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# YAMAHA 2022 ## SERVICE MANUAL ### NMAX GPD155-A BBD-F8197-EK
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EAS20003 IMPORTANT This manual was produced by the PT Yamaha Indonesia Motor Manufacturing. primarily for use by Ya- maha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechan- ic 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 Ya- maha 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 injury 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 in death or serious injury. WARNING A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. NOTICE A TIP provides key information to make procedures easier or clearer. TIP GPD155-A SERVICE MANUAL ©2022 by PT Yamaha Indonesia Motor Manufacturing First edition, November 2021 All rights reserved. Any reproduction or unauthorized use without the written permission of PT Yamaha Indonesia Motor Manufacturing is expressly prohibited.
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EAS20004 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex- planations 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 EAS20046 CYLINDER AND PISTON Removing the cylinder and piston Order Q’ty Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-10. 1 Timing chain guide (exhaust side) 1 2 1 Cylinder 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 1 2nd ring 10 1 Oil ring 11 1 Coolant drain bolt (cylinder side) 5-30 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 CHECKING THE CYLINDER AND PISTON • Before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent them from falling into the crankcase. • Before removing the piston pin, deburr the pis- ton pin clip groove and the piston pin bore ar- ea. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set “4”. 1. Check: • Piston wall • Cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. Piston pin puller set 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 2. Remove: • Top ring • 2nd ring • Oil ring b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter P with the mi- TIP When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. crometer. 5-31
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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 Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium-soap-based grease T R . . Wear limit, clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent (LOCTITE®). E New Engine oil Replace the part with a new one. G M BF B LS M S LT
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TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM SELF DIAGNOSTIC 1 2 3 4 5 6 7 8 9
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# GENERAL INFORMATION ## IDENTIFICATION * VEHICLE IDENTIFICATION NUMBER ................................................................ 1-1 * ENGINE SERIAL NUMBER ............................................................................ 1-1 ## FEATURES * MULTI-FUNCTION METER UNIT .................................................................... 1-2 ## SPECIAL TOOLS .................................................................................... 1-7 1
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EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped onto the frame. 1 EAS30004 ENGINE SERIAL NUMBER The engine serial number “1” is stamped onto the crankcase. 1 1-1 IDENTIFICATION
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EAS20008 FEATURES EAS30982 MULTI-FUNCTION METER UNIT Multi-function meter unit 1 3 4 5 7 6 2 8 1. Fuel meter 2. Yamaha Motorcycle Connect icon 3. VVA (variable valve actuation) indicator 4. Clock 5. Speedometer 6. Smartphone battery level meter 7. Coolant temperature meter 8. Multi-function display EWA12423 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. The “MENU” switch is located on the left side of handlebar. This switch allows you to control or change the settings of multi-function meter unit. 1 1. “MENU” switch 1-2 FEATURES The multi-function meter unit is equipped with the following: • a speedometer • a VVA indicator • a clock • a fuel meter • a Yamaha Motorcycle Connect icon • a smartphone battery level meter • a coolant temperature meter • a multi-function display TIP Be sure to turn the main switch on before using the “MENU” switch. Yamaha Motorcycle Connect icon This icon comes on when CCU and smartphone is connected via Yamaha Motorcycle Connect. TIP 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. Smartphone battery level meter This meter indicates the current battery level of the connected smartphone. The display seg- ment of the meter disappears from full to blank as the battery level decreases. When approxi- mately 10% or less of the battery remains, the last segment starts flashing. TIP 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. Switching the display units The display units can be switched between kilo- meters and miles. To switch the display units 1. Turn the vehicle off. 2. While pushing the “MENU” switch, turn the vehicle on. 3. Continue to push the “MENU” switch until the display unit setting screen comes on (approx- imately 5 seconds). 4. Push the “MENU” switch once to switch the display units. 5. Push the “MENU” switch for 1 second to con- firm the setting.
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Speedometer The speedometer shows the vehicle’s traveling speed. Fuel meter 1 2 1. Fuel meter The fuel meter indicates the amount of fuel in the fuel tank. The display segments of the fuel meter disappear from “F” (full) towards “E” (empty) as the fuel level decreases. When approximately 1.7 L (0.45 US gal, 0.37 Imp.gal) of fuel remains, the last segment starts flashing. Refuel as soon as possible. TIP 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 ve- hicle. Clock 1 1. Clock The clock uses a 12-hour time system. To set the clock 1. Push the “MENU” switch until the hour digits start flashing. 2. Use the “MENU” switch to set the hours. 3. Push the “MENU” switch until the minute dig- its start flashing. 4. Use the “MENU” switch to set the minutes. 5. Push the “MENU” switch until the minute dig- its stop flashing. The setting is confirmed. 1-3 FEATURES TIP When CCU and smartphone is connected after vehicle power on, the clock is automatically ad- justed. Coolant temperature meter 1 1. Coolant temperature meter This meter shows the temperature of the cool- ant, and thereby the condition of the engine. The segments come on from “C” (cold) to “H” (hot) as the engine temperature increases. If the hot seg- ment flashes, stop the engine as soon as possi- ble, and let the engine cool. TIP If a problem is detected in the electrical circuit, all segments will flash repeatedly. Have a Yamaha dealer check the vehicle. VVA indicator 1 1. VVA (variable valve actuation) indicator This model is equipped with variable valve actu- ation (VVA) for good fuel economy and acceler- ation in both the low-speed and high-speed ranges. The VVA indicator comes on when the variable valve actuation system has switched to the high-speed range.
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To turn the VVA indicator on or off 1. Turn the vehicle off. 2. While pushing the “MENU” switch, turn the vehicle on. 3. Continue pushing the “MENU” switch. The display unit setting screen will come on (after 5 seconds), and after that (an additional 10 seconds) all segments other than the VVA in- dicator will start flashing. Now release 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 con- firm the setting. TIP Turning the VVA indicator off does not turn off the variable valve actuation system. Multi-function display 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 oil change tripmeter (OIL TRIP) • an oil change indicator • a V-belt replacement tripmeter (V-BELT TRIP) • a V-belt replacement indicator • an instantaneous fuel consumption display (F/ECO) • an average fuel consumption display (AVE F/ECO) • a battery voltage display (BATT) • a traction control system display (TCS) Push the “MENU” switch to change the display in the following order: ODO and F/ECO → TRIP 1 and AVE F/ECO → TRIP 2 and AVE F/ECO → TRIP F → BATT → TCS → OIL TRIP → V-BELT TRIP → ODO and F/ECO 1-4 FEATURES TIP • The fuel reserve tripmeter appears only when you are low on fuel. • The oil change tripmeter and V-belt replace- ment tripmeter are not displayed while the ve- hicle is moving. • There is an average fuel consumption display for each tripmeter (TRIP 1 and TRIP 2). When a tripmeter is reset, the average fuel consump- tion display for that tripmeter will also be reset. Odometer 1 1. Odometer The odometer shows the total distance traveled by the vehicle. TIP The odometer will lock at 999999 and cannot be reset. Tripmeters 1 1. Tripmeter The tripmeters show the distance traveled since they were last reset. To reset a tripmeter, set the display to the trip- meter you want to reset, and then push the “MENU” switch until it is reset. TIP The tripmeters will reset and continue counting after 9999.9 is reached.
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Fuel reserve tripmeter 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 counting the distance traveled from that point. To reset the fuel reserve tripmeter, push the “MENU” switch until it is reset. TIP If you do not reset the fuel reserve tripmeter manually, it will reset automatically and disap- pear from the display after refueling and travel- ing 5 km (3 mi). Oil change tripmeter 1 2 1. Oil change indicator “OIL” 2. Oil change tripmeter This tripmeter shows the distance traveled since the last engine oil change. The oil change indi- cator “OIL” will flash at the initial 1000 km (600 mi), the next 5000 km (3100 mi), and then every 6000 km (3700 mi) 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 trip- meter are flashing, push the “MENU” switch until the tripmeter is reset. 1-5 FEATURES 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. V-belt replacement tripmeter 1 2 1. V-belt replacement indicator “V-BELT” 2. V-belt replacement tripmeter This tripmeter shows the distance traveled since the V-belt was last replaced. The V-belt replace- ment indicator “V-BELT” will flash every 18000 km (11200 mi) to indicate that the V-belt should be replaced. To reset both the tripmeter and the indicator, se- lect 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 When the V-belt is replaced, the tripmeter and indicator must be reset. Otherwise, the V-belt re- placement indicator will not come on at the cor- rect time.
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Instantaneous fuel consumption display 1 1. Instantaneous fuel consumption display This display shows fuel consumption under cur- rent riding conditions. It can be set to either “km/ L” or “L/100 km”, or “MPG” when using miles. • “km/L”: the distance that can be traveled on 1.0 L of fuel. • “L/100 km”: the amount of fuel necessary to travel 100 km. • “MPG”: the distance that can be traveled on 1.0 Imp.gal of fuel. TIP When traveling under 10 km/h (6 mi/h), “_ _._” is displayed. 1-6 FEATURES Average fuel consumption display 1 1. Average fuel consumption display This display shows the average fuel consump- tion since it was last reset. The average fuel con- sumption display can be set to either “km/L” or “L/100 km”, or “MPG” when using miles. • “km/L”: the average distance that can be trav- eled on 1.0 L of fuel. • “L/100 km”: the average amount of fuel neces- sary to travel 100 km. • “MPG”: the average distance that can be trav- eled on 1.0 Imp.gal of fuel. TIP • To reset the display, push the “MENU” switch until it resets. • After resetting, “_ _._” is shown until the vehicle has traveled some distance. Battery voltage display 1 1. Battery voltage meter This display shows the current charge state of the battery. • Over 12.8 V = Full charge. • Under 12.7 V = Charging is required. TIP If the battery voltage is less than 9.0 V, “_ _._” is displayed.
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EAS20012 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. TIP • For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”. • For others, use part numbers starting with “90890-”. Tool name/Tool No. Illustration Reference pages Yamaha diagnostic tool USB 90890-03267 3-4, 3-7, 4-63, 4-64, 7-15, 7-16, 9-3, 9-20, 9-21 Yamaha diagnostic tool (A/I) 90890-03264 3-4, 3-7, 4-63, 4-64, 7-15, 7-16, 9-3, 9-20, 9-21 Tappet adjusting tool 90890-01311 Six piece tappet set YM-A5970 YM-A5970 Steering nut wrench 90890-01403 Exhaust flange nut wrench YU-A9472 Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 1-7 SPECIAL TOOLS 3-7 ø9 ø8 ø10 ø3 ø4 3-16, 3-17, 4-83 4-28 4-77, 4-78
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SPECIAL TOOLS | Tool name/Tool No. | Illustration | Reference pages | | :----------------------------------------------------------- | :----------- | :-------------- | | Fork seal driver weight<br>90890-01367<br>Replacement hammer<br>YM-A9409-7 | | 4-78, 4-79 | | Fork seal driver attachment (ø30)<br>90890-01400 | | 4-78, 4-79 | | Compression gauge<br>90890-03081<br>Engine compression tester<br>YU-33223 | | 5-2 | | Compression gauge extension 122mm<br>90890-04136<br>Compression gauge extension 122mm<br>YM-04136 | | 5-2 | | Camshaft wrench<br>90890-04162<br>Camshaft wrench<br>YM-04162 | | 5-14, 5-18 | | Yamaha bond No. 1215<br>90890-85505<br>Three bond No. 1215® | | 5-17, 5-59 | | Slide hammer bolt (M8)<br>90890-01085<br>Slide hammer bolt 8 mm<br>YU-01083-2 | | 5-21 | 1-8
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## SPECIAL TOOLS | Tool name/Tool No. | Illustration | Reference pages | | :--------------------------------------- | :----------- | :-------------- | | Weight | | 5-21 | | 90890-01084 | | | | Weight | | | | YU-01083-3 | | | | Valve spring compressor | | 5-25, 5-30 | | 90890-04019 | | | | Valve spring compressor | | | | YM-04019 | | | | Valve spring compressor attachment | | 5-25, 5-30 | | 90890-04108 | | | | Valve spring compressor adapter 22 mm | | | | YM-04108 | | | | Valve guide remover (ø5) | | 5-27 | | 90890-04097 | | | | Valve guide remover (5.0 mm) | | | | YM-04097 | | | | Valve guide installer (ø5) | | 5-27 | | 90890-04098 | | | | Valve guide installer (5.0 mm) | | | | YM-04098 | | | | Valve guide reamer (ø5) | | 5-27 | | 90890-04099 | | | | Valve guide reamer (5.0 mm) | | | | YM-04099 | | | | Piston pin puller set | | 5-32 | | 90890-01304 | | | | Piston pin puller | | | | YU-01304 | | | 1-9
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Tool name/Tool No. Illustration Reference pages Rotor holding tool (including handle and 3 pins) 90890-04195 Rotor holding tool attachment 7 x 12 mm 90890-04197 5-40, 5-46 Rotor holding tool 90890-04166 Rotor holding tool YM-04166 Socket wrench (39 mm) 90890-01493 5-40, 5-44 Sheave spring compressor 90890-04134 Sheave spring compressor YM-04134 Sheave fixed block 90890-04135 Sheave fixed bracket YM-04135 Oil seal guide (37 mm) 90890-04177 5-43 1-10 SPECIAL TOOLS 5-40, 5-46, 5-48, 5-48 ø7 12 5-40, 5-40, 5-44, 5-45 5-41, 5-44 5-41, 5-44 ø37
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## SPECIAL TOOLS | Tool name/Tool No. | Illustration | Reference pages | | :------------------------------------- | :----------- | :-------------- | | Rotor holding tool attachment 7 x 5 mm 90890-04198 | | 5-48, 5-48 | | Flywheel puller 90890-01189 Flywheel puller YM-01189 | | 5-48 | | Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B | | 5-57 | | Crankshaft installer pot 90890-01274 Installing pot YU-90058 | | 5-59 | | Crankshaft installer bolt 90890-01275 Bolt YU-90060 | | 5-59 | | Adapter (M12) 90890-01278 Adapter #3 YU-90063 | | 5-59 | 1-11
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# SPECIAL TOOLS | Tool name/Tool No. | Illustration | Reference pages | | :--------------------------------------------------- | :-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- | :-------------- | | Spacer (crankshaft installer) | 90890-04081 | 5-59 | | 90890-04081 | YM-91044 | | | Pot spacer | | | | YM-91044 | | | | Radiator cap tester | 90890-01325 | 6-4, 6-4 | | 90890-01325 | YU-24460-A | | | Mityvac cooling system tester kit | | | | 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 | | | | 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 | | | 1-12
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Tool name/Tool No. Illustration Reference pages Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 90890-06754 Oppama pet–4000 spark checker YM-34487 1-13 SPECIAL TOOLS 8-36, 8-38, 8-39, 8-39, 8-39, 8-40, 8-41, 8-41, 8-42, 8-42, 8-43, 8-43 8-40
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## SPECIFICATIONS GENERAL SPECIFICATIONS ............................................................................................ 2-1 ENGINE SPECIFICATIONS ............................................................................................... 2-2 CHASSIS SPECIFICATIONS .............................................................................................. 2-6 ELECTRICAL SPECIFICATIONS .......................................................................................... 2-8 TIGHTENING TORQUES .................................................................................................... 2-10 ENGINE TIGHTENING TORQUES ................................................................................ 2-10 CHASSIS TIGHTENING TORQUES ............................................................................. 2-12 CABLE ROUTING .............................................................................................................. 2-15
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GENERAL SPECIFICATIONS EAS20013 **GENERAL SPECIFICATIONS** **Model** Model BBDC **Dimensions** Overall length 1935 mm (76.2 in) Overall width 740 mm (29.1 in) Overall height 1160 mm (45.7 in) Wheelbase 1340 mm (52.8 in) Ground clearance 125 mm (4.92 in) Minimum turning radius 2.0 m (6.56 ft) **Weight** Curb weight 131 kg (289 lb) **Loading** Maximum load 167 kg (368 lb) Riding capacity 2 person 2-1
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EAS20014 ENGINE SPECIFICATIONS Engine Combustion cycle 4-stroke Cooling system Liquid cooled Valve train SOHC Displacement 155 cm³ Number of cylinders Single cylinder Bore × stroke 58.0 × 58.7 mm (2.28 × 2.31 in) 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) Fuel Recommended fuel Regular unleaded gasoline (E10 acceptable) Fuel tank capacity 7.1 L (1.9 US gal, 1.6 Imp.gal) Fuel reserve amount 1.7 L (0.45 US gal, 0.37 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 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9 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) 2-2 ENGINE SPECIFICATIONS
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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 limit (Intake) 32.111 mm (1.2642 in) Lobe height limit (Intake high speed) 32.487 mm (1.2790 in) Lobe height limit (Exhaust) 29.320 mm (1.1543 in) Rocker arm/rocker arm shaft Rocker arm inside diameter limit 10.015 mm (0.3943 in) Rocker arm shaft outside diameter 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 limit (intake) 1.3 mm (0.05 in) Valve seat contact width limit (exhaust) 1.7 mm (0.07 in) Valve stem diameter limit (intake) 4.945 mm (0.1947 in) Valve stem diameter limit (exhaust) 4.930 mm (0.1941 in) Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in) Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in) Valve-stem-to-valve-guide clearance limit (intake) 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance limit (exhaust) 0.100 mm (0.0039 in) Valve stem runout 0.020 mm (0.0008 in) Valve spring Free length limit (intake) 32.10 mm (1.26 in) Free length limit (exhaust) 32.10 mm (1.26 in) Cylinder Bore 58.000–58.010 mm (2.2835–2.2839 in) Wear limit 58.060 mm (2.2858 in) Piston 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 limit 14.043 mm (0.5529 in) Piston pin outside diameter limit 13.975 mm (0.5502 in) 2-3 ENGINE SPECIFICATIONS
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# ENGINE SPECIFICATIONS --- ### Piston ring * **Top ring** * End gap limit: 0.50 mm (0.0197 in) * Side clearance limit: 0.115 mm (0.0045 in) * **2nd ring** * End gap limit: 0.85 mm (0.0335 in) * Side clearance limit: 0.115 mm (0.0045 in) --- ### 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 limit: 2.1 mm (0.08 in) * Clutch housing inside diameter limit: 125.5 mm (4.94 in) * Compression spring free length limit: 104.7 mm (4.12 in) * Weight outside diameter limit: 19.5 mm (0.77 in) * Clutch-in revolution: 2200–2600 r/min * Clutch-stall revolution: 4700–5300 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 * Secondary reduction ratio: 10.208 (56/16 x 35/12) * Transmission ratio: 2.239–0.706 : 1 --- ### Air filter * Air filter element: Oil-coated paper element * V-belt filter element: Wet element --- ### Fuel injector * Resistance: 12.2 Ω --- ### 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 (3.88–4.12 V at 1.01 kgf/cm², 3.88–4.12 V at 14.7 psi) * Coolant temperature sensor resistance: 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F) * Coolant temperature sensor resistance: 210–221 Ω at 100 °C (210–221 Ω at 212 °F) --- 2-4
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ENGINE SPECIFICATIONS ___ **Idling condition** Engine idling speed O2 feedback control Coolant temperature CO% Fuel line pressure (at idle) Throttle grip free play 1500–1700 r/min Active 85 °C (185 °F) 0.0–1.0 % 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi) 3.0–5.0 mm (0.12–0.20 in) 2-5
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# CHASSIS SPECIFICATIONS EAS20015 ## CHASSIS SPECIFICATIONS ### Chassis * Caster angle: 26.5 ° * Trail: 100 mm (3.9 in) ### Front wheel * Wheel type: Cast wheel * Rim size: J13M/C x MT3.00 * 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: J13M/C x 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: 110/70-13M/C 48P * Manufacturer/model: DUNLOP/SCOOT SMART L ### Rear tire * Type: Tubeless * Size: 130/70-13M/C 63P * Manufacturer/model: DUNLOP/SCOOT SMART L ### Tire air pressure (measured on cold tires) * **1 person** * Front: 150 kPa (1.50 kgf/cm², 22 psi) * Rear: 250 kPa (2.50 kgf/cm², 36 psi) * **2 persons** * Front: 150 kPa (1.50 kgf/cm², 22 psi) * Rear: 250 kPa (2.50 kgf/cm², 36 psi) ### Front brake * Brake disc thickness limit: 3.5 mm (0.14 in) * Brake disc runout limit (as measured on wheel): 0.15 mm (0.0059 in) * Brake pad lining thickness limit: 0.8 mm (0.03 in) * Master cylinder inside diameter: 11.00 mm (0.43 in) * Caliper cylinder inside diameter (Right): 33.34 mm (1.31 in) * Specified brake fluid: DOT 4 2-6
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Rear brake Brake disc thickness limit 4.0 mm (0.16 in) Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in) Brake pad lining thickness limit 0.8 mm (0.03 in) Master cylinder inside diameter 12.7 mm (0.50 in) Caliper cylinder inside diameter 33.34 mm (1.31 in) Specified brake fluid DOT 4 Front suspension Shock absorber Hydraulic damper Fork spring free length limit 235.6 mm (9.28 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil G10 Quantity (left) 89.0 cm³ (3.01 US oz, 3.14 Imp.oz) Quantity (right) 89.0 cm³ (3.01 US oz, 3.14 Imp.oz) Level (left) 77 mm (3.1 in) Level (right) 77 mm (3.1 in) Rear suspension Shock absorber Hydraulic damper Spring preload Unit for adjustment Cam position Adjustment value (STD) 1 Adjustment value (Hard) 2 2-7 CHASSIS SPECIFICATIONS
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EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Engine control unit Model TBDY88 Ignition system 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 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 Turn signal indicator light LED High beam indicator light LED Stop and Start System indicator light LED ABS warning light LED Smart key system indicator light LED Traction control system indicator light LED Engine trouble warning light LED Fuel sender unit Sender unit resistance (full) 10.0–14.0 Ω Sender unit resistance (empty) 267.0–273.0 Ω 2-8 ELECTRICAL SPECIFICATIONS
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# ELECTRICAL SPECIFICATIONS ## Fuse(s) | Fuse Type | Amperage | | :-------------------------- | :------- | | 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 1 | 5.0 A | | Backup fuse | 7.5 A | | ABS motor fuse | 30.0 A | | ABS solenoid fuse | 15.0 A | | ABS control unit fuse | 2.0 A | | Smart key system fuse | 2.0 A | 2-9
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EAS20017 TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES | Item | Thread size | Q'ty | Tightening torque | Remarks | | :--------------------------------------- | :---------- | :--- | :-------------------------------- | :------------------------------------------ | | 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) | | | 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) solenoid bolt | M6 | 2 | 10 N·m (1.0 kgf·m, 7.4 lb·ft) | | | 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 pipe) | M8 | 2 | 15 N·m (1.5 kgf·m, 11 lb·ft) | | | 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 locknut | M5 | 4 | 7 N·m (0.7 kgf·m, 5.2 lb·ft) | | | Timing chain tensioner bolt | M6 | 2 | 10 N·m (1.0 kgf·m, 7.4 lb·ft) | Yamaha 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 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) | | | 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) | | 2-10
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# TIGHTENING TORQUES | Item | Thread size | Q'ty | Tightening torque | Remarks | | :-------------------------------------- | :---------- | :--- | :-------------------------------- | :------ | | V-belt case air filter element cover bolt | M6 | 6 | 7 N·m (0.7 kgf·m, 5.2 lb·ft) | | | 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:  2-11
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# TIGHTENING TORQUES ## EAS30017 CHASSIS TIGHTENING TORQUES | Item | Thread size | Q'ty | Tightening torque | Remarks | |---|---|---|---|---| | 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 bolt | M6 | 2 | 16 N·m (1.6 kgf·m, 12 lb·ft) | | | Front brake hose union bolt (master cylinder side) | M10 | 1 | 29 N·m (2.9 kgf·m, 21 lb·ft) | | | Rear brake hose union bolt (master cylinder side) | M10 | 1 | 29 N·m (2.9 kgf·m, 21 lb·ft) | | | Throttle cable holder bolt (handlebar switch side) | M5 | 1 | 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) | | | Rear brake master cylinder holder bolt | M6 | 2 | 16 N·m (1.6 kgf·m, 12 lb·ft) | | | 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) | [circled S symbol] | | 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 caliper side) | M10 | 1 | 29 N·m (2.9 kgf·m, 21 lb·ft) | | | 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) | [circled S symbol] | | Front wheel sensor rotor bolt | M5 | 3 | 8 N·m (0.8 kgf·m, 5.9 lb·ft) | [circled S symbol] | | Rear brake disc bolt | M8 | 3 | 23 N·m (2.3 kgf·m, 17 lb·ft) | [circled S symbol] | | Rear brake caliper bolt | M10 | 2 | 35 N·m (3.5 kgf·m, 26 lb·ft) | | | Rear wheel axle nut | M16 | 1 | 125 N·m (12.5 kgf·m, 92 lb·ft) | | | Rear shock absorber assembly nut | M10 | 2 | 21 N·m (2.1 kgf·m, 15 lb·ft) | | | Rear shock absorber assembly bolt | M8 | 2 | 21 N·m (2.1 kgf·m, 15 lb·ft) | | | Swingarm mounting bolt | M10 | 2 | 57 N·m (5.7 kgf·m, 42 lb·ft) | | 2-12
Halaman 36
Item Thread size Q’ty Tightening torque Remarks 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) 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. 2-13 TIGHTENING TORQUES LT
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TIGHTENING TORQUES ___ 2-14
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2-15 CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) A A B C 1 1 1 7 2 2 2 3 4 5 5 4 6
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1. Front brake hose 2. Rear brake hose 3. Rear brake light switch lead 4. Throttle cable (decelerator cable) 5. Throttle cable (accelerator cable) 6. Front brake light switch lead 7. Accessories coupler A. 15° – 25° B. Insert the projection on the wire harness holder into the hole in the lower handlebar cover. C. Route the throttle cables through the hole in the lower handlebar cover. 2-16 CABLE ROUTING
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Handlebar (side view) 5 1 5 2 1 3 4 2 3 4 B 1 A 2-17 CABLE ROUTING 2 3 4
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1. Rear brake hose 2. Throttle cable (decelerator cable) 3. Throttle cable (accelerator cable) 4. Wire harness 5. Front brake hose A. Route the throttle cable (accelerator cable) to the outside of the throttle cable (deceler- ator cable). B. Insert the projection on the wire harness holder into the hole in the bracket. 2-18 CABLE ROUTING
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2-19 CABLE ROUTING Front frame (front and left side view) 10 18 20 3 3 1 2 3 4 5 6 7 9 8 A B B 11 12 C 9 11 12 9 10 3 4 13 3 4 14 10 6 15 E F 16 G 20 22 23 7 24 5 D 7 6 26 21 18 20 H 6 26 25 27 25 26 8 7 6 25 13 28 I J 29 13 17 18 19
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1. Front side cowling (right) 2. Meter assembly lead 3. Headlight lead 4. Buzzer lead 5. Fuse box 6. Front wheel sensor lead 7. Front brake hose (hydraulic unit to front brake caliper) 8. Hydraulic unit assembly 9. SGCU (Starter Generator Control Unit) 10. Front turn signal light lead (front right turn signal light) 11. Starter charger relay 12. Main relay 13. Front turn signal light lead (front left turn signal light) 14. Meter assembly 15. Auxiliary DC jack lead 16. Auxiliary DC jack 17. Main switch 18. Seat lock cable 19. Fuel tank cap lid lock cable 20. Frame ground lead 21. Main switch steering lock assy 22. Throttle cable (accelerator) 23. Throttle cable (decelerator) 24. Frame 25. Rear brake hose (rear brake master cylin- der to hydraulic unit) 26. Front brake hose (front brake master cylin- der to hydraulic unit) 27. Wire harness 28. Headlight unit 29. Front turn signal light A. Insert the projection of clamp wire harness into the hole of front side cowling (right). B. Insert the projection of clamp wire harness into the hole of stay. C. Make sure the white connector of wire har- ness shall be connected to relay with white paint. D. Make sure the protrusion of wire harness shall be assembled to the stay. E. Make sure the auxiliary DC jack coupler shall be assembled to protrusion of the front side cowling (left). F. Insert the projection of clamp wire harness into the hole of frame. G. Make sure the stopper of seat lock cable and fuel tank cap lid lock cable shall be assembled to the main switch. H. Insert the projection of clamp front wheel sensor into the hole of stay. 2-20 CABLE ROUTING I. Route the headlight lead through the head- light lead guide (two places). J. Route the front turn signal light lead (front left turn signal light) through the guide of front side panel (left).
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2-21 CABLE ROUTING Front fork (rear and right side view) A B C D E F G H 1 2 2 2 3 3 4 4 B C 2 4 4 4 2 2 4 5 5 6
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1. Front wheel sensor 2. Front wheel sensor lead 3. Front brake caliper 4. Front brake hose 5. Horn 6. Front brake hose holder A. Route the front brake hose through the guide. B. Backward C. Frontward D. Install the horn fit to the frame. E. Install the guide fit to the lower bracket. F. The front brake hose and front wheel sen- sor lead should be passed through the vehicle rear side of the guide. G. Inward H. Outward 2-22 CABLE ROUTING
Halaman 46
# CABLE ROUTING ## Frame (left side view) ### Key Labels and Components * **Boxed Letter Labels:** A, B, C, D, E, F, G, H, I, J, K * **Circled Number Labels:** ①, ②, ③, ④, ⑤, ⑥, ⑦, ⑧, ⑨, ⑩, ⑪, ⑫, ⑬ --- ### Inset Details #### Top Inset (E) * Labels: **E**, ①, ② #### Top Inset (F, G, H) * Labels: **F**, **G**, **H**, ③, ④, ⑧ #### Upper Right Inset (I) * Labels: **I**, ⑧ #### Middle Right Inset (B) * Labels: ①, ②, ③, ④, ⑨, ⑩ #### Left Inset (K - Horn Assembly) * Labels: **K**, ⑫, ⑬ #### Middle Left Inset (D, C) * Labels: **D**, **C**, ①, ②, ⑥, ⑦, ⑫ #### Lower Left Inset * Labels: ①, ②, ⑥, ⑦, ⑫ #### Lower Right Inset (J) * Labels: **J**, ①, ②, ⑥, ⑪ #### Bottom Center Inset * Labels: ⑥ #### Bottom Right Inset * Labels: ①, ②, ⑫ --- **2-23**
Halaman 47
1. Throttle cable (decelerator cable) 2. Throttle cable (accelerator cable) 3. Fuel tank cap lid lock cable 4. Seat lock cable 5. Fuel tank overflow tray 6. Sidestand switch lead 7. Fuel tank overflow hose 8. Main switch cover 9. Wire harness 10. Frame ground lead 11. Fuel hose 12. Frame 13. Horn A. Insert the projection on the seat lock cable clamp into the hole in the inner panel. B. Clamp in the fuel tank cap lid lock cable shall be assembled into the inner panel. And the fuel tank cap lid lock cable with white tape is fixed on the front side of the vehicle. Do not cross the fuel tank cap lid lock cable and seat lock cable. C. Install the fuel tank overflow hose so that this part of the fuel tank overflow hose comes to the bottom than clamp. D. Insert the projection on the wire harness into the hole in the frame. E. Install the throttle cable grommet into guide of frame. F. Pass the wire seat lock and fuel tank lid lock cable in upper the main switch cover. G. Push the coupler to forward of vehicle. H. Tighten the bolt while pressing the terminal against the projection of the frame. I. Insert the projection on the wire harness clamp into the hole in the main switch cover. J. Install the fuel hose grommet into guide of frame. K. Install the horn leads in any direction. 2-24 CABLE ROUTING
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# CABLE ROUTING ## Frame (left side view) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) A B C D E F G H I J K L M N O P 2-25
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1. Seat lock cable 2. Smart key unit lead 3. Fuel hose 4. Throttle cable (accelerator cable) 5. Throttle cable (decelerator cable) 6. Starter generator lead 7. O2 sensor lead 8. Throttle body sensor assembly 9. Engine ground lead 10. Injector lead 11. Positive battery lead 12. Yamaha diagnostic tool coupler lead 13. Negative battery lead 14. Wire harness 15. Rear brake hose 16. Rear wheel sensor lead 17. Frame A. Insert the projection on the seat lock cable clamp into the hole in the storage box. B. Insert the projection on the seat lock cable clamp into the hole in the frame. C. Pass the seat lock cable in groove of the rear fender. D. Insert the throttle cable into the clamp. E. Insert the wire harness clamp into the plate. F. Insert the O2 sensor connector into the holder. G. Insert the projection on the seat lock cable clamp into the hole in the bracket. H. Pass the wire harness inside of frame. I. Insert the projection on the wire. J. Insert the projection of clamp wire harness into the hole of the battery stay. K. Pass the wire harness in the inside of frame. L. Insert the projection of clamp wire harness into the hole of the ignition coil stay. M. Pass the coolant reservoir hose in upper side of the holder. N. Insert the projection of clamp wire harness into the hole of the guide. O. Pass the wire harness in the inside of pillar guide. P. Insert the projection of clamp wire harness into the hole of the frame. 2-26 CABLE ROUTING
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2-27 CABLE ROUTING Frame (right side view) A A A B 1 2 3 4 5 7 7 8 9 9 10 10 10 10 1 1 14 6 11 3 2 A
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1. CCU (Communication Control Unit) 2. Positive battery lead 3. Ignition coil 4. Joint 5. Frame ground lead 6. Hydraulic unit assembly 7. Wire harness 8. Footrest board 9. Coolant reservoir breather hose 10. Frame 11. Fuel pump lead 12. Starter generator lead 13. Wire harness (to battery) 14. Wire harness (to engine) A. Insert the projection on the wire harness into the hole in the frame. B. White paint portion of the coolant reservoir breather hose and clamp location should be combined. 2-28 CABLE ROUTING
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Frame (right side view) 1 A 7 5 C 6 2-29 CABLE ROUTING 4 4 B B 1 2 3
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1. Frame ground lead 2. Wire harness 3. Coolant temperature sensor lead 4. Frame 5. Rear fender 6. License light lead 7. O2 sensor lead A. Pass the wire harness in groove of the rear fender. B. Insert the projection on the wire harness clamp into the hole in the frame. C. Pass the license light lead before assem- bled the rear fender. 2-30 CABLE ROUTING
Halaman 54
Hydraulic unit (top and right side view) 5 3 4 5 1 7 6 2-31 CABLE ROUTING 1 2 A 2 3 4
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1. Hydraulic unit assembly 2. Rear brake hose (hydraulic unit to rear brake caliper) 3. Rear brake hose (rear brake master cylin- der to hydraulic unit) 4. Front brake hose (front brake master cylin- der to hydraulic unit) 5. Front brake hose (hydraulic unit to front brake caliper) 6. Main switch lead 7. Hydraulic unit assembly lead A. Insert the projection of claim wire harness into the hole of stay. 2-32 CABLE ROUTING
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CABLE ROUTING Rear brake (right side view) D E F C A B ⑤ ROTATION ⑤ ③ ② ⑧ ③ ⑦ ② G 2-33
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1. Rear brake caliper 2. Rear brake hose 3. Rear wheel sensor lead 4. Radiator 5. Coolant reservoir hose 6. Swingarm 7. Radiator fan cover 8. Rear brake hose bracket 9. Rear brake hose holder A. Turn the clip to the left side of the vehicle. The clip shall not be on the spool. B. Turn the white paint mark to upper side of the vehicle and insert the hose until the radiator assy. C. Connect the coolant reservoir hose to the radiator, and then fasten the hose by inserting the projection on the holder into the hole in the rear brake hose bracket. D. Position the clamp within the range shown in the illustration. E. Upward F. Downward G. The rear brake hose should be passed through the guide. 2-34 CABLE ROUTING
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Fuel tank (top and bottom view) A 4 3 2 D 1 8 E 5 6 2-35 CABLE ROUTING 1 7 C 4 B
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1. Rear brake hose 2. Coolant reservoir cap 3. Coolant reservoir breather hose 4. Rear wheel sensor lead 5. Coolant reservoir hose 6. Fuel hose 7. Clamp 1 8. Clamp 2 A. Install the coolant reservoir cap as shown in the illustration. B. Rear wheel sensor lead between the clamp 1 and clamp 2 is gotten rid of the slack by sliding the clamp 2 toward the arrow mark. After adjustment, the rear wheel sensor lead shall be placed between the upper limit line and lower limit line. C. Slide direction D. Upper limit line E. Lower limit line 2-36 CABLE ROUTING
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# CABLE ROUTING ## Fuel tank (right side view) ### Main Diagram * 1 * 2 * 3 * 4 * 5 * 6 * 7 * 8 * A * B * C * D ### Detailed Views * **Fuel Tank Top Section:** * 9 * E * 7 * 8 * 10 * **Top Middle Clamp Detail:** * H * 5 * I * **Top Right Clamp Details:** * F * 4 * G * 3 * F * G * 4 * 3 * **Bottom Left Bracket Detail:** * 1 * 4 * 3 * **Bottom Middle Routing Detail:** * K * 5 * 12 * 7 * J * **Bottom Right Component Detail:** * 6 * 11 2-37
Halaman 61
1. Ignition coil 2. Ignition coil cord 3. Rear brake hose 4. Rear wheel sensor lead 5. Coolant reservoir breather hose 6. Inner fender 7. Coolant reservoir hose 8. Fuel hose 9. Frame 10. Engine 11. Fuel tank overflow hose 12. Coolant reservoir A. Install the coolant reservoir breather hose on the frontward of vehicle. B. Install the fuel hose grommet into guide of frame. C. Install the coolant reservoir hose so that the hose protector is back of the guide wire. D. Insert the projection on the ignition coil clamp into the hole in the frame. E. Install the curved part of the coolant reser- voir hose as close to the outside of the vehicle. F. Upward G. Downward H. Face the white paint mark on the recovery tank upward. I. Install the knob of coolant reservoir cap as shown in illustration. J. Face the white paint mark on the hose upward. K. Install the coolant reservoir hose fit to the coolant reservoir. 2-38 CABLE ROUTING
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2-39 CABLE ROUTING Canister 1 2 A B D 1 2 4 5 3 6 2 1 7 8 C 3 2 3 1 L 2 14 9 10 E 4 M F 4 B O N 10 11 12 G 13 5 5 2 6 C A I H K 15
Halaman 63
1. Fuel tank breather hose (fuel tank to roll- over valve) 2. Fuel tank breather hose (rollover valve to canister) 3. Rollover valve 4. Canister breather hose 5. Canister purge hose 6. Frame 7. Main switch lead 8. Frame ground lead 9. Fuel hose 10. Canister 11. Throttle body assembly 12. Canister purge hose guide 13. Main switch cover 14. Fuel pump lead 15. Coolant reserver breather hose A. Face the white paint mark on the hose to the right. Install the hose completely onto the hose fitting. B. Point the ends of the hose clamp to the right of the vehicle. C. Face the yellow paint mark on the hose to the rear of the vehicle. Install the hose completely onto the hose fitting. D. Route the fuel tank breather hose (rollover valve to canister) grommet fit in the notch of portion of the flange of fuel tank. E. Face the white paint mark on the hose to the upper. Install the hose completely onto the hose fitting. F. Insert the projection of clamp the canister breather hose in to the hole of frame. G. Face the white paint mark on the hose to the rear and shall be located on this range. H. Upward I. Downward J. Put the rollover valve through the clamp to the main switch cover at rivet. K. Insert the canister breather hose to the hole of frame. L. Pass the roll over valve to the clamp and fasten it with rivet to the main switch cover. M. Direction of the clamp insertion should be aligned with white paint mark of the canis- ter breather hose. N. Face the white paint mark to the right. O. Face the hose clip to the lower direction. 2-40 CABLE ROUTING
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2-41 CABLE ROUTING Radiator (top and right side view) A A A A A B D E D E D F D E G F D F M L D F M L J K 1 1 2 2 2 3 3 4 4 5 5 6 6 7 7 H I I C C
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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 2-42 CABLE ROUTING
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Air filter case (top and left side view) A 3 3 2 2 B C A B C F 1 E A C 2-43 CABLE ROUTING 1 2 C D 3 A
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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 out- ward. E. 5–6 mm (0.20–0.24 in) F. 1–5 mm (0.04–0.20 in) 2-44 CABLE ROUTING
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# CABLE ROUTING --- 2-45
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PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ............................................................................3-1 INTRODUCTION.......................................................................................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM.............................................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL............................................3-4 CHECKING THE FUEL LINE ....................................................................3-4 CHECKING THE SPARK PLUG ...............................................................3-5 ADJUSTING THE VALVE CLEARANCE ..................................................3-6 CHECKING THE ENGINE IDLING SPEED ..............................................3-7 CHECKING THE EXHAUST SYSTEM......................................................3-8 CHECKING THE CANISTER ....................................................................3-8 REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE......................................................3-8 CHECKING THE BREATHER HOSES .....................................................3-9 CLEANING THE V-BELT CASE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE....................................................3-10 CHECKING THE BRAKE OPERATION..................................................3-11 CHECKING THE FRONT BRAKE PADS................................................3-11 CHECKING THE REAR BRAKE PADS ..................................................3-11 CHECKING THE BRAKE FLUID LEVEL.................................................3-11 CHECKING THE FRONT BRAKE HOSES .............................................3-12 CHECKING THE REAR BRAKE HOSES................................................3-12 BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-12 CHECKING THE WHEELS .....................................................................3-14 CHECKING THE TIRES..........................................................................3-14 CHECKING THE WHEEL BEARINGS....................................................3-15 CHECKING AND ADJUSTING THE STEERING HEAD .........................3-16 LUBRICATING THE STEERING HEAD..................................................3-17 CHECKING THE CHASSIS FASTENERS..............................................3-17 LUBRICATING THE LEVERS.................................................................3-17 CHECKING THE SIDESTAND................................................................3-17 LUBRICATING THE SIDESTAND...........................................................3-17 CHECKING THE CENTERSTAND .........................................................3-17 LUBRICATING THE CENTERSTAND ....................................................3-17 CHECKING THE SIDESTAND SWITCH.................................................3-17 CHECKING THE FRONT FORK.............................................................3-18 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................3-18 CHECKING THE ENGINE OIL LEVEL....................................................3-18 CHANGING THE ENGINE OIL ...............................................................3-19 CHECKING THE COOLANT LEVEL.......................................................3-20 CHECKING THE COOLING SYSTEM....................................................3-21 CHANGING THE COOLANT...................................................................3-21 CHANGING THE FINAL TRANSMISSION OIL.......................................3-24 REPLACING THE V-BELT......................................................................3-24 CHECKING THE BRAKE LIGHT SWITCHES.........................................3-25 CHECKING AND LUBRICATING THE CABLES ...................................3-25 CHECKING THE THROTTLE GRIP OPERATION .................................3-25 CHECKING THE SWITCHES, LIGHTS AND SIGNALS .........................3-26 3
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ADJUSTING THE HEADLIGHT BEAM ...................................................3-26
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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. TIP • The annual checks must be performed every year, except if a distance-based maintenance is performed instead. • From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. EAS30614 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ODOMETER READING ANNUAL CHECK 1000 km (600 mi) 6000 km (3500 mi) 12000 km (7000 mi) 18000 km 10500 mi) 24000 km (14000 mi) No. ITEM CHECK OR MAINTENANCE JOB 1 * Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary. √ √ √ √ √ 2 Spark plug • Check condition. • Adjust gap and clean. √ √ • Replace. √ √ 3 * Valve clearance • Check and adjust. √ √ √ √ 4 * Fuel injection • Check engine idle speed. √ √ √ √ √ √ 5 * Exhaust system • Check for leakage. • Tighten if necessary. • Replace gasket if necessary. √ √ √ √ √ 6 * Evaporative emis- sion control sys- tem • Check control system for damage. • Replace if necessary. √ √ EAS30615 GENERAL MAINTENANCE AND LUBRICATION CHART ODOMETER READING ANNUAL CHECK 1000 km (600 mi) 6000 km (3500 mi) 12000 km (7000 mi) 18000 km (10500 mi) 24000 km (14000 mi) No. ITEM CHECK OR MAINTENANCE JOB • Perform dynamic inspection using Yamaha diagnostic tool. • Check the error codes. √ √ √ √ √ √ 1 * Diagnostic sys- tem check 2 * Air filter element • Replace. Every 18000 km (10500 mi) 3 Air filter case check hose • Clean. √ √ √ √ √ 4 * V-belt case air fil- ter element • Clean. • Replace if necessary. √ √ √ √ √ 5 * Battery • Check voltage. • Charge if necessary. √ √ √ √ √ √ • Check operation, fluid level, and for fluid leakage. • Replace brake pads if neces- sary. 6 * Front brake √ √ √ √ √ √ 3-1 PERIODIC MAINTENANCE
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ODOMETER READING ANNUAL CHECK 1000 km (600 mi) 6000 km (3500 mi) 12000 km (7000 mi) 18000 km (10500 mi) 24000 km (14000 mi) No. ITEM CHECK OR MAINTENANCE JOB • Check operation, fluid level, and for fluid leakage. • Replace brake pads if neces- sary. 7 * Rear brake √ √ √ √ √ √ 8 * Brake hose • Check for cracks or damage. √ √ √ √ √ • Replace. Every 4 years 9 * Brake fluid • Change. Every 2 years 10 * Wheels • Check runout and for damage. • Replace if necessary. √ √ √ √ • Check tread depth and for damage. • Replace if necessary. • Check air pressure. • Correct if necessary. 11 * Tires 12 * Wheel bearings • Check bearing for looseness or damage. √ √ √ √ • Check bearing assemblies for looseness. √ √ √ √ 13 * Steering bearings • Moderately repack with lithi- um-soap-based grease. √ 14 * Chassis fasteners • Make sure that all nuts, bolts and screws are properly tight- ened. √ √ √ √ √ 15 Front and rear brake lever pivot shaft • Lubricate with silicone grease. √ √ √ √ √ • Check operation. • Lubricate with lithium-soap- based grease. √ √ √ √ √ 16 Sidestand, center- stand 17 * Sidestand switch • Check operation and replace if necessary. √ √ √ √ √ √ 18 * Front fork • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ • Check operation and for oil leakage. • Replace if necessary. √ √ √ √ 19 * Shock absorber assemblies • Change (warm engine before draining). • Check oil level and vehicle for oil leakage. At the initial interval and when the oil change indicator flash- es or comes on. √ 20 Engine oil 21 * Engine oil strainer • Clean. √ 22 * Final transmis- sion oil • Check vehicle for oil leakage. √ √ √ √ √ • Change. √ √ √ 23 * Cooling system • Check coolant level and vehi- cle for coolant leakage. √ √ √ √ √ • Change. Every 3 years 24 * V-belt • Replace. When the V-belt replacement indicator flashes or comes on. 25 * Front and rear brake switches • Check operation. √ √ √ √ √ √ 26 * Moving parts and cables • Lubricate. √ √ √ √ √ • Check operation and free play. • Adjust the throttle cable free play if necessary. • Lubricate the throttle grip housing and cable. 27 * Throttle grip housing and cable 28 * Lights, signals and switches • Check operation. • Adjust headlight beam. √ √ √ √ √ √ 3-2 PERIODIC MAINTENANCE √ √ √ √ √ √ √ √ √ √
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TIP • Engine air filter and V-belt air filter • This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. • The engine air filter element needs to be replaced and the V-belt air filter element needs to be ser- viced more frequently when riding in unusually wet or dusty areas. • Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required. • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged. 3-3 PERIODIC MAINTENANCE
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EAS32024 CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC TOOL Use the Yamaha diagnostic tool and check the vehicle according to the following procedure. 1. Remove: • Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1. 2. Disconnect the Yamaha diagnostic tool cou- pler from the CCU (Communication Control Unit) “1”, and then connect the Yamaha diag- nostic tool to the coupler. Yamaha diagnostic tool USB 90890-03267 Yamaha diagnostic tool (A/I) 90890-03264 1 3. Check: • Fault code TIP Use the “Diagnosis of malfunction” function of the Yamaha diagnostic tool to check the fault codes. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. Fault code number is displayed → Check and repair the probable cause of the malfunction. Refer to “ FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-37. 4. Perform: • Dynamic inspection TIP Use the “Dynamic inspection” function of the Ya- maha diagnostic tool version 3.0 and after to perform the dynamic inspection. For information about using the Yamaha diagnostic tool, refer to the operation manual that is included with the tool. 3-4 PERIODIC MAINTENANCE 5. Install: • Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1. EAS30619 CHECKING THE FUEL LINE 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 4-12. 2. Check: • Fuel hose “1” Cracks/damage → Replace. Loose connections → Connect properly. 1 3. Install: • Footrest board assembly (left) Refer to “GENERAL CHASSIS (5)” on page 4-12. • Front side cover (left) Refer to “GENERAL CHASSIS (2)” on page 4-3.
