B3L-28197-20 Yamaha YZF R1 2020 Service Manual EU

2020
SERVICE MANUAL
YZF-R1
YZF-R1M
YZF1000L
YZF1000
YZF1000DL
YZF1000D
B3L-28197-20
EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic instructions that
must be observed during servicing.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION

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

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

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
EAS20002
YZF1000L/YZF1000/YZF1000DL/YZF1000D
SERVICE MANUAL
©2020 by Yamaha Motor Co., Ltd.
First edition, October 2019
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. 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.
1
2
4
5
6 7
G088877
EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

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

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

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

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

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
GLOSSARY............................................................................................... 1-2
DISPLAY ...................................................................................................1-2
MENU SCREEN ........................................................................................1-6
BASIC SERVICE INFORMATION.................................................................1-20

ELECTRICAL SYSTEM...........................................................................1-20
SPECIAL TOOLS .......................................................................................... 1-21

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.
1-1
FEATURES
EAS20008
TIP
FEATURES
This model uses a thin-film-transistor liquid-crys-
EAS31706 tal display (TFT LCD) for good contrast and
GLOSSARY readability in various lighting conditions. Howev-
ABS - Anti-lock Brake System er, due to the nature of this technology, it is nor-
ABS ECU - Anti-lock Brake System Electronic mal for a small number of pixels to be inactive.
Control Unit
BC - Brake Control
CCU - Communication Control Unit STREET MODE
EBM - Engine Brake Management 1 2 3 4 5
ECU - Engine Control Unit LCS QS LIF 2 GPS 10 : 00
ERS - Electronic Racing Suspension 1000 r/min
6
GPS - Global Positioning System 7
IMU - Inertial Measurement Unit 13
LCS - Launch Control System km/h 8
LIF - Lift Control System 12
TRIP-1
ODO
1234.5 km
123456 km 1 N 2 9
PWR - Power delivery mode MODE-A PWR 1 TCS 3 SCS 2 EBM 1 T-2
QS - Quick Shift 11 10
QSS - Quick Shift System
SC - Stability Control 1. YRC items LCS/QS/LIF/BC
SCS - Slide Control System 2. Speedometer
SCU - Suspension Control Unit 3. GPS indicator (CCU-equipped models)
TCS - Traction Control System 4. Logging indicator (CCU-equipped models)
YRC - Yamaha Ride Control 5. Clock
6. Revolution peak hold indicator
EAS31707
7. Front brake pressure indicator
DISPLAY
8. Acceleration indicator
The display has two different main screen dis-
9. Transmission gear display
play modes, STREET MODE and TRACK
10. ERS indicator (YZF-R1M)
MODE. Most of the functions are viewable in ei-
11. YRC items MODE/PWR/TCS/SCS/EBM
ther mode, but the layout differs slightly. The fol-
12. Information display
lowing items can be found on the display.
13. Tachometer
• Speedometer
• Tachometer
• Information display TRACK MODE
• Transmission gear display
• Front brake pressure indicator 1 2 3 4 5
10 : 00
• Acceleration indicator LCS QS
1000 r/min
LIF 2 GPS
• YRC setting display MODE/PWR/TCS/SCS/

EBM 11 LATEST GEAR
12 34 12
• YRC setting display LCS/QS/LIF/BC
• ERS indicator (YZF-R1M)
• GPS indicator (CCU-equipped models)
10
LAP
123
01
MODE-A PWR
123456
km/h
1
ODO
TCS 3 SCS 2 EBM

km
1
NT-2
6
7
• Logging indicator (CCU - equipped models)

• Clock 9 8
• Revolution peak hold indicator 1. YRC items LCS/QS/LIF/BC
• Lap timer 2. Lap timer
• Various warning icons 3. GPS indicator (CCU-equipped models)
• Error mode warning “Err” 4. Logging indicator (CCU-equipped models)
5. Clock
6. Transmission gear display
7. Information display
8. ERS indicator (YZF-R1M)
1-2
FEATURES
9. YRC items MODE/PWR/TCS/SCS/EBM TIP

10. Speedometer • ODO will lock at 999999 and cannot be reset.
11. Tachometer • TRIP-1 and TRIP-2 will reset to 0 and begin
EWA18210 counting again after 9999.9 has been reached.
WARNING • When the fuel tank reserve level has been
Stop the vehicle before making any setting reached, F-TRIP appears automatically and
changes. Changing settings while riding can begins recording distance traveled from that
distract the operator and increase the risk of point.
an accident. • After refueling and traveling some distance, F-
TRIP will automatically disappear.
Speedometer • Refer to ““Unit”” on page 1-13 to change the
The speedometer shows the vehicle’s traveling fuel consumption units.
speed. • The air temperature displayed may vary from
the actual ambient temperature.
TIP
• In TRACK MODE, information display items
The display can be switched between kilometers FASTEST (fastest lap time) and AVERAGE
and miles. (Refer to ““Unit”” on page 1-13.) (average lap time) are also available.
Tachometer
TRIP-1, TRIP-2, F-TRIP, FUEL CON, and FUEL
The tachometer shows the engine speed, as AVE items can be individually reset.
measured by the rotational velocity of the crank-
shaft, in revolutions per minute (r/min). [To reset information display items]
TIP 1. Use the wheel switch to scroll through the dis-
• In TRACK MODE, the tachometer starts at play items until the item you want to reset ap-
8000 r/min. pears.
• In STREET MODE, the tachometer can be col- 2. Short push the wheel switch and the item will
or-adjusted and has a revolution peak hold in- flash for five seconds. (For STREET MODE,
dicator which can be turned on or off. if both items are resettable items, the top item
ECA19660 will flash first. Scroll down to select the bot-
NOTICE tom item.)
Do not operate the engine in the tachometer 3. While the item is flashing, press and hold the
red zone. wheel switch for one second.
Transmission gear display

