2021

SERVICE MANUAL

AEROX 155

GDR155-A
BJG-F8197-E0
EAS20003

IMPORTANT
This manual was produced by the PT Yamaha Indonesia Motor Manufacturing primarily for use by
Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a me-
chanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on
Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these
types of vehicles. Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic
instructions that must be observed during servicing. Repair and maintenance work attempted by any-
one without this knowledge is likely to render the vehicle unsafe and unfit for use.
PT Yamaha Indonesia Motor Manufacturing is continually striving to improve all of its models. Modifi-
cations and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
TIP
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• Designs and specifications are subject to change without notice.

EAS30001

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could result

WARNING in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to

NOTICE the vehicle or other property.

TIP A TIP provides key information to make procedures easier or clearer.

EAS20002

GDR155-A
SERVICE MANUAL
©2021 by PT Yamaha Indonesia Motor Manufacturing
First edition, April 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
PT Yamaha Indonesia Motor Manufacturing
is expressly prohibited.
EAS20004

HOW TO USE THIS MANUAL

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

CYLINDER AND PISTON CYLINDER AND PISTON

EAS20046 EAS30289

CYLINDER AND PISTON REMOVING THE PISTON

1. Remove:
Removing the cylinder and piston • Piston pin clips “1”
• Piston pin “2”
• Piston “3”
ECA13810

NOTICE
Do not use a hammer to drive the piston pin
out.

TIP EAS30291

• Before removing the piston pin clips, cover the CHECKING THE CYLINDER AND PISTON
crankcase opening with a clean rag to prevent 1. Check:
them from falling into the crankcase. • Piston wall
• Before removing the piston pin, deburr the pis- • Cylinder wall
ton pin clip groove and the piston pin bore ar- Vertical scratches → Rebore or replace the
ea. If both areas are deburred and the piston cylinder, and replace the piston and piston
pin is still difficult to remove, remove it with the rings as a set.
piston pin puller set “4”. 2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
Piston pin puller set bore gauge.
90890-01304
TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.

Bore
52.000–52.010 mm (2.0472–
2.0476 in)
Wear limit
52.060 mm (2.0496 in)

“C” = maximum of D1 - D2

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-10.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2 2. Remove:
• Top ring
6 Piston pin 1 b. If out of specification, rebore or replace the
• 2nd ring
7 Piston 1
• Oil ring cylinder, and replace the piston and piston
8 Top ring 1 rings as a set.
TIP
9 2nd ring 1 c. Measure piston skirt diameter P with the mi-
When removing a piston ring, open the end gap crometer.
10 Oil ring 1 with your fingers and lift the other side of the ring
11 Coolant drain bolt (cylinder side) 1 over the piston crown.

5-30 5-31
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
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
SELF DIAGNOSTIC 9
 GENERAL INFORMATION

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

FEATURES .....................................................................................................1-2
1
MULTI-FUNCTION METER UNIT ............................................................1-2

SPECIAL TOOLS ...........................................................................................1-7

 IDENTIFICATION

EAS20007

IDENTIFICATION
EAS30002

VEHICLE IDENTIFICATION NUMBER

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

EAS30004

ENGINE SERIAL NUMBER

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

1-1
 FEATURES

EAS20008 EAUN2860

FEATURES Yamaha Motorcycle Connect icon

This icon comes on when CCU and smartphone
EAUV0980 is connected via Yamaha Motorcycle Connect.
MULTI-FUNCTION METER UNIT
TIP
10 9 8
Even if the smartphone is not connected, when
the vehicle is turned on, this icon should come
on for a few seconds. Otherwise have a Yamaha
dealer check the CCU and the electrical circuit.

EAUN2871

Smartphone battery level meter

123 4 5 67 This meter indicates the current battery level of
1. Incoming call indicator light “ ” the connected smartphone. The display seg-
2. Notification indicator light “ ” ment of the meter disappears from full to blank
3. Tachometer as the battery level decreases. When approxi-
4. Multi-function display mately 10% or less of the battery remains, the
5. Fuel meter last segment start flashing.
6. Smartphone battery level meter
TIP
7. Yamaha Motorcycle Connect icon
8. VVA (variable valve actuation) indicator Even if the smartphone is not connected, when
9. Clock the vehicle is turned on, this icon should come
10.Speedometer on for a few seconds. Otherwise have a Yamaha
EWA12423
dealer check the CCU and the electrical circuit.
WARNING
EAUN3000
Be sure to stop the vehicle before making Switching the display units
any setting changes to the multi-function The display units can be switched between kilo-
meter unit. Changing settings while riding meters and miles.
can distract the operator and increase the
risk of an accident. To switch the display units
The “MENU” switch is located on the left side of 1. Turn the vehicle off.
handlebar. This switch allows you to control or 2. While pushing the “MENU” switch, turn the
change the settings of multi-function meter unit. vehicle on.
3. Continue to push the “MENU” switch until
the display unit setting screen comes on
1 (approximately 5 seconds).
4. Push the “MENU” switch once to switch the
display units.
5. Push the “MENU” switch for 1 second to
confirm the setting.

1. “MENU” switch

TIP
Be sure to turn the main switch on before using
the “MENU” switch.

1-2
 FEATURES

EAU86831

Speedometer TIP
1 If a problem is detected in the electrical circuit,
the fuel level segments will flash repeatedly. If
this occurs, have a Yamaha dealer check the
vehicle.

EAU86851

Clock
1
1. Speedometer
The speedometer shows the vehicle’s traveling
speed.
EAU87190

Tachometer

1. Clock
The clock uses a 12-hour time system.

To set the clock

1. Push the “MENU” switch until the hour dig-
its start flashing.
1 2. Use the “MENU” switch to set the hours.
1. Tachometer 3. Push the “MENU” switch until the minute
digits start flashing.
The tachometer allows the rider to monitor the
4. Use the “MENU” switch to set the minutes.
engine speed and keep it within the ideal power
5. Push the “MENU” switch until the minute
range.
digits stop flashing. The setting is con-
EAU86841 firmed.
Fuel meter
EAU86870

VVA indicator
1

1
1. Fuel meter
The fuel meter indicates the amount of fuel in 1. VVA (variable valve actuation) indicator
the fuel tank. The display segments of the fuel
This model is equipped with variable valve actu-
meter disappear from “F” (full) towards “E”
ation (VVA) for good fuel economy and acceler-
(empty) as the fuel level decreases. When ap-
ation in both the low-speed and high-speed
proximately 1.1 L (0.29 US gal, 0.24 Imp.gal) of
ranges. The VVA indicator comes on when the
fuel remains, the last segment starts flashing.
variable valve actuation system has switched to
Refuel as soon as possible.
the high-speed range.

1-3
 FEATURES

To turn the VVA indicator on or off TIP

1. Turn the vehicle off.
2. While pushing the “MENU” switch, turn the • The fuel reserve tripmeter appears only when
vehicle on. you are low on fuel.
3. Continue pushing the “MENU” switch. The • The oil change tripmeter, V-belt replacement
display unit setting screen will come on (af- tripmeter, and backlight dimmer can not be dis-
ter 5 seconds), and after that (an additional played while the vehicle is moving.
10 seconds) all segments other than the
VVA indicator will start flashing. Now re- EAU86890

Odometer
lease the “MENU” switch.
4. Push the “MENU” switch once to change
the on or off setting.
5. Push the “MENU” switch for 1 second to
confirm the setting.
TIP
Turning the VVA indicator off does not turn off
the variable valve actuation system. 1
1. Odometer
EAUV1011

Multi-function display The odometer shows the total distance traveled

by the vehicle.
TIP
The odometer will lock at 999999 and cannot be
reset.

EAU86900

Tripmeters
1
1. Multi-function display
The multi-function display is equipped with the
following:
• an odometer (ODO)
• two tripmeters (TRIP 1 and TRIP 2)
• a fuel reserve tripmeter (TRIP F)
• an instantaneous fuel consumption display (F/ 1
ECO) 1. Tripmeter
• an average fuel consumption display (AVE F/ The tripmeters show the distance traveled since
ECO) they were last reset.
• a battery voltage display (BATT) To reset a tripmeter, set the display to the trip-
• an oil change tripmeter (OIL TRIP) meter you want to reset, and then push the
• a V-belt replacement tripmeter (V-BELT TRIP) “MENU” switch until it is reset.
• a backlight dimmer (bL_02) TIP
Push the “MENU” switch to change the display The tripmeters will reset and continue counting
in the following order: after 9999.9 is reached.

ODO → TRIP 1 → TRIP 2 → TRIP F → F/ECO

→ AVE F/ECO → BATT → OIL TRIP → V-BELT
TRIP → bL_2 → ODO

1-4
 FEATURES

EAU86910

Fuel reserve tripmeter TIP

When the engine oil has been changed, the oil
change tripmeter and the oil change indicator
must be reset. Otherwise, the oil change indica-
tor will not come on at the correct time.

EAU86930

V-belt replacement tripmeter

1 1
1. Fuel reserve tripmeter
If the last segment of the fuel meter starts flash-
ing, the display automatically changes to the
fuel reserve tripmeter “TRIP F” and starts count-
ing the distance traveled from that point.
To reset the fuel reserve tripmeter, push the
“MENU” switch until it is reset. 2
1. V-belt replacement indicator “V-BELT”
TIP 2. V-belt replacement tripmeter
If you do not reset the fuel reserve tripmeter manual-
This tripmeter shows the distance traveled
ly, it will reset automatically and disappear from the
display after refueling and traveling 5 km (3 mi). since the V-belt was last replaced. The V-belt
replacement indicator “V-BELT” will flash every
EAU86920
25000 km (15500 mi) to indicate that the V-belt
Oil change tripmeter should be replaced.
1 To reset both the tripmeter and the indicator,
select the V-belt replacement tripmeter, and
then push the “MENU” switch until “V-BELT”
and the tripmeter start flashing. While “V-BELT”
and the tripmeter are flashing, push the
“MENU” switch until the tripmeter is reset.
TIP
2
1. Oil change indicator “OIL” When the V-belt is replaced, the tripmeter and
2. Oil change tripmeter indicator must be reset. Otherwise, the V-belt
replacement indicator will not come on at the
This tripmeter shows the distance traveled correct time.
since the last engine oil change. The oil change
indicator “OIL” will flash at the initial 1000 km EAUV1030

(600 mi), the next 3000 km (1800 mi), and then Instantaneous fuel consumption display
every PT Yamaha Indonesia Motor Manufactur-
ing thereafter.
To reset the oil change tripmeter and oil change
indicator, select the oil change tripmeter, and
then push the “MENU” switch until “OIL” and
the tripmeter start flashing. While “OIL” and the
tripmeter are flashing, push the “MENU” switch
until the tripmeter is reset. 1
1. Instantaneous fuel consumption display

1-5
 FEATURES

This display shows fuel consumption under cur- This display shows the current charge state of
rent riding conditions. It can be set to either the battery.
“km/L” or “L/100 km”. • Over 12.8 V = Full charge.
• “km/L”: the distance that can be traveled on 1.0 • Under 12.7 V = Charging is required.
L of fuel. TIP
• “L/100 km”: the amount of fuel necessary to
If the battery voltage is less than 9.0 V, “_ _._” is
travel 100 km.
displayed.
TIP
When traveling under 10 km/h, “_ _._” is dis- EAUV1050

played. Backlight dimmer

EAUV1040

Average fuel consumption display

1
1. Backlight dimmer
This function allows you to dim or brighten the
1 display.
1. Average fuel consumption display
This display shows the average fuel consump- To access the backlight dimmer function
tion since it was last reset. The average fuel 1. Make sure the vehicle is completely
consumption display can be set to either “km/L” stopped.
or “L/100 km”. 2. Use the “MENU” switch to cycle through
• “km/L”: the average distance that can be trav- the menu until the current backlight level
eled on 1.0 L of fuel. (bL_01, bL_02, or bL_03) is displayed.
• “L/100 km”: the average amount of fuel neces- 3. Push the “MENU” switch until the figures
sary to travel 100 km. (bL_01, bL_02, or bL_03) flash.
4. Use the “MENU” switch to select the de-
TIP
sired backlight level.
• To reset the display, push the “MENU” switch 5. Push the “MENU” switch to confirm the
until it resets. chosen backlight level and the figure stops
• After resetting, “_ _._” is shown until the vehicle flashing.
has traveled some distance.

EAU86960

Battery voltage display

1
1. Battery voltage meter

1-6
 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.
Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB 3-4, 3-8, 4-56,
90890-03267 4-57, 7-15, 7-16,
9-3, 9-20, 9-21

Yamaha diagnostic tool (A/I) 3-4, 3-8, 4-56,

90890-03264 4-57, 7-15, 7-16,
9-3, 9-20, 9-21

Tappet adjusting tool 3-7

90890-01311

Steering nut wrench 3-15, 3-15, 4-73

90890-01403

Thickness gauge 4-32

90890-03180

T-handle 4-67, 4-68

90890-01326

Fork seal driver weight 4-68, 4-69

90890-01367

Fork seal driver attachment (ø30) 4-68, 4-69

90890-01400

1-7
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Compression gauge 90890-03081 5-2
90890-03081
Engine compression tester
YU-33223

YU-33223

Compression gauge extension 122mm 5-2

90890-04136
Compression gauge extension 122mm
YM-04136

Camshaft wrench 5-13, 5-17

90890-04162
Camshaft wrench
YM-04162

Yamaha bond No. 1215 5-16, 5-56

90890-85505
(Three bond No.1215®)

Slide hammer bolt (M8) 5-19

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

Weight 5-19
90890-01084
Weight
YU-01083-3

YU-01083-3

Valve spring compressor 5-23, 5-27

90890-04019
Valve spring compressor
YM-04019

1-8
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Valve spring compressor attachment 5-23, 5-27
90890-04108
Valve spring compressor adapter 22 mm
YM-04108

Valve guide remover (ø5) 5-24

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

Valve guide installer (ø5) 5-24

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

Valve guide reamer (ø5) 5-24

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

Piston pin puller set 5-29

90890-01304
Piston pin puller
YU-01304

YU-01304

Rotor holding tool (including handle and 3 5-37, 5-42, 5-44,

pins) 5-44
90890-04195

Rotor holding tool attachment 7 x 12 mm 5-37, 5-42

90890-04197

ø7 12

Rotor holding tool 5-37, 5-37, 5-40,

90890-04166 5-41
Rotor holding tool
YM-04166

1-9
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Socket wrench (39 mm) 5-37, 5-40
90890-01493

Sheave spring compressor 5-37, 5-40

90890-04134
Sheave spring compressor
YM-04134

Sheave fixed block 5-37, 5-40

90890-04135
Sheave fixed bracket
YM-04135

Oil seal guide (37 mm) 5-40

90890-04177

ø37
Rotor holding tool attachment 7 x 5 mm 5-44, 5-44
90890-04198

ø7 5

Flywheel puller 5-44

90890-01189
Flywheel puller
YM-01189

1-10
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Crankcase separating tool 5-55
90890-01135
Crankcase separator
YU-01135-B

Crankshaft installer pot 5-56

90890-01274
Installing pot
YU-90058

YU-90058/YU-90059

Crankshaft installer bolt 5-56

90890-01275
Bolt
YU-90060

Adapter (M12) 5-56

90890-01278
Adapter #3
YU-90063

Spacer (crankshaft installer) 5-56

90890-04081
Pot spacer
YM-91044

YM-91044

1-11
 SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration
pages
Radiator cap tester 6-4, 6-4
90890-01325
Mityvac cooling system tester kit
YU-24460-A

YU-24460-A

Radiator cap tester adapter 31mm 6-4

90890-05375
Radiator cap tester adapter 31mm
YM-05375

Mechanical seal installer 6-10

90890-04145 ø30

ø10

Middle driven shaft bearing driver 6-10

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

Pressure gauge 7-5

90890-03153
Pressure gauge
YU-03153

Fuel pressure adapter 6.3mm 7-5

90890-03227

Digital circuit tester (CD732) 8-37, 8-38, 8-39,

90890-03243 8-39, 8-40, 8-40,
Model 88 Multimeter with tachometer 8-41, 8-41, 8-42,
YU-A1927 8-42, 8-43, 8-43,
8-43, 8-44, 8-44

Ignition checker 8-40

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

1-12
 SPECIAL TOOLS

1-13
 SPECIFICATIONS

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

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

CHASSIS SPECIFICATIONS .........................................................................2-6

ELECTRICAL SPECIFICATIONS ..................................................................2-8

TIGHTENING TORQUES ............................................................................. 2-10

2
ENGINE TIGHTENING TORQUES ........................................................ 2-10
CHASSIS TIGHTENING TORQUES ...................................................... 2-11

CABLE ROUTING ........................................................................................ 2-13

 GENERAL SPECIFICATIONS

EAS20013

GENERAL SPECIFICATIONS

Model
Model BJG1

Dimensions
Overall length 1980 mm (78.0 in)
Overall width 700 mm (27.6 in)
Overall height 1150 mm (45.3 in)
Wheelbase 1350 mm (53.1 in)
Ground clearance 143 mm (5.63 in)
Minimum turning radius 2.0 m (6.56 ft)

Weight
Curb weight 124 kg (273 lb)

Loading
Maximum load 153 kg (337 lb)
Riding capacity 2 persons

2-1
 ENGINE SPECIFICATIONS

EAS20014

ENGINE SPECIFICATIONS

Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train SOHC
Displacement 155.09 cm³
Number of cylinders Single cylinder
Bore × stroke 58.0 × 58.7 mm (2.28 × 2.31 in)
Number of cylinders Single cylinder
Compression ratio 11.6 : 1
Compression pressure 1783–2296 kPa/1050 r/min (17.8–23.0 kgf/cm²/
1050 r/min, 253.7–326.6 psi/1050 r/min)
Starting system Electric starter

Fuel
Recommended fuel Regular unleaded gasoline (E10 acceptable)
Fuel tank capacity 5.5 L (1.5 US gal, 1.2 Imp.gal)
Fuel reserve amount 1.1 L (0.29 US gal, 0.24 Imp.gal)

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

Final transmission oil

Type Motor oil SAE 10W-40 type SG or higher
Quantity (disassembled) 0.11 L (0.12 US qt, 0.10 Imp.qt)
Quantity 0.10 L (0.11 US qt, 0.09 Imp.qt)

Oil filter
Oil filter type Centrifugal

Cooling system
Coolant quantity
Radiator (including all routes) 0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.13 L (0.14 US qt, 0.11 Imp.qt)
Radiator cap valve opening pressure 78.6–137.4 kPa (0.78–1.37 kgf/cm², 11.4–19.9
psi)
Cooling system leak test pressure 137.4 kPa (1.37 kgf/cm², 19.9 psi)

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

2-2
 ENGINE SPECIFICATIONS

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

Cylinder head
Warpage limit 0.05 mm (0.0020 in)

Camshaft
Camshaft lobe dimensions
Lobe height (Intake) 32.211–32.311 mm (1.2681–1.2721 in)
Limit 32.111 mm (1.2642 in)
Lobe height (Intake high speed) 32.587–32.687 mm (1.2830–1.2869 in)
Limit (Intake high speed) 32.487 mm (1.2790 in)
Lobe height (Exhaust) 29.420–29.520 mm (1.1583–1.1622 in)
Limit 29.320 mm (1.1543 in)
Camshaft runout limit 0.030 mm (0.0012 in)

Rocker arm/rocker arm shaft

Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in)
Limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in)
Limit 9.935 mm (0.3911 in)

Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve seat contact width (intake) 0.60–0.85 mm (0.0236–0.0335 in)
Limit 1.3 mm (0.05 in)
Valve seat contact width (exhaust) 0.90–1.20 mm (0.0354–0.0472 in)
Limit 1.7 mm (0.07 in)
Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)
Limit 4.945 mm (0.1947 in)
Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in)
Limit 4.930 mm (0.1941 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)

Valve spring
Free length (intake) 33.79 mm (1.33 in)
Limit 32.10 mm (1.26 in)
Free length (exhaust) 33.79 mm (1.33 in)
Limit 32.10 mm (1.26 in)

Cylinder
Bore 58.000–58.010 mm (2.2835–2.2839 in)

2-3
 ENGINE SPECIFICATIONS

Wear limit 58.060 mm (2.2858 in)

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

Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)

Crankshaft
Crank assembly width 51.45–51.50 mm (2.026–2.028 in)
Runout limit 0.030 mm (0.0012 in)

Clutch
Clutch type Dry, centrifugal, shoe

Automatic centrifugal clutch

Clutch shoe thickness 3.0 mm (0.12 in)
Limit 2.1 mm (0.08 in)
Clutch housing inside diameter 125.0 mm (4.92 in)
Limit 125.5 mm (4.94 in)
Compression spring free length 116.4 mm (4.58 in)
Limit 104.7 mm (4.12 in)
Weight outside diameter 20.0 mm (0.79 in)
Limit 19.5 mm (0.77 in)
Clutch-in revolution 2200–2600 r/min
Clutch-stall revolution 4800–5400 r/min

V-belt
V-belt width limit 21.6 mm (0.85 in)

Drivetrain
Transmission type V-belt automatic
Primary reduction ratio 1.000
Final drive Gear
Secondary reduction ratio 10.769 (56/16 × 40/13)
Transmission ratio 2.300–0.724 : 1

Air filter
Air filter element Oil-coated paper element

2-4
 ENGINE SPECIFICATIONS

V-belt filter element Wet element

Fuel injector
Resistance 12.2 Ω

Fuel pump
Pump type Electrical
Maximum consumption amperage 0.7 A

Throttle body
ID mark B651

Fuel injection sensor

Intake air temperature sensor resistance 5700–6300 Ω at 0 °C (5700–6300 Ω at 32 °F)
Atmospheric pressure sensor output voltage 3.88–4.12 V at 101.3 kPa
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)

Idling condition
Engine idling speed 1500–1700 r/min
O2 feedback control Active
Coolant temperature 85 °C (185 °F)
CO% 0.0–1.0 %
Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)

2-5
 CHASSIS SPECIFICATIONS

EAS20015

CHASSIS SPECIFICATIONS

Chassis
Frame type Backbone
Caster angle 26.5 °
Trail 100 mm (3.9 in)

Front wheel
Wheel type Cast wheel
Rim size 14M/C × MT2.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Wheel axle bending limit 0.25 mm (0.01 in)

Rear wheel
Wheel type Cast wheel
Rim size 14M/C × MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Wheel axle bending limit 0.25 mm (0.01 in)

Front tire
Type Tubeless
Size 110/80–14M/C 53P
Manufacturer/model IRC/SCT–005F

Rear tire
Type Tubeless
Size 140/70–14M/C 62P
Manufacturer/model IRC/SCT–005R

Tire air pressure (measured on cold tires)

1 person
Front 200 kPa (2.00 kgf/cm², 29 psi)
Rear 225 kPa (2.25 kgf/cm², 33 psi)
2 persons
Front 200 kPa (2.00 kgf/cm², 29 psi)
Rear 225 kPa (2.25 kgf/cm², 33 psi)

Front brake
Type Hydraulic single disc brake
Disc outside diameter × thickness 230.0 × 4.0 mm (9.06 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 0.8 mm (0.03 in)
Master cylinder inside diameter 11.00 mm (0.43 in)
Caliper cylinder inside diameter (Left) 33.34 mm (1.31 in)
Specified brake fluid DOT 4

2-6
 CHASSIS SPECIFICATIONS

Rear brake
Type Drum brake
Rear brake lever free play 10.0–20.0 mm (0.39–0.79 in)

Rear drum brake

Drum brake type Leading, trailing
Brake drum inside diameter 130.0 mm (5.12 in)
Limit 131.0 mm (5.16 in)
Lining thickness 4.5 mm (0.18 in)
Limit 2.0 mm (0.08 in)
Shoe spring length 52.0 mm (2.05 in)
Shoe spring length 2 48.0 mm (1.89 in)

Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 100 mm (3.9 in)
Fork spring free length 282.1 mm (11.1 in)
Limit 276.4 mm (10.9 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil G10
Quantity (left) 55.0 cm³ (1.85 US oz, 1.93 Imp. oz)
Quantity (right) 55.0 cm³ (1.85 US oz, 1.93 Imp. oz)
Level (left) 87 mm (3.4 in)
Level (right) 87 mm (3.4 in)

Rear suspension
Type
Spring Coil spring
Shock absorber Hydraulic damper
Wheel travel 86 mm (3.4 in)

2-7
 ELECTRICAL SPECIFICATIONS

EAS20016

ELECTRICAL SPECIFICATIONS

Voltage
System voltage 12 V

Engine control unit

Model BJG1

Ignition system
Ignition system TCI
Ignition timing (B.T.D.C.) 3.0–7.0 °/1600 r/min

Ignition coil
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ

Spark plug cap

Resistance 3.75–6.25 kΩ

Charging system
Charging system Starter generator
Standard output 14.0 V, 50.4 A at 5000 r/min
Stator coil resistance 0.048–0.072 Ω

Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.3–14.7 V

Battery
Model YTZ7V
Voltage, capacity 12 V, 6.0 Ah (10 HR)

Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal light 10.0 W
Rear turn signal light 10.0 W
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED

Indicator light
Turn signal indicator light LED
High beam indicator light LED
Engine trouble warning light LED
Stop and Start System indicator light LED
ABS warning light LED
Smart key system indicator light LED

2-8
 ELECTRICAL SPECIFICATIONS

Fuel sender unit

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

Fuse(s)
Main fuse 30.0 A
Headlight fuse 7.5 A
Signaling system fuse 7.5 A
Ignition fuse 7.5 A
Fuel injection system fuse 7.5 A
Terminal fuse 5.0 A
Backup fuse 7.5 A
ABS motor fuse 10.0 A
ABS solenoid fuse 7.5 A
ABS control unit fuse 5.0 A
Smart key system fuse 5.0 A

2-9
 TIGHTENING TORQUES

EAS20017

TIGHTENING TORQUES
EAS30016

ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Muffler nut M8 2 20 N·m (2.0 kgf·m, 15 lb·ft)
Muffler bolt M10 3 53 N·m (5.3 kgf·m, 39 lb·ft)
Muffler protector bolt M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT

Cylinder head bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Cylinder head nut M8 4 24 N·m (2.4 kgf·m, 18 lb·ft) M

VVA (variable valve actuator) sole-

M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
noid bolt
Cylinder head cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Engine oil check bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Cylinder head stud bolt (exhaust
M8 2 15 N·m (1.5 kgf·m, 11 lb·ft)
pipe)
Camshaft sprocket bolt M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Spark plug M10 1 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Valve clearance adjusting screw
M5 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
locknut
Yamaha
Timing chain tensioner bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) bond No.
1215
Coolant temperature sensor M10 1 15 N·m (1.5 kgf·m, 11 lb·ft)
Coolant drain bolt (cylinder side) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Water pump assembly bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator fan case bolt M6 5 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Thermostat assembly bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Radiator fan bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Coolant drain bolt (radiator side) M12 1 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
Oil strainer cover M30 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Fuel injector bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Intake manifold bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Air filter case bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Starter generator rotor nut M12 1 70 N·m (7.0 kgf·m, 52 lb·ft)
Starter generator assembly bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT

Crankcase bolt M6 11 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Transmission case cover bolt M8 6 20 N·m (2.0 kgf·m, 15 lb·ft)
Final transmission oil drain bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)
V-belt case bolt M6 10 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Engine oil drain bolt M12 1 20 N·m (2.0 kgf·m, 15 lb·ft)
V-belt case air filter element cover
M6 6 7 N·m (0.7 kgf·m, 5.2 lb·ft)
bolt

2-10
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Primary fixed sheave nut M12 1 76 N·m (7.6 kgf·m, 56 lb·ft)
Clutch housing nut M12 1 45 N·m (4.5 kgf·m, 33 lb·ft)
Secondary sheave nut M28 1 55 N·m (5.5 kgf·m, 41 lb·ft)
Cylinder head tightening sequence:

3 4

1 2

6 5

EAS30017

CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Engine bracket nut M10 1 52 N·m (5.2 kgf·m, 38 lb·ft)
Engine mounting nut (front side) M10 2 50 N·m (5.0 kgf·m, 37 lb·ft)
Engine mounting nut (rear side) M10 2 28 N·m (2.8 kgf·m, 21 lb·ft)
Meter assembly panel bolt M6 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Grab bar bolt M8 4 17 N·m (1.7 kgf·m, 13 lb·ft)
Seat nut M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Storage box bolt M6 4 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Front brake master cylinder holder
M6 2 16 N·m (1.6 kgf·m, 12 lb·ft)
bolt
Rear brake hose union bolt (master
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
cylinder side)
Throttle cable holder bolt (handlebar
M5 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
switch side)
Brake light switch screw M4 2 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
Handlebar bracket nut M10 1 53 N·m (5.3 kgf·m, 39 lb·ft)
Lower ring nut M25 1 See TIP.
Upper ring nut M25 1 See TIP.
Lower bracket pinch bolt M10 4 53 N·m (5.3 kgf·m, 39 lb·ft)
Front fork damper rod bolt M10 2 23 N·m (2.3 kgf·m, 17 lb·ft) LT

Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Front wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)
Front brake hose union bolt (brake
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
caliper side)
Brake caliper bleed screw M8 2 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front wheel axle nut M10 1 26 N·m (2.6 kgf·m, 19 lb·ft)
Front brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft) LT

2-11
 TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Front wheel sensor rotor bolt M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT

Rear wheel axle nut M16 1 125 N·m (12.5 kgf·m, 92 lb·ft)
Rear shock absorber assembly nut M10 2 23 N·m (2.3 kgf·m, 17 lb·ft)
Rear shock absorber assembly bolt M8 2 23 N·m (2.3 kgf·m, 17 lb·ft)
Swingarm mounting bolt M10 2 57 N·m (5.7 kgf·m, 42 lb·ft)
Fuel tank bolt M6 4 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Coolant reservoir bolt M6 1 11 N·m (1.1 kgf·m, 8.1 lb·ft)
Sidestand switch bolt M5 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) LT

Centerstand spring hook bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Sidestand nut M8 1 32 N·m (3.2 kgf·m, 24 lb·ft)

TIP
Steering column ring nut
1. Tighten the lower ring nut 38 N·m (3.8 kgf·m, 28 lb·ft) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 17 N·m (1.7 kgf·m, 13 lb·ft) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 N·m (7.5 kgf·m, 55 lb·ft)
with a torque wrench and the steering nut wrench.

2-12
 CABLE ROUTING

EAS20021

CABLE ROUTING
Handlebar (front view)

10
F

6
3

A
2 3

4 B
5
9
8

E
D 7 6 C

H 11 7
11 G 11

3
2 7 3
6

2-13
 CABLE ROUTING

1. Swicth handlebar right switch

2. Front brake light switch lead
3. Rear brake cable
4. Rear brake light switch lead
5. Swicth handlebar left switch
6. Front brake hose
7. Wire harness
8. Throttle cable (decelerator cable)
9. Throttle cable (accelerator cable)
10. Projection mark
11. Handlebar
A. Fix the meter connector cover to meter assy
certainly.
B. Pass the rear brake light switch leads through
upper side of the switch handlebar right lead.
C. Set the grommet of the front brake hose into the
guide wire.
D. Clamp the wire harness shall be inserted into the
pipe handlebar.
E. Pass the wire harness through backside the front
brake hose.
F. 73.5°
G. Route the left handlebar switch couplers to the rear
of the rear brake cable.
H. Route the right handlebar switch couplers to the
rear of the front brake hose.

2-14
 CABLE ROUTING

Handlebar (side view)

6
4
3
1

2
5

2-15
 CABLE ROUTING

1. Throttle cable (accelerator)

2. Rear brake cable
3. Front brake hose
4. Wire harness
5. Handlebar
6. Throttle cable (deccelerator)

2-16
 CABLE ROUTING

Headlight stay (right side view)

7
6

1
A

5
3

2-17
 CABLE ROUTING

1. Front brake hose

2. Front wheel sensor lead
3. Hydraulic unit
4. Fuel lid cable
5. Seat lock cable
6. Front brake pipe (hydraulic unit to front brake
caliper)
7. Front brake pipe (front brake master cylinder to
hydraulic unit)
A. 30°

2-18
 CABLE ROUTING

Headlight stay (left side view)

3
1 2
3
4 1

2-19
 CABLE ROUTING

1. Front wheel sensor lead

2. Front brake pipe (front brake master cylinder to
hydraulic unit)
3. Front brake hose
4. Front brake pipe (hydraulic unit to front brake
caliper)
5. Headlight stay

2-20
 CABLE ROUTING

Front fork (rear and right side view)

3
4

B
C
A

1
3 4

E F
4
4

3
3 4 3
B

3 G H

4
2

2-21
 CABLE ROUTING

1. Front wheel sensor

2. Front brake caliper
3. Front wheel sensor lead
4. Front brake hose
A. Route the front brake hose through the guide.
B. Position the holder within the range shown in the
illustration.
C. Make sure the brake pipe touches the projection
on the brake caliper.
D. Align the holder with the white paint mark on the
brake hose.
E. Forward
F. Rearward
G. Inward
H. Outward

2-22
 CABLE ROUTING

Frame (left side view)

E
7

1 G H I
2
3
3
1 2

B 9
A

6 6
1
5 5

2
C
1 3

2 3
2 3

2-23
 CABLE ROUTING

1. Rear brake cable

2. Throttle cable (accelerator cable)
3. Throttle cable (decelerator cable)
4. Horn lead
5. Fuel hose
6. Horn
7. Front wheel sensor lead
8. Buzzer coupler
9. O2 sensor lead
A. Insert the projection of wire harness into the
bracket left.
B. Secure the grommet by inserting the fuel hose
grommet into the hose guide.
C. Insert the projection on the brake cable into the
hole in the frame.
D. Insert the projection on the wire harness holder
completely into the hole in the headlight stay.
E. Install the front wheel sensor coupler to the
headlight stay.
F. Route the buzzer lead as shown in the illustration.
G. Fasten the rear brake cable and throttle cables
with the holder.
H. Route the O2 sensor lead between the cylinder
head cover and the fuel hose bracket.
I. Fasten the throttle cables with the holder.

2-24
 CABLE ROUTING

Frame (left side view)

A B C D
10
E

19
11
12

18
6 13
9
17
F
16

14

7
15
8

20 20

20

2-25
 CABLE ROUTING

1. Wire harness
2. License light lead
3. Rear turn signal light lead (left)
4. Rear turn signal light lead (right)
5. Tail/brake light lead
6. Fuse box 1
7. Main relay
8. Starter charger relay
9. Fuse box 2
10. Starter generator lead
11. Crankshaft position sensor lead
12. Idle Speed Control (ISC) lead
13. Ignition coil
14. Ignition coil lead
15. Throttle body sensor assembly lead
16. Fuel injector lead
17. O2 sensor lead
18. Fuel hose
19. Variable Valve Actuation (VVA) lead
20. Rear brake cable
A. Insert the projection of wire harness into the hole
of plate.
B. Insert the projection of starter generator into the
hole of plate.
C. Insert the projection of high tension cord into the
hole of plate.
D. Cut off the excess end of the band to less than
5 mm (0.20 in).
E. Insert the projection of high tension cord into the
hole of hose bracket.
F. Make sure the engine ground lead shall be
touched the stopper at crankcase.

2-26
 CABLE ROUTING

Frame (right side view)

F C
E 9
J
G

I
7 8
H

3
1
A
I
10
B

3 K

D
4

C 3
6 L
M

C N 11

12
16 14
15

8
3
10 C 16
13

2-27
 CABLE ROUTING

1. Main switch lead

2. Hydraulic unit lead
3. Fuel lid cable
4. SGCU lead
5. Seat lock cable
6. Fuel pump lead
7. Ignition coil stay
8. Fuel pump fitting
9. Flasher relay
10. Frame
11. Inner fender
12. Coolant reservoir breather hose
13. Coolant reservoir hose
14. Sidestand switch lead
15. Starter generator lead
16. Wire harness
A. Insert the projection on the fuel lid cable holder into
the hole in the cover.
B. Pass the wire seat lock cable in front of the wire
harness.
C. Insert the projection on the wire harness holder
into the hole in the frame.
D. Do not route this SGCU lead above the other
SGCU leads.
E. Insert the projection on the wire harness into the
hole in the ignition coil stay.
F. Route the wire set lock cable through the upper
side of the cross tube.
G. Insert the projection on the coolant reservoir
breather hose into the hole in the ignition coil stay.
H. Insert the projection on the starter generator lead
into the hole in the ignition coil stay.
I. Pass the wire set lock cable into the footrest board.
J. Route the seat lock cable through the bracket hole
and route the cable between the wire harness and
the frame.
K. Route the seat lock cable between the wire
harness holder and the frame.
L. Install the frame ground lead terminal as shown in
the illustration.
M. Install the frame ground lead terminal so that the
crimped section of the terminal that secures the
lead is facing upward.
N. Insert the end of the fuel tank overflow hose into
the inner fender. Make sure that the end of the
hose protector on the fuel tank overflow hose
contacts the edge of the hole in the inner fender.

2-28
 CABLE ROUTING

Frame (right side view)

F 3
1

1 2

C
D
E

6
1 I 5

2-29
 CABLE ROUTING

1. Seat lock cable

2. Wire harness
3. Battery cover
4. Communication Control Unit (CCU)
5. Starter generator lead
6. Variable Valve Actuation (VVA) solenoid
7. Radiator hose
A. Pass the wire harness in the inside of cross tube.
B. Fasten the coolant reservoir hose at the white paint
mark with the holder.
C. Route the wire harness through the upper side of
the engine bracket.
D. Route the radiator reservoir hose through the
upper side of the wire harness rear frame.
E. Insert the projection on the wire harness holder
into the hole in the crankcase bracket.
F. Insert the projection on the wire harness holder
into the hole in the rear side cover.
G. Route the spark plug lead between the (VVA)
solenoid and the radiator hose.
H. Route the wire harness through the pillar guide.
I. Route the seat lock cable through the hole of the
rear frame.

2-30
 CABLE ROUTING

Frame (top view)

2 3
L
4
K
1
5 M

J A
16 5 N
I
6
7
T
H B
8
15

17 17

15
18
M

19

11 10 9 8 17
S
17
C

11 18 M

12

14
13 P 17
13 D
13 M
12 12
12
18
P 14

G 13
F
O
M
O

M 13 E
12 M
R 14
P
Q

2-31
 CABLE ROUTING

1. Auxiliary DC jack lead

2. Buzzer
3. Turn signal relay
4. Main switch
5. Sidestand switch lead
6. Radiator recovery breather hose
7. Radiator hose
8. Fuse box 1
9. Main relay
10. Starter charger relay
11. Fuse box 2
12. Rear turn signal light lead
13. License light lead
14. Tail/brake light lead
15. Smart unit lead
16. Horn lead
17. Wire harness
18. Seat lock cable
19. Smart unit
A. Fasten the sidestand switch lead with the band.
Point the end of the band rearward.
B. Route the sidestand switch lead between the wire
harness and the coolant reservoir hose.
C. 30–40 mm (1.18–1.57 in)
D. 10 mm (0.39 in)
E. Route the seat lock cable outside of the vehicle.
F. Position the plastic locking tie to the rear of the rib
on the grab bar.
G. Be sure not to pinch the leads when installing the
grab bar.
H. Route the sidestand switch lead under the throttle
cable and the fuel hose.
I. Route the sidestand switch lead over the frame.
J. Fasten the sidestand switch lead with the holder.
K. Insert the projection on the wire harness holder
into the hole in the front brake hose holder.
L. Insert the projection on the wire harness holder
into the hole in the main switch bracket.
M. 5 mm
N. Install the fuse to the fuse box as shown in the
illustration.
O. Fasten the license light lead, rear turn signal light
lead, and tail/brake light lead with the plastic
locking tie to the hole of the frame.
P. Insert the projection on the wire harness holder
into the hole in the rear fender.
Q. Fasten the license light lead, rear turn signal light
lead, and tail/brake light lead with the plastic
locking tie to the guide.
R. Position the buckle of the plastic locking tie to the
outside of the guide.
S. Fit the slot in the relay onto the rib on the battery
box.
T. Position the buckle of the plastic locking tie to the
outside of the guide.

2-32
 CABLE ROUTING

Headlight

B 2
1

1 D

3
4 E
5
2

2-33
 CABLE ROUTING

1. Front turn signal light lead

2. Headlight lead
3. Auxiliary DC jack lead
4. Front wheel sensor lead
5. Buzzer lead
A. Insert the front turn signal light lead into the groove
in the headlight unit. Be sure to fasten the front turn
signal light lead before the split in the lead.
B. Insert the coupler into the groove in the headlight
unit.
C. Route the front turn signal light lead through the
hole of the front side panel.
D. Be sure not to pinch the front turn signal light lead
when installing the front side panel.
E. Insert the auxiliary DC jack coupler into the slot in
the leg shield.

2-34
 CABLE ROUTING

Radiator (top and right side view)

2 D

1
E

G F 7
E

3
A
D
4

6 5 A D F
C
M L
5 6 H F D

7 B M L
I A 3 C
F

D
A

I
E
2

J
4
K
A

2-35
 CABLE ROUTING

1. Water pump
2. Water pump inlet hose
3. Thermostat assembly
4. Radiator outlet hose
5. Radiator
6. Coolant reservoir hose
7. Radiator inlet hose
A. Install the hose completely onto the hose fitting.
B. Face the white paint mark on the hose to the left.
C. 45°
D. Upward
E. Downward
F. Frontward
G. Backward
H. To coolant reservoir
I. Face the yellow paint mark on the hose to the right.
J. Align the yellow paint mark on the hose with the
center of the thermostat assembly.
K. Face the white paint mark on the hose downward.
L. Outward
M. Inward

2-36
 CABLE ROUTING

Air filter case (top and left side view)

A 3

3 2
2
B

A B C
2
C

1 F

A C

2-37
 CABLE ROUTING

1. V-belt case breather hose

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

2-38
 CABLE ROUTING

2-39
 PERIODIC CHECKS AND ADJUSTMENTS

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

INTRODUCTION ......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ..................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ......................3-1
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL .......................................................................................................3-4
CHECKING THE FUEL LINE ...................................................................3-4
CHECKING THE FUEL FILTER ...............................................................3-4
CHECKING THE SPARK PLUG ..............................................................3-5
ADJUSTING THE VALVE CLEARANCE .................................................3-6
CHECKING THE ENGINE IDLING SPEED .............................................3-8
CHECKING THE EXHAUST SYSTEM .....................................................3-8
REPLACING THE AIR FILTER ELEMENT AND CLEANING THE
CHECK HOSE .........................................................................................3-8
CHECKING THE BREATHER HOSES ....................................................3-9
3
CLEANING THE V-BELT CASE AIR FILTER ELEMENT AND
CLEANING THE CHECK HOSE ........................................................... 3-10
CHECKING THE BRAKE OPERATION ................................................. 3-10
CHECKING THE FRONT BRAKE PADS ............................................... 3-11
CHECKING THE REAR BRAKE SHOES ............................................... 3-11
CHECKING THE BRAKE FLUID LEVEL ................................................ 3-11
CHECKING THE FRONT BRAKE HOSES ............................................ 3-11
BLEEDING THE HYDRAULIC BRAKE SYSTEM .................................. 3-12
CHECKING THE WHEELS ....................................................................3-13
CHECKING THE TIRES ......................................................................... 3-13
CHECKING THE WHEEL BEARINGS ................................................... 3-14
CHECKING AND ADJUSTING THE STEERING HEAD ........................ 3-14
LUBRICATING THE STEERING HEAD ................................................. 3-16
CHECKING THE CHASSIS FASTENERS ............................................. 3-16
LUBRICATING THE LEVERS ................................................................ 3-16
CHECKING THE SIDESTAND ............................................................... 3-16
LUBRICATING THE SIDESTAND .......................................................... 3-16
CHECKING THE CENTERSTAND ........................................................ 3-16
LUBRICATING THE CENTERSTAND ................................................... 3-16
CHECKING THE SIDESTAND SWITCH ................................................ 3-16
CHECKING THE FRONT FORK ............................................................ 3-16
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES ............... 3-17
CHECKING THE ENGINE OIL LEVEL ................................................... 3-17
CHANGING THE ENGINE OIL .............................................................. 3-17
CHECKING THE COOLANT LEVEL ...................................................... 3-19
CHECKING THE COOLING SYSTEM ................................................... 3-19
CHANGING THE COOLANT .................................................................. 3-19
CHANGING THE FINAL TRANSMISSION OIL ...................................... 3-22
REPLACING THE V-BELT ..................................................................... 3-22
CHECKING THE BRAKE LIGHT SWITCHES ........................................ 3-23
CHECKING AND LUBRICATING THE CABLES ................................... 3-23
CHECKING THE THROTTLE GRIP OPERATION ................................ 3-23
CHECKING THE SWITCHES, LIGHTS AND SIGNALS ........................ 3-24
ADJUSTING THE HEADLIGHT BEAM .................................................. 3-24
 PERIODIC MAINTENANCE

EAS20022

PERIODIC MAINTENANCE
EAS30022

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAUP0621

TIP
l The annual checks must be performed every year, except if a kilometer-based maintenance
is performed instead.
l From 16000 km, repeat the maintenance intervals starting from 4000 km.
l Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.

EAU67781

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

CHECK OR MAINTENANCE ODOMETER READING ANNUAL
NO. ITEM
JOB 1000 km 4000 km 7000 km 10000 km 13000 km CHECK
• Check fuel hoses for cracks
1 * Fuel line √ √ √ √ √
or damage.
• Check condition.
2 * Fuel filter First 13000 km and every 12000 km thereafter
• Replace if necessary.
• Check condition.
√ √
3 Spark plug • Clean and regap.
• Replace. √ √
• Check valve clearance.
4 * Valves √ √
• Adjust if necessary.
5 * Fuel injection • Check engine idle speed. √ √ √ √ √
• Check for leakage.
• Tighten if necessary.
6 * Exhaust system √ √ √ √ √
• Replace gasket(s) if neces-
sary.

EAU67794

GENERAL MAINTENANCE AND LUBRICATION CHART

CHECK OR MAINTENANCE ODOMETER READING ANNUAL
NO. ITEM
JOB 1000 km 4000 km 7000 km 10000 km 13000 km CHECK
• Perform dynamic inspec-
Diagnostic sys- tion using Yamaha diagnos-
1 * √ √ √ √ √ √
tem check tic tool.
• Check the error codes.
2 Air filter element • Replace. First 13000 km and every 12000 km thereafter
Air filter check
3 • Clean. √ √ √ √ √
hose
V-belt case air fil- • Clean.
4 * √ √ √ √
ter element • Replace if necessary.
• Check voltage.
5 * Battery √ √ √ √ √ √
• Charge if necessary.

3-1
 PERIODIC MAINTENANCE

CHECK OR MAINTENANCE ODOMETER READING ANNUAL

NO. ITEM
JOB 1000 km 4000 km 7000 km 10000 km 13000 km CHECK
• Check operation, fluid level
and vehicle for fluid leak- √ √ √ √ √ √
6 * Front brake age.
• Replace brake pads. Whenever worn to the limit
• Check operation, fluid level
and vehicle for fluid leak- √ √ √ √ √ √
7 * Rear brake age.
• Replace brake pads. Whenever worn to the limit
• Check for cracks or dam-
age.
√ √ √ √ √
8 * Brake hoses • Check for correct routing
and clamping.
• Replace. Every 4 years
9 * Brake fluid • Change. Every 2 years
• Check runout and for dam-
10 * Wheels √ √ √ √
age.
• Check tread depth and for
damage.
11 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearings for loose-
12 * Wheel bearings √ √ √ √
ness or damage.
• Check bearing play and
√ √ √ √ √
steering for roughness.
13 * Steering bearings
• Lubricate with lithium-soap-
First 13000 km and every 12000 km thereafter
based grease.
• Make sure that all nuts,
14 * Chassis fasteners bolts and screws are prop- √ √ √ √ √
erly tightened.
Front brake lever • Lubricate with silicone
15 √ √ √ √ √
pivot shaft grease.
Rear brake lever • Lubricate with silicone
16 √ √ √ √ √
pivot shaft grease.
• Check operation.
Sidestand, cen-
17 • Lubricate with lithium-soap- √ √ √ √ √
terstand
based grease.
18 * Sidestand switch • Check operation. √ √ √ √ √ √
• Check operation and for oil
19 * Front fork √ √ √ √
leakage.
Shock absorber • Check operation and shock
20 * √ √ √ √
assemblies absorbers for oil leakage.
• Change. √ When the oil change indicator flashes
21 Engine oil • Check oil level and vehicle
√ √ √ √ √
for oil leakage.
22 * Engine oil strainer • Clean. √ √
• Check coolant level and ve-
√ √ √ √ √
23 * Cooling system hicle for coolant leakage.
• Change coolant. First 13000 km and every 12000 km thereafter

3-2
 PERIODIC MAINTENANCE

CHECK OR MAINTENANCE ODOMETER READING ANNUAL

NO. ITEM
JOB 1000 km 4000 km 7000 km 10000 km 13000 km CHECK
• Check vehicle for oil leak-
Final transmis- √ √ √ √ √
24 age.
sion oil
• Change. √ Every 12000 km (7500 mi)
• Check for damage and
√ √ √
wear.
25 * V-belt
When the V-belt replacement indicator flashes [every
• Replace.
25000 km (15500 mi)]
V-belt secondary
26 * • Lubricate. First 13000 km and every 12000 km thereafter
sheave
Front and rear
27 * • Check operation. √ √ √ √ √ √
brake switches
Moving parts and
28 • Lubricate. √ √ √ √ √
cables
• Check operation.
• Check throttle grip free play,
29 * Throttle grip and adjust if necessary. √ √ √ √ √
• Lubricate cable and grip
housing.
Lights, signals • Check operation.
30 * √ √ √ √ √ √
and switches • Adjust headlight beam.