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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 4-12. 2. Remove: • Spark plug cap • Spark plug ECA13330 NOTICE Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 3. Check: • Spark plug type Incorrect → Change. Manufacturer/model NGK/CPR8EA-9 4. Check: • Electrode “1” Damage/wear → Replace the spark plug. • Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • Spark plug (with a spark plug cleaner or wire brush) 3-5 PERIODIC MAINTENANCE 6. Measure: • Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. Spark plug gap 0.8–0.9 mm (0.031–0.035 in) 7. Install: • Spark plug “1” • Spark plug cap Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) T R . . TIP • Before installing the spark plug, clean the spark plug and gasket surface. • 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. a b 2 1 8. Install: • Footrest board assembly (right) Refer to “GENERAL CHASSIS (5)” on page 4-12. • Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page 4-3.
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EAS30622 ADJUSTING THE VALVE CLEARANCE The following procedures are applied to all of the valves. 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 Refer to “GENERAL CHASSIS (1)” on page 4-1. • Front side cover Refer to “GENERAL CHASSIS (3)” on page 4-6. • Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-6. • Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. • Fuel tank Refer to “FUEL TANK” on page 7-1. • Cylinder head cover Refer to “CYLINDER HEAD” on page 5-9. • Radiator cover Refer to “RADIATOR” on page 6-2. 2. Move: • Radiator “1” TIP Move the rear of the radiator outward. 1 3. Move: • Water pump assembly “1” TIP Move the water pump assembly in the direction shown in the illustration. 3-6 PERIODIC MAINTENANCE 1 4. Measure: • Valve clearance Out of specification → Adjust. 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) a. Turn the crankshaft clockwise. b. When the piston is at the Top Dead Center (TDC) on the compression stroke, align the mark “a” on the camshaft sprocket with the match mark “b” on the camshaft stopper plate. a b
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c. Measure the valve clearance with a thick- ness gauge “1”. Out of specification → Adjust. 1 5. Adjust: • Valve clearance a. Loosen the locknut “1”. b. Insert a thickness gauge “2” between the end of the adjusting screw and the valve tip. 1 2 c. Turn the adjusting screw “3” with the tappet adjusting tool “4” until the specified valve clearance is obtained. Tappet adjusting tool 90890-01311 Six piece tappet set YM-A5970 3 4 3-7 PERIODIC MAINTENANCE d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. Valve clearance adjusting screw locknut 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . e. Measure the valve clearance again. f. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance ad- justment steps until the specified clearance is obtained. 6. Install: • All removed parts TIP For installation, reverse the removal procedure. 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. 2. Check: • Engine idling speed Out of specification → Go to next step. Engine idling speed 1500–1700 r/min 3. Check: • ISC (idle speed control) learning value “00” or “01” → Check the intake system. “02” → Clean the ISC (idle speed control) unit and throttle body. Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on page 7-13. a. Connect the Yamaha diagnostic tool. Use the diagnostic code number “67”. Refer to “ FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-37. Yamaha diagnostic tool USB 90890-03267 Yamaha diagnostic tool (A/I) 90890-03264
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EAS30625 CHECKING THE EXHAUST SYSTEM 1. Check: • Muffler “1” Cracks/damage → Replace. • Gasket “2” Exhaust gas leaks → Replace. 2. Check: Tightening torque • Muffler nut “3” • Muffler bolt “4” Muffler nut 20 N·m (2.0 kgf·m, 15 lb·ft) Muffler bolt 53 N·m (5.3 kgf·m, 39 lb·ft) T R . . 4 1 2 4 4 3 EAS31922 CHECKING THE CANISTER 1. Remove: • Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. • Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-6. • Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. 2. Check: • Fuel tank breather hose (rollover valve to canister) • Canister purge hose • Canister breather hose • Canister Damage → Replace. 3-8 PERIODIC MAINTENANCE 3. Install: • Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. • Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-6. • Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. EAS31130 REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE TIP Check the air filter check hose “1” that is located on the rear side of the air filter case. If dust or water or both collects in the hose, clean the hose and replace the air filter element. 1 1. Remove: • Air filter case cover “1” • Air filter element “2” 1 2
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2. Check: • Air filter element Damage → Replace. TIP • Replace the air filter element every 18000 km (10500 mi) of operation. • The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 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 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 and possible overheating. TIP When installing the air filter element into the air filter case, make sure that the sealing surfaces are aligned to prevent any air leaks. EAS31179 CHECKING THE BREATHER HOSES 1. Remove: • Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. • Front side cover 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 4-9. 2. Check: • Cylinder head breather hose “1” • Transmission case breather hose “2” Cracks/damage → Replace. Loose connections → Connect properly. 3-9 PERIODIC MAINTENANCE ECA21600 NOTICE Make sure the cylinder head breather hose and transmission case breather hose are routed correctly. 1 2 3. Install: • Storage box Refer to “GENERAL CHASSIS (4)” on page 4-9. • Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-6. • Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. • Battery Refer to “GENERAL CHASSIS (1)” on page 4-1.
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EAS31704 CLEANING THE V-BELT CASE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE TIP Check the V-belt case air filter check hose “1” that is located on the rear side of the V-belt case. If dust or water or both collects in the hose, clean the hose and replace the V-belt case air filter el- ement. 1 1. Remove: • V-belt case air filter element cover “1” • V-belt case air filter element “2” 1 2 2. Clean: • V-belt case air filter element (with solvent) EWA17971 WARNING Never use low flash point solvents, such as gasoline, to clean the V-belt case air filter el- ement. Such solvents may cause a fire or an explosion. 3-10 PERIODIC MAINTENANCE TIP • The air filter needs more frequent service if you are riding in unusually wet or dusty areas. • After cleaning, gently squeeze the V-belt case air filter element to remove the excess solvent. ECA21590 NOTICE Do not twist the V-belt case air filter element when squeezing it. 3. Check: • V-belt case air filter element Damage → Replace. 4. Apply the recommended oil to the entire sur- face of the V-belt case air filter element and 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- er bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . .
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EAS30801 CHECKING THE BRAKE OPERATION 1. Check: • Brake operation Brake not working properly → Check the brake system. Refer to “FRONT BRAKE” on page 4-32 and “REAR BRAKE” on page 4-46. TIP Drive on the road, operate the front and rear brakes separately and check to see if the brakes are operating properly. EAS30633 CHECKING THE FRONT BRAKE PADS The following procedures are applied to all of the brake pads. 1. Operate the brake. 2. Check: • Front brake pad Wear indicator grooves “a” almost disap- peared → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-32. a EAS30634 CHECKING THE REAR BRAKE PADS The following procedures are applied to all of the brake pads. 1. Operate the brake. 2. Check: • Rear brake pad Wear indicators “a” almost touch the brake disc → Replace the brake pads as a set. Refer to “REAR BRAKE” on page 4-46. a 3-11 PERIODIC MAINTENANCE EAS30632 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. TIP • Place the vehicle on the centerstand. • Make sure the vehicle is upright. • 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 specified brake fluid to the proper level. Specified brake fluid DOT 4 a A B a A. Front brake B. Rear brake
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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. EAS30635 CHECKING THE FRONT BRAKE HOSES 1. Check: • Brake hose “1” Cracks/damage → Replace. 1 1 2. Check: • Brake hose holder • Brake hose guide Loose → Tighten the holder and guide bolt. 3. Hold the vehicle upright and apply the front brake several times. 4. Check: • Brake hose Brake fluid leakage → Replace the damaged hose. Refer to “FRONT BRAKE” on page 4-32. 3-12 PERIODIC MAINTENANCE EAS30636 CHECKING THE REAR BRAKE HOSES 1. Check: • Brake hose “1” Cracks/damage/wear → Replace. 1 1 2. Check: • Brake hose holder Loose → Tighten the holder bolt. 3. Hold the vehicle upright and apply the rear brake several times. 4. Check: • Brake hose Brake fluid leakage → Replace the brake hose. Refer to “REAR BRAKE” on page 4-46. EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA14000 WARNING Always bleed the brake system when the brake related parts are removed. ECA22780 NOTICE • Bleed the brake system in the following or- der. • 1st step: Front brake caliper • 2nd step: Rear brake caliper EWA16530 WARNING Bleed the ABS whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty.
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TIP • Be careful not to spill any brake fluid or allow the brake master cylinder reservoir to overflow. • When bleeding the ABS, make sure that there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the ABS, considerably lengthening the bleeding procedure. • If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. • Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. 1. Bleed: • ABS a. Fill the brake master cylinder reservoir to the proper level with the specified brake flu- id. b. Install the brake master cylinder dia- phragm. c. Connect a clear plastic hose “1” tightly to the bleed screw “2”. A 2 1 B 1 2 A. Front brake caliper B. Rear brake caliper d. Place the other end of the hose into a con- tainer. e. Slowly apply the brake several times. f. Fully squeeze the brake lever and hold it in position. 3-13 PERIODIC MAINTENANCE g. Loosen the bleed screw. TIP Loosening the bleed screw will release the pres- sure and cause the brake lever to contact the throttle grip or handlebar grip. h. Tighten the bleed screw and then release the brake lever. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Check the operation of the hydraulic unit. Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-62. ECA18060 NOTICE Make sure that the main switch is turned to “OFF” before checking the operation of the hydraulic unit. k. After operating the ABS, repeat steps (e) to (i), and then fill the brake master cylinder reservoir to the proper level with the speci- fied brake fluid. l. Tighten the bleed screw to specification. Brake caliper bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) T R . . m. Fill the brake master cylinder reservoir to the proper level with the specified brake flu- id. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-11. EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation.
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EAS31428 CHECKING THE WHEELS The following procedures are applied to all of the wheels. 1. Check: • Wheel Damage/out-of-round → Replace. EWA13260 WARNING Never attempt to make any repairs to the wheel. TIP After a tire or wheel has been changed or re- placed, always balance the wheel. 2. Measure: • Radial wheel runout • Lateral wheel runout Refer to “FRONT WHEEL” on page 4-22 and “REAR WHEEL” on page 4-29. EAS31429 CHECKING THE TIRES The following procedures are applied to all of the tires. 1. Check: • Tire pressure Out of specification → Regulate. EWA13181 WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed. • Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. 3-14 PERIODIC MAINTENANCE Tire air pressure (measured on cold tires) 1 person Front 150 kPa (1.50 kgf/cm², 22 psi) Rear 250 kPa (2.50 kgf/cm², 36 psi) 2 persons Front 150 kPa (1.50 kgf/cm², 22 psi) Rear 250 kPa (2.50 kgf/cm², 36 psi) * Total weight of rider, passenger, cargo and accessories EWA13190 WARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, re- place the tire immediately. 2. Check: • Tire surfaces Damage/wear → Replace the tire. 1. Tire tread depth 2. Side wall 3. Wear indicator Wear limit (front) 1.0 mm (0.04 in) Wear limit (rear) 1.0 mm (0.04 in)
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EWA14080 WARNING • Do not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire fail- ure and personal injury from sudden deflation. • When using a tube tire, be sure to install the correct tube. • Always replace a new tube tire and a new tube as a set. • To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. • Patching a punctured tube is not recom- mended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality re- placement. A B A. Tire B. Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire EWA14090 WARNING After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. Front tire Size 110/70-13M/C 48P Manufacturer/model DUNLOP/SCOOT SMART L 3-15 PERIODIC MAINTENANCE Rear tire Size 130/70-13M/C 63P Manufacturer/model DUNLOP/SCOOT SMART L EWA13210 WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. TIP For tires with a direction of rotation mark “1”: • Install the tire with the mark pointing in the di- rection of wheel rotation. • Align the mark “2” with the valve installation point. 1 2 EAS30641 CHECKING THE WHEEL BEARINGS The following procedures are applied to all of the wheel bearings. 1. Check: • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” on page 4-25.
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EAS30645 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. TIP Place the vehicle on a suitable stand so that the front wheel is off ground. 2. Check: • Steering head Grasp the handlebar and gently rock the han- dlebar. Binding/looseness → Adjust the steering head. 3. Remove: • Front side covers Refer to “GENERAL CHASSIS (2)” on page 4-3. • Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. • Front upper cowling assembly Refer to “GENERAL CHASSIS (6)” on page 4-15. • Handlebar Refer to “HANDLEBAR” on page 4-67. 4. Adjust: • Steering head a. Remove the upper ring nut “1”, lock washer “2”, center ring nut “3” and rubber washer “4”. 1 3 4 2 b. Loosen the lower ring nut “5” and then tight- en it to specification with a steering nut wrench “6”. TIP Set the torque wrench at a right angle to the steering nut wrench. 3-16 PERIODIC MAINTENANCE Steering nut wrench 90890-01403 Exhaust flange nut wrench YU-A9472 Lower ring nut (initial tightening torque) 38 N·m (3.8 kgf·m, 28 lb·ft) T R . . 6 5 c. Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification with a steer- ing nut wrench. EWA13140 WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 17 N·m (1.7 kgf·m, 13 lb·ft) T R . . d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, re- move the lower bracket and check the up- per and lower bearings. Refer to “STEERING HEAD” on page 4-81. e. Install the rubber washer. f. Install the center ring nut. g. Finger tighten the center ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the center ring nut until their slots are aligned.
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h. Install the lock washer “2”. TIP Make sure the lock washer tabs “a” sit correctly in the ring nut slots “b”. 2 a b i. Hold the lower and center ring nuts with a steering nut wrench and tighten the upper ring nut with another steering nut wrench. Steering nut wrench 90890-01403 Exhaust flange nut wrench YU-A9472 Upper ring nut 75 N·m (7.5 kgf·m, 55 lb·ft) T R . . 5. Install: • Handlebar Refer to “HANDLEBAR” on page 4-67. • Front upper cowling assembly Refer to “GENERAL CHASSIS (6)” on page 4-15. • Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. • Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. EAS30646 LUBRICATING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Lower bearing dust seal Recommended lubricant Lithium-soap-based grease 3-17 PERIODIC MAINTENANCE EAS31186 CHECKING THE CHASSIS FASTENERS Make sure that all nuts, bolts, and screws are properly tightened. Refer to “TIGHTENING TORQUES” on page 2- 10. EAS30648 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant Silicone grease EAS30650 CHECKING THE SIDESTAND 1. Check: • Sidestand operation Check that the sidestand moves smoothly. Rough movement → Repair or replace. EAS30651 LUBRICATING THE SIDESTAND Lubricate the pivoting point, metal-to-metal mov- ing parts and spring contact point of the side- stand. Recommended lubricant Lithium-soap-based grease EAS30856 CHECKING THE CENTERSTAND 1. Check: • Centerstand operation Check that the centerstand moves smoothly. Rough movement → Repair or replace. EAS30857 LUBRICATING THE CENTERSTAND Lubricate the pivoting point, metal-to-metal mov- ing parts, and spring contact points of the center- stand. Recommended lubricant Lithium-soap-based grease EAS30652 CHECKING THE SIDESTAND SWITCH Refer to “CHECKING THE SWITCHES” on page 8-35.
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EAS30653 CHECKING THE FRONT FORK 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. Check: • Inner tube Damage/scratches → Replace. • Oil seal Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to “FRONT FORK” on page 4-74. EAS30808 CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES The following procedures are applied to both of the rear shock absorber assemblies. 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. Check: • Rear shock absorber assembly Oil leaks → Replace the rear shock absorber assembly. Refer to “CHECKING THE REAR SHOCK ABSORBER ASSEMBLY” on page 4-87. 3-18 PERIODIC MAINTENANCE 3. Check: • Rear shock absorber assembly operation Push down seat on the vehicle several times and check if the rear shock absorber assem- bly rebounds smoothly. Rough movement → Replace. Refer to “REAR SHOCK ABSORBER AS- SEMBLIES AND SWINGARM” on page 4- 85. EAS30656 CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface. TIP • Place the vehicle on the centerstand. • Make sure the vehicle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Remove: • Dipstick “1” 4. Check: • Engine oil level The engine oil level should be between the 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 the oil level. 1 1 b a Recommended brand YAMALUBE SAE viscosity grades 10W-40 Recommended engine oil grade API service SG type or higher, JASO standard MA or MB
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ECA13370 NOTICE Do not allow foreign materials to enter the crankcase. 5. Start the engine, warm it up for several min- utes, and then turn it off. 6. Check the engine oil level again. TIP Before checking the engine oil level, wait a few minutes until the oil has settled. EAS30657 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • Dipstick “1” • Engine oil drain bolt “2” (along with the gasket “3”) 1 3 2 4. Drain: • Engine oil (completely from the crankcase) 5. If the oil strainer is also to be cleaned, per- form the following procedure. a. Remove the oil strainer cover “1”, spring “3”, and oil strainer “2”. b. Install a new O-ring “4”. TIP Lubricate the O-ring with lithium-soap-based grease. 3-19 PERIODIC MAINTENANCE 2 3 4 1 c. Clean the engine oil strainer with solvent, and then check it for damage and replace it if necessary. d. Install the oil strainer, spring, and oil strain- er cover. Oil strainer cover 20 N·m (2.0 kgf·m, 15 lb·ft) T R . . 6. Install: • Engine oil drain bolt (along with the gasket ) New Engine oil drain bolt 20 N·m (2.0 kgf·m, 15 lb·ft) T R . . 7. Fill: • Crankcase (with the specified amount of the recom- mended engine oil) 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) 8. Install: • Dipstick 9. Start the engine, warm it up for several min- utes, and then turn it off. 10.Check: • Engine (for engine oil leaks) 11.Check: • Engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL” on page 3-18.
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12.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 4-12. 13.Check: • Engine oil pressure a. Slightly loosen the oil check bolt “1”. 1 b. Start the engine and keep it idling until en- gine oil starts to seep from the oil check bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages and the oil pump for damage or leakage. Refer to “OIL PUMP” on page 5-49. d. Start the engine after solving the prob- lem(s) and check the engine oil pressure again. e. Tighten the oil check bolt to specification. Engine oil check bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . 14.Reset: • Oil change indicator Refer to “MULTI-FUNCTION METER UNIT” on page 1-2. 3-20 PERIODIC MAINTENANCE EAS30811 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. TIP • Place the vehicle on the centerstand. • Make sure the vehicle is upright. 2. Check: • Coolant level The coolant level should be between the min- imum level mark “a” and maximum level mark “b”. Below the minimum level mark → Add the recommended coolant to the proper level. b a ECA13470 NOTICE • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used. 3. Start the engine, warm it up for several min- utes, and then turn it off. 4. Check: • Coolant level TIP Before checking the coolant level, wait a few minutes until the coolant has settled.
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EAS30812 CHECKING THE COOLING SYSTEM 1. Remove: • Radiator cover Refer to “RADIATOR” on page 6-2. 2. Check: • Radiator “1” • Coolant reservoir hose “2” • Radiator inlet hose “3” • Radiator outlet hose “4” • Thermostat assembly “5” • Water pump inlet hose “6” Cracks/tears → Replace. Refer to “RADIATOR” on page 6-2 and “THERMOSTAT” on page 6-6. 4. Drain: • Coolant (from the coolant reservoir) 5. Remove: • Radiator cover “1” 2 3 5 1 6 4 3. Install: • Radiator cover Refer to “RADIATOR” on page 6-2. EAS30813 CHANGING THE COOLANT 1. Remove: • Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page 4-3. • Bottom cover • Footrest board assembly (right) Refer to “GENERAL CHASSIS (5)” on page 4-12. 2. Disconnect: • Coolant reservoir hose “1” • Coolant reservoir breather hose “2” 2 1 3-21 PERIODIC MAINTENANCE 3. Remove: • Coolant reservoir cap “2” • Coolant reservoir “1” 1 2 1
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6. Remove: • Radiator cap “1” 1 EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move. 7. Remove: • Coolant drain bolt (radiator side) “1” (along with the O-ring) • Coolant drain bolt (cylinder side) “2” (along with the copper washer) 1 2 3-22 PERIODIC MAINTENANCE 8. Drain: • Coolant (from the engine and radiator) 9. Install: • Coolant drain bolt (cylinder side) (along with the copper washer ) • Coolant drain bolt (radiator side) (along with the O-ring ) New New Coolant drain bolt (cylinder side) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Coolant drain bolt (radiator side) 1.0 N·m (0.10 kgf·m, 0.73 lb·ft) T R . . 10.Connect: • Coolant reservoir breather hose • Coolant reservoir hose 11.Fill: • Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol an- tifreeze containing corrosion inhibitors for aluminum en- gines Mixing ratio 1:1 (antifreeze: water) 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) TIP • Fill the coolant into the radiator, and then re- move the air bleed bolt “1” until coolant comes out. • Tighten the air bleed bolt to specification. Air bleed bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) T R . . 1
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Handling notes for coolant Coolant is potentially harmful and should be handled with special care. EWA13040 WARNING • If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. • If coolant is swallowed, induce vomiting and get immediate medical attention. ECA13481 NOTICE • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used. • If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. • Do not mix different types of antifreeze. 12.Install: • Radiator cap • Coolant reservoir Coolant reservoir bolt 11 N·m (1.1 kgf·m, 8.1 lb·ft) T R . . 13.Fill: • Coolant reservoir (with the recommended coolant to the maxi- mum level mark “a”) a 3-23 PERIODIC MAINTENANCE 14.Install: • Coolant reservoir cap “1” TIP Point the tab “a” on the coolant reservoir cap for- ward. 1 a 15.Start the engine, warm it up for several min- utes, and then turn it off. 16.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-20. TIP Before checking the coolant level, wait a few minutes until the coolant has settled. 17.Install: • Radiator cover Radiator cover bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) T R . . 18.Install: • Footrest board assembly (right) Refer to “GENERAL CHASSIS (5)” on page 4-12. • Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page 4-3.
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EAS31187 CHANGING THE FINAL TRANSMISSION OIL 1. Stand the vehicle on a level surface. TIP • Place the vehicle on the centerstand. • Make sure the vehicle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. Place a container under the final transmis- sion. 4. Remove: • Final transmission oil filler cap “1” (along with the O-ring “2”) • Final transmission oil drain bolt “3” (along with the copper washer “4”) Completely drain the final transmission oil. 1 2 3 4 5. Install: • Final transmission oil drain bolt (along with the copper washer ) New Final transmission oil drain bolt 20 N·m (2.0 kgf·m, 15 lb·ft) T R . . 3-24 PERIODIC MAINTENANCE 6. Fill: • Final transmission oil (with the specified amount of the recom- mended final transmission oil) Final transmission oil Type Motor oil SAE 10W-40 type SG or higher Quantity 0.10 L (0.11 US qt, 0.09 Imp.qt) 7. Install: • Final transmission oil filler cap (along with the O-ring ) New TIP Lubricate the O-ring with lithium-soap-based grease. 8. Start the engine, warm it up for several min- utes, and then turn it off. 9. Check: • Final transmission oil leakage EAS31188 REPLACING THE V-BELT 1. Remove: • Air filter case Refer to “AIR FILTER CASE” on page 7-8. • V-belt case Refer to “V-BELT AUTOMATIC TRANSMIS- SION” on page 5-37. 2. Check: • V-belt Damage/wear → Replace. Grease/oil → Clean the primary and second- ary pulleys. Refer to “V-BELT AUTOMATIC TRANSMIS- SION” on page 5-37. TIP Replace the V-belt every 25000 km (15500 mi) of operation. 3. Install: • V-belt case Refer to “V-BELT AUTOMATIC TRANSMIS- SION” on page 5-37. • Air filter case Refer to “AIR FILTER CASE” on page 7-8.
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EAS30658 CHECKING THE BRAKE LIGHT SWITCHES 1. Check: • Front brake light switch operation • Rear brake light switch operation When operating the brake levers, confirm that the brake light comes on. Faulty → Refer to “CHECKING THE SWITCHES” on page 8-35. EAS31147 CHECKING AND LUBRICATING THE CABLES The following procedures are applied to all of the inner and outer cables. 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 Damage → Replace. 2. Check: • Cable operation Rough movement → Lubricate. 3. Check: • Throttle grip free play “a” Out of specification → Adjust. Recommended lubricant Engine oil or a suitable cable lu- bricant TIP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. 3-25 PERIODIC MAINTENANCE EAS30861 CHECKING THE THROTTLE GRIP OPERATION 1. Check: • Throttle cable Damage/deterioration → Replace. • Throttle cable installation Incorrect → Reinstall the throttle cables. Refer to “HANDLEBAR” on page 4-67. 2. Check: • Throttle grip movement Rough movement → Lubricate or replace the defective part(s). Recommended lubricant Suitable cable lubricant TIP With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle grip turns smoothly and returns properly when released. Repeat this check with the handlebar turned all the way to the left and right. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) a
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4. Adjust: • Throttle grip free play a. Slide back the rubber cover “1”. b. Loosen the locknut “2”. c. Turn the adjusting nut “3” until the specified throttle grip free play is obtained. EAS30664 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • Headlight beam (vertically) Turn the adjusting bolts “1” in direction left or right. • Headlight beam (horizontally) Turn the adjusting bolts “2” in direction left or right. Throttle cable adjusting locknut 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 1 2 3 d. Tighten the locknut. T R . . e. Slide the rubber cover to its original posi- tion. 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. 3-26 PERIODIC MAINTENANCE 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 8-35. 1 2
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CHASSIS GENERAL CHASSIS (1) .................................................................................4-1 REMOVING THE BATTERY COVER .......................................................4-2 GENERAL CHASSIS (2) .................................................................................4-3 REMOVING THE TAIL/BRAKE LIGHT OUTER COVER..........................4-4 INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER.........................4-4 REMOVING THE FRONT SIDE COVER ..................................................4-5 INSTALLING THE FRONT SIDE COVER.................................................4-5 GENERAL CHASSIS (3) .................................................................................4-6 REMOVING THE FUEL TANK COVER ....................................................4-7 INSTALLING THE FUEL TANK COVER...................................................4-7 REMOVING THE FUEL TANK CAP LID COVER .....................................4-8 INSTALLING THE FUEL TANK CAP LID COVER....................................4-8 GENERAL CHASSIS (4) .................................................................................4-9 REMOVING THE REAR SIDE COVER ASSEMBLY ..............................4-11 INSTALLING THE REAR SIDE COVER ASSEMBLY.............................4-11 GENERAL CHASSIS (5) ...............................................................................4-12 INSTALLING THE CENTER LOWER COVER........................................4-14 INSTALLING THE FOOTREST BOARD ASSEMBLY.............................4-14 INSTALLING THE BOTTOM COVER .....................................................4-14 GENERAL CHASSIS (6) ...............................................................................4-15 REMOVING THE FRONT UPPER PANEL .............................................4-16 INSTALLING THE FRONT UPPER PANEL............................................4-16 REMOVING THE FRONT COWLING ASSEMBLY.................................4-17 INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-17 REMOVING THE FRONT SIDE COWLING............................................4-18 INSTALLING THE FRONT SIDE COWLING ..........................................4-18 GENERAL CHASSIS (7) ...............................................................................4-19 REMOVING THE UPPER CENTER COVER..........................................4-21 INSTALLING THE UPPER CENTER COVER ........................................4-21 FRONT WHEEL.............................................................................................4-22 REMOVING THE FRONT WHEEL..........................................................4-24 DISASSEMBLING THE FRONT WHEEL................................................4-24 CHECKING THE FRONT WHEEL ..........................................................4-25 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR..........................................................................4-25 ASSEMBLING THE FRONT WHEEL......................................................4-26 ADJUSTING THE FRONT WHEEL STATIC BALANCE .........................4-26 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)..................4-27 4
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REAR WHEEL...............................................................................................4-29 REMOVING THE REAR WHEEL (DISC)................................................4-30 CHECKING THE REAR WHEEL.............................................................4-30 MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR .................4-30 ADJUSTING THE REAR WHEEL STATIC BALANCE............................4-30 INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-31 FRONT BRAKE.............................................................................................4-32 INTRODUCTION.....................................................................................4-38 CHECKING THE FRONT BRAKE DISC .................................................4-38 REPLACING THE FRONT BRAKE PADS ..............................................4-39 REMOVING THE FRONT BRAKE CALIPER..........................................4-41 DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-41 CHECKING THE FRONT BRAKE CALIPER ..........................................4-42 ASSEMBLING THE FRONT BRAKE CALIPER......................................4-42 INSTALLING THE FRONT BRAKE CALIPER ........................................4-42 REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-43 CHECKING THE FRONT BRAKE MASTER CYLINDER........................4-44 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ...................4-44 INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-44 REAR BRAKE ...............................................................................................4-46 INTRODUCTION.....................................................................................4-51 CHECKING THE REAR BRAKE DISC....................................................4-51 REPLACING THE REAR BRAKE PADS.................................................4-52 REMOVING THE REAR BRAKE CALIPER ............................................4-53 DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-53 CHECKING THE REAR BRAKE CALIPER.............................................4-54 ASSEMBLING THE REAR BRAKE CALIPER ........................................4-54 INSTALLING THE REAR BRAKE CALIPER...........................................4-54 REMOVING THE REAR BRAKE MASTER CYLINDER .........................4-55 CHECKING THE REAR BRAKE MASTER CYLINDER..........................4-56 ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-56 INSTALLING THE REAR BRAKE MASTER CYLINDER........................4-56 ABS (Anti-lock Brake System)....................................................................4-58 REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-60 CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-60 INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-61 HYDRAULIC UNIT OPERATION TESTS................................................4-62 CHECKING THE ABS WARNING LIGHT ...............................................4-66 HANDLEBAR ................................................................................................4-67 REMOVING THE UPPER HANDLEBAR COVER ASSEMBLY ..............4-70 DISASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ....4-70 REMOVING THE HANDLEBAR..............................................................4-70 CHECKING THE HANDLEBAR ..............................................................4-70 INSTALLING THE HANDLEBAR ............................................................4-71 ASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ..........4-72 INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY.............4-73
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FRONT FORK................................................................................................4-74 REMOVING THE FRONT FORK LEGS..................................................4-76 DISASSEMBLING THE FRONT FORK LEGS........................................4-76 CHECKING THE FRONT FORK LEGS ..................................................4-77 ASSEMBLING THE FRONT FORK LEGS..............................................4-77 INSTALLING THE FRONT FORK LEGS ................................................4-80 STEERING HEAD..........................................................................................4-81 REMOVING THE LOWER BRACKET.....................................................4-83 CHECKING THE STEERING HEAD.......................................................4-83 INSTALLING THE STEERING HEAD.....................................................4-84 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM...................4-85 REMOVING THE SWINGARM................................................................4-87 MAINTENANCE OF THE REAR WHEEL SENSOR ...............................4-87 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ...................4-87 CHECKING THE SWINGARM ................................................................4-88 INSTALLING THE SWINGARM ..............................................................4-88
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EAS20026 GENERAL CHASSIS (1) Removing the battery 3 1 2 4 6 5 Order Job/Parts to remove Q’ty Remarks Seat Open. 1 Battery cover 1 2 Negative battery lead 1 Disconnect. 3 Positive battery lead 1 Disconnect. 4 Battery 1 5 CCU (Communication Control Unit) 1 6 Smart key unit 1 4-1 GENERAL CHASSIS (1) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
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EAS31677 REMOVING THE BATTERY COVER 1. Remove: • Battery cover “1” 1 a. Open the seat. b. Remove the battery cover screws. c. Slide the battery cover “1” rearward to re- move from the storage box. 1 4-2 GENERAL CHASSIS (1)
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EAS20155 GENERAL CHASSIS (2) Removing the grab bar and front side covers 17 N•m (1.7 kgf•m, 13 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. T.R. 4 2 Order Job/Parts to remove Q’ty Remarks 1 Grab bar 1 2 Tail/brake light upper cover 1 3 Front side cover (left) 1 4 Front side cover (right) 1 4-3 GENERAL CHASSIS (2) 17 N•m (1.7 kgf•m, 13 lb•ft) T.R. 1 3 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
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EAS31681 REMOVING THE TAIL/BRAKE LIGHT OUTER COVER 1. Remove: • Tail/brake light outer cover “1” 1 a. Remove the tail/brake light outer cover screws. b. Slide the tail/brake light outer cover rear- ward to remove the projection “a” on the cover from the hole “b” in the tail/brake light. a 1 a b 4-4 GENERAL CHASSIS (2) EAS31682 INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER 1. Install: • Tail/brake light outer cover “1” 1 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. a 1 a b b. Install the tail/brake light outer cover screws, and then tighten the screws to specification. Tail/brake light outer cover screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T R . .
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EAS31683 REMOVING THE FRONT SIDE COVER The following procedures are applied to both of the front side covers. 1. Remove: • Front side cover “1” 1 a. Remove the front side cover screws. b. Pull the front side cover outward to remove the projections “a” from the grommets “b”. b a 1 a b 4-5 GENERAL CHASSIS (2) EAS31684 INSTALLING THE FRONT SIDE COVER The following procedures are applied to both of the front side covers. 1. Install: • Front side cover “1” 1 a. Fit the projections “a” on the front side cover into the grommets “b”. b a 1 a b b. Install the front side cover screws, and then tighten the screw to specification. Front side cover screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T R . .
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EAS20156 GENERAL CHASSIS (3) Removing the fuel tank cover and seat assembly 3 4 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 1 Order Job/Parts to remove Q’ty Remarks Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. 1 Fuel tank cover 1 2 Fuel tank cap lid lock cable 1 Disconnect. 3 Fuel tank cap lid cover 1 4 Fuel tank cap lid 1 5 Center cover 1 6 Seat assembly 1 7 Owner’s tool kit 1 8 Seat 1 4-6 GENERAL CHASSIS (3) 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 6 2 8 7 5 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R.
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EAS31685 REMOVING THE FUEL TANK COVER 1. Remove: • Fuel tank cover “1” 1 a. Remove the fuel tank cover screws. 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 4-7 GENERAL CHASSIS (3) EAS31686 INSTALLING THE FUEL TANK COVER 1. Install: • Fuel tank cover “1” 1 a. Slide the fuel tank cover forward and fit the projections “a” on the cover into the holes “b” in the leg shield. 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 . . b a
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EAS32349 REMOVING THE FUEL TANK CAP LID COVER 1. Remove: • Fuel tank cap lid cover “1” 1 a. Remove the screw. b. Remove the projections “a” on the fuel tank cap lid cover from the holes “b” in the fuel tank cap lid. a b 1 4-8 GENERAL CHASSIS (3) EAS32350 INSTALLING THE FUEL TANK CAP LID COVER 1. Install: • Fuel tank cap lid cover “1” 1 a. Fit the projections “a” on the fuel tank cap lid cover into the holes “b” in the fuel tank cap lid. a b 1 b. Install the fuel tank cap lid cover screw, and then tighten the screw to specification. Fuel tank cap lid cover screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T R . .
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EAS20157 GENERAL CHASSIS (4) Removing the rear side covers and storage box 9 N·m (0.9 kgf·m, 6.6 lb·ft) T.R. 11 13 5 12 6 4 Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-6. 1 Rear side cover assembly (left) 1 2 Center side cover (left) 1 3 Rear side cover (left) 1 4 Rear side cover assembly (right) 1 5 Center side cover (right) 1 6 Rear side cover (right) 1 7 Brake light coupler 1 Disconnect. 8 Taillight/rear turn signal coupler 1 Disconnect. 9 Tail/brake light lower cover 1 4-9 GENERAL CHASSIS (4) 10 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) T.R. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 9 7 8 1 3 2
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Removing the rear side covers and storage box 9 N·m (0.9 kgf·m, 6.6 lb·ft) T.R. 11 13 5 12 6 4 Order Job/Parts to remove Q’ty Remarks 10 Tail/brake light assembly 1 11 Storage box 1 12 Flap 1 13 Seat hinge 1 4-10 GENERAL CHASSIS (4) 10 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) T.R. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 9 7 8 1 3 2
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EAS31687 REMOVING THE REAR SIDE COVER ASSEMBLY The following procedures are applied to both of the rear side cover assembly. 1. Remove: • Rear side cover assembly “1” 1 a. Remove the quick fasteners, screw and bolt. b. Remove the projections “a” on the rear side cover assembly from the holes “b” in the storage box. 1 b a 4-11 GENERAL CHASSIS (4) EAS31688 INSTALLING THE REAR SIDE COVER ASSEMBLY The following procedures are applied to both of the rear side cover assembly. 1. Install: • Rear side cover assembly “1” 1 a. Fit the projections “a” on the rear side cover assembly into the holes “b” in the storage box. 1 b a b. Install the quick fasteners, screw, and bolt, and then tighten the screw and bolts to specification.
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EAS20158 GENERAL CHASSIS (5) Removing the bottom cover, center lower cover and footrest board 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) T.R. 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 4 11 9 12 2 10 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) T.R. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 2 5 6 1 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. Seat assembly Refer to “GENERAL CHASSIS (3)” on page 4-6. Storage box Refer to “GENERAL CHASSIS (4)” on page 4-9. 1 Bottom cover 1 2 Clamp 3 3 Footrest board mat (left) 2 4 Footrest board mat (right) 2 5 Center lower cover 1 6 Footrest board assembly (left) 1 7 Front lower cover (left) 1 8 Footrest board (left) 1 4-12 GENERAL CHASSIS (5) 32 N·m (3.2 kgf·m, 24 lb·ft) T.R. LS 13 14 LS 8 3 7 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R.
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Removing the bottom cover, center lower cover and footrest board 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) T.R. 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 4 11 9 12 2 10 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) T.R. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 2 5 6 1 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 9 Footrest board assembly (right) 1 10 Front lower cover (right) 1 11 Coolant reservoir cap cover 1 12 Footrest board (right) 1 13 Sidestand spring 1 14 Sidestand 1 4-13 GENERAL CHASSIS (5) 32 N·m (3.2 kgf·m, 24 lb·ft) T.R. LS 13 14 LS 8 3 7 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R.