Information display This shows which gear the transmission is in.
This section of the main screen is used to show This model has 6 gears and a neutral position.
additional riding related information such as air The neutral position is indicated by the neutral
and coolant temperature readings, tripmeters, indicator light “ ” and by the transmission gear
and fuel consumption statistics. The information display “ ”.
display items can be set into four groups via the
MENU screen. Front brake pressure indicator
The information display items are: This shows how much braking power is being
A.TEMP: air temperature applied to the front brakes.
C.TEMP: coolant temperature
TRIP-1: tripmeter 1 Acceleration indicator
TRIP-2: tripmeter 2 This shows the vehicle’s forward acceleration
F-TRIP: fuel tripmeter and deceleration forces.
ODO: odometer
FUEL CON: the amount of fuel consumed Revolution peak hold indicator
FUEL AVG: average fuel consumption This small bar momentarily appears within the
CRNT FUEL: current fuel consumption tachometer to mark the most recent peak engine
speed.
1-3
FEATURES
YRC items MODE/PWR/TCS/SCS/EBM • When a YRC item is highlighted but cannot be

The current MODE (YRC mode) and its related adjusted, the YRC item box will return to black.
PWR, TCS, SCS, and EBM settings are shown
here.
The individual settings for YRC items PWR,
TCS, SCS, LCS, QSS, LIF, EBM, and BC can LCS QS LIF 2 MODE-A GPS : 00 -A
10MODE
be organized into four groups and set inde- 1000 r/min
pendently for each group. These groups of set- GEAR

LATEST
tings are the YRC modes MODE-A, MODE-B,
12 34 12
MODE-C, and MODE-D. Use the mode switch
to change YRC modes or make YRC item set-
ting changes from the main screen.
LAP
123
01
MODE-A PWR
123456
km/h
1
ODO
TCS 3 SCS 2 EBM

km
1
NT-2
TIP To turn off the traction control system select TCS

The YRC modes come preset from the factory with the center button, then push and hold the up
for different riding conditions. button until TCS OFF is displayed. To turn TCS
When using the factory presets, the suggested back on, select TCS OFF and then press the
YRC modes are as follows. down button (TCS will return to its previous set-
MODE-A: suitable for track riding ting).
MODE-B: softer track-riding setting TIP
MODE-C: suitable for road use
Turning off the traction control system will turn
MODE-D: street use or rainy weather
off the SCS, LCS, and LIF systems for all YRC
modes.
[To change YRC modes or make setting
changes]
YRC items LCS/QS/LIF/BC
1. Push the mode switch center button to scroll
The on/off status of YRC items LCS, QSS, LIF,
left to right and highlight the item you want to
and BC is shown here. When any of these sys-
adjust.
tems are registered (not set to OFF) for the cur-
rently selected YRC mode, its respective icon
2 will appear.
When LCS is registered for the currently select-
3 ed YRC mode, its icon will be grey. To activate
4 the launch control system, press and hold the
center button until the LCS icon stops flashing
1 and turns white.
TIP
LCS, QSS, LIF, and BC system setting levels
1. Mode switch “MODE” can only be adjusted from the MENU screen.
2. Up button
3. Center button ERS indicator (YZF-R1M)
4. Down button This icon shows the current ERS mode. (Refer
2. Use the mode switch up button or down but- to ““YRC Setting”” on page 1-7 and
ton to change the selected item value (verti- “ERS (YZF-R1M)” on page 1-10 to change the
cal scrolling is not possible). registered ERS mode or adjust ERS setting lev-
TIP els.) If the ERS mode disappears from the ERS
indicator (the icon turns blank), stop the vehicle
• When the malfunction indicator light is on, YRC
and wait a few seconds until the mode reap-
settings cannot be adjusted.
pears.
• When a YRC function is actively engaged that
item cannot be adjusted. For example, when TIP
decelerating EBM cannot be adjusted. • The suspension will remain fixed at its most re-
cent settings until self-reset has completed.
1-4
FEATURES
• If the ERS indicator does not return to normal. [To use the lap timer]
(Refer to “ELECTRONICALLY ADJUSTABLE 1. Short push the wheel switch. The information
SUSPENSION SYSTEM (for YZF-R1M)” on display item will flash for five seconds.
page 9-37.) 2. While the information display item is flashing,
rotate the wheel switch upward. The lap timer
GPS indicator (CCU-equipped models) will flash for five seconds.
This icon comes on when a GPS unit is synched 3. While the lap timer is flashing, long push the
with your vehicle. wheel switch to activate the lap timer or stop
the lap timer.
Logging indicator (CCU-equipped models) 4. When the lap timer has been activated, press
This icon comes on when vehicle data is being the Pass/LAP switch to start the lap timer.
recorded via the logging function. TIP
• The engine must be running to use the lap tim-
Clock er.
The clock uses a 12-hour time system. • Set the information display to FASTEST or AV-
ERAGE for additional lap time information.
Lap timer • Accessing the MENU screen will automatically
This stopwatch function measures and records stop the lap timer.
up to forty laps. On the main screen, the lap tim- • Whenever the lap timer is stopped, the current
er shows the current lap time and lap number lap will not be recorded.
(indicated by the LAP mark). Use the Pass/LAP • The lap time record can be viewed and reset
switch to mark lap times. When a lap is complet- from the MENU screen.
ed, the lap timer will show the latest lap time
(marked by the LATEST indicator) for five sec-
Warning icons
onds.
1
LCS QS LIF 2 GPS 10 : 00 1 2 3 4 5
1000 r/min
LATEST GEAR
2
12 34 12 Er r
4 LAP
123
01
MODE-A PWR
123456
km/h
1
ODO
TCS 3 SCS 2 EBM

