8
5 6
4
3 9
10
2
1
11
19 12
13
18
17 14
16 15
1. Intake air temperature sensor
3. Hydraulic unit assembly
4. Intake air pressure sensor
5. Throttle servo motor
6. Accelerator position sensor
7. Throttle position sensor
8. Intake funnel servo motor
9. Fuel pump
10. Relay unit
11. Lean angle sensor
13. Rear wheel sensor
14. Coolant temperature sensor
15. Crankshaft position sensor
16. Cylinder identification sensor
17. Front wheel sensor
18. Air induction system solenoid
19. Radiator fan motor relay
8-149
EAS30549
CHECKING THE SWITCHES

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
1
B/Y B/Y
9
Br Br
2 R,W
Br/L
R,W Br/L Br/R L/Y L/B
ON
10 R/W R/B
OFF L/Y L/B
Br/R
B R/W R/B 11 L B
W/G B/W L
3 Y/B Y 4 Y/B Y
12 W/G B/W
FREE
PUSH
5 P Br
Y L/R P/L Y/B Y/W 13

B P B/W W/B W/Y
6 W/B L/R W/Y
Br Y
7 P/L B/W Y/W

UP
(N)
DOWN
14
Sb
8
B B
1. Clutch switch
2. Main switch
3. Dimmer switch
4. Pass switch
5. Horn switch
6. Turn signal switch
7. Traction control system switch
8. Sidestand switch
9. Front brake light switch
11. Start switch
12. Mode switch
13. Rear brake light switch
14. Neutral switch
8-150
EAS30551
CHECKING THE FUSES Amperage

Fuses Q’ty
The following procedure applies to all of the fus- rating
es. Backup 7.5 A 1
ECA13680
Terminal 2A 1
NOTICE
Spare 30 A 1
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing Spare 15 A 1
a fuse. Spare 10 A 1
1. Remove: Spare 7.5 A 1
• Rider seat Spare 2A 1
Refer to “GENERAL CHASSIS (1)” on page EWA13310
4-1. WARNING
• Front upper panel (left)
Never use a fuse with an amperage rating
other than that specified. Improvising or us-
4-8.
ing a fuse with the wrong amperage rating
2. Check:
may cause extensive damage to the electri-
• Fuse
cal system, cause the lighting and ignition
a. Connect the digital circuit tester to the fuse
systems to malfunction and could possibly
and check the continuity.
cause a fire.
Digital circuit tester (CD732) 4. Install:
90890-03243 • Front upper panel (left)
Model 88 Multimeter with ta- Refer to “GENERAL CHASSIS (5)” on page
chometer 4-8.
YU-A1927
• Rider seat
b. If there is no continuity, replace the fuse. Refer to “GENERAL CHASSIS (1)” on page
3. Replace: 4-1.
• Blown fuse EAS31006
a. Set the main switch to “OFF”. REPLACING THE ECU (engine control unit)
b. Install a new fuse of the correct amperage 1. Turn the main switch to “OFF”.
rating. 2. Replace the ECU (engine control unit).
c. Set on the switches to verify if the electri- 3. Clean the throttle bodies and reset the ISC
cal circuit is operational. (idle speed control) learning value.
d. If the fuse immediately blows again, check Refer to “CHECKING AND CLEANING THE
the electrical circuit. THROTTLE BODIES” on page 7-13.
Amperage
4. Reset the A/F control learning value.
Fuses Q’ty Use the diagnostic code number “87”.
rating
Main 50 A 1 AND DIAGNOSTIC CODE TABLE” on page
ABS motor 30 A 1 9-1.
Ignition 15 A 1
Radiator fan motor (right) 15 A 1 90890-03257
Radiator fan motor (left) 15 A 1 Yamaha diagnostic tool (A/I)
Fuel injection system 15 A 1 90890-03254
Signaling system 10 A 1 5. Check:
ABS solenoid 10 A 1 • Engine idling speed
Turn signal light 7.5 A 1 Start the engine, warm it up, and then mea-
Headlight 7.5 A 1 sure the engine idling speed.
ABS ECU 7.5 A 1 Engine idling speed
Electronic throttle valve 7.5 A 1 1250–1350 r/min
8-151
EAS30552
CHECKING AND CHARGING THE BATTERY 1

TIP
Refer to “CHECKING AND CHARGING THE 2
BATTERY” in “BASIC INFORMATION” (sepa-
rate volume).
1. Remove:
• Rider seat
4-1.
2. Disconnect: 8. Check:
• Battery leads • Battery terminals
(from the battery terminals) Dirt → Clean with a wire brush.
ECA13640 Loose connection → Connect properly.
NOTICE 9. Lubricate:
First, disconnect the negative battery lead • Battery terminals
“1”, and then positive battery lead “2”.
2 Dielectric grease
10.Install:
1 • Rider seat
4-1.
EAS30553
CHECKING THE RELAYS

Check each switch for continuity with the digital
circuit tester. If the continuity reading is incor-
3. Remove: rect, replace the relay.
• Battery band
• Battery Digital circuit tester (CD732)
Refer to “GENERAL CHASSIS (1)” on page 90890-03243
4-1. Model 88 Multimeter with ta-
4. Check: chometer
• Battery charge YU-A1927
5. Charge:
1. Disconnect the relay from the wire harness.
• Battery
2. Connect the digital circuit tester and battery
6. Install:
(12 V) to the relay terminal as shown.
• Battery
Check the relay operation.
• Battery band
4-1.
Starter relay
7. Connect: 1.
• Battery leads 3
(to the battery terminals)
ECA13630 R
NOTICE
First, connect the positive battery lead “1”, R
and then the negative battery lead “2”. R/W L/W
B
2 1
4
1. Positive battery terminal
8-152
2. Negative battery terminal Radiator fan motor relay

3. Positive tester probe
4. Negative tester probe
Result
Continuity R/B
(between “3” and “4”) G/Y
Relay unit (starting circuit cut-off relay)

2. Negative battery terminal
Br/W L/W R/B L R/L
L/W L/WR/W L/B L/Y Sb B/Y Sb/W
Result
Continuity
(between “3” and “4”)
EAS30795
CHECKING THE RELAY UNIT (DIODE)
1. Check:
• Relay unit (diode)
Result
Continuity Digital circuit tester (CD732)
(between “3” and “4”) 90890-03243
Model 88 Multimeter with ta-
chometer
Relay unit (fuel pump relay)
YU-A1927
Br/W L/W R/B L R/L


Result
Continuity
(between “3” and “4”)
8-153
c. Check the relay unit (diode) for continuity.

Continuity d. Check the relay unit (diode) for no continu-
Positive tester probe → ity.
black/yellow “1”
Negative tester probe → EAS30558
sky blue “2” CHECKING THE IGNITION COILS

No continuity The following procedure applies to all of the igni-
Positive tester probe → tion coils.
sky blue “2” 1. Check:
Negative tester probe → • Primary coil resistance
black/yellow “1” Out of specification → Replace.
Continuity
Positive tester probe → Primary coil resistance
blue/yellow “3” 1.19–1.61 Ω
Negative tester probe →
sky blue “2” a. Remove the ignition coil from the spark
No continuity plug.
Positive tester probe → b. Connect the digital circuit tester to the igni-
sky blue “2” tion coil as shown.
blue/yellow “3” Digital circuit tester (CD732)
Continuity 90890-03243
Positive tester probe → Model 88 Multimeter with ta-
sky blue/white “4” chometer
Negative tester probe → YU-A1927
sky blue “2”
No continuity
• Positive tester probe →
Positive tester probe → red/black “1”
sky blue “2” • Negative tester probe →
Negative tester probe → orange or gray/red or orange/green or gray/
sky blue/white “4” green “2”
Continuity
Positive tester probe →
blue/yellow “3” 1
2
blue/black “5”
No continuity
Positive tester probe →
blue/black “5”
blue/yellow “3”
c. Measure the primary coil resistance.