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EAS31689 INSTALLING THE CENTER LOWER COVER 1. Install: • Center lower cover “1” 1 TIP Fit the end of the fuel tank overflow hose “2” into the hole “a” in the center lower cover. 1 a 2 EAS31690 INSTALLING THE FOOTREST BOARD ASSEMBLY 1. Install: • Footrest board assembly “1” 1 Footrest board assembly bolt 3.8 N·m (0.38 kgf·m, 2.8 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. 4-14 GENERAL CHASSIS (5) a b 1 EAS31691 INSTALLING THE BOTTOM COVER 1. Install: • Bottom cover “1” 1 TIP Make sure that the projections “a” on the center lower cover fit into the holes “b” in the bottom cover. 1 b a
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EAS20159 GENERAL CHASSIS (6) Removing the front cowling assembly 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. 1 0.4 N·m (0.04 kgf·m, 0.30 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. 4 8 6 4 7 5 14 13 16 4 (6) 10 15 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 1 Windshield 1 2 Front upper cowling 1 3 Front upper panel 1 4 Clamp 3 5 Headlight unit coupler 1 Disconnect. 6 Front turn signal light coupler (left) 1 Disconnect. 7 Front turn signal light coupler (right) 1 Disconnect. 8 Front cowling assembly 1 9 Front turn signal light (left) 1 10 Front turn signal light (right) 1 11 Front side cowling (left) 1 12 Front side panel (left) 1 13 Front side cowling (right) 1 14 Front side panel (right) 1 15 Front lower cowling 1 16 Headlight unit 1 4-15 GENERAL CHASSIS (6) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 2 T.R. 3 11 4 12 9 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R.
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EAS31197 REMOVING THE FRONT UPPER PANEL 1. Remove: • Front upper panel “1” 1 a. Remove the front upper panel screw. b. Remove the projections “a” on the front up- per panel from the holes “b” in the leg shield and remove the projections “c” from the holes “d” in the headlight unit. a 1 d c c b 4-16 GENERAL CHASSIS (6) EAS31198 INSTALLING THE FRONT UPPER PANEL 1. Install: • Front upper panel “1” 1 a. Fit the projections “a” on the front upper panel into the holes “b” in the headlight unit and fit the projections “c” into the holes “d” in the leg shield. a 1 d c c b b. Install the front upper panel screw, and then tighten the screw to specification. Front upper cowling assembly screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T R . .
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EAS31278 REMOVING THE FRONT COWLING ASSEMBLY 1. Remove: • Front cowling assembly “1” 1 a. Remove the front cowling assembly screws. b. Pull the front cowling assembly forward to remove the projections “a” on the leg shield from the holes “b” in the front cowling as- sembly. b a a b 1 Front cowling assembly screw (M5 × 15) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) Front cowling assembly screw (M5 × 11) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 4-17 GENERAL CHASSIS (6) EAS31279 INSTALLING THE FRONT COWLING ASSEMBLY 1. Install: • Front cowling assembly “1” 1 a. Fit the projections “a” on the leg shield into the holes “b” in the front cowling assembly. b a a b 1 b. Install the front cowling assembly screws, and then tighten the screws to specification. T R . .
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EAS31696 REMOVING THE FRONT SIDE COWLING The following procedures are applied to both of the front side cowling. 1. Remove: • Front side cowling “1” 1 a. Removing the front side cowling screws. b. Remove the projections “a” on the front side cowling from the holes “b” in the front lower cowling. a a b 1 b 4-18 GENERAL CHASSIS (6) EAS31697 INSTALLING THE FRONT SIDE COWLING The following procedures are applied to both of the front side cowling. 1. Install: • Front side cowling “1” 1 a. Fit the projections “a” on the front side cowl- ing into the holes “b” in the front lower cowl- ing. a a b 1 b b. Install the front side cowling screws, and then tighten the screws to specification. Front side cowling screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T R . .
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EAS20193 GENERAL CHASSIS (7) Removing the meter assembly 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 7 6 2 3 4 8 5 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. Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. Seat assembly Refer to “GENERAL CHASSIS (3)” on page 4-6. Storage box Refer to “GENERAL CHASSIS (4)” on page 4-9. Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. Front cowling assembly Refer to “GENERAL CHASSIS (6)” on page 4-15. 1 Upper center cover 1 2 Meter panel assembly 1 3 Meter assembly coupler 1 Disconnect. 4 Clamp 1 5 Buzzer coupler 1 Disconnect. 6 Meter assembly 1 7 Meter assembly inner panel 1 4-19 GENERAL CHASSIS (7) 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 11 9 12 10
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Removing the meter assembly 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 7 6 2 3 4 8 5 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. Order Job/Parts to remove Q’ty Remarks 8 Meter assembly panel 1 9 Auxiliary DC jack coupler 1 Disconnect. 10 Auxiliary DC jack 1 11 Leg shield assembly 1 12 Clamp 2 4-20 GENERAL CHASSIS (7) 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 11 9 12 10
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EAS32329 REMOVING THE UPPER CENTER COVER 1. Remove: • Upper center cover “1” 1 a. Remove the quick fasteners. b. Pull the upper center cover outward to re- move the projections “a” on the cover from the holes “b” in the leg shield. b a 1 4-21 GENERAL CHASSIS (7) EAS32330 INSTALLING THE UPPER CENTER COVER 1. Install: • Upper center cover “1” 1 a. Fit the projections “a” on the upper center cover into the holes “b” in the leg shield. b a 1 b. Install the quick fasteners.
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EAS20028 FRONT WHEEL Removing the front wheel and brake disc 35 N·m (3.5 kgf·m, 26 lb·ft) T.R. 2 1 3 5 9 LT LS New 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 8 6 New New LT 8 N·m (0.8 kgf·m, 5.9 lb·ft) 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 4-22 FRONT WHEEL 26 N·m (2.6 kgf·m, 19 lb·ft) T.R. 4 LS 7 6 LT 23 N·m (2.3 kgf·m, 17 lb·ft) T.R.
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Disassembling the front wheel 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 4-23 FRONT WHEEL New 2 1 New LS
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EAS30145 REMOVING THE FRONT WHEEL ECA22340 NOTICE • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the speed sensor or speed sensor rotor; otherwise, the sensor or rotor may be damaged, resulting in improper op- eration. • Do not drop the speed sensor rotor or sub- 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 NOTICE Do not apply the brake lever when removing the brake caliper. 3. Lift up: • Front wheel TIP Place the vehicle on a suitable stand so that the front wheel is elevated. 4-24 FRONT WHEEL EAS30146 DISASSEMBLING THE FRONT WHEEL 1. Remove: • Oil seal • Wheel bearing a. Clean the surface of the front wheel hub. b. Remove the oil seals “1” with a flat-head screwdriver. TIP To prevent damaging the wheel, place a rag “2” between the screwdriver and the wheel surface. 2 1 c. Remove the wheel bearings “3” with a gen- eral bearing puller. 3
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EAS30147 CHECKING THE FRONT WHEEL 1. Check: • Wheel axle Roll the wheel axle on a flat surface. Bends → Replace. EWA13460 WARNING Do not attempt to straighten a bent wheel ax- le. 2. Check: • Tire • Front wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” on page 3-14 and “CHECKING THE WHEELS” on page 3-14. 3. Measure: • Radial wheel runout “1” • Lateral wheel runout “2” Over the specified limits → Replace. 1. Check: • Front wheel sensor “1” Cracks/bends/distortion → 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) 1 2 4-25 FRONT WHEEL 4. Check: • Wheel bearing Front wheel turns roughly or is loose → Re- place the wheel bearings. • Oil seal Damage/wear → Replace. EAS30155 MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR ECA21630 NOTICE • The speed sensor cannot be disassembled. Do not attempt to disassemble it. If faulty, replace with a new one. • Keep magnets (including magnetic pick-up tools, magnetic screwdrivers, etc.) away from the speed sensor. • Do not drop or shock the speed sensor or the speed sensor rotor.
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2. Check: • Front wheel sensor rotor “1” Cracks/damage/scratches → Replace the front wheel sensor rotor. Iron powder/dust/solvent → Clean. TIP When cleaning the wheel sensor rotor, be care- ful not to damage the surface of the sensor rotor. 1 EAS30151 ASSEMBLING THE FRONT WHEEL 1. Lubricate: • Oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: • Wheel bearing • Oil seal New New a. Install the new wheel bearing (right side). ECA18110 NOTICE Do not contact the wheel bearing inner race “1” or balls “2”. Contact should be made only with the outer race “3”. TIP Use a socket “4” that matches the diameter of the wheel bearing outer race. b. Install the spacer. 4-26 FRONT WHEEL c. Install the new wheel bearing (left side). TIP Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “4” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer “5”. EAS30152 ADJUSTING THE FRONT WHEEL STATIC BALANCE TIP • 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. 1. Remove: • Balancing weight(s) 2. Find: • Front wheel’s heavy spot 3. Adjust: • Front wheel static balance 4. Check: • Front wheel static balance
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EAS30932 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC) 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) LOCTITE® Front brake disc bolt 23 N·m (2.3 kgf·m, 17 lb·ft) LOCTITE® T R . . ECA21011 NOTICE • Do not drop the wheel sensor rotor or sub- ject it to shocks. • If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. • Replace the brake disc bolts and wheel sensor rotor bolts with new ones. 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 a b 2 2. Check: • Front brake disc Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-38. 4-27 FRONT WHEEL 3. Lubricate: • Wheel axle Recommended lubricant Lithium-soap-based grease 4. Install: • Front wheel • Collar • Front wheel axle TIP Install the front wheel with the mark “a” on the front tire pointing in the direction of wheel rota- tion. a 5. Tighten: • Front wheel axle nut Front wheel axle nut 26 N·m (2.6 kgf·m, 19 lb·ft) T R . . ECA14140 NOTICE Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth- ly. 6. Install: • Front wheel sensor Front wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . ECA21020 NOTICE Make sure there are no foreign materials in the front wheel sensor rotor and front wheel sensor. Foreign materials cause damage to the front wheel sensor rotor and front wheel sensor.
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TIP • When installing the front wheel sensor, check the front wheel sensor lead for twists. • To route the front wheel sensor lead, refer to “CABLE ROUTING” on page 2-15. 7. Measure: • Distance “a” (between the front wheel sensor rotor “1” and front wheel sensor “2”) Out of specification → Check the wheel bear- ing for looseness, and the front wheel sensor and sensor rotor installation conditions (warpage caused by overtorque, wrong in- stallation direction, rotor decentering, LOC- TITE® on the mounting surface of the rotor, deformation caused by an impact during ser- vice and caught foreign materials). If there is any defective part, repair or replace the de- fective part. Distance “a” (between the front wheel sensor rotor and front wheel sensor) 0.65–1.66 mm (0.026–0.065 in) TIP Measure the distance between the front wheel sensor rotor and front wheel sensor in several places in one rotation of the front wheel. Do not turn the front wheel while the thickness gauge is installed. This may damage the front wheel sen- sor rotor and the front wheel sensor. Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 a 2 2 1 1 4-28 FRONT WHEEL 8. Install: • Front brake caliper • Front brake hose guide “1” Front brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) Front brake hose guide bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . 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. a 1
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EAS20029 REAR WHEEL Removing the rear wheel and brake disc 1 3 23 N•m (2.3 kgf•m, 17 lb•ft) T.R. Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Front side cover 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 4-9. Muffler Refer to “ENGINE REMOVAL” on page 5-4. Radiator cover Refer to “RADIATOR” on page 6-2. Swingarm assembly Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM” on page 4-85. 1 Rear wheel 1 2 Rear wheel sensor rotor 1 3 Rear brake disc 1 4-29 REAR WHEEL 8 N•m (0.8 kgf•m, 5.9 lb•ft) T.R. 23 N•m (2.3 kgf•m, 17 lb•ft) T.R. LT LT LT LT New LT 2 LT New 8 N•m (0.8 kgf•m, 5.9 lb•ft) T.R.
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EAS30156 REMOVING THE REAR WHEEL (DISC) ECA22870 NOTICE • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor rotor; otherwise, the rotor may be damaged, re- sulting in improper performance of the ABS system. • Do not drop the rear wheel sensor rotor or subject it to shocks. • If any solvent gets on the rear wheel sensor rotor, 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. TIP Place the vehicle on the centerstand so that the rear wheel is off ground. EAS30159 CHECKING THE REAR WHEEL 1. Check: • Tire • Rear wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” on page 3-14 and “CHECKING THE WHEELS” on page 3-14. 2. Measure: • Radial wheel runout • Lateral wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-25. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 1.0 mm (0.04 in) 4-30 REAR WHEEL EAS30167 MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR ECA22890 NOTICE • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor rotor. • Do not drop or shock the wheel sensor ro- tor. 1. Check: • Rear wheel sensor rotor Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-25. EAS30164 ADJUSTING THE REAR WHEEL STATIC BALANCE TIP • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc installed. 1. Adjust: • Rear wheel static balance Refer to “ADJUSTING THE FRONT WHEEL STATIC BALANCE” on page 4-26.
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EAS30911 INSTALLING THE REAR WHEEL (REAR BRAKE DISC) 1. Install: • Rear brake disc “1” • Rear wheel sensor rotor “2” Rear wheel sensor rotor bolt 8 N·m (0.8 kgf·m, 5.9 lb·ft) LOCTITE® Rear brake disc bolt 23 N·m (2.3 kgf·m, 17 lb·ft) LOCTITE® T R . . ECA21011 NOTICE • Do not drop the wheel sensor rotor or sub- ject it to shocks. • If any solvent gets on the wheel sensor ro- tor, wipe it off immediately. • Replace the brake disc bolts and wheel sensor rotor bolts with new ones. TIP • Install the brake disc with its chamfered side “a” facing inward. • Install the rear wheel sensor rotor with the stamped mark “b” facing away from the wheel. • Tighten the bolts in stages. 1 1 a b 2 2. Check: • Rear brake disc Refer to “CHECKING THE REAR BRAKE DISC” on page 4-51. 4-31 REAR WHEEL
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EAS20030 FRONT BRAKE Removing the front brake pads 6 N·m (0.6 kgf·m, 4.4 lb·ft) 7 1 3 6 2 4 5 35 N·m (3.5 kgf·m, 26 lb·ft) 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 4-32 FRONT BRAKE
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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. 1 2 3 12 6 N·m (0.6 kgf·m, 4.4 lb·ft) T.R. 6 S 7 6 5 4 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 4-67. Brake fluid Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm holder 1 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 4-33 FRONT BRAKE 11 29 N·m (2.9 kgf·m, 21 lb·ft) T.R. 9 8 New 10
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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. 1 2 3 12 6 N·m (0.6 kgf·m, 4.4 lb·ft) T.R. 6 S 7 6 5 4 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 4-34 FRONT BRAKE 11 29 N·m (2.9 kgf·m, 21 lb·ft) T.R. 9 8 New 10
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Disassembling the front brake master cylinder S BF BF 1 New Order Job/Parts to remove Q’ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 4-35 FRONT BRAKE 2
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Removing the front brake caliper 1 3 2 New 4 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 Brake fluid Drain. 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 4-36 FRONT BRAKE
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Disassembling the front brake caliper 6 N·m (0.6 kgf·m, 4.4 lb·ft) T.R. 11 New 10 9 New 2 BF S 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 4-37 FRONT BRAKE 6 S 7 8 S S 5 3 4
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EAS30168 INTRODUCTION EWA14101 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. • Never use solvents on internal brake com- ponents. • Use only clean or new brake fluid for clean- ing brake components. • Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean 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. 4-38 FRONT BRAKE EAS30169 CHECKING THE FRONT BRAKE DISC 1. Remove: • Front wheel Refer to “FRONT WHEEL” on page 4-22. 2. Check: • Brake disc Damage/galling → Replace. 3. Measure: • Brake disc runout Out of specification → Correct the brake disc runout or replace the brake disc. Brake disc runout limit (as mea- sured on wheel) 0.15 mm (0.0059 in) a. Place the vehicle on a suitable stand so that the front wheel is off ground. b. Before measuring the front brake disc runout, turn the handlebar to the left or right to ensure that the front wheel is stationary. c. Remove the brake caliper. d. Hold the dial gauge at a right angle against the brake disc surface. e. Measure the runout 1.5 mm (0.06 in) below the edge of the brake disc.
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4. Measure: • Brake disc thickness Measure the brake disc thickness at a few dif- ferent locations. Out of specification → Replace. Brake disc thickness limit 3.5 mm (0.14 in) 5. Adjust: • Brake disc runout a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. Front brake disc bolt 23 N·m (2.3 kgf·m, 17 lb·ft) LOCTITE® T R . . ECA19150 NOTICE Replace the brake disc bolts with new ones. TIP • Install the brake disc “1” with its chamfered side “a” facing inward. • Tighten the brake disc bolts in stages. 1 1 a d. Measure the brake disc runout. e. If out of specification, repeat the adjustment steps until the brake disc runout is within specification. f. If the brake disc runout cannot be brought within specification, replace the brake disc. 4-39 FRONT BRAKE 6. Install: • Front wheel Refer to “FRONT WHEEL” on page 4-22. EAS30170 REPLACING THE FRONT BRAKE PADS TIP When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake pad lining thickness limit 0.8 mm (0.03 in) A a B a A. Inner B. Outer 2. Install: • Brake pad spring • Brake pads TIP Always install new brake pads, and new brake pad spring, as a set. a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container.
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b. Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger. 1 2 c. Tighten the bleed screw. Brake caliper bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) T R . . d. Install new brake pad spring and new brake pads. TIP The longer tangs “a” of the brake pad spring “1” must point in the direction of the brake caliper piston. a 1 3. Install: • Brake pad pin • Brake pad clips • Front brake caliper • Front brake caliper bolt Front brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) T R . . TIP While holding the front wheel sensor lead holder so that the portion “a” of the holder contacts the front fork outer tube, tighten the bolt to specifica- tion. 4-40 FRONT BRAKE a 4. 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. a 5. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12.
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EAS31328 REMOVING THE FRONT BRAKE CALIPER TIP Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Brake hose union bolt “1” • Brake hose gasket “2” • Front brake hose “3” TIP Put the end of the brake hose into a container and pump out the brake fluid carefully. 3 1 2 4-41 FRONT BRAKE EAS30172 DISASSEMBLING THE FRONT BRAKE CALIPER 1. Remove: • Brake caliper piston “1” • Brake caliper piston dust seal “2” • Brake caliper piston seal “3” 1 2 3 a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper “1”. EWA13550 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. • Never try to pry out the brake caliper pis- ton. a 1 b. Remove the brake caliper piston dust seal and brake caliper piston seal.
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EAS30173 CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule Brake pads If necessary Piston seal Every two years Piston dust seal Every two years Brake hose Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: • Brake caliper piston “1” Rust/scratches/wear → Replace the brake caliper piston. • Brake caliper cylinder “2” Scratches/wear → Replace the brake caliper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA17070 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. 1 2 3 2. Check: • Brake caliper bracket Cracks/damage → Replace. 4-42 FRONT BRAKE EAS30174 ASSEMBLING THE FRONT BRAKE CALIPER EWA16560 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and brake caliper piston seals. Specified brake fluid DOT 4 EAS30934 INSTALLING THE FRONT BRAKE CALIPER 1. Install: • Front brake caliper “1” (temporarily) • Brake hose gasket “2” • Front brake hose “3” • Brake hose union bolt “4” New Front brake hose union bolt (brake caliper side) 29 N·m (2.9 kgf·m, 21 lb·ft) T R . . EWA13531 WARNING Proper brake hose routing is essential to in- sure safe vehicle operation. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” passes between the projections “b” on the brake caliper. 3 1 b a 4 2 New
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2. Remove: • Front brake caliper 3. Install: • Brake pad spring • Brake pads • Brake pad pin • Brake pad clips • Front brake caliper • Front wheel sensor lead holder • Front brake caliper bolt 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 4-39. 4. Fill: • Brake master cylinder reservoir (with the specified amount of the specified brake fluid) Specified brake fluid 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. 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. 4-43 FRONT BRAKE 6. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. a 7. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. EAS30179 REMOVING THE FRONT BRAKE MASTER CYLINDER TIP Before removing the front brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Remove: • Brake hose union bolt “1” • Brake hose gasket “2” • Front brake hose “3” TIP To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. 2 3 1
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EAS30725 CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: • Brake master cylinder Damage/scratches/wear → Replace. • Brake fluid delivery passages (Brake master cylinder body) Obstruction → Blow out with compressed air. 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake master cylinder reservoir “1” • Brake master cylinder reservoir cap “2” • Brake master cylinder reservoir diaphragm holder “3” • Brake master cylinder reservoir diaphragm “4” Damage/wear → Replace. 2 1 3 4 4. Check: • Front brake hose Cracks/damage/wear → Replace. 4-44 FRONT BRAKE EAS30181 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents. Specified brake fluid DOT 4 EAS30182 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder • Brake master cylinder holder “1” Front brake master cylinder hold- er bolt 16 N·m (1.6 kgf·m, 12 lb·ft) T R . . TIP • Install the brake master cylinder holder with the “UP” mark “a” facing up. • Align the edge “b” of the brake master cylinder holder with the edge “c” of the stay on the han- dlebar as shown in the illustration. • First, tighten the upper bolt, then the lower bolt. b c 1 a
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2. Install: • Brake hose gasket “1” • Front brake hose “2” • Brake hose union bolt “3” New Front brake hose union bolt (master cylinder side) 29 N·m (2.9 kgf·m, 21 lb·ft) T R . . EWA13531 WARNING Proper brake hose routing is essential to in- sure safe vehicle operation. TIP • Make sure that the distance “a” between the brake hose and the handlebar “4” is 40–44 mm (1.57–1.73 in) as shown in the illustration. • Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. New 1 3 4 2 a 3. Fill: • Brake master cylinder reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT 4 4-45 FRONT BRAKE 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. a 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12.
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EAS20031 REAR BRAKE Removing the rear brake pads 1 7 6 N·m (0.6 kgf·m, 4.4 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 1 Rear 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 4-46 REAR BRAKE 35 N·m (3.5 kgf·m, 26 lb·ft) T.R. 4 5 6 3 2
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Removing the rear brake master cylinder 16 N·m (1.6 kgf·m, 12 lb·ft) 1.5 N·m (0.15 kgf·m, 1.1 lb·ft) 11 6 8 29 N·m (2.9 kgf·m, 21 lb·ft) 9 New 10 6 N·m (0.6 kgf·m, 4.4 lb·ft) 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) Order Job/Parts to remove Q’ty Remarks Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-67. Brake fluid Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. 1 Brake master cylinder reservoir cap 1 2 Brake master cylinder reservoir diaphragm holder 1 3 Brake master cylinder reservoir diaphragm 1 4 Rear brake light switch connector 2 Disconnect. 5 Rear brake light switch 1 6 Rear brake lever pivot bolt/nut 1/1 7 Rear brake lever 1 8 Rear brake hose union bolt 1 9 Brake hose gasket 2 10 Rear brake hose 1 Disconnect. 11 Rear brake master cylinder holder 1 12 Rear brake master cylinder assembly 1 4-47 REAR BRAKE 1 2 3 6 N·m (0.6 kgf·m, 4.4 lb·ft) S 12 7 5 6 4
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Disassembling the rear brake master cylinder 2 Order Job/Parts to remove Q’ty Remarks 1 Brake master cylinder kit 1 2 Brake master cylinder body 1 4-48 REAR BRAKE BF S BF New 1
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Removing the rear brake caliper 35 N·m (3.5 kgf·m, 26 lb·ft) 4 29 N·m (2.9 kgf·m, 21 lb·ft) T.R. New 2 3 1 Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. 1 Rear brake hose union bolt (brake caliper side) 1 2 Brake hose gasket 2 3 Rear brake hose 1 Disconnect. 4 Rear brake caliper 1 4-49 REAR BRAKE T.R.
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Disassembling the rear brake caliper 6 S 7 S 8 New 9 S 10 6 N·m (0.6 kgf·m, 4.4 lb·ft) T.R. 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 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 4-50 REAR BRAKE 3 4 BF New 11 5 2 1
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EAS30183 INTRODUCTION EWA14101 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. • Never use solvents on internal brake com- ponents. • Use only clean or new brake fluid for clean- ing brake components. • Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean 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. 4-51 REAR BRAKE EAS30184 CHECKING THE REAR BRAKE DISC 1. Remove: • Rear wheel Refer to “REAR WHEEL” on page 4-29. 2. Check: • Brake disc Damage/galling → Replace. 3. Measure: • Brake disc runout Out of specification → Correct the brake disc runout or replace the brake disc. Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-38. Brake disc runout limit (as mea- sured on wheel) 0.15 mm (0.0059 in) 4. Measure: • Brake disc thickness Measure the brake disc thickness at a few dif- ferent locations. Out of specification → Replace. Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-38. Brake disc thickness limit 4.0 mm (0.16 in) 5. Adjust: • Brake disc runout Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-38. Rear brake disc bolt 23 N·m (2.3 kgf·m, 17 lb·ft) LOCTITE® T R . . 6. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-29.
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EAS30185 REPLACING THE REAR BRAKE PADS TIP When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disassem- ble the brake caliper. 1. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake pad lining thickness limit 0.8 mm (0.03 in) A a B a A. Inner B. Outer 2. Install: • Brake pad spring • Brake pads TIP Always install new brake pads and brake pad spring as a set. a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. 4-52 REAR BRAKE b. Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger. 2 1 c. Tighten the bleed screw. Brake caliper bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) T R . . d. Install new brake pad spring and new brake pads. TIP The longer tangs “a” of the brake pad spring must point in the direction of the brake caliper position. a a 3. Install: • Brake pad pin • Brake pad clips • Rear brake caliper • Rear brake caliper bolt Rear brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) T R . .
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4. 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. a 5. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. EAS30186 REMOVING THE REAR BRAKE CALIPER TIP Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • Rear brake hose union bolt “1” • Brake hose gasket “2” • Rear brake hose “3” TIP Put the end of the brake hose into a container and pump out the brake fluid carefully. 2 3 1 4-53 REAR BRAKE EAS30187 DISASSEMBLING THE REAR BRAKE CALIPER 1. Remove: • Brake caliper piston “1” • Brake caliper piston dust seal “2” • Brake caliper piston seal “3” 1 2 3 a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the brake caliper. EWA13550 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. • Never try to pry out the brake caliper pis- ton. a b. Remove the brake caliper piston dust seal and brake caliper piston seal.
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EAS30188 CHECKING THE REAR BRAKE CALIPER Recommended brake component replacement schedule Brake pad If necessary Piston seal Every two years Piston dust seal Every two years Brake hose Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: • Brake caliper piston “1” Rust/scratches/wear → Replace the brake caliper piston. • Brake caliper cylinder “2” Scratches/wear → Replace the brake caliper assembly. • Brake caliper body “3” Cracks/damage → Replace the brake caliper assembly. • Brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. EWA17070 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. 1 2 3 2. Check: • Brake caliper bracket Cracks/damage → Replace. 4-54 REAR BRAKE EAS30189 ASSEMBLING THE REAR BRAKE CALIPER EWA17080 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seal and brake caliper piston seal to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston dust seal and brake caliper piston seal. Specified brake fluid DOT 4 EAS30190 INSTALLING THE REAR BRAKE CALIPER 1. Install: • Rear brake caliper “1” (temporarily) • Brake hose gasket “2” • Rear brake hose “3” • Brake hose union bolt “4” New Rear brake hose union bolt (brake caliper side) 29 N·m (2.9 kgf·m, 21 lb·ft) T R . . EWA13531 WARNING Proper brake hose routing is essential to in- sure safe vehicle operation. ECA19080 NOTICE When installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” passes between the projections “b” on the brake caliper. b 1 a 2 New 4 3
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2. Remove: • Rear brake caliper 3. Install: • Brake pad spring • Brake pads • Brake pad pin • Brake pad clips • Rear brake caliper Rear brake caliper bolt 35 N·m (3.5 kgf·m, 26 lb·ft) T R . . Refer to “REPLACING THE REAR BRAKE PADS” on page 4-52. 4. Fill: • Brake master cylinder reservoir (with the specified amount of the specified brake fluid) Specified brake fluid 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. 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. 4-55 REAR BRAKE 6. 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. a 7. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. EAS30193 REMOVING THE REAR BRAKE MASTER CYLINDER TIP Before removing the rear brake master cylinder, drain the brake fluid from the entire brake sys- tem. 1. Remove: • Brake hose union bolt “1” • Brake hose gasket “2” • Brake hose “3” TIP To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. 2 1 3
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EAS30194 CHECKING THE REAR BRAKE MASTER CYLINDER 1. Check: • Brake master cylinder Damage/scratches/wear → Replace. • Brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. 2. Check: • Brake master cylinder kit Damage/scratches/wear → Replace. 3. Check: • Brake master cylinder reservoir “1” • Brake master cylinder reservoir cap • Brake master cylinder reservoir diaphragm holder “2” • Brake master cylinder reservoir diaphragm “3” Damage/wear → Replace. 4. Check: • Brake hose Cracks/damage/wear → Replace. 2 1 3 EAS30195 ASSEMBLING THE REAR BRAKE MASTER CYLINDER EWA13520 WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake com- ponents. Specified brake fluid DOT 4 4-56 REAR BRAKE EAS30196 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder • Brake master cylinder holder “1” Rear brake master cylinder hold- er bolt 16 N·m (1.6 kgf·m, 12 lb·ft) T R . . TIP • Install the brake master cylinder holder with the “UP” mark “a” facing up. • Align the edge “b” of the brake master cylinder holder with the edge “c” of the stay on the han- dlebar as shown in the illustration. • First, tighten the upper bolt, then the lower bolt. b 1 c a 2. Install: • Brake hose gasket “1” • Rear brake hose “2” • Brake hose union bolt “3” New Rear brake hose union bolt (mas- ter cylinder side) 29 N·m (2.9 kgf·m, 21 lb·ft) T R . . EWA13531 WARNING Proper brake hose routing is essential to in- sure safe vehicle operation.
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3. Fill: • Brake master cylinder reservoir (with the specified amount of the specified brake fluid) 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. Specified brake fluid 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. a 4-57 REAR BRAKE
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EAS20032 ABS (Anti-lock Brake System) Removing the hydraulic unit assembly 29 N•m (2.9 kgf•m, 21 lb•ft) T.R. 2 4 New 5 3 3 7 8 2 4 4 New New 6 4 New 1 9 Order Job/Parts to remove Q’ty Remarks Brake fluid Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page 4-3. Front upper cowling assembly Refer to “GENERAL CHASSIS (6)” on page 4-15. 1 ABS ECU coupler 1 Disconnect. 2 Front brake hose union bolt (hydraulic unit assembly side) 2 3 Rear brake hose union bolt (hydraulic unit assembly side) 2 4 Brake hose gasket 8 5 Front brake hose (hydraulic unit to front brake caliper) 1 Disconnect. 6 Front brake hose (front brake master cylinder to hydraulic unit) 1 Disconnect. 7 Rear brake hose (rear brake master cylinder to hydraulic unit) 1 Disconnect. 4-58 ABS (Anti-lock Brake System) 7 N•m (0.7 kgf•m, 5.2 lb•ft) T.R.
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Removing the hydraulic unit assembly 29 N•m (2.9 kgf•m, 21 lb•ft) T.R. 2 4 5 New 3 3 7 8 2 4 4 New New 6 4 New 1 9 Order Job/Parts to remove Q’ty Remarks 8 Rear brake hose (hydraulic unit to rear brake caliper) 1 Disconnect. 9 Hydraulic unit assembly 1 4-59 ABS (Anti-lock Brake System) 7 N•m (0.7 kgf•m, 5.2 lb•ft) T.R.
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EAS30197 REMOVING THE HYDRAULIC UNIT ASSEMBLY ECA21091 NOTICE Unless necessary, avoid removing and in- stalling the brake hoses of the hydraulic unit assembly. EWA13930 WARNING Refill with the same type of brake fluid that is already in the system. Mixing fluids may re- sult in a harmful chemical reaction, leading to poor braking performance. ECA18241 NOTICE • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. • Do not turn the main switch to “ON” when removing the hydraulic unit assembly. • Do not clean with compressed air. • Do not reuse the brake fluid. • Brake fluid may damage painted surfaces 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. 1. Disconnect: • ABS ECU coupler “1” TIP While pushing the portion “a” of the ABS ECU coupler, move the lock lever “b” in the direction of the arrow shown to disconnect the coupler. b 1 a 4-60 ABS (Anti-lock Brake System) 2. Remove: • Brake hose TIP Do not operate the brake levers while removing the brake hoses. ECA14530 NOTICE When removing the brake hoses, cover the area around the hydraulic unit to catch any spilt brake fluid. Do not allow the brake fluid to contact other parts. 3. Remove: • Hydraulic unit assembly “1” TIP • To avoid brake fluid leakage and to prevent for- eign materials from entering the hydraulic unit assembly, insert a rubber plug “a” or a bolt (M10 × 1.25) into each brake hose union bolt hole. • When using a bolt, do not tighten the bolt until the bolt head touches the hydraulic unit. Other- wise, the brake hose union bolt seating surface could be deformed. 1 a EAS30198 CHECKING THE HYDRAULIC UNIT ASSEMBLY 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.
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EAS30200 INSTALLING THE HYDRAULIC UNIT ASSEMBLY 1. Install: • Hydraulic unit assembly Hydraulic unit assembly bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . ECA21110 NOTICE Do not remove the rubber plugs or bolts (M10 × 1.25) installed in the brake hose union bolt holes before installing the hydraulic unit assembly. TIP Do not allow any foreign materials to enter the hydraulic unit assembly or the brake hoses when installing the hydraulic unit assembly. 2. Remove: • Rubber plugs or bolt (M10 × 1.25) 3. Install: • Rear brake hose (hydraulic unit to rear brake caliper) “1” • Rear brake hose (rear brake master cylinder to hydraulic unit) “2” • Front brake hose (front brake master cylinder to hydraulic unit) “3” • Front brake hose (hydraulic unit to front brake caliper) “4” Front brake hose union bolt (hy- draulic unit assembly side) 29 N·m (2.9 kgf·m, 21 lb·ft) Rear brake hose union bolt (hy- draulic unit assembly side) 29 N·m (2.9 kgf·m, 21 lb·ft) T R . . ECA21121 NOTICE If the brake hose union bolt does not turn easily, replace the hydraulic unit assembly, brake hoses, and related parts as a set. TIP As shown in the picture, when the brake hose is assembled, the steel pipe touches the convex. After the position of edge “a”, follow the se- quence of 1 → 2 → 3 → 4. Tighten the connect- ing bolts to the specified torque value. 4-61 ABS (Anti-lock Brake System) a a 4 4 1 3 2 1 2 a 3 a 4. Connect: • ABS ECU coupler “1” TIP • Connect the ABS ECU coupler, and then push the lock lever “a” of the coupler in the direction of the arrow shown. • Make sure that the ABS ECU coupler is con- nected in the correct position as shown in illus- tration “A”. 1 a A B A. The ABS ECU coupler is connected cor- rectly. B. The ABS ECU coupler is not connected.
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5. Fill: • Brake master cylinder reservoir • Brake fluid reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT 4 EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 6. Bleed: • Brake system 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 4-62.) ECA14550 NOTICE Always check the operation of the hydraulic unit according to the brake lever response. 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 4-66.) 4-62 ABS (Anti-lock Brake System) 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 the following two methods. • Brake line routing confirmation: this test checks the function of the ABS after the sys- tem was disassembled, adjusted, or serviced. • ABS reaction-force confirmation: this test gen- erates the same reaction-force pulsating action that is generated in the front brake lever and rear brake lever when the ABS is front activat- ed. Brake line routing confirmation EWA13120 WARNING Securely support the vehicle so that there is 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 wheels are not rotating. 1. Place the vehicle on the centerstand. 2. Turn the main switch to “OFF”. 3. Open the seat. 4. Remove: • Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1.
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5. Check: • Battery voltage Lower than 12.8 V → Charge or replace the battery. Battery voltage Higher than 12.8 V TIP If the battery voltage is lower than 12.8 V, charge the battery, and then perform brake line routing confirmation. 6. Disconnect the Yamaha diagnostic tool cou- pler from the CCU (Communication Control Unit) “1”, and then connect the Yamaha diag- nostic tool to the coupler. Yamaha diagnostic tool USB 90890-03267 Yamaha diagnostic tool (A/I) 90890-03264 1 7. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 8. Select code No. 2, “Brake line routing confir- mation”. 4-63 ABS (Anti-lock Brake System) 9. Click “Actuator Check”, and then operate the front brake lever “1” and rear brake lever “2” simultaneously. TIP • The hydraulic unit operates 1 second after the front brake lever and rear brake lever are oper- ated simultaneously and continues for approx- imately 5 seconds. • The operation of the hydraulic unit can be con- firmed using the indicator. On: The hydraulic unit is operating. Flashing: The conditions for operating the hy- draulic unit have not been met. Off: The front brake lever and rear brake lever are not being operated. 2 1 10.Check: • Hydraulic unit operation Click “Actuator Check”, a single pulse will be generated in the front brake lever “1”, rear brake lever “2”, and again in the front brake lever “1”, in this order. 2 1 TIP “ON” and “OFF” on the tool screen indicate when the brakes are being applied and released respectively.
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ECA22080 NOTICE • Check that the pulse is felt in the front brake lever, rear brake lever, and again in the front brake lever, in this order. • If the pulse is felt in the rear brake lever be- fore it is felt in the front brake lever, check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly. • If the pulse is hardly felt in either the front brake lever or rear brake lever, check that the brake hoses and brake pipes are con- nected correctly to the hydraulic unit as- sembly. 11.If the operation of the hydraulic unit is normal, delete all of the fault codes. ABS reaction-force confirmation EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. TIP • For the ABS reaction-force confirmation, use the diagnosis mode of the Yamaha diagnostic tool. For more information, refer to the opera- tion manual of the Yamaha diagnostic tool. • Before performing the ABS reaction-force con- firmation, make sure that no malfunctions have been detected in the ABS ECU and that the wheels are not rotating. 1. Place the vehicle on a centerstand. 2. Turn the main switch to “OFF”. 3. Open the seat. 4. Remove: • Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1. 4-64 ABS (Anti-lock Brake System) 5. Check: • Battery voltage Lower than 12.8 V → Charge or replace the battery. Battery voltage Higher than 12.8 V TIP If the battery voltage is lower than 12.8 V, charge the battery, and then perform ABS reaction- force confirmation. 6. Disconnect the Yamaha diagnostic tool cou- pler from the CCU (Communication Control Unit) “1”, and then connect the Yamaha diag- nostic tool to the coupler. Yamaha diagnostic tool USB 90890-03267 Yamaha diagnostic tool (A/I) 90890-03264 1 7. Start the Yamaha diagnostic tool and display the diagnosis mode screen. 8. Select code No. 1, “ABS reaction-force con- firmation”.
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9. Click “Actuator Check”, and then operate the front brake lever “1” and rear brake lever “2” simultaneously. TIP • The hydraulic unit operates 1 second after the front brake lever and rear brake lever are oper- ated simultaneously and continues for approx- imately 5 seconds. • The operation of the hydraulic unit can be con- firmed using the indicator. On: The hydraulic unit is operating. Flashing: The conditions for operating the hy- draulic unit have not been met. Off: The front brake lever and rear brake lever are not being operated. 2 1 10.A reaction-force pulsating action is generated in the front brake lever “1” and continues for a few seconds. TIP • The reaction-force pulsating action consists of quick pulses. • Be sure to continue operating the front brake lever and rear brake lever even after the pul- sating action has stopped. • “ON” and “OFF” on the tool screen indicate when the brakes are being applied and re- leased respectively. 1 4-65 ABS (Anti-lock Brake System) 11.After the pulsating action has stopped in the front brake lever, it is generated in the rear brake lever “1” and continues for a few sec- onds. TIP • The reaction-force pulsating action consists of quick pulses. • Be sure to continue operating the front brake lever and rear brake lever even after the pul- sating action has stopped. • “ON” and “OFF” on the tool screen indicate when the brakes are being applied and re- leased respectively. 1 12.After the pulsating action has stopped in the rear brake lever, it is generated in the front brake lever and continues for a few seconds. TIP • The reaction-force pulsating action consists of quick pulses. • “ON” and “OFF” on the tool screen indicate when the brakes are being applied and re- leased respectively. ECA22080 NOTICE • Check that the pulse is felt in the front brake lever, rear brake lever, and again in the front brake lever, in this order. • If the pulse is felt in the rear brake lever be- fore it is felt in the front brake lever, check that the brake hoses and brake pipes are connected correctly to the hydraulic unit assembly. • If the pulse is hardly felt in either the front brake lever or rear brake lever, check that the brake hoses and brake pipes are con- nected correctly to the hydraulic unit as- sembly. 13.Turn the main switch to “OFF”. 14.Remove the Yamaha diagnostic tool from the Yamaha diagnostic tool coupler, and then in- stall the protective cap.
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15.Turn the main switch to “ON”. 16.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. 17.If the operation of the hydraulic unit is normal, delete all of the fault codes. 4-66 ABS (Anti-lock Brake System) EAS30202 CHECKING THE ABS WARNING LIGHT After all checks and servicing are completed, en- sure that the ABS warning light goes off by walk- ing the vehicle at a speed of faster than 10 km/h (6 mph) or performing a trial run.
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EAS20033 HANDLEBAR Removing the rearview mirror and handlebar cover 1 22 N·m (2.2 kgf·m, 16 lb·ft) T.R. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R. (2) Order Job/Parts to remove Q’ty Remarks 1 Rearview mirror 2 2 Upper handlebar cover assembly 1 3 Upper handlebar panel 1 4 Upper handlebar cover 1 4-67 HANDLEBAR 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T.R. 2 1 3 4 22 N·m (2.2 kgf·m, 16 lb·ft) T.R. (2)
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Removing the handlebar 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) T.R. 6 LS 1 LS LS 8 LS 7 6 3 4 2 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) T.R. 15 Order Job/Parts to remove Q’ty Remarks Front cowling assembly Refer to “GENERAL CHASSIS (6)” on page 4-15 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 Rear brake light switch connector 2 Disconnect. 4-68 HANDLEBAR 16 N·m (1.6 kgf·m, 12 lb·ft) T.R. 5 53 N·m (5.3 kgf·m, 39 lb·ft) T.R. 16 N·m (1.6 kgf·m, 12 lb·ft) T.R. 12 10 16 9 13 11 1 12 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) T.R. 14 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R.
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Removing the handlebar 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) T.R. 6 LS 1 LS LS 8 LS 7 6 3 4 2 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) T.R. 15 Order Job/Parts to remove Q’ty Remarks 10 Rear brake master cylinder holder 1 11 Rear brake master cylinder 1 12 Handlebar switch (left) 1 13 Handlebar grip 1 14 Clamp 1 15 Upper handlebar cover 1 16 Handlebar 1 4-69 HANDLEBAR 16 N·m (1.6 kgf·m, 12 lb·ft) T.R. 5 53 N·m (5.3 kgf·m, 39 lb·ft) T.R. 16 N·m (1.6 kgf·m, 12 lb·ft) T.R. 12 10 16 9 13 11 1 12 2.3 N·m (0.23 kgf·m, 1.7 lb·ft) T.R. 14 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T.R.