km
1
NT-2
1000 r/min
3
1. SCU trouble warning “ ”
1. Lap time
2. Auxiliary system warning “ ”
2. Latest lap time indicator “LATEST”
3. Coolant temperature warning “ ”
3. Information display item
4. Lap number 4. Oil pressure warning “ ”
5. Error mode warning “Err”
When an error is detected, the following error-re-
lated warning icons will then be viewable.
SCU trouble warning (YZF-R1M)

This icon appears if a problem is detected in the
front or rear suspension.
Auxiliary system warning

This icon appears if a problem is detected in a
non-engine-related system.
1-5
FEATURES
Coolant temperature warning EAS31708
MENU SCREEN
This icon appears if the coolant temperature
reaches 117 °C (242 °F) or higher. Stop the ve-
km/h MENU GPS 10 : 00
hicle and turn off the engine. Allow the engine to
cool. Display Mode
ECA10022
YRC Setting
NOTICE
Lap Time
Do not continue to operate the engine if it is Logging
overheating.
Maintenance
Unit
Oil pressure warning
This icon appears when the engine oil pressure The MENU screen contains the following setting
is low. When the main switch is first turned to modules. Select a module to make related set-
ON, engine oil pressure has yet to build, so this ting changes. Although some settings can be
icon will come on and stay on until the engine changed or reset via the main screen, the MENU
has been started. screen offers access to all display and control
TIP settings.
If a malfunction is detected, the oil pressure Module Description
warning icon will flash repeatedly.
Switch the main screen dis-
ECA22790 Display Mode play between street and track
NOTICE modes.
If the warning light comes on when the en- Adjust YRC settings (all mod-
gine is running, stop the engine immediately YRC Setting els) and ERS settings
and check oil level. If the oil level is below the (YZF-R1M).
minimum level, add sufficient oil of the rec- Lap Time View and reset lap times.
ommended type to raise it up to the correct Turn vehicle information log-
level. If the oil pressure warning light re- Logging ging function on/off (CCU-
mains on even if the oil level is correct, im- equipped models).
mediately turn the engine off and check the View and reset three mainte-
Maintenance
vehicle. nance item intervals.
Set fuel consumption and dis-
Unit
Error mode warning tance units.
When an internal error occurs (e.g., communica- Wallpaper Set background colors.
tion with a system controller has been cut off), Turn the shift indicator on/off
the error mode warning will appear as follows. Shift Indicator and adjust tachometer set-
“Err” and “ ” indicates an ECU error. tings.
“Err” and “ ” indicates an SCU error. Set the multi-function display
Display Setting
“Err” only indicates an ABS ECU error. window items.
TIP Brightness Adjust screen brightness.
Depending on the nature of the error, the display Clock Adjust the clock.
may not function properly and YRC settings may Return all settings to factory
be impossible to change. Additionally, ABS may All Reset
default settings.
not function properly. Use extra care when brak-
ing and check the vehicle immediately. MENU access and operation
The following wheel switch operations are com-
mon operations for accessing, selecting, and
moving within the MENU screen and its mod-
ules.
Long push - press and hold the wheel switch for
one second to access the MENU screen or exit
MENU entirely.
1-6
FEATURES
Select - rotate the wheel switch up or down to 3. Long push the wheel switch to exit the MENU
highlight the desired module or setting item and screen or use the wheel switch to select an-
then short push the wheel switch (briefly press other module.
the wheel switch inward) to confirm the selec-
tion. “YRC Setting”
Triangle mark - certain setting screens have an This module allows you to customize the four
upward pointing triangle mark item. Select the YRC modes MODE-A, MODE-B, MODE-C, and
triangle mark to save setting changes made and MODE-D by adjusting the setting levels (or on/
exit that screen. off status as applicable) of YRC items PWR,
TIP TCS, SCS, LCS, QSS, LIF, EBM, and BC. For
• Should vehicle motion be detected, the screen YZF-R1M, you can select the ERS mode to be
will automatically exit MENU and change to the associated with each YRC mode, and also ad-
main screen. just the setting levels of the ERS modes.
• To ensure that the desired setting changes are TIP
saved, be sure to exit via the triangle mark. • TCS has 9 setting levels and ERS has 6
Simply performing a long push and exiting the modes.
MENU screen entirely may not save setting • Whenever there are more selections (setting
changes. levels or modes) available than can be shown
on the screen at one time, a scroll bar will ap-
pear to notify you that additional selections are
“Display Mode”
available by scrolling.
There are two main screen display modes,
STREET MODE and TRACK MODE.
PWR
[To set the main screen display mode] Select PWR-1 for the most aggressive throttle
1. From the MENU screen, select “Display response, PWR-2 and PWR-3 for smoother
Mode”. throttle grip/engine response, and use PWR-4
for rainy days or whenever less engine power is
km/h MENU GPS 10 : 00 desirable.
Display Mode
YRC Setting 2
Lap Time 1 3
Logging 4
Maintenance 5
Unit
2. Select “STREET MODE” or “TRACK MODE”