2 1 2. Check:
• Secondary coil resistance
Br/W L/W R/B L R/L
Secondary coil resistance
9.35–12.65 kΩ
a. Connect the digital circuit tester to the igni-

tion coil as shown.
a. Disconnect the relay unit coupler from the
wire harness.
b. Connect the digital circuit tester to the re-
lay unit terminal as shown.
8-154
EAS30560
Digital circuit tester (CD732) CHECKING THE CRANKSHAFT POSITION

90890-03243 SENSOR
Model 88 Multimeter with ta- 1. Disconnect:
chometer • Crankshaft position sensor coupler
YU-A1927 (from the wire harness)
2. Check:
• Negative tester probe → • Crankshaft position sensor resistance
red/black “1” Out of specification → Replace the crank-
• Positive tester probe → shaft position sensor.
spark plug terminal “2”
Crankshaft position sensor resis-
tance
1 248–372 Ω
a. Connect the digital circuit tester to the

crankshaft position sensor coupler as
shown.
Digital circuit tester (CD732)

2 90890-03243
b. Measure the secondary coil resistance. chometer
3. Check: YU-A1927
• Ignition spark gap “a”
Out of specification → Replace. • Positive tester probe →
gray “1”
Minimum ignition spark gap • Negative tester probe →
6.0 mm (0.24 in) black “2”
a. Connect the ignition checker “1” as

shown.
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487
Gy B
1 2
b. Measure the crankshaft position sensor

resistance.
EAS30561
CHECKING THE LEAN ANGLE SENSOR

1. Remove:
• Lean angle sensor
(from the bracket)
2. Check:
2. Ignition coil • Lean angle sensor output voltage
b. Turn the main switch to “ON” and engine Out of specification → Replace.
stop switch to “ ”.
c. Measure the ignition spark gap “a”.
d. Crank the engine by pushing the start
switch “ ” and gradually increase the
spark gap until a misfire occurs.
8-155
EAS30562
Lean angle sensor output voltage CHECKING THE STARTER MOTOR

Operating angle OPERATION
65 ° 1. Check:
Output voltage up to operating • Starter motor operation
angle Does not operate → Perform the electric
0.4–1.4 V starting system troubleshooting, starting with
Output voltage over operating step 4.
angle Refer to “TROUBLESHOOTING” on page
3.7–4.4 V 8-14.
a. Connect the positive battery terminal “1”
a. Connect the test harness-lean angle sen-
and starter motor lead “2” with a jumper
sor (6P) “1” to the lean angle sensor and
lead “3”.
wire harness as shown. EWA13810
b. Connect the digital circuit tester to the test WARNING
harness-lean angle sensor (6P). • A wire that is used as a jumper lead must
Digital circuit tester (CD732) have at least the same capacity of the bat-
90890-03243 tery lead, otherwise the jumper lead may
Model 88 Multimeter with ta- burn.
chometer • This check is likely to produce sparks,
YU-A1927 therefore, make sure no flammable gas or
Test harness– lean angle sensor fluid is in the vicinity.
(6P)
90890-03209
Test harness– lean angle sensor
(6P)
YU-03209

yellow/green (wire harness color)
• Negative tester probe →
black/blue (wire harness color)
b. Check the starter motor operation.

EAS30566
CHECKING THE STATOR COIL

1. Disconnect:
• Stator coil coupler
(from the wire harness)
2. Check:
• Stator coil resistance
Out of specification → Replace the stator coil.
c. Turn the main switch to “ON”. Stator coil resistance
d. Turn the lean angle sensor to 65°. 0.120–0.180 Ω
e. Measure the lean angle sensor output
voltage. a. Connect the digital circuit tester to the sta-
tor coil coupler as shown.

90890-03243
chometer
YU-A1927
8-156
• Positive tester probe → 1

white “1”
white “2”
2
white “1”
white “3”

white “2” b. Start the engine and let it run at approxi-
• Negative tester probe → mately 5000 r/min.
white “3”
c. Measure the charging voltage.
EAS30796
CHECKING THE OIL LEVEL SWITCH

1. Drain:
• Engine oil
2. Remove:
• Oil level switch
(from the oil pan)
W W W 3. Check:
• Oil level switch resistance
1 2 3
Out of specification → Replace the oil level
b. Measure the stator coil resistance. switch.
EAS30680
CHECKING THE RECTIFIER/REGULATOR Oil level switch resistance (maxi-

mum level position)
1. Check:
484.0–536.0 Ω
• Charging voltage Oil level switch resistance (mini-
Out of specification → Replace the rectifier/ mum level position)
regulator. 114.0–126.0 Ω
Charging voltage a. Connect the digital circuit tester to the oil
14 V at 5000 r/min level switch terminal as shown.
a. Connect the digital circuit tester to the bat- Digital circuit tester (CD732)
tery terminals as shown. 90890-03243
Digital circuit tester (CD732) chometer
90890-03243 YU-A1927
chometer
Minimum level position “A”
YU-A1927 • Positive tester probe →
connector (white) “1”
• Positive tester probe → • Negative tester probe →
Positive battery terminal “1” body earth “2”
Negative battery terminal “2” Maximum level position “B”
connector (white) “1”
body earth “2”
8-157
b. Measure the oil level switch resistance. EAS30574
CHECKING THE FUEL LEVEL WARNING

EAS30573
CHECKING THE FUEL SENDER LIGHT

1. Disconnect: This model is equipped with a self-diagnosis de-
• Fuel pump coupler vice for the fuel level detection circuit.
(from the fuel pump) 1. Check:
2. Remove: • Fuel level warning light “1”
• Fuel tank (Turn the main switch to “ON”.)
3. Remove: Warning light comes on for a few seconds,
• Fuel pump then goes off → Warning light is OK.
(from the fuel tank) Warning light does not come on → Replace
4. Check: the meter assembly.
• Fuel sender resistance Warning light flashes eight times, then goes
Out of specification → Replace the fuel pump off for 3 seconds in a repeated cycle (mal-
assembly. function detected in fuel sender) → Replace
the fuel pump assembly.
Sender unit resistance (empty)
137.0–185.0 Ω
a. Connect the digital circuit tester to the fuel 1

sender terminals as shown.

90890-03243
chometer
YU-A1927
EAS30575
CHECKING THE OIL LEVEL WARNING

Fuel sender terminal “1” LIGHT
• Negative tester probe → This model is equipped with a self-diagnosis de-
Fuel sender terminal “2” vice for the oil level detection circuit.
1. Check:
• Oil level warning light “1”
(Turn the main switch to “ON”.)
Warning light comes on for a few seconds,
then goes off → Warning light is OK.
Warning light does not come on → Replace
2 the meter assembly.
Warning light flashes ten times, then goes off
1 for 2.5 seconds in a repeated cycle (malfunc-
tion detected in oil level switch) → Replace
the oil level switch.
b. Set the fuel sender float to minimum “3”
level position.
8-158
Coolant temperature sensor re-

1 sistance
2320–2590 Ω at 20 °C (2320–
2590 Ω at 68 °F)
a. Connect the digital circuit tester to the

coolant temperature sensor as shown.

90890-03243
EAS30577 Model 88 Multimeter with ta-
CHECKING THE RADIATOR FAN MOTORS chometer
1. Check: YU-A1927
• Radiator fan motor
Faulty/rough movement → Replace. b. Immerse the coolant temperature sensor
a. Disconnect the radiator fan motor coupler “1” in a container filled with coolant “2”.
from the wire harness. TIP
b. Connect the battery (DC 12 V) as shown. Make sure the coolant temperature sensor ter-
• Positive tester probe → minals do not get wet.
blue or green “1”
• Negative tester probe → c. Place a thermometer “3” in the coolant.
black “2” d. Slowly heat the coolant, then let it cool
down to the specified temperature.
A B e. Measure the coolant temperature sensor
resistance.
2 2 3
B B
1
G L
1 1
2
A. Radiator fan motor (left)
B. Radiator fan motor (right)
EAS30587
c. Measure the radiator fan motor move-
ment.
SOLENOID
EAS30578 1. Check:
CHECKING THE COOLANT TEMPERATURE • Air induction system solenoid resistance
SENSOR Out of specification → Replace.
1. Remove:
• Coolant temperature sensor Solenoid resistance
Refer to “CYLINDER HEAD” on page 5-26. 20–23 Ω
EWA14130
WARNING a. Disconnect the air induction system sole-

• Handle the coolant temperature sensor noid coupler from the air induction system
with special care. solenoid.
• Never subject the coolant temperature sen- b. Connect the digital circuit tester to the air
sor to strong shocks. If the coolant tem- induction system solenoid terminal as
perature sensor is dropped, replace it. shown.
2. Check:
• Coolant temperature sensor resistance
8-159
Digital circuit tester (CD732) Digital circuit tester (CD732)

90890-03243 90890-03243
Model 88 Multimeter with ta- Model 88 Multimeter with ta-
chometer chometer
YU-A1927 YU-A1927
Test harness– speed sensor (3P)
• Positive tester probe → 90890-03208
brown/red “1” Test harness– speed sensor (3P)
• Negative tester probe → YU-03208
red/white “2”
white/black (wire harness color)
2 1
black/blue (wire harness color)
Br/R R/W
c. Measure the air induction system solenoid

1
resistance.
EAS30589
CHECKING THE CYLINDER c. Turn the main switch to “ON”.