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EAS31622 REMOVING THE UPPER HANDLEBAR COVER ASSEMBLY 1. Remove: • Upper handlebar cover assembly “1” a. Remove the quick fastener and upper han- dlebar cover assembly screws. b. Unhook the projections “a” on the upper handlebar cover assembly from the slots “b” in the lower handlebar cover. 1 a b EAS31701 DISASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY 1. Disassemble: • Upper handlebar panel “1” • Upper handlebar panel “2” TIP Unhook the projections “a” on the front handle- bar cover from the slots “b” in the front handlebar cover. 1 b a 2 4-70 HANDLEBAR EAS30203 REMOVING THE HANDLEBAR 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: • Grip end 3. Remove: • Handlebar grip “1” TIP Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. EAS30204 CHECKING THE HANDLEBAR 1. Check: • Handlebar Bends/cracks/damage → Replace. EWA13690 WARNING Do not attempt to straighten a bent handle- bar as this may dangerously weaken it.
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EAS30205 INSTALLING THE HANDLEBAR 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. Install: • Handlebar “1” Handlebar bracket nut 53 N·m (5.3 kgf·m, 39 lb·ft) T R . . 1 3. Install: • Handlebar switch (left) “1” TIP Align the projection “a” on the left handlebar switch with the hole “b” in the rear handlebar cover. 1 1 a b 4-71 HANDLEBAR 4. Install: • Handlebar grip “1” • Grip end (left) “2” a. Apply a thin coat of a rubber adhesive to the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. TIP Make sure that the distance “a” between the end of the left handlebar switch and the end of the handlebar grip is 0 mm (0 in). 1 a c. Wipe off any excess rubber adhesive with a clean rag. EWA13700 WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried. d. Install the left grip end. TIP There should be 1.0–3.0 mm (0.04–0.12 in) of clearance “a” between the handlebar grip and the grip end. 1 2 1 2 a
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5. Install: • Handlebar switch (right) “1” • Throttle cables “2” • Throttle grip “3” • Grip end (right) Throttle cable holder bolt (han- dlebar switch side) 2.5 N·m (0.25 kgf·m, 1.8 lb·ft) T R . . TIP • Lubricate the end of the throttle cables and the inside of the throttle grip with a thin coat of lith- ium-soap-based grease. • Align the projection “a” on the right handlebar switch with the hole “b” in the rear handlebar cover. • There should be 1.0–3.0 mm (0.04–0.12 in) of clearance between the throttle grip and the grip end. LS 3 LS 1 2 1 b a 2 6. Install: • Front brake master cylinder • Front brake master cylinder holder “1” Front brake master cylinder hold- er bolt 16 N·m (1.6 kgf·m, 12 lb·ft) T R . . TIP • Install the brake master cylinder holder with the “UP” mark “a” facing up. • Align the edge “b” of the brake master cylinder holder with the edge “c” of the stay on the han- dlebar as shown in the illustration. • First, tighten the upper bolt, then the lower bolt. 4-72 HANDLEBAR b c 1 UP a 7. Adjust: • Throttle grip free play Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-25. Throttle grip free play 3.0–5.0 mm (0.12–0.20 in) EAS31702 ASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY 1. Assemble: • Upper handlebar cover “1” • Upper handlebar cover “2” TIP Fit the projections “a” on the front handlebar cov- er into the slots “b” in the front handlebar cover. 1 b a 2
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EAS31623 INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY 1. Install: • Upper handlebar cover assembly “1” a. Fit the projections “a” on the upper handle- bar cover into the slots “b” in the lower han- dlebar cover. 1 a b b. Install the upper handlebar cover assembly screws, and then tighten the screws to specification. Upper handlebar cover assembly screw 1.8 N·m (0.18 kgf·m, 1.3 lb·ft) T R . . 4-73 HANDLEBAR
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EAS20034 FRONT FORK Removing the front fork legs 53 N·m (5.3 kgf·m, 39 lb·ft) T.R. 2 2 8 N·m (0.8 kgf·m, 5.9 lb·ft) T.R. 8 N·m (0.8 kgf·m, 5.9 lb·ft) 1 Order Job/Parts to remove Q’ty Remarks Front wheel Refer to “FRONT WHEEL” on page 4-22. 1 Front fender 1 2 Lower bracket pinch bolt 2 3 Front fork leg 1 4-74 FRONT FORK 3 T.R. The following procedures are applied to both of the front fork legs.
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Disassembling the front fork legs 9 New 14 LS 15 13 8 New LT 7 23 N·m (2.3 kgf·m, 17 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 1 Front fork cap clip 1 2 Front fork cap 1 3 O-ring 1 4 Fork spring 1 5 Dust seal 1 6 Oil seal clip 1 7 Front fork damper rod bolt 1 8 Copper washer 1 9 Oil flow stopper 1 10 Damper rod 1 11 Rebound spring 1 12 Damper rod ring 1 13 Inner tube 1 14 Oil seal 1 15 Outer tube 1 4-75 FRONT FORK 12 1 New 10 2 LS 3 New 11 4 5 New 6 New The following procedures are applied to both of the front fork legs.
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EAS30206 REMOVING THE FRONT FORK LEGS The following procedures are applied to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 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 front wheels are off ground. 2. Loosen: • Lower bracket pinch bolts “1” EWA18000 WARNING Before loosening the lower bracket pinch bolts, support the front fork leg. 1 1 EAS30207 DISASSEMBLING THE FRONT FORK LEGS The following procedures are applied to both of the front fork legs. ECA19110 NOTICE • The front fork leg has a very sophisticated internal construction, which are particular- ly sensitive to foreign material. • 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” TIP Push the front fork cap in the direction of the ar- row shown in the illustration to remove the front fork cap clip. 4-76 FRONT FORK 1 2 2. Drain: • Fork oil TIP Stroke the outer tube several times while drain- ing the fork oil. 3. Remove: • Dust seal “1” • Oil seal clip “2” (with a flathead screwdriver) ECA14180 NOTICE Do not scratch the inner tube. 1 2
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4. Remove: • Front fork damper rod bolt “1” • Copper washer TIP While holding the damper rod with the hexagon bit socket (14 mm) “2” and T-handle “3”, loosen the front fork damper rod bolt. T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 2 3 1 EAS30208 CHECKING THE FRONT FORK LEGS The following procedures are applied to both of the front fork legs. 1. Check: • Inner tube • Outer tube Bends/damage/scratches → Replace. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: • Fork spring free length “a” Out of specification → Replace. Fork spring free length limit 235.6 mm (9.28 in) a 4-77 FRONT FORK 3. Check: • Damper rod Damage/wear → Replace. Obstruction → Blow out all of the oil passag- es with compressed air. • Oil flow stopper Damage → Replace. EAS30209 ASSEMBLING THE FRONT FORK LEGS The following procedures are applied to both of the front fork legs. EWA13660 WARNING • Make sure the oil levels in both front fork 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 – Oil seal – Oil seal clip – Dust seal – Copper washer – O-ring • Before assembling the front fork leg, make sure all of the components are clean. 1. Install: • Damper rod ring “1” • Damper rod “2” • Rebound spring “3” (in the inner tube “4”) • Oil flow stopper “5” ECA22740 NOTICE Allow the damper rod to slide slowly down the inner tube until it protrudes from the bot- tom of the inner tube. Be careful not to dam- 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- jections is facing in the direction shown in the il- lustration.
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2 1 2 1 3 4 5 2. Install: • Oil seal “1” (with the fork seal driver attachment “2” and fork seal driver weight “3”) New ECA14220 NOTICE Make sure the numbered side of the oil seal faces up. TIP • Lubricate the outer surface of the inner tube with fork oil. • Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation. Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø30) 90890-01400 4-78 FRONT FORK 3 2 1 New 3. Lubricate: • Inner tube’s outer surface Recommended oil Yamaha Suspension Oil G10 4. Install: • Inner tube (in the outer tube) 5. Install: • Copper washer • Front fork damper rod bolt “1” New Front fork damper rod bolt 23 N·m (2.3 kgf·m, 17 lb·ft) LOCTITE® T R . . TIP While holding the damper rod assembly with the hexagon bit socket (14 mm) “2” and T-handle “3”, tighten the front fork damper rod bolt. T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 2 3 1
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6. Install: • Oil seal clip “1” New TIP Adjust the oil seal clip so that it fits into the outer tube’s groove. 1 New 7. Install: • Dust seal “1” (with the fork seal driver attachment “2” and fork seal driver weight “3”) New Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø30) 90890-01400 3 2 1 New 8. Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Yamaha Suspension Oil G10 Quantity 89.0 cm³ (3.01 US oz, 3.14 Imp.oz) 4-79 FRONT FORK ECA14230 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 Be sure to stroke the inner tube slowly because the fork oil may spurt out. 1 10.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. TIP Be sure to bleed the front fork leg of any residual air.
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11.Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the inner tube fully compressed and without the fork spring) Out of specification → Correct. Level (left) 77 mm (3.1 in) Level (right) 77 mm (3.1 in) TIP • While filling the front fork leg, keep it upright. • After filling, slowly pump the front fork leg up and down to distribute the fork oil. 12.Install: • Fork spring “1” • O-ring • Front fork cap • Front fork cap clip New New TIP Install the fork spring with its smaller pitch down- ward. 1 4-80 FRONT FORK EAS30210 INSTALLING THE FRONT FORK LEGS The following procedures are applied 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. 1 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. 1 1
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EAS20035 STEERING HEAD Removing the lower bracket 75 N·m (7.5 kgf·m, 55 lb·ft) 38 N·m (3.8 kgf·m, 28 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft) 1st *2nd 15 LS 12 13 LS 14 8 1 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 Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. Front upper cowling assembly Refer to “GENERAL CHASSIS (6)” on page 4-15. Front wheel Refer to “FRONT WHEEL” on page 4-22. Handlebar Refer to “HANDLEBAR” on page 4-67. Front fork legs Refer to “FRONT FORK” on page 4-74. 1 Front brake hose holder 1 2 Ring nut cover 1 3 Upper ring nut 1 4 Lock washer 1 4-81 STEERING HEAD 2 3 4 5 6 LS 9 7 16 10 11
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Removing the lower bracket 75 N·m (7.5 kgf·m, 55 lb·ft) 38 N·m (3.8 kgf·m, 28 lb·ft) 17 N·m (1.7 kgf·m, 13 lb·ft) 1st *2nd LS 15 12 13 LS 14 8 1 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 5 Center ring nut 1 6 Rubber washer 1 7 Lower ring nut 1 8 Lower bracket 1 9 Bearing cover 1 10 Upper bearing inner race 1 11 Upper bearing 1 12 Lower bearing 1 13 Lower bearing inner race 1 14 Dust seal 1 15 Lower bearing outer race 1 16 Upper bearing outer race 1 4-82 STEERING HEAD 2 3 4 5 6 LS 9 7 16 10 11
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EAS30213 REMOVING THE LOWER BRACKET 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: • Ring nut cover • Upper ring nut “1” • Lock washer • Center ring nut • Rubber washer • Lower ring nut • Lower bracket EWA13730 WARNING Securely support the lower bracket so that there is no danger of it falling. TIP 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 2 1 EAS30214 CHECKING THE STEERING HEAD 1. Wash: • Bearing • Bearing race Recommended cleaning solvent Kerosene 2. Check: • Bearing • Bearing race Damage/pitting → Replace the bearings and bearing races as a set. 4-83 STEERING HEAD 3. Replace: • Bearing • Bearing race a. Remove the bearing races from the steer- ing head pipe “1” with a long rod “2” and hammer. b. Remove the bearing race “3” from the lower bracket with a floor chisel “4” and hammer. c. Install a new dust seal and new bearing rac- es. ECA14270 NOTICE If the bearing race is not installed properly, the steering head pipe could be damaged. TIP • Always replace the bearings and bearing races as a set. • Whenever the steering head is disassembled, replace the dust seal. 4. Check: • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace.
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EAS30216 INSTALLING THE STEERING HEAD 1. Install: • Upper bearing “1” • Lower bearing • Lower bearing dust seal TIP • Apply lithium-soap-based grease to each part. • Be sure to install the upper bearing so that the marks “a” on the bearing are facing upward. a 1 2. Install: • 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 3-16. 5 4 3 2 1 4-84 STEERING HEAD 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. a 1
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS20189 REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm 13 New 12 10 5 5 21 N•m (2.1 kgf•m, 15 lb•ft) T.R. 21 N•m (2.1 kgf•m, 15 lb•ft) T.R. 21 N•m (2.1 kgf•m, 15 lb•ft) T.R. Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Front side cover 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 4-9. Muffler Refer to “ENGINE REMOVAL” on page 5-4. Radiator cover Refer to “RADIATOR” on page 6-2. Air filter case Refer to “AIR FILTER CASE” on page 7-8. 1 Rear wheel axle nut 1 2 Rear brake hose holder (rear side) 1 3 Rear wheel sensor 1 4-85 2 4 3 7 N m (0.7 kgf m, 5.2 lb ft) T.R. 57 N m (5.7 kgf m, 42 lb ft) T.R. New 6 11 10 7 9 1 8 7 N•m (0.7 kgf•m, 5.2 lb•ft) T.R. 125 N•m (12.5 kgf•m, 92 lb•ft) T.R. 7 N•m (0.7 kgf•m, 5.2 lb•ft) T.R. 35 N•m (3.5 kgf•m, 26 lb•ft) T.R.
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM Removing the rear shock absorber assemblies and swingarm 13 New 12 10 5 5 21 N•m (2.1 kgf•m, 15 lb•ft) T.R. 21 N•m (2.1 kgf•m, 15 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 Rear brake caliper 1 5 Rear shock absorber assembly 2 6 Swingarm assembly 1 7 Rear brake hose guide 1 8 Spacer 1 9 Bearing retaining plate 1 10 Oil seal 2 11 Bearing 1 12 Swingarm 1 13 Collar 1 4-86 2 4 3 7 N m (0.7 kgf m, 5.2 lb ft) T.R. 57 N m (5.7 kgf m, 42 lb ft) T.R. New 6 11 10 7 9 1 8 7 N•m (0.7 kgf•m, 5.2 lb•ft) T.R. 125 N•m (12.5 kgf•m, 92 lb•ft) T.R. 7 N•m (0.7 kgf•m, 5.2 lb•ft) T.R. 35 N•m (3.5 kgf•m, 26 lb•ft) T.R.
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS31228 REMOVING THE SWINGARM ECA22880 NOTICE Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor; other- wise, the sensor may be damaged, resulting in improper performance of the ABS system. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. TIP Place the vehicle on the centerstand so that the rear wheel is off ground. 2. Remove: • Rear wheel axle nut “1” • Rear brake hose holder (rear side) “2” • Rear wheel sensor “3” • Rear brake caliper “4” ECA21830 NOTICE Do not apply the brake lever when removing the brake caliper. 2 4 3 1 4-87 EAS31734 MAINTENANCE OF THE REAR WHEEL SENSOR ECA22900 NOTICE • Handle the ABS components with care since they have been accurately adjusted. Keep them away from dirt and do not sub- ject them to shocks. • The rear wheel sensor cannot be disassem- bled. Do not attempt to disassemble it. If faulty, replace with a new one. • Keep any type of magnets (including mag- netic pick-up tools, magnetic screwdrivers, etc.) away from the rear wheel sensor. • Do not drop or shock the wheel sensor. 1. Check: • Rear wheel sensor Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-25. 2. Check: • Rear wheel sensor rotor Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-25. EAS31229 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 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. • Bolt Bends/damage/wear → Replace.
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM EAS30227 CHECKING THE SWINGARM 1. Check: • Swingarm Bends/cracks/damage → Replace. 2. Check: • Spacer • Collar • Oil seal • Bearing Damage/wear → Replace. EAS30228 INSTALLING THE SWINGARM 1. Lubricate: • Oil seal lips Recommended lubricant Lithium-soap-based grease 2. Assemble: • Bearing “1” • Oil seals “2” • Bearing retaining plate “3” • Rear brake hose guide “4” • Spacer “5” (to the swingarm “6”) New Bearing retaining plate bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . TIP • Install the oil seal until it is flush with the sur- face “a” of the swingarm. • Install the oil seal until it is flush with the sur- face “b” of the bearing retaining plate. • Install the bearing retaining plate with the punch mark “c” facing outward. • While holding the rear brake hose guide so that the portion “d” of the guide contacts the bearing retaining plate. 4-88 6 3 1 New New 5 2 2 LS 2 New LS 2 New b a 3 d c 4 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)
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 4. Tighten: • Rear wheel axle nut “2” • Swingarm mounting bolt (upper side) “3” • Swingarm mounting bolt (lower side) “4” Rear wheel axle nut 125 N·m (12.5 kgf·m, 92 lb·ft) Swingarm mounting bolt 57 N·m (5.7 kgf·m, 42 lb·ft) T R . . TIP Tighten the rear wheel axle nut “2”, then the swingarm mounting bolts “3”, “4”. 1 3 4 2 5. Install: • Rear shock absorber assembly Rear shock absorber assembly nut 21 N·m (2.1 kgf·m, 15 lb·ft) Rear shock absorber assembly bolt 27 N·m (2.7 kgf·m, 20 lb·ft) T R . . TIP Tighten the rear shock absorber assembly nuts and bolts temporarily, and then tighten them to specification. 4-89 6. Measure: TIP Measure the distance “a” only if the wheel bear- ings, wheel sensor rotor, or both were replaced. • Distance “a” (between the wheel sensor rotor “1” and swingarm “2” (edge of the wheel sensor in- stallation hole “b”)) Out of specification → Reinstall the bearing or replace the wheel sensor rotor. Distance “a” (between the wheel sensor rotor and swingarm (edge of the wheel sensor installation hole)) 18.92–19.60 mm (0.74–0.77 in) b 1 2 a 7. Install: • Rear wheel sensor Rear wheel sensor bolt 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . ECA22910 NOTICE Make sure there are no foreign materials in the rear wheel sensor. Foreign materials cause damage to the rear wheel sensor. TIP To route the rear wheel sensor lead, refer to “CABLE ROUTING” on page 2-15.
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM 8. Install: • Rear brake hose holder (rear side) “1” Rear brake hose holder bolt (rear side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . TIP Fit the projection “a” on the rear brake hose hold- er into the hole “b” in the swingarm. 1 a b 4-90
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REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM _________ 4-91
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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.......................................................5-14 CHECKING THE CYLINDER HEAD .......................................................5-14 CHECKING THE CAMSHAFT SPROCKET............................................5-15 CHECKING THE TIMING CHAIN TENSIONER......................................5-15 CHECKING THE DECOMPRESSION SYSTEM.....................................5-16 CHECKING THE VVA SOLENOID..........................................................5-16 INSTALLING THE CYLINDER HEAD .....................................................5-16 CAMSHAFT...................................................................................................5-20 REMOVING THE CAMSHAFT................................................................5-21 CHECKING THE CAMSHAFT.................................................................5-21 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........5-22 INSTALLING THE CAMSHAFT AND ROCKER ARMS ..........................5-22 VALVES AND VALVE SPRINGS..................................................................5-24 REMOVING THE VALVES......................................................................5-25 CHECKING THE VALVES AND VALVE GUIDES ..................................5-26 CHECKING THE VALVE SEATS............................................................5-27 CHECKING THE VALVE SPRINGS........................................................5-29 INSTALLING THE VALVES ....................................................................5-29 CYLINDER AND PISTON..............................................................................5-31 REMOVING THE PISTON ......................................................................5-32 CHECKING THE CYLINDER AND PISTON ...........................................5-32 CHECKING THE PISTON RINGS...........................................................5-33 CHECKING THE PISTON PIN................................................................5-34 CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) .................5-35 INSTALLING THE PISTON AND CYLINDER .........................................5-35 V-BELT AUTOMATIC TRANSMISSION.......................................................5-37 REMOVING THE PRIMARY SHEAVE....................................................5-40 REMOVING THE SECONDARY SHEAVE .............................................5-40 DISASSEMBLING THE SECONDARY SHEAVE....................................5-41 CHECKING THE CLUTCH HOUSING ....................................................5-41 CHECKING THE CLUTCH SHOES ........................................................5-41 5
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CHECKING THE V-BELT........................................................................5-42 CHECKING THE PRIMARY SHEAVE ....................................................5-42 CHECKING THE PRIMARY SHEAVE WEIGHTS...................................5-42 CHECKING THE PRIMARY SHEAVE SLIDERS....................................5-42 CHECKING THE SECONDARY SHEAVE..............................................5-43 ASSEMBLING THE PRIMARY SHEAVE................................................5-43 ASSEMBLING THE SECONDARY SHEAVE..........................................5-43 INSTALLING THE PRIMARY SHEAVE, V-BELT AND SECONDARY SHEAVE.................................................................5-44 STARTER GENERATOR ..............................................................................5-47 REMOVING THE STARTER GENERATOR ...........................................5-48 INSTALLING THE STARTER GENERATOR..........................................5-48 OIL PUMP......................................................................................................5-49 CHECKING THE OIL STRAINER ...........................................................5-51 CHECKING THE OIL PUMP ...................................................................5-51 ASSEMBLING THE OIL PUMP...............................................................5-51 TRANSMISSION............................................................................................5-52 CHECKING THE TRANSMISSION.........................................................5-54 INSTALLING THE TRANSMISSION.......................................................5-54 CRANKSHAFT ..............................................................................................5-55 DISASSEMBLING THE CRANKCASE....................................................5-57 REMOVING THE CRANKSHAFT ASSEMBLY.......................................5-57 CHECKING THE CRANKSHAFT ASSEMBLY........................................5-58 CHECKING THE CRANKCASE..............................................................5-58 CHECKING THE BEARING ....................................................................5-58 CHECKING THE OIL PUMP DRIVE GEAR............................................5-58 INSTALLING THE CRANKSHAFT..........................................................5-59 ASSEMBLING THE CRANKCASE..........................................................5-59 INSTALLING THE CENTERSTAND .......................................................5-60
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LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20298 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS32362 ENGINE OIL LUBRICATION CHART Rocker arm Camshaft Oil Nozzle Crankshaft Oil pump Oil strainer Oil pan Lubricant System Diagram A 5-1 1 3 4 5 2 A - A A 1. Engine oil port 2. Oil drain plug 3. Oil filter 4. Compression spring 5. O-ring
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EAS20041 ENGINE INSPECTION EAS30249 MEASURING THE COMPRESSION PRESSURE TIP Insufficient compression pressure will result in a loss of performance. 1. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-6. 2. Start the engine, warm it up for several min- utes, and then turn it off. 3. 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 4-12. 4. Disconnect: • Spark plug cap 5. Remove: • Spark plug ECA20470 NOTICE Before removing the spark plug, use com- pressed air to blow away any dirt accumulat- ed in the spark plug well to prevent it from falling into the cylinder. 5-2 ENGINE INSPECTION 6. Install: • Compression gauge “1” • Extension “2” Compression gauge 90890-03081 Engine compression tester YU-33223 Compression gauge extension 122mm 90890-04136 Compression gauge extension 122mm YM-04136 1 2 7. Measure: • Compression pressure Out of specification → Refer to steps (c) and (d). 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) a. Turn the main switch to “ON”. b. With the throttle wide open, crank the en- gine until the reading on the compression gauge stabilizes. EWA12960 WARNING To prevent sparking, ground the spark plug lead before cranking the engine. c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. Carbon deposits → Eliminate.
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d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston ring(s) wear or damage → Repair. Piston, valves, cylin- der head gasket or piston ring(s) possibly defective → Repair. Same as without oil 8. Install: • Spark plug “1” Spark plug 13 N·m (1.3 kgf·m, 9.6 lb·ft) T R . . 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. a b 2 1 9. Connect: • Spark plug cap 10.Install: • Footrest board assembly (right) Refer to “GENERAL CHASSIS (5)” on page 4-12. • Front side cover (right) Refer to “GENERAL CHASSIS (2)” on page 4-3. 5-3 ENGINE INSPECTION
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EAS20042 ENGINE REMOVAL Removing the muffler 8 N·m (0.8 kgf·m, 5.9 lb·ft) T.R. 53 N·m (5.3 kgf·m, 39 lb·ft) T.R. LT 3 2 53 N·m (5.3 kgf·m, 39 lb·ft) LT T.R. 8 N·m (0.8 kgf·m, 5.9 lb·ft) 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 25 N•m (2.5 kgf•m, 18 lb•ft) T.R. 1 5 4 New 20 N·m (2.0 kgf·m, 15 lb·ft) T.R.
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Disconnecting the leads 2 1 4 5 7 Order Job/Parts to remove Q’ty Remarks Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-19. Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-21. Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Front cowling assembly Refer to “GENERAL CHASSIS (2)” on page 4-3. Side cover assembly Refer to “GENERAL CHASSIS (3)” on page 4-6. Storage box Refer to “GENERAL CHASSIS (3)” on page 4-6. Air filter case Refer to “AIR FILTER CASE” on page 7-8. V-belt case air duct Refer to “V-BELT AUTOMATIC TRANSMIS- SION” on page 5-37. Fuel injector Refer to “FUEL INJECTOR” on page 7-6. Throttle body Refer to “THROTTLE BODY” on page 7-11. 5-5 ENGINE REMOVAL 3 6
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Disconnecting the leads 2 1 4 5 7 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 4-29. 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 3 6
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Removing the engine 52 N·m (5.2 kgf·m, 38 lb·ft) T.R. 2 28 N·m (2.8 kgf·m, 21 lb·ft) T.R. 3 4 6 3 7 4 3 4 50 N·m (5.0 kgf·m, 37 lb·ft) 5 T.R. Order Job/Parts to remove Q’ty Remarks 1 Rear shock absorber assembly 2 2 Engine bracket nut/bolt 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 21 N·m (2.1 kgf·m, 15 lb·ft) T.R. 1 1 2 6 7 4
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EAS30251 INSTALLING THE ENGINE 1. Install: a. Temporarily put the stopper “1” and collar “2” on the engine assembly “3”. 1 3 2 b. Install the engine bracket “4” to the engine assembly, then install fixing bolt “5” and nut (below) “6” and use the pin ø3 mm to 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 2 1 6 5 4 a A-A Engine bracket nut (center) 50 N·m (5.0 kgf·m, 37 lb·ft) T R . . c. Remove the ø3 pin, insert the engine mount bracket nut “7”, and then tighten the nut “8”. Engine mount bracket nut 28 N·m (2.8 kgf·m, 21 lb·ft) T R . . 7 8 5-8 ENGINE REMOVAL d. Temporarily install the engine bracket fixed bolt “9” in the engine mount bracket “10”. 9 10 e. Tighten the engine bracket nut (front) “10”. Engine bracket nut (front) 52 N·m (5.2 kgf·m, 38 lb·ft) T R . . 10 f. After the installation is complete, confirm that the stopper “1” will not touch the engine assembly “3” with the main bracket upright. 1 3
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EAS20044 CYLINDER HEAD Removing the cylinder head 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 New 6 New New 7 New New 15 16 14 8 12 5 LS 9 11 M (4) (4) (4) New 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 1st 2nd 1 2 13 N·m (1.3 kgf·m, 9.6 lb·ft) T.R. 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 4 New 15 N·m (1.5 kgf·m, 11 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS (1)” on page 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 4-9. Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-21. 5-9 CYLINDER HEAD 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 17 18 TB1215 19 (4) LT 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 25 26 New 13 24 New M 25 M 20 23 22 13 21 30 N·m (3.0 kgf·m, 22 lb·ft) T.R.
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Removing the cylinder head 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 New 6 7 New New New New 15 16 14 8 12 5 LS 9 11 M (4) (4) (4) New 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 1st 2nd 1 2 13 N·m (1.3 kgf·m, 9.6 lb·ft) T.R. 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 4 New 15 N·m (1.5 kgf·m, 11 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 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. 5-10 CYLINDER HEAD 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 17 18 TB1215 19 (4) LT 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 25 26 New 13 24 New M 25 M 20 23 22 13 21 30 N·m (3.0 kgf·m, 22 lb·ft) T.R.
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Removing the cylinder head 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 New 6 7 New New New New 15 16 14 8 12 5 LS 9 11 M (4) (4) (4) New 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 1st 2nd 1 2 13 N·m (1.3 kgf·m, 9.6 lb·ft) T.R. 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 4 New 15 N·m (1.5 kgf·m, 11 lb·ft) T.R. 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 Spark plug cap 1 Disconnect. 2 Spark plug 1 3 Coolant temperature sensor coupler 1 Disconnect. 5-11 CYLINDER HEAD 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 17 18 TB1215 19 (4) LT 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 25 26 New 13 24 New M 25 M 20 23 22 13 21 30 N·m (3.0 kgf·m, 22 lb·ft) T.R.
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Removing the cylinder head 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 New 6 7 New New New New 15 16 14 8 12 5 LS 9 11 M (4) (4) (4) New 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 1st 2nd 1 2 13 N·m (1.3 kgf·m, 9.6 lb·ft) T.R. 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 4 New 15 N·m (1.5 kgf·m, 11 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 4 Coolant temperature sensor 1 5 VVA (variable valve actuator) solenoid coupler 1 Disconnect. 6 VVA (variable valve actuator) solenoid 1 7 VVA (variable valve actuator) solenoid gasket 1 8 VVA (variable valve actuator) solenoid rod 1 9 Fuel hose holder 1 10 Cylinder head breather hose 1 11 Cylinder head cover 1 12 Cylinder head cover gasket 1 13 Dowel pin 2 5-12 CYLINDER HEAD 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 17 18 TB1215 19 (4) LT 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 25 26 New 13 24 New M 25 M 20 23 22 13 21 30 N·m (3.0 kgf·m, 22 lb·ft) T.R.
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Removing the cylinder head 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 New 6 7 New New New New 15 16 14 8 12 5 LS 9 11 M (4) (4) (4) New 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) 24 N·m (2.4 kgf·m, 18 lb·ft) 1st 2nd 1 2 13 N·m (1.3 kgf·m, 9.6 lb·ft) T.R. 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 4 New 15 N·m (1.5 kgf·m, 11 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 14 Cylinder head cover breather plate 1 15 Cylinder head cover breather plate gasket 1 16 Oil seal 1 17 Timing chain tensioner plug 1 18 Timing chain tensioner 1 19 Timing chain tensioner gasket 1 20 Camshaft sprocket bolt 1 21 Camshaft sprocket 1 22 Decompression cam 1 23 Cylinder head 1 24 Cylinder head gasket 1 25 Dowel pin 2 26 Engine oil check bolt 1 5-13 CYLINDER HEAD 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 17 18 TB1215 19 (4) LT 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 25 26 New 13 24 New M 25 M 20 23 22 13 21 30 N·m (3.0 kgf·m, 22 lb·ft) T.R.
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EAS30276 REMOVING THE CYLINDER HEAD 1. Align: • “I” mark “a” on the AC magneto rotor (with the match mark “b” on the right crank- case) a. Turn the crankshaft clockwise. b a b. When the piston is at TDC on the compres- sion stroke, align the “I” mark “c” on the camshaft sprocket with the match mark “d” on the camshaft stopper plate. d c 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 1 2 5-14 CYLINDER HEAD 3. Remove: • Cylinder head TIP • Loosen the bolts and nuts in the proper se- quence as shown. • Loosen each bolt and nuts 1/2 of a turn at a time. After all of the bolts and nuts are fully loosened, remove them. 4 × 4 3 2 × 6 5 1 2 EAS30277 CHECKING THE CYLINDER HEAD 1. Eliminate: • Combustion chamber carbon deposits (with a rounded scraper) TIP Do not use a sharp instrument to avoid damag- ing or scratching: • Spark plug bore threads • Valve seats 2. Check: • Cylinder head Damage/scratches → Replace. • Cylinder head water jacket Mineral deposits/rust → Eliminate.
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3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. Warpage limit 0.05 mm (0.0020 in) a. Place a straightedge “1” and a thickness gauge “2” across the cylinder head. 1 2 b. Measure the warpage. 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. 5-15 CYLINDER HEAD EAS30936 CHECKING THE CAMSHAFT SPROCKET 1. Check: • Camshaft sprocket More than 1/4 tooth wear “a” → Replace the camshaft sprocket, timing chain and crank- shaft as a set. a. 1/4 tooth b. Correct 1. Timing chain roller 2. Camshaft sprocket EAS30266 CHECKING THE TIMING CHAIN TENSIONER 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
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c. While holding the timing chain tensioner rod in place with your hand, turn the screw- driver counterclockwise, remove the screw- driver, and slowly release the timing chain tensioner rod. d. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner. 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 shown in the illustration. a a. 20.88° 5-16 CYLINDER HEAD EAS31624 CHECKING THE VVA SOLENOID 1. Check: • VVA (variable valve actuator) solenoid “1” Cracks/damage → Replace. 1 EAS30282 INSTALLING THE CYLINDER HEAD 1. Tighten: • Cylinder head nuts “1” • Cylinder head bolts “2” Cylinder head nut 24 N·m (2.4 kgf·m, 18 lb·ft) Cylinder head bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) T R . . TIP • Lubricate the cylinder head nuts and thread of bolt and washers with molybdenum disulfide grease. • Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages. 4 × 3 4 1 1 2 × 1 2 2 2 6 5
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2. Install: • Decompression cam “1” • Camshaft sprocket “2” • Timing chain • Camshaft sprocket bolt a. Turn the crankshaft clockwise. b. Align the “I” mark “a” on the AC magneto ro- tor with the match mark “b” on the right crankcase. b a c. Install the decompression cam. d. Install the timing chain onto the camshaft sprocket, then the camshaft sprocket onto the camshaft, and then finger tighten the camshaft sprocket bolt. ECA20600 NOTICE Do not turn the crankshaft when installing the camshaft sprocket to avoid damage or improper valve timing. TIP • Fit the pin on the decompression cam into the slot “c” in the decompression lever on the cam- shaft sprocket. • Align the “I” mark “d” on the camshaft sprocket with the match mark “e” on the camshaft stop- per plate. 2 e 1 d c e. While holding the camshaft, temporarily tighten the camshaft sprocket bolt. 5-17 CYLINDER HEAD 3. Install: • Timing chain tensioner gasket • Timing chain tensioner New 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”. TIP Make sure that the tensioner rod has been fully turned clockwise. 1 c. Install the gasket and the timing chain ten- sioner “2” onto the cylinder. EWA17620 WARNING Always use a new gasket. 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. Yamaha bond No. 1215 90890-85505 Three bond No. 1215® Timing chain tensioner bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) T R . . a a 2
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d. Turn the timing chain tensioner rod counter- clockwise with a thin screwdriver “1”, make sure it releases, and then install the timing chain tensioner plug. 1 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 the right crankcase. • “I” mark “c” Make sure the “I” mark “c” on the camshaft sprocket is aligned with the match mark “d” on the camshaft stopper plate. Out of alignment → Correct. Refer to the installation steps above. b a d c 5-18 CYLINDER HEAD 6. Tighten: • Camshaft sprocket bolt “1” Camshaft sprocket bolt 30 N·m (3.0 kgf·m, 22 lb·ft) T R . . Camshaft wrench 90890-04162 Camshaft wrench YM-04162 ECA20610 NOTICE Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil- ity of the bolt coming loose and damaging the engine. TIP Tighten the camshaft sprocket bolt with the cam- shaft wrench “2”. 1 2 7. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” on page 3-6.
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8. Install: • Oil seal “1” (into the cylinder head cover “2”) TIP 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”. 2 3 1 9. Install: • VVA (variable valve actuator) solenoid “1” VVA (variable valve actuator) so- lenoid bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) T R . . TIP While holding the VVA (variable valve actuator) solenoid so that it is contacting the cylinder head cover “2”, tighten the bolts to specification. 1 2 5-19 CYLINDER HEAD
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EAS20043 CAMSHAFT Removing the rocker arms and camshaft 1 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 14 11 14 10 12 13 9 M M E 8 7 6 M E 2 7 2 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 5-20 CAMSHAFT New 4 M E 3 5 E M 5 M
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EAS30256 REMOVING THE CAMSHAFT 1. Loosen: • Adjusting screw (intake/exhaust) 2. Remove: • Camshaft assembly “1” Slide hammer bolt (M8) 90890-01085 Slide hammer bolt 8 mm YU-01083-2 Weight 90890-01084 Weight YU-01083-3 a. Align the holes “a” in intake rocker arm 1 “2” and intake rocker arm 2 “3”, and then push the intake rocker arm stopper pin “4” in the direction of the arrow shown in the illustra- tion. 4 a 3 2 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 hammer bolt “5” and weight “6”. 2 3 1 5 6 5-21 CAMSHAFT EAS30257 CHECKING THE CAMSHAFT 1. Check: • Camshaft lobe Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” Out of specification → Replace the camshaft. Camshaft lobe dimensions Lobe height limit (Intake) 32.111 mm (1.2642 in) Lobe height limit (Intake high speed) 32.487 mm (1.2790 in) Lobe height limit (Exhaust) 29.320 mm (1.1543 in) a 3. Measure: • Camshaft runout Out of specification → Replace the camshaft. 4. Check: • Camshaft oil passage Obstruction → Blow out with compressed air.
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EAS30259 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS The following procedures are applied to all of the rocker arms and rocker arm shafts. 1. Check: • Rocker arm • Rocker arm roller “1” Damage/wear → Replace. 1 1 1 2. Check: • Rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrication system. 3. Measure: • Rocker arm inside diameter “a” Out of specification → Replace. Rocker arm inside diameter limit 10.015 mm (0.3943 in) a 5-22 CAMSHAFT 4. Measure: • Rocker arm shaft outside diameter “a” Out of specification → Replace. Rocker arm shaft outside diame- ter limit 9.935 mm (0.3911 in) 5. Calculate: • Rocker-arm-to-rocker-arm-shaft clearance TIP Calculate the clearance by subtracting the rock- er arm shaft outside diameter from the rocker arm inside diameter. Out of specification → Replace the defective part(s). Rocker-arm-to-rocker-arm-shaft clearance limit 0.080 mm (0.0032 in) EAS30270 INSTALLING THE CAMSHAFT AND ROCKER ARMS 1. Lubricate: • Camshaft assembly Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil
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2. Lubricate: • Rocker arms • Rocker arm shafts • Spring • Intake rocker arm stopper pin Recommended lubricant Rocker arm shaft Intake rocker arm stopper pin Molybdenum disulfide oil Spring Rocker arm roller Engine oil 3. Install: • Spring “1” TIP Install the spring so that the ends “a” of the spring are positioned at the locations shown in the illustration. a 1 4. Install: • Camshaft assembly “1” a. Align the holes “a” in intake rocker arm 1 “2” and intake rocker arm 2 “3”, and then push the intake rocker arm stopper pin “4” in the direction of the arrow shown in the illustra- tion. 4 a 3 2 5-23 CAMSHAFT 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. 2 3 a 5. Install: • Camshaft stopper plate Camshaft stopper plate bolt (M5 × 16) 8 N·m (0.8 kgf·m, 5.9 lb·ft) Camshaft stopper plate bolt (M6 × 14) 8 N·m (0.8 kgf·m, 5.9 lb·ft) T R . . 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 bolt holes in the cylinder head and rocker arm shafts are aligned. 2 b a a
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EAS20045 VALVES AND VALVE SPRINGS Removing the valves and valve springs 2 3 1 6 New 7 E 7 6 New 3 2 1 E Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-9. Camshaft/Rocker arm Refer to “CAMSHAFT” on page 5-20. 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 5-24 VALVES AND VALVE SPRINGS 5 8 New M 4 8 New M M
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EAS30283 REMOVING THE VALVES The following procedures are applied to all of the valves and related components. TIP Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • Valve sealing Leakage at the valve seat → Check the valve face, valve seat, and valve seat width. Refer to “CHECKING THE VALVE SEATS” on page 5-27. a. Pour a clean solvent “a” into the intake and exhaust ports. b. Check that the valves properly seal. TIP There should be no leakage at the valve seat “1”. 2. Remove: • Valve cotters “1” TIP Remove the valve cotters by compressing the valve spring with the valve spring compressor and the valve spring compressor attachment “2”. Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapter 22 mm YM-04108 5-25 VALVES AND VALVE SPRINGS 2 1 3. Remove: • Valve spring retainer “1” • Valve spring “2” • Valve “3” • Valve stem seal “4” • Valve spring seat “5” TIP Identify the position of each part very carefully so that it can be reinstalled in its original place. 1 5 2 3 4
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EAS30284 CHECKING THE VALVES AND VALVE GUIDES The following procedures are applied 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” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance limit (intake) 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance limit (exhaust) 0.100 mm (0.0039 in) a 5-26 VALVES AND VALVE SPRINGS 2. Replace: • Valve guide New TIP To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. a. Remove the valve guide with the valve guide remover “1”. 1 b. Install the new valve guide with the valve guide installer “2” and valve guide remover “1”. Valve guide position 9.9–10.3 mm (0.39–0.41 in) 2 a 1 a. Valve guide position
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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. 3 TIP After replacing the valve guide, reface the valve seat. Valve guide remover (ø5) 90890-04097 Valve guide remover (5.0 mm) YM-04097 Valve guide installer (ø5) 90890-04098 Valve guide installer (5.0 mm) YM-04098 Valve guide reamer (ø5) 90890-04099 Valve guide reamer (5.0 mm) YM-04099 3. Eliminate: • Carbon deposits (from the valve face and valve seat) 4. Check: • Valve face Pitting/wear → Grind the valve face. • Valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve. 5. Measure: • Valve stem runout Out of specification → Replace the valve. TIP • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always re- place the valve stem seal. Valve stem runout 0.020 mm (0.0008 in) 5-27 VALVES AND VALVE SPRINGS EAS30285 CHECKING THE VALVE SEATS The following procedures are applied to all of the valves and valve seats. 1. Eliminate: • Carbon deposits (from the valve face and valve seat) 2. Check: • Valve seat Pitting/wear → Replace the cylinder head. 3. Measure: • Valve seat width “a” Out of specification → Replace the cylinder head. Valve seat contact width limit (in- take) 1.3 mm (0.05 in) Valve seat contact width limit (exhaust) 1.7 mm (0.07 in) a a. Apply blue layout fluid “b” onto the valve face. b
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b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. d. Measure the valve seat width. TIP Where the valve seat and valve face contacted one another, the blue layout fluid will have been removed. 4. Lap: • Valve face • Valve seat TIP After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound “a” to the valve face. ECA13790 NOTICE Do not let the lapping compound enter the gap between the valve stem and the valve guide. a b. Apply molybdenum disulfide oil onto the valve stem. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, and then clean off all of the lapping compound. TIP For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hands. 5-28 VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply blue layout fluid “b” onto the valve face. b h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. j. Measure the valve seat width again. If the valve seat width is out of specification, re- face and lap the valve seat.