(or select the triangle mark to exit). 6
1. PWR 1
km/h Display Mode 10 : 00
2. PWR 2
STREET MODE 3. PWR 3
4. PWR 4
TRACK MODE 5. Throttle valve opening
6. Throttle grip operation
TCS
This model uses a variable traction control sys-
tem. For each setting level, the further the vehi-
cle is leaned over, the greater the amount of
traction control (system intervention) is applied.
There are 9 setting levels available. Setting level
1-7
FEATURES
1 applies the least amount of overall system in- tion from the selected YRC mode (the LCS icon
tervention, while setting level 9 applies the great- will not appear and the launch control function
est amount of overall traction control. cannot be activated).
TIP When LCS has been set to level 1 or 2 for the se-
• TCS can only be turned on or off via the main lected YRC mode, the LCS indicator on the main
screen using the mode switch. screen will appear in a grey color to indicate that
• When TCS has been turned off, TCS, SCS, LCS is available. When the launch control sys-
LCS, and LIF will be set to OFF and cannot be tem has been activated (made ready for use via
adjusted. When TCS is turned on again, these the mode switch), the LCS indicator will turn
related-traction control functions will return to white.
their previous setting levels. TIP
LCS works in conjunction with the LIF system.
LCS cannot be used if LIF is turned off.
9
8
7
1 65
4
3 QSS
21
The quick shift system is divided into QS (up-
TCS shift) and QS (downshift) sections. QS
and QS are not linked and can be inde-
pendently turned on or off.
QS can be set to 1, 2, or OFF. Setting level 1
2
is designed for maximum acceleration, while
setting level 2 is designed to give smooth shifts
1. System intervention
at halfway or less throttle openings. OFF turns
2. Lean angle
the respective upshift or downshift function off,
and the clutch lever must then be used when
SCS shifting in that direction.
SCS can be set to OFF, 1, 2, and 3. OFF turns
TIP
the slide control system off, setting level 1 pro-
vides the least amount of system intervention, • Set QS to 1 for track or sporty riding.
and setting level 3 provides the greatest amount • Set QS to 2 for touring or around town-rid-
of system intervention. ing.
LIF
1 3 LIF can be set to 1, 2, 3, or OFF. Setting level 3
2
most strongly reduces wheel lift, and setting lev-
1
el 1 provides the least amount of system inter-
SCS vention. OFF turns LIF off and LCS will be
disabled for the selected YRC mode.
2
1 3
2
1. System intervention 1
2. Sideward slide
LIF
LCS
LCS can be set to 1, 2, or OFF. Setting level 1
keeps engine speed from rising above 9000 r/ 2
min even when the throttle grip is fully turned.
Setting level 2 keeps engine speed from rising 1. System intervention
above 8000 r/min. OFF disables the LCS func- 2. Wheel lift
1-8
FEATURES
EBM 2. The “YRC Setting” screen is displayed, and