IDENTIFICATION SENSOR d. Rotate the crankshaft.
1. Remove: e. Measure the voltage. With each full rota-
• Air filter case tion of the crankshaft, the voltage reading
Refer to “AIR FILTER CASE” on page 7-5. should cycle from 0.8 V to 4.8 V to 0.8 V to
• Air induction system cover 4.8 V.
page 7-19. EAS30594
• Side cowling (right) CHECKING THE INTAKE AIR

Refer to “GENERAL CHASSIS (5)” on page TEMPERATURE SENSOR
4-8. 1. Remove:
• Crankshaft end access cover • Intake air temperature sensor
EWA14110
2. Check: WARNING
• Cylinder identification sensor output voltage
• Handle the intake air temperature sensor
with special care.
Cylinder identification sensor • Never subject the intake air temperature
output voltage (ON) sensor to strong shocks. If the intake air
4.8 V or more temperature sensor is dropped, replace it.
Cylinder identification sensor
2. Check:
output voltage (OFF)
0.8 V or less • Intake air temperature sensor resistance
a. Connect the test harness-speed sensor
(3P) “1” to the cylinder identification sen-
sor coupler and wire harness as shown.
b. Connect the digital circuit tester to the test
harness-speed sensor (3P).
8-160
2. Check:
Intake air temperature sensor re- • Throttle position sensor maximum resistance
sistance Out of specification → Replace the throttle
5400–6600 Ω at 0 °C (5400–6600 position sensor.
Ω at 32 °F)
Intake air temperature sensor re- Resistance
sistance 1.4–2.6 kΩ
289–391 Ω at 80 °C (289–391 Ω
at 176 °F) a. Connect the digital circuit tester to the
throttle position sensor terminals as
a. Connect the digital circuit tester to the in-
shown.
take air temperature sensor terminal as
shown. Digital circuit tester (CD732)
90890-03243
Digital circuit tester (CD732) Model 88 Multimeter with ta-
90890-03243 chometer
Model 88 Multimeter with ta- YU-A1927
chometer
YU-A1927
blue “1”
b. Immerse the intake air temperature sen- • Negative tester probe →
sor “1” in a container filled with water “2”. black/blue “2”
TIP
Make sure that the intake air temperature sensor
terminals do not get wet. 1 2
c. Place a thermometer “3” in the water.
d. Slowly heat the water, then let it cool down
to the specified temperature.
e. Measure the intake air temperature sen-
B L W B/L
sor resistance.
3 b. Measure the throttle position sensor max-

1 imum resistance.
3. Install:
• Throttle position sensor
TIP
2 When installing the throttle position sensor, ad-
just its angle properly. Refer to “ADJUSTING
THE THROTTLE POSITION SENSOR” on page
EAS30581
7-17.
CHECKING THE THROTTLE POSITION
SENSOR EAS30582
1. Remove: CHECKING THE ACCELERATOR POSITION
• Throttle position sensor SENSOR
(from the throttle bodies) 1. Remove:
EWA16690
• Accelerator position sensor
WARNING
(from the throttle bodies)
• Handle the throttle position sensor with EWA16700
special care. WARNING

• Never subject the throttle position sensor • Handle the accelerator position sensor with
to strong shocks. If the throttle position special care.
sensor is dropped, replace it.
8-161
• Never subject the accelerator position sen- 2. Check:

sor to strong shocks. If the accelerator po- • Throttle valve operation
sition sensor is dropped, replace it. Throttle valves do not fully close → Replace
2. Check: the throttle bodies.
• Accelerator position sensor maximum resis- a. Connect two C-size batteries to the throttle
tance servo motor terminals “1” as shown.
ECA20060
Out of specification → Replace the accelera- NOTICE
tor position sensor.
Do not use a 12 V battery to operate the throt-
Resistance tle servo motor.
1.26–2.34 kΩ TIP
a. Connect the digital circuit tester to the ac- Do not use old batteries to operate the throttle
celerator position sensor terminals as servo motor.
shown.
A
Digital circuit tester (CD732) 1
90890-03243
chometer
YU-A1927
• Positive tester probe → 1

blue “1” 2
3V
black/blue “2” B
1
2 1
1
2
W B/L L B 3V
A. Check that the throttle valves “2” open.
B. Check that the throttle valves “2” fully close.
b. Measure the accelerator position sensor
EAS30681
maximum resistance. CHECKING THE FUEL INJECTORS
3. Install: 1. Check:
• Accelerator position sensor • Fuel injector resistance
TIP Out of specification → Replace the fuel injec-
When installing the accelerator position sensor, tor.
adjust its angle properly. Refer to “ADJUSTING
THE ACCELERATOR POSITION SENSOR” on Resistance
page 7-17. 12.0 Ω
a. Disconnect the fuel injector coupler from

EAS30592
CHECKING THE THROTTLE SERVO MOTOR wire harness.

1. Remove: b. Connect the digital circuit tester to the fuel
• Air filter case injector terminals as shown.
8-162

90890-03243
chometer
YU-A1927
• Positive tester probe

Injector terminal “1”
• Negative tester probe
Injector terminal “2”
c. Measure the fuel injector resistance.
8-163
TROUBLESHOOTING
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE............9-1

SELF-DIAGNOSTIC FUNCTION TABLE .................................................. 9-1
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 9-11
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................9-14
EVENT CODE TABLE...................................................................................9-17
9
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20116

EAS31118
SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-31.
Fault code Probable cause of Fail-safe system op-

Item Vehicle symptom
No. malfunction eration
P0030 O2 sensor heater (de- • Open circuit in wire (When the O2 sensor If the O2 sensor does
fective heater control- harness. does not operate be- not operate, O2 feed-
ler detected) • Disconnected cou- cause the exhaust back is not carried
pler. temperature is low) out.
• Defective O2 sensor Increased exhaust
driver (malfunction emissions.
in ECU). Fuel learning cannot
• Open circuit in O2 be carried out.
sensor heater lead.
P0069 Intake air pressure • Malfunction in ECU. Engine is difficult to Intake air pressure is
sensor or atmospher- • Intake air pressure start. fixed to 101.3 [kPa].
ic pressure sensor sensor hose is dis- Engine idling speed is Intake air pressure
(When the main connected, clogged, unstable. difference is fixed to 0
switch is turned to kinked, or pinched. Increased exhaust [kPa].
“ON”, the intake air • Defective intake air emissions. Atmospheric pres-
pressure sensor volt- pressure sensor or Loss of engine power. sure is fixed to 101.3
age and atmospheric atmospheric pres- [kPa].
pressure sensor volt- sure sensor. α–N is fixed.
age differ greatly.) Fuel is not cut off due
to the intake air pres-
sure difference.
Atmospheric pres-
sure sensor output
correction value is
fixed to 0.
O2 feedback is not
carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
9-1

P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure is
P0108 pressure sensor of the intake air pres- unstable. fixed to 101.3 [kPa].
(ground short circuit sure sensor circuit Engine response is Intake air pressure
detected) (0.5 V or less) poor. difference is fixed to 0
[P0108] Intake air [P0108] High voltage Loss of engine power. [kPa].
pressure sensor of the intake air pres- Increased exhaust α–N is fixed.
(open or power short sure sensor circuit emissions. Fuel is not cut off due
circuit detected) (4.8 V or more) to the intake air pres-
• Defective coupler sure difference.
between intake air Atmospheric pres-
pressure sensor and sure sensor output
ECU. correction value is
• Open or short cir- fixed to 0.
cuit in wire harness O2 feedback is not
between intake air carried out.
pressure sensor and ISC feedback is not
ECU. carried out.
• Defective intake air ISC learning is not
pressure sensor. carried out.
• Malfunction in ECU.
P0112 [P0112] Air tempera- [P0112] Low voltage Engine is difficult to The intake air tem-
P0113 ture sensor (ground of the air temperature start. perature is fixed to 20
short circuit detected) sensor circuit (0.1 V Increased exhaust [°C].
[P0113] Air tempera- or less) emissions. O2 feedback is not
ture sensor (open or [P0113] High voltage Engine idling speed is carried out.
power short circuit de- of the air temperature unstable. ISC feedback is not
tected) sensor circuit (4.8 V carried out.
or more) ISC learning is not
• Defective coupler carried out.
between air tem-
perature sensor and
ECU.
• Open or short cir-
cuit in wire harness
between air tem-
perature sensor and
ECU.
• Improperly installed
air temperature sen-
sor.
• Defective air tem-
perature sensor.
9-2