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EAS30286 CHECKING THE VALVE SPRINGS The following procedures are applied to all of the valve springs. 1. Measure: • Valve spring free length “a” Out of specification → Replace the valve spring. Free length limit (intake) 32.10 mm (1.26 in) Free length limit (exhaust) 32.10 mm (1.26 in) a EAS30288 INSTALLING THE VALVES The following procedures are applied to all of the valves and related components. • Valve stem end (with an oil stone) 1. Lubricate: • Valve stem “1” Recommended lubricant Molybdenum disulfide oil • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Engine oil 5-29 VALVES AND VALVE SPRINGS E 2. Install: • Valve spring seat “1” • Valve stem seal “2” • Valve “3” • Valve spring “4” • Valve spring retainer “5” (into the cylinder head) TIP New • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up. 5 1 4 3 2 New b. Smaller pitch
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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”. Valve spring compressor 90890-04019 Valve spring compressor YM-04019 Valve spring compressor attach- ment 90890-04108 Valve spring compressor adapter 22 mm YM-04108 2 1 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. 5.ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 5-30 VALVES AND VALVE SPRINGS
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EAS20046 CYLINDER AND PISTON Removing the cylinder and piston 3 New 2 E 1 New 7 5 11 New 10 10 N·m (1.0 kgf·m, 7.4 lb·ft) 9 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 5-31 CYLINDER AND PISTON 4 4 6 5 New E
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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 • Before removing the piston pin clips, cover the crankcase opening with a clean rag to prevent them from falling into the crankcase. • Before removing the piston pin, deburr the pis- ton pin clip groove and the piston pin bore ar- ea. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller set “4”. Piston pin puller set 90890-01304 Piston pin puller YU-01304 1 2 3 5-32 CYLINDER AND PISTON 2. Remove: • Top ring • 2nd ring • Oil ring TIP When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. EAS30291 CHECKING THE CYLINDER AND PISTON 1. Check: • Piston wall • Cylinder wall Vertical scratches → Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: • Piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. TIP Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder. Bore 58.000–58.010 mm (2.2835– 2.2839 in) Wear limit 58.060 mm (2.2858 in) “C” = maximum of D1 - D2
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b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. c. Measure piston skirt diameter P with the mi- crometer. a P a. 6.0 mm (0.24 in) from the bottom edge of the piston 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 Piston-to-cylinder clearance 0.015–0.048 mm (0.0006–0.0019 in) f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. 5-33 CYLINDER AND PISTON EAS30292 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. TIP Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring Top ring Side clearance limit 0.115 mm (0.0045 in) 2nd ring Side clearance limit 0.115 mm (0.0045 in) 2. Install: • Piston ring (into the cylinder) TIP Use the piston crown to level the piston ring near the bottom of the cylinder where the cylinder wear is lowest.
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3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. TIP The oil ring expander spacer end gap cannot be measured. If the oil ring rail gap is excessive, re- place all three piston rings. Piston ring Top ring End gap limit 0.50 mm (0.0197 in) 2nd ring End gap limit 0.85 mm (0.0335 in) a b a. Bottom of cylinder b. Upper of cylinder 5-34 CYLINDER AND PISTON EAS30293 CHECKING THE PISTON PIN 1. Check: • Piston pin Blue discoloration/grooves → Replace the piston pin, and then check the lubrication sys- tem. 2. Measure: • Piston pin outside diameter “a” Out of specification → Replace the piston pin. Piston pin outside diameter limit 13.975 mm (0.5502 in) 3. Measure: • Piston pin bore diameter “b” Out of specification → Replace the piston. Piston pin bore inside diameter limit 14.043 mm (0.5529 in) 4. Calculate: • Piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin and piston as a set. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter “b” - Piston pin outside diameter “a”
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EAS30290 CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) 1. Check: • 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 Be sure to install the piston rings so that the manufacturer marks face up. 4. Offset: • Piston ring end gaps 5 4 3 2 1 2. Install: • Piston “1” • Piston pin “2” • Piston pin clips “3” New TIP • Apply engine oil to the piston pin. • Make sure the punch mark “a” on the piston points towards the exhaust side of the cylinder. • Before installing the piston pin clips, cover the crankcase opening with a clean rag to prevent the clips from falling into the crankcase. • When installing a piston pin clip, make sure that the clip ends “b” are positioned away from the cutout “c” in the piston as shown in the illus- tration. New 2 3 1 a 5-35 CYLINDER AND PISTON 1 3 2 New b c 3. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil c a b 135˚ 45˚ 45˚ e d 45˚ 45˚ A a. Top ring b. 2nd ring c. Upper oil ring rail d. Oil ring expander e. Lower oil ring rail A. Exhaust side
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5. Install: • Dowel pins • Cylinder gasket • Cylinder “1” New TIP • While holding the piston “2” with one hand, in- stall the cylinder with the other hand. • Pass the timing chain and timing chain guide (intake side) through the timing chain cavity. 1 2 5-36 CYLINDER AND PISTON
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V-BELT AUTOMATIC TRANSMISSION EAS20050 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case 10 New 9 8 7 New 6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. New 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 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 O-ring 1 5 V-belt case 1 6 V-belt case gasket 1 7 Dowel pin 1 8 V-belt case check hose 1 9 Clip 1 10 Bearing 1 5-37 5 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. (10) New 1 2 3 (6)
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V-BELT AUTOMATIC TRANSMISSION Removing the V-belt, primary sheave and secondary sheave 10 10 8 11 9 LS 10 6 7 Order Job/Parts to remove Q’ty Remarks 1 Primary fixed sheave nut 1 2 Conical spring washer 1 3 Primary fixed sheave 1 4 Washer 1 5 V-belt 1 6 Collar 1 7 Primary sliding sheave 1 8 Primary sheave weight 6 9 Cam 1 10 Slider 3 11 Washer 1 12 Clutch housing nut 1 13 Clutch housing 1 14 Secondary sheave assembly 1 5-38 45 N·m (4.5 kgf·m, 33 lb·ft) T.R. 14 13 12 LS 4 3 5 2 1 76 N·m (7.6 kgf·m, 56 lb·ft) T.R.
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V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 7 13 5 14 15 16 New 8 9 10 12 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 Circlip 3 4 Clutch puller fixed plate 1 5 Clutch shoe spring 3 6 Compression spring 1 7 Spring seat 1 8 Guide pin 3 9 Collar 3 10 Secondary sliding sheave 1 11 O-ring 2 12 Oil seal 2 13 Bearing 1 14 Circlip 1 15 Bearing 1 16 Secondary fixed sheave 1 5-39 * 3 6 4 55 N·m (5.5 kgf·m, 41 lb·ft) T.R. 2 1 New 12 11 New
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V-BELT AUTOMATIC TRANSMISSION EAS30310 REMOVING THE PRIMARY SHEAVE 1. Remove: • Primary fixed sheave nut “1” • Conical spring washer • Washer • Primary fixed sheave “2” TIP While holding the primary fixed sheave with the rotor holding tool “3”, loosen 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 3 1 2 5-40 EAS30311 REMOVING THE SECONDARY SHEAVE 1. Remove: • Clutch housing nut “1” • Clutch housing “2” TIP While holding the clutch housing with the rotor holding tool “3”, loosen the clutch housing nut. Rotor holding tool 90890-04166 Rotor holding tool YM-04166 3 2 1 2. Loosen: • Secondary sheave nut “1” ECA21820 NOTICE Do not remove the secondary sheave nut at this stage. TIP While holding the secondary sheave with the ro- tor holding tool “2”, loosen the secondary sheave nut one full turn with the socket wrench “3”. Rotor holding tool 90890-04166 Rotor holding tool YM-04166 Socket wrench (39 mm) 90890-01493 1 3 2
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V-BELT AUTOMATIC TRANSMISSION EAS31619 DISASSEMBLING THE SECONDARY SHEAVE 1. Remove: • Secondary sheave nut “1” TIP Install the sheave spring compressor “2” and sheave fixed block “3” onto the secondary sheave as shown. Then, compress the spring, and remove the secondary sheave nut. Sheave spring compressor 90890-04134 Sheave spring compressor YM-04134 Sheave fixed block 90890-04135 Sheave fixed bracket YM-04135 2 1 3 EAS30352 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing Damage/wear → Replace. 2. Measure: • Clutch housing inside diameter “a” Out of specification → Replace the clutch housing. Clutch housing inside diameter limit 125.5 mm (4.94 in) a 5-41 EAS30314 CHECKING THE CLUTCH SHOES The following procedures are applied 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. TIP After sanding the glazed areas, clean the clutch with a cloth. 2. Measure: • Clutch shoe thickness “a” Out of specification → Replace the clutch shoes and springs as a set. Clutch shoe thickness limit 2.1 mm (0.08 in) a a a a a a
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V-BELT AUTOMATIC TRANSMISSION EAS30315 CHECKING THE V-BELT 1. Check: • V-belt “1” Cracks/damage/wear → Replace. Grease/oil → Clean the primary and second- ary sheave. 2. Measure: • V-belt width “a” Out of specification → Replace. V-belt width limit 21.6 mm (0.85 in) a 1 2 3 2. Plastic board 3. Ruler EAS30316 CHECKING THE PRIMARY SHEAVE 1. Check: • Primary sliding sheave • Primary fixed sheave • Collar Cracks/damage/wear → Replace the primary sliding sheave, primary fixed sheave, and collar as a set. 5-42 EAS30317 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedures are applied to all of the primary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear → Replace. 2. Measure: • Primary sheave weight outside diameter “a” Out of specification → Replace. Weight outside diameter limit 19.5 mm (0.77 in) EAS31233 CHECKING THE PRIMARY SHEAVE SLIDERS 1. Check: • Primary sheave slider Cracks/damage/wear → Replace.
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V-BELT AUTOMATIC TRANSMISSION EAS30319 CHECKING THE SECONDARY SHEAVE 1. Check: • Secondary fixed sheave • Secondary sliding sheave Cracks/damage/wear → Replace the sec- ondary fixed and sliding sheaves as a set. 2. Check: • Torque cam groove “a” Damage/wear → Replace the secondary fixed and sliding sheaves as a set. 3. Check: • Guide pin “1” Damage/wear → Replace the secondary fixed and sliding sheaves as a set. 1 a 4. Check: • Spring free length Out of specification → Replace the spring. Compression spring free length limit 104.7 mm (4.12 in) EAS30320 ASSEMBLING THE PRIMARY SHEAVE 1. Clean: • Primary fixed sheave • Primary sliding sheave • Primary sheave weight • Cam 5-43 EAS30321 ASSEMBLING THE SECONDARY SHEAVE 1. Lubricate: • Secondary sliding sheave inner surface • Oil seal “1” (with the recommended lubricant) Recommended lubricant Shell dolium grease R® TIP Do not apply grease to the inner surface “a” of the secondary fixed sheave “2”. If any grease gets on the inner surface of the secondary fixed sheave, be sure to wipe it off thoroughly. * 2 1 * a 1 2. Install: • Oil seal • Secondary sliding sheave “1” TIP New Install the secondary sliding sheave onto the secondary fixed sheave “2” with the oil seal guide “3”. Oil seal guide (37 mm) 90890-04177 1 3 2 3. Install: • Guide pin “1”
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V-BELT AUTOMATIC TRANSMISSION 4. Lubricate: • Guide pin grooves “a” • O-rings “2” (with the recommended lubricant) New Recommended lubricant Shell dolium grease R® 1 2 New a 5. Install: • Spring seat • Compression spring • Clutch carrier assembly • Secondary sheave nut “1” TIP • Install the sheave spring compressor “2” and sheave fixed block “3” onto the secondary sheave as shown. Then, compress the spring, and install the secondary sheave nut. • Install the secondary sheave nut “1” with its ta- pered side facing the clutch carrier. Sheave spring compressor 90890-04134 Sheave spring compressor YM-04134 Sheave fixed block 90890-04135 Sheave fixed bracket YM-04135 2 1 3 5-44 EAS31234 INSTALLING THE PRIMARY SHEAVE, V- BELT AND SECONDARY SHEAVE 1. Install: • Secondary sheave assembly TIP Before installing the secondary sheave assem- bly, check that there is no grease on the splines “a” of the primary drive gear. If there is any grease on the splines, be sure to wipe it off thor- oughly. a 2. Tighten: • Secondary sheave nut “1” Secondary sheave nut 55 N·m (5.5 kgf·m, 41 lb·ft) T R . . TIP While holding the secondary sheave with the ro- tor holding tool “2”, tighten the secondary sheave nut with the socket wrench “3”. Rotor holding tool 90890-04166 Rotor holding tool YM-04166 Socket wrench (39 mm) 90890-01493 2 1 3
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V-BELT AUTOMATIC TRANSMISSION 3. Install: • Clutch housing “1” • 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 holding tool “3”, tighten the clutch housing nut. Rotor holding tool 90890-04166 Rotor holding tool YM-04166 3 1 2 4. Install: • Primary sliding sheave assembly “1” • Washer TIP When installing the primary sliding sheave as- sembly, hold the cam to prevent the primary sheave weights from falling out of the primary sliding sheave. 1 5-45 5. Install: • V-belt “1” ECA21720 NOTICE Do not allow grease to come in contact with the V-belt. TIP • Install the V-belt with the printed arrow mark on the V-belt facing in the direction shown in the il- lustration. • Install the V-belt onto the primary sheave side. 1 6. Install: • Primary fixed sheave “1” • Washer • Conical spring washer “2” • Primary fixed sheave nut ECA21730 NOTICE Do not allow grease to contact the primary sheave assembly. TIP • Apply lithium-soap-based grease to the prima- ry fixed sheave nut side of the conical spring washer and to the threaded portion of the crankshaft. • Install the conical spring washer with the mark “a” facing outward. • Install the V-belt in the primary sheave (when the pulley is at its widest position) and in the secondary sheave (when the pulley is at its narrowest position), and make sure the V-belt is tight.
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V-BELT AUTOMATIC TRANSMISSION 1 a 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 2 1 5-46
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EAS20714 STARTER GENERATOR Removing the starter generator assembly Order Job/Parts to remove Q’ty Remarks Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-21. Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Side cover (right) Refer to “GENERAL CHASSIS (2)” on page 4-3. Radiator fan Refer to “RADIATOR” on page 6-2. 1 Crankshaft position sensor coupler/Starter gen- 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 5-47 STARTER GENERATOR 1 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.
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EAS33382 REMOVING THE STARTER GENERATOR 1. Remove: • Starter generator rotor nut “1” • Washer TIP While holding the starter generator rotor “2” with the rotor holding tool “3”, loosen the starter gen- erator rotor nut. Rotor holding tool (including handle and 3 pins) 90890-04195 Rotor holding tool attachment 7 x 5 mm 90890-04198 3 2 1 2. Remove: • Starter generator rotor “1” (with the flywheel puller “2”) • 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. Flywheel puller 90890-01189 Flywheel puller YM-01189 1 2 5-48 STARTER GENERATOR EAS33383 INSTALLING THE STARTER GENERATOR 1. Install: • Woodruff key • Starter generator rotor • Washer • Starter generator rotor nut TIP • Clean the tapered portion of the crankshaft and the starter generator rotor hub. • When installing the starter generator rotor, make sure the woodruff key is properly seated in the keyway of the crankshaft. 2. Tighten: • 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 the rotor holding tool “3”, tighten the starter gen- erator rotor nut. Rotor holding tool (including handle and 3 pins) 90890-04195 Rotor holding tool attachment 7 x 5 mm 90890-04198 3 2 1
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EAS20054 OIL PUMP Removing the oil pump 5 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks V-belt automatic transmission Refer to “V-BELT AUTOMATIC TRANSMIS- SION” on page 5-37. 1 Oil seal 1 2 Oil pump cover 1 3 Gasket 1 4 Dowel pin 2 5 Oil pump assembly 1 5-49 OIL PUMP 3 2 New 4 1 4 New LS
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Disassembling the oil pump 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 1 4 5 6 E 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 5-50 OIL PUMP 7 3 2 E
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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 • Oil pump housing • Oil pump housing cover Cracks/damage/wear → Replace the oil pump. 2. Check: • Oil pump operation Rough movement → Repeat steps (1) and (2) or replace the oil pump. 5-51 OIL PUMP EAS30342 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft Recommended lubricant Engine oil 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 . . TIP When installing the inner rotor, align the pin in the oil pump driven gear with the groove “a” in the inner rotor. 5 3 4 2 1 a 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-51.
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EAS20062 TRANSMISSION Removing the transmission 20 N·m (2.0 kgf·m, 15 lb·ft) T.R. LS New 11 New 2 5 12 13 (5) 12 12 E 7 9 New E 8 LS New New 11 12 LS 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. Secondary sheave assembly Refer to “V-BELT AUTOMATIC TRANSMIS- SION” on page 5-37. Swingarm Refer to “REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM” on page 4-85. Rear wheel Refer to “REAR WHEEL” on page 4-29. 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 5-52 TRANSMISSION 12 10 12 E 6 E E E 1 LS 4 3 New 20 N·m (2.0 kgf·m, 15 lb·ft) T.R.
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Removing the transmission 20 N·m (2.0 kgf·m, 15 lb·ft) T.R. LS New 11 New 2 5 12 13 (5) 12 12 E 7 9 New E 8 LS New New 11 12 LS 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 5-53 TRANSMISSION 12 10 12 E 6 E E E 1 LS 4 3 New 20 N·m (2.0 kgf·m, 15 lb·ft) T.R.
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EAS30433 CHECKING THE TRANSMISSION 1. Check: • Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 2. Check: • Transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 3. Check: • Transmission gear movement Rough movement → Replace the defective part(s). EAS30438 INSTALLING THE TRANSMISSION 1. Install: • Oil seal “1” (to the transmission case cover “2”) • Oil seal “3” (to the right crankcase “4”) New New Installed depth “a” 21.7–21.8 mm (0.85–0.86 in) Installed depth “b” 0.25–0.75 mm (0.01–0.03 in) New 2 1 a 3 New b 4 5-54 TRANSMISSION 2. Install: • Circlip “1” (to the drive axle “2”) New TIP Install the circlip with its chamfered side facing as shown. 1 2 New 1 New 2 3. Install: • Primary driven gear “1” (to the main axle “2”) Primary driven gear installed depth “a” 0.5–0.9 mm (0.020–0.035 in) a 2 1 4. Install: • Transmission case cover “1” Transmission case cover bolt 20 N·m (2.0 kgf·m, 15 lb·ft) T R . . TIP Tighten the transmission case cover bolts in the proper tightening sequence as shown. 4 1 5 6 3 1 7 2 8
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EAS20061 CRANKSHAFT Removing the crankshaft 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 1 LS New (11) 10 10 12 7 8 6 4 LS 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. Piston Refer to “CYLINDER AND PISTON” on page 5-31. Secondary sheave assembly Refer to “V-BELT AUTOMATIC TRANSMIS- SION” on page 5-37. Starter clutch Refer to “STARTER GENERATOR” on page 5-47. 1 Dipstick 1 2 Engine oil drain bolt 1 3 Oil strainer cover 1 4 Spring 1 5-55 CRANKSHAFT E 11 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 9 LS New LS New 2 5 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.
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Removing the crankshaft 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 1 LS New (11) 10 10 12 7 8 6 4 LS 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 Dowel pin 2 11 Crankshaft assembly 1 12 Crankcase (right) 1 5-56 CRANKSHAFT E 11 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 9 LS New LS New 2 5 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.
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EAS30389 DISASSEMBLING THE CRANKCASE 1. Remove: • Crankcase bolts TIP Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • Crankcase (left) “1” ECA13900 NOTICE Tap on one side of the crankcase with a soft- face hammer. Tap only on reinforced por- tions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure the crankcase halves sepa- rate evenly. 1 5-57 CRANKSHAFT EAS30414 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: • Crankshaft assembly “1” TIP • Remove the crankshaft assembly with the crankcase separating tool “2” and M6 bolts “3”. • Make sure that the crankcase separating tool is centered over the crankshaft assembly. ECA20630 NOTICE • To protect the end of the crankshaft, place an appropriate sized socket between the crankcase separating tool bolt and the crankshaft. • Do not tap on the crankshaft. Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B 3 2 1 3
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EAS31242 CHECKING THE CRANKSHAFT ASSEMBLY 1. Measure: • Crankshaft runout Out of specification → Replace the crank- shaft assembly. TIP Turn the crankshaft slowly. Runout limit 0.030 mm (0.0012 in) 2. Measure: • Crankshaft width Out of specification → Replace the crank- shaft assembly. Crank assembly width 51.45–51.50 mm (2.026–2.028 in) 5-58 CRANKSHAFT 3. Check: • Crankshaft sprocket “1” Damage/wear → Replace the crankshaft as- sembly. • Bearing “2” Cracks/damage/wear → Replace the crank- shaft assembly. 2 1 EAS30390 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • Crankcase Cracks/damage → Replace. EAS31244 CHECKING THE BEARING 1. Check: • Bearing Clean and lubricate the bearings, and then rotate the inner race with your finger. Rough movement → Replace. EAS31245 CHECKING THE OIL PUMP DRIVE GEAR 1. Check: • Oil pump drive gear Damage/wear → Replace.
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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 (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other. Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the bearing. Crankshaft installer pot 90890-01274 Installing pot YU-90058 Crankshaft installer bolt 90890-01275 Bolt YU-90060 Adapter (M12) 90890-01278 Adapter #3 YU-90063 Spacer (crankshaft installer) 90890-04081 Pot spacer YM-91044 5 4 1 2 3 5-59 CRANKSHAFT EAS30397 ASSEMBLING THE CRANKCASE 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 Three bond No. 1215® TIP Do not allow any sealant to come into contact with the oil gallery. 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.
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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. a 1 2 b 5-60 CRANKSHAFT
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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
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COOLING SYSTEM DIAGRAMS EAS20299 COOLING SYSTEM DIAGRAMS (Diagrams showing cooling system components and coolant flow with numbered labels) 1. Radiator cap 2. Coolant reservoir hose 3. Radiator 4. Radiator inlet hose 5. Thermostat assembly 6. Radiator outlet hose 7. Water pump inlet hose 8. Water pump assembly 6-1
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EAS20063 RADIATOR Removing the radiator 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 4 11 12 5 (3) 9 (5) 7 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 (4) LS 1 New 1.0 N·m (0.10 kgf·m, 0.73 lb·ft) T.R. (3) Order Job/Parts to remove Q’ty Remarks Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-21. 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 4-12. 1 Radiator cover 1 2 Coolant reservoir breather hose 1 3 Coolant reservoir hose 1 4 Rear brake hose bracket 1 5 Rear brake hose holder (front side) 1 6 Coolant reservoir 1 6-2 RADIATOR 3 2 8 6 11 N·m (1.1 kgf·m, 8.1 lb·ft) T.R.
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Removing the radiator 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 7 N·m (0.7 kgf·m, 5.2 lb·ft) T.R. 4 11 12 5 (3) 9 (5) 7 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 10 (4) LS 1 New 1.0 N·m (0.10 kgf·m, 0.73 lb·ft) T.R. (3) Order Job/Parts to remove Q’ty Remarks 7 Radiator inlet hose 1 8 Radiator outlet hose 1 9 Radiator cap 1 10 Radiator 1 11 Radiator fan case 1 12 Radiator fan 1 6-3 RADIATOR 3 2 8 6 11 N·m (1.1 kgf·m, 8.1 lb·ft) T.R.
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EAS30439 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. TIP Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: • Radiator hose • Coolant reservoir hose Cracks/damage → Replace. 3. Measure: • Radiator cap valve opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap valve opening pres- sure 108.0–137.4 kPa (1.08–1.37 kgf/ cm², 15.7–19.9 psi) a. Install the radiator cap tester “1” and radia- tor cap tester adapter “2” to the radiator cap “3”. Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A Radiator cap tester adapter 31mm 90890-05375 Radiator cap tester adapter 31mm YM-05375 6-4 RADIATOR 1 2 3 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) Refer to “CHANGING THE COOLANT” on page 3-21. 2. Check: • Cooling system Leaks → Repair or replace any faulty part. a. Attach the radiator cap tester “1” to the radi- ator. Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A 1 b. Apply 137.4 kPa (1.37 kgf/cm2, 19.9 psi) of pressure. c. Measure the pressure to check its maintain- ing applied pressure.
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3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-4. 4. Install: • Rear brake hose holder (front side) “1” Rear brake hose holder bolt (front side) 7 N·m (0.7 kgf·m, 5.2 lb·ft) T R . . 6-5 RADIATOR
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EAS20065 THERMOSTAT Removing the thermostat assembly 1 * New 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 Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-21. 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 4-12. 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
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EAS31248 CHECKING THE THERMOSTAT ASSEMBLY 1. Check: • Thermostat “1” Do not open at 74–78°C (165–172 °F) → Re- place. 1 a. Suspend the thermostat “1” in a container “2” filled with water. b. Slowly heat the water. c. Place a thermometer “3” in the water. d. While stirring the water “4”, observe the thermostat and thermometer’s indicated temperature. 3 4 1 2 e. Check the thermostat element position “5”. Same level for the thermostat element up- per end and the hole lower line “a” at 90° C (194°F) a 5 6-7 THERMOSTAT B 0.5 mm (0.02 in) 7 mm (0.28 in) A 74 – 78˚C (165 – 172˚F) 90˚C (194˚F) A. Fully closed B. Fully open TIP If the accuracy of the thermostat is in doubt, re- place it. A faulty thermostat could cause serious overheating or overcooling. EAS30445 INSTALLING THE THERMOSTAT ASSEMBLY 1. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-21. 2. Check: • Cooling system Leaks → Repair or replace any faulty part. Refer to “INSTALLING THE RADIATOR” on page 6-4. 3. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-4.
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EAS20066 WATER PUMP Removing the water pump Order Job/Parts to remove Q’ty Remarks Coolant Drain. Refer to “CHANGING THE COOLANT” on page 3-21. Front side cover (left) Refer to “GENERAL CHASSIS (2)” on page 4-3. Footrest board assembly (left)/Bottom cover Refer to “GENERAL CHASSIS (4)” on page 4-9. 1 Water pump inlet hose 1 Disconnect. 2 Water pump assembly 1 3 Dowel pin 2 4 O-ring 2 6-8 WATER PUMP 3 2 New 4 3 1 10 N•m (1.0 kgf•m, 7.4 lb•ft) T.R.
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Disassembling the water pump New 3 7 8 6 New 7 New 6 New 5 LS 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 6-9 WATER PUMP New 2 1 New 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
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EAS30446 DISASSEMBLING THE WATER PUMP 1. Remove: • Water pump seal “1” TIP Remove the water pump seal from the inside of the water pump housing “2”. • Water pump bearing “3” TIP Remove the water pump bearing from the out- side of the water pump housing “2”. 3 1 2 EAS30447 CHECKING THE WATER PUMP 1. Check: • Water pump housing cover • Water pump housing Cracks/damage → Replace. • Impeller shaft Cracks/damage/wear → Replace. • Impeller • Water pump seal Cracks/damage/wear → Replace. 2. Check: • Bearing Rough movement → Replace 6-10 WATER PUMP EAS30448 ASSEMBLING THE WATER PUMP 1. Install: • Water pump seal “1” (into the water pump housing “2”) TIP New Install the water pump seal with the special tools to the specified depth as shown in the illustra- tion. Installed depth of water pump seal 0–0.5 mm (0–0.02 in) Mechanical seal installer 90890-04145 Middle driven shaft bearing driv- er 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 A 4 3 2 New 1 A. Push down 3. Mechanical seal installer 4. Middle driven shaft bearing driver 1 a 2 a. Installed depth of water pump seal • Bearing Install the bearing as same as water pump seal installation procedure.
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2. Lubricate: • Water pump seal and bearing. Recommended lubricant Lithium-soap-based grease 3. Install: • Impeller shaft “1” • Circlip New TIP After installation, check that the impeller shaft ro- tates smoothly. 1 6-11 WATER PUMP EAS30449 INSTALLING THE WATER PUMP 1. Install: • O-rings “1” • Water pump assembly “2” New 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. b a 2 New 1 LS 2. Fill: • Cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” on page 3-21. 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.
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FUEL SYSTEM FUEL TANK.....................................................................................................7-1 REMOVING THE FUEL TANK..................................................................7-3 REMOVING THE FUEL PUMP .................................................................7-3 CHECKING THE FUEL PUMP BODY.......................................................7-3 CHECKING THE ROLLOVER VALVE ......................................................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 ....................................................7-16 INSTALLING THE THROTTLE BODY ....................................................7-16 7
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EAS20067 FUEL TANK Removing the fuel tank 5 6 8 1 2 7 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-6. Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. Canister Refer to “FUEL TANK” on page 7-1. 1 Fuel tank cap 1 2 Fuel tank overflow tray 1 3 Fuel tank overflow hose 1 4 Fuel tank breather hose (fuel tank to rollover valve) 1 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 11 Fuel pump gasket 1 7-1 FUEL TANK 9 N·m (0.9 kgf·m, 6.6 lb·ft) T.R. 4 11 New 10 3 9
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Removing the canister 3 1 2 4 6 7 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks Front side cover Refer to “GENERAL CHASSIS (2)” on page 4-3. Fuel tank cover Refer to “GENERAL CHASSIS (3)” on page 4-6. Center lower cover Refer to “GENERAL CHASSIS (5)” on page 4-12. 1 Fuel tank breather hose (rollover valve to canis- ter) 1 2 Rollover valve holder 1 3 Rollover valve 1 4 Fuel tank breather hose (fuel tank to rollover valve) 1 5 Canister purge hose 1 Disconnect. 6 Canister 1 Disconnect. 7 Canister breather hose 1 Disconnect. 7-2 FUEL TANK 5
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EAS30450 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with an appropriate pump. 2. Disconnect: • Fuel sender coupler • Fuel pump coupler • Fuel hose EWA18020 WARNING Cover the fuel hose connection with a cloth when disconnecting it. Residual pressure in the fuel lines could cause fuel to spurt out when removing the hose. ECA20020 NOTICE Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it. TIP • To remove the fuel hose from the fuel pump, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown, and then remove the hose. • Before removing the hose, place a few rags in the area under where it will be removed. 1 1 3. Remove: • Fuel tank 7-3 FUEL TANK EAS30451 REMOVING THE FUEL PUMP 1. Remove: • Fuel pump ECA14721 NOTICE • Do not drop the fuel pump or give it a strong shock. • Do not touch the base section of the fuel sender. EAS30454 CHECKING THE FUEL PUMP BODY 1. Check: • Fuel pump body Obstruction → Clean. Cracks/damage → Replace the fuel pump assembly. EAS30699 CHECKING THE ROLLOVER VALVE 1. Check: • Rollover valve “1” • Damage/faulty → Replace. TIP • Check that air flows smoothly only in the direc- tion of the arrow shown in the illustration. • The rollover valve must be in an upright posi- tion when checking the airflow.
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EAS30456 INSTALLING THE FUEL PUMP 1. Install: • Fuel pump gasket “1” • Fuel pump • Fuel pump bracket New Fuel pump bracket bolt 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) T R . . TIP • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. • Always use a new fuel pump gasket. • Face the gasket lip “a” toward the fuel pump. • Align the projections “b” (two locations) on the fuel pump gasket with the slots “c” in the fuel pump. • 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- ening sequence as shown. c a 1 b New 1 d 4 3 2 7-4 FUEL TANK EAS30457 INSTALLING THE FUEL TANK 1. Install: • Fuel tank “1” a. Temporarily install the fuel tank. TIP Make sure that the flanges of the fuel tank bolts “2” do not contact the fuel tank. b. Install the fuel tank overflow tray and fuel tank cover “3”. To install the fuel tank cover, refer to “GENERAL CHASSIS (3)” on page 4-6. c. Tighten the fuel tank bolts to specification. Fuel tank bolt 9 N·m (0.9 kgf·m, 6.6 lb·ft) T R . . 3 2 2 1 2. 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 the correct position, otherwise the fuel hose will not be properly installed. TIP • Install the fuel hose securely onto the fuel 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. 1
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EAS30703 CHECKING THE FUEL PRESSURE 1. Remove: • Front side cover assembly (left) Refer to “GENERAL CHASSIS (2)” on page 4-3. • Footrest board (left) Refer to “GENERAL CHASSIS (5)” on page 4-12. 2. Check: • Pressure regulator operation a. Disconnect the fuel hose from the fuel pump. EWA18020 WARNING Cover the fuel hose connection with a cloth when disconnecting it. Residual pressure in the fuel lines could cause fuel to spurt out when removing the hose. ECA20020 NOTICE Although the fuel has been removed from the fuel tank, be careful when removing the fuel hose, since there may be fuel remaining in it. 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 Pressure gauge YU-03153 Fuel pressure adapter 6.3mm 90890-03227 1 YAMAH 3 2 c. Start the engine. 7-5 FUEL TANK d. Measure the fuel pressure. Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi) Faulty → Replace the fuel pump. e. Connect the fuel hose. Refer to “INSTALLING THE FUEL TANK” on page 7-4. 3. Install: • Footrest board (left) Refer to “GENERAL CHASSIS (5)” on page 4-12. • Front side cover assembly (left) Refer to “GENERAL CHASSIS (2)” on page 4-3.
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EAS20191 FUEL INJECTOR Removing the fuel injector 5 1 New 8 E 6 2 New 7 4 Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Front side cover 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 4-9. 1 Fuel hose 1 2 Fuel injector coupler 1 Disconnect. 3 Fuel injector connector 1 4 Fuel injector gasket 1 5 Clamp ring 1 6 Fuel injector 1 7 O-ring 1 8 O-ring 1 7-6 FUEL INJECTOR 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. 3
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EAS31250 REMOVING THE FUEL HOSE 1. Disconnect: • Fuel hose EWA17610 WARNING Cover fuel hose connections with a cloth when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to spurt out when removing the hoses. 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 • To remove the fuel hose from the fuel injector, 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. • Before removing the hose, place a few rags in the area under where it will be removed. 1 EAS31251 CHECKING THE FUEL INJECTOR 1. Check: • Injector Obstruction → Replace and check the fuel pump/fuel supply system. Deposit → Replace. Damage → Replace. 2. Check: • Injector resistance Refer to “INSTALLING THE FUEL INJEC- TOR” on page 7-7. EAS31617 INSTALLING THE FUEL INJECTOR 1. Install: • Fuel injector adaptor “1” • O-ring “2” (to the fuel injector) • Fuel injector “3” New 7-7 FUEL INJECTOR Fuel injector bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) T R . . TIP • Lubricate the O-ring with engine oil. • Align the projection “a” on the fuel injector adapter with the hole “b” in the intake manifold. • Align the projection “c” on the fuel injector with the hole “d” in the fuel injector adapter. 3 New 2 1 a b c d EAS31253 INSTALLING THE FUEL HOSE 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 the correct position, otherwise the fuel hose will not be properly installed. TIP • Install the fuel hose securely onto the fuel in- jector until a distinct “click” is heard. • To install the fuel hose onto the fuel injector, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown. 1
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EAS20068 AIR FILTER CASE Removing the air filter case 4 8 9 6 5 10 N·m (1.0 kgf·m, 7.4 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 Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Front side cover 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 4-9. 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 7 New 3 New 1 2 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) T.R.
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Removing the air filter case 4 8 9 6 5 10 N·m (1.0 kgf·m, 7.4 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 7 New 3 New 1 2 1.2 N·m (0.12 kgf·m, 0.88 lb·ft) T.R.
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EAS31618 INSTALLING THE AIR FILTER CASE 1. Install: • Hose “1” (to the air filter case joint “2”) TIP • Apply Three bond 1521 “3” onto the mating surfaces of the hose and air filter case joint. • Align the slot “b” on the air filter case joint with the projection “a” 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 a b 7-10 AIR FILTER CASE 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”. b a 1 2
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EAS20070 THROTTLE BODY Removing the throttle body 8 5 N·m (0.5 kgf·m, 3.7 lb·ft) T.R. 2 3 7 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R. New 4 5 6 New 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks Battery Refer to “GENERAL CHASSIS (1)” on page 4-1. Side covers Refer to “GENERAL CHASSIS (2)” on page 4-3. Storage box Refer to “GENERAL CHASSIS (3)” on page 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 1 9 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R.
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Removing the throttle body 8 5 N·m (0.5 kgf·m, 3.7 lb·ft) T.R. 10 N·m (1.0 kgf·m, 7.4 lb·ft) 2 3 7 T.R. New 4 5 6 New 4.5 N·m (0.45 kgf·m, 3.3 lb·ft) T.R. Order Job/Parts to remove Q’ty Remarks 3 Canister purge hose 1 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 1 9 10 N·m (1.0 kgf·m, 7.4 lb·ft) T.R.