The engine brake management system reduces the YRC mode box “YRC” is highlighted.
engine torque when decelerating. The fuel injec- Short push the wheel switch to enter the box
tion, ignition timing, and electronic throttle valve and then select the YRC mode A, B, C or D
are electronically adjusted by the ECU. There that you want to adjust.
are 3 settings to suit the track, riding conditions,
or your personal preference. km/h YRC Setting 10 : 00
A 1 1 1 1 1 ON 1 1 1 T-1
B 2 2 2 2 2 2 2 2 T-2
1 C 3 3 3 3 3 R-1
D 4 4 4 M-1
2
5 OFF OFF OFF OFF OFF M-2
4 3 YRC PWR TCS SCS LCS QS QS LIF EBM BC ERS
1 2 3 4 5
1. Triangle mark
5
2. YRC mode box
1. EBM1 3. YRC item
2. EBM2 4. ERS mode (YZF-R1M)
3. EBM3 5. To ERS menu (YZF-R1M)
4. Engine brake force
3. Select the YRC item PWR, TCS, SCS, LCS,
5. Engine r/min
QS , QS , LIF, EBM, BC, or ERS
(YZF-R1M) that you want to adjust.
BC
Select BC1 when only standard ABS is desired. km/h YRC Setting 10 : 00
Select BC2 to have the brake control system 4 A 1 1 1 1 1 ON 1 1 1 T-1
regulate brake pressure while cornering to sup- B 2 2 2 2 2 2 2 2 T-2
press lateral wheel slip. C 3 3 3 3 3 R-1
TIP 3 D 4 4 4 M-1
For skilled riders and when riding at the track, 5 OFF OFF OFF OFF OFF M-2
due to varying conditions BC2 brake system en- 2 YRC PWR TCS SCS LCS QS QS LIF EBM BC ERS
gagement may come on sooner than expected

relative to your desired cornering speed or in- 1
tended cornering line. 1. YRC item
2. Current level setting
[To customize a YRC mode or adjust a YRC 3. Factory preset level
item] 4. YRC mode
1. From the MENU screen, select “YRC Set-
TIP
ting”.
• When a YRC item is selected, the current set-
km/h MENU GPS 10 : 00 ting level is indicated by a blue-framed square
and the factory preset level is indicated in a
Display Mode
grey box.
YRC Setting
• Factory preset levels vary depending on the
Lap Time selected YRC mode.
Logging
4. To customize other YRC modes or adjust in-
Maintenance
dividual YRC items, repeat from step 2.
Unit When finished, select the triangle mark on
the far left to return to the MENU screen, or
for YZF-R1M select the “ ” mark to fine tune
the ERS mode settings.
1-9
FEATURES
ERS (YZF-R1M) 3. Front overall damping level

4. Rear overall damping level
km/h YRC Setting 10 : 00
5. Factory preset level
1 T- 1
H
-2
H
+2
6. Current level
T- 2 8
For the road mode R-1, the following settings
R- 1 7 can be adjusted:
S S BRAKE SUPPORT: reduces nosedive (front-
SETTING
BRAKE CORNER ACCEL
SUPPORT SUPPORT SUPPORT
FRONT
FIRM
REAR
FIRM
end pitch from braking)
FRONT FIRM: hardens “H” or softens “S” overall
2 3 4 5 6 damping of the front suspension
REAR FIRM: hardens “H” or softens “S” overall
1. ERS mode damping of the rear suspension
2. Braking support level
TIP
3. Cornering support level
4. Acceleration support level • T-1 is preset for track use with racing slick tires.
5. Front overall damping level • T-2 is preset for track use with street tires.
6. Rear overall damping level • R-1 is preset for road use with street tires.
8. Current level km/h YRC Setting 10 : 00
The ERS consists of three semi-active automat- 1 M-1 8 18 22 22 7

M-2
ic modes (T-1, T-2, R-1) and three manual set- M-3
ting modes (M-1, M-2, M-3). When an automatic
mode is selected, the SCU will adjust the com-
pression and rebound damping forces based on 6
SETTING Fr COM Fr REB Rr COM Rr REB
running conditions. For all modes and models,
spring preload is physically adjusted by hand. 2 3 4 5
For track modes T-1 and T-2, the following set-
tings can be adjusted: 1. ERS mode
BRAKE SUPPORT: reduces nosedive (front- 2. Front compression damping force
end pitch from braking) 3. Front rebound damping force
CORNER SUPPORT: increases damping to ab- 4. Rear compression damping force
sorb chassis fluctuations for smooth cornering. 5. Rear rebound damping force
Reduce this setting for increased rear wheel 6. Factory preset level
grip. 7. Current level setting
ACCEL SUPPORT: reduces rear-end squat For the manual setting modes M-1, M-2, and M-
(rear-end pitch due to acceleration) 3, the following settings can be adjusted:
FRONT FIRM: hardens “H” or softens “S” overall Fr COM: front compression damping
damping of the front suspension Fr REB: front rebound damping
REAR FIRM: hardens “H” or softens “S” overall Rr COM: rear compression damping
damping of the rear suspension Rr REB: rear rebound damping
TIP
T- 1 -2 +2
• M-1 is preset for track use with racing slick
H H
T- 2
tires.
6 • M-2 is preset for track use with street tires.
1 R- 1
5 • M-3 is preset for street use with street tires.
S S
BRAKE FRONT REAR
SETTING
SUPPORT FIRM FIRM
2 3 4
1. ERS mode
1-10
FEATURES
[To adjust the ERS mode settings] 4. To adjust other ERS modes of the same type,
repeat from step 1. To switch types or when
finished, select the “ ” mark to return to the
A 1 1 1 1 1 ON 1 1 1 T-1
main “YRC Setting” menu.
B 2 2 2 2 2 2 2 2 T-2 3
C 3 3 3 3 3 R-1 “Lap Time”
D 4 4 4 M-1 This module allows you to view and delete the
2
5 OFF OFF OFF OFF OFF M-2
lap time record. The fastest lap and the average
YRC PWR TCS SCS LCS QS QS LIF EBM BC ERS lap time stored in the lap time record are dis-
played at the top of the screen. Use the wheel
1 switch to scroll and see all lap times. The top
1. To ERS menu three fastest laps will be highlighted in silver. Up
2. Manual modes to 40 laps can be stored in memory. If more than
3. Automatic modes 40 laps are recorded, the oldest laps (starting
from lap 1) will be overwritten.
TIP
The ERS setting menu is divided into automatic km/h MENU GPS 10 : 00
and manual setting modes, and the two types Display Mode
are accessed separately. Before moving to the YRC Setting
ERS setting menu, make sure the current ERS
Lap Time
mode corresponds to the same type (automatic
or manual) that you want to adjust. Logging
Maintenance
1. Select the “ ” mark located to the right of
Unit
ERS.
2. The display will change to the relevant sus-
This module has two options. “Display” allows
pension setting screen and the ERS mode
you to view the lap time record. “Reset” allows
selection box “SETTING” is highlighted.
you to delete the lap time record data.
Short push the wheel switch to enter the box
and select the ERS mode that you want to
km/h Lap Time 10 : 00
adjust.
Display
M-1 8 18 22 22 4 Reset
M-2
M-3
SETTING Fr COM Fr REB Rr COM Rr REB
[To view the lap time record data]