EAUN2840

TIP
l Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not
be cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
l V-belt case air filter
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l V-belt
• The V-belt should be checked at the initial 7000 km (4200 mi) and every 3000 km (1800 mi)
thereafter. Replace the V-belt if any damage or excessive wear is found. The V-belt needs to be
replaced every 25000 km (15500 mi) even if there is not wear or damage.
l Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
l Fuel system service
• Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to internal
engine parts, such as the valves and piston rings, as well as to the exhaust system.
• Replace the fuel filler cover every two years or if cracked or damaged.
• Check the fuel filter for clogging or damage every 12000 km (7500 mi).
l Battery service
• Check the condition and service the battery every 3 months.
• Recharge the battery immediately if the voltage is less than 12.7 V.
• If the battery tends to discharge, replace it immediately.

3-3
 PERIODIC MAINTENANCE

EAS32024
4. Perform:
CHECKING THE VEHICLE USING THE
• Dynamic inspection
YAMAHA DIAGNOSTIC TOOL
Use the Yamaha diagnostic tool and check the TIP
vehicle according to the following procedure. Use the “Dynamic inspection” function of the
1. Remove: Yamaha diagnostic tool and after to perform the
• Battery cover dynamic inspection. For information about using
Refer to “GENERAL CHASSIS (1)” on page the Yamaha diagnostic tool, refer to the opera-
4-1. tion manual that is included with the tool.
2. Remove the CCU (Communication Control 5. Install:
Unit) “1”, and then connect the Yamaha diag- • Battery cover
nostic tool “2” to the coupler “3”. Refer to “GENERAL CHASSIS (1)” on page
4-1.
Yamaha diagnostic tool USB
90890-03267 EAS30619

Yamaha diagnostic tool (A/I) CHECKING THE FUEL LINE

90890-03264 1. Remove:
• Front side cover (left)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Footrest board assembly (left)
Refer to “GENERAL CHASSIS (5)” on page
4-10.
1 2. Check:
• Fuel hose “1”
Cracks/damage → Replace.
Loose connections → Connect properly.

3 2
1

3. Install:
• Footrest board assembly (left)
3. Check: Refer to “GENERAL CHASSIS (5)” on page
• Fault codes 4-10.
TIP • Front side cover (left)
Use the “Diagnosis of malfunction” function of Refer to “GENERAL CHASSIS (2)” on page
the Yamaha diagnostic tool to check the fault 4-3.
codes. For information about using the Yamaha
EAS31178
diagnostic tool, refer to the operation manual CHECKING THE FUEL FILTER
that is included with the tool. 1. Remove:
Fault code number is displayed → Check and • Front side covers
repair the probable cause of the malfunction. Refer to “GENERAL CHASSIS (2)” on page
Refer to “SELF-DIAGNOSTIC FUNCTION 4-3.
AND DIAGNOSTIC CODE TABLE” on page • Fuel tank cover
9-37. Refer to “GENERAL CHASSIS (3)” on page
4-6.

3-4
 PERIODIC MAINTENANCE

• Center lower cover 3. Check:

Refer to “GENERAL CHASSIS (5)” on page • Spark plug type
4-10. Incorrect → Change.
• Fuel filter
Refer to “FUEL TANK” on page 7-1. Manufacturer/model
2. Check: NGK/CPR8EA-9
• Fuel filter “1”
4. Check:
Damage/contaminants → Replace.
• Electrode “1”
TIP Damage/wear → Replace the spark plug.
Replace the fuel filter every 12000 km (7500 mi) • Insulator “2”
of operation. Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.

3. Install:
• Fuel filter 5. Clean:
Refer to “FUEL TANK” on page 7-1. • Spark plug
• Center lower cover (with a spark plug cleaner or wire brush)
Refer to “GENERAL CHASSIS (5)” on page 6. Measure:
4-10. • Spark plug gap “a”
• Fuel tank cover (with a wire thickness gauge)
Refer to “GENERAL CHASSIS (3)” on page Out of specification → Regap.
4-6.
Spark plug gap
• Front side covers
0.8–0.9 mm (0.031–0.035 in)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
EAS30620

CHECKING THE SPARK PLUG

1. Remove:
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on page
4-10.
2. Remove: 7. Install:
• Spark plug cap • Spark plug “1”
• Spark plug • Spark plug cap
ECA13330

NOTICE Spark plug

Before removing the spark plug, blow away 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

any dirt accumulated in the spark plug well

with compressed air to prevent it from falling
into the cylinder.

3-5
 PERIODIC MAINTENANCE

TIP • Fuel tank

• Before installing the spark plug, clean the Refer to “FUEL TANK” on page 7-1.
spark plug and gasket surface. • Cylinder head cover
• When tightening the spark plug, make sure Refer to “CYLINDER HEAD” on page 5-9.
that the inside “a” of the spark plug wrench “2” • Radiator cover
does not the contact the portion “b” of the spark Refer to “RADIATOR” on page 6-2.
plug. 2. Move:
• Radiator “1”
b TIP
a 2 Move the rear of the radiator outward.

8. Install:
• Footrest board assembly (right) 1
Refer to “GENERAL CHASSIS (5)” on page
4-10. 3. Move:
• Front side cover (right) • Water pump assembly “1”
Refer to “GENERAL CHASSIS (2)” on page TIP
4-3. Move the water pump assembly in the direction
EAS30622 shown in the illustration.
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
1
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
• Battery 4. Measure:
Refer to “GENERAL CHASSIS (1)” on page • Valve clearance
4-1. Out of specification → Adjust.
• Front side covers
Valve clearance (cold)
Refer to “GENERAL CHASSIS (3)” on page Intake
4-6. 0.10–0.14 mm (0.0039–0.0055 in)
• Fuel tank cover Exhaust
Refer to “GENERAL CHASSIS (3)” on page 0.21–0.25 mm (0.0083–0.0098 in)
4-6.
• Center lower cover
Refer to “GENERAL CHASSIS (5)” on page
4-10.

3-6
 PERIODIC MAINTENANCE

a. Turn the crankshaft clockwise.

c. Turn the adjusting screw “3” with the tap-

pet adjusting tool “4” until the specified
b. When the piston is at the Top Dead Center valve clearance is obtained.
(TDC) on the compression stroke, align
the mark “a” on the camshaft sprocket with Tappet adjusting tool
the edge “b” of the cylinder head. 90890-01311
Six piece tappet set
a YM-A5970
b

c. Measure the valve clearance with a thick-

ness gauge “1”. 4
Out of specification → Adjust. d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifi-
cation.

Valve clearance adjusting screw

locknut
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

e. Measure the valve clearance again.

1 f. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
5. Adjust: adjustment steps until the specified clear-
• Valve clearance ance is obtained.
a. Loosen the locknut “1”. 6. Install:
b. Insert a thickness gauge “2” between the • All removed parts
end of the adjusting screw and the valve TIP
tip. For installation, reverse the removal procedure.

3-7
 PERIODIC MAINTENANCE

EAS31017

CHECKING THE ENGINE IDLING SPEED

TIP
Prior to checking the engine idling speed, the air
filter element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for several
minutes. 4
2. Check:
• Engine idling speed 2
Out of specification → Go to next step. 4 1
4
Engine idling speed 3
1500–1700 r/min EAS31130

REPLACING THE AIR FILTER ELEMENT

3. Check: AND CLEANING THE CHECK HOSE
• ISC (idle speed control) learning value
TIP
“00” or “01” → Check the intake system.
“02” → Clean the ISC (idle speed control) unit Check the air filter check hose “1” that is located
and throttle body. on the rear side of the air filter case. If dust or
Refer to “CLEANING THE ISC (IDLE SPEED water or both collects in the hose, clean the hose
CONTROL) UNIT AND THROTTLE BODY” and replace the air filter element.
on page 7-13.
a. Connect the Yamaha diagnostic tool.
Use the diagnostic code number “67”. 1
Refer to “SELF-DIAGNOSTIC FUNC-
TION AND DIAGNOSTIC CODE TABLE”
on page 9-37.

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264
1. Remove:
EAS30625
• Air filter case cover “1”
CHECKING THE EXHAUST SYSTEM • Air filter element “2”
1. Check:
• Muffler “1”
Cracks/damage → Replace. 1
• Gasket “2”
Exhaust gas leaks → Replace.
2. Check:
Tightening torque
• Muffler nuts “3”
• Muffler bolts “4”

Muffler nut
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

Muffler bolt
53 N·m (5.3 kgf·m, 39 lb·ft)

3-8
 PERIODIC MAINTENANCE

2. Check:
• Cylinder head breather hose “1”
2 • Transmission case breather hose “2”
Cracks/damage → Replace.
Loose connections → Connect properly.
ECA21600

NOTICE
Make sure the cylinder head breather hose
and transmission case breather hose are
routed correctly.
2. Check:
• Air filter element
Damage → Replace.
TIP
• Replace the air filter element every 12000 km 1
(7000 mi) of operation.
3. Install:
• Air filter element
• Air filter case cover

Air filter case cover screw

1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
T.
R.

ECA20480
2
NOTICE
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
tuning, leading to poor engine performance 3. Install:
and possible overheating. • Storage box
TIP
Refer to “GENERAL CHASSIS (4)” on page
4-8.
When installing the air filter element into the air
• Fuel tank cover
filter case, make sure that the sealing surfaces
Refer to “GENERAL CHASSIS (3)” on page
are aligned to prevent any air leaks.
4-6.
• Front side covers
EAS31179

CHECKING THE BREATHER HOSES Refer to “GENERAL CHASSIS (2)” on page

1. Remove: 4-3.
• Battery • Battery
Refer to “GENERAL CHASSIS (1)” on page Refer to “GENERAL CHASSIS (1)” on page
4-1. 4-1.
• Front side covers
Refer to “GENERAL CHASSIS (2)” on page
4-3.
• Fuel tank cover
Refer to “GENERAL CHASSIS (3)” on page
4-6.
• Storage box
Refer to “GENERAL CHASSIS (4)” on page
4-8.

3-9
 PERIODIC MAINTENANCE

EAS31704

CLEANING THE V-BELT CASE AIR FILTER TIP

ELEMENT AND CLEANING THE CHECK • The air filter needs more frequent service if you
HOSE are riding in unusually wet or dusty areas.
TIP
• After cleaning, gently squeeze the V-belt case
air filter element to remove the excess solvent.
Check the V-belt case air filter check hose “1”
ECA21590
that is located on the rear side of the V-belt case.
NOTICE
If dust or water or both collects in the hose, clean
the hose and replace the V-belt case air filter el- Do not twist the V-belt case air filter element
ement. when squeezing it.

1. Remove: 3. Check:
• V-belt case air filter element cover “1” • V-belt case air filter element
• V-belt case air filter element “2” Damage → Replace.
4. Apply the recommended oil to the entire sur-
face of the V-belt case air filter element and
1
squeeze out the excess oil. The V-belt case
air filter element should be wet but not drip-
ping.

Recommended oil
Engine oil

5. Install:
• V-belt case air filter element
• V-belt case air filter element cover

V-belt case air filter element cov-

2
er bolt
T.
R.

7 N·m (0.7 kgf·m, 5.2 lb·ft)

EAS30801

CHECKING THE BRAKE OPERATION

1. Check:
• Brake operation
2. Clean: Brake not working properly → Check the
• V-belt case air filter element brake system.
(with solvent) Refer to “FRONT BRAKE” on page 4-36 and
EWA17971 “REAR BRAKE” on page 4-49.
WARNING TIP
Never use low flash point solvents, such as Drive on the road, operate the front and rear
gasoline, to clean the V-belt case air filter el- brakes separately and check to see if the brakes
ement. Such solvents may cause a fire or an are operating properly.
explosion.

3-10
 PERIODIC MAINTENANCE

EAS30633

CHECKING THE FRONT BRAKE PADS Specified brake fluid

The following procedure applies to all of the DOT 4
brake pads.
1. Operate the brake.
2. Check: a
• Front brake pad
Wear indicator grooves “a” almost disap-
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-36.

a EWA13540

a WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
EAS00126
• Refill with the same type of brake fluid that
CHECKING THE REAR BRAKE SHOES is already in the system. Mixing brake fluids
1. Operate the brake. may result in a harmful chemical reaction,
2. Check: leading to poor brake performance.
• Wear indicator “1” • When refilling, be careful that water does
Reaches the wear limit line “2” → Replace the not enter the brake master cylinder reser-
brake shoes as a set. voir. Water will significantly lower the boil-
Refer to “REAR BRAKE” on page 4-49. ing point of the brake fluid and could cause
vapor lock.
ECA13540

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
2
1 any spilt brake fluid immediately.

EAS30635

CHECKING THE FRONT BRAKE HOSES

1. Check:
EAS30632 • Brake hoses “1”
CHECKING THE BRAKE FLUID LEVEL Cracks/damage → Replace.
1. Stand the vehicle on a level surface.
TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright. 1
• In order to ensure a correct reading of the
brake fluid level, make sure the top of the brake
fluid reservoir is horizontal.
2. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the 2. Check:
specified brake fluid to the proper level. • Brake hose holder
• Brake hose guide
Loose → Tighten the holder and guide bolt.

3-11
 PERIODIC MAINTENANCE

3. Hold the vehicle upright and apply the front

brake several times. 2
4. Check:
• Brake hoses
Brake fluid leakage → Replace the damaged 1
hose.
Refer to “FRONT BRAKE” on page 4-36.
EAS30893

BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA14000 d. Place the other end of the hose into a con-
WARNING tainer.
Always bleed the brake system when the e. Slowly apply the brake several times.
brake related parts are removed. f. Fully squeeze the brake lever and hold it in
ECA22780
position.
NOTICE g. Loosen the bleed screw.
• Bleed the brake system in the following or- TIP
der. Loosening the bleed screw will release the pres-
• 1st step: Front brake caliper sure and cause the brake lever to contact the
• 2nd step: Rear brake caliper throttle grip or handlebar grip.
EWA16530
h. Tighten the bleed screw and then release
WARNING the brake lever.
Bleed the ABS whenever: i. Repeat steps (e) to (h) until all of the air
• the system is disassembled. bubbles have disappeared from the brake
• a brake hose is loosened, disconnected or fluid in the plastic hose.
replaced. j. Check the operation of the hydraulic unit.
• the brake fluid level is very low. Refer to “HYDRAULIC UNIT OPERA-
• brake operation is faulty. TION TESTS” on page 4-56.
ECA18060

TIP NOTICE
• Be careful not to spill any brake fluid or allow Make sure that the main switch is turned to
the brake master cylinder reservoir to overflow. “OFF” before checking the operation of the
• When bleeding the ABS, make sure that there hydraulic unit.
is always enough brake fluid before applying
the brake. Ignoring this precaution could allow k. After operating the ABS, repeat steps (e)
air to enter the ABS, considerably lengthening to (i), and then fill the brake master cylin-
the bleeding procedure. der reservoir to the proper level with the
• If bleeding is difficult, it may be necessary to let specified brake fluid.
the brake fluid settle for a few hours. l. Tighten the bleed screw to specification.
• Repeat the bleeding procedure when the tiny Brake caliper bleed screw
bubbles in the hose have disappeared. 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.

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

3-12
 PERIODIC MAINTENANCE

EAS30638

CHECKING THE WHEELS Tire air pressure (measured on

The following procedure applies to all of the cold tires)
wheels. 1 person
1. Check: Front
• Wheel 200 kPa (2.00 kgf/cm², 29 psi)
Damage/out-of-round → Replace. Rear
EWA13260 225 kPa (2.25 kgf/cm², 33 psi)
WARNING 2 persons
Never attempt to make any repairs to the Front
wheel. 200 kPa (2.00 kgf/cm², 29 psi)
Rear
TIP 225 kPa (2.25 kgf/cm², 33 psi)
After a tire or wheel has been changed or re- * Total weight of rider, passenger, cargo
placed, always balance the wheel. and accessories
2. Measure: EWA13190

• Radial wheel runout WARNING

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

1. Tire tread depth

2. Side wall
3. Wear indicator
EWA13181

WARNING Wear limit (front)

• The tire pressure should only be checked 1.0 mm (0.04 in)
Wear limit (rear)
and regulated when the tire temperature
1.0 mm (0.04 in)
equals the ambient air temperature.
• The tire pressure and the suspension must EWA14080

be adjusted according to the total weight WARNING

(including cargo, rider, passenger and ac- • Do not use a tubeless tire on a wheel de-
cessories) and the anticipated riding signed only for tube tires to avoid tire fail-
speed. ure and personal injury from sudden
• Operation of an overloaded vehicle could deflation.
cause tire damage, an accident or an injury. • When using a tube tire, be sure to install the
NEVER OVERLOAD THE VEHICLE. correct tube.
• Always replace a new tube tire and a new
tube as a set.

3-13
 PERIODIC MAINTENANCE

• To avoid pinching the tube, make sure the EWA13210

wheel rim band and tube are centered in the WARNING

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

2
1

A. Tire
B. Wheel

Tube wheel Tube tire only

Tubeless wheel Tube or tubeless tire
EWA14090
EAS30641
WARNING CHECKING THE WHEEL BEARINGS
After extensive tests, the tires listed below The following procedure applies to all of the
have been approved by Yamaha Motor Co., wheel bearings.
Ltd. for this model. The front and rear tires 1. Check:
should always be by the same manufacturer • Wheel bearings
and of the same design. No guarantee con- Refer to “CHECKING THE FRONT WHEEL”
cerning handling characteristics can be giv- on page 4-29.
en if a tire combination other than one
EAS30645
approved by Yamaha is used on this vehicle. CHECKING AND ADJUSTING THE
STEERING HEAD
Front tire 1. Stand the vehicle on a level surface.
Size EWA13120

110/80–14M/C 53P WARNING

Manufacturer/model Securely support the vehicle so that there is
IRC/SCT-005F no danger of it falling over.
TIP
Rear tire
Place the vehicle on a suitable stand so that the
Size
140/70–14M/C 62P front wheel elevated.
Manufacturer/model 2. Check:
IRC/SCT-005R • Steering head
Grasp the handlebar and gently rock the han-
dlebar.
Binding/looseness → Adjust the steering
head.

3-14
 PERIODIC MAINTENANCE

3. Remove: c. Loosen the lower ring nut 1/4 of a turn, and

• Front side covers then tighten it to specification with a steer-
Refer to “GENERAL CHASSIS (2)” on page ing nut wrench.
4-3. EWA13140

• Center lower cover WARNING

Refer to “GENERAL CHASSIS (5)” on page Do not overtighten the lower ring nut.
4-10.
• Front upper cowling assembly Lower ring nut (final tightening
Refer to “GENERAL CHASSIS (6)” on page torque)

T.
R.
4-15. 17 N·m (1.7 kgf·m, 13 lb·ft)
• Handlebar
Refer to “HANDLEBAR” on page 4-59. d. Check the steering head for looseness or
4. Adjust: binding by turning the front fork all the way
• Steering head in both directions. If any binding is felt, re-
a. Remove the upper ring nut “1”, lock wash- move the lower bracket and check the up-
er “2”, center ring nut “3” and rubber wash- per and lower bearings.
er “4”. Refer to “STEERING HEAD” on page
4-71.
e. Install the rubber washer.
f. Install the center ring nut.
g. Finger tighten the center ring nut, then
1 align the slots of both ring nuts. If neces-
sary, hold the lower ring nut and tighten
3 the center ring nut until their slots are
4 aligned.
h. Install the lock washer “2”.
2
TIP
b. Loosen the lower ring nut “5” and then Make sure the lock washer tabs “a” sit correctly
tighten it to specification with a steering in the ring nut slots “b”.
nut wrench “6”.
TIP
Set the torque wrench at a right angle to the 2
steering nut wrench.
a
Steering nut wrench
90890-01403
b

Lower ring nut (initial tightening

torque)
T.

i. Hold the lower and center ring nuts with a

R.

38 N·m (3.8 kgf·m, 28 lb·ft)

steering nut wrench and tighten the upper
ring nut with a another steering nut
wrench.

Steering nut wrench

90890-01403

Upper ring nut

6 75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.

3-15
 PERIODIC MAINTENANCE

5. Install: EAS30856

CHECKING THE CENTERSTAND

• Handlebar
1. Check:
Refer to “HANDLEBAR” on page 4-59.
• Centerstand operation
• Front upper cowling assembly
Check that the centerstand moves smoothly.
Refer to “GENERAL CHASSIS (6)” on page
Rough movement → Repair or replace.
4-15.
• Center lower cover EAS30857

Refer to “GENERAL CHASSIS (5)” on page LUBRICATING THE CENTERSTAND

4-10. Lubricate the pivoting point, metal-to-metal mov-
• Front side covers ing parts, and spring contact points of the center-
Refer to “GENERAL CHASSIS (2)” on page stand.
4-3.
Recommended lubricant
EAS30646 Lithium-soap-based grease
LUBRICATING THE STEERING HEAD
1. Lubricate: EAS30652

• Upper bearing CHECKING THE SIDESTAND SWITCH

• Lower bearing Refer to “CHECKING THE SWITCHES” on
• Lower bearing dust seal page 8-36.
EAS30653
Recommended lubricant
CHECKING THE FRONT FORK
Lithium-soap-based grease
1. Stand the vehicle on a level surface.
EWA13120
EAS31186
WARNING
CHECKING THE CHASSIS FASTENERS
Make sure that all nuts, bolts, and screws are Securely support the vehicle so that there is
properly tightened. no danger of it falling over.
Refer to “TIGHTENING TORQUES” on page 2. Check:
2-10. • Inner tube
EAS30648
Damage/scratches → Replace.
LUBRICATING THE LEVERS • Oil seal
Lubricate the pivoting point and metal-to-metal Oil leakage → Replace.
moving parts of the levers. 3. Hold the vehicle upright and apply the front
brake.
Recommended lubricant 4. Check:
Silicone grease • Front fork operation
Push down hard on the handlebar several
EAS30650
times and check if the front fork rebounds
CHECKING THE SIDESTAND
smoothly.
1. Check:
Rough movement → Repair.
• Sidestand operation
Refer to “FRONT FORK” on page 4-64.
Check that the sidestand moves smoothly.
Rough movement → Repair or replace.
EAS30651

LUBRICATING THE SIDESTAND

Lubricate the pivoting point, metal-to-metal mov-
ing parts, and spring contact point of the side-
stand.

Recommended lubricant
Lithium-soap-based grease

3-16
 PERIODIC MAINTENANCE

EAS30808

CHECKING THE REAR SHOCK ABSORBER

ASSEMBLIES
The following procedure applies to both of the 1
rear shock absorber assemblies.
1. Stand the vehicle on a level surface.
EWA13120

WARNING 1 a
Securely support the vehicle so that there is
no danger of it falling over. b
2. Check:
• Rear shock absorber assembly Recommended brand
Oil leaks → Replace the rear shock absorber YAMALUBE
SAE viscosity grades
assembly.
10W-40
Refer to “CHECKING THE REAR SHOCK Recommended engine oil grade
ABSORBER ASSEMBLY” on page 4-77. API service SG type or higher,
3. Check: JASO standard MA or MB
• Rear shock absorber assembly operation
Push down seat on the vehicle several times ECA13370

and check if the rear shock absorber assem- NOTICE

bly rebounds smoothly. Do not allow foreign materials to enter the
Rough movement → Replace. crankcase.
Refer to “REAR SHOCK ABSORBER AS- 5. Start the engine, warm it up for several min-
SEMBLIES AND SWINGARM” on page utes, and then turn it off.
4-75. 6. Check the engine oil level again.
EAS30656 TIP
CHECKING THE ENGINE OIL LEVEL Before checking the engine oil level, wait a few
1. Stand the vehicle on a level surface. minutes until the oil has settled.
TIP
• Place the vehicle on the centerstand. EAS30657

• Make sure the vehicle is upright. CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
2. Start the engine, warm it up for several min- utes, and then turn it off.
utes, and then turn it off. 2. Place a container under the engine oil drain
3. Remove: bolt.
• Dipstick “1” 3. Remove:
4. Check: • Dipstick “1”
• Engine oil level • Engine oil drain bolt “2”
The engine oil level should be between the (along with the gasket “3”)
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
TIP
• Before checking the engine oil level, wait a few
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting 1
the oil level.

3-17
 PERIODIC MAINTENANCE

Engine oil quantity

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

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

c. Clean the engine oil strainer with solvent, 1

and then check it for damage and replace
it if necessary.
d. Install the oil strainer, spring, and oil strain-
er cover.
b. Start the engine and keep it idling until en-
Oil strainer cover
20 N·m (2.0 kgf·m, 15 lb·ft) gine oil starts to seep from the oil check
T.

bolt. If no engine oil comes out after one

R.

6. Install: minute, turn the engine off so that it will not

• Engine oil drain bolt seize.
c. Check the engine oil passages and the oil
(along with the gasket New )
pump for damage or leakage. Refer to
Engine oil drain bolt “OIL PUMP” on page 5-45.
20 N·m (2.0 kgf·m, 15 lb·ft) d. Start the engine after solving the prob-
T.
R.

lem(s) and check the engine oil pressure

7. Fill: again.
• Crankcase e. Tighten the oil check bolt to specification.
(with the specified amount of the recom-
mended engine oil)

3-18
 PERIODIC MAINTENANCE

EAS30812

Engine oil check bolt CHECKING THE COOLING SYSTEM

7 N·m (0.7 kgf·m, 5.2 lb·ft) 1. Remove:
T.
R.

• Radiator cover
14.Reset: Refer to “RADIATOR” on page 6-2.
• Oil change indicator 2. Check:
Refer to “MULTI-FUNCTION METER UNIT” • Radiator “1”
on page 1-2. • Coolant reservoir hose “2”
• Radiator inlet hose “3”
EAS30811

CHECKING THE COOLANT LEVEL • Radiator outlet hose “4”

1. Stand the vehicle on a level surface. • Thermostat assembly “5”
• Water pump inlet hose “6”
TIP
Cracks/tears → Replace.
• Place the vehicle on the centerstand. Refer to “RADIATOR” on page 6-2 and
• Make sure the vehicle is upright. “THERMOSTAT” on page 6-6.
2. Check:
• Coolant level
3 2
The coolant level should be between the min-
5
imum level mark “a” and maximum level mark
“b”.
Below the minimum level mark → Add the 1
recommended coolant to the proper level.

4 6

3. Install:
b • Radiator cover
Refer to “RADIATOR” on page 6-2.
a
EAS30813

CHANGING THE COOLANT

1. Remove:
• Front side cover (right)
ECA13470
Refer to “GENERAL CHASSIS (2)” on page
NOTICE
4-3.
• Adding water instead of coolant lowers the • Bottom cover
antifreeze content of the coolant. If water is • Footrest board assembly (right)
used instead of coolant check, and if nec- Refer to “GENERAL CHASSIS (5)” on page
essary, correct the antifreeze concentra- 4-10.
tion of the coolant. 2. Disconnect:
• Use only distilled water. However, if dis- • Coolant reservoir hose “1”
tilled water is not available, soft water may • Coolant reservoir breather hose “2”
be used.
3. Start the engine, warm it up for several min-
utes, and then turn it off. 2
4. Check:
• Coolant level 1
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.

3-19
 PERIODIC MAINTENANCE

3. Remove: sound has stopped, press down on the radi-

• Coolant reservoir cap “1” ator cap and turn it counterclockwise to re-
• Coolant reservoir “2” move.
7. Remove:
• Coolant drain bolt (radiator side) “1”
1 (along with the O-ring)
• Coolant drain bolt (cylinder side) “2”
2 (along with the copper washer)

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

1
2
6. Remove:
• Radiator cap “1” 8. Drain:
• Coolant
1 (from the engine and radiator)
9. Install:
• Coolant drain bolt (cylinder side)
(along with the copper washer New )
• Coolant drain bolt (radiator side)
(along with the O-ring New )

Coolant drain bolt (cylinder side)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

EWA13030 Coolant drain bolt (radiator side)

WARNING 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en- 10.Connect:
gine is hot. Scalding hot fluid and steam may • Coolant reservoir breather hose
be blown out, which could cause serious in- • Coolant reservoir hose
jury. When the engine has cooled, open the 11.Fill:
radiator cap as follows: • Cooling system
Place a thick rag or a towel over the radiator (with the specified amount of the recom-
cap and slowly turn the radiator cap counter- mended coolant)
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing

3-20
 PERIODIC MAINTENANCE

• Use only distilled water. However, if dis-

Recommended antifreeze tilled water is not available, soft water may
High-quality ethylene glycol an- be used.
tifreeze containing corrosion in- • If coolant comes into contact with painted
hibitors for aluminum engines
surfaces, immediately wash them with wa-
Mixing ratio
1:1 (antifreeze: water) ter.
Radiator (including all routes) • Do not mix different types of antifreeze.
0.46 L (0.49 US qt, 0.40 Imp.qt) 12.Install:
Coolant reservoir (up to the • Radiator cap
maximum level mark) • Coolant reservoir
0.13 L (0.14 US qt, 0.11 Imp.qt)
Coolant reservoir bolt
TIP 11 N·m (1.1 kgf·m, 8.1 lb·ft)

T.
R.
• Fill the coolant into the radiator, and then re-
move the air bleed bolt “1” until coolant comes 13.Fill:
out. • Coolant reservoir
• Tighten the air bleed bolt to specification. (with the recommended coolant to the maxi-
mum level mark “a”)
Air bleed bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

1 a

14.Install:
• Coolant reservoir cap “1”
TIP
Handling notes for coolant Point the tab “a” on the coolant reservoir cap for-
Coolant is potentially harmful and should be ward.
handled with special care.
EWA13040

WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
• If coolant splashes on your clothes, quickly
FWD
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting 1 a
and get immediate medical attention.
ECA13481
15.Start the engine, warm it up for several min-
NOTICE utes, and then turn it off.
16.Check:
• Adding water instead of coolant lowers the • Coolant level
antifreeze content of the coolant. If water is Refer to “CHECKING THE COOLANT LEV-
used instead of coolant, check, and if nec-
EL” on page 3-19.
essary, correct the antifreeze concentra-
tion of the coolant.

3-21
 PERIODIC MAINTENANCE

TIP 5. Install:
Before checking the coolant level, wait a few • Final transmission oil drain bolt
minutes until the coolant has settled. (along with the copper washer New )
17.Install: Final transmission oil drain bolt
• Radiator cover 20 N·m (2.0 kgf·m, 15 lb·ft)

T.
R.
Radiator cover bolt 6. Fill:
10 N·m (1.0 kgf·m, 7.4 lb·ft) • Final transmission oil
T.
R.

(with the specified amount of the recom-

18.Install:
mended final transmission oil)
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on page Final transmission oil
4-10. Type
• Front side cover (right) Motor oil SAE 10W-30 type SE
Refer to “GENERAL CHASSIS (2)” on page or higher or Gear oil SAE 85W
4-3. GL-3
Quantity
EAS31187
0.10 L (0.11 US qt, 0.09 Imp.qt)
CHANGING THE FINAL TRANSMISSION OIL
1. Stand the vehicle on a level surface. 7. Install:
TIP • Final transmission oil filler cap
• Place the vehicle on the centerstand. (along with the O-ring New )
• Make sure the vehicle is upright. TIP
2. Start the engine, warm it up for several min- Lubricate the O-ring with lithium-soap-based
utes, and then turn it off. grease.
3. Place a container under the final transmis-
8. Start the engine, warm it up for several min-
sion.
utes, and then turn it off.
4. Remove:
9. Check:
• Final transmission oil filler cap “1”
• Final transmission oil leakage
(along with the O-ring “2”)
• Final transmission oil drain bolt “3” EAS31188

(along with the copper washer “4”) REPLACING THE V-BELT

Completely drain the final transmission oil. 1. Remove:
• Air filter case
1 Refer to “AIR FILTER CASE” on page 7-8.
• V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-33.
2. Check:
2
• V-belt
Damage/wear → Replace.
Grease/oil → Clean the primary and second-
ary pulleys.
Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-33.
TIP
Replace the V-belt every 24000 km (15000 mi)
of operation.
4 3

3-22
 PERIODIC MAINTENANCE

3. Install: 2. Check:
• V-belt case • Throttle grip movement
Refer to “V-BELT AUTOMATIC TRANSMIS- Rough movement → Lubricate or replace the
SION” on page 5-33. defective part(s).
• Air filter case
Refer to “AIR FILTER CASE” on page 7-8. Recommended lubricant
Suitable cable lubricant
EAS30658

CHECKING THE BRAKE LIGHT SWITCHES TIP

1. Check:
With the engine stopped, turn the throttle grip
• Front brake light switch operation
slowly and release it. Make sure that the throttle
• Rear brake light switch operation
grip turns smoothly and returns properly when
When operating the brake levers, confirm
released.
that the brake light comes on.
Repeat this check with the handlebar turned all
Faulty → Refer to “CHECKING THE
the way to the left and right.
SWITCHES” on page 8-36.
3. Check:
EAS30660

CHECKING AND LUBRICATING THE • Throttle grip free play “a”

CABLES Out of specification → Adjust.
The following procedure applies to all of the in-
Throttle grip free play
ner and outer cables. 3.0–5.0 mm (0.12–0.20 in)
EWA13270

WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable a
Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate. 4. Adjust:
• Throttle grip free play
Recommended lubricant a. Slide back the rubber cover “1”.
Engine oil or a suitable cable lu- b. Loosen the locknut “2”.
bricant c. Turn the adjusting nut “3” until the speci-
fied throttle grip free play is obtained.
TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.

EAS30861

CHECKING THE THROTTLE GRIP

OPERATION 1
1. Check: 3
2
• Throttle cables
Damage/deterioration → Replace. d. Tighten the locknut.
• Throttle cable installation
Incorrect → Reinstall the throttle cables.
Refer to “HANDLEBAR” on page 4-59.

3-23
 PERIODIC MAINTENANCE

Throttle cable adjusting locknut

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.

e. Slide the rubber cover its original position.

TIP
Make sure that the adjusting nut is covered com-
pletely by the rubber cover.
EWA17990

WARNING
After adjusting the throttle grip free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.

EAS30663

CHECKING THE SWITCHES, LIGHTS AND

SIGNALS
1. Check that all switches operate and that all
lights come on.
Refer to “Instrument and control functions” in
OWNER’S MANUAL.
Faulty → Refer to “CHECKING THE
SWITCHES” on page 8-36.
EAS30664

ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• Headlight beam (vertically)
a. Turn the adjusting bolt “1”.

3-24
 PERIODIC MAINTENANCE

3-25
 CHASSIS

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

REMOVING THE BATTERY COVER ......................................................4-2
INSTALLING THE BATTERY COVER .....................................................4-2

GENERAL CHASSIS (2) ................................................................................4-3

REMOVING THE FRONT SIDE COVER ASSEMBLY .............................4-4
INSTALLING THE FRONT SIDE COVER ASSEMBLY ...........................4-4
REMOVING THE MOLE SIDE COVER ...................................................4-4
INSTALLING THE MOLE SIDE COVER ..................................................4-5

GENERAL CHASSIS (3) ................................................................................4-6

INSTALLING THE FOOTREST BOARD ..................................................4-7
INSTALLING THE LOWER MOLE COVER .............................................4-7

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

REMOVING THE FRONT UPPER COWLING ASSEMBLY ....................4-9
INSTALLING THE FRONT UPPER COWLING ASSEMBLY ...................4-9

GENERAL CHASSIS (5) .............................................................................. 4-10

REMOVING THE FRONT COWLING ASSEMBLY ................................ 4-12
4
INSTALLING THE FRONT COWLING ASSEMBLY .............................. 4-12
REMOVING THE FRONT SIDE COWLING ........................................... 4-12
INSTALLING THE FRONT SIDE COWLING ......................................... 4-13
REMOVING THE FRONT BODY COWLING ......................................... 4-13
INSTALLING THE FRONT BODY COWLING ........................................ 4-13
INSTALLING THE FRONT TURN SIGNAL LIGHT ................................ 4-14

GENERAL CHASSIS (6) .............................................................................. 4-15

REMOVING THE FUEL TANK COVER ................................................. 4-17
INSTALLING THE FUEL TANK COVER ................................................ 4-17

GENERAL CHASSIS (7) .............................................................................. 4-18

INSTALLING THE CENTER LOWER COVER ....................................... 4-20

GENERAL CHASSIS (8) .............................................................................. 4-21

REMOVING THE TAIL/BRAKE LIGHT OUTER COVER ....................... 4-23
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER ...................... 4-23
REMOVING THE REAR SIDE COVER ASSEMBLY ............................. 4-23
INSTALLING THE REAR SIDE COVER ASSEMBLY ............................ 4-24

GENERAL CHASSIS (9) .............................................................................. 4-25

FRONT WHEEL ............................................................................................ 4-27
REMOVING THE FRONT WHEEL .........................................................4-29
DISASSEMBLING THE FRONT WHEEL ............................................... 4-29
CHECKING THE FRONT WHEEL .........................................................4-29
MAINTENANCE OF THE FRONT WHEEL SENSOR AND
SENSOR ROTOR ................................................................................. 4-30
ASSEMBLING THE FRONT WHEEL ..................................................... 4-30
ADJUSTING THE FRONT WHEEL STATIC BALANCE ........................ 4-31
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC) ................. 4-31

REAR WHEEL .............................................................................................. 4-34

CHECKING THE REAR WHEEL ............................................................ 4-35
ADJUSTING THE REAR WHEEL STATIC BALANCE ........................... 4-35

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

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

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

REMOVING THE REAR BRAKE ............................................................ 4-50
CHECKING THE REAR BRAKE SHOES ............................................... 4-50
ASSEMBLING THE REAR BRAKE SHOE PLATE ................................ 4-51
CHECKING THE REAR BRAKE DRUM WEAR LIMIT .......................... 4-52

ABS (ANTI-LOCK BRAKE SYSTEM) .......................................................... 4-53

REMOVING THE HYDRAULIC UNIT ASSEMBLY ................................ 4-54
CHECKING THE HYDRAULIC UNIT ASSEMBLY ................................. 4-54
INSTALLING THE HYDRAULIC UNIT ASSEMBLY ............................... 4-54
HYDRAULIC UNIT OPERATION TESTS ............................................... 4-56
CHECKING THE ABS WARNING LIGHT ..............................................4-58

HANDLEBAR ............................................................................................... 4-59

REMOVING THE FRONT HANDLEBAR COVER ASSEMBLY ............. 4-61
DISASSEMBLING THE FRONT HANDLEBAR COVER ASSEMBLY ... 4-61
REMOVING THE HANDLEBAR ............................................................. 4-61
CHECKING THE HANDLEBAR ............................................................. 4-61
INSTALLING THE HANDLEBAR ........................................................... 4-61
ASSEMBLING THE FRONT HANDLEBAR COVER ASSEMBLY ......... 4-63
INSTALLING THE FRONT HANDLEBAR COVER ASSEMBLY ............ 4-63
FRONT FORK ............................................................................................... 4-64
REMOVING THE FRONT FORK LEGS ................................................. 4-66
DISASSEMBLING THE FRONT FORK LEGS ....................................... 4-66
CHECKING THE FRONT FORK LEGS ................................................. 4-67
ASSEMBLING THE FRONT FORK LEGS ............................................. 4-67
INSTALLING THE FRONT FORK LEGS ............................................... 4-70

STEERING HEAD ......................................................................................... 4-71

REMOVING THE LOWER BRACKET .................................................... 4-73
CHECKING THE STEERING HEAD ...................................................... 4-73
INSTALLING THE STEERING HEAD .................................................... 4-73

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM .................. 4-75

REMOVING THE SWINGARM ............................................................... 4-77
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................. 4-77
CHECKING THE SWINGARM ............................................................... 4-77
INSTALLING THE SWINGARM ............................................................. 4-77
 GENERAL CHASSIS (1)

EAS20026

GENERAL CHASSIS (1)

Removing the battery

4
2
6

5
7

Order Job/Parts to remove Q’ty Remarks

1 Battery cover 1

2 CCU (Communication Control Unit) coupler 1 Disconnect.

GDR155-A only.
3 CCU (Communication Control Unit) 1 GDR155-A only.
4 Band 1 GDR155-A only.
5 Negative battery lead 1 Disconnect.
6 Positive battery lead 1 Disconnect.
7 Battery 1
8 Tool 1

4-1
 GENERAL CHASSIS (1)

EAS31677

REMOVING THE BATTERY COVER 1

1. Remove: a
• Battery cover “1”

a
b. Install the battery cover screws, and then
1
tighten the screws to specification.

Battery cover screw

a. Open the seat. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
b. Remove the battery cover screws.
c. Slide the battery cover rearward to re-
move the projections “a” on the battery
cover from the holes “b” in the storage
box.
1
a

a
EAS31678

INSTALLING THE BATTERY COVER

1. Install:
• Battery cover “1”

a. Fit the projections “a” on the battery cover

into the holes “b” in the storage box, and
then slide the cover forward.

4-2
 GENERAL CHASSIS (2)

EAS20155

GENERAL CHASSIS (2)

Removing the front side cover assembly and rear side cover assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
5

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

1

T.R
.

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

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

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Front side cover assembly (left) 1
2 Front side cover (left) 1
3 Front side cover moulding (left) 1
4 Front side cover assembly (right) 1
5 Front side cover (right) 1
6 Front side cover moulding (right) 1

4-3
 GENERAL CHASSIS (2)

EAS31683
a. Fit the projections on the front side cover
REMOVING THE FRONT SIDE COVER
assembly into the grommets.
ASSEMBLY
The following procedure applies to both of the
2
front side cover assembly.
1. Remove:
• Front side cover assembly “1”

b. Install the front side cover assembly

screws, and then tighten the screw to
1
specification.
c. Close the fuel tank cap lid “2”.
a. Open the fuel tank cap lid “2”. Front side cover screw
b. Remove the front side cover assembly 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

screws.
c. Pull the front side cover assembly outward
REMOVING THE MOLE SIDE COVER
to remove the projections from the grom-
1. Remove:
mets.
• Mole side cover “1”
2

1
1

EAS31684

INSTALLING THE FRONT SIDE COVER a. Remove the mole side cover screws.
ASSEMBLY b. Pull the mole side cover outward to re-
The following procedure applies to both of the move the projections “a” from the hole of
front side cover assembly. front side cover “b”.
1. Install:
• Front side cover assembly “1”

b
a
1
1

4-4
 GENERAL CHASSIS (2)

INSTALLING THE MOLE SIDE COVER

1. Install:
• Mole side cover “1”

a. Fit the projections “a” on the mole side

cover into the hole of front side cover “b”.

b
a
1

b. Install the mole side cover screws and

then tighten the screws to specification.

Front side cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

4-5
 GENERAL CHASSIS (3)

EAS20157

GENERAL CHASSIS (3)

Removing the footrest board assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 5

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
7
6

1 8

2 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

4
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
.

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

3
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side cover assembly
4-3.
1 Footrest board mat (left) 1
2 Footrest board assembly (left) 1
3 Footrest board cover (left) 1
4 Footrest board (left) 1
5 Footrest board mat (right) 1
6 Footrest board assembly (right) 1
7 Footrest board cap 1
8 Footrest board cover (right) 1
9 Footrest board (left) 1

4-6
 GENERAL CHASSIS (3)

EAS31690

INSTALLING THE FOOTREST BOARD a

1. Install:
• Footrest board “1”
b

Footrest board assembly bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

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

EAS31691

INSTALLING THE LOWER MOLE COVER

1. Install:
• Lower mole cover “1”

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

4-7
 GENERAL CHASSIS (4)

EAS20158

GENERAL CHASSIS (4)

Removing the front upper cowling

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Front upper cowling 1

4-8
 GENERAL CHASSIS (4)

EAS31692

REMOVING THE FRONT UPPER COWLING

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

b. Install the front upper cowling assembly

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

Front upper cowling assembly

a. Remove the front upper cowling assembly T. screw
screw.
R.

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

b. Remove the projections “a” on the front
upper cowling assembly from the holes “b”
in the leg shield and the holes “c” in the
front body cowling.

ab
a c

b
1 c

EAS31693

INSTALLING THE FRONT UPPER COWLING

ASSEMBLY
1. Install:
• Front upper cowling assembly “1”

a. Fit the projections “a” on the front upper

cowling assembly into the holes “b” in the
leg shield and into the holes “c” in the front
body cowling.

4-9
 GENERAL CHASSIS (5)

EAS20193

GENERAL CHASSIS (5)

Removing the front cowling assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R

T.R
.

.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 8 7
3
T.R
.

10 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
11 16 17
15

1 2

18 9
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

.
T.R

6 12
.

1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 4

T.R
.

19
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.

14
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.

5
13
9 N•m (0.9 kgf•m, 6.6 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
T.R

.
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side cover assembly 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Footrest board assembly 4-6.
Refer to “GENERAL CHASSIS (4)” on page
Front upper cowling 4-8.
1 Headlight unit coupler 1 Disconnect.
2 Front turn signal light coupler 1 Disconnect.
3 Front cowling assembly 1
4 Side cover (left) 1
5 Front side cowling assembly (left) 1
6 Front turn signal light (left) 1
7 Side cover (right) 1
8 Front side cowling assembly (right) 1
9 Front turn signal light (right) 1
10 Front upper panel 1

4-10
 GENERAL CHASSIS (5)

Removing the front cowling assembly

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

T.R
.

.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 8 7
3
T.R
.

10 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
11 16 17
15

1 2

18 9
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

.
T.R

6 12
.

1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 4

T.R
.

19
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.

14
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.

5
13
9 N•m (0.9 kgf•m, 6.6 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
T.R

.
.

Order Job/Parts to remove Q’ty Remarks

11 Headlight assembly 1
12 Front side cowling inner panel (left) 1
13 Front side cowling (left) 1
14 Front side panel (left) 1
15 Front side cowling inner panel (right) 1
16 Front side cowling (right) 1
17 Front side panel (right) 1
18 Headlight cover 1
19 Headlight unit 1

4-11
 GENERAL CHASSIS (5)

EAS31278
a. Fit the projections “a” on the leg shield into
REMOVING THE FRONT COWLING
the holes “b” in the front cowling assembly.
ASSEMBLY
1. Remove: a
• Front cowling assembly “1” b
• Disconnect turn signal light coupler a
a
• Disconnect head light coupler
b
b
a
b
1

b. Install the front cowling assembly screws,

and then tighten the screws to specifica-
tion.
1
Front cowling assembly screw
a. Remove the front cowling assembly (M5 × 6)
T.
R.

screws. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

b. Pull the front cowling assembly forward to Front cowling assembly bolt
remove the projections “a” on the leg 10 N·m (1.0 kgf·m, 7.4 lb·ft)
shield from the holes “b” in the front cowl- EAS31696
ing assembly. REMOVING THE FRONT SIDE COWLING
The following procedure applies to both of the
a b front side cowling.
a 1. Remove:
a • Front side cowling “1”
b
b
a
b
1

EAS31279

INSTALLING THE FRONT COWLING

ASSEMBLY 1
1. Install:
• Disconnect turn signal light coupler a. Removing the front side cowling screws.
• Disconnect head light coupler b. Remove the projections “a” on the front
• Front cowling assembly “1” side cowling from the holes “b” in the front
lower cowling.

a b

a
b
1
1 a

4-12
 GENERAL CHASSIS (5)

EAS31697
REMOVING THE FRONT BODY COWLING
INSTALLING THE FRONT SIDE COWLING
1. Remove:
The following procedure applies to both of the
• Front body cowling “1”
front side cowling.
1. Install:
• Front side cowling “1”

1 a. Remove the front body cowling screws.

b. Pull the front body cowling forward to re-
move the projections “a” on the front cowl-
a. Fit the projections “a” on the front side
ing assembly from the holes “b” in the front
cowling into the holes “b” in the front lower
body cowling.
cowling.

a b

a
b
1 b
a
a 1

b. Install the front side cowling screws, and INSTALLING THE FRONT BODY COWLING
then tighten the screws to specification. 1. Install:
• Front body cowling “1”
Front side cowling screw
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

a. Fit the projections “a” on the front body

cowling into the holes “b” in the front cowl-
ing assembly.

4-13
 GENERAL CHASSIS (5)

b
a 1
b. Install the front body cowling screws and
then tighten the screws to specification.

Front body cowling screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

EAS31698

INSTALLING THE FRONT TURN SIGNAL

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

Turn signal light screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

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

4-14
 GENERAL CHASSIS (6)

EAS20194

GENERAL CHASSIS (6)

Removing the fuel tank cover and seat assembly
6 N•m (0.6 kgf•m, 4.4 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.

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

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
4

.
1

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

10
7 N•m (0.7 kgf•m, 5.2 lb•ft) 2
T.R
.