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EAS30979 REMOVING THE THROTTLE BODY 1. Remove: • Throttle body ECA20500 NOTICE Do not remove the throttle body sensor as- sembly from the throttle body. EAS30479 CHECKING THE THROTTLE BODY TIP Before checking the throttle body, check the fol- lowing items: • Valve clearance • Spark plug • Air filter element • Intake manifold • Fuel hose • Exhaust system • Cylinder head breather hose 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. 2. Check: • Butterfly valve Damage/scratches/wear → Replace the throttle body. ECA21770 NOTICE Do not adjust the stop screw “1”. 1 7-13 THROTTLE BODY EAS31254 CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY 1. Remove the throttle body from the vehicle. TIP Before removing the throttle body, disconnect the throttle cables, canister purge hose and cou- plers. 2. Remove: • Screw “1” • ISC (Idle Speed Control) unit holder “2” • ISC (Idle Speed Control) unit “3” ECA21780 NOTICE Because the force of the spring may push out the ISC unit unexpectedly, be sure to hold the ISC unit when removing the compo- nents. 2 3 1 3. Remove: • Spring “1” • O-ring “2” 2 1
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4. Check: • ISC (Idle Speed Control) unit Plunger “1” does not rotate smoothly/plunger rotates together with the motor shaft “2” → Replace. 1 2 5. Check: • Spring Damage/bent → Replace. 6. Clean: • Area “a” of the ISC unit • Areas “b” and “c” of the throttle body Clogs or foreign materials cannot be re- moved → Replace. a b c 7-14 THROTTLE BODY a. Use a rag soaked in the recommended cleaning agent to wipe off any deposits and foreign materials. Recommended cleaning agent Yamaha oil & brake cleaner ECA21790 NOTICE • Be sure to use the recommended cleaning agent. • Do not spray the cleaning agent directly onto the ISC unit or throttle body and do not immerse them in the cleaning agent. • To prevent scratching the components, do not use a brush, metal file, or other abra- sive tool. • Do not clean with compressed air. • Do not allow the removed deposits or for- eign materials to adhere to the sealing sur- faces of the O-ring. • Do not scratch or deform the ISC valve or air passage; otherwise, poor starting per- 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) a
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8. Install: • Spring • O-ring “1” • ISC (Idle Speed Control) unit “2” New ECA21800 NOTICE • Do not use the ISC unit if it was dropped. • Do not allow water to enter the ISC unit and do not allow foreign materials to adhere to the assembly. • Do not touch the terminals of the coupler directly. • Because the force of the spring may push out the ISC unit unexpectedly, be sure to hold the motor assembly when installing the components. TIP • Install the new O-ring until it contacts the raised portion of the ISC unit body. • When installing the ISC unit, be sure to align the oval portion “a” of the ISC unit with the oval hole “b” in the throttle body. 1 New 2 b a 7-15 THROTTLE BODY 9. Install: • ISC (Idle Speed Control) unit holder “1” • Screw ISC (Idle Speed Control) unit holder screw 5 N·m (0.5 kgf·m, 3.7 lb·ft) T R . . TIP Align the slot “a” in the ISC unit holder with the projection “b” on the ISC unit “2”. 1 2 a b 10.Install the throttle body to the vehicle. 11.Reset: • ISC learning valves Use the diagnostic code number “67”. Refer to “ FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-37. • ISC valve position Use the diagnostic code number “54”. Refer to “ FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-37. 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 off ground. 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. Out of specification → Replace the throttle body. Refer to “REPLACING THE THROTTLE BODY” on page 7-16. Engine idling speed 1500–1700 r/min
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EAS31160 REPLACING THE THROTTLE BODY 1. Remove the throttle body from the vehicle. 2. Install a new throttle body to the vehicle. 3. Reset: • ISC learning valves Use the diagnostic code number “67”. Refer to “ FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-37. • ISC valve position Use the diagnostic code number “54” Refer to “ 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 off ground. 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 7-16 THROTTLE BODY 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
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<p align="right"><b>THROTTLE BODY</b></p> --- <br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br> <p align="center"><b>7-17</b></p>
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ELECTRICAL SYSTEM IGNITION SYSTEM .........................................................................................8-1 CIRCUIT DIAGRAM ..................................................................................8-1 ..............................................................................8-3 ELECTRIC STARTING SYSTEM....................................................................8-5 CIRCUIT DIAGRAM ..................................................................................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ..........................8-7 ..............................................................................8-8 STOP AND START SYSTEM........................................................................8-11 CIRCUIT DIAGRAM ................................................................................8-11 STOP AND START SYSTEM OPERATION ...........................................8-13 ............................................................................8-14 CHARGING SYSTEM....................................................................................8-17 CIRCUIT DIAGRAM ................................................................................8-17 ............................................................................8-19 LIGHTING SYSTEM ......................................................................................8-21 CIRCUIT DIAGRAM ................................................................................8-21 ............................................................................8-23 SIGNALING SYSTEM ...................................................................................8-25 CIRCUIT DIAGRAM ................................................................................8-25 ............................................................................8-27 FUEL PUMP SYSTEM...................................................................................8-31 CIRCUIT DIAGRAM ................................................................................8-31 ............................................................................8-33 ELECTRICAL COMPONENTS......................................................................8-34 CHECKING THE SWITCHES .................................................................8-35 CHECKING THE FUSES ........................................................................8-36 REPLACING THE SGCU (starter generator control unit)........................8-36 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 CHECKING THE FUEL SENDER ...........................................................8-41 CHECKING THE COOLANT TEMPERATURE SENSOR.......................8-41 CHECKING THE FUEL INJECTOR ........................................................8-42 CHECKING THE VVA SOLENOID..........................................................8-42 CHECKING THE SMART KEY BATTERY..............................................8-43 8
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CHECKING THE BUZZER......................................................................8-43 CHECKING THE MAIN SWITCH SOLENOID.........................................8-43
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IGNITION SYSTEM EAS20072 IGNITION SYSTEM EAS30490 CIRCUIT DIAGRAM 8-1
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# IGNITION SYSTEM --- 1. Battery 9. Main fuse 10. Ignition fuse 13. Main switch 36. Sidestand switch 43. SGCU (starter generator control unit) 44. Ignition coil 45. Spark plug 51. Crankshaft position sensor 72. Frame ground 8-2
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EAS30492 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 cover 3. Fuel tank cover 4. Storage box 5. Footrest board assembly 6. Front cowling assembly 1. Check the fuse. (Main and ignition) Refer to “CHECKING THE FUS- ES” on page 8-36. NG→ Replace the fuse. OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in SERVICE MANUAL BASIC IN- FORMATION. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the spark plug. Refer to “CHECKING THE SPARK PLUG” on page 3-5. NG→ Re-gap or replace the spark plug. OK↓ 4. Check the ignition spark gap. Refer to “CHECKING THE IGNI- TION SPARK GAP” on page 8-40. OK→ Ignition system is OK. NG↓ 5. Check the spark plug cap. Refer to “CHECKING THE SPARK PLUG CAP” on page 8-39. NG→ Replace the spark plug cap. OK↓ 6. Check the ignition coil. Refer to “CHECKING THE IGNI- TION COIL” on page 8-39. NG→ Replace the ignition coil. OK↓ 7. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the main switch. OK↓ 8-3 IGNITION SYSTEM
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8. Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the sidestand switch. OK↓ 9. Check the entire ignition system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-1. NG→ Properly connect or replace the wire har- ness. OK↓ Replace the starter generator assem- bly or the SGCU. Refer to “REPLAC- ING THE SGCU (starter generator control unit)” on page 8-36. 8-4 IGNITION SYSTEM
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ELECTRIC STARTING SYSTEM EAS20073 ELECTRIC STARTING SYSTEM EAS30493 CIRCUIT DIAGRAM 8-5
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ELECTRIC STARTING SYSTEM 1. Battery 6. Signaling system fuse 7. Fuel injection system fuse 9. Main fuse 10. Ignition fuse 13. Main switch 27. Handlebar switch (right) 28. Start switch 31. Main relay 33. Front brake light switch 34. Rear brake light switch 35. Starter charge relay 36. Sidestand switch 40. Joint 3 43. SGCU (starter generator control unit) 51. Crankshaft position sensor 55. Starter generator 72. Frame ground 73. Engine ground 8-6
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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 op- erate 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 1 2 5 6 3 4 1. Battery 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 15. Crankshaft position sensor 8-7 ELECTRIC STARTING SYSTEM 14 13 15 8 9 10 11 12
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EAS30495 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. (Main, ignition, fuel injection sys- tem, and signaling system) Refer to “CHECKING THE FUS- ES” on page 8-36. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in SERVICE MANUAL BASIC IN- FORMATION. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the starter generator. Refer to “CHECKING THE START- ER GENERATOR” on page 8-40. NG→ Replace the starter generator assembly. OK↓ 4. Check the main relay. Refer to “CHECKING THE RE- LAYS” on page 8-38. NG→ Replace the main relay. OK↓ 5. Check the starter charge relay. Refer to “CHECKING THE RE- LAYS” on page 8-38. NG→ Replace the starter charge relay. OK↓ 6. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the main switch. OK↓ 7. Check the sidestand switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the sidestand switch. OK↓ 8-8 ELECTRIC STARTING SYSTEM
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8. Check the start switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ The start switch is faulty. Replace the right handlebar switch. OK↓ 9. Check the brake light switches. (Front and rear) Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the brake light switch(es). OK↓ 10.Check the entire starting system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-5. NG→ Properly connect or replace the wire har- ness. OK↓ Replace the starter generator assem- bly or SGCU. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. 8-9 ELECTRIC STARTING SYSTEM
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ELECTRIC STARTING SYSTEM 8-10
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EAS20715 STOP AND START SYSTEM EAS33384 CIRCUIT DIAGRAM B/L Y L P/W Br/W B/L W/L Br/B W/Y (B) W/R W/B (B) G W/R W/L W/B L/Y Br/B (B) G/R B/L (B) 50 51 49 52 47 48 W/B W/L G W/R W/Y L/Y B/L Y L Br/B B/L G/R B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y R B Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G B Y/B Y/R G/Y W/R O B/Y P Lg/L O/B G B Ch W/L W/R W/L W/B W/Y Br/B G/R B/L L Y B/L B/L B/L (B) 43 P/B W/G Y/R R/B L/Y R Br B 39 G W R W/G Y/W L/Y L/Y Br Br Br Br Br Br B L/Y B Y/R R/B Br R 36 35 B Br/R Br Y/R B/W R R/B L/Y B/W Y/W 29 ON OFF Y/W B/W Y/W (B) 27 12 13 ON OPEN OFF LOCK B B/W R/Y Br/R Br R R Br Br/R R R/Y R R R R Br Br 10 7 9 R Br R R 8-11 STOP AND START SYSTEM Br Y W B 55 R/Y R/W R/L R W G 56 Y Br Y B W Br B/W Y Br G L W B R/L W/B Lg/WB/W R R/L G R W R/W R/Y W/L R Ch Br Br Lg/L L/G L/G B (B) Br/R G W/R Br/W Y/W Dg (Gy) W/B Br W Y W/L L/W R L/R G/B W/B 59 R/W G R W W B/W 61 B B 68 60 Br B B B B B B B B 72 73 72 72 B/W B B B B (L) B (L) B B B B B B B B B B B B B B B 1 B B B
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1. Battery 7. Fuel injection system fuse 9. Main fuse 10. Ignition fuse 12. ABS control unit fuse 13. Main switch 27. Handlebar switch (right) 29. Stop and Start System switch 35. Starter charge relay 36. Sidestand switch 39. Joint 2 43. SGCU (starter generator control unit) 47. Throttle body sensor assembly 48. Intake air pressure sensor 49. Intake air temperature sensor 50. Throttle position sensor 51. Crankshaft position sensor 52. Coolant temperature sensor 55. Starter generator 56. Front wheel sensor 59. ABS ECU 60. Meter assembly 61. Multi-function meter 68. Stop and Start System indicator light 72. Frame ground 73. Engine ground 8-12 STOP AND START SYSTEM
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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 7 1 2 6 8 3 9 4 5 1. Battery 2. Main fuse 3. Main switch 4. ABS control unit fuse 5. Ignition fuse 6. Fuel injection system fuse 7. Starter charge relay 8. Yamaha diagnostic tool coupler 9. Multi-function meter 10. Stop and Start System indicator light 11. SGCU (starter generator control unit) 12. Starter generator 13. Crankshaft position sensor 14. Coolant temperature sensor 8-13 STOP AND START SYSTEM 12 13 11 14 15 16 17 19 18 10 15. Throttle position sensor 16. Front wheel sensor 17. ABS ECU 18. Sidestand switch 19. Stop and Start System switch
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EAS33386 • 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. (Main, ignition, fuel injection sys- tem, and ABS control unit) Refer to “CHECKING THE FUS- ES” on page 8-36. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in SERVICE MANUAL BASIC IN- FORMATION. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the main switch. OK↓ 4. Check the Stop and Start System switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ The Stop and Start System switch is faulty. Replace the right handlebar switch. OK↓ 5. Check the entire starting system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-11. NG→ Properly connect or replace the wire har- ness. OK↓ Check the condition of each of the Stop and Start System circuits. Refer to “Checking the Stop and Start Sys- tem” on page 8-15. 8-14 STOP AND START SYSTEM
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Checking the Stop and Start System The engine stop function does not operate. 1. Check the coolant temperature sensor. Refer to “CHECKING THE COOL- ANT TEMPERATURE SENSOR” on page 8-41. NG→ Replace the coolant temperature sensor. OK↓ 2. Check the throttle position sensor. NG→ The throttle position sensor is faulty. Re- place the throttle body assembly. OK↓ 3. Check the front wheel sensor. NG→ Replace the front wheel sensor. OK↓ 4. Check the entire wiring. Refer to TIP. NG→ Properly connect or replace the wiring har- ness. OK↓ Replace the SGCU. Refer to “RE- PLACING THE SGCU (starter gener- ator control unit)” on page 8-36. 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. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the sidestand switch. OK↓ 2. Check the starter generator. Refer to “CHECKING THE START- ER GENERATOR” on page 8-40. NG→ Replace the starter generator assembly. OK↓ 3. Check the start charge relay. Refer to “CHECKING THE RE- LAYS” on page 8-38. NG→ Replace the start charge relay. OK↓ 4. Check the throttle position sensor. NG→ The throttle position sensor is faulty. Re- place the throttle body assembly. OK↓ 8-15 STOP AND START SYSTEM
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5. Check the entire Stop and Start System wiring. Refer to “CIRCUIT DIAGRAM” on page 8-11. NG→ Properly connect or replace the wiring har- ness. OK↓ Replace the starter generator assem- bly or the SGCU. Refer to “REPLAC- ING THE SGCU (starter generator control unit)” on page 8-36. The Stop and Start System indicator light fails to come on. 1. Check the entire wiring. Refer to TIP. NG→ Properly connect or replace the wiring har- ness. OK↓ Replace the SGCU or meter assem- bly. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. 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 STOP AND START SYSTEM
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CHARGING SYSTEM EAS20074 CHARGING SYSTEM EAS20496 CIRCUIT DIAGRAM 8-17
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CHARGING SYSTEM ___ 1. Battery 9. Main fuse 10. Ignition fuse 13. Main switch 31. Main relay 35. Starter charge relay 43. SGCU (starter generator control unit) 55. Starter generator 72. Frame ground 73. Engine ground 8-18
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EAS30497 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. (Main and ignition) Refer to “CHECKING THE FUS- ES” on page 8-36. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in SERVICE MANUAL BASIC IN- FORMATION. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the starter generator. Refer to “CHECKING THE START- ER GENERATOR” on page 8-40. NG→ Replace the starter generator assembly. OK↓ 4. Check the main relay. Refer to “CHECKING THE RE- LAYS” on page 8-38. NG→ Replace the main relay. OK↓ 5. Check the starter charge relay. Refer to “CHECKING THE RE- LAYS” on page 8-38. NG→ Replace the starter charge relay. OK↓ 6. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the main switch. OK↓ 8-19 CHARGING SYSTEM
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7. Check the entire charging system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-17. NG→ Properly connect or replace the wire har- ness. OK↓ Replace the starter generator assem- bly or the SGCU. Refer to “REPLAC- ING THE SGCU (starter generator control unit)” on page 8-36. 8-20 CHARGING SYSTEM
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LIGHTING SYSTEM EAS20075 LIGHTING SYSTEM EAS20498 CIRCUIT DIAGRAM 8-21
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# LIGHTING SYSTEM 1. Battery 8. Backup fuse 9. Main fuse 10. Ignition fuse 11. Headlight fuse 13. Main switch 22. Handlebar switch (left) 25. Dimmer switch 43. SGCU (starter generator control unit) 60. Meter assembly 61. Multi-function meter 62. ABS warning light 72. Frame ground 73. Engine ground 74. License plate light 75. Tail/brake light assembly 76. Taillight 82. Headlight assembly 83. Headlight control unit 84. High beam 85. Low beam 86. Auxiliary light 8-22
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EAS30499 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 cover 3. Footrest board assembly 4. Front cowling assembly 5. Leg shield 6. Upper handlebar cover assembly 1. Check the condition of each bulb and bulb socket. Refer to “CHECKING THE BULBS AND BULB SOCKETS” in “BASIC INFORMATION” (separate vol- ume). NG→ Replace the bulb(s) and bulb socket(s). OK↓ 2. Check the fuses. (Main, ignition, and headlight) Refer to “CHECKING THE FUS- ES” on page 8-36. NG→ Replace the fuse(s). OK↓ 3. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in SERVICE MANUAL BASIC IN- FORMATION. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 4. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the main switch. OK↓ 5. Check the dimmer switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ The dimmer switch is faulty. Replace the left handlebar switch. OK↓ 8-23 LIGHTING SYSTEM
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6. Check the entire lighting system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-21. NG→ Properly connect or replace the wire har- ness. OK↓ Replace the SGCU, meter assembly, tail/brake light assembly or headlight unit. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. 8-24 LIGHTING SYSTEM
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SIGNALING SYSTEM EAS20076 SIGNALING SYSTEM EAS20500 CIRCUIT DIAGRAM 8-25
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SIGNALING SYSTEM ___________ 1. Battery 6. Signaling system fuse 8. Backup fuse 9. Main fuse 10. Ignition fuse 12. ABS control unit fuse 13. Main switch 20. Horn 21. Diode 22. Handlebar switch (left) 24. Horn switch 26. Turn signal switch 27. Handlebar switch (right) 30. Hazard switch 31. Main relay 33. Front brake light switch 34. Rear brake light switch 37. Joint 1 42. Fuel sender 43. SGCU (starter generator control unit) 52. Coolant temperature sensor 56. Front wheel sensor 59. ABS ECU 60. Meter assembly 61. Multi-function meter 65. Turn signal indicator light (left) 66. Turn signal indicator light (right) 72. Frame ground 73. Engine ground 75. Tail/brake light assembly 76. Taillight 77. Brake light 78. Front turn signal light (left) 79. Front turn signal light (right) 80. Rear turn signal light (left) 81. Rear turn signal light (right) 8-26
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EAS30501 • 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 cover 3. Fuel tank cover 4. Storage box 5. Center lower cover 6. Upper handlebar cover assembly 1. Check the fuses. (Main, ignition, signaling system ABS control unit) Refer to “CHECKING THE FUS- ES” on page 8-36. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in SERVICE MANUAL BASIC IN- FORMATION. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the main switch. OK↓ 4. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-25. NG→ Properly connect or replace the wire har- ness. OK↓ Check the condition of each of the sig- naling system circuits. Refer to “Checking the signaling system”. 8-27 SIGNALING SYSTEM
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Checking the signaling system The horn fails to sound. 1. Check the horn switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ The horn switch is faulty. Replace the left handlebar switch. OK↓ 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-25. NG→ Properly connect or replace the wire har- ness. OK↓ Replace the horn. The brake light fails to come on. 1. Check the front brake light switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the front brake light switch. OK↓ 2. Check the rear brake light switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the rear brake light switch. OK↓ 3. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-25. NG→ Properly connect or replace the wire har- ness. 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 and sockets. Refer to “CHECKING THE BULBS AND BULB SOCKETS” in “BASIC INFORMATION” (separate vol- ume). NG→ Replace the turn signal light bulb, socket or both. OK↓ 2. Check the turn signal switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ The turn signal switch is faulty. Replace the left handlebar switch. OK↓ 8-28 SIGNALING SYSTEM
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3. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-25. NG→ Properly connect or replace the wire har- ness. OK↓ Replace the meter assembly. The coolant temperature warning light fails to come on. 1. Check the coolant temperature sensor. Refer to “CHECKING THE COOL- ANT TEMPERATURE SENSOR” on page 8-41. NG→ Replace the coolant temperature sensor. OK↓ 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-25. NG→ Properly connect or replace the wire har- ness. OK↓ Replace the meter assembly or SGCU. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. The fuel meter, fuel level warning light, or both fails to come on. 1. Check the fuel sender. Refer to “CHECKING THE FUEL SENDER” on page 8-41. NG→ Replace the fuel pump. OK↓ 2. Check the entire signaling system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-25. NG→ Properly connect or replace the wire har- ness. OK↓ Replace the meter assembly. 8-29 SIGNALING SYSTEM
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The speedometer, V-belt replacement indicator, engine oil change indicator, instantaneous fuel consumption meter fails to operate. 1. Check the front wheel sensor. Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-25. NG→ Replace the front wheel sensor. OK↓ 2. Check the entire wiring. Refer to TIP. NG→ Properly connect or replace the wiring har- ness. OK↓ Replace the SGCU, or meter assem- bly. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. 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 SIGNALING SYSTEM
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FUEL PUMP SYSTEM EAS20061 **FUEL PUMP SYSTEM** EAS20513 **CIRCUIT DIAGRAM** 8-31
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FUEL PUMP SYSTEM --- 1. Battery 7. Fuel injection system fuse 9. Main fuse 10. Ignition fuse 13. Main switch 41. Fuel pump 43. SGCU (starter generator control unit) 72. Frame ground 8-32
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EAS30514 If the fuel pump fails to operate. TIP • Before troubleshooting, remove the following part(s): 1. Battery cover 2. Front side cover 3. Footrest board assembly 4. Fuel tank 1. Check the fuses. (Main, ignition and fuel injection) Refer to “CHECKING THE FUS- ES” on page 8-36. NG→ Replace the fuse(s). OK↓ 2. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 3. Check the main switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the main switch. OK↓ 4. Check the fuel pump. Refer to “CHECKING THE FUEL PRESSURE” on page 7-5. NG→ Replace the fuel pump. OK↓ 5. Check the entire fuel pump system wiring. Refer to “CIRCUIT DIAGRAM” on page 8-31. NG→ Properly connect or replace the wiring har- ness. OK↓ Replace the SGCU. Refer to “RE- PLACING THE SGCU (starter gener- ator control unit)” on page 8-36. 8-33 FUEL PUMP SYSTEM
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ELECTRICAL COMPONENTS EAS20089 ELECTRICAL COMPONENTS 1. Battery 2. Main switch 3. Front brake light switch 4. Rear brake light switch 5. Auxiliary DC jack 6. Buzzer 7. SGCU (starter generator control unit) 8. Main relay 9. Starter charge relay 10. Fuse box 11. ABS ECU 12. Horn 13. Front wheel sensor 14. Fuel pump 15. Fuel sender 16. Sidestand switch 17. VVA (variable valve actuator) solenoid 18. O₂ sensor 19. Spark plug 20. Coolant temperature sensor 21. Starter generator 22. Crankshaft position sensor 23. Rear wheel sensor 24. Throttle body sensor assembly 25. Intake air pressure sensor 26. Intake air temperature sensor 27. Throttle position sensor 28. ISC (Idle Speed Control) unit 29. Fuel injector 30. Ignition coil 31. CCU (Communication Control Unit) 32. Smart key unit 8-34
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EAS30549 CHECKING THE SWITCHES 11 L/B B Y/W P FREE PUSH Y/W 10 Ch Dg Y L/B Y B 9 L/W B P PUSH FREE 8 Ch B/W Dg 7 6 B B B 1. Main switch 2. Start switch 3. Start and Stop System switch 4. Hazard switch 5. Front brake light switch 6. Sidestand switch 7. Rear brake light switch 8. Turn signal light switch 9. Horn switch 10. Dimmer switch 11. Menu switch 8-35 ELECTRICAL COMPONENTS 1 R R/Y R Br/R ON OPEN OFF LOCK R/Y Br/R 2 L/W B L/W B 3 Y/W B/W Y/W ON OFF B/W 4 Dg Ch Br/W Dg Br/W Ch 5
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EAS30551 CHECKING THE FUSES The following procedures are applied to all of the fuses. ECA20520 NOTICE To avoid a short circuit, always turn the main switch to “OFF” when checking or replacing a fuse. 1. Remove: • Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1. 2. Check: • Fuse a. Connect the digital circuit tester to the fuse and check the continuity. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 b. If the digital circuit tester indicates “∞”, re- place the fuse. 3. Replace: • Blown fuse a. Turn the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. Fuses Amper- age rating Q’ty Main fuse 30 A 1 Headlight fuse 7.5 A 1 Backup fuse 7.5 A 1 Ignition fuse 7.5 A 1 Fuel injection system fuse 7.5 A 1 Signaling system fuse 7.5 A 1 Terminal fuse 5 A 1 ABS motor fuse 30.0 A 1 ABS solenoid fuse 15.0 A 1 ABS control unit fuse 2.0 A 1 Smart key system fuse 2.0 A 1 8-36 ELECTRICAL COMPONENTS Fuses Amper- age rating Q’ty Spare 30 A 1 Spare 7.5 A 1 Spare 5 A 1 EWA13310 WARNING Never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Install: • Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1. EAS33388 REPLACING THE SGCU (starter generator control unit) 1. Turn the main switch to “OFF”. 2. Replace the SGCU (starter generator control unit). 3. Clean the throttle body. Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on page 7-13. 4. 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
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EAS30552 CHECKING AND CHARGING THE BATTERY TIP Refer to “CHECKING AND CHARGING THE BATTERY” in “BASIC INFORMATION” (sepa- rate volume). 1. Remove: • Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1. 2. Disconnect: • Battery lead (from the battery terminals) ECA13640 NOTICE First, disconnect the negative battery lead “1”, and then positive battery lead “2”. 1 2 3. Remove: • Battery 4. Check: • Battery charge a. Connect a digital circuit tester to the battery terminals. • Positive tester probe → positive battery terminal • Negative tester probe → negative battery terminal 5. Install: • Battery 8-37 ELECTRICAL COMPONENTS 6. Connect: • Battery leads (to the battery terminals) ECA13630 NOTICE First, connect the positive battery lead “1”, and then the negative battery lead “2”. 2 1 7. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 8. Lubricate: • Battery terminals Recommended lubricant Dielectric grease 9. Install: • Battery cover Refer to “GENERAL CHASSIS (1)” on page 4-1.
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EAS30553 CHECKING THE RELAYS Check each switch for continuity with the digital circuit tester. If the continuity reading is incor- rect, replace the relay. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 1. Disconnect the relay from the wire harness. 2. Connect the digital circuit tester and battery (12 V) to the relay terminals as shown. Check the relay operation. Out of specification → Replace. 3 4 1 + 2 Br B Br/R R 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) 8-38 ELECTRICAL COMPONENTS Starter charge relay First step: 1 3 2 Br Br/R R/B R Y/R 1. Positive tester probe 2. Negative tester probe 3. Negative tester probe Result Continuity (between “1” and “2”) No continuity (between “1” and “3”) Second step: 3 5 4 2 + 1 Br R/B Br/R R Y/R 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe 5. Negative tester probe Result No continuity (between “3” and “4”) Continuity (between “3” and “5”)
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EAS30557 CHECKING THE SPARK PLUG CAP 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) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 c. Measure the spark plug cap resistance. EAS30558 CHECKING THE IGNITION COIL 1. Check: • Primary coil resistance Out of specification → Replace. Primary coil resistance 2.16–2.64 Ω a. Disconnect the ignition coil connectors from the ignition coil terminals. b. Connect the digital circuit tester to the igni- tion coil as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 8-39 ELECTRICAL COMPONENTS • Positive tester probe → Brown “1” • Negative tester probe → Orange “2” 2 1 c. Measure the primary coil resistance. 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. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe → Orange “1” • Negative tester probe → High tension cord “2” 2 1 b. Measure the secondary coil resistance.
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EAS30556 CHECKING THE IGNITION SPARK GAP 1. Check: • Ignition spark gap Out of specification → Perform the ignition system troubleshooting, starting with step 5. Refer to “” on page 8- 3. Minimum ignition spark gap 6.0 mm (0.24 in) TIP If the ignition spark gap is within specification, the ignition system circuit is operating normally. a. Disconnect the spark plug cap from the spark plug. b. Connect the ignition checker “1” as shown. Ignition checker 90890-06754 Oppama pet–4000 spark checker YM-34487 2. Ignition coil c. Turn the main switch to “ON”. d. Measure the ignition spark gap “a”. e. Crank the engine by pushing the “ ” of the start switch and gradually increase the spark gap until a misfire occurs. 8-40 ELECTRICAL COMPONENTS EAS33389 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 a. Connect the digital circuit tester to the start- er generator coupler as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe → Red/Yellow “1” • Negative tester probe → Red/Blue “3” • Positive tester probe → Red/Yellow “1” • Negative tester probe → Red/White “2” • Positive tester probe → Red/Blue “3” • Negative tester probe → Red/White “2” R/Y R/W R/L 1 2 3 b. Measure the starter generator resistance.
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EAS30573 CHECKING THE FUEL SENDER 1. Remove: • Fuel pump (from the fuel tank) 2. Check: • Fuel sender resistance Out of specification → Replace the fuel pump assembly. Fuel sender Sender unit resistance (full) 10.0–14.0 Ω Sender unit resistance (empty) 267.0–273.0 Ω a. Connect the digital circuit tester to the fuel sender terminals as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe → Green “1” • Negative tester probe → Black “2” 2 B/Y B R G 1 b. Move the fuel sender float to minimum “3” and maximum “4” level position. 4 3 c. Measure the fuel sender resistance. 8-41 ELECTRICAL COMPONENTS EAS30578 CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: • Coolant temperature sensor Refer to “CYLINDER HEAD” on page 5-9. EWA14130 WARNING • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sen- sor to strong shocks. If the coolant tem- perature sensor is dropped, replace it. 2. Check: • Coolant temperature sensor resistance Out of specification → Replace. Coolant temperature sensor re- sistance 2513–2777 Ω at 20 °C (2513– 2777 Ω at 68 °F) Coolant temperature sensor re- sistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F) a. Connect the digital circuit tester to the cool- ant temperature sensor terminals as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 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. 3 1 2 d. Heat the coolant or let it cool down to the specified temperatures.
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e. Measure the coolant temperature sensor resistance. 3. Install: • Coolant temperature sensor Coolant temperature sensor 15 N·m (1.5 kgf·m, 11 lb·ft) T R . . EAS30681 CHECKING THE FUEL INJECTOR 1. Check: • Fuel injector resistance Out of specification → Replace the fuel injec- tor. Resistance 12.2 Ω a. Disconnect the fuel injector coupler from fuel injector. b. Connect the digital circuit tester to the fuel injector terminals as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe → Injector terminal “1” • Negative tester probe → Injector terminal “2” 1 2 c. Measure the fuel injector resistance. 8-42 ELECTRICAL COMPONENTS EAS31612 CHECKING THE VVA SOLENOID 1. Check: • VVA solenoid resistance Out of specification → Replace. Resistance 1.8–2.2 Ω at 20 °C (1.8–2.2 Ω at 68 °F) a. Disconnect the VVA solenoid coupler from the VVA solenoid. b. Connect the digital circuit tester to the VVA solenoid terminal as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe Solenoid terminal “1” • Negative tester probe Solenoid terminal “2” 2 1 c. Measure the VVA solenoid resistance.
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EAS31553 CHECKING THE SMART KEY BATTERY 1. Check: • Smart key battery voltage Out of specification → Replace the smart key battery. Smart key battery voltage 2.7–3.2 V a. Remove the smart key battery from the smart key. b. Connect the digital circuit tester to the smart key battery as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe → Positive battery terminal “1” • Negative tester probe → Negative battery terminal “2” 1 2 c. Measure the smart key battery voltage. 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. • Positive battery lead → Red “1” • Negative battery lead → Black “2” 8-43 ELECTRICAL COMPONENTS 2 1 R B c. Check that the buzzer sounds. EAS31257 CHECKING THE MAIN SWITCH SOLENOID 1. Check: • Main switch solenoid a. Disconnect the main switch solenoid cou- pler from the wire harness. b. Connect the digital circuit tester to the main switch solenoid as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with ta- chometer YU-A1927 • Positive tester probe → Red/White “1” • Negative tester probe → Black “2” 1 2 B R/W c. Check the main switch solenoid continuity. d. If there is no continuity, replace the main switch assembly.
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SELF DIAGNOSTIC FUNCTION.....................................................................9-1 GLOSSARY...............................................................................................9-1 OUTLINE...................................................................................................9-1 CHECKING THE WARNING LIGHT .........................................................9-2 YDT ...........................................................................................................9-3 PARTS CONNECTED TO THE SGCU .....................................................9-3 PARTS CONNECTED TO THE ABS ECU................................................9-4 SYSTEM DIAGRAM ........................................................................................9-5 ECU CIRCUIT DIAGRAM..........................................................................9-5 ECU COUPLER LAYOUT .........................................................................9-6 FUEL INJECTION SYSTEM............................................................................9-9 CIRCUIT DIAGRAM ..................................................................................9-9 BASIC PROCESS FOR .....................................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 OUTLINE....................................................9-16 BASIC INSTRUCTIONS FOR ............................9-17 BASIC PROCESS FOR .....................................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................................................................................9-21 SMART KEY SYSTEM ..................................................................................9-23 CIRCUIT DIAGRAM ................................................................................9-23 ............................................................................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
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FUNCTION AND DIAGNOSTIC CODE TABLE..........9-37 DTC TABLE.............................................................................................9-37 COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL............................................9-39 FUNCTION TABLE................................................9-40 FUNCTION TABLE (FOR ABS (Anti-lock Brake System)).....................................................9-51 DIAGNOSTIC CODE: SENSOR OPERATION TABLE...........................9-56 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................9-58 EVENT CODE TABLE...................................................................................9-59 P0030.............................................................................................................9-61 ............................................................................9-61 P00D1, P2195................................................................................................9-65 ............................................................................9-65 P0106.............................................................................................................9-69 ............................................................................9-69 P0107, P0108 ................................................................................................9-71 ............................................................................9-71 P0112, P0113 ................................................................................................9-75 ............................................................................9-75 P0117, P0118 ................................................................................................9-79 ............................................................................9-79 P0122, P0123 ................................................................................................9-83 ............................................................................9-83 P0132.............................................................................................................9-87 ............................................................................9-87 P0201.............................................................................................................9-90 ............................................................................9-90 P0335.............................................................................................................9-93 ............................................................................9-93 P0351.............................................................................................................9-97 ............................................................................9-97
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P0500...........................................................................................................9-101 ..........................................................................9-101 P0507...........................................................................................................9-105 ..........................................................................9-105 P0511...........................................................................................................9-112 ..........................................................................9-112 P0560, P0563 ..............................................................................................9-116 ..........................................................................9-116 P0601...........................................................................................................9-117 ..........................................................................9-117 P062F ..........................................................................................................9-118 ..........................................................................9-118 P1602...........................................................................................................9-120 ..........................................................................9-120 P2158...........................................................................................................9-125 ..........................................................................9-125 P2645...........................................................................................................9-130 ..........................................................................9-130 Er-1, Er-2, Er-3, Er-4 ...................................................................................9-134 ..........................................................................9-134 11, 25_ABS .................................................................................................9-138 ..........................................................................9-138 12_ABS .......................................................................................................9-139 ..........................................................................9-139 13, 26_ABS .................................................................................................9-140 ..........................................................................9-140 14, 27_ABS .................................................................................................9-141 ..........................................................................9-141 15_ABS .......................................................................................................9-142
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TROUBLESHOOTING .................................................................................................................... 9-142 **16_ABS** ............................................................................................................................................. **9-144** TROUBLESHOOTING .................................................................................................................... 9-144 **17, 45_ABS** ...................................................................................................................................... **9-146** TROUBLESHOOTING .................................................................................................................... 9-146 **18, 46_ABS** ...................................................................................................................................... **9-147** TROUBLESHOOTING .................................................................................................................... 9-147 **21_ABS** ............................................................................................................................................. **9-148** TROUBLESHOOTING .................................................................................................................... 9-148 **31_ABS** ............................................................................................................................................. **9-149** TROUBLESHOOTING .................................................................................................................... 9-149 **32_ABS** ............................................................................................................................................. **9-151** TROUBLESHOOTING .................................................................................................................... 9-151 **33_ABS** ............................................................................................................................................. **9-152** TROUBLESHOOTING .................................................................................................................... 9-152 **34_ABS** ............................................................................................................................................. **9-154** TROUBLESHOOTING .................................................................................................................... 9-154 **41_ABS** ............................................................................................................................................. **9-155** TROUBLESHOOTING .................................................................................................................... 9-155 **42, 47_ABS** ...................................................................................................................................... **9-156** TROUBLESHOOTING .................................................................................................................... 9-156 **43_ABS** ............................................................................................................................................. **9-157** TROUBLESHOOTING .................................................................................................................... 9-157 **44_ABS** ............................................................................................................................................. **9-158** TROUBLESHOOTING .................................................................................................................... 9-158 **51, 52_ABS** ...................................................................................................................................... **9-159** TROUBLESHOOTING .................................................................................................................... 9-159 **53_ABS** ............................................................................................................................................. **9-160** TROUBLESHOOTING .................................................................................................................... 9-160
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54_ABS .......................................................................................................9-162 ..........................................................................9-162 55_ABS .......................................................................................................9-164 ..........................................................................9-164 56_ABS .......................................................................................................9-165 ..........................................................................9-165 63_ABS .......................................................................................................9-166 ..........................................................................9-166 64_ABS .......................................................................................................9-168 ..........................................................................9-168
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EAS20437 FUNCTION EAS33142 GLOSSARY Word Description MIL (Malfunction indica- tor light) MIL is an indicator light that comes on when a control unit determines a malfunction. DTC (Diagnostic trouble code) DTC is a code that is saved within a control unit’s memory when the control unit determines a malfunction. Pending DTC (Pending diagnostic trouble code) Pending DTC is a code that is saved within a control unit’s memory when the control unit detects an abnormal condition. If the abnormal condition continues, a malfunction may be determined. Driving cycle Driving cycle is the duration from the main switch is turned to ON, OBD re- quirements are met, and until the main switch is turned to OFF. FFD (Freeze frame data) FFD is the data of all signal sensors saved at the moment a malfunction is determined. Current malfunction A DTC for an unrecovered, current malfunction. Recovered malfunc- tion A DTC for a previously determined but now recovered malfunction. Pending abnormality Abnormal condition that is detected but not yet determined to be a malfunc- tion. Threshold Threshold is a point set to detect if the output from sensors are abnormal or not. OBD (On-board diagnos- tics) Self-diagnostic system is equipped in a control unit for the emission control system. GST (Generic scan tool) Generic diagnostic tool that complies with OBD standards. YDT (Yamaha diagnostic tool) Diagnostic tool developed especially for Yamaha vehicles. 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 un- der 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. 9-1 FUNCTION
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EAS32859 CHECKING THE WARNING LIGHT The warning light comes on after the main switch has been turned to 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. 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 “2” 2.0 seconds ABS (Anti-lock Brake Sys- tem) ABS warning light “1” *1 TIP *1: The ABS warning light goes off when the vehicle is judged to normal with running. 9-2 FUNCTION
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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. • A GST can also be used to identify malfunctions. Disconnect the YDT Disconnect the YDT coupler from the CCU (Communication Control Unit) “1”, and then connect the YDT to the coupler. EAS33550 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 9-3 FUNCTION 1
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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 • Rear wheel sensor • ABS motor fuse • Meter assembly • ABS ECU fuse • SGCU (Starter Generator Control Unit) • Front wheel sensor 9-4 FUNCTION
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EAS20387 SYSTEM DIAGRAM EAS32920 ECU CIRCUIT DIAGRAM * EFI FUSE * BACKUP FUSE * METER ASSEMBLY * IGNITION COIL * FUEL INJECTOR * FUEL PUMP * O2 SENSOR HEATER * OS SENSOR * ISC (IDLE SPEED CONTROL) * SGCU (STARTER GENERATOR CONTROL UNIT) * THROTTLE BODY SENSOR ASSEMBLY * THROTTLE POSITION S * INTAKE AIR TEMPERAT * INTAKE AIR PRESSURE * COOLANT TEMPERATURE SENSOR * VVA (VARIABLE VALVE ACTUATION) * YAMAHA DIAGNOSTIC TOOL --- * IGNITION FUSE * LOW BEAM * HIGH BEAM * DIMMER SWITCH * HEADLIGHT SWITCH * MAIN RELAY * MAIN SWITCH * HEADLIGHT FUSE * MAIN FUSE * SIGNALING FUSE * BRAKE LIGHT SWITCH * TERMINAL FUSE * BATTERY * ABS ECU * FRONT WHEEL SENSOR * REAR WHEEL SENSOR * START SWITCH * SSS SWITCH * SIDESTAND SWITCH * STARTER CHARGER RELAY * STARTER GENERATOR * CRANKSHAFT POSITION SENSOR --- **Pin Numbers** | Left Column | Right Column | | :---------- | :----------- | | 40 | 1 | | 47 | 5 | | 33 | 3 | | 43 | 25 | | | 38 | | | 8 | | 48 | 13 | | 44 | 15 | | 42 | 29 | | 7 | 31 | | 35 | 23 | | 17 | 20 | | 50 | 34 | | 51 | 36 | | 49 | 21 | | 52 | 46 | | 54 | 45 | | 53 | 9 | | 18 | 11 | | 4 | 39 | | 12 | 16 | | 24 | 32 | | 26 | | | 19 | | 9-5
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# SYSTEM DIAGRAM EAS33369 ### ECU COUPLER LAYOUT ``` ┌───────────────────────────────────────────────────┐ │ 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 │ │ 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 │ │ 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 │ └───────────────────────────────────────────────────┘ ┌───┐ ┌───┐ │49│50│51│ │52│53│54│ └───┘ └───┘ ``` | No. | Connected parts | Wire harness color | | :---: | :--- | :---: | | **1** | Yamaha diagnostic tool | Lg/L | | **2** | ISC (Idle Speed Control) | G/Y | | **3** | — | — | | **4** | ISC (Idle Speed Control) | Ch | | **5** | Crankshaft position sensor | W/L | | **6** | VVA (Variable valve actuation) solenoid | Ch | | **7** | — | — | | **8** | VVA (Variable valve actuation) solenoid | G | | **9** | $\text{O}_2$ sensor | B/L | | **10** | Ground | B | | **11** | — | — | | **12** | Fuel injector | O/B | | **13** | Crankshaft position sensor | W/R | | **14** | Fuel pump | B/Y | | **15** | — | — | | **16** | Ignition coil | O | | **17** | Yamaha diagnostic tool | Lg/W | | **18** | ISC (Idle Speed Control) | Sb | | **19** | — | — | | **20** | ISC (Idle Speed Control) | Gy | | **21** | — | — | | **22** | — | — | | No. | Connected parts | Wire harness color | | :---: | :--- | :---: | | **23** | Crankshaft position sensor | W/Y | | **24** | $\text{O}_2$ sensor | P/B | | **25** | Crankshaft position sensor | W/B | | **26** | Throttle body sensor assemblies | L | | **27** | — | — | | **28** | Throttle body sensor assemblies | B/L | | **29** | Throttle body sensor assemblies | Y | | **30** | Crankshaft position sensor | B/L | | **31** | Crankshaft position sensor | Br/B | | **32** | Starter charge relay | R/B | | **33** | Starter switch | L/B | | **34** | Fuel injection system fuse | R | | **35** | Coolant temperature sensor | G/R | | **36** | Coolant temperature sensor | B/L | | **37** | Stop Start System switch | W/G | | **38** | ABS ECU | W | | **39** | Sidestand switch | L/Y | | **40** | — | — | | **41** | Meter assembly | L/R | | **42** | Ground | B | | **43** | $\text{O}_2$ sensor | Gy/R | | **44** | ABS ECU | W/B | <br> <div style="text-align: center; font-weight: bold; font-size: 1.2em;">9-6</div>
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# SYSTEM DIAGRAM | No. | Connected parts | Wire harness color | | :---: | :--- | :---: | | 45 | Throttle body sensor assemblies | Br/W | | 46 | Ground | B | | 47 | Throttle body sensor assemblies | P/W | | 48 | Main relay | Br | | 49 | Starter charge relay | Y/R | | 50 | Headlight unit | Y/B | | 51 | Battery | B | | 52 | Starter generator | R | | 53 | Starter generator | W | | 54 | Starter generator | G | <br> <div style="text-align: center;">9-7</div>
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SYSTEM DIAGRAM 9-8
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# FUEL INJECTION SYSTEM EAS20440 ## FUEL INJECTION SYSTEM EAS32871 ### CIRCUIT DIAGRAM 9-9
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# FUEL INJECTION SYSTEM 1. Battery 7. Fuel injection system fuse 8. Backup fuse 9. Main fuse 10. Ignition fuse 12. ABS control unit fuse 13. Main switch 32. Yamaha diagnostic tool coupler 36. Sidestand switch 38. Injector 41. Fuel pump 43. SGCU (starter generator control unit) 44. Ignition coil 45. Spark plug 46. ISC (Idle Speed Control) unit 47. Throttle body sensor assembly 48. Intake air pressure sensor 49. Intake air temperature sensor 50. Throttle position sensor 51. Crankshaft position sensor 52. Coolant temperature sensor 53. VVA (variable valve actuator) solenoid 54. O₂ sensor 56. Front wheel sensor 59. ABS ECU 60. Meter assembly 61. Multi-function meter 67. Engine trouble warning light 72. Frame ground 73. Engine ground 9-10
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EAS32917 BASIC PROCESS FOR 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 turning the main switch to ON, does the MIL come on? Does the MIL (LED) work properly? No Yes Yes Yes [B] Perform the checking with the diagnostic mode. The MIL goes off after 2 seconds? 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 No Check the MIL (LED).
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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 “mal- function” 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 9-56 and “DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE” on page 9-58. 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 en- gine. 9-12 FUEL INJECTION SYSTEM
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ABS (Anti-lock Brake System) EAS2D443 ABS (Anti-lock Brake System) EAS32890 CIRCUIT DIAGRAM 9-13
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ABS (Anti-lock Brake System) ___ 1. Battery 2. ABS solenoid fuse 3. ABS motor fuse 6. Signaling system fuse 8. Backup fuse 9. Main fuse 10. Ignition fuse 12. ABS control unit fuse 13. Main switch 31. Main relay 32. Yamaha diagnostic tool coupler 33. Front brake light switch 34. Rear brake light switch 37. Joint 1 43. SGCU (starter generator control unit) 56. Front wheel sensor 57. Rear wheel sensor 58. Joint 4 59. ABS ECU 60. Meter assembly 61. Multi-function meter 62. ABS warning light 72. Frame ground 73. Engine ground 75. Tail/brake light assembly 77. Brake light 9-14
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ABS (Anti-lock Brake System) EAS32892 ABS COUPLER LOCATION CHART 1. ABS ECU coupler - **(B)** - Row 1: R, Br, Y, G, L, W/L, B/W - Row 2: R/L, Y, Br, L/B, B/W, B 2. Rear wheel sensor coupler - Connector 1: G, L - Connector 2: W, B 3. Yamaha diagnostic tool coupler - Top Left: Lg/L - Top Right: B - Bottom Left: R - Bottom Right: Lg/W 4. Meter assembly coupler - **(Gy)** - Row 1: R/W, L/W, Br/W, Y/W, Dg, Ch, Br, R - Row 2: L/R, G/B, W/L, Br/R, W/R, G, B, R 5. Front wheel sensor coupler - Connector 1: Br, Y - Connector 2: W, B 9-15
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EAS32893 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. 2 1 EAS33284 ABS 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 Yama- ha 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 9-21. 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 ” on page 9-17. 9-16 ABS (Anti-lock Brake System)
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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 detected, it is possible to check the recorded malfunction data by utilizing the Yamaha di- agnostic tool when the ABS ECU has entered the self-diagnosis mode. Special precautions for handling and servicing a vehicle equipped with ABS ECA17620 NOTICE Care should be taken not to damage components by subjecting them to shocks or pulling on them with too much force since the ABS components are precisely adjusted. • The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled. • The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser- vice is finished. (This is because the past fault codes will be displayed again if another malfunction oc- curs.) EAS32895 BASIC INSTRUCTIONS FOR 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)
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EAS32878 BASIC PROCESS FOR Fails to come on [A] Turn the main switch to “ON”, and check the ABS warning light. [A-1] Does only the ABS warning light fail to come on? Comes on No [A-2] Do all indicator lights fail to come on? [A-3] The ABS warning light comes on. Connect the Yamaha diagnostic tool, and then execute functional diagnosis. Can the tool communicate with the ABS ECU? Cannot communicate Can communicate [B-2] Diagnose by the fault code. [B-3] Delete the fault codes. [B-1] Yes Check for ABS fault codes in the screen for the Yamaha diagnostic tool. Execute fault diagnosis. Are fault codes displayed on the screen? The reaction force generated during brake line routing confirmation is incorrect. • The brake hoses and brake pipes are not connected correctly. The ABS warning light does not go off when the light is checked. • The malfunction is not 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. No [C-1] Perform the final checks. Were all of the final checks completed normally? No Yes (Check that the ABS warning light goes off during the ABS warning light check.) Finished. 9-18 ABS (Anti-lock Brake System) • The ABS warning light (LED) is defective. • The wire harness is grounded between the ABS ECU and the meter assembly. • The meter assembly circuit is defective. • The hydraulic unit assembly is defective. Yes Return to [A]. • The main switch is defective. • The battery voltage is low. • The taillight fuse is blown. • The meter assembly circuit is defective. Yes Return to [A]. • The connection with the Yamaha diagnostic tool is defective. • The ABS control unit fuse is blown. • The ABS ECU coupler is disconnected. • The wire harness is defective. • The hydraulic unit assembly is defective. • The ABS solenoid fuse is blown. Refer to “ Troubleshooting details of fault code No. 31 ”. Return to [A]. Return to [A]. Return to [A].