P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The coolant tempera-
P0118 perature sensor of the coolant tem- start. ture is fixed to 60 [°C].
(ground short circuit perature sensor circuit Increased exhaust The radiator fan motor
detected) (0.1 V or less) emissions. relay is on only when
[P0118] Coolant tem- [P0118] High voltage Engine idling speed is the vehicle is traveling
perature sensor (open of the coolant tem- unstable. at low speeds.
or power short circuit perature sensor circuit O2 feedback is not
detected) (4.9 V or more) carried out.
• Defective coupler ISC feedback is not
between coolant carried out.
temperature sensor ISC learning is not
and ECU. carried out.
between coolant
temperature sensor
and ECU.
coolant temperature
sensor.
• Defective coolant
temperature sensor.
P0122 [P0122, P0222] Throt- [P0122, P0222] Low Engine idling speed is Change in the throttle
P0123 tle position sensor voltage of the throttle high. opening is 0 (transient
P0222 (ground short circuit position sensor circuit Engine idling speed is control is not carried
P0223 detected) (0.25 V or less) unstable. out).
P2135 [P0123, P0223] Throt- [P0123, P0223] High Engine response is D–j is fixed.
tle position sensor voltage of the throttle poor. Throttle opening is
(open or power short position sensor circuit Loss of engine power. fixed to 125 [°].
circuit detected) (4.75 V or more) Deceleration is poor. O2 feedback is not
[P2135] Deviation er- [P2135] Difference in Increased exhaust carried out.
ror output voltage 1 and emissions. Fuel is not cut off due
output voltage 2 of the Vehicle cannot be to the throttle open-
throttle position sen- driven. ing.
sor Output is restricted.
• Defective coupler Power is constantly
between throttle po- supplied to the air in-
sition sensor and duction system sole-
ECU. noid (air induction
• Open or short cir- system air is cut off).
cuit in wire harness ISC feedback is not
between throttle po- carried out.
sition sensor and ISC learning is not
ECU. carried out.
throttle position sen-
sor.
• Defective throttle po-
sition sensor.
9-3

P0132 O2 sensor (power [P0132] High voltage Increased exhaust O2 feedback is not
short circuit detected) of the O2 sensor cir- emissions. carried out.
cuit (4.8 V or more) O2 feedback learning
• Improperly installed is not carried out.
O2 sensor. Power is constantly
• Defective coupler supplied to the air in-
between O2 sensor duction system sole-
and ECU. noid (air induction
• Open or short cir- system air is cut off).
between O2 sensor
and ECU.
• Incorrect fuel pres-
sure.
• Defective O2 sensor.
P0201 [P0201] Primary injec- • Defective coupler Loss of engine power. O2 feedback is not
P0202 tor #1 (malfunction in between injector Engine is difficult to carried out.
P0203 primary injector #1) and ECU. start. Power is constantly
P0204 [P0202] Primary injec- • Open or short cir- Engine cannot be supplied to the air in-
tor #2 (malfunction in cuit in wire harness started. duction system sole-
primary injector #2) between injector Engine stops. noid (air induction
[P0203] Primary injec- and ECU. Engine idling speed is system air is cut off).
tor #3 (malfunction in • Defective injector. unstable. ISC feedback is not
primary injector #3) • Malfunction in ECU. Increased exhaust carried out.
[P0204] Primary injec- • Improperly installed emissions. ISC learning is not
tor #4 (malfunction in injector. carried out.
primary injector #4) Injection to the appli-
cable cylinder group
(cylinders #1 and #4
or cylinders #2 and
#3) is cut off.
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor (no normal between crankshaft started. ISC feedback is not
signals are received position sensor and carried out.
from the crankshaft ECU. ISC learning is not
position sensor) • Open or short cir- carried out.
between crankshaft
position sensor and
ECU.
crankshaft position
sensor.
• Defective pickup ro-
tor.
• Defective crank-
shaft position sen-
sor.
9-4

P0340 Cylinder identification • Defective coupler Engine cannot be The vehicle is operat-
sensor (no normal between cylinder started. ed using only the cyl-
signals are received identification sensor inder identification
from the cylinder iden- and ECU. information stored
tification sensor) • Open or short cir- during operation.
cuit in wire harness ISC feedback is not
between cylinder carried out.
identification sensor ISC learning is not
and ECU. carried out.
cylinder identifica-
tion sensor.
• Defective pickup ro-
tor.
• Defective cylinder
identification sensor.
P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. Injection to the appli-
P0352 ignition coil (open or between ignition coil Loss of engine power. cable cylinder group
P0353 short circuit detected and ECU. Engine is difficult to (cylinders #1 and #4
P0354 in the primary lead of • Open or short cir- start. or cylinders #2 and
the cylinder-#1 igni- cuit in wire harness Engine cannot be #3) is cut off.
tion coil) between ignition coil started. Power is constantly
[P0352] Cylinder-#2 and ECU. Engine idling speed is supplied to the air in-
ignition coil (open or • Improperly installed unstable. duction system sole-
short circuit detected ignition coil. Increased exhaust noid (air induction
in the primary lead of • Defective ignition emissions. system air is cut off).
the cylinder-#2 igni- coil. O2 feedback is not
tion coil) • Malfunction in ECU. carried out.
[P0353] Cylinder-#3 ISC feedback is not
ignition coil (open or carried out.
short circuit detected ISC learning is not
in the primary lead of carried out.
the cylinder-#3 igni-
tion coil)
[P0354] Cylinder-#4
ignition coil (open or
short circuit detected
in the primary lead of
the cylinder-#4 igni-
tion coil)
P0476 EXUP servo motor • Defective coupler Loss of engine power. Learning values for
(stuck EXUP servo between EXUP ser- fully closed EXUP are
motor is detected) vo motor and ECU. fixed.
• Open or short cir- Learning values for
cuit in wire harness fully open EXUP are
between EXUP ser- fixed.
vo motor and ECU. O2 feedback is not
• Improperly installed carried out.
EXUP servo motor
and cables.
• Defective EXUP ser-
vo motor.
• Stuck EXUP servo
motor (mechanism
or motor).
9-5

P0480 Radiator fan motor re- • Open or short cir- Engine is difficult to Radiator fan is al-
lay (open or short circuit in wire harness start. ways off (stopped).
cuit is detected) between radiator fan Loss of engine power. O2 feedback is not
motor relay and Engine overheats. carried out.
ECU. Increased exhaust ISC feedback is not
• Disconnected cou- emissions. carried out.
pler. ISC learning is not
• Defective radiator carried out.
fan motor.
• Defective driver
(malfunction in
ECU).
P048D [P048D] EXUP servo • Defective coupler Loss of engine power. Learning values for
P048E motor (open or between EXUP ser- fully closed EXUP are
ground short circuit vo motor and ECU. fixed.
detected) • Open or short cir- Learning values for
[P048E] EXUP servo cuit in wire harness fully open EXUP are
motor (power short between EXUP ser- fixed.
circuit detected) vo motor and ECU. O2 feedback is not
• Defective EXUP ser- carried out.
vo motor.
P0500 [P0500, P1500] Rear • Open or short cir- Vehicle speed is not Vehicle speed dis-
P1500 wheel sensor (no nor- cuit in wire harness displayed on the me- played on the meter =
mal signals are re- between rear wheel ter. 0 [km/h]
ceived from the rear sensor and ABS Indication of the neu- O2 feedback is not
wheel sensor) unit. tral indicator light is in- carried out.
[P1500] Neutral • Open or short cir- correct. Fuel cut-off control
switch (open or short cuit in wire harness Engine idling speed is when the rear wheel
circuit detected) between ABS unit unstable. sensor or neutral
[P1500] Clutch switch and ECU. Traction control sys- switch malfunctions is
(open or short circuit • Open or short cir- tem does not operate. carried out.
detected) cuit in wire harness ISC feedback is not
between neutral carried out.
switch and ECU. ISC learning is not
• Open or short cir- carried out.
cuit in wire harness Traction control sys-
between clutch tem does not operate.
switch and ECU.
• Defective rear wheel
sensor.
• Defective neutral
switch.
• Defective clutch
switch.
• Improper adjust-
ment of clutch lever.
9-6

P0560 Charging voltage is • Battery overcharg- Engine is difficult to O2 feedback is not
abnormal. ing (defective rectifi- start. carried out.
er/regulator). Increased exhaust
• Battery overcharg- emissions.
ing (broken or dis- Battery performance
connected rectifier/ has deteriorated or
regulator lead). battery is defective.
• Battery over-dis-
charging (broken or
disconnected lead in
charging system).
• Battery over-dis-
charging (defective
rectifier/regulator).
P0601 Faulty ECU memory. • Malfunction in ECU. Engine cannot be Engine cannot be
(When this malfunc- started. started.
tion is detected in the
ECU, the fault code
number might not ap-
pear on the tool dis-
play.)
P0606 ECU internal malfunc- • Malfunction in ECU. Engine cannot be Engine cannot be
tion. (When this mal- started. started.
function is detected in Engine response is Ignition and injection
the ECU, the fault poor. are not carried out.
code number might Loss of engine power. Judgment for other
not appear on the tool fault codes is not car-
display.) ried out.
Load control is not
carried out. (The relay
unit and other relays
are all turned off.)
The CO adjustment
mode and diagnostic
mode cannot be acti-
vated.
Output is restricted.
P062F EEPROM fault code • CO adjustment val- Increased exhaust CO adjustment value
number (an error is ue is not properly emissions. for the faulty cylinder
detected while read- written. Engine cannot be = 0 (default value)
ing or writing on EE- • ISC learning value is started or is difficult to ISC learning values =
PROM) not properly written. start. Default values
• OBD memory value Engine idling speed is OBD memory value is
is not properly writ- unstable. initialized.
ten. OBD memory value is O2 feedback learning
• Malfunction in ECU. not correct. value is initialized.
9-7