1 2 3 1. Select “Display”.
1. To YRC Setting menu
km/h Lap Time 10 : 00
2. ERS mode selection box “SETTING”
3. Factory preset level Display

Reset
3. Select the suspension item that you want to
adjust, and then rotate the wheel switch to
adjust the setting level.
TIP
All ERS modes regardless of type are indepen-
dent. Offset level setting changes made in one
mode are not transferred to another mode.
1-11
FEATURES
[To start and stop logging]

Lap Time GPS
GP 10 : 00
1. From the MENU screen, select “Logging”.
km/h
1 FASTEST / LAP 12 02:34.56 km/h MENU GPS 10 : 00

2 AVERAGE 02:53.00
Display Mode
3 LAP 1 02:54.56
YRC Setting
LAP 2 02:55.20
Lap Time
LAP 3 02:56.04
Logging
LAP 4 02:56.80
Maintenance
Unit
1. Fastest lap
2. Average lap time
3. Lap time record TIP
If a CCU is not installed, then the “Logging” mod-
[To reset the lap time record data] ule cannot be selected.
1. Select “Reset”.
2. Select “START” to start logging.
km/h Lap Time 10 : 00 TIP
The arrow of the logging indicator is displayed in
Display
green.
Reset 1
km/h Logging GPS 10 : 00
START
STOP
2. Select “YES” to delete all lap time data. (Se-
lect “NO” to exit and return to the previous
screen without resetting the lap record.)
km/h Lap Time GPS

GP 10 : 00
1. Logging indicator
Reset ?
3. To stop the “Logging” function, select “STOP”
or turn the vehicle off.
NO
km/h Logging GPS 10 : 00

YES
START
STOP
“Logging” (for CCU-equipped models)
Vehicle and riding information can be recorded
(logged) and this data can be accessed with a
smart device. (Refer to “CONNECTING TO THE
CCU (for YZF-R1M)” on page 4-8.)
TIP
The logging function will also start automatically
when you start off.
1-12
FEATURES
“Maintenance” [To set the distance or fuel consumption

This module allows you to record distance trav- units]
eled between engine oil changes (use the OIL 1. From the MENU screen, select “Unit”.
item), and for two other items of your choice (use
INTERVAL 1 and INTERVAL 2). km/h MENU GPS 10 : 00
Display Mode
[To reset a maintenance item]
YRC Setting
1. From the MENU screen, select “Mainte-
Lap Time
nance”.
Logging
km/h MENU GPS 10 : 00 Maintenance
Display Mode Unit
YRC Setting
2. Select the distance or consumption unit item
Lap Time
you want to adjust.
Logging
Maintenance km/h Unit GPS
GP 10 : 00
Unit
km or mile km
2. Select the item you want to reset.