8
11

9
7 N•m (0.7 kgf•m, 5.2 lb•ft) 7
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
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side cover assembly 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Footrest board assembly 4-6.
Refer to “GENERAL CHASSIS (4)” on page
Front upper cowling 4-8.
Refer to “GENERAL CHASSIS (5)” on page
Front cowling assembly 4-10.
1 Fuel tank cover 1
2 Fuel tank cap lid lock cable 1
3 Fuel tank cap lid lock assembly 1
4 Fuel tank cap lid 1
5 Fuel tank cap lid hinge 1
6 SGCU (starter generator control unit) coupler 1/1/1 Disconnect.
7 SGCU (starter generator control unit) 1
8 Flap 1

4-15
 GENERAL CHASSIS (6)

Removing the fuel tank cover and seat assembly

6 N•m (0.6 kgf•m, 4.4 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.

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

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
4

.
1

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

10
7 N•m (0.7 kgf•m, 5.2 lb•ft) 2
T.R
.

8
11

9
7 N•m (0.7 kgf•m, 5.2 lb•ft) 7
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
.

Order Job/Parts to remove Q’ty Remarks

9 SGCU (starter generator control unit) bracket 1
10 Seat assembly 1
11 Seat hinge 1

4-16
 GENERAL CHASSIS (6)

EAS31685
a. Slide the fuel tank cover forward and fit the
REMOVING THE FUEL TANK COVER
projections “a” on the cover into the holes
1. Remove:
“b” in the leg shield.
• Fuel tank cover “1”
b. Install the fuel tank cover screws, and then
tighten the screws to specification.

Fuel tank cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.
R.
1

a. Remove the fuel tank cover screws. b a

b. Slide the fuel tank cover rearward to re-
move the projections “a” on the cover from
the holes “b” in the leg shield.

b a

EAS31686

INSTALLING THE FUEL TANK COVER

1. Install:
• Fuel tank cover “1”

4-17
 GENERAL CHASSIS (7)

GENERAL CHASSIS (7)

Removing the leg shield

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

.
T.R
.

10
7

(2)
4 6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
5
2.8 N•m (0.28 kgf•m, 2.1 lb•ft)

T.R
.
15
9
6

3 (2)
2 8 14

13
12

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.

11 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

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

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side cover assembly 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Footrest board assembly 4-6.
Refer to “GENERAL CHASSIS (4)” on page
Front upper cowling 4-8.
Refer to “GENERAL CHASSIS (5)” on page
Front cowling assembly 4-10.
Refer to “GENERAL CHASSIS (6)” on page
Fuel tank cover 4-15.
1 Center lower cover 1
2 Wire harness 1
3 Main switch cover 1
4 Fuel tank cap lid lock cable 1 Disconnect.
5 Seat lock cable 1 Disconnect.
6 Main switch coupler 1 Disconnect.
7 Main switch 1
8 Auxiliary DC jack coupler 1 Disconnect.

4-18
 GENERAL CHASSIS (7)

Removing the leg shield

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

.
T.R
.

10
7

(2)
4 6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
5
2.8 N•m (0.28 kgf•m, 2.1 lb•ft)

T.R
.
15
9
6

3 (2)
2 8 14

13
12

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.

11 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

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

Order Job/Parts to remove Q’ty Remarks

9 Auxiliary DC jack 1
10 Turn signal relay 1
11 Auxiliary DC jack lid hinge cover 1
12 Auxiliary DC jack lid hinge 1
13 Auxiliary DC jack lid hinge bracket 1
14 Auxiliary DC jack lid 1
15 Leg shield assembly 1

4-19
 GENERAL CHASSIS (7)

EAS31689

INSTALLING THE CENTER LOWER COVER

1. Install:
• Center lower cover “1”
TIP
Fit the end of the fuel tank overflow hose “2” into
the hole “a” in the center lower cover.

a 2

4-20
 GENERAL CHASSIS (8)

GENERAL CHASSIS (8)

Removing the grab bars, rear upper cowlings, and rear lower cowling assembly
1.0 N•m (0.10 kgf•m, 0.73 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R

T.R
.

.
6
9 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.R
.
10 8 11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
5

T.R
.
4 11 15
17 12
13 16
14

9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

2
T.R
.

1 3

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side cover assembly 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Footrest board assembly 4-6.
Refer to “GENERAL CHASSIS (4)” on page
Front upper cowling 4-8.
Refer to “GENERAL CHASSIS (5)” on page
Front cowling assembly 4-10.
Refer to “GENERAL CHASSIS (6)” on page
Seat assembly 4-15.
1 Fuse box 1
2 Relay 1
3 Relay 1
4 Storage box dust cover 1
5 Storage box 1
6 Tail/brake light outer cover 1
7 Rear side cover assembly 1
8 Rear side cover (left) 1

4-21
 GENERAL CHASSIS (8)

Removing the grab bars, rear upper cowlings, and rear lower cowling assembly
1.0 N•m (0.10 kgf•m, 0.73 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R

T.R
.

.
6
9 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.R
.
10 8 11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
5

T.R
.
4 11 15
17 12
13 16
14

9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

2
T.R
.

1 3

Order Job/Parts to remove Q’ty Remarks

9 Rear side cover (right) 1
10 Rear side lower cover 1
11 Seat lock cable 1 Disconnect.
12 Seat lock assembly 1
13 Tail/brake light assembly lead 1
14 Rear turn signal light lead 1
15 Holder 1
16 Grab bar (left) 1
17 Grab bar (right) 1

4-22
 GENERAL CHASSIS (8)

EAS31681

REMOVING THE TAIL/BRAKE LIGHT OUTER 1 a

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

a. Install the tail/brake light outer cover

screws, and then tighten the screws to
specification.

Tail/brake light outer cover screw

a. Remove the tail/brake light outer cover T.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
R.
screws.
b. Slide the tail/brake light outer cover rear- EAS31687

ward to remove the projection “a” on the REMOVING THE REAR SIDE COVER
cover from the hole “b” in the tail/brake ASSEMBLY
light. The following procedure applies to both of the
rear side cover assembly.
1 a 1. Remove:
• Rear side cover assembly “1”
b

EAS31682

INSTALLING THE TAIL/BRAKE LIGHT

OUTER COVER
1. Install: a. Remove the screws.
• Tail/brake light outer cover “1” b. Remove the projections “a” on the rear
side cover assembly from the holes “b” of
the mole rear side cover.
1

a
a. Slide the tail/brake light outer cover for-
ward, fit the projection “a” on the cover into
the hole “b” in the tail/brake light.

4-23
 GENERAL CHASSIS (8)

EAS31688

INSTALLING THE REAR SIDE COVER

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

a. Fit the projections “a” on the rear side cov-

er assembly into the holes “b” of the mole
rear side cover.

b. Install the screws, and then tighten the

screws to specification.

Rear side cover assembly screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.

4-24
 GENERAL CHASSIS (9)

GENERAL CHASSIS (9)

Removing the tail/brake light assembly, rear turn signal light, and rear fender
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.

1.0 N•m (0.10 kgf•m, 0.73 lb•ft) 8

1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.

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

2 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

3 10

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

6
T.R
.
4.8 N•m (0.48 kgf•m, 3.5 lb•ft)
5 12 N•m (1.2 kgf•m, 8.9 lb•ft)
T.R
.

1
11

3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side cover assembly 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Footrest board assembly 4-6.
Refer to “GENERAL CHASSIS (4)” on page
Front upper cowling 4-8.
Refer to “GENERAL CHASSIS (5)” on page
Front cowling assembly 4-10.
Refer to “GENERAL CHASSIS (6)” on page
Seat assembly 4-15.
Refer to “GENERAL CHASSIS (8)” on page
Storage box / Grab bar 4-21.
1 Tail/brake light assembly coupler 1 Disconnect.
2 Tail/brake light assembly 1
3 Tail/brake light cover 1
4 Rear turn signal light connector (left) 1 Disconnect.
5 Rear turn signal light connector (right) 1 Disconnect.
6 License plate light coupler 1 Disconnect.
7 Rear turn signal light (left) 1

4-25
 GENERAL CHASSIS (9)

Removing the tail/brake light assembly, rear turn signal light, and rear fender
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.

1.0 N•m (0.10 kgf•m, 0.73 lb•ft) 8

1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.

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

2 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

3 10

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

6
4.8 N•m (0.48 kgf•m, 3.5 lb•ft)

T.R
.
5 T.R
.

12 N•m (1.2 kgf•m, 8.9 lb•ft)

4

1
11

3.8 N•m (0.38 kgf•m, 2.8 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

8 Rear turn signal light (right) 1
9 License plate light 1
10 Rear fender 1 1
11 Rear fender 2 1

4-26
 FRONT WHEEL

EAS20028

FRONT WHEEL
Removing the front wheel and brake disc

26 N•m (2.6 kgf•m, 19 lb•ft)

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

LS

2 7
6
1

3 5 9
LS LT

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

New LT

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

T.R
.

Order Job/Parts to remove Q’ty Remarks

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

4-27
 FRONT WHEEL

Disassembling the front wheel

New 1
New 2

LS

3
New 2
New 1

LS

Order Job/Parts to remove Q’ty Remarks

1 Oil seal 2
2 Wheel bearing 2
3 Spacer 1

4-28
 FRONT WHEEL

EAS30145

REMOVING THE FRONT WHEEL

ECA22340

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

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

TIP WARNING
Place the vehicle on a suitable stand so that the Do not attempt to straighten a bent wheel ax-
front wheel is elevated. le.

EAS30146

DISASSEMBLING THE FRONT WHEEL

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

4-29
 FRONT WHEEL

3. Measure: 1. Check:
• Radial wheel runout “1” • Front wheel sensor “1”
• Lateral wheel runout “2” Cracks/bends/distortion → Replace.
Over the specified limits → Replace. Iron powder/dust → Clean.

Radial wheel runout limit

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

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

EAS30151

ASSEMBLING THE FRONT WHEEL

1. Lubricate:
EAS30155
• Oil seal lips
MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR Recommended lubricant
ECA21630
Lithium-soap-based grease
NOTICE
• The speed sensor cannot be disassembled. 2. Install:
Do not attempt to disassemble it. If faulty, • Wheel bearings New
replace with a new one.
• Oil seals New
• Keep magnets (including magnetic pick-up
a. Install the new wheel bearing (right side).
tools, magnetic screwdrivers, etc.) away ECA18110

from the speed sensor. NOTICE

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

4-30
 FRONT WHEEL

EAS30154
TIP INSTALLING THE FRONT WHEEL (FRONT
Use a socket “4” that matches the diameter of BRAKE DISC)
the wheel bearing outer race. 1. Install:
• Front brake disc “1”
• Front wheel sensor rotor “2”

Front wheel sensor rotor bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)

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

NOTICE
b. Install the spacer.
c. Install the new wheel bearing (left side). • Do not drop the wheel sensor rotor or sub-
TIP ject it to shocks.
• If any solvent gets on the wheel sensor ro-
Place a suitable washer “1” between the socket
tor, wipe it off immediately.
“2” and the bearing so that both the inner race
• Replace the brake disc bolts and wheel
“3” and outer race “4” are pressed at the same
sensor rotor bolts with new ones.
time, and then press the bearing until the inner
race makes contact with the spacer “5”. TIP
• Install the brake disc with its chamfered side
“a” facing inward.
• Install the front wheel sensor rotor with the
stamped mark “b” facing away from the wheel.
• Tighten the bolts in stages.

1
1

EAS30152

ADJUSTING THE FRONT WHEEL STATIC

BALANCE
TIP a
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed. b
1. Remove:
• Balancing weight(s)
2. Find:
• Front wheel’s heavy spot
3. Adjust: 2
• Front wheel static balance
4. Check:
• Front wheel static balance

4-31
 FRONT WHEEL

2. Check: ECA21020

• Front brake disc NOTICE

Refer to “CHECKING THE FRONT BRAKE Make sure there are no foreign materials in
DISC” on page 4-42. the front wheel sensor rotor and front wheel
3. Lubricate: sensor. Foreign materials cause damage to
• Wheel axle the front wheel sensor rotor and front wheel
sensor.
Recommended lubricant
Lithium-soap-based grease TIP
• When installing the front wheel sensor, check
4. Install: the wheel sensor lead for twists.
• Front wheel • To route the front wheel sensor lead, refer to
• Collars “CABLE ROUTING” on page 2-13.
• Front wheel axle
7. Measure:
TIP • Distance “a”
Install the front wheel with the mark “a” on the (between the front wheel sensor rotor “1” and
front tire pointing in the direction of wheel rota- front wheel sensor “2”)
tion. Out of specification → Check the wheel bear-
ing for looseness, and the front wheel sensor
and sensor rotor installation conditions (war-
a page caused by overtorque, wrong installa-
tion direction, rotor decentering, LOCTITE®
on the mounting surface of the rotor, defor-
mation caused by an impact during service
and caught foreign materials). If there is any
defective part, repair or replace the defective
part.

Distance “a” (between the front

5. Tighten:
wheel sensor rotor and front
• Front wheel axle nut wheel sensor)
0.65–1.66 mm (0.026–0.065 in)
Front wheel axle nut
26 N·m (2.6 kgf·m, 19 lb·ft)
T.

TIP
R.

ECA14140
Measure the distance between the front wheel
NOTICE sensor rotor and front wheel sensor in several
Before tightening the wheel axle nut, push places in one rotation of the front wheel. Do not
down hard on the handlebar(s) several times turn the front wheel while the thickness gauge is
and check if the front fork rebounds smooth- installed. This may damage the front wheel sen-
ly. sor rotor and the front wheel sensor.
6. Install:
• Front wheel sensor Thickness gauge
90890-03180
Front wheel sensor bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

4-32
 FRONT WHEEL

a
2

2
1
1

8. Install:
• Front brake caliper
• Front brake hose guide “1”

Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

Front brake hose guide bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
EWA13500

WARNING
Make sure the brake hose is routed properly.
TIP
While holding the front brake hose guide so that
the portions “a” of the guide and holder contact
the front fork outer tube, tighten the bolts to
specification.

4-33
 REAR WHEEL

EAS22020

REAR WHEEL
Removing the rear wheel

95 N•m (9.5 kgf•m, 69 lb•ft)

.R
.

Order Job/Parts to remove Q’ty Remarks

Place the vehicle on the centerstand so that
the rear wheel is elevated.
Muffler Refer to “ENGINE REMOVAL” on page 5-4.
1 Rear arm 1
2 Rear wheel 1

4-34
 REAR WHEEL

EAS22090

CHECKING THE REAR WHEEL

1. Check:
• Tire
• Rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-13 and “CHECKING THE WHEELS” on
page 3-13.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-29.
EAS22150

ADJUSTING THE REAR WHEEL STATIC

BALANCE
TIP
After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” in SERVICE MANUAL
BASIC INFORMATION.

4-35
 FRONT BRAKE

EAS20030

FRONT BRAKE
Removing the front brake pads

6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.

1
3

6
2 35 N•m (3.5 kgf•m, 25 lb•ft)
T.R
.

4
5

Order Job/Parts to remove Q’ty Remarks

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

4-36
 FRONT BRAKE

Removing the front brake master cylinder

16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.

3
29 N•m (2.9 kgf•m, 21 lb•ft)

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

6
S

5 4
6

6 N•m (0.6 kgf•m, 4.4 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-59.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Front brake light switch connector 2 Disconnect.
5 Front brake light switch 1
6 Front brake lever pivot bolt/nut 1/1
7 Front brake lever 1
8 Front brake hose union bolt 1
9 Brake hose gasket 2

4-37
 FRONT BRAKE

Removing the front brake master cylinder

16 N•m (1.6 kgf•m, 12 lb•ft)

11

T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.

29 N•m (2.9 kgf•m, 21 lb•ft)

T.R
12

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

10

6 N•m (0.6 kgf•m, 4.4 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R

T.R
.

Order Job/Parts to remove Q’ty Remarks

10 Front brake hose 1 Disconnect.
11 Front brake master cylinder holder 1
12 Front brake master cylinder assembly 1

4-38
 FRONT BRAKE

Disassembling the front brake master cylinder

BF
S

BF
2

1 New

Order Job/Parts to remove Q’ty Remarks

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

4-39
 FRONT BRAKE

Removing the front brake caliper

1 3

2 New
5
29 N•m (2.9 kgf•m, 21 lb•ft)
T .R
.

35 N•m (3.5 kgf•m, 26 lb•ft)

T.
R
.

Order Job/Parts to remove Q’ty Remarks

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

4-40
 FRONT BRAKE

Disassembling the front brake caliper

6
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
S

7
11 New 8
New 9
10

2 5

BF
S 3

4
1

Order Job/Parts to remove Q’ty Remarks

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

4-41
 FRONT BRAKE

EAS30168
e. Measure the runout 1.5 mm (0.06 in) 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.
Out of specification → Replace.
ing brake components.
• Brake fluid may damage painted surfaces Brake disc thickness limit
and plastic parts. Therefore, always clean 3.5 mm (0.14 in)
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.

EAS30169

CHECKING THE FRONT BRAKE DISC

1. Remove:
• Front wheel 5. Adjust:
Refer to “FRONT WHEEL” on page 4-27. • Brake disc runout
2. Check: a. Remove the brake disc.
• Brake disc b. Rotate the brake disc by one bolt hole.
Damage/galling → Replace. c. Install the brake disc.
3. Measure:
• Brake disc runout Front brake disc bolt
Out of specification → Correct the brake disc 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.

runout or replace the brake disc. LOCTITE®

Brake disc runout limit (as mea- ECA19150

sured on wheel) NOTICE

0.15 mm (0.0059 in) Replace the brake disc bolts with new ones.

a. Place the vehicle on a suitable stand so TIP

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

4-42
 FRONT BRAKE

B
1
1
a

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

Brake pad lining thickness limit

0.8 mm (0.03 in)

A c. Tighten the bleed screw.

Brake caliper bleed screw

6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.

a
R.

d. Install new brake pad spring “1” and new

brake pads.
TIP
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
piston.

4-43
 FRONT BRAKE

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

REMOVING THE FRONT BRAKE CALIPER

TIP
3. Install: Before removing the brake caliper, drain the
• Brake pad pin brake fluid from the entire brake system.
• Brake pad clips 1. Remove:
• Front brake caliper • Brake hose union bolt “1”
• Front brake caliper bolts • Brake hose gaskets “2”
• Front brake hose “3”
Front brake caliper bolt
TIP
35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

Put the end of the brake hose into a container

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

a EAS30172

DISASSEMBLING THE FRONT BRAKE

CALIPER
1. Remove:
• Brake caliper piston “1”
4. Check:
• Brake caliper piston dust seal “2”
• Brake fluid level
• Brake caliper piston seal “3”
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-11.
3
2
1

a. Blow compressed air into the brake hose

joint opening “a” to force out the piston
from the brake caliper “1”.

4-44
 FRONT BRAKE

EWA13550

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

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

ASSEMBLING THE FRONT BRAKE CALIPER

1 EWA13621

WARNING
b. Remove the brake caliper piston dust seal • Before installation, all internal brake com-
and brake caliper piston seal. ponents should be cleaned and lubricated
with clean or new brake fluid.
EAS30173

CHECKING THE FRONT BRAKE CALIPER • Never use solvents on internal brake com-
ponents as they will cause the brake caliper
Recommended brake component replacement piston dust seals and brake caliper piston
schedule
seals to swell and distort.
Brake pads If necessary • Whenever a brake caliper is disassembled,
Piston seal Every two years replace the brake caliper piston dust seals
and brake caliper piston seals.
Piston dust seal Every two years
Brake hose Every four years
Specified brake fluid
Every two years and lDOT 4
Brake fluid whenever the brake is
disassembled EAS30934

INSTALLING THE FRONT BRAKE CALIPER

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

assembly.
R.

29 N·m (2.9 kgf·m, 21 lb·ft)

• Brake fluid delivery passages
(brake caliper body) EWA13531

Obstruction → Blow out with compressed air. WARNING

EWA17070
Proper brake hose routing is essential to in-
WARNING
sure safe vehicle operation.
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.

4-45
 FRONT BRAKE

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

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

Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.

Refer to “REPLACING THE FRONT BRAKE

PADS” on page 4-43. 7. Check:
4. Fill: • Brake lever operation
• Brake master cylinder reservoir Soft or spongy feeling → Bleed the brake sys-
(with the specified amount of the specified tem.
brake fluid) Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
Specified brake fluid
DOT 4 EAS30179

REMOVING THE FRONT BRAKE MASTER

EWA13540 CYLINDER
WARNING TIP
• Use only the designated brake fluid. Other Before removing the front brake master cylinder,
brake fluids may cause the rubber seals to drain the brake fluid from the entire brake sys-
deteriorate, causing leakage and poor tem.
brake performance.
1. Remove:
• Refill with the same type of brake fluid that
• Brake hose union bolt “1”
is already in the system. Mixing brake fluids
• Brake hose gaskets “2”
may result in a harmful chemical reaction,
• Front brake hose “3”
leading to poor brake performance.
TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.

4-46
 FRONT BRAKE

Specified brake fluid

DOT 4

2 EAS30182

INSTALLING THE FRONT BRAKE MASTER

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

EAS30725 Front brake master cylinder hold-

CHECKING THE FRONT BRAKE MASTER er bolt

T.
R.
CYLINDER 16 N·m (1.6 kgf·m, 12 lb·ft)
1. Check:
• Brake master cylinder TIP
Damage/scratches/wear → Replace. • Install the brake master cylinder holder with the
• Brake fluid delivery passages “UP” mark “a” facing up.
(brake master cylinder body) • Align the edge “b” of the brake master cylinder
Obstruction → Blow out with compressed air. holder with the edge “c” of the stay on the han-
2. Check: dlebar as shown in the illustration.
• Brake master cylinder kit • First, tighten the upper bolt, then the lower bolt.
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir “1” b
• Brake master cylinder reservoir cap “2” c
1
• Brake master cylinder reservoir diaphragm
holder “3”
• Brake master cylinder reservoir diaphragm
“4”
Damage/wear → Replace. a
2
1 2. Install:
• Brake hose gaskets “1” New
3 • Front brake hose “2”
• Brake hose union bolt “3”

4 Front brake hose union bolt

(master cylinder side)
T.
R.

29 N·m (2.9 kgf·m, 21 lb·ft)

4. Check: EWA13531

• Front brake hose WARNING

Cracks/damage/wear → Replace. Proper brake hose routing is essential to in-
EAS30181
sure safe vehicle operation.
ASSEMBLING THE FRONT BRAKE MASTER
TIP
CYLINDER
EWA13520 • Make sure that the distance “a” between the
WARNING brake hose and the handlebar “4” is 40–44 mm
• Before installation, all internal brake com- (1.57–1.73 in) as shown in the illustration.
ponents should be cleaned and lubricated • Turn the handlebar to the left and right to make
with clean or new brake fluid. sure the brake hose does not touch other parts
• Never use solvents on internal brake com- (e.g., wire harness, cables, leads). Correct if
ponents. necessary.

4-47
 FRONT BRAKE

New 1
a
3
4
2 a

3. Fill: 6. Check:
• Brake master cylinder reservoir • Brake lever operation
(with the specified amount of the specified Soft or spongy feeling → Bleed the brake sys-
brake fluid) tem.
Refer to “BLEEDING THE HYDRAULIC
Specified brake fluid BRAKE SYSTEM” on page 3-12.
DOT 4
EWA13540

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

NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
5. Check:
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-11.

4-48
 REAR BRAKE

EAS5P03037

REAR BRAKE
Disassembling the brake shoe

7 N·m (0.7 kgf·m, 5.2 lb·ft)

6
9

3 6

4
1

10

Order Job/Parts to remove Q’ty Remarks

Rear wheel Refer to “REAR WHEEL” on page 4-34.
1 Brake shoe 2
2 Brake shoe spring 2
3 Rear brake cable adjusting nut 1
4 Compression spring 1
5 Rear brake cable assembly 1
6 Pin 1
7 Brake camshaft lever 1
8 Washer 1
9 Brake shoe wear indicator 1
10 Brake camshaft 1

4-49
 REAR BRAKE

EAS5P03038
4. Remove:
REMOVING THE REAR BRAKE
• Brake camshaft “1”
1. Remove:
• Brake shoes “1”
• Brake shoe spring “2”

1
1 EAS5P03039

CHECKING THE REAR BRAKE SHOES

1. Check:
2. Remove: • Brake shoe lining
• Adjusting nut “1” Glazed areas → Repair.
• Rear brake cable “2” Sand the glazed areas with coarse sandpa-
• Pin “3” per.
• Brake camshaft lever bolt “4”
TIP
• Brake camshaft lever “5”
After sanding the glazed areas, clean the brake
shoe with a cloth.

1
2
3
3. Remove:
• Wave washer “1”
• Brake shoe wear indicator “2”
2. Measure:
• Brake shoe lining thickness “a”
Out of specification → Replace.

Lining thickness
4.0 mm (0.16 in)
2 Limit
2.0 mm (0.08 in)
1

4-50
 REAR BRAKE

EWA3C11004
c. Check that the brake shoes are properly
WARNING positioned.
Do not allow oil or grease on the brake
shoes. b
TIP 1
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
• Brake drum inside diameter “a” 2
Out of specification → Replace the wheel. a

Brake drum inside diameter

130.0 mm (5.12 in) EWA5P03004

Limit WARNING
131.0 mm (5.16 in) After installing the brake camshaft, remove
any excess grease.

a 2. Install:
• Brake camshaft lever “1”

Brake camshaft lever pinch bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

TIP
Align the punch mark on the brake camshaft with
the mark on the brake camshaft lever positioned
as shown “a”.
4. Check:
• Brake drum inner surface
Oil deposits → Clean.
Remove the oil with a rag soaked in lacquer
thinner or solvent.
Scratches → Repair. a
Lightly and evenly polish the scratches with
an emery cloth.
5. Check: 1
• Brake camshaft
Damage/wear → Replace.
EAS5P03040
3. Install:
ASSEMBLING THE REAR BRAKE SHOE • Brake shoe springs “1”
PLATE • Brake shoes
1. Install: TIP
• Brake camshaft “1” • Lubricate the pivot pin with a thin coat of sili-
• Brake shoe wear indicator “2” cone grease.
• Wave washer • Do not to damage the springs during installa-
a. Install the brake camshaft so its punch tion.
mark “a” is positioned as shown. • Install the brake shoe springs as shown.
b. Align the projection “b” on the brake shoe
wear indicator with the notch in the brake
camshaft.

4-51
 REAR BRAKE

EWA3C11005
2. Check:
WARNING • Brake pedal free play
Do not apply grease to the brake shoe lin- If the free play is out of specification.
ings. Refer to “CHECKING THE REAR BRAKE
SHOES” on page 3-11.
1 3. While pressing the brake pedal all the way
down, push the brake camshaft lever fully in
the arrow indicated direction and check that
the brake shoe wear indicator does not reach
the brake drum wear indicator.
Not reaching → Still usable.
Reaching → Replace the wheel.

EAS5P03041

CHECKING THE REAR BRAKE DRUM WEAR

LIMIT
TIP
After the new brake shoes are installed, the
brake drum inside diameter can be checked as
to whether it is within the wear limit “a” by means
of the brake drum wear indicator on the brake
shoe plate.

1. Check:
• Position at which to install the brake camshaft
lever
Reinstall the brake camshaft lever if its
installed position is out of specification.

4-52
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS20032

ABS (ANTI-LOCK BRAKE SYSTEM)

Removing the hydraulic unit assembly

T .R
.
29 N•m (2.9 kgf•m, 21 lb•ft)

3
New 4
2

5 3
New

1 6

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T .R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
Refer to “GENERAL CHASSIS (5)” on page
Front cowling assembly
4-10.
Refer to “GENERAL CHASSIS (4)” on page
Front upper cowling assembly
4-8.
1 ABS ECU coupler 1 Disconnect.
Front brake hose union bolt (hydraulic unit as-
2 sembly side) 2

3 Brake hose gasket 4

Front brake hose (front brake master cylinder to
4 1 Disconnect.
hydraulic unit)
Front brake hose (hydraulic unit to front brake
5 1 Disconnect.
caliper)
6 Hydraulic unit assembly 1

4-53
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30197

REMOVING THE HYDRAULIC UNIT TIP

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

Unless necessary, avoid removing and in- NOTICE

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

CHECKING THE HYDRAULIC UNIT

1. Disconnect: ASSEMBLY
• ABS ECU coupler “1” 1. Check:
• Hydraulic unit assembly
Cracks/damage → Replace the hydraulic unit
assembly and the brake hoses that are con-
nected to the assembly as a set.
1 EAS30200

INSTALLING THE HYDRAULIC UNIT

ASSEMBLY
1. Install:
• Hydraulic unit assembly

2. Remove: Hydraulic unit assembly bolt

• Brake hoses 7 N·m (0.7 kgf·m, 5.1 lb·ft)
T.
R.

4-54
 ABS (ANTI-LOCK BRAKE SYSTEM)

ECA21110
TIP
NOTICE
• Connect the ABS ECU coupler 1.
Do not remove the rubber plugs or bolts
• Make sure that the ABS ECU coupler is con-
(M10 × 1.25) installed in the brake hose union
nected in the correct position.
bolt holes before installing the hydraulic unit
assembly.
TIP
Do not allow any foreign materials to enter the 1
hydraulic unit assembly or the brake hoses
when installing the hydraulic unit assembly.
2. Remove:
• Rubber plugs or bolts (M10 × 1.25)
3. Install:
• Front brake hose (front brake master cylinder
to hydraulic unit) “1” 5. Fill:
• Front brake hose (hydraulic unit to front brake • Brake master cylinder reservoir
caliper) “2” • Brake fluid reservoir
(with the specified amount of the specified
Front brake hose union bolt brake fluid)
(hydraulic unit assembly side)
T.
R.

29 N·m (2.9 kgf·m, 21 lb·ft) Specified brake fluid

DOT 4
ECA21121

NOTICE EWA13090

If the brake hose union bolt does not turn WARNING

easily, replace the hydraulic unit assembly, • Use only the designated brake fluid. Other
brake hoses, and related parts as a set. brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
TIP brake performance.
Position the pipe sections of the brake hoses at • Refill with the same type of brake fluid that
a 30° angle from the line “a” as shown in the il- is already in the system. Mixing brake fluids
lustration, and then tighten the brake hose union may result in a harmful chemical reaction,
bolts to specification. leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
2 will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
ECA13540

NOTICE
a
a Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
1
6. Bleed:
4. Connect: • Brake system
• ABS ECU coupler “1” Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
7. Check the operation of the hydraulic unit ac-
cording to the brake levers response. (Refer
to “HYDRAULIC UNIT OPERATION TESTS”
on page 4-56.)

4-55
 ABS (ANTI-LOCK BRAKE SYSTEM)

ECA14550
TIP
NOTICE
If the battery voltage is lower than 12.8 V, charge
Always check the operation of the hydraulic
the battery, and then perform brake line routing
unit according to the brake lever response.
confirmation.
8. Delete the fault codes. (Refer to “[B-3] DE-
LETING THE FAULT CODES” on page
9-21.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-58.)
EAS30201

HYDRAULIC UNIT OPERATION TESTS

The reaction-force pulsating action generated in
the brake levers when the ABS is activated can
be tested when the vehicle is stopped.
The hydraulic unit operation can be tested using 6. Remove the CCU (Communication Control
the following two methods. Unit) “1”, and then connect the Yamaha diag-
• Brake line routing confirmation: this test nostic tool “2” to the coupler “3”.
checks the function of the ABS after the sys-
tem was disassembled, adjusted, or serviced. Yamaha diagnostic tool USB
• ABS reaction-force confirmation: this test gen- 90890-03267
erates the same reaction-force pulsating action Yamaha diagnostic tool (A/I)
that is generated in the front brake lever when 90890-03264
the ABS is front activated.

Brake line routing confirmation

EWA13120

WARNING
Securely support the vehicle so that there is
1
no danger of it falling over.
TIP
• For the brake line routing confirmation, use the
diagnosis mode of the Yamaha diagnostic tool.
• Before performing the brake line routing confir-
mation, make sure that no malfunctions have
been detected in the ABS ECU and that the 2
3
wheels are not rotating.
1. Place the vehicle on a center stand.
2. Turn the main switch to “OFF”.
3. Open the seat.
4. Remove:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.
7. Start the Yamaha diagnostic tool and display
5. Check:
the diagnosis mode screen.
• Battery voltage
8. Select code No. 2, “Brake line routing confir-
Lower than 12.8 V → Charge or replace the
mation”.
battery.
9. Click “Action” “1”, and then operate the front
Battery voltage brake lever “2” simultaneously.
Higher than 12.8 V

4-56
 ABS (ANTI-LOCK BRAKE SYSTEM)

TIP ABS reaction-force confirmation

EWA13120
• The hydraulic unit operates 1 second after the WARNING
front brake lever operated and continues for
Securely support the vehicle so that there is
approximately 1 second.
no danger of it falling over.
• The operation of the hydraulic unit can be con-
firmed using the indicator. TIP
On: The hydraulic unit is operating. • For the ABS reaction-force confirmation, use
Flashing: The conditions for operating the hy- the diagnosis mode of the Yamaha diagnostic
draulic unit have not been met. tool. For more information, refer to the opera-
Off: The front brake lever is not being operated. tion manual of the Yamaha diagnostic tool.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
1. Place the vehicle on a center stand.
2. Turn the main switch to “OFF”.
3. Open the seat.
4. Remove:
1 • Battery cover
Refer to “GENERAL CHASSIS (1)” on page
10.Check: 4-1.
• Hydraulic unit operation 5. Check:
Click “Action”, a single pulse will be generat- • Battery voltage
ed in the front brake lever “1”, operate only Lower than 12.8 V → Charge or replace the
once. battery.

Battery voltage
Higher than 12.8 V

TIP
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform ABS reaction-
force confirmation.
1

TIP
“ON” and “OFF” on the tool screen indicate
when the brakes are being applied and released
respectively.
ECA22080

NOTICE
• Check that the pulse is felt in the front
brake lever.
6. Remove the CCU (Communication Control
11.If the operation of the hydraulic unit is normal, Unit) “1”, and then connect the Yamaha diag-
delete all of the fault codes. nostic tool “2” to the coupler “3”.

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

4-57
 ABS (ANTI-LOCK BRAKE SYSTEM)

10.A reaction-force pulsating action is generated

in the front brake lever “1” and continues for a
few seconds.
TIP

1 • The reaction-force pulsating action consists of

quick pulses.
• Be sure to continue operating the front brake
lever even after the pulsating action has
stopped.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
3 2

7. Start the Yamaha diagnostic tool and display 1

the diagnosis mode screen.
ECA22080
8. Select code No. 1, “ABS reaction-force con-
NOTICE
firmation”.
9. Click “Action” “1”, and then operate the front • Check that the pulse is felt in the front
brake lever “2” simultaneously. brake lever.
TIP • If the pulse is hardly felt in either the front
brake lever, check that the brake hoses and
• The hydraulic unit operates 1 second after the
brake pipes are connected correctly to the
front brake lever operated and continues for
hydraulic unit assembly.
approximately 1 second.
• The operation of the hydraulic unit can be con- 11.Turn the main switch to “OFF”.
firmed using the indicator. 12.Remove the Yamaha diagnostic tool from the
On: The hydraulic unit is operating. Yamaha diagnostic tool coupler, and then in-
Flashing: The conditions for operating the hy- stall the protective cap.
draulic unit have not been met. 13.Turn the main switch to “ON”.
Off: The front brake lever is not being operated. 14.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage → Replace the hydraulic
unit, brake hoses, and related parts as a set.
15.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-
1 ing the vehicle at a speed of faster than 10 km/h
(6 mph) or performing a trial run.

4-58
 HANDLEBAR

EAS20033

HANDLEBAR
Removing the rearview mirror and handlebar cover

1
1
22 Nm (2.2 kgfm, 16 lbft)

5
7

8
(2)
6
(4)

0.4 Nm (0.04 kgfm, 0.30 lbft)

4
2

1.8 Nm (0.18 kgfm, 1.3 lbft)

(4) (2)

Order Job/Parts to remove Q’ty Remarks

1 Rearview mirror 2
2 Visor 1
3 Front handlebar cover 1
4 Rear handlebar cover assembly 1
5 Meter assembly coupler 1 Disconnect.
6 Meter assembly 1
7 Meter assembly cover 1
8 Rear handlebar cover 1

4-59
 HANDLEBAR

Removing the handlebar

2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.

LS

LS
1
LS 6
8 16 N•m (1.6 kgf•m, 12 lb•ft)

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

T.R
.
7 6 13
12
4 3 14
2

2.3 N•m (0.23 kgf•m, 1.7 lb•ft)

T.R
.

10

11 9
1

53 N•m (5.3 kgf•m, 3.9 lb•ft)

13
T.R
.

2.3 N•m (0.23 kgf•m, 1.7 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Grip end (left and right) 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder 1
5 Handlebar switch coupler (right) 2 Disconnect.
6 Handlebar switch (right) 1
7 Throttle cable 2 Disconnect.
8 Throttle grip 1
9 Handlebar grip 1
10 Rear brake light switch connector 2 Disconnect.
11 Rear brake lever with parking lock 1
12 Handlebar switch coupler (left) 2 Disconnect.
13 Handlebar switch (left) 1
14 Handlebar 1

4-60
 HANDLEBAR

EAS31622

REMOVING THE FRONT HANDLEBAR TIP

COVER ASSEMBLY Blow compressed air between the handlebar
1. Remove: and the handlebar grip, and gradually push the
• Front handlebar cover assembly “1” grip off the handlebar.
a. Remove the quick fastener and front han-
dlebar cover assembly screws.
b. Unhook the projections “a” on the front
handlebar cover assembly from the slots
“b” in the lower handlebar cover.
1
a
b

EAS30204

CHECKING THE HANDLEBAR

1. Check:
• Handlebar
Bends/cracks/damage → Replace.
EWA13690
EAS31701

DISASSEMBLING THE FRONT HANDLEBAR WARNING

COVER ASSEMBLY Do not attempt to straighten a bent handle-
1. Disassemble: bar as this may dangerously weaken it.
• Front handlebar cover “1”
• Front handlebar cover “2” EAS30205

INSTALLING THE HANDLEBAR

TIP
1. Stand the vehicle on a level surface.
Unhook the projections “a” on the front handle- EWA13120

bar cover from the slots “b” in the front handlebar WARNING
cover. Securely support the vehicle so that there is
no danger of it falling over.
b 1 2. Install:
2 a • Handlebar “1”

Handlebar bolt
a 53 N·m (5.3 kgf·m, 38 lb·ft)
T.
R.

TIP

b Align the pipe “a” on the handlebar with the slit

“b” on the lower bracket.
EAS30203

REMOVING THE HANDLEBAR

1. Stand the vehicle on a level surface.
EWA13120

WARNING
Securely support the vehicle so that there is 1
no danger of it falling over.
2. Remove: b a
• Grip end
3. Remove:
• Handlebar grip “1”

4-61
 HANDLEBAR

3. Install:
• Handlebar switch (left) “1” 1
TIP 2
Align the projection “a” on the left handlebar
switch with the hole “b” in the rear handlebar 1
cover. 2

b a

1 5. Install:
a • Handlebar switch (right) “1”
• Throttle cables “2”
• Throttle grip “3”
• Grip end (right) “4”

Throttle cable holder bolt (han-

4. Install: dlebar switch side)
T.
R.

• Handlebar grip “1” 3.5 N·m (0.35 kgf·m, 2.5 lb·ft)

• Grip end (left) “2”
TIP
a. Apply a thin coat of a rubber adhesive to
the left end of the handlebar. • Lubricate the end of the throttle cables and the
b. Slide the handlebar grip over the left end inside of the throttle grip with a thin coat of lith-
of the handlebar. ium-soap-based grease.
• Align the projection “a” on the right handlebar
TIP
switch with the hole “b” in the rear handlebar
Make sure that the distance “a” between the end
cover.
of the left handlebar switch and the end of the
• There should be 1.0–3.0 mm (0.04–0.12 in) of
handlebar grip is 0 mm (0 in).
clearance “c” between the throttle grip and the
grip end.

1 a
2 3 4
b LS

c
3
1
a

c. Wipe off any excess rubber adhesive with

a clean rag.
EWA13700
6. Install:
WARNING • Front brake master cylinder
• Front brake master cylinder holder “1”
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried. Front brake master cylinder
d. Install the left grip end. holder bolt
T.
R.

TIP
10 N·m (1.0 kgf·m, 7.2 lb·ft)
There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “a” between the handlebar grip and
the grip end.

4-62
 HANDLEBAR

TIP a. Fit the projections “a” on the front handle-

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

b
c
1
UP
b. Install the front handlebar cover assembly
a screws and quick fasteners, and then
tighten the screws to specification.

Upper handlebar cover assembly

7. Adjust: screw
T.
R.

• Throttle grip free play 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Refer to “CHECKING THE THROTTLE GRIP
OPERATION” on page 3-23.

Throttle grip free play

3.0–5.0 mm (0.12–0.20 in)

EAS31702

ASSEMBLING THE FRONT HANDLEBAR

COVER ASSEMBLY
1. Assemble:
• Front handlebar cover “1”
• Front handlebar cover “2”
TIP
Fit the projections “a” on the front handlebar
cover into the slots “b” in the front handlebar
cover.

b 1
2 a

EAS31623

INSTALLING THE FRONT HANDLEBAR

COVER ASSEMBLY
1. Install:
• Front handlebar cover assembly “1”

4-63
 FRONT FORK

EAS20034

FRONT FORK
Removing the front fork legs

53 N•m (5.3 kgf•m, 39 lb•ft)

T.R
.

8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.

1 8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-27.
1 Front fender 1
2 Lower bracket pinch bolt 2
3 Front fork leg 1

4-64
 FRONT FORK

Disassembling the front fork legs

10
13 1 New
New 15
2
LS
11 LS
3 New
16

12
4

14
5

LT 9 New
6 New

8
7 New
23 N•m (2.3 kgf•m, 17 lb•ft)
T .R
.

Order Job/Parts to remove Q’ty Remarks

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

4-65
 FRONT FORK

EAS30206

REMOVING THE FRONT FORK LEGS

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

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

The following procedure applies to both of the NOTICE

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

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

4-66
 FRONT FORK

EAS30209

T-handle ASSEMBLING THE FRONT FORK LEGS

90890-01326 The following procedure applies to both of the
front fork legs.
EWA13660

WARNING
• Make sure the oil levels in both front fork
1 2 3 legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
–Front fork cap clip
EAS30208

CHECKING THE FRONT FORK LEGS –Oil seal

The following procedure applies to both of the –Oil seal clip
front fork legs. –Dust seal
1. Check: –Copper washer
• Inner tube –O-ring
• Outer tube • Before assembling the front fork leg, make
Bends/damage/scratches → Replace. sure all of the components are clean.
EWA13650
1. Install:
WARNING
• Damper rod ring “1”
Do not attempt to straighten a bent inner • Damper rod “2”
tube as this may dangerously weaken it. • Rebound spring “3”
2. Measure: (in the inner tube “4”)
• Fork spring free length “a” • Oil flow stopper “5”
Out of specification → Replace.
ECA22740

NOTICE
Fork spring free length Allow the damper rod to slide slowly down
282.1 mm (11.1 in) the inner tube until it protrudes from the bot-
Limit tom of the inner tube. Be careful not to dam-
276.4 mm (10.9 in) age the inner tube.
TIP
Fit the damper rod ring into the damper rod
groove so that the side of the ring with the pro-
a jections is facing in the direction shown in the il-
lustration.

2
1

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

4-67
 FRONT FORK

3. Lubricate:
• Inner tube’s outer surface

Recommended oil
Yamaha Suspension Oil G10

4. Install:
• Inner tube
5 4 3 1 2 (in the outer tube)
5. Install:
• Copper washer New
2. Install:
• Front fork damper rod bolt “1”
• Oil seal “1” New
(with the fork seal driver attachment “2” and Front fork damper rod bolt
fork seal driver weight “3”) 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
ECA14220
LOCTITE®
NOTICE
Make sure the numbered side of the oil seal TIP
faces up. While holding the damper rod assembly with the
TIP hexagon bit socket (14 mm) “2” and T-handle
“3”, tighten the front fork damper rod bolt.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of T-handle
the front fork leg with a plastic bag to protect 90890-01326
the oil seal during installation.

Fork seal driver weight

90890-01367 1 2 3
Fork seal driver attachment (ø30)
90890-01400

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

2 1 New

1 New

4-68
 FRONT FORK

7. Install:
• Dust seal “1” New
(with the fork seal driver attachment “2” and
fork seal driver weight “3”)
1
Fork seal driver weight
90890-01367
Fork seal driver attachment (ø30)
90890-01400

10.Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
3 bubbles have dispersed.
TIP

2 Be sure to bleed the front fork leg of any residual

air.
1 New 11.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the inner
8. Fill: tube fully compressed and without the fork
• Front fork leg spring)
(with the specified amount of the recom- Out of specification → Correct.
mended fork oil)
Level
Recommended oil 87 mm (3.4 in)
Yamaha Suspension Oil G10
Quantity TIP
55.0 cm³ (1.85 US oz, 1.93
• While filling the front fork leg, keep it upright.
Imp.oz)
• After filling, slowly pump the front fork leg up
ECA14230 and down to distribute the fork oil.
NOTICE
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
9. After filling the front fork leg, slowly stroke the
inner tube “1” up and down (at least ten
times) to distribute the fork oil.
TIP 12.Install:
Be sure to stroke the inner tube slowly because • Fork spring “1”
the fork oil may spurt out. • O-ring New
• Front fork cap
• Front fork cap clip New
TIP
Install the fork spring with its smaller pitch down-
ward.

4-69
 FRONT FORK

1
1

EAS30210

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Remove:
• Front side cover
• Refer to “GENERAL CHASSIS (2)” on page
4-3.
2. Install:
• Front fork leg “1”
Temporarily tighten the lower bracket pinch
bolts.
TIP
Make sure the inner tube end is flush with the top
of the lower bracket.

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

Lower bracket pinch bolt

53 N·m (5.3 kgf·m, 39 lb·ft)
T.
R.

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

4-70
 STEERING HEAD

EAS20035

STEERING HEAD
Removing the lower bracket

1st 38 N·m (3.8 kgf·m, 28 lb·ft)

*2nd 17 N·m (1.7 kgf·m, 13 lb·ft) 75 N·m (7.5 kgf·m, 55 lb·ft)

LS

LS

3 2

LS 4
5

7 N·m (0.7 kgf·m, 5.2 lb·ft)

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

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side covers
4-3.
Refer to “GENERAL CHASSIS (5)” on page
Center lower cover
4-10.
Refer to “GENERAL CHASSIS (6)” on page
Front upper cowling assembly
4-15.
Front wheel Refer to “FRONT WHEEL” on page 4-27.
Handlebar Refer to “HANDLEBAR” on page 4-59.
Front fork legs Refer to “FRONT FORK” on page 4-64.
1 Front brake hose holder 1
2 Ring nut cover 1
3 Upper ring nut 1
4 Lock washer 1
5 Center ring nut 1

4-71
 STEERING HEAD

Removing the lower bracket

1st 38 N·m (3.8 kgf·m, 28 lb·ft)

*2nd 17 N·m (1.7 kgf·m, 13 lb·ft) 75 N·m (7.5 kgf·m, 55 lb·ft)

LS 14

11
12
LS

13

LS
8
6
15
7 9
10

7 N·m (0.7 kgf·m, 5.2 lb·ft)

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

Order Job/Parts to remove Q’ty Remarks

6 Lower ring nut 1
7 Lower bracket 1
8 Bearing cover 1
9 Upper bearing inner race 1
10 Upper bearing 1
11 Lower bearing 1
12 Lower bearing inner race 1
13 Dust seal 1
14 Lower bearing outer race 1
15 Upper bearing outer race 1

4-72
 STEERING HEAD

EAS30213
3. Replace:
REMOVING THE LOWER BRACKET
• Bearings
1. Stand the vehicle on a level surface.
EWA13120
• Bearing races
WARNING a. Remove the bearing races from the 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 “3” from the low-
2. Remove: er bracket with a floor chisel “4” and ham-
• Ring nut cover mer.
• Upper ring nut “1” c. Install a new dust seal and new bearing
• Lock washer races.
• Center ring nut ECA14270

• Rubber washer NOTICE

• Lower ring nut If the bearing race is not installed properly,
• Lower bracket the steering head pipe could be damaged.
EWA13730

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

Steering nut wrench

90890-01403
Exhaust flange nut wrench
YU-A9472

1
EAS30214

CHECKING THE STEERING HEAD

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

2. Check: INSTALLING THE STEERING HEAD

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

4-73
 STEERING HEAD

TIP 4. Install:
• Apply lithium-soap-based grease to each part. • Handlebar bracket “1”
• Be sure to install the upper bearing so that the
Handlebar bracket nut
marks “a” on the bearing are facing upward. 53 N·m (5.3 kgf·m, 39 lb·ft)

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

1 1

2. Install: a
• Lower ring nut “1”
• Rubber washer “2”
• Center ring nut “3”
• Lock washer “4”
• Upper ring nut “5”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-14.

5
4 3
2
1
3. Install:
• Front brake hose holder “1”

Front brake hose holder bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.

TIP
While holding the front brake hose holder so that
the holder contacts the projection “a” on the low-
er bracket, tighten the bolt to specification.

4-74
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

EAS20189

REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

Removing the rear shock absorber assemblies and swingarm

LS
3

New

57 N•m (5.7 kgf•m, 42 lb•ft)

T.R
.
LS
New

1
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

21 N•m (2.1 kgf•m, 15 lb•ft) 125 N•m (12.5 kgf•m, 92 lb•ft)

T.R
.

T.R
.

21 N•m (2.1 kgf•m, 15 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R

T.R
.