P0638 YCC-T drive system • Defective coupler Engine response is O2 feedback is not
(malfunction detect- between throttle ser- poor. carried out.
ed) vo motor and ECU. Loss of engine power. YCC-T evacuation is
• Open or short cir- Engine idling speed is activated.
cuit in wire harness unstable. Output is restricted.
between throttle ser- ISC feedback is not
vo motor and ECU. carried out.
• Defective throttle ISC learning is not
servo motor. carried out.
• Stuck throttle servo
motor (mechanism
or motor).
• Blown electronic
throttle valve fuse.
P0657 Fuel system voltage • Open or short cir- Engine is difficult to Monitor voltage = 12
(incorrect voltage sup- cuit in wire harness start. [V]
plied to the fuel injec- between relay unit Increased exhaust O2 feedback is not
tor and fuel pump) and ECU. emissions. carried out.
• Open circuit in wire
harness between
battery and ECU.
• Defective relay unit.
P0916 [P0916] Gear posi- • Defective coupler Improper display for Maintains the gear
P0917 tion sensor (open or between gear posi- gear position. position value at the
ground short circuit tion sensor and Defective engine re- previous value.
detected) ECU. sponse.
[P0917] Gear posi- • Open or power short
tion sensor (power circuit in wire har-
short circuit detected) ness between gear
position sensor and
ECU.
gear position sen-
sor.
• Defective gear posi-
tion sensor.
P1400 Air induction system • Open circuit in wire Increased exhaust No power is supplied
solenoid (open or harness. emissions. to the air induction
short circuit detected) • Disconnected cou- system solenoid (air
pler. induction system air is
• Defective air induc- supplied).
tion system sole- O2 feedback is not
noid. carried out.
• Defective driver
(malfunction in
ECU).
9-8

P1602 Malfunction in ECU • Open or short cir- Engine idling speed is O2 feedback learning
internal circuit (mal- cuit in wire harness unstable. is not carried out.
function of ECU pow- between battery and Engine idling speed is O2 feedback learning
er cut-off function) ECU. high. value writing error.
• Open or short cir- Increased exhaust
cuit in wire harness emissions.
between main Engine is difficult to
switch and ECU. start.
• Blown backup fuse.
P1604 [P1604] Lean angle [P1604] Low voltage Engine cannot be Engine cannot be
P1605 sensor (ground short of the lean angle sen- started. started.
circuit detected) sor circuit (0.2 V or
[P1605] Lean angle less)
sensor (open or pow- [P1605] High voltage
er short circuit detect- of the lean angle sen-
ed) sor circuit (4.8 V or
more)
between lean angle
sensor and ECU.
• Defective lean an-
gle sensor.
P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is Change in the accel-
P2123 position sensor (open voltage of the acceler- poor. erator angle is 0 (tran-
P2127 or ground short cir- ator position sensor Loss of engine power. sient control is not
P2128 cuit detected) circuit (0.25 V or less) Engine idling speed is carried out).
P2138 [P2123] Accelerator [P2123, P2128] High unstable. Accelerator angle is
position sensor (pow- voltage of the acceler- fixed to 0 [°].
er short circuit detect- ator position sensor O2 feedback is not
ed) circuit (4.75 V or carried out.
[P2127] Accelerator more) YCC-T evacuation is
position sensor [P2138] Difference in activated.
(ground short circuit output voltage 1 and Output is restricted.
detected) output voltage 2 of the Fuel is not cut off due
[P2128] Accelerator accelerator position to the accelerator an-
position sensor (open sensor. gle.
or power short circuit • Defective coupler ISC feedback is not
detected) between accelera- carried out.
[P2138] Deviation er- tor position sensor ISC learning is not
ror and ECU. carried out.
between accelera-
tor position sensor
and ECU.
accelerator position
sensor.
• Defective accelera-
tor position sensor.
9-9

P2158 Front wheel sensor • Open or short cir- Traction control sys- Traction control sys-
(no normal signals are cuit in wire harness tem does not operate. tem does not operate.
received from the between front wheel Traction control sys-
front wheel sensor) sensor and ECU. tem indicator/warning
• Defective front light on the multi-func-
wheel sensor. tion meter comes on.
• Malfunction in ECU. “TCS” switch on the
left handlebar switch
cannot be used (the
traction control sys-
tem is turned off).
P2195 O2 sensor (open cir- • Signal voltage is Increased exhaust O2 feedback is not
cuit detected) 0.25–0.45 V. emissions. carried out.
• Improperly installed O2 feedback learning
O2 sensor. is not carried out.
• Defective coupler Power is constantly
between O2 sensor supplied to the air in-
and ECU. duction system sole-
• Open or short cir- noid (air induction
cuit in wire harness system air is cut off).
between O2 sensor
and ECU.
• Defective O2 sensor.
P21CF [P21CF] Secondary • Defective coupler Loss of engine power. O2 feedback is not
P21D0 injector #1 (malfunc- between injector carried out.
P21D1 tion in secondary in- and ECU. Power is constantly
P21D2 jector #1) • Open or short cir- supplied to the air in-
[P21D0] Secondary cuit in wire harness duction system sole-
injector #2 (malfunc- between injector noid (air induction
tion in secondary in- and ECU. system air is cut off).
jector #2) • Defective injector. ISC feedback is not
[P21D1] Secondary • Malfunction in ECU. carried out.
injector #3 (malfunc- • Improperly installed ISC learning is not
tion in secondary in- injector. carried out.
jector #3) Injection to the appli-
[P21D2] Secondary cable cylinder group
injector #4 (malfunc- (cylinders #1 and #4
tion in secondary in- or cylinders #2 and
jector #4) #3) is cut off.
9-10