km/L or L/100km km/L
km/h Maintenance GPS 10 : 00
OIL 123456 km
INTERVAL 1 123456 km
TIP
When “km” is selected, “km/L” or “L/100km” can
be set as the fuel consumption units. To set the
fuel consumption units, proceed as follows. If
“mile” is selected, skip step 3.
3. Long push the wheel switch to reset the item.
3. Select the units you want to use.
km/h Maintenance GPS 10 : 00
km/h Unit GPS
GP 10 : 00
OIL 0 km
km or mile km
km/L or L/100km km/L
TIP
4. Select the triangle symbol to exit.
Maintenance item names cannot be changed.
“Wallpaper”
“Unit” This module allows you to individually set the
This module allows you to switch the display be- STREET MODE and TRACK MODE display
tween kilometers and miles. background colors to black or white for both day
When using kilometers, the fuel consumption and night settings. A photo sensor equipped in
units can be changed between km/L or L/ the instrument panel detects lighting conditions
100km. When using miles, MPG will be avail- and will automatically change the display be-
able. tween its day and night settings. The photo sen-
1-13
FEATURES
sor also controls a subtle automatic brightness 4. Select the triangle symbol to exit.
adjustment function within both day and night 5. To set another background color, repeat from
modes to suit ambient light conditions. step 2 or select the triangle symbol to exit this
module.
“Shift indicator”
The shift indicator module contains the following
1
modules.
Module Description
Set the shift indicator pattern
to “ON”, “Flash”, or “OFF” and
Shift IND Setting
adjust at what r/min the indi-
cator will come on and go off.
1. Photo sensor Shift IND Bright- Adjust the brightness of the
ness shift indicator.
[To set the wallpaper] Set the tachometer color dis-
1. From the MENU screen, select “Wallpaper”. play to “ON” or “OFF” and ad-
Tach IND Setting just at what r/min the
GP
tachometer will be green and
orange.
Logging
Peak Rev IND Set the tachometer peak rev
Maintenance Setting indicator to “ON” or “OFF”.
Unit
Wallpaper
GP
Shift Indicator
Maintenance
Display Setting
Unit
2. Select the mode you want to adjust (select Wallpaper

DAY for daytime display settings or NIGHT Shift Indicator
for nighttime display settings). Display Setting
Brightness
km/h Wallpaper GPS 10 : 00
GP
STREET MODE (day)

[To make setting changes]
STREET MODE (night) 1. Select “Shift IND Setting”.
TRACK MODE (day)
TRACK MODE (night) km/h Shift Indicator GPS 10 : 00
GP
Shift IND Setting

Shift IND Brightness
Tach IND Setting
3. Select the background color (select “BLACK”
Peak Rev IND Setting
for a black background or “WHITE” for a
white background).
km/h Wallpaper GPS

GP 10 : 00
STREET MODE (day)

BLACK
WHITE
1-14
FEATURES
2. Select “IND Mode”. tional range is 8500–15000 r/min.

TIP
Shift Indicator GPS 10 : 00
km/h
1000 r/min
The blue area on the tachometer indicates the
currently set operational range of the shift indica-
Shift IND Setting
tor light.
IND Mode ON
IND Start 10000 r/min “Shift IND Brightness”
IND Stop 15000 r/min The shift timing indicator light has six brightness
levels.
3. Select “ON” to have the indicator light steadi- km/h Shift Indicator GPS 10 : 00
GP
ly, “OFF” to turn the indicator off, or “Flash” to Shift IND Setting
have the shift indicator flash when the indica- Shift IND Brightness
tor start threshold has been reached. Tach IND Setting
km/h Shift Indicator GPS 10 : 00
1000 r/min
Shift IND Setting

IND Mode ON Select “Shift IND Brightness”, then use the
IND Start 10000 r/min wheel switch to adjust the setting. Short push
IND Stop 15000 r/min the wheel switch to confirm the setting and exit.
4. Select “IND Start”. Shift IND Brightness

1000 r/min
3
Shift IND Setting
IND Mode ON
IND Start 10000 r/min
IND Stop 15000 r/min

“Tach IND Setting”
This module allows you to turn the tachometer
color display on or off. When turned off, the ta-
5. Rotate the wheel switch to adjust the r/min at chometer will display all r/min levels below the
which the shift timing indicator light will come red zone in black or white (depending on wallpa-
on. “IND Start” operational range is 8000– per settings). When turned on, the mid and mid-
14800 r/min. to-high r/min zones can be set to come on in
green and then orange colors.
km/h
1. Select “Tach IND Setting”.
1000 r/min

GP
Shift IND Setting
IND Mode ON Shift IND Setting
IND Start 10000 r/min Shift IND Brightness
IND Stop 15000 r/min Tach IND Setting
6. Select “IND Stop” then rotate the wheel

switch to adjust the r/min at which the shift
timing indicator will go off. “IND Stop” opera-
1-15
FEATURES
2. Select “IND Mode”. TIP

Green bar start setting range: 8000–10000 r/
km/h
1000 r/min
min.
6. Select “Tach IND 2nd”.
Tach IND Setting
IND Mode ON km/h Shift Indicator GPS 10 : 00
Tach IND 1st 8000 r/min 1000 r/min
Tach IND 2nd 11000 r/min

Tach IND Setting
IND Mode ON
Tach IND 1st 8000 r/min
3. Select ON to turn the tachometer color dis-
play mode on (or select OFF to turn this func-
tion off).
km/h Shift Indicator GPS 10 : 00 7. Set the orange color starting r/min by rotating
1000 r/min and then short pushing the wheel switch. All
r/min above this figure until the 14000 r/min
Tach IND Setting red zone, will be displayed in orange.
IND Mode ON
TIP
Orange bar start setting range: 8000–14000 r/
Tach IND 2nd 11000 r/min min.