35 N•m (3.5 kgf•m, 26 lb•ft)

T.R

21 N•m (2.1 kgf•m, 15 lb•ft)

.
T.R
.

Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Radiator cover Refer to “RADIATOR” on page 6-2.
1 Rear wheel axle nut 1
2 Rear shock absorber assembly 2
3 Swingarm assembly 1

4-75
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

Removing the rear shock absorber assemblies and swingarm

9
LS

New 8

6 57 N•m (5.7 kgf•m, 42 lb•ft)

T.R
.
LS
New
7
5 4

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

21 N•m (2.1 kgf•m, 15 lb•ft) 125 N•m (12.5 kgf•m, 92 lb•ft)

T.R
.

T.R
.

21 N•m (2.1 kgf•m, 15 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R

T.R
.

35 N•m (3.5 kgf•m, 26 lb•ft)

T.R

21 N•m (2.1 kgf•m, 15 lb•ft)

.
T.R
.

Order Job/Parts to remove Q’ty Remarks

4 Spacer 1
5 Bearing retaining plate 1
6 Oil seals 2
7 Bearing 1
8 Swingarm 1
9 Collar 1

4-76
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

EAS31228 EAS31230

REMOVING THE SWINGARM CHECKING THE SWINGARM

1. Stand the vehicle on a level surface. 1. Check:
EWA13120
• Swingarm
WARNING Bends/cracks/damage → Replace.
Securely support the vehicle so that there is 2. Check:
no danger of it falling over. • Spacer
• Collar
TIP
• Oil seal
Place the vehicle on the centerstand so that the
• Circlip
rear wheel is elevated.
• Bearing
2. Remove: Damage/wear → Replace.
• Rear wheel axle nut “1” EAS31231

• Rear shock absorber assembly lower bolt INSTALLING THE SWINGARM

(right side) “2” 1. Lubricate:
• Swingarm mounting bolt (lower side) “3” • Oil seal lips
• Swingarm mounting bolt (upper side) “4”
Recommended lubricant
Lithium-soap-based grease

2. Assemble:
• Bearing “1”
2
• Oil seals “2” New
4
• Bearing retaining plate “3”
• Spacer “4”
(to the swingarm “5”)
1 3
TIP
• Install the oil seal until it is flush with the sur-
3. Remove:
face “a” of the swingarm.
• Swingarm
• Install the oil seal until it is flush with the sur-
EAS31229
face “b” of the bearing retaining plate.
CHECKING THE REAR SHOCK ABSORBER
• Install the bearing retaining plate with the
ASSEMBLY
punch mark “c” facing outward.
1. Check:
• Rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• Rear shock absorber assembly
Oil leaks → Replace the rear shock absorber
assembly.
• Spring
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bushings
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bolts
Bends/damage/wear → Replace.

4-77
 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

TIP
Tighten the rear wheel axle nut “2”, then the
swingarm mounting bolts “3”, “4”.
5

5
3
1
1
2 New 3
New 2
4
LS

2 4
2 New
LS
5. Install:
2 New • Rear shock absorber assemblies “5”
b Rear shock absorber assembly
a nut
T.
R.

23 N·m (2.3 kgf·m, 41 lb·ft)

Rear shock absorber assembly
bolt
23 N·m (2.3 kgf·m, 41 lb·ft)
3
TIP
Tighten the rear shock absorber assembly nuts
and bolts temporarily, and then tighten them to
c
specification.

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

Rear wheel axle nut

95 N·m (9.5 kgf·m, 69 lb·ft)
T.
R.

Swingarm mounting bolt

57 N·m (5.7 kgf·m, 41 lb·ft)

4-78
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM

4-79
 ENGINE

LUBRICATION SYSTEM CHART AND DIAGRAMS .....................................5-1

ENGINE OIL LUBRICATION CHART ......................................................5-1

ENGINE INSPECTION ...................................................................................5-2

MEASURING THE COMPRESSION PRESSURE ...................................5-2

ENGINE REMOVAL .......................................................................................5-4

INSTALLING THE ENGINE ......................................................................5-8

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

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

CAMSHAFT .................................................................................................. 5-18

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

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

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

CYLINDER AND PISTON ............................................................................. 5-28

REMOVING THE PISTON ..................................................................... 5-29
CHECKING THE CYLINDER AND PISTON .......................................... 5-29
CHECKING THE PISTON RINGS .......................................................... 5-30
CHECKING THE PISTON PIN ............................................................... 5-31
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................ 5-31
INSTALLING THE PISTON AND CYLINDER ........................................ 5-31
V-BELT AUTOMATIC TRANSMISSION ...................................................... 5-33
REMOVING THE PRIMARY SHEAVE ................................................... 5-37
REMOVING THE SECONDARY SHEAVE ............................................ 5-37
DISASSEMBLING THE SECONDARY SHEAVE ................................... 5-37
CHECKING THE CLUTCH HOUSING ................................................... 5-38
CHECKING THE CLUTCH SHOES ....................................................... 5-38
CHECKING THE V-BELT ....................................................................... 5-38
CHECKING THE PRIMARY SHEAVE ................................................... 5-38
CHECKING THE PRIMARY SHEAVE WEIGHTS .................................. 5-38
CHECKING THE PRIMARY SHEAVE SLIDERS ................................... 5-39
CHECKING THE SECONDARY SHEAVE ............................................. 5-39
ASSEMBLING THE PRIMARY SHEAVE ............................................... 5-39
ASSEMBLING THE SECONDARY SHEAVE ......................................... 5-39
INSTALLING THE PRIMARY SHEAVE,
V-BELT AND SECONDARY SHEAVE .................................................. 5-40

STARTER GENERATOR ............................................................................. 5-43

REMOVING THE STARTER GENERATOR .......................................... 5-44
INSTALLING THE STARTER GENERATOR ......................................... 5-44

OIL PUMP ..................................................................................................... 5-45

CHECKING THE OIL STRAINER .......................................................... 5-47
CHECKING THE OIL PUMP .................................................................. 5-47
ASSEMBLING THE OIL PUMP .............................................................. 5-47

TRANSMISSION ........................................................................................... 5-48

CHECKING THE TRANSMISSION ........................................................ 5-50
INSTALLING THE TRANSMISSION ...................................................... 5-50

CRANKSHAFT ............................................................................................. 5-52

DISASSEMBLING THE CRANKCASE ................................................... 5-55
REMOVING THE CRANKSHAFT ASSEMBLY ...................................... 5-55
CHECKING THE CRANKSHAFT ASSEMBLY ....................................... 5-55
CHECKING THE CRANKCASE ............................................................. 5-56
CHECKING THE BEARING ................................................................... 5-56
CHECKING THE OIL PUMP DRIVE GEAR ........................................... 5-56
INSTALLING THE CRANKSHAFT .........................................................5-56
ASSEMBLING THE CRANKCASE .........................................................5-56
INSTALLING THE CENTERSTAND ...................................................... 5-57
 LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20298

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS32784

ENGINE OIL LUBRICATION CHART

Rocker arm

Camshaft Oil Nozzle

Crankshaft

Oil pump

Oil pan Oil strainer

Lubricant System Diagram 3

4

5 2 A-A
A

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

5-1
 ENGINE INSPECTION

EAS20041
7. Measure:
ENGINE INSPECTION • Compression pressure
EAS30249
Out of specification → Refer to steps (c) and
MEASURING THE COMPRESSION (d).
PRESSURE
Compression pressure
TIP 1783–2296 kPa/1050 r/min
Insufficient compression pressure will result in a (17.8–23.0 kgf/cm²/1050 r/min,
loss of performance. 253.7–326.6 psi/1050 r/min)
1. Measure:
a. Turn the main switch to “ON”.
• Valve clearance
b. With the throttle wide open, crank the en-
Out of specification → Adjust.
gine until the reading on the compression
Refer to “ADJUSTING THE VALVE CLEAR-
gauge stabilizes.
ANCE” on page 3-6. EWA12960

2. Start the engine, warm it up for several min- WARNING

utes, and then turn it off. To prevent sparking, ground the spark plug
3. Remove: lead before cranking the engine.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page c. If the compression pressure is above the
4-3. maximum specification, check the cylinder
• Footrest board assembly (right) head, valve surfaces and piston crown for
Refer to “GENERAL CHASSIS (5)” on page carbon deposits.
4-10. Carbon deposits → Eliminate.
4. Disconnect: d. If the compression pressure is below the
• Spark plug cap minimum specification, pour a teaspoonful
5. Remove: of engine oil into the spark plug bore and
• Spark plug measure again.
ECA20470 Refer to the following table.
NOTICE Compression pressure (with oil applied into the
Before removing the spark plug, use com- cylinder)
pressed air to blow away any dirt accumulat- Reading Diagnosis
ed in the spark plug well to prevent it from Piston ring(s) wear or
falling into the cylinder. Higher than without oil
damage → Repair.
6. Install: Piston, valves, cylinder
• Compression gauge “1” head gasket or piston
Same as without oil
• Extension “2” ring(s) possibly defec-
tive → Repair.
Compression gauge
8. Install:
90890-03081
Compression gauge extension • Spark plug “1”
122mm
Spark plug
90890-04136
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.

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

5-2
 ENGINE INSPECTION

b
a 2

9. Connect:
• Spark plug cap
10.Install:
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on page
4-10.
• Front side cover (right)
Refer to “GENERAL CHASSIS (2)” on page
4-3.

5-3
 ENGINE REMOVAL

EAS20042

ENGINE REMOVAL
Removing the muffler

8 N·m (0.8 kgf·m, 5.9 lb·ft)

T.R
.

25 N•m (2.5 kgf•m, 18 lb•ft)

T.R
.
53 N·m (5.3 kgf·m, 39 lb·ft)
T.R
.

LT
1
3 5
4 New

LT
2 53 N·m (5.3 kgf·m, 39 lb·ft)
T.R
.

8 N·m (0.8 kgf·m, 5.9 lb·ft) 20 N·m (2.0 kgf·m, 15 lb·ft)

T.R
.
T.R
.

53 N·m (5.3 kgf·m, 39 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

1 O2 sensor coupler 1 Disconnect.

2 Muffler protector 1
3 Muffler 1
4 Exhaust gasket 1
5 O2 sensor 1

5-4
 ENGINE REMOVAL

Disconnecting the leads

Order Job/Parts to remove Q’ty Remarks

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front cowling assembly 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Side cover assembly 4-6.
Refer to “GENERAL CHASSIS (3)” on page
Storage box 4-6.
Air filter case Refer to “AIR FILTER CASE” on page 7-8.
Refer to “V-BELT AUTOMATIC TRANSMIS-
V-belt case air duct
SION” on page 5-33.
Fuel injector Refer to “FUEL INJECTOR” on page 7-6.
Throttle body Refer to “THROTTLE BODY” on page 7-11.

5-5
 ENGINE REMOVAL

Disconnecting the leads

5
6

Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Rear wheel Refer to “REAR WHEEL” on page 4-34.
1 Coolant reservoir hose 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Crankshaft position sensor coupler 1 Disconnect.
4 Starter generator lead coupler 1 Disconnect.
5 Spark plug cap 1 Disconnect.
6 Engine ground lead 1 Disconnect.
7 VVA (variable valve actuator) solenoid coupler 1 Disconnect.

5-6
 ENGINE REMOVAL

Removing the engine

52 N·m (5.2 kgf·m, 38 lb·ft) 21 N·m (2.1 kgf·m, 15 lb·ft)

T.R
T.R

.
.

28 N·m (2.8 kgf·m, 21 lb·ft)

T.R

6
.

3
4 3
7

4 3 6
4 7
50 N·m (5.0 kgf·m, 37 lb·ft) 5 4
T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Rear shock absorber assembly 2
2 Engine bracket nut/bolt 1/1
3 Engine bracket fixed nut/bolt (upper) 2/2
4 Engine mount bracket nut/bolt 2/2
5 Engine bracket 1
6 Stopper 2
7 Collar 2

5-7
 ENGINE REMOVAL

EAS30251
d. Temporarily install the engine bracket
INSTALLING THE ENGINE
fixed bolt “9” in the engine mount bracket
1. Install:
“10”.
a. Temporarily put the stopper “1” and collar
“2” on the engine assembly “3”.
1
3

2
9
10

e. Tighten the engine bracket nut (front) “10”.

b. Install the engine bracket “4” to the engine
assembly, then install fixing bolt “5” and Engine bracket nut (front)
nut (below) “6” and use the pin ø3 mm to 50 N·m (5.0 kgf·m, 37 lb·ft)
T.
R.

insert in the hole of the engine bracket and

the collar “a”, then tighten. Fix the nut to
the specified torque (first lock the right and
then the left side).
a
4

A A
10
2 1
f. After the installation is complete, confirm
6 5
4 a that the stopper “1” will not touch the en-
A-A gine assembly “3” with the main bracket
upright.
Engine bracket nut (center)
52 N·m (5.2 kgf·m, 38 lb·ft) 1
T.
R.

c. Remove the ø3 pin, insert the engine

mount bracket nut “7”, and then tighten the
nut “8”.

Engine bracket nut (rear)

21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.

5-8
 CYLINDER HEAD

EAS20044

CYLINDER HEAD
Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New

New New TB1215

New New

(4)
LS LT

7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

M
New
(4) (4) (4) New
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft)

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft)
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R
.

New
15 N·m (1.5 kgf·m, 11 lb·ft) 25 N·m (2.5 kgf·m, 18 lb·ft)
T.R

T.R
.

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

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery
4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers
4-3.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover
4-6.
Refer to “GENERAL CHASSIS (4)” on page
Storage box
4-8.
Refer to “GENERAL CHASSIS (5)” on page
Center lower cover
4-10.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Radiator Refer to “RADIATOR” on page 6-2.
Thermostat assembly Refer to “THERMOSTAT” on page 6-6.
Water pump Refer to “WATER PUMP” on page 6-8.

5-9
 CYLINDER HEAD

Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
T.R

10
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New
7
8 New New TB1215

9 New New

6
(4)
LS LT

7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

M
New
1 (4) (4) (4) New
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft)

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 2 3
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.R
.

4
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R

5
.

New
15 N·m (1.5 kgf·m, 11 lb·ft) 25 N·m (2.5 kgf·m, 18 lb·ft)
T.R

T.R
.

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

Order Job/Parts to remove Q’ty Remarks

Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-8.
Fuel injector Refer to “FUEL INJECTOR” on page 7-6.
Intake manifold Refer to “THROTTLE BODY” on page 7-11.
1 Fuel hose holder 1
2 Spark plug cap 1 Disconnect.
3 Spark plug 1
4 Coolant temperature sensor coupler 1 Disconnect.
5 Coolant temperature sensor 1
6 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
7 VVA (variable valve actuator) solenoid 1
8 VVA (variable valve actuator) solenoid gasket 1
9 VVA (variable valve actuator) solenoid rod 1
10 Cylinder head breather hose 1

5-10
 CYLINDER HEAD

Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New
18
New New 19 TB1215

New 15 New
13
17 20
16
(4)
LS LT

11 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

27 26
12 New
M 14
(4) (4) (4) 25 New
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 26

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft)
13 N·m (1.3 kgf·m, 9.6 lb·ft) 21
T.R
.

24 23
14
22
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R
.

New
15 N·m (1.5 kgf·m, 11 lb·ft) 25 N·m (2.5 kgf·m, 18 lb·ft)
T.R

T.R
.

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

Order Job/Parts to remove Q’ty Remarks

11 Water pump inlet hose holder 1
12 Cylinder head cover 1
13 Cylinder head cover gasket 1
14 Dowel pin 2
15 Cylinder head cover breather plate 1
16 Cylinder head cover breather plate gasket 1
17 Oil seal 1
18 Timing chain tensioner plug 1
19 Timing chain tensioner 1
20 Timing chain tensioner gasket 1

5-11
 CYLINDER HEAD

Removing the cylinder head

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
New

New New TB1215

New New

LS LT

7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.

27 26
M
New
25 New
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.

10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R

M
.

1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 26

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft)
13 N·m (1.3 kgf·m, 9.6 lb·ft) 21
T.R
.

24 23
22
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.

T.R
.

New
15 N·m (1.5 kgf·m, 11 lb·ft) 25 N·m (2.5 kgf·m, 18 lb·ft)
T.R

T.R
.

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

Order Job/Parts to remove Q’ty Remarks

21 Camshaft sprocket bolt 1
22 Camshaft sprocket 1
23 Decompression cam 1
24 Cylinder head 1
25 Cylinder head gasket 1
26 Dowel pin 2
27 Engine oil check bolt 1

5-12
 CYLINDER HEAD

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

×
4 3 4
b
×
2
6 5
a
b. When the piston is at TDC on the com- 1 2
pression stroke, align the “I” mark “c” on
the camshaft sprocket with the edge “d” of EAS30277
the cylinder head. CHECKING THE CYLINDER HEAD
1. Eliminate:
c d • 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
• Valve seats

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

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

Warpage limit
0.05 mm (0.0020 in)

5-13
 CYLINDER HEAD

a. Place a straightedge “1” and a thickness EAS30279

CHECKING THE TIMING CHAIN TENSIONER

gauge “2” across the cylinder head.
1. Check:
• Timing chain tensioner
Cracks/damage → Replace.
a. Remove the timing chain tensioner plug.
b. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver “1”.

1 2

c. While holding the timing chain tensioner

rod in place with your hand, turn the
screwdriver counterclockwise, remove the
screwdriver, and slowly release the timing
b. Measure the warpage. chain tensioner rod.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.

EAS31232

CHECKING THE CAMSHAFT SPROCKET d. Make sure that the timing chain tensioner
1. Check: rod comes out of the timing chain tension-
• Camshaft sprocket er housing smoothly. If there is rough
More than 1/4 tooth wear “a” → Replace the movement, replace the timing chain ten-
camshaft sprocket, timing chain and crank- sioner.
shaft as a set. e. Install the timing chain tensioner plug.
EAS30280

CHECKING THE DECOMPRESSION SYSTEM

1. Check:
• Decompression system
TIP
• Check that the decompression lever moves
smoothly.
• Check that the operating range “a” of the de-
compression lever is the same as the range
a. 1/4 tooth shown in the illustration.
b. Correct
1. Timing chain roller
2. Camshaft sprocket

5-14
 CYLINDER HEAD

a ×
3 4 4

1 1 ×
2
2 1 2 2

6 5

a. 20.88° 2. Install:
• Decompression cam “1”
EAS31624
• Camshaft sprocket “2”
CHECKING THE VVA SOLENOID
• Timing chain
1. Check:
• Camshaft sprocket bolt
• VVA (variable valve actuator) solenoid “1”
a. Turn the crankshaft clockwise.
Cracks/damage → Replace.
b. Align the “I” mark “a” on the AC magneto
rotor with the match mark “b” on the right
1 crankcase.

EAS30282

INSTALLING THE CYLINDER HEAD a

1. Tighten:
• Cylinder head nuts “1” c. Install the decompression cam.
• Cylinder head bolts “2” d. Install the timing chain onto the camshaft
sprocket, then the camshaft sprocket onto
Cylinder head nut the camshaft, and then finger tighten the
24 N·m (2.4 kgf·m, 18 lb·ft) camshaft sprocket bolt.
T.
R.

Cylinder head bolt ECA20600

10 N·m (1.0 kgf·m, 7.4 lb·ft) NOTICE

Do not turn the crankshaft when installing
TIP the camshaft sprocket to avoid damage or
• Lubricate the cylinder head nuts and thread of improper valve timing.
bolt and washers with molybdenum disulfide TIP
grease.
• Fit the pin on the decompression cam into the
• Tighten the cylinder head nuts and bolts in the
slot “c” in the decompression lever on the cam-
proper tightening sequence as shown and
shaft sprocket.
torque them in two stages.
• Align the “I” mark “d” on the camshaft sprocket
with the edge “e” of the cylinder head.

5-15
 CYLINDER HEAD

d a
e a

2
c 1

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

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

Yamaha bond No. 1215

90890-85505 a
(Three bond No.1215®)

Timing chain tensioner bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

5-16
 CYLINDER HEAD

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

3 2

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

Camshaft sprocket bolt

30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.

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

10 N·m (1.0 kgf·m, 7.4 lb·ft)

ECA20610

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

1
2

7. Measure:
• Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-6.
8. Install:
• Oil seal “1”
(into the cylinder head cover “2”)

5-17
 CAMSHAFT

EAS20043

CAMSHAFT
Removing the rocker arms and camshaft
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.

7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

2
New M
11 14
14

12 10
13 4 New
9
M

3
M

M E
8
6 7
E

E 5
2 M

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

Order Job/Parts to remove Q’ty Remarks

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

5-18
 CAMSHAFT

EAS30256

REMOVING THE CAMSHAFT Camshaft lobe dimensions

1. Loosen: Lobe height (Intake)
• Adjusting screws (intake/exhaust) 32.211–32.311 mm (1.2681–
2. Remove: 1.2721 in)
• Camshaft assembly “1” Limit
32.111 mm (1.2642 in)
Slide hammer bolt (M8) Lobe height (Intake high speed)
90890-01085 32.587–32.687 mm (1.2830–
Weight 1.2869 in)
90890-01084 Limit (Intake high speed)
32.487 mm (1.2790 in)
a. Align the holes “a” in intake rocker arm 1 Lobe height (Exhaust)
“2” and intake rocker arm 2 “3”, and then 29.420–29.520 mm (1.1583–
push the intake rocker arm stopper pin “4” 1.1622 in)
in the direction of the arrow shown in the Limit
illustration. 29.320 mm (1.1543 in)

4
a

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

intake rocker arm 2 “3” in the direction of
the arrow shown in the illustration, remove
the camshaft assembly using a slide ham-
mer bolt “5” and weight “6”.

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

Camshaft runout limit

EAS30257
0.030 mm (0.0012 in)
CHECKING THE CAMSHAFT
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.

5-19
 CAMSHAFT

4. Check:
• Camshaft oil passage Rocker arm shaft outside diame-
Obstruction → Blow out with compressed air. ter
9.966–9.976 mm (0.3924–0.3928
EAS30259 in)
CHECKING THE ROCKER ARMS AND Limit
ROCKER ARM SHAFTS 9.935 mm (0.3911 in)
The following procedure applies to all of the
rocker arms and rocker arm shafts.
1. Check:
• Rocker arm
• Rocker arm roller “1”
Damage/wear → Replace.

5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
TIP
1 1 Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
2. Check: arm inside diameter.
• Rocker arm shaft
Blue discoloration/excessive wear/pitting/ Out of specification → Replace the defective
scratches → Replace or check the lubrication part(s).
system.
Rocker-arm-to-rocker-arm-shaft
3. Measure: clearance
• Rocker arm inside diameter “a” 0.009–0.034 mm (0.0004–0.0013
Out of specification → Replace. in)
Limit
Rocker arm inside diameter 0.080 mm (0.0032 in)
9.985–10.000 mm (0.3931–
0.3937 in) EAS30270
Limit INSTALLING THE CAMSHAFT AND ROCKER
10.015 mm (0.3943 in) ARMS
1. Lubricate:
• Camshaft assembly

Recommended lubricant
a Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil

2. Lubricate:
• Rocker arms
4. Measure: • Rocker arm shafts
• Rocker arm shaft outside diameter “a” • Spring
Out of specification → Replace. • Intake rocker arm stopper pin

5-20
 CAMSHAFT

Recommended lubricant
Rocker arm shaft 2
Intake rocker arm stopper pin
3
Molybdenum disulfide oil
Spring
Rocker arm roller
Engine oil

3. Install: a
• Spring “1”
TIP 5. Install:
• Camshaft stopper plate
Install the spring so that the ends “a” of the
spring are positioned at the locations shown in Camshaft stopper plate bolt
the illustration. (M5×16)
T.
R.
8 N·m (0.8 kgf·m, 5.9 lb·ft)
a 1 Camshaft stopper plate bolt
(M6×14)
8 N·m (0.8 kgf·m, 5.9 lb·ft)

TIP
Before installing the camshaft stopper plate,
make sure that the slots “a” in the rocker arm
shafts “2” are parallel with the edge “b” of the cyl-
inder head and that the camshaft stopper plate
4. Install: bolt holes in the cylinder head and rocker arm
• Camshaft assembly shafts are aligned.
a. Align the holes “a” in intake rocker arm 1
b
“2” and intake rocker arm 2 “3”, and then 2
push the intake rocker arm stopper pin “4” a
in the direction of the arrow shown in the
illustration. a

4
a

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

intake rocker arm 2 “3” in the direction of
the arrow shown in the illustration, install
the camshaft assembly.
TIP
Install the camshaft with the punch mark “a” fac-
ing upward.

5-21
 VALVES AND VALVE SPRINGS

EAS20045

VALVES AND VALVE SPRINGS

Removing the valves and valve springs

1 2 3 8 New
6 New

8 New
4
7
E

7
M
M
6 New

1
E

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
Camshaft/Rocker arms Refer to “CAMSHAFT” on page 5-18.
1 Valve cotter 8
2 Valve spring retainer 4
3 Valve spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Valve spring seat 4
8 Valve guide 4

5-22
 VALVES AND VALVE SPRINGS

EAS30283
3. Remove:
REMOVING THE VALVES
• Valve spring retainer “1”
The following procedure applies to all of the
• Valve spring “2”
valves and related components.
• Valve “3”
TIP • Valve stem seal “4”
Before removing the internal parts of the cylinder • Valve spring seat “5”
head (e.g., valves, valve springs, valve seats), TIP
make sure the valves properly seal.
Identify the position of each part very carefully so
1. Check: that it can be reinstalled in its original place.
• Valve sealing
Leakage at the valve seat → Check the valve 1
face, valve seat, and valve seat width.
5
Refer to “CHECKING THE VALVE SEATS”
on page 5-25. 2
a. Pour a clean solvent “a” into the intake and
exhaust ports. 3
b. Check that the valves properly seal.
4
TIP
There should be no leakage at the valve seat “1”.
EAS30284

CHECKING THE VALVES AND VALVE

GUIDES
The following procedure applies to all of the
valves and valve guides.
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” -
2. Remove:
Valve stem diameter “b”
• Valve cotters “1”
TIP
Remove the valve cotters by compressing the Valve-stem-to-valve-guide clear-
ance (intake)
valve spring with the valve spring compressor
0.010–0.037 mm (0.0004–0.0015
and the valve spring compressor attachment “2”. in)
Limit
Valve spring compressor 0.080 mm (0.0032 in)
90890-04019 Valve-stem-to-valve-guide clear-
Valve spring compressor attach- ance (exhaust)
ment 0.025–0.052 mm (0.0010–0.0020
90890-04108 in)
Limit
0.100 mm (0.0039 in)
2

5-23
 VALVES AND VALVE SPRINGS

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.

2. Replace:
• Valve guide New
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder TIP
head to 100 °C (212 °F) in an oven.
After replacing the valve guide, reface the valve
a. Remove the valve guide with the valve seat.
guide remover “1”.
Valve guide remover (ø5)
90890-04097
Valve guide installer (ø5)
90890-04098
Valve guide reamer (ø5)
90890-04099

3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
b. Install the new valve guide with the valve 4. Check:
guide installer “2” and valve guide remov- • Valve face
er “1”. Pitting/wear → Grind the valve face.
• Valve stem end
Valve guide position Mushroom shape or diameter larger than the
9.9–10.3 mm (0.39–0.41 in) body of the valve stem → Replace the valve.
5. Measure:
• Valve stem runout
Out of specification → Replace the valve.

5-24
 VALVES AND VALVE SPRINGS

TIP a. Apply Blue layout fluid “b” onto the valve

• When installing a new valve, always replace face.
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.

Valve stem runout

0.010 mm (0.0004 in)

b. Install the valve into the cylinder head.

c. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted
EAS30285 one another, the blue layout fluid will have been
CHECKING THE VALVE SEATS removed.
The following procedure applies to all of the
4. Lap:
valves and valve seats.
• Valve face
1. Eliminate:
• Valve seat
• Carbon deposits
(from the valve face and valve seat) TIP
2. Check: After replacing the cylinder head or replacing the
• Valve seat valve and valve guide, the valve seat and valve
Pitting/wear → Replace the cylinder head. face should be lapped.
3. Measure: a. Apply a coarse lapping compound “a” to
• Valve seat width “a” the valve face.
Out of specification → Replace the cylinder ECA13790

head. NOTICE
Do not let the lapping compound enter the
Valve seat contact width (intake)
gap between the valve stem and the valve
0.60–0.85 mm (0.0236–0.0335 in)
Limit guide.
1.3 mm (0.05 in)
Valve seat contact width (ex-
haust)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.7 mm (0.07 in)

b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.

5-25
 VALVES AND VALVE SPRINGS

d. Turn the valve until the valve face and

valve seat are evenly polished, and then Free length (intake)
clean off all of the lapping compound. 33.79 mm (1.33 in)
Limit
TIP 32.10 mm (1.26 in)
For the best lapping results, lightly tap the valve Free length (exhaust)
seat while rotating the valve back and forth be- 33.79 mm (1.33 in)
tween your hands. Limit
32.10 mm (1.26 in)

e. Apply a fine lapping compound to the

valve face and repeat the above steps. EAS30288
f. After every lapping procedure, be sure to INSTALLING THE VALVES
clean off all of the lapping compound from The following procedure applies to all of the
the valve face and valve seat. valves and related components.
g. Apply blue layout fluid “b” onto the valve • Valve stem end
face. (with an oil stone)

h. Install the valve into the cylinder head. 1. Lubricate:

i. Press the valve through the valve guide • Valve stem “1”
and onto the valve seat to make a clear
impression. Recommended lubricant
j. Measure the valve seat width again. If the Molybdenum disulfide oil
valve seat width is out of specification,
reface and lap the valve seat. • Valve stem seal “2”
(with the recommended lubricant)
EAS30286

CHECKING THE VALVE SPRINGS Recommended lubricant

The following procedure applies to all of the Engine oil
valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
spring.

5-26
 VALVES AND VALVE SPRINGS

Valve spring compressor

90890-04019
Valve spring compressor attach-
E
ment
90890-04108

2. Install:
• Valve spring seat “1”
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4” 1
• Valve spring retainer “5”
(into the cylinder head) 4. To secure the valve cotters onto the valve
TIP stem, lightly tap the valve tip with a soft-face
• Make sure each valve is installed in its original hammer.
ECA13800
place. NOTICE
• Install the valve springs with the larger pitch “a”
facing up. Hitting the valve tip with excessive force
could damage the valve.

5
1
4

3
2 New

b. Smaller pitch
3. Install:
• Valve cotters “1”
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.

5-27
 CYLINDER AND PISTON

EAS20046

CYLINDER AND PISTON

Removing the cylinder and piston

3 New
4
2

E
1 5 New
7
New
10
9
11 6
10 N•m (1.0 kgf•m, 7.4 lb•ft) 5 New
T.R
.

8 E

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
11 Coolant drain bolt (cylinder side) 1

5-28
 CYLINDER AND PISTON

EAS30289

REMOVING THE PISTON

1. Remove:
• Piston pin clips “1”
• Piston pin “2”
• Piston “3”
ECA13810

NOTICE
Do not use a hammer to drive the piston pin
out.
TIP EAS30291

• Before removing the piston pin clips, cover the CHECKING THE CYLINDER AND PISTON
crankcase opening with a clean rag to prevent 1. Check:
them from falling into the crankcase. • Piston wall
• Before removing the piston pin, deburr the pis- • Cylinder wall
ton pin clip groove and the piston pin bore ar- Vertical scratches → Rebore or replace the
ea. If both areas are deburred and the piston cylinder, and replace the piston and piston
pin is still difficult to remove, remove it with the rings as a set.
piston pin puller set “4”. 2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylin-
Piston pin puller set
90890-01304 der bore gauge.
TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.

2 1 Bore
58.000–58.010 mm (2.2835–
2.2839 in)
Wear limit
58.060 mm (2.2858 in)
3
“C” = maximum of D1 - D2

2. Remove:
• Top ring b. If out of specification, rebore or replace the
• 2nd ring cylinder, and replace the piston and piston
• Oil ring rings as a set.
c. Measure piston skirt diameter “P” with the
TIP
micrometer.
When removing a piston ring, open the end gap
with your fingers and lift the other side of the ring
over the piston crown.

5-29
 CYLINDER AND PISTON

Piston ring
Top ring
a Ring side clearance
0.030–0.065 mm (0.0012–
0.0026 in)
P Side clearance limit
0.115 mm (0.0045 in)
2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–
a. 6.0 mm (0.24 in) from the bottom edge of the 0.0022 in)
piston Side clearance limit
0.115 mm (0.0045 in)
Piston
Diameter
57.962–57.985 mm (2.2820–
2.2829 in)

d. If out of specification, replace the piston

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

5-30
 CYLINDER AND PISTON

a. Bottom of cylinder 4. Calculate:

b. Upper of cylinder • Piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston pin
EAS30293
and piston as a set.
CHECKING THE PISTON PIN
1. Check: Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” -
• Piston pin Piston pin outside diameter “a”
Blue discoloration/grooves → Replace the
piston pin, and then check the lubrication sys-
tem. Piston-pin-to-piston-pin-bore
2. Measure: clearance
• Piston pin outside diameter “a” 0.002–0.018 mm (0.0001–0.0007
Out of specification → Replace the piston pin. in)

Piston pin outside diameter EAS30290

13.995–14.000 mm (0.5510– CHECKING THE TIMING CHAIN GUIDE

0.5512 in) (EXHAUST SIDE)
Limit 1. Check:
13.975 mm (0.5502 in) • Timing chain guide (exhaust side)
Damage/wear → Replace.
EAS30294

INSTALLING THE PISTON AND CYLINDER

1. Install:
• Lower oil ring rail “1”
• Oil ring expander “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
3. Measure: Be sure to install the piston rings so that the
• Piston pin bore diameter “b” manufacturer marks face up.
Out of specification → Replace the piston.
5
Piston pin bore inside diameter
14.002–14.013 mm (0.5513–
0.5517 in)
Limit 4
14.043 mm (0.5529 in) 3

5-31
 CYLINDER AND PISTON

2. Install: c
• Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
b a
TIP
135˚
• Apply engine oil to the piston pin. 45˚ 45˚
• Make sure the punch mark “a” on the piston
points towards the exhaust side of the cylinder. e 45˚ 45˚ d
• Before installing the piston pin clips, cover the A
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase. a. Top ring
• When installing a piston pin clip, make sure b. 2nd ring
that the clip ends “b” are positioned away from c. Upper oil ring rail
the cutout “c” in the piston as shown in the illus- d. Oil ring expander
tration. e. Lower oil ring rail
A. Exhaust side
5. Install:
New 3
• Dowel pins
2
• Cylinder gasket New
• Cylinder “1”
TIP
1 • While holding the piston “2” with one hand, in-
stall the cylinder with the other hand.
a • Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.

3 New 2
1 2
1
b

3. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)

Recommended lubricant
Engine oil

4. Offset:
• Piston ring end gaps

5-32
 V-BELT AUTOMATIC TRANSMISSION

EAS20050

V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt case

4
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

New (10)

New 1

3 2
New

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

New

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

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-6.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-8.
Air filter case Refer to “AIR FILTER CASE” on page 7-8.
1 V-belt case air filter element cover 1
2 V-belt case air filter element 1
3 V-belt case air filter element support 1
4 V-belt case 1

5-33
 V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt case

8 10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
New (10)
7
New
6

New 5

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

New

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

Order Job/Parts to remove Q’ty Remarks

TIP
When removing the V-belt case gasket, cut
the center portion of the gasket. Before in-
5 V-belt case gasket 1 stalling a new V-belt case gasket, remove
the V-belt.
Refer to “Removing the V-belt, primary
sheave and secondary sheave”.

6 Dowel pin 1
7 V-belt case check hose 1
8 Bearing 1

5-34
 V-BELT AUTOMATIC TRANSMISSION

Removing the V-belt, primary sheave and secondary sheave

45 N•m (4.5 kgf•m, 33 lb•ft)

T.R
.
14

13

11
10 12
11
9
LS

11 6

8 7

LS
5 3
4 1

2
76 N•m (7.6 kgf•m, 56 lb•ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

1 Primary fixed sheave nut 1
2 Conical spring washer 1
3 Washer 1
4 Primary fixed sheave 1
5 Washer 1
6 V-belt 1
7 Collar 1
8 Primary sliding sheave 1
9 Primary sheave weight 6
10 Cam 1
11 Slider 3
12 Clutch housing nut 1
13 Clutch housing 1
14 Secondary sheave assembly 1

5-35
 V-BELT AUTOMATIC TRANSMISSION

Disassembling the secondary sheave

* 55 N•m (5.5 kgf•m, 41 lb•ft)

T.R
.
4

3
2
10
11 New 13
12
5 1
6

9 New 7

9 New
* 8 New

* Apply Shell dolium grease R®.

Order Job/Parts to remove Q’ty Remarks

1 Secondary sheave nut 1
2 Clutch carrier assembly 1
3 Compression spring 1
4 Spring seat 1
5 Guide pin 3
6 Collar 3
7 Secondary sliding sheave 1
8 O-ring 2
9 Oil seal 2
10 Bearing 1
11 Circlip 1
12 Bearing 1
13 Secondary fixed sheave 1

5-36
 V-BELT AUTOMATIC TRANSMISSION

EAS30310
2. Loosen:
REMOVING THE PRIMARY SHEAVE
• Secondary sheave nut “1”
1. Remove: ECA21820

• Primary fixed sheave nut “1” NOTICE

• Conical spring washer Do not remove the secondary sheave nut at
• Washer this stage.
• Primary fixed sheave “2”
TIP TIP
While holding the primary fixed sheave with the While holding the secondary sheave with the ro-
rotor holding tool “3”, loosen the primary fixed tor holding tool “2”, loosen the secondary
sheave nut. sheave nut one full turn with the socket wrench
“3”.
Rotor holding tool (including
handle and 3 pins) Rotor holding tool
90890-04195 90890-04166
Rotor holding tool attachment Socket wrench (39 mm)
7 × 12 mm 90890-01493
90890-04197

3
1

3 2
1

2
EAS30312

EAS30311
DISASSEMBLING THE SECONDARY
REMOVING THE SECONDARY SHEAVE SHEAVE
1. Remove: 1. Remove:
• Clutch housing nut “1” • Secondary sheave nut “1”
• Clutch housing “2” TIP
TIP Install the sheave spring compressor “2” and
While holding the clutch housing with the rotor sheave fixed block “3” onto the secondary
holding tool “3”, loosen the clutch housing nut. sheave as shown. Then, compress the spring,
and remove the secondary sheave nut.
Rotor holding tool
90890-04166 Sheave spring compressor
90890-04134
Sheave fixed block
90890-04135

3 1

2
1

5-37
 V-BELT AUTOMATIC TRANSMISSION

EAS30313

CHECKING THE CLUTCH HOUSING a a

1. Check:
• Clutch housing a
Damage/wear → Replace.
2. Measure: a
• Clutch housing inside diameter “a”
Out of specification → Replace the clutch
housing.
a a
Clutch housing inside diameter
125.0 mm (4.92 in) EAS30315

Limit CHECKING THE V-BELT

125.5 mm (4.94 in) 1. Check:
• V-belt “1”
Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and second-
ary sheave.
a 2. Measure:
• V-belt width “a”
Out of specification → Replace.

V-belt width limit

21.6 mm (0.85 in)

EAS30314

CHECKING THE CLUTCH SHOES

The following procedure applies to all of the
clutch shoes.
1. Check:
• Clutch shoe
Damage/wear → Replace the clutch shoes
and springs as a set.
Glazed areas → Sand with coarse sandpa-
per.
EAS30316
TIP
CHECKING THE PRIMARY SHEAVE
After sanding the glazed areas, clean the clutch 1. Check:
with a cloth. • Primary sliding sheave
2. Measure: • Primary fixed sheave
• Clutch shoe thickness “a” • Collar
Out of specification → Replace the clutch Cracks/damage/wear → Replace the primary
shoes and springs as a set. sliding sheave, primary fixed sheave, and
collar as a set.
Clutch shoe thickness
EAS30317
3.0 mm (0.12 in)
CHECKING THE PRIMARY SHEAVE
Limit
WEIGHTS
2.1 mm (0.08 in)
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
• Primary sheave weight
Cracks/damage/wear → Replace.

5-38
 V-BELT AUTOMATIC TRANSMISSION

2. Measure:
• Primary sheave weight outside diameter “a” Compression spring free length
Out of specification → Replace. 116.4 mm (4.58 in)
Limit
Weight outside diameter 104.7 mm (4.12 in)
20.0 mm (0.79 in)
Limit
19.5 mm (0.77 in)

EAS30320

ASSEMBLING THE PRIMARY SHEAVE

1. Clean:
EAS31233 • Primary fixed sheave
CHECKING THE PRIMARY SHEAVE • Primary sliding sheave
SLIDERS • Primary sheave weights
1. Check: • Cam
• Primary sheave slider
EAS30321
Cracks/damage/wear → Replace. ASSEMBLING THE SECONDARY SHEAVE
EAS30319 1. Lubricate:
CHECKING THE SECONDARY SHEAVE • Secondary sliding sheave inner surface
1. Check: • Oil seals “1”
• Secondary fixed sheave (with the recommended lubricant)
• Secondary sliding sheave
Cracks/damage/wear → Replace the sec- Recommended lubricant
ondary fixed and sliding sheaves as a set. Shell dolium grease R®
2. Check:
• Torque cam groove “a” TIP
Damage/wear → Replace the secondary Do not apply grease to the inner surface “a” of
fixed and sliding sheaves as a set. the secondary fixed sheave “2”. If any grease
3. Check: gets on the inner surface of the secondary fixed
• Guide pin “1” sheave, be sure to wipe it off thoroughly.
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
2 *
1
1

*
a 1
a

2. Install:
• Oil seals New
4. Check:
• Secondary sliding sheave “1”
• Spring free length
Out of specification → Replace the spring.

5-39
 V-BELT AUTOMATIC TRANSMISSION

TIP
Sheave spring compressor
Install the secondary sliding sheave onto the 90890-04134
secondary fixed sheave “2” with the oil seal Sheave fixed block
guide “3”. 90890-04135

Oil seal guide (37 mm)

90890-04177 2

3
3
2
EAS31234

INSTALLING THE PRIMARY SHEAVE, V-

BELT AND SECONDARY SHEAVE
3. Install: 1. Install:
• Guide pins “1” • Secondary sheave assembly
4. Lubricate: TIP
• Guide pin grooves “a” Before installing the secondary sheave assem-
• O-rings “2” New bly, check that there is no grease on the splines
(with the recommended lubricant) “a” of the primary drive gear. If there is any
grease on the splines, be sure to wipe it off thor-
Recommended lubricant oughly.
Shell dolium grease R®

1
New 2
a
a

2. Tighten:
5. Install: • Secondary sheave nut “1”
• Spring seat
• Compression spring Secondary sheave nut
• Clutch carrier assembly 55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.

• Secondary sheave nut “1”

TIP
TIP
While holding the secondary sheave with the ro-
• Install the sheave spring compressor “2” and
tor holding tool “2”, tighten the secondary
sheave fixed block “3” onto the secondary
sheave nut with the socket wrench “3”.
sheave as shown. Then, compress the spring,
and install the secondary sheave nut.
• Install the secondary sheave nut “1” with its ta- Rotor holding tool
pered side facing the clutch carrier. 90890-04166
Socket wrench (39 mm)
90890-01493

5-40
 V-BELT AUTOMATIC TRANSMISSION

5. Install:
2 • V-belt “1”
ECA21720

NOTICE
Do not allow grease to come in contact with
the V-belt.
1
TIP
• Install the V-belt with the printed arrow mark on
3 the V-belt facing in the direction shown in the il-
3. Install: lustration.
• Clutch housing “1” • Install the V-belt onto the primary sheave side.
• Clutch housing nut “2”

Clutch housing nut

45 N·m (4.5 kgf·m, 33 lb·ft)
T.
R.

TIP
While holding the clutch housing with the rotor 1
holding tool “3”, tighten the clutch housing nut.

Rotor holding tool

90890-04166 6. Install:
• Primary fixed sheave “1”
• Washer
3 • Conical spring washer “2”
• Primary fixed sheave nut
ECA21730

NOTICE
Do not allow grease to contact the primary
sheave assembly.

1 TIP
2 • Apply lithium-soap-based grease to the prima-
4. Install: ry fixed sheave nut side of the conical spring
• Primary sliding sheave assembly “1” washer and to the threaded portion of the
• Washer crankshaft.
TIP • Install the conical spring washer with the mark
“a” facing outward.
When installing the primary sliding sheave as-
• Install the V-belt in the primary sheave (when
sembly, hold the cam to prevent the primary
the pulley is at its widest position) and in the
sheave weights from falling out of the primary
secondary sheave (when the pulley is at its
sliding sheave.
narrowest position), and make sure the V-belt
is tight.

5-41
 V-BELT AUTOMATIC TRANSMISSION

2
7. Tighten:
• Primary fixed sheave nut “1”

Primary fixed sheave nut

76 N·m (7.6 kgf·m, 56 lb·ft)
T.
R.

TIP
While holding the primary fixed sheave with the
rotor holding tool “2”, tighten the primary fixed
sheave nut.

Rotor holding tool (including

handle and 3 pins)
90890-04195
Rotor holding tool attachment 7 x
12 mm
90890-04197

5-42
 STARTER GENERATOR

EAS20714

STARTER GENERATOR
Removing the starter generator assembly

4 LT

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
3

5 2

LT

70 N•m (7.0 kgf•m, 52 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Refer to “GENERAL CHASSIS (1)” on page
Battery
4-1.
Refer to “GENERAL CHASSIS (2)” on page
Side cover (right)
4-3.
Radiator fan Refer to “RADIATOR” on page 6-2.
Crankshaft position sensor coupler/Starter gen-
1 erator coupler 1/1 Disconnect.

2 Starter generator rotor nut 1

3 Starter generator rotor 1
4 Woodruff key 1
5 Starter generator/Crankshaft position sensor 1

5-43
 STARTER GENERATOR

EAS33382 EAS33383

REMOVING THE STARTER GENERATOR INSTALLING THE STARTER GENERATOR

1. Remove: 1. Install:
• Starter generator rotor nut “1” • Woodruff key
• Washer • Starter generator rotor
TIP • Washer
While holding the starter generator rotor “2” with • Starter generator rotor nut
the rotor holding tool “3”, loosen the starter gen- TIP
erator rotor nut. • Clean the tapered portion of the crankshaft and
the starter generator rotor hub.
Rotor holding tool (including • When installing the starter generator rotor,
handle and 3 pins) make sure the woodruff key is properly seated
90890-04195 in the keyway of the crankshaft.
Rotor holding tool attachment 7 x
2. Tighten:
5 mm
90890-04198 • Starter generator rotor nut “1”

Starter generator rotor nut

70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.

TIP
While holding the starter generator rotor “2” with
3 the rotor holding tool “3”, tighten the starter gen-
2
erator rotor nut.

Rotor holding tool (including

1 handle and 3 pins)
2. Remove: 90890-04195
• Starter generator rotor “1” Rotor holding tool attachment 7 x
5 mm
(with the flywheel puller “2”)
90890-04198
• Woodruff key
ECA21740

NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller center bolt and the crankshaft.
3
2
Flywheel puller
90890-01189

5-44
 OIL PUMP

EAS20054

OIL PUMP
Removing the oil pump

3 New
2
4

5 4
1 New

4.0 N•m (0.40 kgf•m, 3.0 lb•ft) LS

T.R
.

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

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

Order Job/Parts to remove Q’ty Remarks

Refer to “V-BELT AUTOMATIC TRANSMIS-
V-belt automatic transmission
SION” on page 5-33.
1 Oil seal 1
2 Oil pump cover 1
3 Gasket 1
4 Dowel pin 2
5 Oil pump assembly 1

5-45
 OIL PUMP

Disassembling the oil pump

1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.

7
5
3
6

Order Job/Parts to remove Q’ty Remarks

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump driven gear 1
4 Oil pump rotor assembly 1
5 Oil pump inner rotor 1
6 Oil pump outer rotor 1
7 Oil pump housing 1

5-46
 OIL PUMP

EAS30340

CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS30337

CHECKING THE OIL PUMP

1. Check:
• Oil pump drive gear
• Oil pump driven gear EAS30342

• Oil pump housing ASSEMBLING THE OIL PUMP

• Oil pump housing cover 1. Lubricate:
Cracks/damage/wear → Replace the oil • Inner rotor
pump. • Outer rotor
2. Measure: • Oil pump shaft
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance Recommended lubricant
“b” Engine oil
Out of specification → Replace the oil pump.
2. Install:
• Oil pump housing “1”
• Oil pump outer rotor “2”
• Oil pump inner rotor “3”
• Oil pump driven gear “4”
• Pin “5”
• Oil pump housing cover

Oil pump housing cover screw

1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
T.
R.

1. Inner rotor TIP

2. Outer rotor When installing the inner rotor, align the pin in
3. Oil pump housing the oil pump driven gear with the groove “a” in
the inner rotor.
Inner-rotor-to-outer-rotor-tip
clearance
4
Less than 0.15 mm (0.006 in) 3
5
Limit
0.23 mm (0.0091 in) 2
Outer-rotor-to-oil-pump-housing
clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit 1
0.25 mm (0.0098 in)
a

3. Check: 3. Check:
• Oil pump operation • Oil pump operation
Rough movement → Repeat steps (1) and Refer to “CHECKING THE OIL PUMP” on
(2) or replace the oil pump. page 5-47.