P2228 [P2228] Atmospheric [P2228] Low voltage Engine is difficult to α–N is fixed.
P2229 pressure sensor of the atmospheric start. Intake air pressure
(ground short circuit pressure sensor cir- Increased exhaust difference is fixed to 0
detected) cuit (0.5 V or less) emissions. [kPa].
[P2229] Atmospheric [P2229] High voltage Insufficient power at Atmospheric pres-
pressure sensor of the atmospheric high altitudes. sure is fixed to 101.3
(open or power short pressure sensor cir- Engine idling speed is [kPa].
circuit detected) cuit (4.8 V or more) unstable. Atmospheric pres-
• Defective coupler sure sensor output
between atmospher- correction value is
ic pressure sensor fixed to 0.
and ECU. Fuel is not cut off due
• Open or short cir- to the intake air pres-
cuit in wire harness sure difference.
between atmospher- O2 feedback is not
ic pressure sensor carried out.
and ECU. ISC feedback is not
• Improperly installed carried out.
atmospheric pres- ISC learning is not
sure sensor. carried out.
• Defective atmo-
spheric pressure
sensor.
U0155 CAN communication • Defective coupler Communication be- MAP changeover:
error (with the meter) between meter cou- tween the ECU and State is fixed.
pler and ECU cou- the meter is not possi- Traction control sys-
pler. ble tem does not operate.
• Open or short cir- Meter switch input:
cuit in the wire har- OFF is fixed.
ness between the
meter and the ECU.
• Defective meter.
EAS31057
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor sig-
nal 1
• Fully closed position 11–21 Check with throttle valves ful-
ly closed.
• Fully open position 96–106 Check with throttle valves ful-
ly open.
02 Atmospheric pressure Displays the atmospheric Compare the actually mea-
pressure. sured atmospheric pressure
with the tool display value.
03 Intake air pressure Displays the intake air pres- Operate the throttle while
sure. pushing the start switch “ ”.
(If the display value changes,
the performance is OK.)
05 Air temperature Displays the air temperature. Compare the actually mea-
sured air temperature with
the tool display value.
9-11
Diagnostic
code No.
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
air temperature. with the tool display value.
When engine is hot: Displays
current coolant temperature.
07 Rear wheel vehicle speed Rear wheel speed pulse Check that the number in-
pulses 0–999 creases when the rear wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
08 Lean angle sensor Lean angle sensor output Remove the lean angle sen-
voltage sor and incline it more than
65 degrees.
• Upright 0.4–1.4
• Overturned 3.7–4.4
09 Fuel system voltage Approximately 12.0 Set the engine stop switch to
(battery voltage) “ ”, and then compare the
actually measured battery
voltage with the tool display
value. (If the actually mea-
sured battery voltage is low,
recharge the battery.)
13 Throttle position sensor sig-
nal 2
• Fully closed position 9–23 Check with throttle valves ful-
ly closed.
• Fully open position 93–109 Check with throttle valves ful-
ly open.
14 Accelerator position sensor
signal 1
• Fully closed position 11–21 Check with throttle grip fully
closed position.
• Fully open position 96–106 Check with throttle grip fully
open position.
15 Accelerator position sensor
signal 2
• Fully closed position 9–23 Check with throttle grip fully
closed position.
• Fully open position 93–109 Check with throttle grip fully
open position.
16 Front wheel vehicle speed Front wheel speed pulse Check that the number in-
pulses 0–999 creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
20 Sidestand switch Extend and retract the side-
• Stand retracted ON stand (with the transmission
in gear).
• Stand extended OFF
9-12
Diagnostic
code No.
21 Neutral switch and clutch Operate the transmission,
switch clutch lever, and side stand.
• Transmission is in neutral ON
• Transmission is in gear or OFF
the clutch lever released
• Clutch lever is squeezed ON
with the transmission in
gear and when the side-
stand is retracted
• Clutch lever is squeezed OFF
with the transmission in
gear and when the side-
stand is extended
60 EEPROM fault code display
• No history 00 —
• No malfunctions detected
(If the self-diagnosis fault
code P062F is indicated,
the ECU is defective.)
• History exists 01–04 (CO adjustment val- —
Display the EEPROM writ- ue)
ing error for fault code No. • (If more than one cylinder is
P062F. defective, the display alter-
If more than one item is de- nates every two seconds to
fective, the displays alter- show all the detected cylin-
nates every two seconds to der numbers.
show all the detected num- When all cylinder numbers
bers. are shown, the display re-
peats the same process.)
11 (Data error for ISC (idle
speed control) learning val-
ues)
12 (O2 feedback learning val-
ue)
13 (OBD memory value)
67 ISC (idle speed control) 00 To erase the ISC (idle speed
learning condition display ISC (idle speed control) control) learning data, set the
ISC (idle speed control) learning data has been engine stop switch from “ ”
learning data erasure erased. to “ ” 3 times in 5 seconds.
01
It is not necessary to erase
the ISC (idle speed control)
learning data.
02
It is necessary to erase the
ISC (idle speed control)
learning data.
70 Program version number 0–254 [-] —
86* Shift switch Check the switch condition
by operating the shift pedal.
• Shift pedal up position ON
• Other position than the shift OFF
pedal up position
9-13
Diagnostic
code No.
87 A/F control learning data era- 00 To erase the O2 feedback
sure A/F control learning data has learning data, set the engine
been erased. stop switch from “ ” to “ ”
01 3 times in 5 seconds.
A/F control learning data has
not been erased.
* Diagnostic code No. 86 is the diagnostic code number for the optional shift switch.
EAS31121
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Cylinder-#1 ignition coil Actuates the cylinder-#1 igni- Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. • Connect an ignition check-
The “check” indicator on the er.
Yamaha diagnostic tool
screen come on each time
the ignition coil is actuated.
34 Intake funnel Actuates the intake funnel Check the operating of the
(up position down position for intake funnel servo motor.
each 6 seconds).
The “check” indicator on the
the intake funnel servo motor
is actuated.
9-14
Diagnostic
code No.
36 Primary injector #1 Actuates the primary injector Disconnect the fuel pump
#1 five times at one-second coupler.
intervals. Check that primary injector
The “check” indicator on the #1 is actuated five times by
Yamaha diagnostic tool listening for the operating
screen come on each time sound.
the primary injector is actuat-
ed.
ed.
ed.
ed.
40 Secondary injector #1 Actuates the secondary in- Disconnect the fuel pump
jector #1 five times at one- coupler.
second intervals. Check that secondary injec-
The “check” indicator on the tor #1 is actuated five times
Yamaha diagnostic tool by listening for the operating
the secondary injector is ac-
tuated.
tuated.
tuated.
9-15
Diagnostic
code No.
tuated.
47* Steering damper solenoid — —
48 Air induction system solenoid Actuates the air induction Check that the air induction
system solenoid five times at system solenoid is actuated
one-second intervals. five times by listening for the
The “check” indicator on the operating sound.
the air induction system sole-
noid is actuated.
50 Relay unit Actuates the relay unit five Check that the relay unit is
times at one-second inter- actuated five times by listen-
vals. ing for the operating sound.
the relay is actuated.
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
second intervals. times by listening for the op-
The “check” indicator on the erating sound.
the relay is actuated.
52 Headlight Actuates the headlight five Check that the headlight
times at five-second inter- comes on five times.
vals.
the headlight is actuated.
53 EXUP servo motor After the EXUP is fully Check the operating sound.
closed, it stops at the open-
ing base position (intermedi-
ate position).
This operation takes approxi-
mately 3 seconds during
which the “check” indicator is
displayed on the Yamaha di-
agnostic tool.
* Although this diagnostic code number is displayed, the device will not be actuated because the vehi-
cle is not equipped with this device.
9-16
EVENT CODE TABLE
EAS20164
EVENT CODE TABLE

No. Item Symptom Possible cause Remarks
30 Latch up detected Latch up detected • Vehicle has over- Perform the checks
turned and maintenance jobs
• Improperly installed for event code number
sensor 30.
• Sensor malfunction
• Defective ECU
70 Engine idling stop Engine is forcefully This is not a malfunc- Activation of the en-
stopped because it tion. gine idling stop control
was left idling for a is not a system mal-
long time function.
192 Intake air pressure Brief abnormality de- Same as for fault code Perform the checks
sensor tected in intake air number P0107 and and maintenance jobs
pressure sensor P0108 for fault code number
P0107 and P0108.
193 Throttle position sen- Brief abnormality de- Same as for fault code Perform the checks
sor tected in throttle posi- number P0122, and maintenance jobs
tion sensor P0123, P0222 and for fault code number
P0223 P0122, P0123, P0222
and P0223.
194 EXUP servo motor cir- Brief abnormality de- Same as for fault code Perform the checks
cuit tected in EXUP servo number P048D and and maintenance jobs
motor circuit P048E for fault code number
P048D and P048E.
196 Coolant temperature Brief abnormality de- Same as for fault code Perform the checks
sensor tected in coolant tem- number P0117 and and maintenance jobs
perature sensor P0118 for fault code number
P0117 and P0118.
197 Intake air temperature Brief abnormality de- Same as for fault code Perform the checks
sensor tected in intake air number P0112 and and maintenance jobs
temperature sensor P0113 for fault code number
P0112 and P0113.
198 Atmospheric pressure Brief abnormality de- Same as for fault code Perform the checks
sensor tected in atmospheric number P2228 and and maintenance jobs
pressure sensor P2229 for fault code number
P2228 and P2229.
203 Lean angle sensor Brief abnormality de- Same as for fault code Perform the checks
tected in lean angle number P1604 and and maintenance jobs
sensor P1605 for fault code number
P1604 and P1605.
207 Accelerator position Brief abnormality de- Same as for fault code Perform the checks
sensor tected in the accelera- number P2122, and maintenance jobs
tor position sensor P2123, P2127 and for fault code number
P2128 P2122, P2123, P2127
and P2128.
220 Gear position sensor Brief abnormality de- Same as for fault code Perform the checks
tected in the gear posi- number P0916 and and maintenance jobs
tion sensor P0917 for fault code number
P0916 and P0917.
9-17
EVENT CODE TABLE