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EWA16710 WARNING When maintenance or checks have been performed on components related to the ABS, be sure to perform a final check before delivering the vehicle to the customer. TIP To final check, refer to “[C-1] FINAL CHECK” on page 9-21. EAS32897 [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] EAS32898 [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. EAS32899 [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 8-35. • 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 8-36. • If the taillight fuse is blown, replace the fuse. 4. Circuit • Check the meter assembly circuit. Refer to “CIRCUIT DIAGRAM” on page 9-13. • If the meter assembly circuit is open, replace the wire harness. EAS32900 [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)
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EAS32903 [B-1] MALFUNCTION ARE CURRENTLY DETECTED When the Yamaha diagnostic tool is connected to the Yamaha diagnostic tool coupler, the fault codes will be displayed on the computer screen. • A fault code is displayed. [B-2] • A fault code is not displayed. [C-1] EAS32904 [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. Disconnect the Yamaha diagnostic tool coupler from the CCU (Communication Control Unit) “1”, and then connect the Yamaha diagnostic tool to the coupler. 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) 1
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EAS33339 [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 Disconnect the YDT coupler from the CCU (Communication Control Unit) “1”, and then connect the YDT to the coupler. EAS32905 [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 the rear brake master cyl- inder 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 4-27 and “INSTALL- ING THE REAR WHEEL (REAR BRAKE DISC)” on page 4-31. 3. Perform brake line routing confirmation. Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-62. 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 4-66. 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. 9-21 ABS (Anti-lock Brake System) 1
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ABS (Anti-lock Brake System) ___ 9-22
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SMART KEY SYSTEM EAS20717 SMART KEY SYSTEM EAS334D3 CIRCUIT DIAGRAM *(Circuit diagram with various components and connections)* **Component Labels (Circled Numbers):** (21), (22), (23), (24), (25), (26), (27), (28), (29), (30), (31), (32), (33), (34), (35), (36), (37), (38), (39), (40), (41), (42), (43), (44), (45), (46), (47), (48), (49), (50), (51), (52), (53), (54), (55), (56), (57), (58), (59), (60), (61), (62), (63), (64), (65), (66), (67), (68), (69), (70), (71), (72), (73), (74), (75) **Other Labels:** L1, L2, L3, L4, L5, L6, L7, L8 I=A, J=B 9-23
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SMART KEY SYSTEM ___ 1. Battery 4. Smart key system fuse 8. Backup fuse 9. Main fuse 10. Ignition fuse 13. Main switch 14. Request switch 15. Main switch solenoid 18. Smart key unit 19. Buzzer 36. Sidestand switch 43. SGCU (starter generator control unit) 60. Meter assembly 61. Multi-function meter 64. Smart key system indicator light 65. Turn signal indicator light (left) 66. Turn signal indicator light (right) 72. Frame ground 73. Engine ground 78. Front turn signal light (left) 79. Front turn signal light (right) 80. Rear turn signal light (left) 81. Rear turn signal light (right) 9-24
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EAS33404 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. Windshield 3. Front panel 4. Front cowling assembly Checking the vehicle power 1. Check the smart key. → The smart key indicator light comes on when the smart key but- ton is pushed. → Check the button cell battery. Refer to “CHECKING THE SMART KEY BATTERY” on page 8-43. NG→ Replace the button cell battery of the smart key. Standard battery: CR2032 OK↓ 2. Check the fuses. (Main, backup, ignition, and smart key system) Refer to “CHECKING THE FUS- ES” on page 8-36. NG→ Replace the fuse(s). OK↓ 3. Check the battery. Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-37. NG→ • Clean the battery terminals. • Recharge or replace the battery. OK↓ 4. Check the main switch and request switch. Refer to “CHECKING THE SWITCHES” on page 8-35. NG→ Replace the main switch. OK↓ 5. Check the main switch solenoid. Refer to “CHECKING THE MAIN SWITCH SOLENOID” on page 8- 43. NG→ Replace the main switch. OK↓ 9-25 SMART KEY SYSTEM
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6. Check the entire smart key sys- tem’s wiring. Refer to “CIRCUIT DIAGRAM” on page 9-23. NG→ Properly connect or replace the wire har- ness. 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. Refer to “Checking the vehicle power” on page 9-25. NG→ Repair or replace any defective parts. 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 on, the smart key indicator light “ ” flashes 4 times. Refer to “SMART KEY SYSTEM SELF-DIAGNOSIS” on page 9-29. NO→ Check and repair the electric starting sys- tem. Refer to “ELECTRIC STARTING SYSTEM” on page 8-5. YES↓ 2. Turn the main switch to “OFF”, and then push the main switch and check that it can be turned back to “ON”. NG→ Repair or replace any defective parts. Re- fer to “Checking the vehicle power” on page 9-25. OK↓ 9-26 SMART KEY SYSTEM
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3. Check for continuity in the commu- nication line between the SGCU and the smart key unit (blue/red – blue/red). NG→ Replace the wire harness. OK↓ • Replace the SGCU. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. • Replace the smart key unit. Seat does not open. (Vehicle power is turned on.) 1. Check the vehicle power. Refer to “Checking the vehicle power” on page 9-25. NG→ Repair or replace any defective parts. 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. Refer to “Checking the vehicle power” on page 9-25. NG→ Repair or replace any defective parts. 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 turned counterclockwise. NG→ Repair or replace any defective parts. 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
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Answer back function does not operate. 1. Check the vehicle power. Refer to “Checking the vehicle power” on page 9-25. NG→ Repair or replace any defective parts. OK↓ 2. Check the buzzer operation. Refer to “CHECKING THE BUZZ- ER” on page 8-43. NG→ Replace the buzzer. OK↓ 3. Check the turn signal light bulbs and sockets. Refer to “CHECKING THE BULBS AND BULB SOCKETS” in “BASIC INFORMATION” (separate vol- ume). NG→ Replace the turn signal light bulb, socket or both. OK↓ Replace the smart key unit. 9-28 SMART KEY SYSTEM
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EAS33405 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. Item Flash pattern Flashing time/num- ber of flashes Malfunction and check point 0.5 (s) a b Low voltage of smart key button cell battery 0.5 (s) a.LED on b.LED off 0.15 (s) a b Vehicle power off ver- ification error 0.15 (s) a.LED on b.LED off 0.15 (s) a b Running detection er- ror* 0.15 (s) a.LED on b.LED off 0.3 (s) • SGCU communica- tion error • Data error • SGCU malfunction a.LED on b.LED off a b 0.3 (s) 1.0 (s) * 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-sec- ond 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 inter- vals), the vehicle power cannot be turned back on. 9-29 SMART KEY SYSTEM Replace the button cell battery of the smart key. Refer to “SMART KEY SYSTEM” on page 9-23. 20 (seconds) The smart key cannot be recognized. Check that there are no sources of strong electromagnetic waves in the vicinity, the smart key is not lost, and the battery is not discharged. 30 (seconds) The smart key cannot be recognized. Check that there are no sources of strong electromagnetic waves in the vicinity, the smart key is not lost, and the battery is not discharged. Flashes continuously until the error is re- solved. Flashes continuously until the error is re- solved/flashes 4 times in a repeating cycle. Check the wire har- ness. Check the SGCU. Check the smart key unit.
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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- tected the mal- function Symptom Cause Check or mainte- nance job Fault code No. 51 Smart key unit Communication error between the smart key and the smart key unit. 53 Smart key unit Communication error between the SGCU and the smart key unit. 54 Smart key unit Codes transmitted between the SGCU and the smart key unit do not match. 56 SGCU Unidentified code is received. Radio wave noise in- terference or discon- nected lead. • Obstruction due to radio wave noise • Disconnection in the wire harness • Defective SGCU • Defective smart key unit 9-30 SMART KEY SYSTEM Radio wave noise in- terference. • Lock condition in the smart key • Defective smart key • Defective smart key unit Perform the checks and maintenance job for “Engine does not start even though ve- hicle power is turned on.” Radio wave noise in- terference or discon- nected lead. • Obstruction due to radio wave noise • Disconnection in the wire harness • Defective SGCU • Defective smart key unit Perform the checks and maintenance job for “Engine does not start even though ve- hicle power is turned on.” Radio wave noise in- terference or discon- nected lead. • Obstruction due to radio wave noise. • Disconnection in the wire harness • Defective SGCU (when the SGCU or smart key unit is re- placed with a unit from a different ve- hicle) • Defective smart key unit Perform the checks and maintenance job for “Engine does not start even though ve- hicle power is turned on.” Perform the checks and maintenance job for “Engine does not start even though ve- hicle power is turned on.”
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EAS33406 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.) 1 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. → 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. → 9-31 SMART KEY SYSTEM 1
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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 in- dicator 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. EAS33407 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. 1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch. a 2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 9-31. 9-32 SMART KEY SYSTEM 1
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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.) 1 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 1
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EAS33408 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. a 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 1 1
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EAS33409 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. a 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 1
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EAS33410 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 8-36. Required item when replacing parts Replacement parts (when an item is required in order to replace parts) ○ : Required. ○ : Replace. Smart key identifica- tion number or smart key is required. △ : × : Do not replace. Faulty part × : Not required. * : This part must be re- placed even if it is not faulty. Smart key identifi- cation number Smart key Smart key Smart key ○ × ○ × × Register the smart key identi- fication number in the emer- gency mode. Smart key unit × × ○* ○ ○* Replace the smart key, smart key unit, and SGCU as a set. SGCU △ △ × × ○ Smart key unit/ SGCU × × ○* ○ ○ Replace the smart key, smart key unit, and SGCU as a set. Smart key/Smart key unit × × ○ ○ ○* Replace the smart key, smart key unit, and SGCU as a set. Smart key/SGCU ○ × ○ × ○ Smart key/Smart key unit/SGCU × × ○ ○ ○ Replace the smart key, smart key unit, and SGCU as a set. 9-36 SMART KEY SYSTEM Remarks Smart key unit SGCU When the vehicle system is turned on, the smart key iden- tification number is automati- cally registered to the SGCU. Register the smart key identi- fication number in the emer- gency mode. When the vehicle system is turned on, the smart key iden- tification number is automati- cally registered to the SGCU.
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FUNCTION AND DIAGNOSTIC CODE TABLE EAS20551 FUNCTION AND DIAGNOSTIC CODE TABLE EAS33149 DTC TABLE DTC Symptom Fail-safe system Diagnos- tic code Starting the engine Driving the vehicle “11, 25_ABS” Front wheel sensor (intermittent pulses or no pulses) — — — “12_ABS” Rear wheel sensor (intermittent pulses or no pulses) — — — “13, 26_ABS” Front wheel sensor (abnormal pulse pe- riod) — — — “14, 27_ABS” Rear wheel sensor (abnormal pulse peri- od) — — — “15_ABS” Front wheel sensor (open or short circuit) — — — “16_ABS” Rear wheel sensor (open or short circuit) — — — “17, 45_ABS” Front wheel sensor (missing pulses) — — — “18, 46_ABS” Rear wheel sensor (missing pulses) — — — “21_ABS” Hydraulic unit assembly (defective sole- noid drive circuit) — — — “31_ABS” Hydraulic unit assembly (abnormal ABS solenoid power supply) — — — “32_ABS” Hydraulic unit assembly (short circuit in ABS solenoid power supply circuit) — — — “33_ABS” Hydraulic unit assembly (abnormal ABS motor power supply) — — — “34_ABS” Hydraulic unit assembly (short circuit in ABS motor power supply circuit) — — — “41_ABS” Front wheel ABS (intermittent wheel speed pulses or incorrect depressuriza- tion) — — — Rear wheel ABS (intermittent wheel speed pulses or incorrect depressuriza- tion) — — — “42, 47_ABS” “43_ABS” Front wheel sensor (missing pulses) — — — “44_ABS” Rear wheel sensor (missing pulses) — — — • 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) “51, 52_ABS” “53_ABS” Vehicle system power supply (voltage of ABS ECU power supply is low) — — — 9-37 — — —
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Symptom Fail-safe system Diagnos- tic code Starting the engine Driving the vehicle “54_ABS” Hydraulic unit assembly (defective ABS solenoid and ABS motor power supply circuits) — — — “55_ABS” Hydraulic unit assembly (defective ABS ECU) — — — “56_ABS” Hydraulic unit assembly (abnormal pow- er supply) — — — “63_ABS” Front wheel sensor power supply (volt- age of power supply is low) — — — “64_ABS” Rear wheel sensor power supply (volt- age of power supply is low) — — — “P0030” O2 sensor heater: defective heater or heater driver ON / OFF command and er- ror signal is mismatching. Able Able — • [P00D1] O2 sensor: heater perfor- mance deteriorated. Normal signal is not received from the O2 sensor while driving the O2 sensor. • [P2195] O2 sensor: open circuit is de- tected. “P00D1, P2195” “P0106” • [P0106] Intake air pressure sensor: clogging hole or sensor installation im- properly. Able Able D03 • [P0107] Intake air pressure sensor: short to ground circuit is detected. • [P0108] Intake air pressure sensor: open or short to power circuit is detect- ed. “P0107, P0108” • [P0112] Intake air temperature sensor: short to ground circuit is detected. • [P0113] Intake air temperature sensor: open or short to power circuit is detect- ed. “P0112, P0113” • [P0117] Coolant temperature sensor: short to ground circuit is detected. • [P0118] Coolant temperature sensor: open or short to power circuit is detect- ed. “P0117, P0118” • [P0122] Throttle position sensor: open or short to ground circuit is detected. • [P0123] Throttle position sensor: short to power circuit is detected. “P0122, P0123” “P0132” O2 sensor: short to power circuit is de- tected. Able Able — “P0201” Fuel injector: malfunction in fuel injector. Unable Unable D36 9-38 Able Able — Able Able D03 Able Able D05 Able Able D06 Able Able D01
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Symptom Fail-safe system Diagnos- tic code Starting the engine Driving the vehicle “P0335” Crankshaft position sensor: normal sig- nal is not received from the crankshaft position sensor. Unable Unable — “P0351” Ignition coil: open or short circuit is de- tected in the primary lead of the ignition coil. Unable Unable D30 “P0500” Front wheel sensor: normal signal is not received from the front wheel speed sen- sor. Able Able D07 “P0507” Engine idling speed is too high. Able Able D54 “P0511” ISC valve malfunction is detected. Able Able — Charging voltage is abnormal. [P0560] Discharged condition / [P0563] Overcharged condition. Able Able — “P0560, P0563” Internal malfunction in SGCU. (When this malfunction is detected in the SGCU, the DTC might not appear on the tool dis- play.) “P0601” “P062F” EEPROM DTC: an error is detected while reading or writing on EEPROM. Able Able D60 “P1602” Malfunction in SGCU internal circuit (malfunction of SGCU power cut-off func- tion). Able Able — “P2158” Rear wheel sensor: normal signal is not received from the rear wheel speed sen- sor. Able Able — “P2645” Normal signal is not received from the VVA solenoid circuit while driving the VVA solenoid. Able Able D45 EAS33030 COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL DTC Symptom Fail-safe system Diagnos- tic code Starting the engine Driving the vehicle Er-1 SGCU internal malfunction (Output sig- nal error) Able Able — Er-2 SGCU internal malfunction (Output sig- nal error) Able Able — Er-3 SGCU internal malfunction (Output sig- nal error) Able Able — Er-4 SGCU internal malfunction (Input signal error) Able Able — 9-39 Unable Unable —
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FUNCTION AND DIAGNOSTIC CODE TABLE EAS33028 FUNCTION TABLE TIP For details of the fault code, refer to “” on page 8-33. DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P0030 O2 sensor heater: defective heater or heater driver ON / OFF command and error signal is mis- matching. • Open or short cir- cuit in wire har- ness. • Disconnected cou- pler • Defective O2 sen- sor heater driver (Malfunction in SGCU) • Broken or discon- nected lead in O2 sensor heater. P00D1 O2 sensor: heater performance deteri- orated. (Normal sig- nal is not received from the O2 sensor while driving the O2 sensor.) • Open or short cir- cuit in wire har- ness between O2 sensor and SGCU. • Defective coupler between O2 sen- sor and SGCU. • Disconnected cou- pler • Improperly in- stalled O2 sensor. • Defective O2 sen- sor. • Malfunction in SGCU. 9-40 When the O2 sensor does not operate due to the exhaust temperature is low condition. Increased exhaust emissions. Display only (If O2 sensor does not op- erate, O2 feedback is not carried out.) Increased exhaust emissions. O2 feedback is not carried out.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P0106 Intake air pressure sensor (clogged hole or loose) • Detached throttle body sensor as- sembly. • Improperly in- stalled throttle body. • Clogged intake air pressure sensor hole. P0107 P0108 [P0107] Intake air pressure sensor (short to ground cir- cuit is detected) [P0108] Intake air pressure sensor (open or short to power circuit is de- tected) [P0107] Low voltage of the intake air pressure sensor cir- cuit (0.2 V or less) [P0108] High volt- age of the intake air pressure sensor cir- cuit (4.9 V or more) • Defective coupler between throttle body sensor as- sembly and SGCU. • Open or short cir- cuit in wire har- ness between throttle body sen- sor assembly and SGCU. • Defective intake air pressure sen- sor. • Malfunction in SGCU. 9-41 Engine idling speed is high. Engine idling speed is unstable. Engine response is poor. Loss of engine pow- er. Increased exhaust emissions. Stop and start sys- tem is not operated. Idling does not stop. Intake air pressure difference is fixed to 0 [kPa]. Load is detected ac- cording to the throt- tle opening. Intake manifold pressure is calculat- ed using the throttle position sensor. Transient control according to the in- take 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. Engine idling speed is high. Engine idling speed is unstable. Engine response is poor. Loss of engine pow- er. Increased exhaust emissions. Stop and start sys- tem is not operated. Idling does not stop. Intake air pressure difference is fixed to 0 [kPa]. Load is detected ac- cording to the throt- tle opening. Intake manifold pressure is calculat- ed using the throttle position sensor. Transient control according to the in- take 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.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P0112 P0113 [P0112] Intake air temperature sensor (short to ground cir- cuit is detected) [P0113] Intake air temperature sensor (open or short to power circuit is de- tected) [P0112] Low voltage of the intake air tem- perature sensor cir- cuit (0.2 V or less) [P0113] High volt- age of the intake air temperature sensor circuit (4.8 V or more) • Defective coupler between throttle body sensor as- sembly and SGCU. • Open or short cir- cuit in wire har- ness between throttle body sen- sor assembly and SGCU. • Improperly in- stalled throttle body sensor as- sembly. • Defective intake air temperature sensor. • Malfunction in SGCU. 9-42 Engine is difficult to start. Increased exhaust emissions. Engine idling speed is unstable. Stop and start sys- tem is not operated. Idling does not stop. The intake air tem- perature is fixed to 20 [°C]. O2 feedback is not carried out. Stop and start sys- tem is not carried out.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P0117 P0118 [P0117] Coolant temperature sensor (short to ground cir- cuit is detected) [P0118] Coolant temperature sensor (open or short to power circuit is de- tected) [P0117] Low voltage of the coolant tem- perature sensor cir- cuit (0.1 V or less) [P0118] High volt- age of the coolant temperature sensor circuit (4.8 V or more) • Defective coupler between coolant temperature sen- sor and SGCU. • Open or short cir- cuit in wire har- ness between coolant tempera- ture sensor and SGCU. • Improperly in- stalled coolant temperature sen- sor. • Defective coolant temperature sen- sor. • Malfunction in SGCU. 9-43 Engine is difficult to start. Increased exhaust emissions. Engine idling speed is unstable. Stop and start sys- tem is not operated. Idling does not stop. O2 feedback is not carried out. The coolant tem- perature is fixed to 30 [°C] (when key is ON) or 80 [°C] (when riding). Stop and start sys- tem is not carried out.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P0122 P0123 [P0122] Throttle po- sition sensor (open or short to ground circuit is detected) [P0123] Throttle po- sition sensor (short to power circuit is detected) [P0122] Low voltage of the throttle posi- tion sensor circuit (0.2 V or less) [P0123] High volt- age of the throttle position sensor cir- cuit (4.8 V or more) • Defective coupler between throttle body sensor as- sembly and SGCU. • Open or short cir- cuit in wire har- ness between throttle body sen- sor assembly and SGCU. • Improperly in- stalled throttle body sensor as- sembly. • Defective throttle position sensor. • Malfunction in SGCU. P0132 O2 sensor (short to power circuit is de- tected) High voltage of the O2 sensor circuit (4.8 V or more) • Improperly in- stalled O2 sensor. • Defective coupler between O2 sen- sor and SGCU. • Power short circuit in wire harness be- tween O2 sensor and SGCU. • Defective O2 sen- sor. • Malfunction in SGCU. 9-44 Engine idling speed is high. Engine idling speed is unstable. Engine response is poor. Loss of engine pow- er. Deceleration is poor. Increased exhaust emissions. Stop and start sys- tem is not operated. Idling does not stop. Change in the throt- tle valve opening is 0 (transient control is not carried out). Throttle valve open- ing is fixed to 15 [°]. Intake air pressure is fixed to 101.3 [kPa]. Fuel is not cut off due to the throttle opening. O2 feedback is not carried out. Stop and start sys- tem is not carried out. Increased exhaust emissions. O2 feedback is not carried out.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P0201 Fuel injector (Nor- mal signal is not re- ceived from the fuel injector circuit) • Defective coupler between fuel injec- tor and SGCU. • Open or short cir- cuit in wire har- ness between fuel injector and SGCU. • Defective fuel in- jector. • Malfunction in SGCU. • Improperly in- stalled fuel injec- tor. P0335 Crankshaft position sensor (no normal signals are received from the crankshaft position sensor) • Defective coupler between crank- shaft position sen- sor and SGCU. • Open or short cir- cuit in wire har- ness between crankshaft position sensor and SGCU. • Improperly in- stalled crankshaft position sensor. • Defective starter generator rotor. • Defective crank- shaft position sen- sor. • Malfunction in SGCU. P0351 Ignition system (Normal signal is not received from the ig- nition circuit) • Defective coupler between ignition coil and SGCU. • Open or short cir- cuit in wire har- ness between ignition coil and SGCU. • Improperly in- stalled ignition coil. • Defective ignition coil. • Malfunction in SGCU. 9-45 Loss of engine pow- er. Engine is difficult to start. Engine cannot be started. Engine stops. When engine is run- ning: Engine is forcefully stopped. When engine is stopped: Engine cannot be started. Injection is not car- ried out. Engine cannot be started. Does not operate. Engine stops. Loss of engine pow- er. Engine is difficult to start. Engine cannot be started. When engine is run- ning: Engine is forcefully stopped. When engine is stopped: Engine cannot be started. Injection is not car- ried out.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P0500 Front wheel sensor (Normal signal is not received from the front wheel sensor) • Open or short cir- cuit in wire har- ness between front wheel sensor and ABS unit. • Open or short cir- cuit in wire har- ness between ABS unit and SGCU. • Defective front wheel sensor. • Malfunction in SGCU. P0507 ISC valve (stuck ful- ly open) • Defective front wheel sensor. • Defective coupler between ISC unit and SGCU. • Open or short cir- cuit in wire har- ness between ISC unit and SGCU. • Improperly in- stalled ISC unit. • Air sucking from intake air passage. • Defective throttle valve or throttle ca- bles. • Defective ISC unit (ISC valve stuck fully open). • Malfunction in SGCU. P0511 ISC valve (ISC valve malfunction is detected. ISC valve does not operate) • Defective coupler between ISC valve and SGCU. • Open or short cir- cuit in wire har- ness between ISC valve and SGCU. • Defective ISC stepping motor. • Malfunction in SGCU. 9-46 Vehicle speed is not displayed on the meter. Engine stalls when the vehicle is decel- erating to a stop. Engine idling speed is high. Engine idling speed is unstable. Increased exhaust emissions. Stop and start sys- tem is not operated. Idling does not stop. O2 feedback is not carried out. Stop and start sys- tem is not carried out. Engine idling speed is high. Stop and start sys- tem is not operated. Idling does not stop. ISC is stopped. Stop and start sys- tem is not carried out. Engine is difficult to start. Engine idling speed is unstable. Engine idling speed is high. Stop and start sys- tem is not operated. Idling does not stop. Power is not sup- plied to the ISC unit. Stop and start sys- tem is not carried out.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P0560 Vehicle system power voltage per- formance: Charging voltage is abnormal. (Discharged condi- tion) • Battery discharg- ing. • Battery discharg- ing (broken rectifi- er / regulator or disconnected lead in rectifier / regula- tor system). P0563 Vehicle system power voltage out of range: charging voltage is abnormal. (Overcharged con- dition) • Battery overcharg- ing. • Battery overcharg- ing (broken rectifi- er / regulator or disconnected lead in rectifier / regula- tor system). P0601 Faulty SGCU mem- ory. (When this mal- function is detected in the SGCU, the DTC might not ap- pear on the tool dis- play.) • Malfunction in SGCU. Engine cannot be started. Engine cannot be started. Ignition and injec- tion are not carried out. Judgment for other DTCs are not car- ried out. Writing to EEPROM is not carried out. P062F EEPROM fault code number (an error is detected while read- ing or writing on EE- PROM) • Malfunction in SGCU. • O2 feedback learn- ing value is not properly written. • CO adjustment value is not prop- erly written. • OBD memory val- ue is not properly written. 9-47 Engine is difficult to start. Increased exhaust emissions. Battery perfor- mance has deterio- rated or battery is defective. Stop and start sys- tem is not operated. Idling does not stop. O2 feedback learn- ing is not carried out. Stop and start sys- tem is not carried out. Engine is difficult to start. Increased exhaust emissions. Battery perfor- mance has deterio- rated or battery is defective. Stop and start sys- tem is not operated. Idling does not stop. O2 feedback learn- ing is not carried out. Stop and start sys- tem is not carried out. Increased exhaust emissions. Engine cannot be started or is difficult to start. Engine idling speed is unstable. OBD memory value is not correct. Stop and start sys- tem is not operated. O2 feedback learn- ing value is initial- ized. CO adjustment val- ue is initialized. OBD memory value is initialized. Stop and start sys- tem is not carried out.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P1602 Malfunction in SGCU internal cir- cuit (normal backup voltage is not sup- plied to the SGCU) • Improperly con- nected battery lead. • Defective coupler between main switch and SGCU. • Open circuit in wire harness between main switch and SGCU. • Malfunction in SGCU. P2158 Rear wheel sensor: normal signals are not received from the rear wheel sen- sor. • Open or short cir- cuit in wire har- ness between rear wheel sensor and ABS ECU. • Open or short cir- cuit in wire har- ness between ABS ECU and SGCU. • Defective rear wheel sensor. • Malfunction ABS ECU. • Malfunction in SGCU. P2195 O2 sensor (open cir- cuit is detected) • Improperly in- stalled O2 sensor. • Defective coupler between O2 sen- sor and SGCU. • Open or short cir- cuit in wire har- ness between O2 sensor and SGCU. • Defective O2 sen- sor. • Malfunction in SGCU. • Normal signal is not received from O2 sensor. EU3 specified volt- age: (0.25 V or more to 0.53 V or less) EU4/5 specified voltage: (0.25 V or more to 0.40 V or less) 9-48 Engine idling speed is high. Engine idling speed is unstable. Increased exhaust emissions. Engine is difficult to start. — Traction control does not work. Traction control sys- tem indicator on the meter comes on. Traction control sys- tem switch is dis- able. Traction control sys- tem indicator on the meter goes OFF. Traction control does not work. Increased exhaust emissions. O2 feedback is not carried out.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation P2645 VVA solenoid mal- function (normal sig- nal is not received from the VVA sole- noid circuit while driving the VVA so- lenoid) • Defective coupler between VVA so- lenoid and SGCU. • Open or short cir- cuit in wire har- ness between VVA solenoid and SGCU. • Open circuit in VVA solenoid. Er-1 SGCU internal mal- function (Output sig- nal error) • Open or short cir- cuit in wire har- ness between meter and SGCU. • Defective coupler between meter and SGCU. • Defective meter unit. • Malfunction in SGCU. Er-2 SGCU internal mal- function (Output sig- nal error) • Open or short cir- cuit in wire har- ness between meter and SGCU. • Defective coupler between meter and SGCU. • Defective meter unit. • Malfunction in SGCU. Er-3 SGCU internal mal- function (Output sig- nal error) • Open or short cir- cuit in wire har- ness between meter and SGCU. • Defective coupler between meter and SGCU. • Defective meter unit. • Malfunction in SGCU. 9-49 Decreased engine torque in the high speed range. Fixed to the low speed cam position. Upper limit for the engine speed is de- creased. Signals cannot be transmitted between the SGCU and the meter. Signals cannot be transmitted between the SGCU and the YDT (Yamaha Diag- nostic Tool). Meter operation is impossible. Normally operated except for the me- ter. Signals are not re- ceived from the SGCU within the specified duration. Meter operation is impossible. Normally operated except for the me- ter. Sending data from the SGCU cannot be received correct- ly. Meter operation is impossible. Normally operated except for the me- ter.
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Probable cause of malfunction Vehicle symptom Fail-safe system operation Er-4 SGCU internal mal- function (Input sig- nal error) • Open or short cir- cuit in wire har- ness between meter and SGCU. • Defective coupler between meter and SGCU. • Defective meter unit. • Malfunction in SGCU. 9-50 Registered data is not received from the meter. Normal signals are not received from the YDT (Yamaha Diagnostic Tool). Meter operation is impossible. Normally operated except for the me- ter.
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FUNCTION AND DIAGNOSTIC CODE TABLE EAS33286 FUNCTION TABLE (FOR ABS (Anti-lock Brake System)) TIP For details of the DTC, refer to “BASIC INSTRUCTIONS FOR ” on page 9-17. DTC Item Symptom Check point 11* 25* Front wheel sensor (inter- mittent pulses or no puls- es) Front wheel sensor signal is not received properly. (Pulses are not received or are received intermit- tently while the vehicle is traveling.) 12 Rear wheel sensor (inter- mittent pulses or no puls- es) Rear wheel sensor signal is not received properly. (Pulses are not received or are received intermit- tently while the vehicle is traveling.) 13* 26* Front wheel sensor (ab- normal pulse period) Front wheel sensor signal is not received properly. (The pulse period is ab- normal while the vehicle is traveling.) 14* 27* Rear wheel sensor (abnor- mal pulse period) Rear wheel sensor signal is not received properly. (The pulse period is ab- normal while the vehicle is traveling.) 9-51 • Foreign material ad- hered around the front wheel sensor • Incorrect installation of the front wheel • Defective sensor rotor or incorrect installation of the rotor • Defective front wheel sensor or incorrect in- stallation of the sensor • Foreign material ad- hered around the rear wheel sensor • Incorrect installation of the rear wheel • Defective sensor rotor or incorrect installation of the rotor • Defective rear wheel sensor or incorrect in- stallation of the sensor • Foreign material ad- hered around the front wheel sensor • Incorrect installation of the front wheel • Defective sensor rotor or incorrect installation of the rotor • Defective front wheel sensor or incorrect in- stallation of the sensor • Foreign material ad- hered around the rear wheel sensor • Incorrect installation of the rear wheel • Defective sensor rotor or incorrect installation of the rotor • Defective rear wheel sensor or incorrect in- stallation of the sensor
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Symptom Check point 15 Front wheel sensor (open or short circuit) Open or short circuit is de- tected in the front wheel sensor. 16 Rear wheel sensor (open or short circuit) Open or short circuit is de- tected in the rear wheel sensor. 17* 45* Front wheel sensor (miss- ing pulses) Front wheel sensor signal is not received properly. (Missing pulses are de- tected in the signal while the vehicle is traveling.) 18* 46* Rear wheel sensor (miss- ing pulses) Rear wheel sensor signal is not received properly. (Missing pulses are de- tected in the signal while the vehicle is traveling.) 21 Hydraulic unit assembly (defective solenoid drive circuit) Solenoid drive circuit in the hydraulic unit assem- bly is open or short-circuit- ed. 9-52 • Defective coupler be- tween the front wheel sensor and the hydraulic unit assembly • Open or short circuit in the wire harness be- tween the front wheel sensor and the hydraulic unit assembly • Defective front wheel sensor or hydraulic unit assembly • Defective coupler be- tween the rear wheel sensor and the hydraulic unit assembly • Open or short circuit in the wire harness be- tween the rear wheel sensor and the hydraulic unit assembly • Defective rear wheel sensor or hydraulic unit assembly • Foreign material ad- hered around the front wheel sensor • Incorrect installation of the front wheel • Defective sensor rotor or incorrect installation of the rotor • Defective front wheel sensor or incorrect in- stallation of the sensor • Foreign material ad- hered around the rear wheel sensor • Incorrect installation of the rear wheel • Defective sensor rotor or incorrect installation of the rotor • Defective rear wheel sensor or incorrect in- stallation of the sensor • Defective hydraulic unit assembly
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Symptom Check point 24 Brake light switch or tail/ brake light Brake light signal is not re- ceived properly while the vehicle is traveling. (Brake light circuit, or front or rear brake light switch circuit.) 31 Hydraulic unit assembly (abnormal ABS solenoid power supply) Power is not supplied to the solenoid circuit in the hydraulic unit assembly. 32 Hydraulic unit assembly (short circuit in ABS sole- noid power supply circuit) Short circuit is detected in the solenoid power supply circuit in the hydraulic unit assembly. 33 Hydraulic unit assembly (abnormal ABS motor power supply) Power is not supplied to the motor circuit in the hy- draulic unit assembly. 34 Hydraulic unit assembly (short circuit in ABS motor power supply circuit) Short circuit is detected in the motor power supply circuit in the hydraulic unit assembly. 9-53 • Defective signaling sys- tem (tail/brake light or brake light switch) • Defective coupler be- tween the signaling sys- tem (tail/brake light or brake light switch) and the hydraulic unit assem- bly • Open or short circuit in the wire harness be- tween the signaling sys- tem (tail/brake light or brake light switch) and the hydraulic unit assem- bly • Defective hydraulic unit assembly • Blown ABS solenoid fuse • Defective coupler be- tween the battery and the hydraulic unit assembly • Open or short circuit in the wire harness be- tween the battery and the hydraulic unit assembly • Defective hydraulic unit assembly • Defective hydraulic unit assembly • Blown ABS motor fuse • Defective coupler be- tween the battery and the hydraulic unit assembly • Open or short circuit in the wire harness be- tween the battery and the hydraulic unit assembly • Defective hydraulic unit assembly • Defective hydraulic unit assembly
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Symptom Check point 41 Front wheel ABS (intermit- tent wheel speed pulses or incorrect depressuriza- tion) • Pulses from the front wheel sensor are re- ceived intermittently while the vehicle is trav- eling. • Front wheel will not re- cover from the locking tendency even though the signal is transmitted from the ABS ECU to re- duce the hydraulic pres- sure. 42 47 Rear wheel ABS (intermit- tent wheel speed pulses or incorrect depressuriza- tion) • Pulses from the rear wheel sensor are re- ceived intermittently while the vehicle is trav- eling. (for DTC No. 42) • Rear wheel will not re- cover from the locking tendency even though the signal is transmitted from the ABS ECU to re- duce the hydraulic pres- sure. 43 Front wheel sensor (miss- ing pulses) Front wheel sensor signal is not received properly. (Missing pulses are de- tected in the signal while the vehicle is traveling.) 44 Rear wheel sensor (miss- ing pulses) Rear wheel sensor signal is not received properly. (Missing pulses are de- tected in the signal while the vehicle is traveling.) 51 52 • Vehicle system power supply (voltage of ABS ECU power supply is high) (for DTC No. 51) • Vehicle system power supply (voltage of wheel sensor power supply is high) (for DTC No. 52) • Power voltage supplied to the ABS ECU in the hydraulic unit assembly is too high. (for DTC No. 51) • Power voltage supplied to the wheel sensor is too high. (for DTC No. 52) 9-54 • Incorrect installation of the front wheel sensor • Incorrect rotation of the front wheel • Front brake dragging • Defective hydraulic unit assembly • Incorrect installation of the rear wheel sensor (for DTC No. 42) • Incorrect rotation of the rear wheel • Rear brake dragging • Defective hydraulic unit assembly • Foreign material ad- hered around the front wheel sensor • Incorrect installation of the front wheel • Defective sensor rotor or incorrect installation of the rotor • Defective front wheel sensor or incorrect in- stallation of the sensor • Foreign material ad- hered around the rear wheel sensor • Incorrect installation of the rear wheel • Defective sensor rotor or incorrect installation of the rotor • Defective rear wheel sensor or incorrect in- stallation of the sensor • Defective battery • Disconnected battery terminal • Defective charging sys- tem
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FUNCTION AND DIAGNOSTIC CODE TABLE DTC Item Symptom Check point 53 Vehicle system power supply (voltage of ABS ECU power supply is low) Power voltage supplied to the ABS ECU in the hy- draulic unit assembly is too low. 54 Hydraulic unit assembly (defective ABS solenoid and ABS motor power supply circuits) Abnormality is detected in the solenoid or motor pow- er supply circuit in the hy- draulic unit assembly. 55 Hydraulic unit assembly (defective ABS ECU) Abnormal data is detected in the hydraulic unit as- sembly. 56 Hydraulic unit assembly (abnormal internal power supply) Abnormality is detected in the power supply circuit in the hydraulic unit assem- bly. 63 Front wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the front wheel sensor is too low. 64 Rear wheel sensor power supply (voltage of power supply is low) Power voltage supplied from the ABS ECU to the rear wheel sensor is too low. * The DTC No. varies according to the vehicle conditions. 9-55 • Defective battery • Defective coupler be- tween the battery and the hydraulic unit assembly • Open or short circuit in the wire harness be- tween the battery and the hydraulic unit assembly • Defective charging sys- tem • Defective battery • Defective coupler be- tween the battery and the hydraulic unit assembly • Open or short circuit in the wire harness be- tween the battery and the hydraulic unit assembly • Defective charging sys- tem • Defective hydraulic unit assembly • Defective hydraulic unit assembly • Defective hydraulic unit assembly • Short circuit in the wire harness between the front wheel sensor and the hydraulic unit assem- bly • Defective front wheel sensor • Defective hydraulic unit assembly • Short circuit in the wire harness between the rear wheel sensor and the hydraulic unit assem- bly • Defective rear wheel sensor • Defective hydraulic unit assembly
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FUNCTION AND DIAGNOSTIC CODE TABLE EAS33031 DIAGNOSTIC CODE: SENSOR OPERATION TABLE Diagnostic code No. Item Tool display Procedure 01 Throttle position sensor signal 0–125 • Fully closed position 12–22 Check the fully closed throttle valve. • Fully opened position 94–110 Check the fully opened throttle valve. 03 Intake air pressure Displays the intake air pressure. When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is indi- cated. At sea level: Approx. 101 kPa 3000 m above sea level: Approx. 70 kPa 05 Intake air temperature Displays the intake air temperature. -30–120 [°C] When engine is cold: Dis- plays temperature closer to air temperature When engine is hot: Air temperature + approx. 20 [°C] 06 Coolant temperature Displays the coolant tem- perature. -30–120 [°C] When engine is cold: Dis- plays temperature closer to air temperature When engine is hot: Dis- plays current coolant tem- perature. 07 Vehicle speed pulse Front wheel speed pulse 0–999 Check that the number in- creases when the front wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped. 09 Fuel system voltage (battery voltage) Displays the fuel system voltage 0–18.7 [V] Standard voltage: Approxi- mately 12.0 [V] 9-56 Check the intake air pres- sure when cranking the engine. (If the displaying value changes, the perfor- mance is OK.) Compare the actually measured air temperature with the tool displayed val- ue. Compare the actually measured coolant tem- perature with the tool dis- played value. Compare the actually measured battery voltage with the tool displayed val- ue. (If the actually mea- sured battery voltage is low, recharge the battery.)
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FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic code No. Item Tool display Procedure 20 Sidestand switch Check the sidestand switch condition. • Stand retracted ON • Stand extended OFF 60 EEPROM DTC display — • Defective EEPROM DTC is indicated. 00 • No malfunctions detect- ed (If the self-diagnosis fault code P062F is indi- cated, the SGCU is de- fective.) • DTCs are indicated 2- second interval. Display the EEPROM writing error for fault code No. P062F. If more than one item is defective, the displays al- ternates every two sec- onds to show all the detected numbers. 01 (CO adjustment value) 11 (ISC learning values) 12 (O2 feedback learning value) 14 (Wheel diameter learn- ing value) 67 ISC learning condition dis- play ISC learning data erasure 00 ISC learning data has been erased. 01 It is not necessary to erase the ISC learning data. 02 It is necessary to erase the ISC learning data. 70 Programmed unit Ver. number 0–254 [-] Check the programmed unit Ver. number 87 A/F learning data erasure 00 A/F learning data has been erased. 01 A/F learning data has not been erased 90 Idle stop selection switch Check the idle stop selec- tion switch is turned ON / OFF. • Set to “ON” position Indicated ON • Set to “OFF” position Indicated OFF 9-57 — To erase the ISC learning data, click “ON / OFF but- ton” on the Yamaha diag- nostic tool screen 3 times in 5 seconds. To erase the A / F learning data, click “ON / OFF but- ton” on the Yamaha diag- nostic tool screen 3 times in 5 seconds.
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FUNCTION AND DIAGNOSTIC CODE TABLE EAS33032 DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE Diagnostic code No. Item Actuation Procedure 30 Ignition coil Actuates the ignition coil five times at one–second intervals. The “CHECK” indicator “ ” on the Yamaha diag- nostic tool screen comes on each time the ignition coil is actuated. 36 Fuel injector Actuates the fuel injector five times at one–second intervals. The “CHECK” indicator “ ” on the Yamaha diag- nostic tool screen comes on each time the fuel injec- tor is actuated. 45 VVA solenoid Actuates the VVA solenoid five times at five-second intervals. The “CHECK” indicator “ ” on the Yamaha diag- nostic tool screen comes on each time the VVA so- lenoid is actuated. 52 Headlight Actuates the headlight five times at five-second inter- vals. The “CHECK” indicator “ ” on the Yamaha diag- nostic tool screen comes on each time the headlight is actuated. 54 ISC unit Fully closes the ISC valve, and then opens the valve to the standby opening po- sition. This operation takes ap- proximately 3 seconds each time. The “CHECK” indicator “ ” on the Yamaha diag- nostic tool screen comes on during the operation. 9-58 Check the energization of the ignition coil. • Check the sparking per- formance on the spark plug. Disconnect the fuel pump coupler. Check that the injector is actuated five times by lis- tening for the operating sound. Check that the VVA sole- noid is operated five times. Check that the headlight comes on five times. Check that the ISC unit operates by listening for the operating sound while the ISC unit operates for 3 seconds.