5-47
 TRANSMISSION

EAS20062

TRANSMISSION
Removing the transmission

20 N·m (2.0 kgf·m, 15 lb·ft)

T.R
.

LS

New

5
E
E
E
(5)

E
1
E

LS
LS 3
New 4
LS New
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Radiator cover Refer to “RADIATOR” on page 6-2.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-33.
Refer to “REAR SHOCK ABSORBER AS-
Swingarm SEMBLIES AND SWINGARM” on page
4-75.
Rear wheel Refer to “REAR WHEEL” on page 4-34.
1 Final transmission oil filler cap 1
2 Final transmission oil drain bolt 1
3 Transmission case cover 1
4 Transmission case cover gasket 1
5 Dowel pin 2

5-48
 TRANSMISSION

Removing the transmission

20 N·m (2.0 kgf·m, 15 lb·ft)

T.R
.

LS
New 11

New 12

10

12
12
6 E
E
E
(5)
12 13
12
E

E
7
9 New
E
8
LS
LS New 11
New
LS 12 20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

6 Main axle assembly 1
7 Drive axle 1
8 1st wheel gear 1
9 Circlip 1
10 Primary drive gear 1
11 Oil seal 2
12 Bearing 6
13 Transmission breather pipe 1

5-49
 TRANSMISSION

EAS30433

CHECKING THE TRANSMISSION

1. Check:
• Transmission gears 2
1
Blue discoloration/pitting/wear → Replace New
the defective gear(s).
• Transmission gear dogs 1 New
Cracks/damage/rounded edges → Replace
the defective gear(s).
2
2. Check:
• Transmission gear engagement
3. Install:
(each pinion gear to its respective wheel
• Primary driven gear “1”
gear)
(to the main axle “2”)
Incorrect → Reassemble the transmission
axle assemblies. Primary driven gear installed
3. Check: depth “a”
• Transmission gear movement 0.5–0.9 mm (0.020–0.035 in)
Rough movement → Replace the defective
part(s). a
EAS30438

INSTALLING THE TRANSMISSION

1. Install: 2
• Oil seal “1” New
(to the transmission case cover “2”)
• Oil seal “3” New 1
(to the right crankcase “4”)

Installed depth “a” 4. Install:

21.7–21.8 mm (0.85–0.86 in)
• Transmission case cover “1”
Installed depth “b”
0.25–0.75 mm (0.01–0.03 in) Transmission case cover bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

New 1 2 TIP
Tighten the transmission case cover bolts in the
a proper tightening sequence as shown.

3 New
1
b 4
2. Install: 1
• Circlip “1” New
(to the drive axle “2”)
TIP
Install the circlip with its chamfered side facing
as shown.

5-50
 TRANSMISSION

4
2
5

3 8 6
7

5-51
 CRANKSHAFT

EAS20061

CRANKSHAFT
Removing the crankshaft

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.

1 E

LS
New

(11) 11
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10

10

12
LS
7

New
8 LS
New
6 2
4
5
LS
New 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.

3
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL” on page 5-4.
Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
Refer to “CYLINDER AND PISTON” on page
Piston 5-28.
Refer to “V-BELT AUTOMATIC TRANSMIS-
Secondary sheave assembly SION” on page 5-33.
Refer to “STARTER GENERATOR” on page
Starter generator 5-43.
1 Dipstick 1
2 Engine oil drain bolt 1
3 Oil strainer cover 1
4 Spring 1

5-52
 CRANKSHAFT

Removing the crankshaft

10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.

1 E

LS
New

(11) 11
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.
10

10

12
LS
7

New
8 LS
New
6 2
4
5
LS
New 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.

3
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

Order Job/Parts to remove Q’ty Remarks

5 Centerstand shaft 1
6 Centerstand 1
7 Timing chain guide (intake side) 1
8 Timing chain 1
9 Crankcase (left) 1
10 Pin dowel 2
11 Crankshaft assembly 1
12 Crankcase (right) 1

5-53
 CRANKSHAFT

Removing the crankshaft

10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.

8
E

LS
New

(9)

7
9
LS

7 N•m (0.7 kgf•m, 5.2 lb•ft)

5
T.R
.

New New
LS

LS
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.

LS

Order Job/Parts to remove Q’ty Remarks

5 Centerstand 1
6 Crankcase (left) 1
7 Dowel pin 2
8 Crankshaft assembly 1
9 Crankcase (right) 1

5-54
 CRANKSHAFT

EAS31241 ECA20630

DISASSEMBLING THE CRANKCASE NOTICE

1. Remove: • To protect the end of the crankshaft, place
• Crankcase bolts an appropriate sized socket between the
TIP crankcase separating tool bolt and the
Loosen each bolt 1/4 of a turn at a time, in stag- crankshaft.
es and in a crisscross pattern. After all of the • Do not tap on the crankshaft.
bolts are fully loosened, remove them.
Crankcase separating tool
90890-01135

1
2. Remove:
• Crankcase (left) “1” 3
ECA13900

NOTICE EAS31242

CHECKING THE CRANKSHAFT ASSEMBLY

Tap on one side of the crankcase with a soft-
1. Measure:
face hammer. Tap only on reinforced por-
• Crankshaft runout
tions of the crankcase, not on the crankcase
Out of specification → Replace the crank-
mating surfaces. Work slowly and carefully
shaft assembly.
and make sure the crankcase halves sepa-
rate evenly. TIP
Turn the crankshaft slowly.

Runout limit
0.030 mm (0.0012 in)

EAS30414

REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:
• Crankshaft assembly “1”
TIP 2. Measure:
• Remove the crankshaft assembly with the • Crankshaft width
crankcase separating tool “2” and M6 bolts “3”. Out of specification → Replace the crank-
• Make sure that the crankcase separating tool shaft assembly.
is centered over the crankshaft assembly.
Crank assembly width
51.45–51.50 mm (2.026–2.028 in)

5-55
 CRANKSHAFT

EAS30791

INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft assembly “1”
TIP
• Install the crankshaft assembly with the crank-
shaft installer pot “2”, crankshaft installer bolt
“3”, adapter “4”, and crankshaft installer spacer
“5”.
• Hold the connecting rod at top dead center
3. Check: (TDC) with one hand while turning the nut of
• Crankshaft sprocket “1” the crankshaft installer bolt with the other. Turn
Damage/wear → Replace the crankshaft as- the crankshaft installer bolt until the crankshaft
sembly. assembly bottoms against the bearing.
• Bearing “2”
Cracks/damage/wear → Replace the crank- Crankshaft installer pot
shaft assembly. 90890-01274
Crankshaft installer bolt
2 90890-01275
Adapter (M12)
90890-01278
1 Spacer (crankshaft installer)
90890-04081

5
1 4
EAS31243
2
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves in a 3
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
EAS31246
• Crankcase ASSEMBLING THE CRANKCASE
Cracks/damage → Replace. 1. Thoroughly clean all the gasket mating sur-
EAS31244 faces and crankcase mating surfaces.
CHECKING THE BEARING 2. Apply:
1. Check: • Sealant
• Bearing (onto the crankcase mating surfaces)
Clean and lubricate the bearings, and then
rotate the inner race with your finger. Yamaha bond No. 1215
Rough movement → Replace. 90890-85505
(Three bond No.1215®)
EAS31245

CHECKING THE OIL PUMP DRIVE GEAR TIP

1. Check:
Do not allow any sealant to come into contact
• Oil pump drive gear
with the oil gallery.
Damage/wear → Replace.

5-56
 CRANKSHAFT

3. Install:
• Crankcase (right)
(onto the crankcase (left))
• Crankcase bolts

Crankcase bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

TIP
• Thoroughly wipe off any sealant that protrudes
from between the left crankcase and the right
crankcase.
• Tighten the crankcase bolts in stages and in a
crisscross pattern.

EAS31247

INSTALLING THE CENTERSTAND

1. Install:
• Centerstand “1”
• Spring “2”
TIP
• Make sure that the hooked end “a” of the spring
is positioned to the outside.
• Make sure that the hooked end “b” of the spring
is positioned to the outside.

1
2 b

5-57
 COOLING SYSTEM

COOLING SYSTEM DIAGRAMS ...................................................................6-1

RADIATOR .....................................................................................................6-2
CHECKING THE RADIATOR ...................................................................6-4
INSTALLING THE RADIATOR .................................................................6-4

THERMOSTAT ...............................................................................................6-6
CHECKING THE THERMOSTAT ASSEMBLY ........................................6-7
INSTALLING THE THERMOSTAT ASSEMBLY ......................................6-7

WATER PUMP ................................................................................................6-8

DISASSEMBLING THE WATER PUMP ................................................. 6-10
CHECKING THE WATER PUMP ........................................................... 6-10
ASSEMBLING THE WATER PUMP ....................................................... 6-10
INSTALLING THE WATER PUMP .........................................................6-11

6
 COOLING SYSTEM DIAGRAMS

EAS20299

COOLING SYSTEM DIAGRAMS

8
1 2 3 4 7 5

1 2 3 4 5

1. Radiator cap 5. Thermostat assembly

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

6-1
 RADIATOR

EAS20063

RADIATOR
Removing the radiator

7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
T.R

.
.

(3)

(5)

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

(4)

New 11 N•m (1.1 kgf•m, 8.1 lb•ft)

T.R
.

LS

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Refer to “GENERAL CHASSIS (2)” on page
Side cover (right)
4-3.
Refer to “GENERAL CHASSIS (5)” on page
Footrest board assembly (right)/Bottom cover
4-10.
1 Radiator cover 1
2 Coolant reservoir breather hose 1
3 Coolant reservoir hose 1
4 Coolant reservoir hose 1

6-2
 RADIATOR

Removing the radiator

7 Nm (0.7 m•kgf, 5.1 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
T.R

.
.

10

(3) 11

(5) 6

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

(4) 9 5

7
New 11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.

LS

10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Order Job/Parts to remove Q’ty Remarks

5 Coolant reservoir 1
6 Radiator inlet hose 1
7 Radiator outlet hose 1
8 Radiator cap 1
9 Radiator 1
10 Radiator fan case 1
11 Radiator fan 1

6-3
 RADIATOR

EAS30439

CHECKING THE RADIATOR

1. Check: 2
1
• Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radia-
tor.
Damage → Repair or replace.
TIP 3
Straighten any flattened fins with a thin, flathead
screwdriver. b. Apply the specified pressure for ten sec-
onds and make sure there is no drop in
pressure.
4. Check:
• Radiator fan
Damage → Replace.
EAS30440

INSTALLING THE RADIATOR

1. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
2. Check:
Refer to “CHANGING THE COOLANT” on
• Radiator hoses
page 3-19.
• Coolant reservoir hose
2. Check:
Cracks/damage → Replace.
• Cooling system
3. Measure:
Leaks → Repair or replace any faulty part.
• Radiator cap valve opening pressure
a. Attach the radiator cap tester “1” to the ra-
Below the specified pressure → Replace the
diator.
radiator cap.
Radiator cap tester
Radiator cap valve opening pres-
90890-01325
sure
78.6–137.4 kPa (0.78–1.37 kgf/
cm², 11.4–19.9 psi)

a. Install the radiator cap tester “1” and radi-

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

Radiator cap tester 1

90890-01325
Radiator cap tester adapter
31mm
90890-05375 b. Apply 196 kPa (1.96 kg/cm², 27.87 psi) of
pressure.
c. Measure the pressure to check its main-
taining applied pressure.

6-4
 RADIATOR

3. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-4.

6-5
 THERMOSTAT

EAS20065

THERMOSTAT
Removing the thermostat assembly

* New
1
4

2 3

9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

*: Apply water

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.

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

4-3.

Footrest board assembly (right)/Bottom cover Refer to “GENERAL CHASSIS (5)” on page
4-10.
1 Radiator inlet hose 1 Disconnect.
2 Radiator outlet hose 1 Disconnect.
3 Water pump inlet hose 1 Disconnect.
4 Thermostat assembly 1

6-6
 THERMOSTAT

EAS31248

CHECKING THE THERMOSTAT ASSEMBLY

B
1. Check:
• Thermostat “1”
Does not open at 74–78°C (165–172°F) → 0.5 mm
(0.02 in) 7 mm
Replace.
(0.28 in)

A
74 – 78˚C 90˚C
(165 – 172˚F) (194˚F)
1
A. Fully closed
B. Fully open

TIP
If the accuracy of the thermostat is in doubt, re-
a. Suspend the thermostat “1” in a container place it. A faulty thermostat could cause serious
“2” filled with water. overheating or overcooling.
b. Slowly heat the water.
EAS30445
c. Place a thermometer “3” in the water. INSTALLING THE THERMOSTAT
d. While stirring the water “4”, observe the ASSEMBLY
thermostat and thermometer’s indicated 1. Fill:
temperature. • Cooling system
(with the specified amount of the recom-
3 mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
2. Check:
4 • Cooling system
1
Leaks → Repair or replace any faulty part.
2 Refer to “INSTALLING THE RADIATOR” on
page 6-4.
3. Measure:
e. Check the thermostat element position • Radiator cap opening pressure
“5”. Below the specified pressure → Replace the
Same level for the thermostat element up- radiator cap.
per end and the hole lower line “a” at 90 °C Refer to “CHECKING THE RADIATOR” on
(194 °F) page 6-4.

6-7
 WATER PUMP

EAS20066

WATER PUMP
Removing the water pump

3 2

LS

4 New 3

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Refer to “GENERAL CHASSIS (2)” on page
Front side cover (left)
4-3.
Refer to “GENERAL CHASSIS (4)” on page
Footrest board assembly (left)/Bottom cover
4-8.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1
3 Dowel pin 2
4 O-ring 2

6-8
 WATER PUMP

Disassembling the water pump

New
9
New 8

3
7 10 Nm (1.0 • , 7.2 • )

T .R
.
7

2 New
New
1
New
5 New

9 4

10 Nm (1.0 • , 7.2 • )
T .R
.

Order Job/Parts to remove Q’ty Remarks

1 Water pump housing cover 1
2 Water pump housing gasket 1
3 Circlip 1
4 Impeller shaft 1
5 Water pump seal 1
6 O-ring 2
7 Bearing 2
8 Water pump housing 1
9 Pin dowel 2

6-9
 WATER PUMP

EAS30446

DISASSEMBLING THE WATER PUMP A

1. Remove:
• Water pump seal “1” 4
TIP
3
Remove the water pump seal from the inside of
the water pump housing “2”. 2 1 New

1
2 A. Push down
3. Mechanical seal installer
4. Middle driven shaft bearing driver

1 New
a

EAS30447

CHECKING THE WATER PUMP 2

1. Check:
• Water pump housing cover
• Water pump housing
• Impeller shaft
Cracks/damage/wear → Replace.
a. Installed depth of water pump seal
EAS30448

ASSEMBLING THE WATER PUMP 2. Lubricate:

1. Install: • Water pump seal
• Water pump seal “1” New
Recommended lubricant
(into the water pump housing “2”) Lithium-soap-based grease
TIP
Install the water pump seal with the special tools 3. Install:
to the specified depth as shown in the illustra- • Impeller shaft “1”
tion. • Circlip New
TIP
Installed depth of water pump After installation, check that the impeller shaft ro-
seal tates smoothly.
0–0.5 mm (0–0.02 in)

Mechanical seal installer

90890-04145
Middle driven shaft bearing driv-
er
90890-04058

6-10
 WATER PUMP

EAS30449

INSTALLING THE WATER PUMP

1. Install:
• O-rings “1” New
• Water pump assembly “2”

Water pump assembly bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

TIP
• Align the projection “a” on the impeller shaft
with the slit “b” on the camshaft sprocket bolt.
• Lubricate the O-ring with a thin coat of lithium-
soap-based grease.

a b
2

New 1
LS

2. Fill:
• Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-19.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-4.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-4.

6-11
 FUEL SYSTEM

FUEL TANK ....................................................................................................7-1

REMOVING THE FUEL TANK .................................................................7-3
REMOVING THE FUEL PUMP ................................................................7-3
REMOVING THE FUEL FILTER ..............................................................7-3
CHECKING THE FUEL PUMP BODY ......................................................7-3
CHECKING THE FUEL FILTER ...............................................................7-3
INSTALLING THE FUEL FILTER .............................................................7-3
INSTALLING THE FUEL PUMP ...............................................................7-4
INSTALLING THE FUEL TANK ................................................................7-4
CHECKING THE FUEL PRESSURE .......................................................7-5

FUEL INJECTOR ............................................................................................7-6

REMOVING THE FUEL HOSE ................................................................7-7
CHECKING THE FUEL INJECTOR .........................................................7-7
INSTALLING THE FUEL INJECTOR .......................................................7-7
INSTALLING THE FUEL HOSE ...............................................................7-7

AIR FILTER CASE .........................................................................................7-8

INSTALLING THE AIR FILTER CASE ................................................... 7-10

THROTTLE BODY ........................................................................................ 7-11

REMOVING THE THROTTLE BODY ..................................................... 7-13
CHECKING THE THROTTLE BODY ..................................................... 7-13
CLEANING THE ISC (IDLE SPEED CONTROL)
UNIT AND THROTTLE BODY .............................................................. 7-13
REPLACING THE THROTTLE BODY ................................................... 7-15
INSTALLING THE THROTTLE BODY ................................................... 7-16

7
 FUEL TANK

EAS20067

FUEL TANK
Removing the fuel tank

9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.R
.
4

5
8
6
New
1 12

7 2 11

10

3
9

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-6.
Refer to “GENERAL CHASSIS (5)” on page
Center lower cover 4-10.
1 Fuel tank cap 1
2 Fuel tank overflow tray 1
3 Fuel tank overflow hose 1
Fuel tank breather hose (fuel tank to rollover
4 1
valve)
5 Fuel sender coupler 1 Disconnect.
6 Fuel pump coupler 1 Disconnect.
7 Fuel hose 1 Disconnect.
8 Fuel tank 1
9 Fuel pump bracket 1
10 Fuel pump 1

7-1
 FUEL TANK

Removing the fuel tank

9 N·m (0.9 kgf·m, 6.6 lb·ft)

T.R
.
4

5
8
6
New
1 12

7 2 11

10

3
9

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

11 Fuel filter 1
12 Fuel pump gasket 1

7-2
 FUEL TANK

EAS30450 EAS31376

REMOVING THE FUEL TANK REMOVING THE FUEL FILTER

1. Extract the fuel in the fuel tank through the 1. Remove:
fuel tank cap with a pump. • Fuel filter “1”
2. Disconnect: TIP
• Fuel sender coupler Remove the projections “a” on the fuel pump
• Fuel pump coupler from the holes “b” in the fuel filter and slide the
• Fuel hose fuel filter in the direction of the arrow shown to
EWA18020

WARNING remove it.

Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in a 1
the fuel lines could cause fuel to spurt out
when removing the hose.
ECA20020 a
NOTICE b
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
EAS30454

TIP CHECKING THE FUEL PUMP BODY

• To remove the fuel hose from the fuel pump, 1. Check:
slide the fuel hose connector cover “1” on the • Fuel pump body
end of the hose in the direction of the arrow Obstruction → Clean.
shown, and then remove the hose. Cracks/damage → Replace fuel pump as-
• Before removing the hose, place a few rags in sembly.
the area under where it will be removed. EAS31249

CHECKING THE FUEL FILTER

1. Check:
• Fuel filter
Damage → Replace.
Contaminants → Clean with solvent.
1 EAS31377

INSTALLING THE FUEL FILTER

1. Install:
• Fuel filter “1”
TIP
3. Remove: Fit the projections “a” on the fuel pump into the
• Fuel tank holes “b” in the fuel filter and slide the fuel filter
EAS30451 in the direction of the arrow shown to install it.
REMOVING THE FUEL PUMP
1. Remove: 1
• Fuel pump a
ECA14721

NOTICE
• Do not drop the fuel pump or give it a a
strong shock. b
• Do not touch the base section of the fuel
sender.

7-3
 FUEL TANK

EAS30456 EAS30457

INSTALLING THE FUEL PUMP INSTALLING THE FUEL TANK

1. Install: 1. Install:
• Fuel pump gasket “1” New • Fuel tank “1”
• Fuel pump a. Temporarily install the fuel tank.
• Fuel pump bracket TIP
Make sure that the flanges of the fuel tank bolts
Fuel pump bracket bolt “2” do not contact the fuel tank.
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.

b. Install the fuel tank overflow tray and fuel

TIP tank cover “3”. To install the fuel tank cov-
• Do not damage the installation surfaces of the er, refer to “GENERAL CHASSIS (3)” on
fuel tank when installing the fuel pump. page 4-6.
• Always use a new fuel pump gasket. c. Tighten the fuel tank bolts to specification.
• The gasket lip “a” shall face toward the fuel
Fuel tank bolt
pump. T. 9 N·m (0.9 kgf·m, 6.6 lb·ft)
• Align the projections “b” (two locations) on the
R.

fuel pump gasket with the slots “c” in the fuel

pump. 3
• Align the projection “d” on the fuel pump with
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight- 2
ening sequence as shown.
2

1
2. Install:
a • Fuel hose
c ECA17500

NOTICE
1 New
b When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
1 the correct position, otherwise the fuel hose
d will not be properly installed.
TIP
4 • Install the fuel hose securely onto the fuel
3 pump until a distinct “click” is heard.
• To install the fuel hose, slide the fuel hose con-
nector cover “1” on each end of the hose in the
direction of the arrow shown.
2

7-4
 FUEL TANK

EAS30703

CHECKING THE FUEL PRESSURE Fuel line pressure (at idle)

1. Remove: 220–300 kPa (2.2–3.0 kgf/cm²,
• Front side cover assembly (left) 31.9–43.5 psi)
Refer to “GENERAL CHASSIS (2)” on page
4-3. Faulty → Replace the fuel pump.
• Footrest board (left) e. Connect the fuel hose.
Refer to“GENERAL CHASSIS (5)” on page Refer to “INSTALLING THE FUEL TANK”
4-10. on page 7-4.
2. Check: 3. Install:
• Pressure regulator operation • Footrest board (left)
a. Disconnect the fuel hose from the fuel Refer to “GENERAL CHASSIS (5)” on page
pump. 4-10.
EWA18020
• Front side cover assembly (left)
WARNING Refer to “GENERAL CHASSIS (2)” on page
Cover the fuel hose connection with a cloth 4-3.
when disconnecting it. Residual pressure in
the fuel lines could cause fuel to spurt out
when removing the hose.
ECA20020

NOTICE
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
TIP
Before removing the hose, place a few rags in
the area under where it will be removed.
b. Connect the pressure gauge “1” and fuel
pressure adapter “2” to the fuel hose “3”.

Pressure gauge
90890-03153
Fuel pressure adapter 6.3mm
90890-03227

1
YAMA
H

2 3

c. Start the engine.

d. Measure the fuel pressure.

7-5
 FUEL INJECTOR

EAS20191

FUEL INJECTOR
Removing the fuel injector

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
3

1
2
4

New
E

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-6.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-8.
Refer to “GENERAL CHASSIS (5)” on page
Center lower cover 4-10.
1 Fuel hose 1
2 Fuel injector coupler 1 Disconnect.
3 Fuel injector 1
4 Fuel injector adaptor 1

7-6
 FUEL INJECTOR

EAS31250

REMOVING THE FUEL HOSE Fuel injector bolt

1. Disconnect: 10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.
R.
• Fuel hose
EWA17610
TIP
WARNING
• Lubricate the O-ring with engine oil.
Cover fuel hose connections with a cloth
• Align the projection “a” on the fuel injector
when disconnecting them. Residual pres-
adapter with the hole “b” in the intake manifold.
sure in the fuel lines could cause fuel to
• Align the projection “c” on the fuel injector with
spurt out when removing the hoses.
the hole “d” in the fuel injector adapter.
ECA20020

NOTICE
Although the fuel has been removed from 3
the fuel tank, be careful when removing the New 2
fuel hose, since there may be fuel remaining c
a
in it.
b 1
TIP
• To remove the fuel hose from the fuel injector, d
slide the fuel hose connector cover “1”on the
end of the hose in the direction of the arrow
shown, and then remove the hose. EAS31253

• Before removing the hose, place a few rags in INSTALLING THE FUEL HOSE
the area under where it will be removed. 1. Install:
• Fuel hose
ECA17500

NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
1
the correct position, otherwise the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel in-
EAS31251 jector until a distinct “click” is heard.
CHECKING THE FUEL INJECTOR • To install the fuel hose onto the fuel injector,
1. Check: slide the fuel hose connector cover “1” on the
• Injector end of the hose in the direction of the arrow
Obstruction → Replace and check the fuel shown.
pump/fuel supply system.
Deposit → Replace.
Damage → Replace.
2. Check:
• Injector resistance
Refer to “INSTALLING THE FUEL INJEC- 1
TOR” on page 7-7.
EAS31617

INSTALLING THE FUEL INJECTOR

1. Install:
• Fuel injector adaptor “1”
• O-ring “2” New
(to the fuel injector)
• Fuel injector “3”

7-7
 AIR FILTER CASE

EAS20068

AIR FILTER CASE

Removing the air filter case

New

3
New

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

2
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.

2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Front side covers 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Fuel tank cover 4-6.
Refer to “GENERAL CHASSIS (4)” on page
Storage box 4-8.
1 Air filter case cover 1
2 Air filter case duct 1
3 Air filter element 1
4 Transmission case breather hose 1

7-8
 AIR FILTER CASE

Removing the air filter case

8
New

New

10 N•m (1.0 kgf•m, 7.4 lb•ft)

9
T.R
.

1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

T.R
.

2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

5 Cylinder head breather hose 1 Disconnect.
6 Air filter case joint clamp screw 1 Loosen.
7 Air filter case 1
8 Air filter check hose 1
9 Air filter case joint 1

7-9
 AIR FILTER CASE

EAS31618

INSTALLING THE AIR FILTER CASE

1. Install:
• Hose “1”
(to the air filter case joint “2”) b
TIP
• Apply Three bond 1521 “3” onto the mating
surfaces of the hose and air filter case joint.
• Align the slot “a” on the air filter case joint with
2 1 a
the projection “b” in the hose.

2
b
a
1

3
2. Install:
• Air filter case joint clamp “1”
(to the air filter case joint “2”)

Air filter case joint clamp screw

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.

TIP
Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.

1 2

b a

3. Install:
• Air filter case duct “1”
TIP
Fit the projection “a” on the air filter case duct be-
tween the projections “b” on the air filter case
cover “2”.

7-10
 THROTTLE BODY

EAS20070

THROTTLE BODY
Removing the throttle body
5 N•m (0.5 kgf•m, 3.7 lb•ft)

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

T.R
.
1
2

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

MS
L

New
New
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

Refer to “GENERAL CHASSIS (1)” on page
Battery 4-1.
Refer to “GENERAL CHASSIS (2)” on page
Side covers 4-3.
Refer to “GENERAL CHASSIS (3)” on page
Storage box 4-6.
Air filter case joint Refer to “AIR FILTER CASE” on page 7-8.
Fuel injector Refer to “FUEL INJECTOR” on page 7-6.
1 ISC (Idle Speed Control) unit coupler 1 Disconnect.
2 Throttle body sensor assembly coupler 1 Disconnect.

7-11
 THROTTLE BODY

Removing the throttle body

5 N•m (0.5 kgf•m, 3.7 lb•ft)

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

T.R
.
8
9 5

10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

6
MS
L
New
New 4 3 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Order Job/Parts to remove Q’ty Remarks

3 Throttle cable 2 Disconnect.
4 Throttle cable holder 1
5 Throttle body 1 Loosen.
6 Intake manifold 1
7 ISC (Idle Speed Control) unit holder 1
8 ISC (Idle Speed Control) unit 1
9 Spring 1

7-12
 THROTTLE BODY

EAS30979 EAS31254

REMOVING THE THROTTLE BODY CLEANING THE ISC (IDLE SPEED

1. Remove: CONTROL) UNIT AND THROTTLE BODY
• Throttle body 1. Remove the throttle body from the vehicle.
ECA20500
TIP
NOTICE
Before removing the throttle body, disconnect
Do not remove the throttle body sensor as-
the throttle cables and couplers.
sembly from the throttle body.
2. Remove:
EAS30479 • Screw “1”
CHECKING THE THROTTLE BODY • ISC (Idle Speed Control) unit holder “2”
TIP • ISC (Idle Speed Control) unit “3”
ECA21780
Before checking the throttle body, check the fol-
NOTICE
lowing items:
• Valve clearance Because the force of the spring may push
• Spark plug out the ISC unit unexpectedly, be sure to
• Air filter element hold the ISC unit when removing the compo-
• Intake manifold nents.
• Fuel hose
• Exhaust system 2
• Cylinder head breather hose 3 1
EWA18030

WARNING
If the throttle body is subjected to strong
shocks or dropped during, replace it.
1. Check:
• Throttle body
Cracks/damage → Replace the throttle body.
3. Remove:
2. Check: • Spring “1”
• Butterfly valve • O-ring “2”
Damage/scratches/wear → Replace the
throttle body.
ECA21770

NOTICE 1
Do not adjust the stop screw “1”. 2

1
4. Check:
• ISC (Idle Speed Control) unit
Plunger “1” does not rotate smoothly/plunger
rotates together with the motor shaft “2” →
Replace.

7-13
 THROTTLE BODY

Recommended cleaning agent

Yamaha oil & brake cleaner
1
ECA21790

NOTICE
• Be sure to use the recommended cleaning
agent.
2 • Do not spray the cleaning agent directly
onto the ISC unit or throttle body and do
not immerse them in the cleaning agent.
5. Check:
• To prevent scratching the components, do
• Spring
not use a brush, metal file, or other abra-
Damage/bent → Replace. sive tool.
6. Clean: • Do not clean with compressed air.
• Area “a” of the ISC unit • Do not allow the removed deposits or for-
• Areas “b” and “c” of the throttle body
eign materials to adhere to the sealing sur-
Clogs or foreign materials cannot be re-
faces of the O-ring.
moved → Replace.
• Do not scratch or deform the ISC valve or
air passage; otherwise, poor starting per-
a formance, an unstable engine idling speed,
or uncontrollable engine speed could re-
sult.
• Do not clean any areas other than the areas
“a”, “b”, and “c”. If the cleaning agent en-
ters the ISC unit or throttle body, thorough-
ly wipe it off.
7. Adjust the ISC unit plunger to the specified
distance “a” from the motor assembly body.

Distance “a”
0.0–3.0 mm (0.0–0.12 in)

b a

8. Install:
• Spring
• O-ring “1” New
• ISC (Idle Speed Control) unit “2”
c

a. Use a rag soaked in the recommended

cleaning agent to wipe off any deposits
and foreign materials.

7-14
 THROTTLE BODY

ECA21800

NOTICE 1
• Do not use the ISC unit if it was dropped. 2
• Do not allow water to enter the ISC unit and
do not allow foreign materials to adhere to
the assembly.
a
• Do not touch the terminals of the coupler
directly. b
• Because the force of the spring may push
out the ISC unit unexpectedly, be sure to
hold the motor assembly when installing 10.Install the throttle body to the vehicle.
the components. 11.Reset:
• ISC learning valves
TIP
Use the diagnostic code number “67”.
• Install the new O-ring until it contacts the raised Refer to “SELF-DIAGNOSTIC FUNCTION
portion of the ISC unit body. AND DIAGNOSTIC CODE TABLE” on page
• When installing the ISC unit, be sure to align 9-37.
the oval portion “a” of the ISC unit with the oval • ISC valve position
hole “b” in the throttle body. Use the diagnostic code number “54”.
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-37.
2 1 New
Yamaha diagnostic tool USB
90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

12.Place the vehicle on the centerstand so that

the rear wheel is elevated.
13.Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed. Within specifi-
cation → Service is finished.
b Out of specification → Replace the throttle
body.
a Refer to “REPLACING THE THROTTLE
BODY” on page 7-15.

9. Install: Engine idling speed

• ISC (Idle Speed Control) unit holder “1” 1500–1700 r/min
• Screw
EAS31160

ISC (Idle Speed Control) unit REPLACING THE THROTTLE BODY

holder screw 1. Remove the throttle body from the vehicle.
T.
R.

5 N·m (0.5 kgf·m, 3.7 lb·ft) 2. Install a new throttle body to the vehicle.
3. Reset:
TIP • ISC learning valves
Align the slot “a” in the ISC unit holder with the Use the diagnostic code number “67”.
projection “b” on the ISC unit “2”. Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-37.

7-15
 THROTTLE BODY

• ISC valve position

Use the diagnostic code number “54”
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-37.

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

4. Place the vehicle on the centerstand so that

the rear wheel is elevated.
5. Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed.

Engine idling speed

1500–1700 r/min

EAS30980

INSTALLING THE THROTTLE BODY

1. Install:
• Throttle body

Throttle body bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.

TIP
• Align the projection “a” on the O-ring with the
slot “b” in the throttle body.

b a

7-16
 THROTTLE BODY

7-17
 ELECTRICAL SYSTEM

IGNITION SYSTEM ........................................................................................8-1

CIRCUIT DIAGRAM .................................................................................8-1
TROUBLESHOOTING .............................................................................8-3

ELECTRIC STARTING SYSTEM ...................................................................8-5

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

STOP AND START SYSTEM ....................................................................... 8-11

CIRCUIT DIAGRAM ...............................................................................8-11
STOP AND START SYSTEM OPERATION .......................................... 8-13
TROUBLESHOOTING ........................................................................... 8-14

CHARGING SYSTEM ................................................................................... 8-17

CIRCUIT DIAGRAM ...............................................................................8-17
TROUBLESHOOTING ........................................................................... 8-19

LIGHTING SYSTEM ..................................................................................... 8-21

CIRCUIT DIAGRAM ...............................................................................8-21
TROUBLESHOOTING ........................................................................... 8-23

SIGNALING SYSTEM .................................................................................. 8-25

CIRCUIT DIAGRAM ...............................................................................8-25
TROUBLESHOOTING ........................................................................... 8-27

FUEL PUMP SYSTEM .................................................................................. 8-31

CIRCUIT DIAGRAM ...............................................................................8-31
TROUBLESHOOTING ........................................................................... 8-33

ELECTRICAL COMPONENTS ..................................................................... 8-35

CHECKING THE SWITCHES ................................................................ 8-36
CHECKING THE FUSES ....................................................................... 8-37
REPLACING THE SGCU (starter generator control unit) ....................... 8-37
CHECKING AND CHARGING THE BATTERY ...................................... 8-37
CHECKING THE RELAYS ..................................................................... 8-38
CHECKING THE SPARK PLUG CAP .................................................... 8-39
CHECKING THE IGNITION COIL .......................................................... 8-39
CHECKING THE IGNITION SPARK GAP ..............................................8-40
CHECKING THE STARTER GENERATOR ........................................... 8-40
8
CHECKING THE FUEL SENDER .......................................................... 8-41
CHECKING THE THROTTLE BODY SENSOR ASSEMBLY ................. 8-41
CHECKING THE COOLANT TEMPERATURE SENSOR ...................... 8-42
CHECKING THE FUEL INJECTOR ....................................................... 8-43
CHECKING THE VVA SOLENOID .........................................................8-43
CHECKING THE SMART KEY BATTERY ............................................. 8-44
CHECKING THE BUZZER ..................................................................... 8-44
CHECKING THE MAIN SWITCH SOLENOID ........................................ 8-44
 EAS30490
R R EAS20072

CIRCUIT DIAGRAM
R
R
Br Br
9 10 Br
Br Br
IGNITION SYSTEM

Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O

13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R
L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON
OPEN
Br Br
OFF (B)
LOCK

Br Br

O O
47
Br
R/W 48

R/W

54
W/R W/R G W/R W/R B/L
W/L W/L Br/B W/L W/L Br/B
W/B W/B
46 W/Y W/Y L/Y L/Y W/B W/B W/Y
Br/B Br/B
B/L B/L G (B)
(B)

8-1
B B L/Y L/Y L/Y L/Y

R L/Y B
B B 39
(L) (L)

B/R
B
B/W

B B/W
B/R B

61 61

B B B
B B

B B

61
89
IGNITION SYSTEM
 IGNITION SYSTEM

1. Battery
9. Main fuse
10.Ignition fuse
13.Main switch
39.Sidestand switch
46.SGCU (starter generator control unit)
47.Ignition coil
48.Spark plug
54.Crankshaft position sensor
61.Engine ground
89.Frame ground

8-2
 IGNITION SYSTEM

EAS30492

TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Footrest board assemblies
6. Front cowling assembly

1. Check the fuse. NG →

(Main and ignition)
Replace the fuse.
Refer to “CHECKING THE FUS-
ES” on page 8-37.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in
• Recharge or replace the battery.
SERVICE MANUAL BASIC INFOR-
MATION.

OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-5.

OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 8-40.

NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE IGNI- Replace the spark plug cap.
TION SPARK GAP” on page 8-40.

OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-39.

OK ↓
7. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-36.

OK ↓

8-3
 IGNITION SYSTEM

8. Check the sidestand switch. NG →

Refer to “CHECKING THE Replace the sidestand switch.
SWITCHES” on page 8-36.

OK ↓
9. Check the entire ignition system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-1.

OK ↓
Replace the starter generator assem-
bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-37.

8-4
 EAS30493
Br/R Br R
EAS20073
R R
4

CIRCUIT DIAGRAM
R

R
7
R
Br
9 10 Br
Br Br Br

Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O

13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R
L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON
OPEN
Br Br
OFF (B)
LOCK
R W G
Br

Br/R R
B Br
R/W

Br/R R 34
Br/R Br/R
Br/R Br,R/W B

(B) R/W
ELECTRIC STARTING SYSTEM

Br
36
L/W Br Br B/Y B/Y L/W
Br
30 B B/Y
31 37 L/B
L/W Br B/Y
43
L/B L/B
46
B
L/W Y/R
R 38
L/B R/B Br/R Br Y/R Y/R
L/B
R Br/R

8-5
Br R/B R/B
L/W

B B L/Y L/Y L/Y L/Y

R L/Y B B
R
B B 39
(L) (L)

1
G G R/Y
R R R/L 58
B B W W R/W

R/Y R/W R/L

B
B/W
R W G

B B/W
B

61 61

B B
B B B
B B

B B

61
89
ELECTRIC STARTING SYSTEM
 ELECTRIC STARTING SYSTEM

1. Battery
4. Signaling system fuse
7. Fuel injection system fuse
9. Main fuse
10.Ignition fuse
13.Main switch
30.Handlebar switch (right)
31.Start switch
34.Main relay
36.Front brake light switch
37.Rear brake light switch
38.Starter charge relay
39.Sidestand switch
46.SGCU (starter generator control unit)
58.Starter generator
61.Engine ground
89.Frame ground

8-6
 ELECTRIC STARTING SYSTEM

EAS30494

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to “ON” and the start switch “ ” is pushed, the starter generator can only
operate if at least one of the following conditions is met:
• The front brake lever is pulled to the handlebar (the front brake light switch is closed) and the side-
stand is up (the sidestand switch is closed).
• The rear brake lever is pulled to the handlebar (the rear brake light switch is closed) and the sidestand
is up (the sidestand switch is closed).

7
14

1 13 15
2
5
6

3 8

4 9 10 11 12

1. Battery 15. Crankshaft position sensor

2. Main fuse
3. Main switch
4. Ignition fuse
5. Fuel injection system fuse
6. Main relay
7. Starter charge relay
8. Signaling system fuse
9. Rear brake light switch
10. Front brake light switch
11. Start switch
12. Sidestand switch
13. SGCU (starter generator control unit)
14. Starter generator

8-7
 ELECTRIC STARTING SYSTEM

EAS30495

TROUBLESHOOTING
The starter generator fails to turn.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Center cover
3. Side cover
4. Storage box

1. Check the fuses. NG →

(Main, ignition, fuel injection sys-
tem, and signaling system) Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-37.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in
• Recharge or replace the battery.
SERVICE MANUAL BASIC INFOR-
MATION.

OK ↓
3. Check the starter generator. NG →
Refer to “CHECKING THE START- Replace the starter generator assembly.
ER GENERATOR” on page 8-40.

OK ↓
4. Check the main relay. NG →
Refer to “CHECKING THE RE- Replace the main relay.
LAYS” on page 8-38.

OK ↓
5. Check the starter charge relay. NG →
Refer to “CHECKING THE RE- Replace the starter charge relay.
LAYS” on page 8-38.

OK ↓
6. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-36.

OK ↓
7. Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
SWITCHES” on page 8-36.

OK ↓

8-8
 ELECTRIC STARTING SYSTEM

8. Check the start switch. NG →

The start switch is faulty. Replace the right
Refer to “CHECKING THE
handlebar switch.
SWITCHES” on page 8-36.

OK ↓
9. Check the brake light switches. NG →
(Front and rear)
Replace the brake light switch(es).
Refer to “CHECKING THE
SWITCHES” on page 8-36.

OK ↓
10.Check the entire starting system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-5.

OK ↓
Replace the starter generator assem-
bly or SGCU. Refer to “REPLACING
THE SGCU (starter generator control
unit)” on page 8-37.

8-9
 ELECTRIC STARTING SYSTEM

8-10
 EAS33384
EAS20715
R
R R

CIRCUIT DIAGRAM
R

R
7 R
R
Br
9 10 Br Br Br
Br Br Br

12 Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O

Br
13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R
L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON
OPEN R
Br Br
OFF (B)
LOCK R
Y/R W/B B
R W G
Br

Br/R R
B Br
R/W

R 34
Br/R Br/R
Br/R Br,R/W B
R
(B) R/W
50
STOP AND START SYSTEM

P/W P/W
Br/W Br/W
B/L B/L
Y Y
L L 53
Y/W W/G
W/G 42 B/L Y L P/W Br/W

Y/W (B)
30 54
W/R W/R G W/R W/R B/L
Y/W 32 W/L W/L Br/B W/L W/L Br/B
W/B W/B
ON 46 W/Y W/Y L/Y L/Y W/B W/B W/Y
OFF Br/B Br/B
B/W B/L B/L G (B)
(B) B/W Y/R L/R L/R (B)
R 38 L/R
B R/B Br/R Br Y/R Y/R
Y/W G/R G/R G/R B/L
R Br/R B/L B/L 55
Br R/B R/B (B)
B
(B) B B L/Y L/Y L/Y L/Y

8-11
R L/Y B B
R
B B 39
(L) (L)

1
G G R/Y
R R R/L 58
B B B W W R/W

R/Y R/W R/L

B
B/W W
R W G

W
Br
Br Br B

Y Y W
59
B 60
W B
B/W

B B/W
B Br Y

B
B 61 61 R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B

(B)
B B B L/R
B B B R Br
B B B

62
B B B/W
Ch W/R Dg W/L B Br R
Y/B L/R B/W G Y/W
63 70
61 61
89
B
STOP AND START SYSTEM
 STOP AND START SYSTEM

1. Battery
7. Fuel injection system fuse
9. Main fuse
10.Ignition fuse
12.ABS control unit fuse
13.Main switch
30.Handlebar switch (right)
32.Stop and Start System switch
34.Main relay
38.Starter charge relay
39.Sidestand switch
42.Joint 4
46.SGCU (starter generator control unit)
50.Throttle body sensor assembly
53.Throttle position sensor
54.Crankshaft position sensor
55.Coolant temperature sensor
58.Starter generator
59.Front wheel sensor
60.ABS ECU
61.Engine ground
62.Meter assembly
63.Multi-function meter
70.Stop and Start System indicator light
89.Frame ground

8-12
 STOP AND START SYSTEM

EAS33385

STOP AND START SYSTEM OPERATION

If the main switch is turned to “ON” and the Stop and Start System switch is set to “ON” (both switches
are closed), the following functions operate when the conditions for each function are met.
Engine stop function:
When all of the following conditions are met, this function cuts off the fuel after 5 seconds (or 0 seconds
depending on the circumstances) to stop the engine.
• Vehicle speed: stopped
• Engine speed: idling
• Throttle valve: fully closed
• Coolant temperature: 70°C or more
• Operating condition: vehicle has traveled at a speed of more than 10 km/h after the engine was started
TIP
The engine stop function may not operate when the vehicle is traveling at a speed of 10 km/h or less,
such as when traveling in heavy traffic. This, however, does not indicate a malfunction.
Engine start function:
When all of the following conditions are met, this function restarts the engine.
• Sidestand: UP
• Throttle valve: opened

11
7
12
10
1 2 14
6
13

15
3 16
17 18
8
4 5 9

1. Battery 14. Throttle position sensor

2. Main fuse 15. Front wheel sensor
3. Main switch 16. ABS ECU
4. ABS control unit fuse 17. Sidestand switch
5. Ignition fuse 18. Stop and Start System switch
6. Fuel injection system fuse
7. Starter charge relay
8. Multi-function meter
9. Stop and Start System indicator light
10. SGCU (starter generator control unit)
11. Starter generator
12. Crankshaft position sensor
13. Coolant temperature sensor

8-13
 STOP AND START SYSTEM

EAS33386

TROUBLESHOOTING
• The engine stop function does not operate.
• The engine start function does not operate.
• The Stop and Start System indicator light fails to come on.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Center cover
3. Side cover
4. Storage box

1. Check the fuses. NG →

(Main, ignition, fuel injection sys-
tem, and ABS control unit)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-37.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in
• Recharge or replace the battery.
SERVICE MANUAL BASIC INFOR-
MATION.

OK ↓
3. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-36.

OK ↓
4. Check the Stop and Start System NG →
switch. The Stop and Start System switch is faulty.
Refer to “CHECKING THE Replace the right handlebar switch.
SWITCHES” on page 8-36.

OK ↓
5. Check the entire starting system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-11.

OK ↓
Check the condition of each of the
Stop and Start System circuits. Refer
to “Checking the Stop and Start Sys-
tem”.

8-14
 STOP AND START SYSTEM

Checking the Stop and Start System

The engine stop function does not operate.
1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-42.

OK ↓
NG → The throttle position sensor is faulty. Re-
2. Check the throttle position sensor.
place the throttle body assembly.

OK ↓
3. Check the front wheel sensor. NG → Replace the front wheel sensor.

OK ↓
4. Check the entire wiring. NG → Properly connect or replace the wiring har-
Refer to TIP. ness.

OK ↓
Replace the SGCU. Refer to “RE-
PLACING THE SGCU (starter genera-
tor control unit)” on page 8-37.

TIP
Replace the wire harness if there is an open or short circuit.

The engine start function does not operate.

1. Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
SWITCHES” on page 8-36.

OK ↓
2. Check the starter generator. NG →
Refer to “CHECKING THE START- Replace the starter generator assembly.
ER GENERATOR” on page 8-40.

OK ↓
3. Check the start charge relay. NG →
Refer to “CHECKING THE RE- Replace the start charge relay.
LAYS” on page 8-38.

OK ↓
NG → The throttle position sensor is faulty. Re-
4. Check the throttle position sensor.
place the throttle body assembly.

OK ↓

8-15
 STOP AND START SYSTEM

5. Check the entire Stop and Start NG →

System wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-11.

OK ↓
Replace the starter generator assem-
bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-37.

The Stop and Start System indicator light fails to come on.
1. Check the entire wiring. NG → Properly connect or replace the wiring har-
Refer to TIP. ness.

OK ↓
Replace the SGCU or meter assembly.
Refer to “REPLACING THE SGCU
(starter generator control unit)” on
page 8-37.

TIP
Replace the wire harness if there is an open or short circuit.
• Between SGCU coupler and meter assembly coupler.
(Blue/Red–Blue/Red)

8-16
 EAS30496
R R
R
EAS20074

Br
9 10
R

Br
Br

Br
CIRCUIT DIAGRAM
Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O
13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R
L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
CHARGING SYSTEM

R R/Y R/Y R ON
OPEN
Br Br
OFF (B)
LOCK
Y/R W/B B
R W G
Br

Br/R R
B Br
R/W

R 34
Br/R Br/R
Br/R Br,R/W B

(B) R/W

46
Y/R
R 38
R/B Br/R Br Y/R Y/R

Br/R

8-17
R B

1
G G R/Y
R R R/L 58
B B W W R/W

R/Y R/W R/L

B
B/W
R W G

B B/W
B

61 61

B B
B B B
B

B B

61
89
CHARGING SYSTEM
 CHARGING SYSTEM

1. Battery
9. Main fuse
10.Ignition fuse
13.Main switch
34.Main relay
38.Starter charge relay
46.SGCU (starter generator control unit)
58.Starter generator
61.Engine ground
89.Frame ground

8-18
 CHARGING SYSTEM

EAS30497

TROUBLESHOOTING
The battery is not being charged.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Center cover
3. Side cover
4. Storage box
5. Front side cover

1. Check the fuses. NG →

(Main and ignition)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-37.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in
• Recharge or replace the battery.
SERVICE MANUAL BASIC INFOR-
MATION.

OK ↓
3. Check the starter generator. NG →
Refer to “CHECKING THE START- Replace the starter generator assembly.
ER GENERATOR” on page 8-40.

OK ↓
4. Check the main relay. NG →
Refer to “CHECKING THE RE- Replace the main relay.
LAYS” on page 8-38.

OK ↓
5. Check the starter charge relay. NG →
Refer to “CHECKING THE RE- Replace the starter charge relay.
LAYS” on page 8-38.

OK ↓
6. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-36.

OK ↓

8-19
 CHARGING SYSTEM

7. Check the entire charging system NG →

wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-17.

OK ↓
Replace the starter generator assem-
bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-37.