240 O2 sensor Correction value re- • Open or short circuit • If a fault code is indi-
(Correction value remains at upper limit in the wire harness cated, perform the
mains at upper limit) during O2 feedback between the sensor checks and mainte-
and the ECU nance jobs for the
• Low fuel pressure fault code first.
• Clogged fuel injector * Event code number
• Sensor malfunction 240 may be indicated
• Defective ECU even if the system is
• Defective fuel injec- normal.
tion system
241 O2 sensor Correction value re- • Open or short circuit • If a fault code is indi-
(Correction value remains at lower limit in the wire harness cated, perform the
mains at lower limit) during O2 feedback between the sensor checks and mainte-
and the ECU nance jobs for the
• Low fuel pressure fault code first.
• Clogged fuel injector * Event code number
• Sensor malfunction 241 may be indicated
• Defective ECU even if the system is
• Defective fuel injec- normal.
tion system
242 ISC (idle speed con- Correction value re- Low engine idling • Execute the diagnos-
trol) mains at upper limit speed tic mode (diagnostic
(Correction value re- while the engine is • Clogged throttle body code number 67) and
mains at upper limit) idling • Improperly adjusted check the ISC main-
throttle cable tenance require-
• Improperly adjusted ments.
clutch cable • If a fault code is indi-
• Defective fuel injec- cated, perform the
tion system checks and mainte-
• Dirty or worn spark nance jobs for the
plug fault code first.
• Defective battery * Event code number
• Defective ECU 242 may be indicated
even if the system is
normal.
243 ISC (idle speed con- Correction value re- High engine idling • If a fault code is indi-
trol) mains at lower limit speed cated, perform the
(Correction value re- while the engine is • Improperly adjusted checks and mainte-
mains at lower limit) idling throttle cable nance jobs for the
• Improperly adjusted fault code first.
clutch cable * Event code number
• Defective fuel injec- 243 may be indicated
tion system even if the system is
• Dirty or worn spark normal.
plug
• Defective battery
• Defective ECU
244 Difficult/unable to start Engine starting diffi- • Empty fuel tank • If a fault code is indi-
engine cult/unable condition • Defective fuel injec- cated, perform the
detected tion system checks and mainte-
• Dirty or worn spark nance jobs for the
plug fault code first.
• Defective battery * Event code number
• Defective ECU 244 may be indicated
even if the system is
normal.
9-18
EVENT CODE TABLE

245 Engine stall Engine stall detected • Empty fuel tank • If a fault code is indi-
• Improperly adjusted cated, perform the
throttle cable checks and mainte-
• Improperly adjusted nance jobs for the
clutch cable fault code first.
• Defective fuel injec- * Event code number
tion system 245 may be indicated
• Dirty or worn spark even if the system is
plug normal.
• Defective battery
• Defective ECU
9-19
EVENT CODE TABLE
9-20
EAS20091
57. Secondary injector #3 EAS30613
WIRING DIAGRAM 58. Secondary injector #4 COLOR CODE

YZFR6H/YZFR6HC 2017 59. Accelerator position sensor B Black
1. AC magneto 60. Throttle position sensor Dg Dark green
2. Rectifier/regulator 61. Intake funnel servo motor Db Dark blue
3. Main switch 62. Throttle servo motor Gy Gray
4. Main fuse 63. ABS ECU L Blue
5. Battery 64. Front wheel sensor W White
65. Rear wheel sensor Br Brown
6. Engine ground
66. Yamaha diagnostic tool coupler Ch Chocolate
7. Fuel injection system fuse
G Green
8. ABS ECU fuse 67. Shift switch (OPTION)
O Orange
9. Terminal fuse (for optional 68. Fuel pump
P Pink
equipment) 69. Fuel sender
R Red
10. Electronic throttle valve fuse 70. Meter assembly Sb Sky blue
11. Backup fuse 71. Fuel level warning light V Violet
12. ABS solenoid fuse 72. Oil level warning light Y Yellow
13. Turn signal light fuse 73. Neutral indicator light B/G Black/Green
14. Headlight fuse 74. Shift light B/L Black/Blue
15. Ignition fuse 75. Multi-function meter B/R Black/Red
16. Signaling system fuse 76. Traction control system indica- B/W Black/White
17. Radiator fan motor fuse (right) tor light B/Y Black/Yellow
18. Radiator fan motor fuse (left) 77. Coolant temperature warning Br/B Brown/Black
19. ABS motor fuse light Br/L Brown/Blue
20. Starter relay 78. Engine trouble warning light Br/R Brown/Red
21. Starter motor 79. High beam indicator light Br/W Brown/White
22. Auxiliary light 80. Turn signal indicator light Br/Y Brown/Yellow
23. Front brake light switch 81. Meter light G/B Green/Black
24. Handlebar switch (right) 82. ABS warning light G/L Green/Blue
25. Engine stop switch 83. Oil level switch G/O Green/Orange
26. Start switch 84. Handlebar switch (left) G/W Green/White
85. Traction control system switch G/Y Green/Yellow
27. D-Mode switch
86. Pass switch Gy/B Gray/Black
28. Relay unit
Gy/G Gray/Green
29. Starting circuit cut-off relay 87. Dimmer switch
Gy/R Gray/Red
30. Fuel pump relay 88. Horn switch
L/B Blue/Black
31. Joint coupler 89. Turn signal switch
L/R Blue/Red
32. Neutral switch 90. Clutch switch L/W Blue/White
33. Sidestand switch 91. Horn L/Y Blue/Yellow
34. Cylinder identification sensor 92. Rear turn signal light (right) Lg/L Light green/Blue
35. Gear position sensor 93. Rear turn signal light (left) Lg/R Light green/Red
36. Lean angle sensor 94. Front turn signal/position light Lg/W Light green/White
37. Intake air pressure sensor (right) O/B Orange/Black
38. Atmospheric pressure sensor 95. Front turn signal/position light O/G Orange/Green
39. Intake air temperature sensor (left) P/B Pink/Black
40. O2 sensor 96. Headlight assembly P/L Pink/Blue
41. Crankshaft position sensor 97. Rear brake light switch P/W Pink/White
42. Coolant temperature sensor 98. Tail/brake light assembly R/B Red/Black
43. EXUP servo motor 99. License plate light R/G Red/Green
44. ECU (Engine Control Unit) 100.Radiator fan motor (right) R/L Red/Blue
45. Spark plug 101.Radiator fan motor (left) R/W Red/White
102.Auxiliary DC jack (OPTION) R/Y Red/Yellow
46. Ignition coil #1
103.Radiator fan motor relay Sb/W Sky blue/White
47. Ignition coil #2
A. Wire harness W/B White/Black
48. Ignition coil #3 W/G White/Green
49. Ignition coil #4 B. Sub-wire harness (ignition)
C. Sub-wire harness (secondary W/L White/Blue
50. Air induction system solenoid W/R White/Red
51. Primary injector #1 injector)
W/Y White/Yellow
52. Primary injector #2 Y/B Yellow/Black
53. Primary injector #3 Y/G Yellow/Green
54. Primary injector #4 Y/L Yellow/Blue
55. Secondary injector #1 Y/R Yellow/Red
56. Secondary injector #2 Y/W Yellow/White
YZFR6H/YZFR6HC 2017 WIRING DIAGRAM
WW
WWW WWW
B WR
(Dg) R R
1
W
W
W
W 2 R 4 R
R/W L/W
W W R R R R (B) R/L R/L R/L R/L R/L R/L
R R/L R/L R/L
R R R R R/B R/B
R/B R/B R/B
B R R/B
46 O R/B
R R 19 R/B
R/B
R/B
O (B)
L/W L/W R/B Sb/W Br/W R/G
R R R/W B/R R/G 28 L/W L/W
L /W 45
R
5 20 R/G
R/L
R/G R/G
29 31
W 3 L/W
30 L/W L/W L/W L/W L /W
R/B
R,W ON
L/Y L/B L/B L/Y
B
Br/W L/W R/B L R/L
L/W L/W
Gy/G O/G Gy/R O P/B L L 47 Gy/R R/B
OFF B B R/W R/W R/W R/W R/W Y/R R/W R/G Gy B/G G P/W Y/G W/G Lg/W Gy/R
Br/L B/Y B/Y B O/B L/B G/B R/B Br/R W W (B)
Br/R Br/R
R/W R/W R/W Lg/R W W/B L/R B/R P G/W P/L B/Y Lg/L
R/W L B/Y Sb L /Y L /B L /W 31 B Br/B Br/Y Sb/W W/L G/Y B B
45
R
Br/L
Br/L Br/R L /B
L /Y
21 R/L B/Y B/Y B/Y
R/L B/W B/L L Gy/B W/Y W/R Br/W Gy/G Y/W L/W L/Y V B/W R/L Y/L Sb L/W Y/B
(B)
B/L B/L
B/Y
(B) L /Y
R/B
B/Y
W /G
48 O/G R/B
R/W O/G (B)

B B B B/W
B
L /B 31 35 45
W W
L /Y L /Y
6 Sb 33 B
L/R G W
G G
R/B
(Db)
L /R L /R
49 Gy/G R/B
Br Br L/B B B B L/Y L/Y R/B A R/B Gy/G (B)