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EAS20707 EVENT CODE TABLE Fuel injection system No. Item Symptom Possible cause Remarks 192 Intake air pres- sure sensor Brief abnormality detected in intake air pressure sensor Same as for DTC P0107 and P0108 Perform the checks and maintenance jobs for DTC P0107 and P0108. 193 Throttle position sensor Brief abnormality detected in throttle position sensor Same as for DTC P0122 and P0123 Perform the checks and maintenance jobs for DTC P0122 and P0123. 196 Coolant tem- perature sensor Brief abnormality detected in coolant temperature sensor Same as for DTC P0117 and P0118 Perform the checks and maintenance jobs for DTC P0117 and P0118. 197 Intake air tem- perature sensor Brief abnormality detected in intake air temperature sensor Same as for DTC P0112 and P0113 Perform the checks and maintenance jobs for DTC P0112 and P0113. 218 Crankshaft posi- tion sensor Brief abnormality detected in crank- shaft position sen- sor Same as for DTC P0335 Perform the checks and maintenance jobs for DTC P0335. 240 O2 sensor (Correction val- ue remains at upper limit) Correction value re- mains at upper limit during O2 feedback • Open or short circuit in the wire harness between the sensor and the SGCU gray/ red–gray/red • Low fuel pressure • Clogged fuel injector • Sensor malfunction • Defective SGCU • Defective fuel injec- tion system 241 O2 sensor (Correction val- ue remains at lower limit) Correction value re- mains at lower limit during O2 feedback • Open or short circuit in the wire harness between the sensor and the SGCU gray/ red–gray/red • Low fuel pressure • Clogged fuel injector • Sensor malfunction • Defective SGCU • Defective fuel injec- tion system 9-59 EVENT CODE TABLE • If a DTC is indicated, perform the checks and maintenance jobs for the DTC first. * Event code number 240 may be indicated even if the system is normal. • If a DTC is indicated, perform the checks and maintenance jobs for the DTC first. * Event code number 241 may be indicated even if the system is normal.
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No. Item Symptom Possible cause Remarks 242 ISC (Stuck at the up- per limit for ad- justment) During idling, the adjustment is main- tained at the upper limit Idling engine speed is slow • Clogged throttle body • Poorly adjusted throt- tle cable • Poorly adjusted clutch cable • Malfunction in the fuel injection system • Dirty or worn spark plug • Malfunction in the battery • Malfunction in SGCU 243 ISC (Stuck at the lower limit for adjustment) During idling, the adjustment is main- tained at the lower limit Idling engine speed is fast • Poorly adjusted throt- tle cable • Poorly adjusted clutch cable • Malfunction in the fuel injection system • Dirty or worn spark plug • Malfunction in the battery • Malfunction in SGCU 244 Difficult/unable to start engine Engine starting diffi- cult/unable condi- tion detected • Empty fuel tank • Defective fuel injec- tion system • Dirty or worn spark plug • Defective battery • Defective SGCU 245 Engine stall Engine stall detect- ed • Empty fuel tank • Improperly adjusted throttle cable • Improperly adjusted clutch cable • Defective fuel injec- tion system • Dirty or worn spark plug • Defective battery • Defective SGCU 9-60 EVENT CODE TABLE • Implement diagnosis mode D67, and check the ISC maintenance request. • If a DTC is indicated, perform to that first. * Event code number 242 may be indicated even if the system is normal. • If a DTC is indicated, perform to that first. * Event code number 243 may be indicated even if the system is normal. • If a DTC is indicated, perform the checks and maintenance jobs for the DTC first. * Event code number 244 may be indicated even if the system is normal. • If a DTC is indicated, perform the checks and maintenance jobs for the DTC first. * Event code number 245 may be indicated even if the system is normal.
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EAS20397 P0030 EAS33134 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. Start the engine, 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. Start the engine, 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. 9-61 P0030
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3. Wire harness continuity. • Disconnect the O2 sensor coupler, SGCU coupler and ignition fuse. • Open circuit check Between O2 sensor coupler “1” and SGCU cou- pler “2” pink/black–pink/black Between O2 sensor coupler “1” and ignition fuse holder “3” brown/red–brown 3 1 2 Br/R P/B Gy/R B/L Is resistance 0 Ω? YES → Go to “Short circuit check”. NO a. Replace the wire harness. b. Start the engine, 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”. 9-62 P0030 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G
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• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between O2 sensor coupler “1” and ground pink/black–ground brown/red–ground Lines short circuit check “B” O2 sensor coupler “1” pink/black–any other coupler terminal brown/red–any other coupler terminal SGCU coupler “2” pink/black–any other coupler terminal Ignition fuse holder “3” brown–any other coupler terminal A B 1 1 Br/R P/B Gy/R B/L Br/R P/B Gy/R B/L 3 Is resistance ∞ Ω? YES → Go to step 4. NO a. Replace the wire harness. b. Start the engine, 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. 9-63 P0030 2 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G
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4. Defective O2 sensor heater. • Replace the O2 sensor. Refer to “ENGINE REMOVAL” on page 5-4. • Start the engine, 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 8-36. 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. 9-64 P0030
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EAS20660 P00D1, P2195 EAS33115 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 up it. 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 up it. 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. 9-65 P00D1, P2195
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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 up it. 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, SGCU coupler and ignition fuse coupler. • Open circuit check Between O2 sensor coupler “1” and SGCU cou- pler “2” Between O2 sensor coupler “1” and ignition fuse holder “3” brown/red–brown 3 1 2 Br/R P/B Gy/R B/L 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 up it. And then, racing the engine. c. Check the DTC using the malfunction mode of the YDT. 9-66 P00D1, P2195 pink/black–pink/black gray/red–gray/red black/blue–black/blue G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G
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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 9-3. Ground short circuit check “A” Between O2 sensor coupler “1” and ground Lines short circuit check “B” O2 sensor coupler “1” SGCU coupler “2” pink/black–any other coupler terminal gray/red–any other coupler terminal black/blue–any other coupler terminal Ignition fuse holder “3” brown/red–any other coupler terminal A B 1 1 3 2 Br/R P/B Br/R P/B Gy/R B/L Gy/R B/L G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G Is resistance ∞ Ω? YES → Go to step 5. NO a. Replace the wire harness. b. Start the engine and warm up it. 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 5. 9-67 P00D1, P2195 pink/black–ground brown/red–ground gray/red–ground black/blue–ground pink/black–any other coupler terminal brown/red–any other coupler terminal gray/red–any other coupler terminal black/blue–any other coupler terminal
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5. Defective 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 up it. 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. • Check 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 up it. 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 8-36. 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. 9-68 P00D1, P2195
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EAS20421 P0106 EAS32840 Item Intake air pressure sensor: clogging of hole or sensor installation improperly. Fail-safe system • Able to start engine • Able to drive vehicle Procedure ECA20500 NOTICE Do not remove the throttle body sensor assembly from the throttle body. 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 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. 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. 9-69 P0106
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2. Defective intake air pressure sensor. • Execute the diagnostic mode. (Code 03) • 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. 3.99 V 1000 m (3300 ft) above sea level Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap- prox. 3.55 V 2000 m (6700 ft) above sea level Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap- prox. 3.16 V 3000 m (9800 ft) above sea level Approx. 70 kPa (525.0 mmHg, 20.7 inHg), ap- prox. 2.76 V • When engine is cranking: Make sure that the indication value changes. Is check result OK? YES → Go to step 3, and complete the service. NO a. Replace the throttle body. 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. 9-70 P0106
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EAS20567 P0107, P0108 EAS33047 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 ECA20500 NOTICE Do not remove the throttle body sensor assembly from the throttle body. 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 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. 9-71 P0107, P0108
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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 Between throttle body sensor assembly coupler “1” and SGCU coupler “2” B R Br/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G B/L Y L P/W Br/W 1 2 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y 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 7, and complete the service. NO → Go to “Short circuit check”. 9-72 P0107, P0108 [P0108] black/blue–black/blue [P0107] pink/white–pink/white [P0107] blue–blue W/B P/W
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• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between throttle body sensor assembly coupler “1” and ground [P0107] pink/white–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 A B 1 B/L Y L P/W Br/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 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 the throttle body sensor 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 7, and complete the service. NO → Go to step 5. 9-73 P0107, P0108 1 2 B/L Y L P/W Br/W G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
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5. Defective intake air pressure sensor. • Execute the diagnostic mode. (Code 03) • When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in- dicated. At sea level Approx. 101 kPa (757.6 mmHg, 29.8 inHg), ap- prox. 3.99 V 1000 m (3300 ft) above sea level Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap- prox. 3.55 V 2000 m (6700 ft) above sea level Approx. 80 kPa (600.0 mmHg, 23.6 inHg), ap- prox. 3.16 V 3000 m (9800 ft) above sea level Approx. 70 kPa (525.0 mmHg, 20.7 inHg), ap- prox. 2.76 V • 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 8-36. 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. 9-74 P0107, P0108
Halaman 408
EAS20568 P0112, P0113 EAS33048 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 ECA20500 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 and/or sub-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. 9-75 P0112, P0113
Halaman 409
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” and SGCU coupler “2” [P0113] brown/white–brown/white [P0113] black/blue–black/blue B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G B/L Y L P/W Br/W 1 2 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y 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 7, and complete the service. NO → Go to “Short circuit check”. 9-76 P0112, P0113 W/B
Halaman 410
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between throttle body sensor assembly coupler “1” and ground [P0112] brown/white–ground Lines short circuit check “B” SGCU coupler “2” [P0113] brown/white–any other coupler terminal A B 1 B/L Y L P/W Br/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 7, and complete the service. NO → Go to step 4. 4. Installed condition of throttle body sensor assembly. • Check for looseness. Refer to “THROTTLE BODY” on page 7-11. Is check result OK? YES → Go to step 5. NO a. Reinstall the throttle body sensor 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 7, and complete the service. NO → Go to step 5. 9-77 P0112, P0113 2 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
Halaman 411
5. Defective intake air temperature sensor. • Execute the diagnostic mode. (Code 05) • When engine is cold: Displayed temperature is close to the ambient temperature. Is check result OK? YES → Go to step 6. NO a. The displayed temperature is not close to the ambient temperature → 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 8-36. 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. 9-78 P0112, P0113
Halaman 412
EAS20569 P0117, P0118 EAS33049 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. 9-79 P0117, P0118
Halaman 413
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 SGCU coupler “2” [P0118] green/red–green/red [P0118] black/blue–black/blue G/R B/L 1 2 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”. 9-80 P0117, P0118 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
Halaman 414
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between coolant temperature sensor coupler “1” and ground [P0117] green/red–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 A B 1 1 G/R B/L 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. 9-81 P0117, P0118 2 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L G/R B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
Halaman 415
5. Defective coolant temperature sensor. • Execute the diagnostic mode. (Code 06) • 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 8-41. 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 8-36. 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. 9-82 P0117, P0118
Halaman 416
EAS20757 P0122, P0123 EAS33050 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 to start engine • Able to drive vehicle Procedure ECA20500 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 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. 9-83 P0122, P0123
Halaman 417
3. Wire harness continuity. • Disconnect the throttle body sensor assembly coupler and SGCU coupler. • Open circuit check Between throttle body sensor assembly coupler “1” and SGCU coupler “2” B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G 1 2 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B/L Y L P/W Br/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 9, and complete the service. NO → Go to “Short circuit check”. 9-84 P0122, P0123 [P0122] blue–blue [P0122] yellow–yellow [P0123] black/blue–black/blue
Halaman 418
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between throttle body sensor assembly coupler “1” and ground [P0122] yellow–ground Lines short circuit check “B” Throttle body sensor assembly coupler “1” [P0123] yellow–any other coupler terminal SGCU coupler “2” [P0123] yellow–any other coupler terminal B A 1 1 B/L Y L P/W Br/W B/L Y L P/W Br/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 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 the throttle body. 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. 9-85 P0122, P0123 2 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G
Halaman 419
5. Defective throttle position sensor. • Check throttle position sensor signal 1. • Execute the diagnostic mode. (Code 01) When the throttle valves are fully closed 12–22 When throttle valves are fully open 94–110 Is check result OK? YES → Go to step 7. NO a. Replace the throttle body assembly. Refer to “REPLACING THE THROTTLE BODY” on page 7-16. b. Start 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 8-36. 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. 9-86 P0122, P0123
Halaman 420
EAS20571 P0132 EAS33051 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. 9-87 P0132
Halaman 421
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. 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 9-3. Lines short circuit check SGCU coupler “1” gray/red–any other coupler terminal 1 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G 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. 9-88 P0132 W/B
Halaman 422
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 8-36. 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. 9-89 P0132
Halaman 423
EAS20574 P0201 EAS33054 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 36) Is operating sound heard? 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 8-42. 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 36) Is operating sound heard? YES → Go to step 6. NO → Go to step 3. 9-90 P0201
Halaman 424
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. Execute the diagnostic mode. (Code 36) Is operating sound heard? YES → Go to step 6. NO → Go to step 4. 4. Wire harness continuity. • Disconnect the ignition fuse, fuel injector coupler and SGCU coupler • Open circuit check Between ignition fuse holder “1” and fuel injec- tor coupler “2” brown–brown Between fuel injector coupler “2” and SGCU coupler “3” orange/black–orange/black 1 2 3 B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G Br O/B Is resistance 0 Ω? YES → Go to “Short circuit check”. NO a. Replace the wire harness. b. Execute the diagnostic mode. (Code 36) Is operating sound heard? YES → Go to step 6. NO → Go to “Short circuit check”. 9-91 P0201 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y
Halaman 425
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between fuel injector coupler “2” and ground orange/black–ground brown–ground Lines short circuit check “B” Fuel injector coupler “2” orange/black–any other coupler terminal brown–any other coupler terminal SGCU coupler “1” orange/black–any other coupler terminal A B 2 1 2 O/B O/B Br Br Is resistance ∞ Ω? YES → Go to step 5. NO a. Replace the wire harness. b. Execute the diagnostic mode. (Code 36) Is operating sound heard? 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 8-36. 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. 9-92 P0201 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
Halaman 426
EAS20578 P0335 EAS33058 Item Crankshaft position sensor: normal signals are 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. 9-93 P0335
Halaman 427
3. Wire harness continuity. • Disconnect the crankshaft position sensor coupler and SGCU coupler. • Open circuit check Between crankshaft position sensor coupler “1” and SGCU coupler “2” 1 2 W/R B/L W/L Br/B W/B W/Y 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”. 9-94 P0335 white/red–white/red white/blue–white/blue white/black–white/black white/yellow–white/yellow brown/black–brown/black black/blue–black//blue G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
Halaman 428
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between crankshaft position sensor coupler “1” and ground Lines short circuit check “B” Crankshaft position sensor coupler “1” SGCU coupler “2” 2 A 1 B 1 W/R B/L W/L Br/B W/B W/Y 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. 9-95 P0335 white/red–ground white/blue–ground white/black–ground white/yellow–ground brown/black–ground black/blue–ground white/red–any other coupler terminal white/blue–any other coupler terminal white/black–any other coupler terminal 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 white/yellow–any other coupler terminal brown/black–any other coupler terminal black/blue–any other coupler terminal W/R B/L W/L Br/B G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L W/B W/Y Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
Halaman 429
4. Installed condition of crankshaft position sensor. • Check for looseness or pinching. • Check the gap (1.15 mm (0.05 in)) between the crankshaft position sensor and the generator rotor. 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. 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 8-36. 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. 9-96 P0335
Halaman 430
EAS20580 P0351 EAS33060 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. 9-97 P0351
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3. Wire harness continuity. • Disconnect the ignition coil coupler and SGCU coupler. • Open circuit check Between ignition coil coupler “1” and SGCU coupler “2” orange–orange 2 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B 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 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”. 9-98 P0351 1
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• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. 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 A B 2 1 1 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. 9-99 P0351 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
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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 30) • Confirm that spark plug does not spark. • Replace the SGCU, and complete the service. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. 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. 9-100 P0351
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EAS20674 P0500 EAS33303 Item Front wheel sensor: normal signal 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 07) 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 07) 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. 9-101 P0500
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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. Execute the diagnostic mode. (Code 07) 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 ECU coupler “2” brown–brown yellow–yellow Between ABS ECU coupler “2” and SGCU cou- pler “3” white–white 1 2 3 R B/W W L G r B Y W/L W/B B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G Br Y B R/L Y Br Lg/L L/G L/G Lg/WB/W Is resistance 0 Ω? YES → Go to “Short circuit check”. NO a. Replace the wire harness. b. Execute the diagnostic mode. (Code 07) 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”. 9-102 P0500 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y W/B
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• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between ABS ECU coupler “2” and ground brown–ground yellow–ground Lines short circuit check “B” Front wheel sensor coupler “1” brown–any other coupler terminal yellow–any other coupler terminal ABS ECU coupler “2” brown–any other coupler terminal yellow–any other coupler terminal SGCU coupler “3” white–any other coupler terminal A B 1 2 B/W W L G r B Y Br Y R W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W 2 B/W W L G r B Y R B R/L Y Br Lg/L L/G L/G Is resistance ∞ Ω? YES → Go to step 5. NO a. Replace the wire harness. b. Execute the diagnostic mode. (Code 07) 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. 9-103 P0500 3 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L W/L W/B Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y Lg/WB/W B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G
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5. Defective front wheel sensor. • Check the installed condition of front wheel sensor. Is check result OK? YES → Go to step 8. NO a. Reinstall or replace the front wheel sensor. Refer to “FRONT WHEEL” on page 4-22. b. Execute the diagnostic mode. (Code 07) c. Rotate the front wheel by hand and check that the indicated value increases. Is that value increased? YES → Go to step 6, and complete the service. NO → Go to step 8. 6. Malfunction in SGCU. • Replace the SGCU. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36 • Execute the diagnostic mode. (Code 07) • 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”. 9-104 P0500
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EAS20589 P0507 EAS33069 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 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 9, and complete the service. NO → Go to step 3. 9-105 P0507
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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 3-25. 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 9, 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 9, 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 9, and complete the service. NO → Go to step 6. 9-106 P0507
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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 9, 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 9, 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 8-36. • 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, and complete the service. 9-107 P0507
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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 Between ISC unit coupler “1” and SGCU cou- pler “2” 2 B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G P G/Y Gy Sb 1 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y 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”. 9-108 P0507 pink–pink green/yellow–green/yellow gray–gray sky blue–sky blue W/B
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• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between ISC unit coupler “1” and ground Lines short circuit check “B” ISC unit coupler “1” SGCU coupler “2” A B 1 2 1 P G/Y Gy Sb P G/Y Gy Sb 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. 9-109 P0507 pink–ground green/yellow–ground gray–ground sky blue–ground pink–any other coupler terminal green/yellow–any other coupler terminal gray–any other coupler terminal sky blue–any other coupler terminal pink–any other coupler terminal green/yellow–any other coupler terminal gray–any other coupler terminal sky blue–any other coupler terminal G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
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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 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 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. 9-110 P0507
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16.Malfunction in SGCU. • Replace the SGCU, and complete the service. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. • 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. 9-111 P0507
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EAS20590 P0511 EAS33070 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. 9-112 P0511
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3. Wire harness continuity. • Disconnect the ISC unit coupler and SGCU coupler. • Open circuit check Between ISC unit coupler “1” and SGCU cou- pler “2” 2 G/R B L/R L/Y W W/G P G/Y Gy Sb 1 G/Y W/R O B/Y P Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y B R Br/W P/W Br Gy/R L/B 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”. 9-113 P0511 pink–pink green/yellow–green/yellow gray–gray sky blue–sky blue B/L P/B B/L W/B
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• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between ISC unit coupler “1” and ground Lines short circuit check “B” ISC unit coupler “1” SGCU coupler “2” A B 1 1 2 P G/Y Gy Sb P G/Y Gy Sb 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. 9-114 P0511 pink–ground green/yellow–ground gray–ground sky blue–ground pink–any other coupler terminal green/yellow–any other coupler terminal gray–any other coupler terminal sky blue–any other coupler terminal pink–any other coupler terminal green/yellow–any other coupler terminal gray–any other coupler terminal sky blue–any other coupler terminal G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y P/B B R Br/W P/W Br Gy/R L/B G/R B L/R L/Y W W/G B/L W/B
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4. Faulty the ISC unit operation • Execute the diagnostic mode. (Code 54) • Check the operating sound of the ISC valve. 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. 5. Malfunction in SGCU. • Replace the SGCU, and complete the service. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. 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. 9-115 P0511
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EAS20434 P0560, P0563 EAS33138 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 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. 9-116 P0560, P0563
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EAS20676 P0601 EAS33305 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 8-36. • Turn the main switch to “ON”. • Check that the MIL does not come on. 9-117 P0601
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EAS20598 P062F EAS33078 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 60) 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 60). 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 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 diagnostic mode (Code 60). EEPROM data error for ISC learning value and/or “12” is indicated in the diagnostic mode (Code 60). 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 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. 9-118 P062F
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4. “14” is indicated in the diagnostic mode (Code 60). 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 87) b. Repeat step 1. c. If the same number is indicated, 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 8-36. 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. 9-119 P062F
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EAS20615 P1602 EAS33095 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. 9-120 P1602
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3. Wire harness continuity. • Disconnect the main fuse, fuel injection system fuse and SGCU coupler. • Open circuit check Between battery “1” and main fuse holder “2” red–red Between fuel injection system fuse holder “2” and SGCU coupler “3” red–red 2 3 1 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”. 9-121 P1602 G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/R L/B B/L G/R B L/R L/Y W W/G W/B
Halaman 455
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. 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 3 A B G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G 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. 9-122 P1602 3 G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G
Halaman 456
4. Wire harness continuity. • Disconnect the main switch coupler, ignition fuse, starter charge relay coupler and SGCU coupler. • Open circuit check Between main switch coupler “1” and ignition fuse holder “2” brown–brown Between ignition fuse holder “2” and starter charger relay coupler “3” brown–brown Between starter charge relay “3” and SGCU coupler “4” red/black–red/black 2 3 4 1 Y/R R/Y R Br R/B Br/R 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”. 9-123 P1602 G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y P/B B R Br/W P/W Br Gy/RW/B L/B G/R B L/R L/Y W W/G B/L
Halaman 457
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. 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 3 A B 4 3 Y/R R R/B Br/R Br R/B 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 8-36. 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. 9-124 P1602 Y/R R G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L Br/R Br Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y P/B B R Br/W P/W Br Gy/RW/B L/B G/R B L/R L/Y W W/G B/L
Halaman 458
EAS20633 P2158 EAS33113 Item Rear wheel sensor: normal signals are not received from the rear wheel sensor. Fail-safe system • Able to start engine • Able to drive vehicle Procedure 1. Locate the malfunction. • Check the ABS warning light. Is the ABS warning light on? YES → Refer to “ABS OUTLINE” on page 9-16. NO → Go to step 2. 2. Connection of rear 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. Check the rear wheel speed with YDT monitor item. c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? YES → Go to step 9, and complete the service. NO → Go to step 3. 9-125 P2158
Halaman 459
3. 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 4. NO a. Connect the coupler securely or replace the wire harness. b. Check the rear wheel speed with YDT monitor item. c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? YES → Go to step 9, and complete the service. NO → Go to step 4. 4. 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 5. NO a. Connect the coupler securely or replace the wire harness. b. Check the rear wheel speed by YDT monitor item. c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? YES → Go to step 9, and complete the service. NO → Go to step 5. 9-126 P2158
Halaman 460
5. Wire harness continuity. • Disconnect the rear wheel sensor coupler, ABS ECU coupler and SGCU coupler. • Open circuit check Between rear wheel sensor coupler “1” and ABS ECU coupler “2” green–green blue–blue Between ABS ECU coupler “2” and SGCU cou- pler “3” white/black–white/black 1 2 3 R B/W W L G r B Y W/L G/R B L/R L/Y W W/G G L B R/L Y Br Lg/L L/G L/G Lg/WB/W Is resistance 0 Ω? YES → Go to “Short circuit check”. NO a. Replace the wire harness. b. Check the rear wheel speed with YDT monitor item. c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? YES → Go to step 9, and complete the service. NO → Go to “Short circuit check”. 9-127 P2158 G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L W/B Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y P/B B R Br/W P/W Br Gy/R L/B B/L W/B
Halaman 461
• Short circuit check TIP Disconnect the SGCU and ABS ECU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3 and “PARTS CONNECTED TO THE ABS ECU” on page 9-4. Ground short circuit check “A” Between ABS ECU coupler “2” and ground green–ground blue–ground white/black–ground Lines short circuit check “B” Rear wheel sensor coupler “1” green–any other coupler terminal blue–any other coupler terminal ABS ECU coupler “2” green–any other coupler terminal blue–any other coupler terminal white/black–any other coupler terminal ECU coupler “3” white/black–any other coupler terminal A B 2 3 1 G L B/W W L G r B Y W/L W/B R B R/L Y Br Lg/L L/G L/G Lg/WB/W 2 R B R/L Is resistance ∞ Ω? YES → Go to step 5. NO a. Replace the wire harness. b. Check the rear wheel speed with YDT monitor item. c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? YES → Go to step 9, and complete the service. NO → Go to step 6. 9-128 P2158 G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y P/B B R Br/W P/W Br Gy/RW/B L/B G/R B L/R L/Y W W/G B/L B/W W L G r B Y W/L W/B Y Br Lg/L L/G L/G Lg/WB/W
Halaman 462
6. Defective rear wheel sensor. • Check the installed condition of rear wheel sensor. Is check result OK? YES → Go to step 7. NO a. Reinstall or replace the rear wheel sensor. Refer to “REAR WHEEL” on page 4-29. b. Check the rear wheel speed with YDT monitor item. c. Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? YES → Go to step 9, and complete the service. NO → Go to step 7. 7. Malfunction in SGCU. • Replace the SGCU. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. • Check the rear wheel speed with YDT monitor item. • Rotate the rear wheel by hand and check that the indicated value increases. Is that value increased? YES → Go to step 9, and complete the service. NO → Go to step 8. 8. Malfunction in ABS ECU. • Replace the ABS ECU. Refer to “REMOVING THE HYDRAULIC UNIT ASSEMBLY” on page 4-60. • Go to step 9, and complete the service. 9. Delete the DTC and check that the MIL goes off. • Turn the main switch to “ON”, and then rotate the rear 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”. 9-129 P2158
Halaman 463
EAS20642 P2645 EAS33122 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. 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. 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. 9-130 P2645
Halaman 464
3. Wire harness continuity. • Disconnect the VVA solenoid coupler and SGCU coupler. • Open circuit check Between VVA solenoid coupler “1” and SGCU coupler “2” green–green chocolate–chocolate Between SGCU coupler “2” and ground black–ground 2 G/R B L/R L/Y W W/G G Ch 1 G/Y W/R O B/Y P Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y B R Br/W P/W Br Gy/RW/B L/B 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”. 9-131 P2645 B/L P/B B/L
Halaman 465
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. Ground short circuit check “A” Between VVA solenoid coupler “1” and ground green–ground chocolate–ground Lines short circuit check “B” VVA solenoid coupler “1” green–any other coupler terminal chocolate–any other coupler terminal SGCU coupler “2” green–any other coupler terminal chocolate–any other coupler terminal A B 1 1 2 G Ch Is resistance ∞ Ω? YES → Go to step 4. NO a. Replace the wire harness. b. 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. 9-132 P2645 G Ch G/Y W/R O B/Y P Lg/L O/B G B Ch W/L B/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B W/Y P/B B R Br/W P/W Br Gy/RW/B L/B G/R B L/R L/Y W W/G B/L
Halaman 466
4. Faulty the VVA solenoid operation • Check the VVA solenoid resistance. Refer to “CHECKING THE VVA SOLENOID” on page 8-42. Is check result OK? YES → Go to step 5. NO a. Replace the VVA solenoid. b. 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 8-36. 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. 9-133 P2645
Halaman 467
EAS20776 Er-1, Er-2, Er-3, Er-4 EAS33508 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 9-134 Er-1, Er-2, Er-3, Er-4
Halaman 468
3. Meter assembly wire harness continuity. • Disconnect the meter assembly coupler and SGCU coupler. • Open circuit check Between meter assembly coupler “1” and SGCU coupler “2” blue/red–blue/red 1 2 L/R W/L G/B Br/R R R R/W B G L/W Ch Dg Y/W Br/W Br W/R 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” 9-135 Er-1, Er-2, Er-3, Er-4 G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G
Halaman 469
• Short circuit check TIP Disconnect the SGCU related connectors before checking. Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3. 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 A B 1 2 1 L/R W/L G/B Br/R R R L/W R/W B G L/W Ch Dg Y/W Br/W Br L/R W/L G/B Br/R R R G/Y W/R O B/Y P B/L Lg/L O/B G B Ch W/L R/W B G Ch Dg Y/W Br/W Br W/R W/R 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. 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. 9-136 Er-1, Er-2, Er-3, Er-4 Y Lg/W Sb B/L Gy Br/B R/B B/L L W/B P/B W/Y B R Br/W P/W Br Gy/RW/B L/B B/L G/R B L/R L/Y W W/G
Halaman 470
5. Malfunction in SGCU. • Replace the SGCU, and complete the service. Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36. 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. 9-137 Er-1, Er-2, Er-3, Er-4
Halaman 471
EAS20685 11, 25_ABS EAS33314 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 4-25. 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- 25. 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- 25. Is check result OK? YES → Replace the hydraulic unit assembly (ABS ECU). NO → Repair or replace the wheel sensor. 9-138 11, 25_ABS
Halaman 472
EAS20686 12_ABS EAS33315 Item Rear wheel sensor (intermittent pulses or no pulses) Procedure 1. Foreign material adhered around the rear 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 rear wheel • Check the components for looseness, distortion, and bends. Refer to “CHECKING THE REAR WHEEL” on page 4-30. Is check result OK? YES → Go to step 3. NO → Replace the wheel axle, tire, rear 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 REAR WHEEL SENSOR ROTOR” on page 4-30. Is check result OK? YES → Go to step 4. NO → Replace the sensor rotor. 4. Defective rear 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 REAR WHEEL 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. 9-139 12_ABS
Halaman 473
EAS20687 13, 26_ABS EAS33316 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 FRONT WHEEL” on page 4-25. 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- 25. 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- 25. Is check result OK? YES → Replace the hydraulic unit assembly (ABS ECU). NO → Repair or replace the wheel sensor. 9-140 13, 26_ABS
Halaman 474
EAS20688 14, 27_ABS EAS33317 Item Rear wheel sensor (abnormal pulse period) Procedure TIP • If the rear brake ABS operates continuously for 20 seconds or more, DTC No. 27 will be recorded. If the rear brake ABS operates continuously for 36 seconds or more, DTC No. 14 will be recorded. • Vehicle possibly ridden on uneven roads. 1. Foreign material adhered around the rear 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 rear sensor. 2. Incorrect installation of the rear wheel • Check the components for looseness, distortion, and bends. Refer to “CHECKING THE REAR WHEEL” on page 4-30. Is check result OK? YES → Go to step 3. NO → Replace the wheel axle, tire, rear 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 REAR WHEEL SENSOR ROTOR” on page 4-30. Is check result OK? YES → Go to step 4. NO → Replace the sensor rotor. 4. Defective rear 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 REAR WHEEL 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. 9-141 14, 27_ABS
Halaman 475
EAS20662 15_ABS EAS33040 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 sensor coupler “2” brown–brown yellow–yellow 1 2 R B/W W L G r B Y W/L W/B Lg/WB/W Br Y B R/L Y Br Lg/L L/G L/G Is resistance 0 Ω? YES → Go to “Short circuit check”. NO → Replace the wire harness. 9-142 15_ABS
Halaman 476
• 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 “1” and ground brown–ground yellow–ground Lines short circuit check “B” ABS ECU coupler “1” brown–any other coupler terminal yellow–any other coupler terminal Front wheel sensor “2” brown–any other coupler terminal yellow–any other coupler terminal A B 1 R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W 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 4-22 and “ABS (Anti-lock Brake System)” on page 4-58. 9-143 15_ABS 1 2 Br Y B/W W L G r B Y R W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 477
EAS20663 16_ABS EAS33285 Item Rear wheel sensor (open or short circuit) Procedure 1. Defective coupler between the rear 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 rear wheel sensor coupler. • Open circuit check Between ABS ECU coupler “1” and rear wheel sensor coupler “2” green–green blue–blue 1 2 R B/W W L G r B Y W/L W/B Lg/WB/W G L B R/L Y Br Lg/L L/G L/G Is resistance 0 Ω? YES → Go to “Short circuit check”. NO → Replace the wire harness. 9-144 16_ABS
Halaman 478
• 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 “1” and ground green–ground blue–ground Lines short circuit check “B” ABS ECU coupler “1” green–any other coupler terminal blue–any other coupler terminal Rear wheel sensor “2” green–any other coupler terminal blue–any other coupler terminal A B 1 R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W Is resistance ∞ Ω? YES → Go to step 3. NO → Replace the wire harness. 3. Defective rear 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 “REAR WHEEL” on page 4-29 and “ABS (Anti-lock Brake System)” on page 4-58. 9-145 16_ABS 1 2 G L B/W W L G r B Y R W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 479
EAS20708 17, 45_ABS EAS33372 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 4-25. 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- 25. 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- 25. Is check result OK? YES → Replace the hydraulic unit assembly (ABS ECU). NO → Repair or replace the wheel sensor. 9-146 17, 45_ABS
Halaman 480
EAS20709 18, 46_ABS EAS33373 Item Rear 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. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 46 will be recorded first and DTC No. 18 will be recorded if the condition continues. 1. Foreign material adhered around the rear 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 rear wheel • Check the components for looseness, distortion, and bends. Refer to “CHECKING THE REAR WHEEL” on page 4-30. Is check result OK? YES → Go to step 3. NO → Replace the wheel axle, tire, rear 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 REAR WHEEL SENSOR ROTOR” on page 4-30. Is check result OK? YES → Go to step 4. NO → Replace the sensor rotor. 4. Defective rear 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 REAR WHEEL 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. 9-147 18, 46_ABS
Halaman 481
EAS20690 21_ABS EAS33320 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 4-58. 9-148 21_ABS
Halaman 482
EAS20691 31_ABS EAS33321 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 8-36. 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 coupler “2” red–red Lg/WB/W 1 2 Is resistance 0 Ω? YES → Go to “Short circuit check”. NO → Replace the wire harness. 9-149 31_ABS R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G
Halaman 483
• 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 B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W 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 4-58. 9-150 31_ABS R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 484
EAS20712 32_ABS EAS33376 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 4-58. 9-151 32_ABS
Halaman 485
EAS20692 33_ABS EAS33322 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 8-36. 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 coupler “2” red/blue–red/blue Lg/WB/W 1 2 Is resistance 0 Ω? YES → Go to “Short circuit check”. NO → Replace the wire harness. 9-152 33_ABS R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G
Halaman 486
• 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 B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W 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 4-58. 9-153 33_ABS R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 487
EAS20693 34_ABS EAS33323 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 4-58. 9-154 34_ABS
Halaman 488
EAS20694 41_ABS EAS33331 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- 25. 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 4-25 and “CHECKING THE FRONT BRAKE DISC” on page 4-38. 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 4-38. 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 4-58. 9-155 41_ABS
Halaman 489
EAS20695 42, 47_ABS EAS33324 Item Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization) Procedure 1. Incorrect installation of the rear wheel sensor (DTC No. 42) • Check the components for looseness, distortion, and bends. Refer to “MAINTENANCE OF THE REAR WHEEL 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 rear wheel • Check that there is no brake disc drag on the rear wheel and make sure that it rotates smoothly. Refer to “CHECKING THE REAR WHEEL” on page 4-30 and “CHECKING THE REAR BRAKE DISC” on page 4-51. Is check result OK? YES → Go to step 3. NO → Repair or replace the defective part. 3. Rear brake dragging • Check that the brake fluid pressure is correctly transmitted to the brake caliper when the rear brake lever is operated and that the pressure decreases when the lever is released. Refer to “CHECKING THE REAR BRAKE DISC” on page 4-51. 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 4-58. 9-156 42, 47_ABS
Halaman 490
EAS20696 43_ABS EAS33330 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 4-25. 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- 25. 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- 25. Is check result OK? YES → Replace the hydraulic unit assembly (ABS ECU). NO → Repair or replace the wheel sensor. 9-157 43_ABS
Halaman 491
EAS20697 44_ABS EAS33325 Item Rear wheel sensor (missing pulses) Procedure 1. Foreign material adhered around the rear 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 rear wheel • Check the components for looseness, distortion, and bends. Refer to “CHECKING THE REAR WHEEL” on page 4-30. Is check result OK? YES → Go to step 3. NO → Replace the wheel axle, tire, rear 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 REAR WHEEL SENSOR ROTOR” on page 4-30. Is check result OK? YES → Go to step 4. NO → Replace the sensor rotor. 4. Defective rear 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 REAR WHEEL 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. 9-158 44_ABS
Halaman 492
EAS20698 51, 52_ABS EAS33326 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. 9-159 51, 52_ABS
Halaman 493
EAS20699 53_ABS EAS33327 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 coupler “2” brown 2 1 Is resistance 0 Ω? YES → Go to “Short circuit check”. NO → Replace the wire harness. 9-160 53_ABS R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 494
• 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 A B 2 R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W 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. 9-161 53_ABS 2 R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 495
EAS20711 54_ABS EAS33375 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 coupler “3” brown Between ABS motor fuse holder “2” and ABS ECU coupler “3” red/blue–red/blue 1 2 Is resistance 0 Ω? YES → Go to “Short circuit check”. NO → Replace the wire harness. 9-162 54_ABS 3 R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 496
• 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 “3” and ground brown–ground red/blue–ground Lines short circuit check “B” ABS ECU coupler “3” brown–any other coupler terminal red/blue–any other coupler terminal A 3 3 R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W 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 4-58. 9-163 54_ABS B R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 497
EAS20700 55_ABS EAS33328 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 4-58. 9-164 55_ABS
Halaman 498
EAS20701 56_ABS EAS33329 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 4-58. 9-165 56_ABS
Halaman 499
EAS20703 63_ABS EAS33334 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” Between front wheel sensor coupler “1” and ground brown–ground yellow–ground Lines short circuit check “B” Front wheel sensor coupler “1” brown–any other coupler terminal yellow–any other coupler terminal ABS ECU coupler “2” brown–any other coupler terminal yellow–any other coupler terminal A B Br Y Br Y 1 2 1 Is resistance ∞ Ω? YES → Go to step 2. NO → Replace the wire harness. 9-166 63_ABS R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 500
2. Defective front wheel sensor Ground short circuit check “A” Between front wheel sensor “1” and ground white–ground black–ground Lines short circuit check “B” Front wheel sensor “1” white–any other coupler terminal black–any other coupler terminal A B 1 1 W B W B 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 4-58. 9-167 63_ABS
Halaman 501
EAS20704 64_ABS EAS33335 Item Rear 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” Between rear wheel sensor coupler “1” and ground green–ground blue–ground Lines short circuit check “B” Rear wheel sensor coupler “1” green–any other coupler terminal blue–any other coupler terminal ABS ECU coupler “2” green–any other coupler terminal blue–any other coupler terminal A B G L G L 1 2 1 Is resistance ∞ Ω? YES → Go to step 2. NO → Replace the wire harness. 9-168 64_ABS R B/W W L G r B Y W/L W/B B R/L Y Br Lg/L L/G L/G Lg/WB/W
Halaman 502
2. Defective rear wheel sensor Ground short circuit check “A” Between rear wheel sensor coupler “1” and ground white–ground black–ground Lines short circuit check “B” Rear wheel sensor coupler “1” white–any other coupler terminal black–any other coupler terminal A B 1 1 W B W B 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 4-58. 9-169 64_ABS
Halaman 503
EAS20091 WIRING DIAGRAM 55.Starter generator 56.Front wheel sensor 57.Rear wheel sensor 58.Joint 4 59.ABS ECU 60.Meter assembly 61.Multi-function meter 62.ABS warning light 63.High beam indicator light 64.Smart key system indicator light 65.Turn signal indicator light (left) 66.Turn signal indicator light (right) 67.Engine trouble warning light 68.Stop and Start System indica- tor light 69.Traction control system indica- tor light 70.Notification indicator light 1 71.Notification indicator light 2 72.Frame ground 73.Engine ground 74.License plate light 75.Tail/brake light assembly 76.Taillight 77.Brake light 78.Front turn signal light (left) 79.Front turn signal light (right) 80.Rear turn signal light (left) 81.Rear turn signal light (right) 82.Headlight assembly 83.Headlight control unit 84.High beam 85.Low beam 86.Auxiliary light GPD155-A 2022 1. Battery 2. ABS solenoid fuse 3. ABS motor fuse 4. Smart key system fuse 5. Terminal fuse 6. Signaling system fuse 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 14.Request switch 15.Main switch solenoid 16.Auxiliary DC jack 17.DC outlet 18.Smart unit 19.Buzzer 20.Horn 21.Diode 22.Handlebar switch (left) 23.Menu switch 24.Horn switch 25.Dimmer switch 26.Turn signal switch 27.Handlebar switch (right) 28.Start switch 29.Stop and Start System switch 30.Hazard switch 31.Main relay 32.Yamaha diagnostic tool cou- pler 33.Front brake light switch 34.Rear brake light switch 35.Starter charge relay 36.Sidestand switch 37.Joint 1 38.Injector 39.Joint 2 40.Joint 3 41.Fuel pump 42.Fuel sender 43.SGCU (starter generator con- trol unit) 44.Ignition coil 45.Spark plug 46.ISC (idle speed control) unit 47.Throttle body sensor assembly 48.Intake air pressure sensor 49.Intake air temperature sensor 50.Throttle position sensor 51.Crankshaft position sensor 52.Coolant temperature sensor 53.VVA (variable valve actuator) solenoid 54.O2 sensor EAS30613 COLOR CODE B Black Br Brown Ch Chocolate Dg Dark green G Green Gy Gray L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B/L Black/Blue B/R Black/Red B/W Black/White B/Y Black/Yellow Br/R Brown/Red Br/W Brown/White G/B Green/Black G/R Green/Red G/W Green/White G/Y Green/Yellow Gy/G Gray/Green Gy/R Gray/Red L/B Blue/Black L/R Blue/Red L/W Blue/White L/Y Blue/Yellow P/B Pink/Black P/L Pink/Blue P/W Pink/White R/B Red/Black R/G Red/Green R/L Red/Blue R/W Red/White R/Y Red/Yellow Sb/W Sky blue/White W/R White/Red W/Y White/Yellow Y/B Yellow/Black Y/G Yellow/Green Y/L Yellow/Blue Y/R Yellow/Red Y/W Yellow/White