8-20
 EAS30498
EAS20075
R R

CIRCUIT DIAGRAM
R
R
Br
9 10 Br
Br Br Br
Br
Br
Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O
11 13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R
LIGHTING SYSTEM

L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON
OPEN
Br Br
OFF (B)
LOCK
Y/R W/B B
Br

Br
R/W

R/W

Br Br
L/B

L/B
Y 23
Y

P L/B L/B P
26
Y/W Y/W
46
Dg Ch Ch Dg L/R L/R
(B) (B) L/R
20

R B

8-21
W/B

1
Br
B B Br
Br
G

Br 74 Br B
B/W
L L
83 Y G Br 75 73
L
L Y Y Br
B
85 G Y Y G B B

86 87 W B B W/B (W) (B) B

85 Br
L Br Br Y/B
B B B B
86
84 W W/B B B/W
L Y/B B

B B B 61 61
B B
B 88
B B B
L/R
B B B B B B
Br
B B

62
B B
Ch W/R Dg W/L B Br R
Y/B L/R B/W G Y/W
63 72
61
89 Y/B

B
LIGHTING SYSTEM
 LIGHTING SYSTEM

1. Battery
9. Main fuse
10.Ignition fuse
11.Headlight fuse
13.Main switch
20.Joint 2
23.Handlebar switch (left)
26.Dimmer switch
46.SGCU (starter generator control unit)
61.Engine ground
62.Meter assembly
63.Multi-function meter
72.High beam indicator light
73.License plate light
74.Tail/brake light assembly
75.Taillight
83.Headlight assembly
84.Headlight control unit
85.High beam
86.Low beam
87.Auxiliary light
88.Joint 7
89.Frame ground

8-22
 LIGHTING SYSTEM

EAS30499

TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary lights or meter
light.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Footrest board assembly
4. Front cowling assembly
5. Leg shield
6. Upper handlebar cover assembly

1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” in “BASIC
INFORMATION” (separate volume).

OK ↓
2. Check the fuses. NG →
(Main, ignition, and headlight)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-37.

OK ↓
3. Check the battery. NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in
• Recharge or replace the battery.
SERVICE MANUAL BASIC INFOR-
MATION.

OK ↓
4. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-36.

OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
Refer to “CHECKING THE
left handlebar switch.
SWITCHES” on page 8-36.

OK ↓

8-23
 LIGHTING SYSTEM

6. Check the entire lighting system NG →

wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-21.

OK ↓
Replace the SGCU, meter assembly,
tail/brake light assembly or headlight
unit. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-37.

8-24
 EAS30500
EAS20076
Br/R Br R
Br R R
4

CIRCUIT DIAGRAM
8
R R
R
Br
9 10 Br
Br Br Br

12 Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O

Br
13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R
L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON
R
SIGNALING SYSTEM

OPEN
Br Br
OFF (B)
LOCK R

Br

Br/R R
B Br
R/W

Br/R R 34
Br/R
Br/R Br,R/W B

(B) R/W

Br Br/W
Br Br/B
Br Br
28 Br/W 29 (R)
Br
Br/B Br/W Br
P 21 22
Br
P Br 36
P Br/B Br/B
P Br Br B/Y B/Y
Br B/Y
23 L/W
30 B/Y
25 27 33 Dg Dg 37 40
P L/B L/B P Y Br/B Br/B Br B/Y B/Y
Y/W Y/W
46
PUSH B Ch Ch Y
Dg Ch Ch Dg L/R L/R
L/W (R) (R)
(B) (B) L/R
ChDg
B Ch Dg G/R G/R G/R B/L
Y B/L B/L 55
B (B)
Br/B
Br/B

8-25
R B
Ch
Ch Ch
Ch
Ch Dg
1 Dg Dg
Dg
Dg
Ch
Ch Dg 45
B B B Dg B/W G
B/W
B B 82 81 G (Gy)
Ch Ch
78
Y 74 B
Dg Dg 77 B/W W
Ch
(B) (B) L
Dg
B 76 W
Ch Dg Br

L Y Y Br Br Br B
B B Y Y W
59
80 79 (W) (B) B 60
B B B W B
B B/W

B B/W
B Br Y

B B B B 61 61 R Lg/L Lg/W Y/L B/W

R/L Y Br W/L Y Br W B

BB (B)
B B B L/R
B B B B B R Br G Ch Dg
B B

62
B B B/W
Ch W/R Dg W/L B Br R
Y/B L/R B/W G Y/W
63 68 69
61 61
89
B B/W
SIGNALING SYSTEM
 SIGNALING SYSTEM

1. Battery
4. Signaling system fuse
8. Backup fuse
9. Main fuse
10.Ignition fuse
12.ABS control unit fuse
13.Main switch
21.Diode 1
22.Horn
23.Handlebar switch (left)
25.Horn switch
27.Turn signal switch
28.Diode 2
29.Turn signal relay
30.Handlebar switch (right)
33.Hazard switch
34.Main relay
36.Front brake light switch
37.Rear brake light switch
40.Joint 3
45.Fuel sender
46.SGCU (starter generator control unit)
55.Coolant temperature sensor
59.Front wheel sensor
60.ABS ECU
61.Engine ground
62.Meter assembly
63.Multi-function meter
68.Turn signal indicator light (left)
69.Turn signal indicator light (right)
74.Tail/brake light assembly
76.Brake light
77.Jont 5
78.Joint 6
79.Rear turn signal light (right)
80.Rear turn signal light (left)
81.Front turn signal light (right)
82.Front turn signal light (left)
89.Frame ground

8-26
 SIGNALING SYSTEM

EAS30501

TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light, warning lights or indicator lights.
• The horn fails to sound.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The instantaneous fuel consumption meter fails to operation.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Center lower cover
6. Upper handlebar cover assembly

1. Check the fuses. NG →

(Main, ignition, signaling system
ABS control unit) Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-37.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in
• Recharge or replace the battery.
SERVICE MANUAL BASIC INFOR-
MATION.

OK ↓
3. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-36.

OK ↓
4. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.

Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
The horn switch is faulty. Replace the left
Refer to “CHECKING THE
handlebar switch.
SWITCHES” on page 8-36.

OK ↓

8-27
 SIGNALING SYSTEM

2. Check the entire signaling system NG →

wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK ↓
Replace the horn.

The brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
SWITCHES” on page 8-36.

OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
SWITCHES” on page 8-36.

OK ↓
3. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK ↓
Replace the tail/brake light assembly.

The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulbs NG →
and sockets.
Replace the turn signal light bulb, socket or
Refer to “CHECKING THE BULBS
both.
AND BULB SOCKETS” in “BASIC
INFORMATION” (separate volume).

OK ↓
2. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
Refer to “CHECKING THE
the left handlebar switch.
SWITCHES” on page 8-36.

OK ↓
3. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK ↓
Replace the meter assembly.

8-28
 SIGNALING SYSTEM

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 8-42.

OK ↓
2. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK ↓
Replace the meter assembly or
SGCU. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-37.

The fuel meter, fuel level warning light, or both fails to come on.
1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
SENDER” on page 8-41.

OK ↓
2. Check the entire signaling system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-25.

OK ↓
Replace the meter assembly.

The speedometer, V-belt replacement indicator, engine oil change indicator, instantaneous fuel con-
sumption meter fails to operate.
1. Check the front wheel sensor. NG →
Refer to “MAINTENANCE OF THE
Replace the front wheel sensor.
FRONT WHEEL SENSOR AND
SENSOR ROTOR” on page 4-30.

OK ↓
2. Check the entire wiring. NG → Properly connect or replace the wiring har-
Refer to TIP. ness.

OK ↓
Replace the SGCU, or meter assem-
bly. Refer to “REPLACING THE SGCU
(starter generator control unit)” on
page 8-37.

8-29
 SIGNALING SYSTEM

TIP
Replace the wire harness if there is an open or short circuit.
• Between front speed sensor coupler and SGCU coupler.
(Brown–Brown)
(Yellow–Yellow)
• Between SGCU coupler and meter assembly coupler.
(Blue/Red–Blue/Red)

8-30
 EAS30513
EAS20081

R R

R CIRCUIT DIAGRAM
R
7
R
Br
9 10 Br
Br Br
FUEL PUMP SYSTEM

Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O

13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R
L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON
OPEN
Br Br
OFF (B)
LOCK

Br

Br
R/W

R/W

46

8-31
R

R B/Y

1 B/Y R 44
(B)
B

B
B/W

B B/W
B

61 61
FUEL PUMP SYSTEM
 FUEL PUMP SYSTEM

1. Battery
7. Fuel injection system fuse
9. Main fuse
10.Ignition fuse
13.Main switch
44.Fuel pump
46.SGCU (starter generator control unit)
61.Engine ground

8-32
 FUEL PUMP SYSTEM

EAS30514

TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Footrest board assemblies
4. Fuel tank

1. Check the fuses. NG →

(Main, ignition and fuel injection)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-37.

OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-37.

OK ↓
3. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-36.

OK ↓
4. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-5.

OK ↓
5. Check the entire fuel pump system NG →
wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-31.

OK ↓
Replace the SGCU. Refer to “RE-
PLACING THE SGCU (starter genera-
tor control unit)” on page 8-37.

8-33
 FUEL PUMP SYSTEM

8-34
 ELECTRICAL COMPONENTS

EAS20089

ELECTRICAL COMPONENTS

6 7
8 9
5 10
11
3
12
2 4

1
13

33
32
14

28,29,30,31
15

27 16

26 18
17
25 24

23 19
22
21 20

1. CCU (Communication Control Unit) 18.Fuel pump

2. Smart key unit 19.Fuel sender
3. Main relay 20.Sidestand switch
4. Starter charge relay 21.VVA (variable valve actuator) solenoid
5. Fuse box 22.O2 sensor
6. Battery 23.Spark plug
7. Main switch 24.Coolant temperature sensor
8. Front brake light switch 25.Starter generator
9. Rear brake light switch 26.Crankshaft position sensor
10.Auxiliary DC jack 27.Ignition coil
11.Turn signal relay 28.Throttle body sensor assembly
12.ABS ECU 29.Intake air pressure sensor
13.Buzzer 30.Intake air temperature sensor
14.Diode 31.Throttle position sensor
15.Horn 32.ISC (idle speed control) unit
16.Front wheel sensor 33.Fuel injector
17.SGCU (Starter Generator Control Unit)

8-35
 ELECTRICAL COMPONENTS

EAS30549

CHECKING THE SWITCHES

12 1
R R R/Y Br/R
B Y/W ON
L/B P
FREE OPEN
PUSH Y/W OFF
R/Y LOCK
Ch Dg
11 Br/R
Y L/B
Y
2
B
B L
10 L/W
P B
3
L/W B L/W

9 PUSH
FREE
Ch B/W Dg B

4
Y/W B/W
Y/W
ON
OFF
8
B/W

5
Dg Dg Br/W Ch

Br/W
Ch

6
7
B
B
B

1. Main switch
2. Request switch
3. Start switch
4. Start and Stop System switch
5. Hazard switch
6. Front brake light switch
7. Sidestand switch
8. Rear brake light switch
9. Turn signal light switch
10.Horn switch
11.Dimmer switch
12.Menu switch

8-36
 ELECTRICAL COMPONENTS

EAS30551 EWA13310

CHECKING THE FUSES WARNING

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

NOTICE ing a fuse with the wrong amperage rating

may cause extensive damage to the electri-
To avoid a short circuit, always turn the main
cal system, cause the lighting and ignition
switch to “OFF” when checking or replacing
systems to malfunction and could possibly
a fuse.
cause a fire.
1. Remove:
4. Install:
• Battery cover
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
Refer to “GENERAL CHASSIS (1)” on page
4-1.
4-1.
2. Check:
• Fuse EAS33388

a. Connect the digital circuit tester to the fuse REPLACING THE SGCU (starter generator
and check the continuity. control unit)
1. Turn the main switch to “OFF”.
Digital circuit tester (CD732) 2. Replace the SGCU (starter generator control
90890-03243 unit).
3. Clean the throttle body.
b. If the digital circuit tester indicates “∞”, re- Refer to “CLEANING THE ISC (IDLE SPEED
place the fuse. CONTROL) UNIT AND THROTTLE BODY”
3. Replace: on page 7-13.
• Blown fuse 4. Check:
a. Turn the main switch to “OFF”. • Engine idling speed
b. Install a new fuse of the correct amperage Start the engine, warm it up, and then mea-
rating. sure the engine idling speed.
c. Set on the switches to verify if the electri-
cal circuit is operational. Engine idling speed
d. If the fuse immediately blows again, check 1500–1700 r/min
the electrical circuit.
EAS30552
Amperage CHECKING AND CHARGING THE BATTERY
Fuses Q’ty
rating
TIP
Main fuse 30 A 1 Refer to “CHECKING AND CHARGING THE
Headlight fuse 7.5 A 1 BATTERY” in “BASIC INFORMATION” (sepa-
Backup fuse 7.5 A 1 rate volume).
Ignition fuse 7.5 A 1 1. Remove:
Fuel injection system fuse 7.5 A 1 • Battery cover
Signaling fuse 7.5 A 1 Refer to “GENERAL CHASSIS (1)” on page
4-1.
Terminal fuse 5A 1
2. Disconnect:
ABS motor fuse 10.0 A 1 • Battery leads
ABS solenoid fuse 7.5 A 1 (from the battery terminals)
ECA13640
ABS control unit fuse 5.0 A 1
NOTICE
Smart key system fuse 5.0 A 1
First, disconnect the negative battery lead
Spare 30 A 1 “1”, and then positive battery lead “2”.
Spare 7.5 A 1
Spare 5A 1

8-37
 ELECTRICAL COMPONENTS

EAS30553

CHECKING THE RELAYS

Check each switch for continuity with the digital
2 1 circuit tester. If the continuity reading is incor-
rect, replace the relay.

Digital circuit tester (CD732)

90890-03243

1. Disconnect the relay from the wire harness.

2. Connect the digital circuit tester and battery
3. Remove: (12 V) to the relay terminals as shown.
• Battery Check the relay operation.
4. Check: Out of specification → Replace.
• Battery charge
a. Connect a digital circuit tester to the bat- 3
tery terminals. 4 +
• Positive tester probe →
positive battery terminal
2 1
• Negative tester probe →
negative battery terminal
B Br
Br/R
5. Install:
R
• Battery
6. Connect:
• Battery leads 1. Positive battery terminal
(to the battery terminals) 2. Negative battery terminal
ECA13630 3. Positive tester probe
NOTICE 4. Negative tester probe
First, connect the positive battery lead “1”,
and then the negative battery lead “2”. Result
Continuity
(between “3” and “4”)

1 2 Starter charge relay

First step:

1
3
2
7. Check:
• Battery terminals Br Br/R R/B

Dirt → Clean with a wire brush. R

Loose connection → Connect properly. Y/R

8. Lubricate:
• Battery terminals 1. Positive tester probe
2. Negative tester probe
Recommended lubricant 3. Negative tester probe
Dielectric grease

9. Install:
• Battery cover
Refer to “GENERAL CHASSIS (1)” on page
4-1.

8-38
 ELECTRICAL COMPONENTS

Result
Continuity
(between “1” and “2”)
No continuity
(between “1” and “3”)

Second step:
3
5 +
4 c. Measure the spark plug cap resistance.
1 2 EAS30558

CHECKING THE IGNITION COIL

Br Br/R R/B
1. Check:
R
• Primary coil resistance
Y/R
Out of specification → Replace.

1. Positive battery terminal Primary coil resistance

2. Negative battery terminal 2.16–2.64 Ω
3. Positive tester probe
4. Negative tester probe a. Disconnect the ignition coil connectors
5. Negative tester probe from the ignition coil terminals.
b. Connect the digital circuit tester to the igni-
tion coil as shown.
Result
No continuity Digital circuit tester (CD732)
(between “3” and “4”) 90890-03243
Continuity
(between “3” and “5”)
• Positive tester probe →
Brown “1”
• Negative tester probe →
EAS30557

CHECKING THE SPARK PLUG CAP

Orange “2”
1. Check:
• Spark plug cap resistance
Out of specification → Replace.

Resistance
3.75–6.25 kΩ

a. Remove the spark plug cap from the spark

plug lead.
b. Connect the digital circuit tester to the
spark plug cap as shown.

Digital circuit tester (CD732) c. Measure the primary coil resistance.

90890-03243 2. Check:
• Secondary coil resistance
Out of specification → Replace.

Secondary coil resistance

8.64–12.96 kΩ

a. Connect the digital circuit tester to the igni-

tion coil as shown.

8-39
 ELECTRICAL COMPONENTS

c. Turn the main switch to “ON”.

Digital circuit tester (CD732) d. Measure the ignition spark gap “a”.
90890-03243 e. Crank the engine by pushing the “ ” of
the start switch and gradually increase the
• Positive tester probe → spark gap until a misfire occurs.
Orange “1”
• Negative tester probe → EAS33389

High tension cord “2” CHECKING THE STARTER GENERATOR

1. Disconnect:
• Starter generator coupler
(from the wire harness)
2. Check:
• Starter generator resistance
Out of specification → Replace the starter
generator assembly.

Starter generator resistance

0.048–0.072 Ω

b. Measure the secondary coil resistance. a. Connect the digital circuit tester to the
starter generator coupler as shown.
EAS30556

CHECKING THE IGNITION SPARK GAP Digital circuit tester (CD732)

1. Check: 90890-03243
• Ignition spark gap
Out of specification → Perform the ignition • Positive tester probe →
system troubleshooting, starting with step 5. Red/Yellow “1”
Refer to “TROUBLESHOOTING” on page • Negative tester probe →
8-3. Red/Blue “2”

Minimum ignition spark gap • Positive tester probe →

6.0 mm (0.24 in) Red/Yellow “1”
• Negative tester probe →
Red/White “3”
TIP
If the ignition spark gap is within specification, • Positive tester probe →
the ignition system circuit is operating normally. Red/Blue “2”
• Negative tester probe →
a. Disconnect the spark plug cap from the Red/White “3”
spark plug.
b. Connect the ignition checker “1” as
shown.
1
Ignition checker R/Y
90890-06754
2 R/L

R/W

b. Measure the starter generator resistance.

2. Ignition coil

8-40
 ELECTRICAL COMPONENTS

EAS30573 EAS30596

CHECKING THE FUEL SENDER CHECKING THE THROTTLE BODY SENSOR

1. Remove: ASSEMBLY
• Fuel pump EWA20700

(from the fuel tank) WARNING

2. Check: • Do not remove the throttle body sensor as-
• Fuel sender resistance sembly.
Out of specification → Replace the fuel pump • Handle the throttle body sensor assembly
assembly. with special care.
• Never subject the throttle body sensor as-
Fuel sender sembly to strong shocks. If the throttle
Sender unit resistance (full) body sensor assembly is dropped, replace
10.0–14.0 Ω it.
Sender unit resistance (empty)
267.0–273.0 Ω
Throttle position sensor
a. Connect the digital circuit tester to the fuel 1. Check:
sender terminals as shown. • Throttle position sensor
a. Connect the digital circuit tester to the ter-
Digital circuit tester (CD732) minals of the throttle body sensor assem-
90890-03243 bly coupler as shown.

• Positive tester probe → Digital circuit tester (CD732)

Green “1” 90890-03243
• Negative tester probe →
Black “2” • Positive tester probe →
blue terminal “1”
• Negative tester probe →
black/blue terminal “2”
2
b. Measure the throttle position sensor input
voltage.
B/Y B
Out of specification → Replace the wire
R G
harness.

1 Throttle position sensor input

voltage
5V
b. Move the fuel sender float to minimum “3”
and maximum “4” level position. c. Connect the digital circuit tester to the ter-
minals of the throttle body sensor assem-
4 bly coupler as shown.
• Positive tester probe →
yellow/white terminal “3”
• Negative tester probe →
3 black/blue terminal “2”

d. While slowly opening the throttle, check

that the throttle position sensor output volt-
age is increased.
c. Measure the fuel sender resistance. Voltage does not change or it changes
abruptly → Replace the throttle body.
Out of specification (closed position) →
Replace the throttle body.

8-41
 ELECTRICAL COMPONENTS

Intake air temperature sensor

Throttle position sensor output 1. Check:
voltage (closed position) • Intake air temperature sensor resistance
0.63–0.73 V Out of specification → Replace the throttle
body.

Intake air temperature sensor re-

sistance
5700–6300 Ω at 0 °C (5700–6300
Ω at 32 °F)

Br/W P/W L Y B/L a. Connect the digital circuit tester (Ω × 1k) to

the throttle body sensor assembly coupler
as shown.
1 3 2
Digital circuit tester (CD732)
Intake air pressure sensor 90890-03243
1. Check:
• Intake air pressure sensor output voltage • Positive tester probe →
Out of specification → Replace the throttle brown/white “1”
• Negative tester probe →
body. black/blue “2”
Intake air pressure sensor output
voltage
4.70–5.20 V

a. Connect the digital circuit tester (DC 20 V)

to the throttle body sensor assembly cou-
pler as shown. Br/W P/W L Y B/L
Digital circuit tester (CD732)
90890-03243
1 2
• Positive tester probe → b. Measure the intake air temperature sen-
pink/white “1” sor resistance.
• Negative tester probe →
black/blue “2” EAS30578

CHECKING THE COOLANT TEMPERATURE

SENSOR
1. Remove:
• Coolant temperature sensor
Refer to “CYLINDER HEAD” on page 5-9.
EWA14130

WARNING
Br/W P/W L Y B/L • Handle the coolant temperature sensor
with special care.
• Never subject the coolant temperature sen-
1 2 sor to strong shocks. If the coolant temper-
ature sensor is dropped, replace it.
b. Set the main switch to “ON”.
c. Measure the intake air pressure sensor 2. Check:
output voltage. • Coolant temperature sensor resistance
Out of specification → Replace.

8-42
 ELECTRICAL COMPONENTS

a. Disconnect the fuel injector coupler from

Coolant temperature sensor re- fuel injector.
sistance b. Connect the digital circuit tester to the fuel
2513–2777 Ω at 20 °C (2513– injector terminals as shown.
2777 Ω at 68 °F)
Coolant temperature sensor re- Digital circuit tester (CD732)
sistance 90890-03243
210–221 Ω at 100 °C (210–221 Ω
at 212 °F)
• Positive tester probe
Injector terminal “1”
a. Connect the digital circuit tester to the • Negative tester probe
coolant temperature sensor terminals as Injector terminal “2”
shown.

Digital circuit tester (CD732) 2 1

90890-03243

b. Immerse the coolant temperature sensor

“1” in a container filled with coolant “2”.
TIP
Make sure that the coolant temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the coolant.
c. Measure the fuel injector resistance.
EAS31612

3 CHECKING THE VVA SOLENOID

1 1. Check:
• VVA solenoid resistance
Out of specification → Replace.

Resistance
2 1.8–2.2 Ω at 20 °C (1.8–2.2 Ω at
68 °F)
d. Heat the coolant or let it cool down to the a. Disconnect the VVA solenoid coupler from
specified temperatures. the VVA solenoid.
e. Measure the coolant temperature sensor b. Connect the digital circuit tester to the
resistance. VVA solenoid terminal as shown.
3. Install:
• Coolant temperature sensor Digital circuit tester (CD732)
90890-03243
Coolant temperature sensor
15 N·m (1.5 kgf·m, 11 lb·ft) • Positive tester probe
T.
R.

Solenoid terminal “1”

EAS30681 • Negative tester probe
CHECKING THE FUEL INJECTOR Solenoid terminal “2”
1. Check:
• Fuel injector resistance
Out of specification → Replace the fuel injec-
tor.

Resistance
12.2 Ω at 20 °C (12.2 Ω at 68 °F)

8-43
 ELECTRICAL COMPONENTS

• Positive battery lead →

Red “1”
1 2 • Negative battery lead →
Black “2”

2 1

B R

c. Measure the VVA solenoid resistance.

EAS31553

CHECKING THE SMART KEY BATTERY

1. Check:
• Smart key battery voltage c. Check that the buzzer sounds.
Out of specification → Replace the smart key
EAS31257
battery. CHECKING THE MAIN SWITCH SOLENOID
Smart key battery voltage 1. Check:
2.7–3.2 V • Main switch solenoid
a. Disconnect the main switch solenoid cou-
a. Remove the smart key battery from the pler from the wire harness.
smart key. b. Connect the digital circuit tester to the
b. Connect the digital circuit tester to the main switch solenoid as shown.
smart key battery as shown.
Digital circuit tester (CD732)
Digital circuit tester (CD732) 90890-03243
90890-03243
• Positive tester probe →
• Positive tester probe → Red/White “1”
Positive battery terminal “1” • Negative tester probe →
• Negative tester probe → Black “2”
Negative battery terminal “2”

1 2
R/W B
1

c. Check the main switch solenoid continuity.

c. Measure the smart key battery voltage. d. If there is no continuity, replace the main
switch assembly.
EAS31555

CHECKING THE BUZZER

1. Check:
• Buzzer operation
Buzzer does not sound → Replace.
a. Disconnect the buzzer coupler from the
wire harness.
b. Connect the battery (12 V) to the buzzer
coupler as shown.

8-44
 ELECTRICAL COMPONENTS

8-45
 SELF DIAGNOSTIC

SELF-DIAGNOSTIC FUNCTION ....................................................................9-1

GLOSSARY ..............................................................................................9-1
OUTLINE ..................................................................................................9-1
CHECKING THE WARNING LIGHT ........................................................9-1
YDT ..........................................................................................................9-3
PARTS CONNECTED TO THE SGCU ....................................................9-4
PARTS CONNECTED TO THE ABS ECU ...............................................9-4

SYSTEM DIAGRAM .......................................................................................9-5

SGCU CIRCUIT DIAGRAM ......................................................................9-5
SGCU COUPLER LAYOUT .....................................................................9-7

FUEL INJECTION SYSTEM ...........................................................................9-9

CIRCUIT DIAGRAM .................................................................................9-9
BASIC PROCESS FOR TROUBLESHOOTING .................................... 9-11
[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION
IS NOT NORMAL .................................................................................. 9-12
[B] THE MIL DOES NOT COME ON, BUT THE ENGINE OPERATION
IS NOT NORMAL .................................................................................. 9-12

ABS (ANTI-LOCK BRAKE SYSTEM) .......................................................... 9-13

CIRCUIT DIAGRAM ...............................................................................9-13
ABS COUPLER LOCATION CHART ..................................................... 9-15
MAINTENANCE OF THE ABS ECU ...................................................... 9-16
ABS TROUBLESHOOTING OUTLINE ................................................... 9-16
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ........................... 9-17
BASIC PROCESS FOR TROUBLESHOOTING .................................... 9-18
[A] CHECKING THE ABS WARNING LIGHT ......................................... 9-19
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON ............ 9-19
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ............................. 9-19
[A-3] THE ABS WARNING LIGHT COMES ON ..................................... 9-19
[B-1] MALFUNCTION ARE CURRENTLY DETECTED ......................... 9-20
[B-2] DIAGNOSIS USING THE FAULT CODES .................................... 9-20
[B-3] DELETING THE FAULT CODES ................................................... 9-21
[C-1] FINAL CHECK ...............................................................................9-22

SMART KEY SYSTEM ................................................................................. 9-23

CIRCUIT DIAGRAM ...............................................................................9-23
TROUBLESHOOTING ........................................................................... 9-25
SMART KEY SYSTEM SELF-DIAGNOSIS ............................................ 9-29
SMART KEY SYSTEM EMERGENCY MODE ....................................... 9-31
REGISTERING A SMART KEY .............................................................. 9-32
DISABLING A SMART KEY ................................................................... 9-34
DISABLING THE POWER-ON ALARM .................................................. 9-35
REPLACEMENT PARTS LIST ............................................................... 9-36 9
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE ......... 9-37
DTC TABLE ............................................................................................ 9-37
COMMUNICATION ERROR WITH THE
YAMAHA DIAGNOSTIC TOOL ............................................................. 9-39
SELF-DIAGNOSTIC FUNCTION TABLE ............................................... 9-39
SELF-DIAGNOSTIC FUNCTION TABLE
(FOR ABS (Anti-lock Brake System)) .................................................... 9-47
DIAGNOSTIC CODE: SENSOR OPERATION TABLE .......................... 9-50
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ..................... 9-51

EVENT CODE TABLE .................................................................................. 9-53

11, 25_ABS .................................................................................................. 9-55

TROUBLESHOOTING ........................................................................... 9-55

13, 26_ABS .................................................................................................. 9-56

TROUBLESHOOTING ........................................................................... 9-56

15_ABS ........................................................................................................ 9-57

TROUBLESHOOTING ........................................................................... 9-57

17, 45_ABS .................................................................................................. 9-59

TROUBLESHOOTING ........................................................................... 9-59

21_ABS ........................................................................................................ 9-60

TROUBLESHOOTING ........................................................................... 9-60

31_ABS ........................................................................................................ 9-61

TROUBLESHOOTING ........................................................................... 9-61

32_ABS ........................................................................................................ 9-63

TROUBLESHOOTING ........................................................................... 9-63

33_ABS ........................................................................................................ 9-64

TROUBLESHOOTING ........................................................................... 9-64

34_ABS ........................................................................................................ 9-66

TROUBLESHOOTING ........................................................................... 9-66

41_ABS ........................................................................................................ 9-67

TROUBLESHOOTING ........................................................................... 9-67

43_ABS ........................................................................................................ 9-68

TROUBLESHOOTING ........................................................................... 9-68

51, 52_ABS .................................................................................................. 9-69

TROUBLESHOOTING ........................................................................... 9-69
53_ABS ........................................................................................................ 9-70
TROUBLESHOOTING ........................................................................... 9-70

54_ABS ........................................................................................................ 9-72

TROUBLESHOOTING ........................................................................... 9-72

55_ABS ........................................................................................................ 9-74

TROUBLESHOOTING ........................................................................... 9-74

56_ABS ........................................................................................................ 9-75

TROUBLESHOOTING ........................................................................... 9-75

63_ABS ........................................................................................................ 9-76

TROUBLESHOOTING ........................................................................... 9-76

Er-1, Er-2, Er-3, Er-4 .................................................................................... 9-78

TROUBLESHOOTING ........................................................................... 9-78

P0030 ............................................................................................................ 9-81

TROUBLESHOOTING ........................................................................... 9-81

P00D1, P2195 ............................................................................................... 9-84

TROUBLESHOOTING ........................................................................... 9-84

P0106 ............................................................................................................ 9-88

TROUBLESHOOTING ........................................................................... 9-88

P0107, P0108 ............................................................................................... 9-90

TROUBLESHOOTING ........................................................................... 9-90

P0112, P0113 ............................................................................................... 9-94

TROUBLESHOOTING ........................................................................... 9-94

P0117, P0118 ............................................................................................... 9-98

TROUBLESHOOTING ........................................................................... 9-98

P0122, P0123 .............................................................................................9-102

TROUBLESHOOTING .........................................................................9-102

P0132 ..........................................................................................................9-106
TROUBLESHOOTING .........................................................................9-106

P0201 ..........................................................................................................9-109
TROUBLESHOOTING .........................................................................9-109

P0335 ..........................................................................................................9-112
TROUBLESHOOTING .........................................................................9-112
P0351 ..........................................................................................................9-116
TROUBLESHOOTING .........................................................................9-116

P0500 ..........................................................................................................9-120
TROUBLESHOOTING .........................................................................9-120

P0507 ..........................................................................................................9-124
TROUBLESHOOTING .........................................................................9-124

P0511 ..........................................................................................................9-131
TROUBLESHOOTING .........................................................................9-131

P0560, P0563 .............................................................................................9-135

TROUBLESHOOTING .........................................................................9-135

P0601 ..........................................................................................................9-136
TROUBLESHOOTING .........................................................................9-136

P062F .........................................................................................................9-137
TROUBLESHOOTING .........................................................................9-137

P1602 ..........................................................................................................9-139
TROUBLESHOOTING .........................................................................9-139

P2645 ..........................................................................................................9-143
TROUBLESHOOTING .........................................................................9-143
 SELF-DIAGNOSTIC FUNCTION

EAS20437

SELF-DIAGNOSTIC FUNCTION
EAS33142

GLOSSARY
Word Description
MIL MIL is an indicator light that comes on when a control unit determines a malfunction.
(Malfunction indica-
tor light)
DTC DTC is a code that is saved within a control unit’s memory when the control unit de-
(Diagnostic trouble termines a malfunction.
code)
Pending DTC Pending DTC is a code that is saved within a control unit’s memory when the control
(Pending diagnostic unit detects an abnormal condition. If the abnormal condition continues, a malfunc-
trouble code) tion may be determined.
Driving cycle Driving cycle is the duration from the ON/start switch is pushed, OBD requirements
are met, and until the OFF/lock switch is pushed.
FFD FFD is the data of all signal sensors saved at the moment a malfunction is deter-
(Freeze frame data) mined.
Current malfunction A DTC for an unrecovered, current malfunction.
Recovered malfunc- A DTC for a previously determined but now recovered malfunction.
tion
Pending abnormality Abnormal condition that is detected but not yet determined to be a malfunction.
Threshold Threshold is a point set to detect if the output from sensors are abnormal or not.
OBD Self-diagnostic system is equipped in a control unit for the emission control system.
(On-board diagnos-
tics)
GST Generic diagnostic tool that complies with OBD standards.
(Generic scan tool)
YDT Diagnostic tool developed especially for Yamaha vehicles.
(Yamaha diagnostic
tool)

EAS32858

OUTLINE
The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat-
ing normally. If this function detects a malfunction in the system, it immediately operates the system
under substitute characteristics and illuminates the warning light to alert the rider that a malfunction has
occurred in the system. Once a malfunction has been detected, a DTC is stored in the memory of the
control unit.
EAS32859

CHECKING THE WARNING LIGHT

The warning light comes on after the ON/start switch has been pushed on. Refer to the following table
for lighting up time.
If the warning light still comes on, refer to a check item of a troubleshooting of each system, check and
repair it. If the warning light does not come on, the warning light (LED) may be defective.

9-1
 SELF-DIAGNOSTIC FUNCTION

TIP
• This engine equips self-diagnostic function. It’s controlled delicately for detecting defective and mal-
function of the exhaust emission control system. Therefore, the vehicle modifying, poor maintenance,
and improper using of the vehicle may also become the cause of the MIL come on. These events may
cause the occurrence of the warning light coming on without malfunction.
• Reprogramming of the SGCU software.
• Using the electrical accessory which may affect the SGCU.
• Using the incorrect specification of spark plug and fuel injector. Using the third party accessories such
as suspension and exhaust system.
• Removing or modifying the O2 sensor, the exhaust system part (catalyst, etc.).

1 2

System Lighting up warning light Lighting time

FUEL INJECTION SYSTEM MIL “1” 2.0 seconds
ABS (Anti-lock Brake System) ABS warning light “2” *1

TIP
*1: The ABS warning light goes off when the vehicle is judged to normal with running.

9-2
 SELF-DIAGNOSTIC FUNCTION

EAS32806

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

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

TIP
• Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P)
(90890-03266) is separately required.

Disconnect the YDT

Removing the battery cover. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Remove the CCU (Communication Control Unit) “1”, and then connect the Yamaha diagnostic tool “2”
to the coupler “3”.

3 2

9-3
 SELF-DIAGNOSTIC FUNCTION

EAS32864

PARTS CONNECTED TO THE SGCU

The following parts are connected to the SGCU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Fuel pump
• Injector • Starter generator
• Ignition coil • ABS ECU (Electronic Control Unit)
• Throttle position sensor • Starter charge relay
• Intake air pressure sensor • ISC (Idle Speed Control)
• Coolant temperature sensor • VVA (Variable Valve Actuation) solenoid
• Intake air temperature sensor • CCU (Communication Control Unit)
• O2 sensor • Meter assembly

EAS32918

PARTS CONNECTED TO THE ABS ECU

The following parts are connected to the hydraulic unit assembly (ABS ECU).
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• ABS solenoid fuse • Front wheel sensor
• ABS motor fuse • Meter assembly
• ABS ECU fuse • SGCU (Starter Generator Control Unit)

9-4
 SYSTEM DIAGRAM

EAS20387

SYSTEM DIAGRAM
EAS32920

SGCU CIRCUIT DIAGRAM

2. Fuel injection
system fuse 11.Backup fuse 24.Ignition
16.Multi-function coil
meter display 40

47
1

33

25.Fuel injector

3. Ignition fuse 5

26.Fuel pump
12.Headlight
low 3

4. Dimmer
switch 13.Headlight
high
1. SGCU
(Starter
Generator
5. Headlight Control Unit)
fuse
17.Front wheel
25
sensor 27.Heater
43
38 28.O2 sensor
6. Main switch
18.ABS ECU

13
14.Main relay 48 15 29.ISC (Idle Speed
7. Main fuse
19.Start switch 29 Control)
31

8. Signaling 15.Brake light

switch 20.Sidestand 30.Throttle body
fuse switch sensor assemblies
9. Terminal 24 31.Throttle position
fuse 42 sensor
21
7 32.Intake air pressure
34
sensor
35 36
21.Starter charge relay 33.Intake air tempera-
17 22 ture sensor
50
10.Battery 49
46 34.Coolant temperature
51 sensor
52 45
54
9 35.VVA (Variable
53
Valve Actuation)
11
solenoid
22.Starter 39
generator 18
4
16
23.Crankshaft 36.Yamaha diagnostic
position 12
tool coupler
sensor 24
26 32
19

9-5
 SYSTEM DIAGRAM

1. SGCU (Starter Generator Control Unit)

2. Fuel injection system fuse
3. Ignition fuse
4. Dimmer switch
5. Headlight fuse
6. Main switch
7. Main fuse
8. Signaling fuse
9. Terminal fuse
10.Battery
11.Backup fuse
12.Headlight low
13.Headlight high
14.Main relay
15.Brake light switch
16.Multi-function meter display
17.Front wheel sensor
18.ABS ECU
19.Starter switch
20.Sidestand switch
21.Starter charge relay
22.Starter generator
23.Crankshaft position sensor
24.Ignition coil
25.Fuel injector
26.Fuel pump
27.Heater
28.O2 sensor
29.ISC (Idle Speed Control)
30.Throttle body sensor assemblies
31.Throttle position sensor
32.Intake air pressure sensor
33.Intake air temperature sensor
34.Coolant temperature sensor
35.VVA (Variable Valve Actuation) solenoid
36.Yamaha diagnostic tool coupler

9-6
 SYSTEM DIAGRAM

EAS33369

SGCU COUPLER LAYOUT

1 3 4 5 7 9 11 12 13 15 16
17 18 19 20 21 23 24 25 26 29 31 32
33 34 35 36 38 39 40 42 43 45 46 47 48 49 50 51 52 5354

Wire har- Wire har-

No. Connected parts No. Connected parts
ness color ness color

1 Ignition coil O 28 — —
2 — — 29 ISC (Idle Speed Control) Gy
3 Fuel pump B/Y 30 — —
4 Crankshaft position sensor W/R 31 ISC (Idle Speed Control) Sb
5 Fuel injector O/B 32 Yamaha diagnostic tool Lg/Y
6 — — 33 Main relay Br
7 Ground B 34 Throttle body sensor as- P/W
semblies
8 — —
35 Ground B
9 VVA (Variable valve actua- G
tion) solenoid 36 Throttle body sensor as- Br/W
semblies
10 — —
37 — —
11 VVA (Variable valve actua- Ch
tion) solenoid 38 O2 sensor Gy/R
12 Crankshaft position sensor W/L 39 Ground B
13 ISC (Idle Speed Control) Ch 40 Meter assembly L/R
14 — — 41 — —
15 ISC (Idle Speed Control) G/Y 42 Sidestand switch L/Y
16 Yamaha diagnostic tool Lg/W 43 ABS ECU W
17 Starter charge relay R/B 44 — —
18 Crankshaft position sensor Br/B 45 Coolant temperature sen- B/L
sor
19 Crankshaft position sensor B/L
46 Coolant temperature sen- G/R
20 Throttle body sensor as- Y
sor
semblies
47 Fuel injection system fuse R
21 Throttle body sensor as- B/L
semblies 48 Starter switch L/B
22 — — 49 Starter charge relay Y/R
23 Throttle body sensor as- L 50 Headlight unit Y/B
semblies 51 Battery B
24 Crankshaft position sensor W/B 52 Starter generator G
25 Heater P/B 53 Starter generator W
26 Crankshaft position sensor W/Y 54 Starter generator R
27 — —

9-7
 SYSTEM DIAGRAM

9-8
 EAS32871
EAS20440
R R

R
R

CIRCUIT DIAGRAM
7 8 R
R R
R Br Br
Br Br
9 10 Br Br
Br Br Br

Br
Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O
11 12 13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br R
R
R L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON
OPEN R
Br Br
OFF (B)
LOCK R
Y/R W/B B
R W G
Br Br

Br O/B O O
47
Br
R/W 41 48
O/B Br

(B) P P
G/Y G/Y
Lg/L B Gy Gy 49
Sb Sb
R Lg/W R
R/W
(R) P G/Y Sb Gy 50
FUEL INJECTION SYSTEM

Lg/W (B)
R
Lg/W 51
Lg/L 35 B P/W P/W 52
Lg/L Br/W Br/W
B/L B/L
Y Y
L L 53
B/L Y L P/W Br/W

(B)
54
W/R W/R G W/R W/R B/L
W/L W/L Br/B W/L W/L Br/B
W/B W/B
46 W/Y W/Y L/Y L/Y W/B W/B W/Y
Br/B Br/B
B/L B/L G (B)
L/R L/R (B)
L/R

G/R G/R G/R B/L

B/L B/L 55
(B)

B B L/Y L/Y L/Y L/Y G G

Ch Ch 56 G Ch
R L/Y B B (Gy)
B B 39

9-9
Gy/R Gy/R Br/R B B P/B
(L) (L)
R B/Y
B/L B/L B/L W L Gy/R
1 B/Y R 44 P/B P/B

(B) B B Br/R P/B

Br
57 W L Gy/R B/L
B B B Br/R
(B) (B)

B/R
Lg/W B
Lg/W B/W W

W
Br
Lg/L
Lg/L Br Br B

Y Y W
59
B 60
W B
B/W

B B/W
B/R B Br Y

61 61 R Lg/L Lg/W Y/L B/W

R/L Y Br W/L Y Br W B

(B)
B L/R
B B B R Br
B B B

62
B B B/W
B Ch W/R Dg W/L B Br R
Y/B L/R B/W G Y/W
63 66
61 61
89
B
FUEL INJECTION SYSTEM
 FUEL INJECTION SYSTEM

1. Battery
7. Fuel injection system fuse
8. Backup fuse
9. Main fuse
10.Ignition fuse
11.Headlight fuse
12.ABS control unit fuse
13.Main switch
35.Yamaha diagnostic tool coupler
39.Sidestand switch
41.Fuel injector
44.Fuel pump
46.SGCU (starter generator control unit)
47.Ignition coil
48.Spark plug
49.ISC (Idle Speed Control) unit
50.Throttle body sensor assembly
51.Intake air pressure sensor
52.Intake air temperature sensor
53.Throttle position sensor
54.Crankshaft position sensor
55.Coolant temperature sensor
56.VVA (variable valve actuator) solenoid
57.O2 sensor
59.Front wheel sensor
60.ABS ECU
61.Engine ground
62.Meter assembly
63.Multi-function meter
66.Engine trouble warning light
89.Frame ground

9-10
 FUEL INJECTION SYSTEM

EAS32917

BASIC PROCESS FOR TROUBLESHOOTING

This section describes the basic process about fuel injection system troubleshooting.
But because a work procedure varies depending to symptom and DTC, check and repair it according
to applicable troubleshooting.

When pushing the ON/start switch, No Does the MIL (LED) work No
does the MIL come on? properly? Check the MIL (LED).

No Yes

Yes [B] Perform the checking with the

The MIL goes off after 2 seconds?
diagnostic mode.

No

Still on/flash.
[A] Check the DTC.

Do the troubleshooting according

to the DTCs of "malfunction".

Check the DTCs of "malfunction"

are not displayed on the screen.

Finished.

9-11
 FUEL INJECTION SYSTEM

EAS33147

[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS NOT NORMAL
1. Check the DTC of “malfunction” using the YDT.
2. Delete the DTC using the YDT. (Only for *1)
3. Check and repair the malfunction according to applicable DTC troubleshooting.
4. Turn the main switch to “OFF” and then turn the main switch to “ON” and then check the DTC of
“malfunction” is not displayed.
TIP
• If another DTC is displayed, repeat steps (1) to (4) until no DTC is displayed.
• Turn the main switch to “OFF” will not erase the malfunction history.

EAS33148

[B] THE MIL DOES NOT COME ON, BUT THE ENGINE OPERATION IS NOT NORMAL
1. Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode.
Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-50 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-51.
D01: Throttle position sensor signal
D30: Ignition coil
D36: Injector

If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.

9-12
 EAS30843
EAS20085
R R

2 3
R/L
Br/R Br R
R R
4

CIRCUIT DIAGRAM
8 R
R R
R
Br
9 10 Br
Br Br Br

12 Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O

Br
13 Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R R
R L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON
OPEN R
Br Br
OFF (B)
LOCK R

Br

Br/R R
B Br
R/W

Br/R R 34
Br/R
Br/R Br,R/W B Lg/L B
R Lg/W
(B) R/W
(R)

Lg/W
R
Lg/W
Lg/L 35 B
Lg/L

Br
36
Br Br B/Y B/Y
Br B/Y
B/Y
37 40
Br B/Y B/Y Y 46
Y
Y/L L/R L/R
L/R
ABS (ANTI-LOCK BRAKE SYSTEM)

R R B

9-13
1

B B B

Lg/W B
Y 74 B/W W
Lg/W
L Lg/W

76 R W
Br
Lg/L R/L
L Y Y Br Lg/L Y Br Br B
Lg/W
B B Lg/L Lg/L 59
Y Y W
(W) (B) B 60
Y/L W B
B B B
B/W
W/L
B B/W
B Br Y

61 61 R Lg/L Lg/W Y/L B/W

R/L Y Br W/L Y Br W B

(B)
B B B
L/R
B B B B B R Br
B B

62
B B B/W
B Ch W/R Dg W/L B Br R
Y/B L/R B/W G Y/W
63 65
61 61
89
B W/ L
ABS (ANTI-LOCK BRAKE SYSTEM)
 ABS (ANTI-LOCK BRAKE SYSTEM)

1. Battery
2. ABS solenoid fuse
3. ABS motor fuse
4. Signaling system fuse
8. Backup fuse
9. Main fuse
10.Ignition fuse
12.ABS control unit fuse
13.Main switch
34.Main relay
35.Yamaha diagnostic tool coupler
36.Front brake light switch
37.Rear brake light switch
40.Joint 3
46.SGCU (starter generator control unit)
59.Front wheel sensor
60.ABS ECU
61.Engine ground
62.Meter assembly
63.Multi-function meter
65.ABS warning light
74.Tail/brake light assembly
76.Brake light
89.Frame ground

9-14
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30844

ABS COUPLER LOCATION CHART

R Lg/L Lg/W Y/L B/W

R/L Y Br W/L Y Br W B

Br Y W B

2
Lg/L B
R Lg/W

3 (R)

Ch W/R Dg W/L B Br R
Y/B L/R B/W G Y/W

1. ABS ECU coupler

2. ABS test coupler
3. Meter assembly coupler
4. Front wheel sensor coupler

9-15
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30845

MAINTENANCE OF THE ABS ECU

Checking the ABS ECU

1. Check:
• Terminals “1” of the ABS ECU
Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off → Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.

1
2

EAS30528

ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU (electronic control unit) has a self-diagnosis function. When failures occur in the system,
the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the
Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2]
DIAGNOSIS USING THE FAULT CODES” on page 9-20. 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 9-22.

ABS operation when the ABS warning light comes on

1. The ABS warning light remains on → ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 10 km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h)). → ABS operation is normal.
3. The ABS warning light flashes → ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-17.

9-16
 ABS (ANTI-LOCK BRAKE SYSTEM)

Self-diagnosis and servicing

The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page 9-21.
By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause correctly
if another malfunction occurs.
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned to “ON”. During this test, a “clicking” noise can be heard from front side, and if
the front brake lever or rear brake lever are even slightly applied, a vibration can be felt at the levers,
but these do not indicate a malfunction.
Self-diagnosis using the ABS ECU
The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”. It also
checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are detect-
ed, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the
ABS ECU has entered the self-diagnosis mode.

Special precautions for handling and servicing a vehicle equipped with ABS
ECA18490

NOTICE
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction
occurs.)
EAS30529

BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420

WARNING
• Perform the troubleshooting [A]→[B]→[C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.

9-17
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS30530

BASIC PROCESS FOR TROUBLESHOOTING

[A] Turn the main switch to “ ON ”, Fails to • The ABS warning light (LED)
come on [A-1] Does only the ABS
and check the ABS warning is defective.
warning light fail to Return to [A].
light. • The wire harness is grounded
come on?
between the ABS ECU and the
Comes on
meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.
No
• The main switch is defective.
[A-2] Do all indicator lights Yes • The battery voltage is low.
fail to come on? Return to [A].
• The taillight fuse is blown.
• The meter assembly circuit is
defective.

[A-3] The ABS warning light comes Cannot communicate • The connection with the Yamaha
on. diagnostic tool is defective. Return to [A].
Connect the Yamaha • The ABS control unit fuse is
diagnostic tool, and then blown.
execute functional diagnosis. • The ABS ECU coupler is
Can the tool communicate disconnected.
with the ABS ECU? • The wire harness is defective.
• The hydraulic unit assembly is
Can communicate defective.
• The ABS solenoid fuse is blown.
• Refer to “ Troubleshooting details
of fault code No. 31 ”.