Br Br (B) 34 O O
Gy/R
A O
45
Br
23 32 (B)
L/Y L L A L
L L L L L L
L
Gy/R
O/G
Gy/G
O/G
Gy/G
A
A
A
Gy/R
O/G
Gy/G
Br B W W /B W /B A W /B W /B
Br/R R/W
7 Br
B/Y
Br
Br 24 R/W R/B L W /G
B/L B/L B/L A B/L R/L
R Br/W
B/R B/Y L /Y
W L/Y L W/B 50 (L)
Br/L 8 25 26 Br Br Y Br L /B B/L B/L
G
36 G
L
Br/R Br/R A Br/R Br/R R/W R/W A R/W
Br/L
Br/L R/B
22 27 FREE
L /Y
(B) (B)
L Y/G B/L B/L
R/L R/B
PUSH B R/W R/B R/B R/W B
9 Br B/W W/G B/W L L B W/G R/L G/W
Y/G Y/G
51 (Gy)
Br/Y B/L
B/L R/B R/B R/L
10
B B/Y B/Y B
Br Y B B B/L 37 R/L G/B
R/L
B/R B/R
68 69
B/L
B/L B/L P/W L
L
B/L
52 (Gy)
R/L B G/W B/W B/L G/B G/B R/L
11 83 (B)
B/L
B/L
(Db) P/W P/W
W G/L
R R/G B/L R/L L/B
R/G
B
W G/L
B/L
38 L
53
12 (B) (B)
B B/W B/L P L
B/L L /B L /B R/L
(Gy)
L /W P P R/L O/B
(Db)
R
54 (Gy)
O/B O/B R/L
R/W
13
Br/R L /R
103 70 Br/W B/L 39 Br/W Br/W
55
R/L W/L
14 R/Y
84 Y/B Br B/Y L /Y L /R L/Y B/Y 71 B/L
44 W/L W/L B W/L W /L R/L
(Gy)
R/L R/L R/L B R/L
R/Y (B)
Sb/W Sb/W B Sb/W
P Br/Y Br/Y B Br/Y
15 B/Y B/Y B/Y
72 40 Br/B Br/B B Br/B R/L Sb/W R/L R/L
Br/L R/W 85 86 87 88 89 R/L B B P/B P/B 56 (Gy)
R/L
UP R/L Br/Y Sb /W R/L

R/B
G/Y R 16 (N)
Y L/R P/L Y/B Y/W 73 B/L W L Gy/G Gy/G 57 (Gy)
Br DOWN R/W Sb/W
R/B B P B/W W/B W/Y Br/Y R/L
Br Br
R/L P/B
R/W G/Y
17 (B)
74 Gy/G B/L
B B
W L R/L Br/B
R/B L
B/W Y B W /B W /Y
Y/W Y/B P/L L/R Y
(B) (B) 58 (Gy)
18 P/L Y/W Y
90 W/Y W/B B/W Br B B Gy
Br/B R/L
L /W
31 91 41
Y Y Y (B) B/L L L
Gy
Gy B/L Gy B
Y Y Gy B B
L /W L
75 W W W B/L L B
G
G/W
R/G G/WB/L 42 G/W G/W
B/L B/L
59 (B)
B B B B R/G B/L
L/ W G 101 L L 100 Br
Y
Y/B Y/B Lg/L
Lg/W
(B) L L
Y/B B/L
(B) (B) (B) (B)
97 Y Y 31 G/L
B B
B B
Br Y Y Br 76 L
43
W /R
B/G W W B/L W L B
B (B) (B) Y
B/L B/R
B/L B/L
60 (B)
B B
Y Y/B Y/B Y/B
77 L W/R B/L
W /Y
W /B
31 Lg/L Lg/L Lg/L Lg/L B/G B/R
Y/L
Sb
Y/L
Sb
R
B 61 R B Sb Y/L
B Br/Y
Br/Y 78 L g /L L g /L (B)
(Gy)
102 B
Br Y L g /L
L g /L Gy/B G Y L R/B B Lg/L
Lg/R Lg/R L/W B/W
98 Br/R
W /R
B/G
Y/R Y/R 62 Y/R Lg/R
R B
Br (B) G/O W/Y L B W W Lg/W
G B/R
Ch
Dg 79 31 Lg/W Lg/W Lg/W Lg/W Y/B
B R/Y Y Lg/W Lg/W

Lg/W
67 B Y V B
G/Y
P/L
(B)
Br G
99 B B R/Y Y/B Br Br/R
B B
Ch B
Dg B
80 Lg/W
(Gy) (Gy) Y/W G
L
R
L /W
B Y V V
Br/R Br G Br Ch Dg R/B
(Gy) (B) (B)
Gy/B
B
96 Br L /R Br L/R L /R G L/R Br G Y 81 B/W L g /L
Lg/L W /Y W
B Br BG
L g /W
Lg/L Lg/W Lg/W
63 B B/W
B
B B
(B) (W) B/W 66 R/G B/W Gy/B
L g /L
L g /W W
64
B
B/W
B Y Br
B
(Gy) (B)
82 R/G G/O
Y
B
B/W
G/O W
(B)
95 94 93 92 B B
W/Y L B W B B/W
B B B B B/W B
R/Y B Y/B Y B R/Y B/W B W
B/W B/W B/W B B
A (B) B/W
B/W B/W B/W B
B B
O/G R/B O Gy/R Gy/G Gy/G Gy/R O R/B O/G
B/W R/W G Br/R Dg Ch W/B W/Y
Lg/L Lg/W G/W R/G R/G Sb/W G/L G/O Y
B 65
W W B
L Br/R W/B R/W B/L B/L R/W W/B Br/R L B
(Gy)
(B)
(B) B W
A B B B B B B B B B B B B B B
W/L Br/Y R/L R/L Br/Y W/L
Sb/W Br/B Br/B Sb/W
A C
YZFR6H/YZFR6HC 2017 WIRING DIAGRAM
(Dg)
1 2 4
(B)
46
19 (B)
28 45
5 20
29 31
3 30
ON 47
OFF
(B)
31 45
21 (B)
(B)
48
(B)
31 35 45
6 33
(Db)
49
A (B)
(B) 34 A
45
23 32 (B)
A
A
A
A
A
7 24
A
50 (L)
8 25 26 36 A A
22 27 FREE (B) (B)

PUSH
9 51 (Gy)
10 37
68 69 52 (Gy)
11 83 (B)
(Db)
38 53
12 (B) (B)
(Gy)
(Db)
54 (Gy)
13
103 70 39 55
14 84 71 44 B
(Gy)
B
(B) B
B
15 72 40 B
85 86 87 88 89 56 (Gy)
UP
16 (N) 73 57 (Gy)
DOWN
17 (B)
74
(B) (B) 58 (Gy)
18 90
31 91 41
(B)
75
42 59 (B)
101 100 (B)
(B) (B) (B) (B)

97 31
76 43
(B) (B) 60 (B)
77
31 61
78 (B)
(Gy)
102
98 62
(B)
79 31
67 (B)
99 80
(Gy) (Gy)
(Gy) (B) (B)

96 81 63
(B) (W) 66 64
(Gy) (B)
82
(B)
95 94 93 92
A (B)
65
(Gy)
(B)
(B)
A B
B
A C

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2017

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could result

A NOTICE indicates special precautions that must be taken to avoid damage to

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

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

SPECIAL TOOLS ............................................................................................ 1-8

VEHICLE IDENTIFICATION NUMBER

INSTRUMENT FUNCTIONS Speedometer

[To set the clock:] [To use the lap timer]

[To view the lap time history]

1. Lap number/Fastest rank

Transmission gear display

Air intake temperature display

1. Drive mode display

1. Air intake temperature display

TCS display Odometer and tripmeters

TRIP F → km/L, L/100 km or MPG → AVE _ _

Navigating the multi-function display

• “km/L”: The distance that can be traveled on Total fuel used

1. Average fuel consumption display

[To set the shift light deactivation point]

[To set the shift light activation point]

Yamaha diagnostic tool (A/I) 3-4, 4-62, 4-63,

Thickness gauge 3-6, 4-22, 4-32,

Valve lapper 90890-04101

Vacuum gauge 3-10

Oil filter wrench 3-26

Oil pressure gauge set 3-28

Oil pressure adapter H 3-28

Hexagon wrench (41) 4-28, 4-29

Hydraulic unit holding tool 4-59, 4-60

Fork spring compressor 4-74, 4-80

Rod holder 4-74, 4-80

Damper rod holder (ø30) 4-75, 4-77

Rod puller 4-78, 4-80

Rod puller attachment (M10) 4-78, 4-80

Ring nut wrench 4-84

Ring nut wrench 4-92, 4-94

Drive chain cut & rivet tool 4-97

Compression gauge 90890-03081 5-8

Valve spring compressor 5-30, 5-35

Valve spring compressor attachment 5-30, 5-35

Valve guide remover (ø4.5) 5-32

Valve guide reamer (ø4.5) 5-32

Rotor holding tool 5-37, 5-38, 5-40,