[B-1] Check for ABS fault codes in Yes [B-2] Diagnose by the fault [B-3] Delete the fault codes.
Return to [A].
the screen for the Yamaha code.
diagnostic tool.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
The reaction force generated
No
during brake line routing
confirmation is incorrect.
• The brake hoses and brake
[C-1] Perform the final checks. No pipes are not connected
Were all of the final checks correctly. Return to [A].
completed normally? The ABS warning light does
not go off when the light is
Yes
(Check that the ABS warning checked.
light goes off during the ABS • The malfunction is not
warning light check.) corrected.
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The meter assembly circuit is
defective.
• The ABS warning light circuit in
the hydraulic unit assembly is
defective.

Finished.

9-18
 ABS (ANTI-LOCK BRAKE SYSTEM)

EWA16710

WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 9-22.

EAS30531

[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS30532

[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the White/Blue terminal of the ABS ECU coupler and
White/Blue terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS30964

[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-36.
• 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 8-37.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Taillight fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-37.
• If the taillight fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 8-31.
• 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.)

9-19
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS31165

[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed
on the computer screen.
• A fault code is displayed. [B-2]
• A fault code is not displayed. [C-1]
EAS31166

[B-2] DIAGNOSIS USING THE FAULT CODES

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

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

Connecting the Yamaha diagnostic tool

Removing the battery cover. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Removing the CCU (Communication Control Unit) “1”, and then connect the Yamaha diagnostic tool
“2” to the coupler “3”.

3 2

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.

9-20
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS31167

[B-3] DELETING THE FAULT CODES

To delete the fault codes, use the YDT. For information about deleting the fault codes, refer to the op-
eration manual of the YDT.
Check that all the displayed fault codes are deleted.

Yamaha diagnostic tool USB

90890-03267
Yamaha diagnostic tool (A/I)
90890-03264

Connecting the Yamaha diagnostic tool

Removing the battery cover. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Removing the CCU (Communication Control Unit) “1”, and then connect the Yamaha diagnostic tool
“2” to the coupler “3”.

3 2

9-21
 ABS (ANTI-LOCK BRAKE SYSTEM)

EAS31168

[C-1] FINAL CHECK

Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.

Checking procedures
1. Check the brake fluid level in the front brake master cylinder reservoir and rear brake master cylinder
reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-11.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)” on page 4-31.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-56.
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 9-21.
5. Checking the ABS warning light.
Check that the ABS warning light goes off.
If the ABS warning light does not come on or if it does not go off, refer to “CHECKING THE ABS
WARNING LIGHT” on page 4-58.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between White/Blue terminal of the ABS ECU coupler and White/Blue terminal
of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.

9-22
 EAS31452
EAS20201
R R
5
R/Y G/W

CIRCUIT DIAGRAM
7 8 R
R R
R Br
Br Br
9 10 Br Br
Br Br Br

Lg/L G/Y P W/L Ch G B/L B/W O/B W/R B/Y O

13 R/B 18
L L R/B R Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R
G/W R R L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON Br
OPEN B B R
Br Br R/B R/B B R R
OFF (B)
LOCK R
G/W L/R R/B L/Y B/W Ch B
R/W R/W R/B
R/Y R L W/R Br R/W Dg 19
Br B B 17 R R
SMART KEY SYSTEM

14 (B) (B) L/R

B 15 L L W/R Br
B R/W R/W L/Y
Dg R/W
B/W Ch

R
R/W

46
L/R
L/R L/R
L/R

L/Y
B B L/Y L/Y L/Y L/Y

R L/Y B
B B 39
Ch Ch (L) (L)

9-23
Ch
1 Dg Dg
Dg
Ch
Ch Dg Ch
B Dg
Dg
B B 82 81
Ch Ch
78
B
Dg Dg 77 B/W
Ch
(B) (B)
Dg
B
Ch Dg

80 79
B
B

B B/W
B

B
B B B B 61 61

B B BB
L/R
B B B B B R Br Ch Dg
B B B

62
B B
B B/W Ch W/R Dg W/L B Br R
Y/B L/R B/W G Y/W
63 68 69 71
61 61
89
B W/R
SMART KEY SYSTEM
 SMART KEY SYSTEM

1. Battery
5. Smart key system fuse
7. Fuel injection system fuse
8. Backup fuse
9. Main fuse
10.Ignition fuse
13.Main switch
14.Request switch
15.Main switch solenoid
17.Smart unit
18.Joint 1
19.Buzzer
46.SGCU (starter generator control unit)
61.Engine ground
62.Meter assembly
63.Multi-function meter
68.Turn signal indicator light (left)
69.Turn signal indicator light (right)
71.Smart key system indicator light
77.Joint 5
78.Joint 6
79.Rear turn signal light (right)
80.Rear turn signal light (left)
81.Front turn signal light (right)
82.Front turn signal light (left)
89.Frame ground

9-24
 SMART KEY SYSTEM

EAS31453

TROUBLESHOOTING
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
Engine does not start even though vehicle power is turned on.
Seat does not open. (Vehicle power is turned on.)
Left front storage box does not open. (Vehicle power is turned on.)
Fuel tank cap lid does not open.
Answer back function does not operate.
TIP
Before troubleshooting, remove the following part(s):
1. Battery cover
2. Side covers
3. Front side cover

Checking The Vehicle Power

1. Check the smart key. NG →
→ The smart key indicator light
comes on when the smart key but-
Replace the button cell battery of the
ton is pushed.
smart key. Standard battery: CR2032
→ Check the button cell battery.
Refer to “CHECKING THE SMART
KEY BATTERY” on page 8-44.
OK ↓
2. Check the fuses. NG →
(Main, backup, ignition, and smart
key system) Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-37.

OK ↓
3. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-37.

OK ↓
4. Check the main switch and request NG →
switch.
Replace the main switch.
Refer to “CHECKING THE
SWITCHES” on page 8-36.

OK ↓
5. Check the main switch solenoid. NG →
Refer to “CHECKING THE MAIN
Replace the main switch.
SWITCH SOLENOID” on page
8-44.

OK ↓

9-25
 SMART KEY SYSTEM

6. Check the entire smart key sys- NG →

tem’s wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-31.

OK ↓
Replace the smart key unit.

Checking the smart key system

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

1. Check the vehicle power. NG →

Refer to “Checking The Vehicle Repair or replace any defective parts.
Power” on page 9-25.

OK ↓
• There are sources of strong electro-
magnetic waves in the vicinity →
Move the vehicle.
• Smart key malfunction → Register
and use a different smart key.
• Smart key unit malfunction → Re-
place the smart key unit.

Engine does not start even though vehicle power is turned on.

1. When the vehicle power is turned NO →

on, the smart key indicator light “ ” Check and repair the electric starting sys-
flashes 4 times. tem. Refer to “ELECTRIC STARTING
Refer to “SMART KEY SYSTEM SYSTEM” on page 8-5.
SELF-DIAGNOSIS” on page 9-29.

YES ↓
2. Turn the main switch to “OFF”, and NG →
Repair or replace any defective parts. Re-
then push the main switch and
fer to “Checking The Vehicle Power” on
check that it can be turned back to
page 9-25.
“ON”.

OK ↓

9-26
 SMART KEY SYSTEM

3. Check for continuity in the commu- NG →

nication line between the SGCU
Replace the wire harness.
and the smart key unit (blue/red –
blue/red).

OK ↓
• Replace the SGCU.
Refer to “REPLACING THE SGCU
(starter generator control unit)” on
page 8-37.
• Replace the smart key unit.

Seat does not open. (Vehicle power is turned on.)

1. Check the vehicle power. NG →
Refer to “Checking The Vehicle Repair or replace any defective parts.
Power” on page 9-25.

OK ↓
• Check the mechanical components
of the lock for malfunctions. Repair or
replace any defective parts.
• Adjust or replace the seat lock cable.

Left front storage box does not open. (Vehicle power is turned on.)
1. Check the vehicle power. NG →
Refer to “Checking The Vehicle Repair or replace any defective parts.
Power” on page 9-25.

OK ↓
• Check the mechanical components
of the lock for malfunctions. Repair or
replace any defective parts.
• Adjust or replace the left front stor-
age box lock cable.

Fuel tank cap lid does not open.

1. Check that the main switch can be NG →
Repair or replace any defective parts.
turned counterclockwise.

OK ↓
• Check the mechanical components
of the lock for malfunctions. Repair or
replace any defective parts.
• Adjust or replace the fuel tank cap lid
lock cable.

9-27
 SMART KEY SYSTEM

Answer back function does not operate.

1. Check the vehicle power. NG →
Refer to “Checking The Vehicle Repair or replace any defective parts.
Power” on page 9-25.

OK ↓
2. Check the buzzer operation. NG →
Refer to “CHECKING THE BUZZ- Replace the buzzer.
ER” on page 8-44.

OK ↓
3. Check the turn signal light bulbs NG →
and sockets.
Replace the turn signal light bulb, socket or
Refer to “CHECKING THE BULBS
both.
AND BULB SOCKETS” in “BASIC
INFORMATION” (separate volume).

OK ↓
Replace the smart key unit.

9-28
 SMART KEY SYSTEM

EAS31534

SMART KEY SYSTEM SELF-DIAGNOSIS

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

Flashing time/number Malfunction and check

Item Flash pattern
of flashes point

0.5 (s)
a Replace the button cell
battery of the smart key.
Low voltage of smart b
0.5 (s)
20 (seconds) Refer to “SMART KEY
key button cell battery
SYSTEM” on page
a.LED on 9-23.
b.LED off
The smart key cannot
0.15 (s) be recognized.
a Check that there are no
sources of strong elec-
Vehicle power off verifi- b
0.15 (s)
30 (seconds) tromagnetic waves in
cation error
the vicinity, the smart
a.LED on key is not lost, and the
b.LED off battery is not dis-
charged.
The smart key cannot
0.15 (s) be recognized.
a Check that there are no
Flashes continuously sources of strong elec-
Running detection er- b
0.15 (s)
until the error is re- tromagnetic waves in
ror*
solved. the vicinity, the smart
a.LED on key is not lost, and the
b.LED off battery is not dis-
charged.

0.3 (s)
• SGCU communica- a Flashes continuously Check the wire harness.
tion error b until the error is re- Check the SGCU.
• Data error 0.3 (s) 1.0 (s) solved./flashes 4 times Check the smart key
• SGCU malfunction in a repeating cycle. unit.
a.LED on
b.LED off

* The running detection error

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

9-29
 SMART KEY SYSTEM

SMART KEY SYSTEM SELF-DIAGNOSIS

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

Device that de-

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

9-30
 SMART KEY SYSTEM

EAS31535

SMART KEY SYSTEM EMERGENCY MODE

If the smart key is lost or if it cannot be used due a discharged battery or malfunction, this mode can be
used to turn on the smart key system.
TIP
The emergency mode operation will be canceled if the respective steps are not carried out within the
time set for each operation.
1. Stop the vehicle in a safe place and turn the main switch to “OFF”.
2. Push the main switch for 5 seconds until the smart key indicator light flashes once, then release it.
Repeat two more times. The smart key indicator light “1” will come on for 3 seconds to indicate the
transition to emergency mode.

3. After the smart key indicator light “ ” goes off, use the main switch to enter the identification number
“1” located on the identification number card. (Refer to the following procedure on how to input the
identification number.)

868588

4. The input identification number is indicated by the number of flashes of the smart key indicator light
“ ” while the main switch is pushed.
For example, if the smart key identification number is 123456:
Push and hold the main switch. →
The smart key indicator light “ ” will start to flash. →

9-31
 SMART KEY SYSTEM

Release the main switch after the smart key indicator light “ ” flashes 1 time. →
The first digit of the identification number has been set as 1. →
Push and hold the main switch again. →

Release the main switch after the smart key indicator light “ ” flashes 2 times. →
The second digit of the identification number has been set as 2. →
Repeat the above procedure until all 6 digits of the identification number have been set.
5. The smart key indicator light “ ” will come on for 10 seconds if the correct 6-digit identification num-
ber was entered.
TIP
When one of the following situations applies, emergency mode will be terminated and the smart key
indicator light will flash quickly for 3 seconds. In this case, start over again from step 2.
• When there are no main switch operations for 10 seconds during the identification number input pro-
cess.
• When the smart key indicator light is allowed to flash nine or more times.
• The identification number is not entered correctly.
6. While the smart key indicator light is on, push the main switch once more to complete emergency
mode access. The smart key indicator light will go off and then come back on for approximately 4
seconds.
7. While the smart key indicator light is on, turn the main switch to “ON”. The vehicle can now be oper-
ated normally.
EAS31536

REGISTERING A SMART KEY

The following procedure can be used to register additional smart keys or a new smart key in case the
original smart key is lost.
TIP
• A maximum of 6 smart keys can be registered to the smart key unit.
• Be sure to register the smart keys one at a time. Do not register multiple smart keys at the same time.

9-32
 SMART KEY SYSTEM

1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.

2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 9-31.
3. While the smart key indicator light “ ” is on for 10 seconds, push the main switch “1” for 5 seconds
until buzzer sounds once.

4. The smart key indicator light (red) “1” on the new smart key comes on for 10 seconds.
TIP
While the smart key indicator light on the smart key is on, the smart key indicator light “ ” flashes ac-
cording to the number of currently registered smart keys. (For example, if 5 smart keys are registered,
the indicator light flashes 5 times.)

5. While the smart key indicator light is on for 10 seconds, push the button on the smart key to transmit
a signal from the smart key to the smart key unit.
6. If the smart key is registered successfully, the smart key indicator light “ ” will come on for 3 sec-
onds, and then the smart key system will turn off.
If the smart key was not registered successfully, the smart key indicator light “ ” will flash for 3 sec-
onds, and then the smart key system will turn off.
TIP
If this registration procedure is performed for a smart key that is already registered, the smart key indi-
cator light “ ” will flash for 7 seconds (on for 0.2 second and off for 0.8 second).

9-33
 SMART KEY SYSTEM

EAS31537

DISABLING A SMART KEY

If a smart key is lost or stolen, the smart key can be disabled.
1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com-
munication.

2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 9-31.
3. While the smart key indicator light “ ” is on for 10 seconds, perform the following procedure.
a. Push the main switch “1” 5 times or more until buzzer sounds 3 times.

4. Check that the smart key indicator light “ ” goes off (the smart key disable mode is activated).
5. Turn on (unlocked setting) the smart keys that you want to enable and place them within 80 cm (31.5
in) of the smart key unit.
6. Push the main switch for 5 seconds or more to start the communication between the smart key unit
and the smart keys that are located within 80 cm (31.5 in) of the unit.
TIP
The number of smart keys that currently can be used will be indicated.
Number of flashes = Number of verified smart keys. (1 cycle of on for 0.3 second and off for 0.3 second
= 1 smart key)
7. Push the main switch for 5 seconds or more. The use of only the verified smart keys will be enabled.
The use of all other smart keys will be disabled.
TIP
• If the procedure was not completed successfully, repeat the procedure from step 1.
• To enable a smart key after its use has been disabled, perform this procedure again.

9-34
 SMART KEY SYSTEM

EAS32347

DISABLING THE POWER-ON ALARM

1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.

2. Push the main switch and the smart key indicator light will come on for approximately 4 seconds.
3. While the smart key indicator light is on, turn the main switch to “ON”.
4. Extend and retract the sidestand by hand for 10 times or more within 15 seconds from vehicle power
on.
5. When the buzzer sounds, the setting is complete.
• If the buzzer sounds 2 times: The power-on alarm is turned off.
• If the buzzer sounds 1 times: The power-on alarm is turned on.

9-35
 SMART KEY SYSTEM

EAS31719

REPLACEMENT PARTS LIST

TIP
When replacing the parts, refer to the following sections.
• Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 9-31.
• Refer to “REGISTERING A SMART KEY” on page 9-32.
• Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.

Required item Replacement parts (when

when replacing an item is required in order
parts to replace parts)

 : Required.  : Replace.

Smart key
identification
 : number or × : Do not replace.
smart key is
Faulty part Remarks
required.

This part must be re-

× : Not required. * : placed even if it is not
faulty.

Smart
key iden- Smart Smart Smart
SGCU
tification key key key unit
number
Register the smart key identifi-
Smart key  ×  × × cation number in the emergency
mode.
Replace the smart key, smart
Smart key unit × × *  *
key unit, and SGCU as a set.
When the vehicle system is
turned on, the smart key identifi-
SGCU   × × 
cation number is automatically
registered to the SGCU.
Smart key unit/ Replace the smart key, smart
× × *  
SGCU key unit, and SGCU as a set.
Smart key/Smart Replace the smart key, smart
× ×   *
key unit key unit, and SGCU as a set.
Register the smart key identifi-
cation number in the emergency
mode.
Smart key/SGCU  ×  ×  When the vehicle system is
turned on, the smart key identifi-
cation number is automatically
registered to the SGCU.
Smart key/Smart Replace the smart key, smart
× ×   
key unit/SGCU key unit, and SGCU as a set.

9-36
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS20551

SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33149

DTC TABLE
Fail-safe system
Diagnostic
DTC Symptom Starting the Driving the code
engine vehicle
“11, Front wheel sensor (intermittent pulses or no
— — —
25_ABS” pulses)
“13,
Front wheel sensor (abnormal pulse period) — — —
26_ABS”
“15_ABS” Front wheel sensor (open or short circuit) — — —
“17,
Front wheel sensor (missing pulses) — — —
45_ABS”
Hydraulic unit assembly (defective solenoid
“21_ABS” — — —
drive circuit)
“24_ABS” Brake light switch or tail/brake light — — —
Hydraulic unit assembly (abnormal ABS sole-
“31_ABS” — — —
noid power supply)
Hydraulic unit assembly (short circuit in ABS
“32_ABS” — — —
solenoid power supply circuit)
Hydraulic unit assembly (abnormal ABS motor
“33_ABS” — — —
power supply)
Hydraulic unit assembly (short circuit in ABS
“34_ABS” — — —
motor power supply circuit)
Front wheel ABS (intermittent wheel speed
“41_ABS” — — —
pulses or incorrect depressurization)
“43_ABS” Front wheel sensor (missing pulses) — — —
• Vehicle system power supply (voltage of
ABS ECU power supply is high)
“51, (DTC No. 51)
— — —
52_ABS” • Vehicle system power supply (voltage of
wheel sensor power supply is high)
(DTC No. 52)
Vehicle system power supply (voltage of ABS
“53_ABS” — — —
ECU power supply is low)
Hydraulic unit assembly (defective ABS sole-
“54_ABS” — — —
noid and ABS motor power supply circuits)
“55_ABS” Hydraulic unit assembly (defective ABS ECU) — — —
Hydraulic unit assembly (abnormal power sup-
“56_ABS” — — —
ply)
Front wheel sensor power supply (voltage of
“63_ABS” — — —
power supply is low)
O2 sensor heater: defective heater or heater
“P0030” driver ON / OFF command and error signal is Able Able —
mismatching.
• [P00D1] O2 sensor: heater performance de-
“P00D1, teriorated. Normal signal is not received from
the O2 sensor while driving the O2 sensor. Able Able —
P2195”
• [P2195] O2 sensor: open circuit is detected.

9-37
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fail-safe system
Diagnostic
DTC Symptom Starting the Driving the code
engine vehicle
• [P10106] Intake air pressure sensor : clog-
ging of hole or senser installation improperly.
“P0106 ,
• [P10107] Intake air pressure sensor : open
P0107, Able Able D03
or short to ground circuit is detected.
P0108”
• [P10108] Intake air pressure sensor : short
to power circuit is detected.
• [P0112] Intake air temperature sensor: short
“P0112, to ground circuit is detected.
Able Able D05
P0113” • [P0113] Intake air temperature sensor: open
or short to power circuit is detected.
• [P0117] Coolant temperature sensor: short
“P0117, to ground circuit is detected.
Able Able D06
P0118” • [P0118] Coolant temperature sensor: open
or short to power circuit is detected.
• [P0122] Throttle position sensor: open or
“P0122, short to ground circuit is detected.
Able Able D01
P0123” • [P0123] Throttle position sensor: short to
power circuit is detected.
“P0132” O2 sensor: short to power circuit is detected. Able Able —
“P0201” Fuel injector: malfunction in fuel injector. Unable Unable D36
Crankshaft position sensor: normal signal is
“P0335” not received from the crankshaft position sen- Unable Unable —
sor.
Ignition coil: open or short circuit detected in
“P0351” Unable Unable D30
the primary lead of the ignition coil.
Front wheel sensor: normal signal is not re-
“P0500” Able Able D07
ceived from the front wheel sensor.
“P0507” Engine idling speed is too high. Able Able D54
ISC valve malfunction is detected. (Open or
“P0511” short circuit is detected between ISC valve Able Able —
and SGCU.)
• [P0560] Battery charging voltage is abnor-
“P0560, mal. (Discharged condition)
Able Able —
P0563” • [P0563] Battery charging voltage is abnor-
mal. (Overcharged condition)
Internal malfunction in SGCU. (When this mal-
“P0601” function is detected in the SGCU, the DTC Unable Unable —
might not appear on the tool display.)
EEPROM DTC: an error is detected while
“P062F” Able Able D60
reading or writing on EEPROM.
Malfunction in SGCU internal circuit (malfunc-
“P1602” Able Able —
tion of SGCU power cut-off function).
Normal signal is not received from the VVA so-
“P2645” Able Able D45
lenoid circuit while driving the VVA solenoid.

9-38
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33030

COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL

Fail-safe system
Diagnostic
DTC Symptom Starting the Driving the code
engine vehicle
SGCU internal malfunction (Output signal
Er-1 Able Able —
error)
SGCU internal malfunction (Output signal
Er-2 Able Able —
error)
SGCU internal malfunction (Output signal
Er-3 Able Able —
error)
Er-4 SGCU internal malfunction (Input signal error) Able Able —

EAS32423

SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING” on page 8-33.

Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
Er-1 SGCU internal mal- • Open or short cir- Signals cannot be Normally operated ex-
function (Output sig- cuit in wire harness transmitted between cept for the meter.
nal error) between meter and the SGCU and the
SGCU. meter.
• Defective coupler Signals cannot be
between meter and transmitted between
SGCU. the SGCU and the
• Defective meter unit. YDT (Yamaha Diag-
• Malfunction in nostic Tool).
SGCU. Meter operation is im-
possible.
Er-2 SGCU internal mal- • Open or short cir- Signals are not re- Normally operated ex-
function (Output sig- cuit in wire harness ceived from the cept for the meter.
nal error) between meter and SGCU within the
SGCU. specified duration.
• Defective coupler Meter operation is im-
between meter and possible.
SGCU.
• Defective meter unit.
• Malfunction in
SGCU.
Er-3 SGCU internal mal- • Open or short cir- Sending data from the Normally operated ex-
function (Output sig- cuit in wire harness SGCU cannot be re- cept for the meter.
nal error) between meter and ceived correctly.
SGCU. Meter operation is im-
• Defective coupler possible.
between meter and
SGCU.
• Defective meter unit.
• Malfunction in
SGCU.

9-39
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
Er-4 SGCU internal mal- • Open or short cir- Registered data is not Normally operated ex-
function (Input signal cuit in wire harness received from the me- cept for the meter.
error) between meter and ter.
SGCU. Normal signals are
• Defective coupler not received from the
between meter and YDT (Yamaha Diag-
SGCU. nostic Tool).
• Defective meter unit. Meter operation is im-
• Malfunction in possible.
SGCU.
P0030 O2 sensor heater: de- • Open or short cir- When the O2 sensor Display only (If O2
fective heater or heat- cuit in wire harness. does not operate due sensor does not oper-
er driver ON/OFF • Disconnected cou- to the exhaust tem- ate, O2 feedback is
command and error pler. perature is low condi- not carried out.)
signal is mismatching. • Defective O2 sensor tion. Increased
heater driver (Mal- exhaust emissions.
function in SGCU).
• Broken or discon-
nected lead in O2
sensor heater.
P00D1 O2 sensor: heater • Open or short cir- Increased exhaust O2 feedback is not
performance deterio- cuit in wire harness emissions. carried out.
rated. between O2 sensor
Normal signal is not and SGCU.
received from the O2 • Defective coupler
sensor while driving between O2 sensor
the O2 sensor. and SGCU.
• Disconnected cou-
pler.
• Improperly installed
O2 sensor.
• Defective O2 sensor.
P0106 Intake air pressure • Detached throttle Engine idling speed is Intake air pressure
sensor (clogged hole body sensor assem- high. difference is fixed to
or sensor installation bly. Engine idling speed is 0 [kPa].
improperly) • Improperly installed unstable. Load is detected ac-
throttle body. Engine response is cording to the throttle
• Clogged intake air poor. opening.
pressure sensor Loss of engine power. Intake manifold pres-
hole. Increased exhaust sure is calculated us-
emissions. ing the throttle
Stop and start sys- position sensor.
tem is not operated. Transient control ac-
cording to the intake
air pressure is not
carried out.
Intake air pressure is
fixed to 101.3 [kPa].
O2 feedback is not
carried out.
Stop and start sys-
tem is not carried out.

9-40
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure
P0108 pressure sensor of the intake air pres- high. difference is fixed to
(short to ground cir- sure sensor circuit Engine idling speed is 0 [kPa].
cuit is detected) (0.2 V or less) unstable. Load is detected ac-
[P0108] Intake air [P0108] High voltage Engine response is cording to the throttle
pressure sensor of the intake air pres- poor. opening.
(open or short to pow- sure sensor circuit Loss of engine power. Intake manifold pres-
er circuit is detected) (4.9 V or more) Increased exhaust sure is calculated us-
• Defective coupler emissions. ing the throttle posi-
between throttle Stop and start sys- tion sensor.
body sensor assem- tem is not operated. Transient control ac-
bly and SGCU. cording to the intake
• Open or short cir- air pressure is not
cuit in wire harness carried out.
between throttle Intake air pressure is
body sensor assem- fixed to 101.3 [kPa].
bly and SGCU. O2 feedback is not
• Defective intake air carried out.
pressure sensor. Stop and start sys-
• Malfunction in tem is not carried out
SGCU.
P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air temper-
P0113 temperature sensor of the intake air tem- start. ature is fixed to 20
(short to ground cir- perature sensor circuit Increased exhaust [°C].
cuit is detected) (0.2 V or less) emissions. O2 feedback is not
[P0113] Intake air [P0113] High voltage Engine idling speed is carried out.
temperature sensor of the intake air tem- unstable. Stop and start sys-
(open or short to pow- perature sensor circuit Stop and start sys- tem is not carried out.
er circuit is detected) (4.8 V or more) tem is not operated.
• Defective coupler
between throttle
body sensor assem-
bly and SGCU.
• Open or short cir-
cuit in wire harness
between throttle
body sensor assem-
bly and SGCU.
• Improperly installed
throttle body sensor
assembly.
• Defective intake air
temperature sensor.
• Malfunction in
SGCU.

9-41
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to O2 feedback is not
P0118 perature sensor (short of the coolant temper- start. carried out.
to ground circuit is de- ature sensor circuit Increased exhaust The coolant tempera-
tected) (0.2 V or less) emissions. ture is fixed to 30 [°C]
[P0118] Coolant tem- [P0118] High voltage Engine idling speed is (when key is ON) or
perature sensor (open of the coolant temper- unstable. 80 [°C] (when riding).
or short to power cir- ature sensor circuit Stop and start sys- Stop and start sys-
cuit is detected. (4.8 V or more) tem is not operated. tem is not carried out.
• Defective coupler
between coolant
temperature sensor
and SGCU.
• Open or short cir-
cuit in wire harness
between coolant
temperature sensor
and SGCU.
• Improperly installed
coolant temperature
sensor.
• Defective coolant
temperature sensor.
• Malfunction in
SGCU.
P0122 [P0122] Throttle posi- [P0122] Low voltage Engine idling speed is Change in the throttle
P0123 tion sensor (open or of the throttle position high. opening is 0 (transient
short to ground circuit sensor circuit (0.2 V Engine idling speed is control is not carried
is detected) or less) unstable. out).
[P0123] Throttle posi- [P0123] High voltage Engine response is Throttle opening is
tion sensor (short to of the throttle position poor. fixed to 15 [°].
power circuit is de- sensor circuit (4.8 V Loss of engine power. Intake air pressure is
tected. or more) Deceleration is poor. fixed to 101.3 [kPa].
• Defective coupler Increased exhaust Fuel is not cut off due
between throttle emissions. to the throttle open-
body sensor assem- Stop and start sys- ing.
bly and SGCU. tem is not operated. O2 feedback is not
• Open or short cir- carried out.
cuit in wire harness Stop and start sys-
between throttle tem is not carried out.
body sensor assem-
bly and SGCU.
• Improperly installed
throttle body sensor
assembly.
• Defective throttle po-
sition sensor.
• Malfunction in
SGCU.

9-42
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
P0132 O2 sensor (short to [P0132] High voltage Increased exhaust O2 feedback is not
power circuit is de- of the O2 sensor cir- emissions. carried out.
tected) cuit (4.8 V or more)
• Improperly installed
O2 sensor.
• Defective coupler
between O2 sensor
and SGCU.
• Short to power cir-
cuit in wire harness
be-tween O2 sensor
and SGCU.
• Defective O2 sensor.
• Malfunction in
SGCU.
P0201 Fuel injector (normal • Defective coupler Loss of engine power. When engine is run-
signal is not received between fuel injector Engine is difficult to ning:
from the injector cir- and SGCU. start. Engine is forcefully
cuit.) • Open or short cir- Engine cannot be stopped.
cuit in wire harness started. When engine is
between fuel injector Engine stops. stopped:
and SGCU. Engine cannot be
• Defective fuel injec- started.
tor. Injection is not car-
• Malfunction in ried out.
SGCU.
• Improperly installed
fuel injector.
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor (normal sig- between crankshaft started.
nals are not received position sensor and
from the crankshaft SGCU.
position sensor) • Open or short cir-
cuit in wire harness
between crankshaft
position sensor and
SGCU.
• Improperly installed
crankshaft position
sensor.
• Defective starter
generator rotor.
• Defective crank-
shaft position sen-
sor.
• Malfunction in
SGCU.

9-43
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
P0351 Ignition system (nor- • Defective coupler Engine stops. When engine is run-
mal signal is not re- between ignition coil Loss of engine power. ning:
ceived from the and SGCU. Engine is difficult to Engine is forcefully
ignition circuit) • Open or short cir- start. stopped.
cuit in wire harness Engine cannot be When engine is
between ignition coil started. stopped:
and SGCU. Engine cannot be
• Improperly installed started.
ignition coil. Injection is not car-
• Defective ignition ried out.
coil.
• Malfunction in
SGCU.
P0500 Front wheel sensor • Open or short cir- Vehicle speed is not O2 feedback is not
(normal signal is not cuit in wire harness displayed on the me- carried out.
received from the between front wheel ter. Stop and start sys-
front wheel sensor) sensor and ABS Engine stalls when tem is not carried out.
ECU. the vehicle is deceler-
• Open or short cir- ating to a stop.
cuit in wire harness Engine idling speed is
between ABS ECU high.
and SGCU. Engine idling speed is
• Defective front unstable.
wheel sensor. Increased exhaust
• Malfunction in emissions.
SGCU. Stop and start sys-
tem is not operated.
P0507 ISC valve (stuck fully • Defective front Engine idling speed is ISC learning is not
open) wheel sensor (or high. carried out.
speed sensor). Stop and start sys- Stop and start sys-
• Defective coupler tem is not operated. tem is not carried out
between ISC unit
and SGCU.
• Open or short cir-
cuit in wire harness
between ISC unit
and SGCU.
• Improperly installed
ISC unit.
• Air sucking from the
intake air passage.
• Defective throttle
valve or throttle ca-
bles.
• Defective ISC unit
(ISC valve stuck ful-
ly open).
• Malfunction in
SGCU.

9-44
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
P0511 ISC unit (ISC unit • Defective coupler Engine is difficult to Power is not supplied
does not operate) between ISC unit start. to the ISC unit.
and SGCU. Engine idling speed is Stop and start sys-
• Open or short cir- unstable. tem is not carried out.
cuit in wire harness Engine idling speed is
between ISC unit high.
and SGCU. Stop and start sys-
• Defective ISC step- tem is not operated.
ping motor.
• Malfunction in
SGCU.
P0560 Charging voltage is • Battery discharging. Engine is difficult to O2 feedback learning
abnormal (dis- • Battery discharging start. is not carried out.
charged condition) (broken or discon- Increased exhaust Stop and start sys-
nected lead in rectifi- emissions. tem is not carried out.
er/regulator system). Battery performance
has deteriorated or
battery is defective.
Stop and start sys-
tem is not operated.
P0563 Charging voltage is • Battery overcharg- Engine is difficult to O2 feedback learning
abnormal. (Over- ing. start. is not carried out.
charged condition) • Battery overcharg- Increased exhaust Stop and start sys-
ing (broken or dis- emissions. tem is not carried out.
connected lead in Battery performance
rectifier/regulator has deteriorated or
system). battery is defective.
Stop and start sys-
tem is not operated.
P0601 Faulty SGCU memo- • Malfunction in Engine cannot be Engine cannot be
ry. (When this mal- SGCU. started. started.
function is detected in Ignition and injection
the SGCU, the DTC are not carried out.
might not appear on Judgment for other
the tool display.) DTC is not carried
out.
Writing to EEPROM is
not carried out.
P062F EEPROM fault code • Malfunction in Increased exhaust O2 feedback learning
number (an error is SGCU. emissions. value is initialized.
detected while read- • O2 feedback learn- Engine cannot be CO adjustment value
ing or writing on ing value is not started or is difficult to is initialized.
EEPROM) properly written. start. OBD memory value is
• CO adjustment val- Engine idling speed is initialized.
ue is not properly unstable. Stop and start sys-
written. OBD memory value is tem is not carried out.
• OBD memory value not correct.
is not properly writ- Stop and start sys-
ten. tem is not operated.

9-45
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
P1602 Malfunction in SGCU • Improperly connect- Engine idling speed is —
internal circuit (normal ed battery lead. high.
backup voltage is not • Defective coupler Engine idling speed is
supplied to the between main unstable.
SGCU) switch and SGCU. Increased exhaust
• Open circuit in wire emissions.
harness between Engine is difficult to
main switch and start.
SGCU.
• Malfunction in
SGCU.
P2195 O2 sensor (open cir- • Improperly installed Increased exhaust O2 feedback is not
cuit is detected) O2 sensor. emissions. carried out.
• Defective coupler
between O2 sensor
and SGCU.
• Open or short cir-
cuit in wire harness
between O2 sensor
and SGCU.
• Defective O2 sensor.
• Malfunction in
SGCU.
P2645 VVA solenoid mal- • Defective coupler Decreased engine Fixed to the low
function (normal sig- between VVA sole- torque in the high speed cam position.
nal is not received noid and SGCU. speed range. Upper limit for the en-
from the VVA solenoid • Open or short cir- gine speed is de-
circuit while driving cuit in wire harness creased.
the VVA solenoid) between VVA sole-
noid and SGCU.
• Open circuit in VVA
solenoid.

9-46
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS33286

SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))

TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-17.

DTC Item Symptom Check point

11* Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
25* tent pulses or no pulses) not received properly. around the front wheel sen-
(Pulses are not received or sor
are received intermittently • Incorrect installation of the
while 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
13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. around the front wheel sen-
(The pulse period is abnor- sor
mal while the vehicle is trav- • Incorrect installation of the
eling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
15 Front wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the front wheel sen- the front wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
• Defective front wheel sen-
sor or hydraulic unit as-
sembly
17* Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
45* pulses) not received properly. around the front wheel sen-
(Missing pulses are detect- sor
ed in the signal while the ve- • Incorrect installation of the
hicle is traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
21 Hydraulic unit assembly (de- Solenoid drive circuit in the • Defective hydraulic unit as-
fective solenoid drive circuit) hydraulic unit assembly is sembly
open or short-circuited.

9-47
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

24 Brake light switch or tail/ Brake light signal is not re- • Defective signaling system
brake light ceived properly while the ve- (tail/brake light or brake
hicle is traveling. (Brake light light switch)
circuit, or front or rear brake • Defective coupler between
light switch circuit.) the signaling system (tail/
brake light or brake light
switch) and the hydraulic
unit assembly
• Open or short circuit in the
wire harness between the
signaling system (tail/brake
light or brake light switch)
and the hydraulic unit as-
sembly
• Defective hydraulic unit as-
sembly
31 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS solenoid fuse
normal ABS solenoid power solenoid circuit in the hy- • Defective coupler between
supply) draulic unit assembly. the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS solenoid the solenoid power supply sembly
power supply circuit) circuit in the hydraulic unit
assembly.
33 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS motor fuse
normal ABS motor power motor circuit in the hydraulic • Defective coupler between
supply) unit assembly. the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS motor the motor power supply cir- sembly
power supply circuit) cuit in the hydraulic unit as-
sembly.
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.

9-48
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

DTC Item Symptom Check point

43 Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
pulses) not received properly. around the front wheel sen-
(Missing pulses are detect- sor
ed in the signal while the ve- • Incorrect installation of the
hicle is traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
51 • Vehicle system power sup- • Power voltage supplied to • Defective battery
52 ply (voltage of ABS ECU the ABS ECU in the hy- • Disconnected battery ter-
power supply is high) (for draulic unit assembly is too minal
DTC No. 51) high. (for DTC No. 51) • Defective charging system
• Vehicle system power sup- • Power voltage supplied to
ply (voltage of wheel sen- the wheel sensor is too
sor power supply is high) high. (for DTC No. 52)
(for DTC No. 52)
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lic unit assembly is too low. the battery and the hydrau-
lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
54 Hydraulic unit assembly (de- Abnormality is detected in • Defective battery
fective ABS solenoid and the solenoid or motor power • Defective coupler between
ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau-
cuits) unit assembly. lic unit assembly
• Open or short circuit in the
wire harness between the
battery and the hydraulic
unit assembly
• Defective charging system
• Defective hydraulic unit as-
sembly
55 Hydraulic unit assembly (de- Abnormal data is detected in • Defective hydraulic unit as-
fective ABS ECU) the hydraulic unit assembly. sembly
56 Hydraulic unit assembly (ab- Abnormality is detected in • Defective hydraulic unit as-
normal internal power sup- the power supply circuit in sembly
ply) the hydraulic unit assembly.
63 Front wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the front ness between the front
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
• Defective front wheel sen-
sor
• Defective hydraulic unit as-
sembly

* The DTC No. varies according to the vehicle conditions.

9-49
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

EAS32425

DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor sig- 0–125
nal
• Fully closed position 13–21 Check the fully closed throt-
tle valve.
• Fully opened position 97–107 Check the fully opened throt-
tle valve.
03 Intake air pressure Displays the intake air pres- Check the intake air pressure
sure. when cranking the engine. (If
When engine is stopped: At- the displaying value chang-
mospheric pressure at the es, the performance is OK.)
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
3000 m above sea level: Ap-
prox. 70 kPa
05 Intake air temperature Displays the intake air tem- Compare the actually mea-
perature. sured air temperature with
-30–120 [°C] the tool displayed value.
When engine is cold: Dis-
plays temperature closer to
air temperature
When engine is hot: Air tem-
perature + approx. 20 [°C]
06 Coolant temperature Displays the coolant temper- Compare the actually mea-
ature. sured coolant temperature
-30–120 [°C] with the tool displayed value.
When engine is cold: Dis-
plays temperature closer to
air temperature.
When engine is hot: Displays
current coolant temperature.
07 Vehicle speed pulse Front wheel speed pulse Check that the number in-
0–999 creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
09 Fuel system voltage Approximately 12.0 [V] Compare the actually mea-
(battery voltage) sured battery voltage with
the tool displayed value. (If
the actually measured bat-
tery voltage is low, recharge
the battery.)
20 Sidestand switch Check the sidestand switch
• Stand retracted ON condition.

• Stand extended OFF

9-50
 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Tool display Procedure
code No.
60 EEPROM DTC display —
• Defective EEPROM DTC is 00
indicated. • No malfunctions detected
(If the self-diagnosis fault
code P062F is indicated,
the SGCU is defective.)
• Maltiple DTCs are indicated 01 (CO adjustment value) —
2-second interval. 11 (ISC learning values)
Display the EEPROM writ- 12 (O2 feedback learning val-
ing error for fault code No. ue)
P062F. 14 (Wheel diameter learning
If more than one item is de- value)
fective, the displays alter-
nates every two seconds to
show all the detected num-
bers.
67 ISC learning condition dis- 00 To erase the ISC learning da-
play ISC learning data has been ta, click “Actuator Check” on
ISC learning data erasure erased. the Yamaha diagnostic tool
01 screen 3 times in 5 seconds.
It is not necessary to erase
the ISC learning data.
02
It is necessary to erase the
ISC learning data.
70 Programmed unit ver. num- 0–254 [-] —
ber
87 O2 feedback learning data 00 To erase the O2 feedback
erasure O2 feedback learning data learning data, click the
has been erased. Yamaha diagnostic tool
01 “Actuator Check” button
O2 feedback learning data three times in 5 seconds.
has not been erased.
90 Idle stop selection switch Check the idle stop selection
• Set to “ON” ON switch is turned ON / OFF.

• Set to “OFF” OFF

EAS32426

DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil five Check the energization of
times at one-second inter- the ignition coil.
vals. • Check the sparking perfor-
The “CHECK” indicator “ ” mance on the spark plug.
on the Yamaha diagnostic
tool screen comes on each
time the ignition coil is actu-
ated.

9-51
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE

Diagnostic
Item Actuation Procedure
code No.
36 Fuel injector Actuates the fuel injector five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that the injector is ac-
The “CHECK” indicator “ ” tuated five times by listening
on the Yamaha diagnostic for the operating sound.
tool screen comes on each
time the fuel injector is actu-
ated.
45 VVA solenoid Actuates the VVA solenoid Check that the VVA solenoid
five times at five-second in- is operated five times.
tervals.
The “CHECK” indicator “ ”
on the Yamaha diagnostic
tool screen comes on each
time the VVA solenoid is ac-
tuated.
52 Headlight Actuates the headlight five Check that the headlight
times at five-second inter- comes on five times.
vals.
The “CHECK” indicator “ ”
on the Yamaha diagnostic
tool screen comes on each
time the headlight is actuat-
ed.
54 ISC unit Fully closes the ISC valve, Check that the ISC unit oper-
and then opens the valve to ates by listening for the oper-
the standby opening posi- ating sound while the ISC
tion. unit operates for 3 seconds.
This operation takes approxi-
mately 3 seconds each time.
The “CHECK” indicator “ ”
on the Yamaha diagnostic
tool screen on during the op-
eration.

9-52
 EVENT CODE TABLE

EAS20164

EVENT CODE TABLE

Fuel injection system
No. Item Symptom Possible cause Remarks
192 Intake air pressure sen- Brief abnormality de- Same as for DTC Perform the checks and
sor tected in intake air pres- P0107 and P0108 maintenance jobs for
sure sensor DTC P0107 and P0108.
193 Throttle position sensor Brief abnormality de- Same as for DTC Perform the checks and
tected in throttle posi- P0122 and P0123 maintenance jobs for
tion sensor DTC P0122 and P0123.
196 Coolant temperature Brief abnormality de- Same as for DTC Perform the checks and
sensor tected in coolant tem- P0117 and P0118 maintenance jobs for
perature sensor DTC P0117 and P0118.
197 Intake air temperature Brief abnormality de- Same as for DTC Perform the checks and
sensor tected in intake air tem- P0112 and P0113 maintenance jobs for
perature sensor DTC P0112 and P0113.
218 Crankshaft position Brief abnormality de- Same as for DTC Perform the checks and
sensor tected in crankshaft po- P0335 maintenance jobs for
sition sensor DTC P0335.
240 O2 sensor Correction value re- • Open or short circuit • If a DTC is indicated,
(Correction value re- mains at upper limit in the wire harness perform the checks
mains at upper limit) during O2 feedback between the sensor and maintenance jobs
and the SGCU for the DTC first.
gray/red–gray/red * Event code number
• Low fuel pressure 240 may be indicated
• Clogged fuel injector even if the system is
• Sensor malfunction normal.
• Defective SGCU
• Defective fuel injec-
tion system
241 O2 sensor Correction value re- • Open or short circuit • If a DTC is indicated,
(Correction value re- mains at lower limit dur- in the wire harness perform the checks
mains at lower limit) ing O2 feedback between the sensor and maintenance jobs
and the SGCU for the DTC first.
gray/red–gray/red * Event code number
• Low fuel pressure 241 may be indicated
• Clogged fuel injector even if the system is
• Sensor malfunction normal.
• Defective SGCU
• Defective fuel injec-
tion system
242 ISC During idling, the ad- Idling engine speed is • Implement diagnosis
(Stuck at the upper limit justment is maintained slow mode D67, and check
for adjustment) at the upper limit • Clogged throttle body the ISC maintenance
• Poorly adjusted throt- request.
tle cable • If a DTC is indicated,
• Poorly adjusted clutch perform to that first.
cable * Rarely, Code 242 de-
• Malfunction in the fuel tects even when the
injection system system is functioning
• Dirty or worn spark properly.
plug
• Malfunction in the bat-
tery
• Malfunction in SGCU

9-53
 EVENT CODE TABLE

No. Item Symptom Possible cause Remarks

243 ISC During idling, the ad- Idling engine speed is • If a DTC is indicated,
(Stuck at the lower limit justment is maintained fast perform to that first.
for adjustment) at the lower limit • Poorly adjusted throt- * Rarely, Code 243 de-
tle cable tects even when the
• Poorly adjusted clutch system is functioning
cable properly.
• Malfunction in the fuel
injection system
• Dirty or worn spark
plug
• Malfunction in the bat-
tery
• Malfunction in SGCU
244 Difficult/unable to start Engine starting difficult/ • Empty fuel tank • If a DTC is indicated,
engine unable condition detect- • Defective fuel injec- perform the checks
ed tion system and maintenance jobs
• Dirty or worn spark for the DTC first.
plug * Event code number
• Defective battery 244 may be indicated
• Defective SGCU even if the system is
normal.
245 Engine stall Engine stall detected • Empty fuel tank • If a DTC is indicated,
• Improperly adjusted perform the checks
throttle cable and maintenance jobs
• Improperly adjusted for the DTC first.
clutch cable * Event code number
• Defective fuel injec- 245 may be indicated
tion system even if the system is
• Dirty or worn spark normal.
plug
• Defective battery
• Defective SGCU

9-54
 11, 25_ABS

EAS20685

11, 25_ABS
EAS33314

TROUBLESHOOTING
Item
Front wheel sensor (intermittent pulses or no pulses)

Procedure
TIP
With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (DTC No.
11) or for longer than about 2 seconds (DTC No. 25).
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-29.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-55
 13, 26_ABS

EAS20687

13, 26_ABS
EAS33316

TROUBLESHOOTING
Item
Front wheel sensor (abnormal pulse period)

Procedure
TIP
• If the front brake ABS operates continuously for 20 seconds or more, DTC No. 26 will be recorded. If
the front brake ABS operates continuously for 36 seconds or more, DTC No. 13 will be recorded.
• Vehicle possibly ridden on uneven roads.

1. Foreign material adhered around the front wheel sensor

• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE REAR WHEEL” on page 4-35.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-56
 15_ABS

EAS20662

15_ABS
EAS33040

TROUBLESHOOTING
Item
Front wheel sensor (open or short circuit)

Procedure
1. Defective coupler between the front wheel sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 2.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
2. Wire harness continuity
• Disconnect the ABS ECU coupler and front wheel sensor coupler.
• Open circuit check
Between ABS ECU coupler “1” and front wheel sen- brown–brown
sor coupler “2” yellow–yellow

1
2
R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B Br Y

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.
• Short circuit check
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.

Ground short circuit check “A”

brown–ground
Between ABS ECU coupler “1” and ground
yellow–ground

9-57
 15_ABS

Lines short circuit check “B”

brown–any other coupler terminal
ABS ECU coupler “1”
yellow–any other coupler terminal
brown–any other coupler terminal
Front wheel sensor “2”
yellow–any other coupler terminal

A B
1 2 1
R Lg/L Lg/W Y/L B/W
R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B Br Y
R/L Y Br W/L Y Br W B

Is resistance ∞ Ω?
YES
→ Go to step 3.
NO
→ Replace the wire harness.
3. Defective front wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions were found, the wheel sensor or hydraulic
unit assembly is defective.
• Replace the wheel sensor or hydraulic unit assembly.
Refer to “FRONT WHEEL” on page 4-27 and “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-58
 17, 45_ABS

EAS20708

17, 45_ABS
EAS33372

TROUBLESHOOTING
Item
Front wheel sensor (missing pulses)

Procedure
TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC
No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 45
will be recorded first and DTC No. 17 will be recorded if the condition continues.

1. Foreign material adhered around the front wheel sensor

• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-29.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-59
 21_ABS

EAS20690

21_ABS
EAS33320

TROUBLESHOOTING
Item
Hydraulic unit assembly (defective solenoid drive circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-60
 31_ABS

EAS20691

31_ABS
EAS33321

TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS solenoid power supply)

Procedure
1. Blown ABS solenoid fuse
• Check the ABS solenoid fuse.
Refer to “CHECKING THE FUSES” on page 8-37.

Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 3.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS solenoid fuse and ABS ECU coupler.
• Open circuit check
Between ABS solenoid fuse holder “1” and ABS ECU
red–red
coupler “2”

1 2

R Lg/L Lg/W Y/L B/W

R/L Y Br W/L Y Br W B

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.

9-61
 31_ABS

• Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.

Ground short circuit check “A”

Between ABS ECU coupler “2” and ground red–ground

Lines short circuit check “B”

ABS ECU coupler “2” red–any other coupler terminal

A B
2
2
R Lg/L Lg/W Y/L B/W R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B R/L Y Br W/L Y Br W B

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
→ Replace the wire harness.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-62
 32_ABS

EAS20712

32_ABS
EAS33376

TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS solenoid power supply circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-63
 33_ABS

EAS20692

33_ABS
EAS33322

TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal ABS motor power supply)

Procedure
1. Blown ABS motor fuse
• Check the ABS motor fuse.
Refer to “CHECKING THE FUSES” on page 8-37.

Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 3.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS motor fuse and ABS ECU coupler.
• Open circuit check
Between ABS motor fuse holder “1” and ABS ECU
red/blue–red/blue
coupler “2”

1 2
R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.

9-64
 33_ABS

• Short circuit check

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.

Ground short circuit check “A”

Between ABS ECU coupler “2” and ground red/blue–ground

Lines short circuit check “B”

ABS ECU coupler “2” red/blue–any other coupler terminal

A B

2 2
R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B
R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
→ Replace the wire harness.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-65
 34_ABS

EAS20693

34_ABS
EAS33323

TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS motor power supply circuit)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-66
 41_ABS

EAS20694

41_ABS
EAS33331

TROUBLESHOOTING
Item
Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization)

Procedure
1. Incorrect installation of the front wheel sensor
• Check the components for looseness, distortion, and bends.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Go to step 2.
NO
→ Repair or replace the defective part.
2. Incorrect rotation of the front wheel
• Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” on page 4-29 and “CHECKING THE FRONT BRAKE
DISC” on page 4-42.

Is check result OK?

YES
→ Go to step 3.
NO
→ Repair or replace the defective part.
3. Front brake dragging
• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever
is operated and that the pressure decreases when the lever is released.
Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-42.

Is check result OK?

YES
→ Go to step 4.
NO
→ Repair or replace the defective part.
4. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-67
 43_ABS

EAS20696

43_ABS
EAS33330

TROUBLESHOOTING
Item
Front wheel sensor (missing pulses)

Procedure
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.

Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-29.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page
4-30.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.

9-68
 51, 52_ABS

EAS20698

51, 52_ABS
EAS33326

TROUBLESHOOTING
Item
• Vehicle system power supply (voltage of ABS ECU power supply is high) (DTC No. 51)
• Vehicle system power supply (voltage of wheel sensor power supply is high) (DTC No. 52)

Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.
2. Disconnected battery terminal
• Check the connection.

Is check result OK?

YES
→ Go to step 3.
NO
→ Replace or reconnect the terminal.
3. Defective charging system
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Confirm the cause of the problem and repair it, and check again.

9-69
 53_ABS

EAS20699

53_ABS
EAS33327

TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is low)

Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 3.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS ECU fuse and ABS ECU coupler.
• Open circuit check
Between ABS ECU fuse holder “1” and ABS ECU
brown–brown
coupler “2”

1 2
R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.
• Short circuit check
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.

Ground short circuit check “A”

Between ABS ECU coupler “2” and ground brown–ground

Lines short circuit check “B”

ABS ECU coupler “2” brown–any other coupler terminal

9-70
 53_ABS

A B

2 2

R Lg/L Lg/W Y/L B/W R Lg/L Lg/W Y/L B/W

R/L Y Br W/L Y Br W B R/L Y Br W/L Y Br W B

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
→ Replace the wire harness.
4. Defective charging system
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.

Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Confirm the cause of the problem and repair it, and check again.

9-71
 54_ABS

EAS20711

54_ABS
EAS33375

TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS solenoid and ABS motor power supply circuits)

Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.
2. Defective coupler between the battery and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
• Check the locking condition of the coupler.
TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.

Is check result OK?

YES
→ Go to step 3.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
3. Wire harness continuity
• Disconnect the ABS ECU fuse, ABS motor fuse and ABS ECU coupler.
• Open circuit check
Between ABS ECU fuse holder “1” and ABS ECU
brown–brown
coupler “3”
Between ABS motor fuse holder “2” and ABS ECU
red/blue–red/blue
coupler “3”

3
R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B
2

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
→ Replace the wire harness.
• Short circuit check
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.

9-72
 54_ABS

Ground short circuit check “A”

brown–ground
Between ABS ECU coupler “3” and ground
red/blue–ground

Lines short circuit check “B”

brown–any other coupler terminal
ABS ECU coupler “3”
red/blue–any other coupler terminal

A B

3 3

R Lg/L Lg/W Y/L B/W R Lg/L Lg/W Y/L B/W

R/L Y Br W/L Y Br W B R/L Y Br W/L Y Br W B

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
→ Replace the wire harness.
4. Defective charging system
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.

Is check result OK?

YES
→ Go to step 5.
NO
→ Confirm the cause of the problem and repair it, and check again.
5. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-73
 55_ABS

EAS20700

55_ABS
EAS33328

TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS ECU)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-74
 56_ABS

EAS20701

56_ABS
EAS33329

TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal internal power supply)

Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-75
 63_ABS

EAS20703

63_ABS
EAS33334

TROUBLESHOOTING
Item
Front wheel sensor power supply (voltage of power supply is low)

Procedure
1. Wire harness continuity.
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.

Ground short circuit check “A”

brown–ground
Between front wheel sensor coupler “1” and ground
yellow–ground

Lines short circuit check “B”

brown–any other coupler terminal
Front wheel sensor coupler “1”
yellow–any other coupler terminal
brown–any other coupler terminal
ABS ECU coupler “2”
yellow–any other coupler terminal

A B
1 1 2
Br Y
Br Y R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B

Is resistance ∞ Ω?
YES
→ Go to step 2.
NO
→ Replace the wire harness.
2. Defective front wheel sensor
Ground short circuit check “A”
brown–ground
Between front wheel sensor “1” and ground
yellow–ground

Lines short circuit check “B”

brown–any other coupler terminal
Front wheel sensor “1”
yellow–any other coupler terminal

9-76
 63_ABS

A B

1 1
Br Y Br Y

Is resistance ∞ Ω?
YES
→ Go to step 3.
NO
→ Replace the wire harness.
3. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page 4-53.

9-77
 Er-1, Er-2, Er-3, Er-4

Er-1, Er-2, Er-3, Er-4

TROUBLESHOOTING
Item
• [Er-1] SGCU internal malfunction (output signal error): signals cannot be transmitted between the
SGCU and the multi-function meter.
• [Er-2] SGCU internal malfunction (output signal error): signals are not received from the SGCU within
the specified duration
• [Er-3] SGCU internal malfunction (output signal error): data from the SGCU cannot be received cor-
rectly.
• [Er-4] SGCU internal malfunction (input signal error): registered data is not received from the meter.
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of meter assembly coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3

9-78
 Er-1, Er-2, Er-3, Er-4

3. meter assembly Wire harness continuity.

• Disconnect the meter assembly coupler and SGCU coupler.
• Open circuit check.
Between meter assembly coupler “1” and SGCU cou-
blue/red–blue/red
pler “2”

1 2

Ch W/R Dg W/L B Br R Lg/L G/Y P W/L Ch G B/W Or/B W/R B/Y Or

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

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”
• Short circuit check.
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

Between meter assembly coupler “1” and ground blue/red–ground

Lines short circuit check “B”

Meter assembly coupler “1” blue/red–any other coupler terminal
SGCU coupler “2” blue/red–any other coupler terminal

9-79
 Er-1, Er-2, Er-3, Er-4

A B

1 1 2
Ch W/R Dg W/L B Br R
Y/B L/R B/W G Y/W
Ch W/R Dg W/L B Br R Lg/L G/Y G B/W
P W/L Ch Or/B W/R B/Y Or
Y/B L/R B/W G Y/W Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W

Is resistance ∞Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.
4. Defective meter assembly
• Check that the installed condition of meter assembly.
• Check for looseness or pinching.
Refer to “METER ASSEMBLY” on page *-**.

Is check result OK?

YES
→ Go to step 6, and complete the service.
NO
a. Replace the meter assembly.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-80
 P0030

EAS20397

P0030
EAS33134

TROUBLESHOOTING
Item
O2 sensor heater: defective heater or heater driver ON/OFF command and error signal is mismatching.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of O2 sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3.
3. Wire harness continuity.
• Disconnect the O2 sensor coupler, SGCU coupler and fuse box (ignition fuse) coupler.
• Open circuit check
Between O2 sensor coupler “1” and SGCU coupler
pink/black–pink/black
“2”
Between O2 sensor coupler “1” and fuse box (ignition
brown/red–brown
fuse)

9-81
 P0030

3
2
1
Br/R P/B Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Gy/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

pink/black–ground
Between O2 sensor coupler “1” and ground
brown/red–ground

Lines short circuit check “B”

pink/black–any other coupler terminal
O2 sensor coupler “1”
brown/red–any other coupler terminal
SGCU coupler “2” pink/black–any other coupler terminal
Fuse box (ignition fuse) “3” brown/red–any other coupler terminal

9-82
 P0030

A B
1 1 2
Br/R P/B
Gy/R B/L
Br/R P/B
Gy/R B/L Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.
4. Defective O2 sensor heater.
• Replace the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
• Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-83
 P00D1, P2195

EAS20660

P00D1, P2195
EAS33115

TROUBLESHOOTING
Item
• [P00D1] O2 sensor: heater performance deteriorated. Normal signal is not received from the O2 sen-
sor while driving the O2 sensor.
• [P2195] O2 sensor: open circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Installed condition of O2 sensor.
• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
b. Start the engine and warm it up. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Delete the DTC, and then go to step 2.
2. Connection of O2 sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and warm it up. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Delete the DTC, and then go to step 3.

9-84
 P00D1, P2195

3. Connection of SGCU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and warm it up. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Delete the DTC, and then go to step 4.
4. Wire harness continuity.
• Disconnect the O2 sensor coupler and SGCU coupler and fuse box (ignition fuse) coupler.
• Open circuit check
pink/black–pink/black
Between O2 sensor coupler “1” and SGCU coupler “2” gray/red–gray/red
black/blue–black/blue
Between O2 sensor coupler “1” and fuse box (ignition
brown/red–brown
fuse) coupler “3”

3
2
1
Br/R P/B Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Gy/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ [P00D1] → Go to “Short circuit check”.
→ [P2195] → Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and warm it up. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

9-85
 P00D1, P2195

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

pink/black–ground
brown/red–ground
Between O2 sensor coupler “1” and ground
gray/red–ground
black/blue–ground

Lines short circuit check “B”

pink/black–any other coupler terminal
brown/red–any other coupler terminal
O2 sensor coupler “1”
gray/red–any other coupler terminal
black/blue–any other coupler terminal
pink/black–any other coupler terminall
SGCU coupler “2” gray/red–any other coupler terminal
black/blue–any other coupler terminal
Fuse box (ignition fuse) coupler “3” brown/red–any other coupler terminal

A B

1 2 3
1
Br/R P/B Br/R P/B
Gy/R B/L Gy/R B/L Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Start the engine and warm it up. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

9-86
 P00D1, P2195

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Go to step 5.
5. Check fuel pressure.
• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-5.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-3.
b. Start the engine and warm it up. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Go to step 6.
6. Defective O2 sensor.
• Replace the O2 sensor.

Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
b. Start the engine and warm it up. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 8, and complete the service.
NO
→ Go to step 7.
7. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
8. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-87
 P0106

EAS20421

P0106
EAS32840

TROUBLESHOOTING
Item
Intake air pressure sensor: clogging of hole or sensor installation improoerly.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
.

TIP
If the DTC “P0107/P0108” or “P0106” are detected at the same time, perform the check and service for
DTC listed below first.
• P0107, P0108

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
1. Installed condition of throttle body sensor assembly.
• Check for detached or clogged.
Refer to “THROTTLE BODY” on page 7-11.

Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall the throttle body sensor assembly.
Refer to “THROTTLE BODY” on page 7-11.
b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then
check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 3, and complete the service.
NO
→ Go to step 2.
2. Defective intake air pressure sensor.
• Execute the diagnostic mode. (Code D03)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
At sea level 101 kPa (757.6 mmHg, 29.8 inHg), approx. 3.99V
1000 m (3300 ft) above sea level Approx. 90 kPa (675.1 mmHg, 26.6 inHg), approx. 3.55V
2000 m (6700 ft) above sea level Approx. 80 kPa (600.0 mmHg, 23.6 inHg), approx. 3.16V
3000 m (9800 ft) above sea level Approx. 70 kPa (525.0 mmHg, 20.7 inHg), approx. 2.76V

• When engine is cranking: Make sure that the indication value changes.

9-88
 P0106

Is check result OK?

YES
→ Go to step 3, and complete the service.
NO
a. Replace the throttle body sensor assembly.
Refer to “THROTTLE BODY” on page 7-11.
b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then
check the DTC using the malfunction mode of the YDT.
c. Confirm the “Recovered” condition, then go to step 3.
3. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-89
 P0107, P0108

EAS20567

P0107, P0108
EAS33047

TROUBLESHOOTING
Item
• [P0107] Intake air pressure sensor: open or short to ground circuit is detected.
• [P0108] Intake air pressure sensor: short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
.

TIP
If the DTC “P0107/P0108” or “P0106” are detected at the same time, perform the check and service for
DTC listed below first.
• P0107, P0108

NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
1. Connection of throttle body sensor assembly coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

9-90
 P0107, P0108

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.
3. Wire harness continuity.
• Disconnect the throttle body sensor assembly coupler and SGCU coupler.
• Open circuit check
[P0108] black/blue–black/blue
Between throttle body sensor assembly coupler “1”
[P0107] pink/white–pink/white
and SGCU coupler “2”
[P0107] blue–blue

2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
Or/B W/R B/Y Or
B/L Y B/L Br/B R/B
B/L Y L P/W Br/W L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
.

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.
Ground short circuit check “A”
Between throttle body sensor assembly coupler
[P0107] pink/white–ground
“1” and ground

Lines short circuit check “B”

Throttle body sensor assembly coupler “1” [P0108] pink/white–any other coupler terminal
SGCU coupler “2” [P0108] pink/white–any other coupler terminal

9-91
 P0107, P0108

A B

1 1 2

B/L Y L P/W Br/W

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

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of throttle body sensor assembly.
• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Turn the main switch to “ON” and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.
5. Defective intake air pressure sensor.
• Execute the diagnostic mode. (Code D03)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.

9-92
 P0107, P0108

Approx.101 kPa (757.6 mmHg, 29.8 inHg), approx.

At sea level
3.64 V, approx. 3.99V
Approx. 90 kPa (675.1 mmHg, 26.6 inHg), approx.
1000 m (3300 ft) above sea level
3.30 V, approx. 3.55V
Approx. 80 kPa (600.0 mmHg, 23.6 inHg), approx.
2000 m (6700 ft) above sea level
3.00 V, approx. 3.16V
Approx. 70 kPa (525.0 mmHg, 20.7 inHg), approx.
3000 m (9800 ft) above sea level
2.70 V, approx. 2.76V

• When engine is cranking: Make sure that the indication value changes.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the throttle body.
Refer to “THROTTLE BODY” on page 7-11.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to ““REPLACING THE SGCU (starter generator control unit)” on page 8-37.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-93
 P0112, P0113

EAS20568

P0112, P0113
EAS33048

TROUBLESHOOTING
Item
• [P0112] Intake air temperature sensor: short to ground circuit is detected.
• [P0113] Intake air temperature sensor: open or short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
TIP
Perform this procedure when the engine is cold.

1. Connection of throttle body sensor assembly coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-94
 P0112, P0113

3. Wire harness continuity.

• Disconnect the throttle body sensor assembly coupler and SGCU coupler.

Is DTC P0112 displayed?

YES
→ Go to “Short circuit check”.
NO
→ Go to “Open circuit check”.
• Open circuit check
Between throttle body sensor assembly coupler “1” [P0113] brown/white–brown/white
and SGCU coupler “2” [P0113] black/blue–black/blue

2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
Or/BW/R B/Y Or
B/L Y B/L Br/B R/B
B/L Y L P/W Br/W L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

Between throttle body sensor assembly coupler “1”
[P0112] brown/white–ground
and ground

Lines short circuit check “B”

SGCU coupler “2” [P0113] brown/white–any other coupler terminal

9-95
 P0112, P0113

A B
2
1
B/L Y L P/W Br/W Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of throttle body sensor assembly.
• Check for looseness.
Refer to “GENERAL CHASSIS (3)” on page 4-6.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Turn the main switch to “ON” and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

9-96
 P0112, P0113

5. Defective intake air temperature sensor.

• Execute the diagnostic mode. (Code D05)
• When engine is cold: Displayed temperature is close to the ambient temperature.
• The displayed temperature is not close to the ambient temperature → Replace the throttle body.
Refer to “REPLACING THE THROTTLE BODY” on page 7-15.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the intake air temperature sensor.
Refer to “GENERAL CHASSIS (3)” on page 4-6.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to ““REPLACING THE SGCU (starter generator control unit)” on page 8-37.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-97
 P0117, P0118

EAS20569

P0117, P0118
EAS33049

TROUBLESHOOTING
Item
• [P0117] Coolant temperature sensor: short to ground circuit is detected.
• [P0118] Coolant temperature sensor: open or short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of coolant temperature sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-98
 P0117, P0118

3. Wire harness continuity.

• Disconnect the coolant temperature sensor coupler and SGCU coupler.

Is DTC P0117 displayed?

YES
→ Go to “Short circuit check”.
NO
→ Go to “Open circuit check”.
• Open circuit check
Between coolant temperature sensor coupler “1” and [P0118] green/red–green/red
SGCU coupler “2” [P0118] black/blue–black/blue

1 2
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
G/R B/L
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to step “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

Between coolant temperature sensor coupler “1” and
[P0117] green/red–ground
ground

Lines short circuit check “B”

Coolant temperature sensor coupler “1” [P0118] green/red–any other coupler terminal
SGCU coupler “2” [P0118] green/red–any other coupler terminal

9-99
 P0117, P0118

A B

1 1 2
G/R B/L
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
G/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of coolant temperature sensor.
• Check for looseness or pinching.
Refer to “CYLINDER HEAD” on page 5-9.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the sensor.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.
5. Defective coolant temperature sensor.
• Execute the diagnostic mode. (Code D06)
• When engine is cold: Displayed temperature is close to the ambient temperature.
• The displayed temperature is not close to the ambient temperature → Check the coolant tempera-
ture sensor.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR” on page 8-42.

9-100
 P0117, P0118

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the coolant temperature sensor.
Refer to “CYLINDER HEAD” on page 5-9.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-101
 P0122, P0123

EAS20570

P0122, P0123
EAS33050

TROUBLESHOOTING
Item
• [P0122] Throttle position sensor: open or short to ground circuit is detected.
• [P0123] Throttle position sensor: short to power circuit is detected.
Fail-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
1. Connection of throttle body sensor assembly.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

9-102
 P0122, P0123

3. Wire harness continuity.

• Disconnect the throttle position sensor coupler and SGCU coupler.
• Open circuit check
[P0122] blue–blue
Between throttle position sensor coupler “1” and
[P0122] yellow–yellow
SGCU coupler “2”
[P0123] black/blue–black/blue

2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
Or/BW/R B/Y Or
B/L Y B/L Br/B R/B
B/L Y L P/W Br/W L/B R G/R B/L W/G W L/Y L/R B Gy/R W Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 9, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

Between throttle position sensor coupler “1” and
[P0122] yellow–ground
ground

Lines short circuit check “B”

Throttle position sensor coupler “1” [P0123] yellow–any other coupler terminal
SGCU coupler “2” [P0123] yellow–any other coupler terminal

9-103
 P0122, P0123

A B
1 1 2

Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or

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

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of throttle body sensor assembly.
• Check for looseness or pinching.
Refer to “CHECKING THE THROTTLE BODY SENSOR ASSEMBLY” on page 8-41.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.
5. Defective throttle position sensor.
• Check throttle position sensor signal 1.
• Execute the diagnostic mode. (Code D01)
When the throttle valves are fully closed 13–21
When throttle valves are fully open 97–107

9-104
 P0122, P0123

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the throttle body sensor assembly.
Refer to “REPLACING THE THROTTLE BODY” on page 7-15.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-105
 P0132

EAS20571

P0132
EAS33051

TROUBLESHOOTING
Item
O2 sensor: short to power circuit is detected.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Installed condition of O2 sensor.
• Check for looseness or pinching.
Refer to “ENGINE REMOVAL” on page 5-4.

Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the sensor.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of O2 sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.
3. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

9-106
 P0132

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Wire harness continuity.
• Disconnect the O2 sensor coupler and SGCU coupler.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Lines short circuit check

SGCU coupler “2” gray/red–any other coupler terminal

Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or

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

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

9-107
 P0132

5. Defective O2 sensor.
• Check the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-108
 P0201

EAS20574

P0201
EAS33054

TROUBLESHOOTING
Item
Fuel injector: malfunction in fuel injector.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Connection of fuel injector coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
→ Go to step 6.
NO
→ Go to step 2.
2. Defective fuel injector.
• Measure the injector resistance.
Refer to “CHECKING THE FUEL INJECTOR” on page 8-43.

Is check result OK?

YES
→ Go to step 3.
NO
a. Replace the fuel injector.
Refer to “THROTTLE BODY” on page 7-11.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
→ Go to step 6.
NO
→ Go to step 3
3. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

9-109
 P0201

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
→ Go to step 6.
NO
→ Go to step 4.
4. Wire harness continuity.
• Disconnect the fuel injector coupler and SGCU coupler
• Open circuit check
Between fuse box (ignition fuse) terminal “1” and fuel
brown–brown
injector coupler “2”
Between fuel injector coupler “2” and SGCU coupler
orange/black–orange/black
“3”

1
3
2
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Or/B Br Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
→ Go to step 6.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

9-110
 P0201

Ground short circuit check “A”

orange/black–ground
Between fuel injector coupler “2” and ground
brown–ground

Lines short circuit check “B”

orange/black–any other coupler terminal
Fuel injector coupler “2”
brown–any other coupler terminal
SGCU coupler “1” orange/black–any other coupler terminal

A B
2 2 1
Or/B Br
Or/B Br
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D36)

Is it hear operating sound?

YES
→ Go to step 6.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
6. Delete the DTC and check that the MIL goes off.
• Start the engine and let it idle for approximately 5 seconds.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.

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 P0335

EAS20578

P0335
EAS33058

TROUBLESHOOTING
Item
Crankshaft position sensor: normal signals is not received from the crankshaft position sensor.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Connection of crankshaft position sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of wire harness SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

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 P0335

3. Wire harness continuity.

• Disconnect the crankshaft position sensor coupler and SGCU coupler.
• Open circuit check
white/red–white/red
white/blue–white/blue
Between crankshaft position sensor coupler “1” and white/black–white/black
SGCU coupler “2” white/yellow–white/yellow
brown/black–brown/black
black/blue–black/blue

1
W/R B/L
2
W/L Br/B Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
W/B W/Y Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

white/red–ground
white/blue–ground
Between crankshaft position sensor coupler “1” and white/black–ground
ground white/yellow–ground
brown/black–ground
black/blue–ground

9-113
 P0335

Lines short circuit check “B”

white/red–any other coupler terminal
white/blue–any other coupler terminal
white/black–any other coupler terminal
Crankshaft position sensor coupler “1”
white/yellow–any other coupler terminal
brown/black–any other coupler terminal
black/blue–any other coupler terminal
white/red–any other coupler terminal
white/blue–any other coupler terminal
white/black–any other coupler terminal
SGCU coupler “2”
white/yellow–any other coupler terminal
brown/black–any other coupler terminal
black/blue–any other coupler terminal

A B
1 1 2

W/R B/L W/R B/L

W/L Br/B W/L Br/B
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
W/B W/Y W/B W/Y Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of crankshaft position sensor.
• Check for looseness or pinching.

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 P0335

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the sensor.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.
5. Defective crankshaft position sensor.
a. Replace the crankshaft position sensor and stator generator assembly.
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

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 P0351

EAS20580

P0351
EAS33060

TROUBLESHOOTING
Item
Ignition coil: open or short circuit is detected in the primary lead of the ignition coil.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Connection of ignition coil coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 3.

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 P0351

3. Wire harness continuity.

• Disconnect the ignition coil coupler and SGCU coupler.
• Open circuit check
Between ignition coil coupler “1” and SGCU coupler
orange–orange
“2”

2 1

Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or

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

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

Between ignition coil coupler “1” and ground orange–ground

Lines short circuit check “B”

Ignition coil coupler “1” orange–any other coupler terminal
SGCU coupler “2” orange–any other coupler terminal

9-117
 P0351

A B
1 2 1

Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or

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

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 4.
4. Installed condition of ignition coil.
• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 5.

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 P0351

5. Defective ignition coil.

• Measure the primary coil resistance of the ignition coil.
Refer to “CHECKING THE IGNITION COIL” on page 8-39.

Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the ignition coil.
Refer to “GENERAL CHASSIS (3)” on page 4-6.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 6.
6. Malfunction in SGCU.
• Execute the diagnostic mode. (Code D30)
• Confirm that spark plug does not sparking.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
7. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-119
 P0500

EAS20674

P0500
EAS33303

TROUBLESHOOTING
Item
Front wheel sensor: normal signals is not received from the front wheel sensor.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of front wheel sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 2.
2. Connection of ABS ECU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 3.
3. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

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 P0500

Is the coupler condition normal?

YES
→ Go to step 4.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 7.
NO
→ Go to step 4.
4. Wire harness continuity.
• Disconnect the front wheel sensor coupler, ABS ECU coupler and SGCU coupler.
• Open circuit check
Between front wheel sensor coupler “1” and ABS brown–brown
ECU coupler “2” yellow–yellow
Between ABS ECU coupler “2” and SGCU coupler “3” white–white

1 2 3
Lg/L G/Y P W/L Ch G B/W O/B W/R B/Y Or
R Lg/L Lg/W Y/L B/W Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Y R/L Y Br W/L Y Br W B L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

brown–ground
Between ABS ECU coupler “2” and ground
yellow–ground

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 P0500

Lines short circuit check “B”

brown–any other coupler terminal
Front wheel sensor coupler “1”
yellow–any other coupler terminal
brown–any other coupler terminal
ABS ECU coupler “2”
yellow–any other coupler terminal
SGCU coupler “3” white–any other coupler terminal

A B
1 2 3

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

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code D07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 5.
5. Defective front wheel sensor.
• Check the installed condition of front wheel sensor.

Is check result OK?

YES
→ Go to step 6.
NO
a. Reinstall or replace the front wheel sensor.
Refer to “FRONT WHEEL” on page 4-27.
b. Execute the diagnostic mode. (Code No.07)
c. Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8, and complete the service.
NO
→ Go to step 6.

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 P0500

6. Malfunction in SGCU.
• Replace the SGCU.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
• Execute the diagnostic mode. (Code D07)
• Rotate the front wheel by hand and check that the indicated value increases.

Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 7.
7. Malfunction in ABS ECU.
• Replace the ABS ECU and go to step 8.
8. Delete the DTC and check that the MIL goes off.
• Turn the main switch to “ON” and then rotate the front wheel by hand.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC. Delete this DTC even if it has a condition of “Detected”.

9-123
 P0507

EAS20589

P0507
EAS33069

TROUBLESHOOTING
Item
Engine idling speed is too high.
A. Component other than ISC unit is defective (ISC unit operating sound is heard).
B. Defective ISC unit (ISC unit operating sound is not heard).
Fail-safe system
• Able to start engine
• Able to drive vehicle
TIP
If the DTCs P0507, P0560 are detected at the same time, perform the checked service for DTC listed
below first.
• P0560
If the DTCs P0507, P0500 are detected at the same time, perform the checked service for DTC listed
below first.
• P0500
If the DTCs P0507, P0511 are detected at the same time, perform the checked service for DTC listed
below first.
• P0511

Procedure
1. Locate the malfunction.
• Execute the diagnostic mode. (Code 54)
• Fully close the ISC valve, and then open the valve to the standby opening position.
• This operation takes approximately 3 seconds.

Is ISC operating sound heard?

YES
→ Go to step 2.
NO
→ Go to step 10.

2. Incorrect front wheel sensor signal.

• Execute the diagnostic mode. (Code 07)
• Front wheel stopped: Check that the cumulative pulse value does not increase.
• Front wheel is rotated several turns by hand: Check that the cumulative pulse value increases.

Is check result OK?

YES
→ Go to step 3.
NO
a. Go to the section for the defective front wheel sensor for DTC P0500.
b. Start the engine and let it idle for approximately 10 seconds.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 3.

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 P0507

3. Throttle valve does not fully close due to malfunction in throttle cables.
• Check the throttle grip free play.
Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-23.

Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the throttle bodies.
b. Start the engine and let it idle for approximately 10 seconds.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 4.

4. Air sucking from the throttle body.

• Check the throttle body.
Refer to “THROTTLE BODY” on page 7-11.

Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the throttle body.
b. Start the engine and let it idle for approximately 10 seconds.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 5.

5. Air sucking from the ISC unit.

• Check for looseness or pinching.
• Check the intake air passages for air sucking.

Is check result OK?

YES
→ Go to step 6.
NO
a. Reinstall the ISC unit.
b. Start the engine and let it idle for approximately 10 seconds.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 6.

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 P0507

6. The air volume for the throttle body and ISC unit is excessive.
• Clean the throttle body and ISC unit.
Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on page
7-13.

Is check result OK?

YES
→ Go to step 7.
NO
a. Start the engine and let it idle for approximately 10 seconds.
b. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 7.

7. The ISC valve is not moving correctly.

• Replace the ISC unit.
• Start the engine and let it idle for approximately 10 seconds.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 8.

8. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
• Execute the diagnostic mode. (Code 54)
• Return the ISC valve to the initial opening position.

9. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

10.Connection of ISC unit coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is check result OK?

YES
→ Go to step 11.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 54)

Is check result OK?

YES
→ Go to step 17.
NO
→ Go to step 11.

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 P0507

11.Connection of SGCU coupler.

• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 12.
NO
a. Connect the coupler securely or replace the wire harness.
b. Execute the diagnostic mode. (Code 54)

Is ISC operating sound heard ?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 12.

12.Wire harness continuity.

• Disconnect the ISC unit coupler and SGCU coupler.
• Open circuit check
pink–pink
green/yellow–green/yellow
Between ISC unit coupler “1” and SGCU coupler “2”
gray–gray
sky blue–sky blue

2
1 Lg/L G/Y P W/L Ch G B Or/B W/R B/Y Or
Lg/W Sb Gy W/Y W/B L B/L Y B/L Br/B R/B
P G/Y Sb Gy L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 54)

Is hear operating sound?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step “Short circuit check”.

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 P0507

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

pink–ground
green/yellow–ground
Between ISC unit coupler “1” and ground
gray–ground
sky blue–ground

Lines short circuit check “B”

pink–any other coupler terminal
green/yellow–any other coupler terminal
ISC unit coupler “1”
gray–any other coupler terminal
sky blue–any other coupler terminal
pink–any other coupler terminal
green/yellow–any other coupler terminal
SGCU coupler “2”
gray–any other coupler terminal
sky blue–any other coupler terminal

A B

1 1 2

P G/Y Sb Gy P G/Y Sb Gy
Lg/L G/Y P W/L Ch G B Or/B W/R B/Y Or
Lg/W Sb Gy W/Y W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 13.
NO
a. Replace the wire harness.
b. Execute the diagnostic mode. (Code 54)

Is hear operating sound?

YES
→ Go to step 17.
NO
→ Go to step 13.

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 P0507

13.Installed condition of ISC unit.

• Check for looseness or pinching.

Is check result OK?

YES
→ Go to step 14.
NO
a. Reinstall the ISC unit.
b. Execute the diagnostic mode. (Code 54)

Is ISC operating sound heard?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 14.

14.Battery malfunction.
• Check the battery voltage.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37.

Is check result OK?

YES
→ Go to step 15.
NO
→ Execute the diagnostic mode. (Code 54)

Is ISC operating sound heard?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 15.

15.ISC valve is not moving correctly.

• Replace the ISC valve.
Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on page
7-13.

Is check result OK?

YES
→ Go to step 16.
NO
→ Execute the diagnostic mode. (Code 54)

Is ISC operating sound heard?

YES
→ Go to step 17, and complete the service.
NO
→ Go to step 16.

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 P0507

16.Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
• Execute the diagnostic mode. (Code 54)
• Return the ISC valve to the standby opening position.

17.Delete the DTC and check that the MIL goes off.
• Start the engine and let it idle for approximately 10 seconds.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-130
 P0511

EAS20567

P0511
EAS33047

TROUBLESHOOTING
Item
ISC unit: ISC valve malfunction is detected. (Open or short circuit is detected between ISC valve and
SGCU.)
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of ISC unit coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3.

9-131
 P0511

3. Wire harness continuity.

• Disconnect the ISC unit coupler and SGCU coupler.
• Open circuit check
pink–pink
green/yellow–green/yellow
Between ISC unit coupler “1” and SGCU coupler “2”
gray–gray
sky blue–sky blue

2
1 Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
P G/Y Sb Gy L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the condition of the DTC using the malfunction
mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

pink–ground
green/yellow–ground
Between ISC unit coupler “1” and ground
gray–ground
sky blue–ground

9-132
 P0511

Lines short circuit check “B”

pink–any other coupler terminal
green/yellow–any other coupler terminal
ISC unit coupler “1”
gray–any other coupler terminal
sky blue–any other coupler terminal
pink–any other coupler terminal
green/yellow-any other coupler terminal
SGCU coupler “2”
gray–any other coupler terminal
sky blue–any other coupler terminal

A B

1 1 2

P G/Y Sb Gy
P G/Y Sb Gy
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.
Is it in the “Recovered” condition?
YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.
4. Faulty the ISC unit operation
• Execute the diagnostic mode. (Code D54)
• Check the operating sound of the relay.
Is ISC operating sound heard?
YES
→ Go to step 5.
NO
a. Replace the ISC unit.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.
Is it in the “Recovered” condition?
YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.

9-133
 P0511

5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-134
 P0560, P0563

EAS20434

P0560, P0563
EAS33138

TROUBLESHOOTING
Item
• [P0560] Battery charging voltage is abnormal. (Discharged condition)
• [P0563] Battery charging voltage is abnormal. (Overcharged condition)
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Malfunction in charging system.
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.

Is check result OK?

YES
→ Repeat step 1.
NO
a. Defective connection in the charging system circuit → Properly connect or replace the wire har-
ness.
b. Start the engine and let it idle for approximately 5 seconds.
c. Check the condition of the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 2, and complete the service.
NO
→ Repeat step 1.
2. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-135
 P0601

EAS20676

P0601
EAS33305

TROUBLESHOOTING
Item
Internal malfunction in SGCU. (When this malfunction is detected in the SGCU, the DTC might not ap-
pear on the tool display.)
Fail-safe system
• Unable to start engine
• Unable to drive vehicle

Procedure
1. Malfunction in SGCU.
• Replace the SGCU.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
• Turn the main switch to “ON”.
• Check that the MIL does not come on.

9-136
 P062F

EAS20598

P062F
EAS33078

TROUBLESHOOTING
Item
EEPROM DTC: an error is detected while reading or writing on EEPROM.
Fail-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle

Procedure
1. Locate the malfunction.
• Execute the diagnostic mode (Code D60)
00
Go to step 5.
01
Go to step 2.
11
Go to step 3.
12
Go to step 3.
14
Go to step 4.
2. “01” is indicated in diagnostic mode (code D60). EEPROM data error for adjustment of CO adjust-
ment value.
• Activate the CO volume adjustment mode using the YDT.
• Click the “Step up” or “Step down” button 1 time. (Clicking the “Step up” or “Step down” button during
this procedure does not change the CO volume.)
• After this adjustment is made, turn the main switch to “OFF”.
• Turn the main switch to “ON” and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
a. Repeat step 1.
b. If the same number is indicated, go to step 5.
3. “11” is indicated in the diagnostic mode (code D60). EEPROM data error for ISC learning value and/
or “12” is indicated in the diagnostic mode (code D60). EEPROM data error for A/F learning values.
• After this adjustment is made, turn the main switch to “OFF”.
• Turn the main switch to “ON” and then check the condition of the DTC using the malfunction mode
of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
a. Repeat step 1.
b. If the same number is indicated, go to step 5.

9-137
 P062F

4. “14” is indicated in the diagnostic mode (code D60). EEPROM data error for outside diameter of tire
learning value.
• Turn the main switch to “OFF”.
• Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
a. Execute the diagnostic mode (Code D87)
b. Repeat step 1.
c. If the same number is indicated, go to item 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-138
 P1602

EAS20615

P1602
EAS33095

TROUBLESHOOTING
Item
Malfunction in SGCU internal circuit (malfunction of SGCU power cut-off function).
Fail-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle
Procedure
1. Installed condition of battery leads.
• Check the installed condition of the battery and battery leads (loose bolts).

Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the battery leads.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of starter charge coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3.
3. Wire harness continuity.
• Disconnect the starter charger relay coupler and SGCU coupler.
• Open circuit check
Between battery “1” and fuse box (main fuse) terminal
red–red
“2”
Between fuse box (EFI fuse) terminal “2” and SGCU
red–red
coupler “3”

9-139
 P1602

2 3
1
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the condition of the DTC using the malfunction
mode of the YDT.
Is it in the “Recovered” condition?
YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

Between SGCU coupler “3” and ground red–ground
Lines short circuit check “B”
SGCU coupler “3” red–any other coupler terminal

A B
3 3

Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

9-140
 P1602

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.
4. Wire harness continuity.
• Disconnect the main switch coupler, fuse box (ignition fuse) terminal, starter charge relay coupler
and SGCU coupler.
• Open circuit check
Between main switch coupler “1” and fuse box (igni- brown–brown
tion fuse) terminal “2”
Between fuse box (ignition fuse) terminal “2” and brown–brown
starter charger relay coupler “3”
Between starter charge relay “3” and SGCU coupler red/black–red/black
“4”

4
1 3
Y/R
R/Y R Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Br R/B Br/R Br Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.

9-141
 P1602

• Short circuit check

TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.
Ground short circuit check “A”
Between starter charge relay coupler “3” and ground red/black–ground

Lines short circuit check “B”

Starter charge relay coupler “3” red/black–any other coupler terminal
SGCU coupler “4” red/black–any other coupler terminal

A B 3 4
3
Y/R Y/R
R R
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
R/B Br/R Br R/B Br/R Br
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 5.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-142
 P2645

EAS20567

P2645
EAS33047

TROUBLESHOOTING
Item
VVA solenoid: Normal signal is not received from the VVA solenoid circuit while driving the VVA sole-
noid.
Fail-safe system
• Able to start engine
• Able to drive vehicle

Procedure
1. Connection of VVA solenoid coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” start the engine and accelerate to 6000 r/min and then check the
DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).

Is the coupler condition normal?

YES
→ Go to step 3.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON” start the engine and accelerate to 6000 r/min and then check the
DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 3.

9-143
 P2645

3. Wire harness continuity.

• Disconnect the VVA solenoid coupler and SGCU coupler.
• Open circuit check
Between VVA solenoid coupler “1” and SGCU coupler green–green
“2” chocolate–chocolate
Between SGCU coupler “2” and ground black–ground

2
1 Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br
G Ch

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” and then check the DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to “Short circuit check”.
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-4.

Ground short circuit check “A”

green–ground
Between VVA solenoid coupler “1” and ground
chocolate–ground

Lines short circuit check “B”

green–any other coupler terminal
VVA solenoid coupler “1”
chocolate–any other coupler terminal
green–any other coupler terminal
SGCU coupler “2”
chocolate–any other coupler terminal

9-144
 P2645

A B

1 1 2
G Ch
G Ch
Lg/L G/Y P W/L Ch G B/L B Or/BW/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R Br/W B P/W Br

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
a. Replace the wire harness.
b. Turn the main switch to “ON” start the engine and accelerate to 6000 r/min and then check the
DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 4.
4. Faulty the VVA solenoid operation
• Check the VVA solenoid resistance.
Refer to “CHECKING THE VVA SOLENOID” on page 8-43.

Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the VVA solenoid.
b. Turn the main switch to “ON” start the engine and accelerate to 6000 r/min and then check the
DTC using the malfunction mode of the YDT.

Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-37.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.

9-145
EAS20091
56. VVA (variable valve actuator) EAS30613

WIRING DIAGRAM solenoid COLOR CODE

GDR155-A 2021 57. O2 sensor B Black
1. Battery 58. Starter generator Br Brown
2. ABS solenoid fuse 59. Front wheel sensor Ch Chocolate
3. ABS motor fuse 60. ABS ECU Dg Dark green
4. Signaling system fuse G Green
61. Engine ground
5. Smart keys system fuse Gy Gray
62. Meter assembly
L Blue
6. Terminal fuse 63. Multi-function meter
O Orange
7. Fuel injection system fuse 64. Water cooling warning light P Pink
8. Backup fuse 65. ABS warning light R Red
9. Main fuse 66. Engine trouble warning light Sb Sky blue
10. Ignition fuse 67. Meter light W White
11. Headlight fuse 68. Turn signal indicator light (left) Y Yellow
12. ABS control unit fuse 69. Turn signal indicator light (right) B/L Black/Blue
13. Main switch 70. Stop and Start System indica- B/R Black/Red
14. Request switch tor light B/W Black/White
15. Main switch solenoid 71. Smart key system indicator B/Y Black/Yellow
16. Auxiliary DC jack light Br/R Brown/Red
17. Smart unit 72. High beam indicator light Br/W Brown/White
18. Joint 1 73. License plate light G/B Green/Black
19. Buzzer 74. Tail/brake light assembly G/R Green/Red
20. Joint 2 75. Tail light G/W Green/White
21. Diode 1 76. Brake light G/Y Green/Yellow
22. Horn 77. Joint 5 Gy/G Gray/Green
23. Handlebar switch (left) 78. Joint 6 Gy/R Gray/Red
24. Menu switch 79. Rear turn signal light (right) L/B Blue/Black
25. Horn switch 80. Rear turn signal light (left) L/R Blue/Red
26. Dimmer switch L/W Blue/White
81. Front turn signal light (right)
27. Turn signal switch
L/Y Blue/Yellow
82. Front turn signal light (left)
P/B Pink/Black
28. Diode 2 83. Headlight assembly
P/L Pink/Blue
29. Turn signal relay 84. Headlight control unit P/W Pink/White
30. Handlebar switch (right) 85. Low beam R/B Red/Black
31. Start switch 86. High beam R/G Red/Green
32. Stop and Start System switch 87. Auxiliary light R/L Red/Blue
33. Hazard switch 88. Joint 7 R/W Red/White
34. Main relay 89. Frame ground R/Y Red/Yellow
35. Yamaha diagnostic tool cou- Sb/W Sky blue/White
pler W/R White/Red
36. Front brake light switch W/Y White/Yellow
37. Rear brake light switch Y/B Yellow/Black
38. Starter charge relay Y/G Yellow/Green
39. Sidestand switch Y/L Yellow/Blue
40. Joint 3 Y/R Yellow/Red
41. Fuel injector Y/W Yellow/White
42. Joint 4
43. Joint 5
44. Fuel pump
45. Fuel sender
46. SGCU (starter generator con-
trol unit)
47. Ignition coil
48. Spark plug
49. ISC (idle speed control) unit
50. Throttle body sensor assembly
51. Intake air pressure sensor
52. Intake air temperature sensor
53. Throttle position sensor
54. Crankshaft position sensor
55. Coolant temperature sensor
GDR155-A 2021
WIRING DIAGRAM

R R

2 3
R/L
Br/R Br R
Br
4 5 R R Br W/R
R/Y G/W
W/R
16
B B
6 W/R Br B

R
R

7 8 R
R R
R Br Br
Br Br
9 10 Br
Br
Br
Br
Br
Br Br
Br
Br
11 12 13 L L
R/B 18 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B/W
W/Y P/B W/B L
O/B W/R B/Y O
B/L Y B/L Br/B R/B
Br R/B R
R
G/W R R R L/B R G/R B/L W/G W L/Y L/R B/R Gy/R Br/W B P/W R/W
R R/Y R/Y R ON Br
OPEN B B R
Br Br R/B R/B B R R
OFF (B)
LOCK R
G/W L/R R/B L/Y B/W Ch B Y/R W/B B
R/W R/W R/B
R/Y
Br B B
R L W/R Br R/W Dg
17 19 R R
R W G
Br

14 (B) (B) Br O/B O O

47
15 L/R
W/R
Br/R R
B
B
L
R/W
L
R/W L/Y
Dg
B Br
R/W 41 48
O/B Br
Br/R
B/W Ch
R 34 P P
Br/R Br/R (B)
Br/R Br,R/W B Lg/L B
G/Y
Gy
Sb
G/Y
Gy
Sb
49
R Lg/W R
(B) R/W
(R) P G/Y Sb Gy 50
Br Br Lg/W (B)
Br L/B
Br/W Lg/L 35
R
Lg/W 51
Br Br/B
Br
B
Lg/L
P/W
Br/W
P/W
Br/W
52
Br
28 Br/W 29 B/L B/L
Br
(R) Y
L
Y
L 53
P 21 22 Br/B Br/W Br
Y/W W/G

P Br
Br
36 W/G 42 B/L Y L P/W Br/W
P Br/B Br/B
L/W Y/W Br/B Br Br B/Y B/Y L/W (B)
Y
Y 23
Y/W P L/B
30 Br B/Y 54
24 25 26 27 L/W
31 B
32 33 37 B/Y
40 W/R W/R G W/R W/R B/L

P L/B L/B P Y
L/W
Y/W Dg
Br/B
Dg
Br/B Br B/Y B/Y Y
L/B 43 46
W/L
W/B
W/Y
W/L
W/B
W/Y L/Y
Br/B W/L
L/Y W/B
W/L Br/B
W/B W/Y
FREE ON L/B L/B
Y/W Y/W PUSH Y Br/B Br/B
PUSH B B/W OFF Ch Ch L/R B/L B/L G
Dg Ch Ch Dg B (B)
L/W L/W B/W Y/R Y/L L/R L/R (B)
(B) (B)
(B) (R) (R)
R 38 L/R
20 L /B
L/B
Y /W
B ChDg R/B Br/R Br Y/R Y/R
B Y Ch Dg
Y
R Br/R
G/R
B/L
G/R
B/L 55 G/R B/L
B Br R/B R/B (B)
Br/B L/W B
L/Y
Br/B (B) B B L/Y L/Y L/Y L/Y G
Ch
G
Ch 56 G Ch
R R L/Y B B
R
Ch
B B 39 W/B
(Gy)
Gy/R Gy/R Br/R B B P/B
Ch Ch (L) (L)
Ch R B/Y
Ch
1 Dg
Dg
Dg B/Y R 44
B/L
P/B
B/L
P/B
B/L W L Gy/R

Dg
Dg
Ch (B) G G R/Y B B Br/R P/B
B B B Br/R
Br
Br
Ch Dg Ch
Dg
45 B/W G
R
W
R
W
R/L
R/W
58 57 W L Gy/R B/L
Br Dg B/W (B) (B)
G
B B 82 81 78 G (Gy)
R/Y R/W R/L
B/R
Ch
Dg
Ch
Dg 77 Br Y 74 Br
Lg/W
Lg/W
B
B/W W
Ch
(B) (B) L L Lg/W R W G

83 Y G Br
Dg
75 76 73
B R W
Ch Dg Br
L Lg/L R/L
L Y Y Br Lg/L Y Br Br B
85 B
B
Lg/L
Lg/W
Lg/L 59
87 G Y Y G
80 79 B
60 Y Y W

85 86 W B
L Br
B W/B
Br Y/B
(W) (B)
Br B B
Y/L
B B B W B
86 B B
B/W
84 W W/B B B/W
W/L
L Y/B B/R B Br Y

B B B

B B B B
B
61 61 R Lg/L Lg/W Y/L B/W
R/L Y Br W/L Y Br W B
B B

BB
B 88 (B)
B B B L/R
B B B B B B R Br G Ch Dg
B B B

62
B B B/W
B B B/W Ch W/R Dg W/L B Br R

63 64 65 66 67 68 69 70 71 72
Y/B L/R B/W G Y/W

61 61
89 Y/B

B Y/W B/W W /L W/R

GDR155-A 2021
WIRING DIAGRAM

2 3
4 5
16
6

7 8
9 10
11 12 13 18
ON
OPEN
OFF (B)
LOCK

17 19
14 (B) (B)
47
15
41 48
34
(B)
49
(B)
(R) 50
(B)
35 51
52
28 29 (R)
53
21 22
36 42
(B)
23 30 54
24 25 26 27 31 32 33 37 40
43 46
FREE ON
PUSH PUSH OFF
(B)
(B)
(B) (B)
(B) (R) (R)
38
20
55
(B)

(B)
56
39
(L) (L)

1 44
(B)
45 58 57
(B)
82 81 78 (Gy)
(B)

77 74
(B) (B)
83 75 76 73

85 59
87 80 79 60
85 86 (W) (B)

86
84

61 61
88 (B)

62

63 64 65 66 67 68 69 70 71 72
61 61
89