4. Select “Tach IND 1st” to set the green zone 1000 r/min
starting r/min.
Tach IND Setting
IND Mode ON
1000 r/min
Tach IND Setting Tach IND 2nd 11000 r/min
IND Mode ON
Tach IND 2nd 11000 r/min 8. Select the triangle symbol to exit.
“Peak Rev IND Setting”

This module allows you to turn the revolution
5. Set the starting r/min by rotating and then
peak hold indicator on or off.
short pushing the wheel switch. All r/min
1. Select “Peak Rev IND Setting”.
above this value up to the “Tach IND 2nd”
setting value (or the 14000 r/min red zone),
GP
will be displayed in green.
Shift IND Setting
km/h Shift Indicator GPS 10 : 00 Shift IND Brightness
1000 r/min
Tach IND Setting
Tach IND Setting
IND Mode ON
1-16
FEATURES
2. Select “IND Mode” and then select ON (to [To set the display groups]
turn on the indicator) or OFF (to turn off the in- 1. Select “Display Setting”.
dicator).
GP
km/h Shift Indicator GPS
GP 10 : 00
Logging
Peak Rev IND Setting Maintenance
IND Mode ON Unit
Wallpaper
Shift Indicator
Display Setting
2. “DISPLAY-1”, “DISPLAY-2”, “DISPLAY-3”

3. Select the triangle symbol to exit. and “DISPLAY-4” are displayed.
“Display Setting” km/h Display Setting GPS 10 : 00

GP
This module allows you to set how the informa- DISPLAY-1
tion display items (like TRIP-1, ODO, C. TEMP,
DISPLAY-2
etc.) are grouped on the main screen. There are
DISPLAY-3
four display groups.
DISPLAY-4
LCS QS LIF 2 GPS 10 : 00

1000 r/min
3. For example, let’s select “DISPLAY-1”.

km/h 4. Select “STREET MODE 1-1”.
1
TRIP-1
ODO
MODE-A PWR
1234.5 km
123456 km
1 TCS 3
1
SCS
N22 EBM 1 T-2
km/h Display Setting GPS 10 : 00
DISPLAY-1
STREET MODE 1-1 A.TEMP

1. Information display item (STREET MODE)
STREET MODE 1-2 C.TEMP
TRACK MODE C.TEMP
LCS QS LIF 2 GPS 10 : 00

1000 r/min
GEAR
LATEST
5. Select the desired information display item
12 34 12
LAP
123
01
MODE-A PWR
123456
km/h
1
ODO
TCS 3 SCS 2 EBM

km
1
N T-2
1
with the wheel switch.
km/h Display Setting GPS 10 : 00
DISPLAY-1
STREET MODE 1-1 A.TEMP

1. Information display item (TRACK MODE)
TRACK MODE C.TEMP
TIP
The information display items which can be se-
lected are:
A.TEMP: air temperature
C.TEMP: coolant temperature
1-17
FEATURES
TRIP-1: tripmeter 1 “Clock”

TRIP-2: tripmeter 2 This module allows you to set the clock.
ODO: odometer
FUEL CON: the amount of fuel consumed [To set the clock]
FUEL AVG: average fuel consumption 1. From the MENU screen, select “Clock”.
CRNT FUEL: current fuel consumption
GP
6. Select “STREET MODE 1-2” or “TRACK
MODE” to set the remaining DISPLAY-1 Unit
group items. Wallpaper

Shift Indicator
km/h Display Setting GPS 10 : 00 Display Setting
DISPLAY-1 Brightness
STREET MODE 1-1 A.TEMP Clock

TRACK MODE C.TEMP
2. When “Clock” is selected, the hours figure will
be highlighted.
km/h Clock 10 : 00
7. Select the triangle symbol to exit. To set the
11 : 34
other display groups, repeat from step 3.
“Brightness”
This module allows you to adjust the general
brightness level of the display screen.
[To set the brightness]

1. Select “Brightness”. 3. Set the hour by rotating and then short push
the wheel switch.
GP
km/h Clock 10 : 00
Maintenance
Unit
Wallpaper
Shift Indicator
Display Setting
10 : 34
Brightness
2. Select the desired brightness level by rotating

the wheel switch, and then short push the 4. The minutes figure will become highlighted.
wheel switch to fix the setting.
km/h Clock 10 : 00
km/h Brightness GPS 10 : 00
2
10 : 34
1-18
FEATURES
5. Set the minutes figure by rotating and then

short push the wheel switch.
km/h Clock 10 : 00
10 : 58
6. Short push the wheel switch again to exit and
go back to the MENU screen.
“All Reset”
This module resets everything, except the
odometer and clock, to its factory preset or de-
fault setting.
Select YES to reset all items. After selecting
YES, all items will be reset and the screen will
automatically return to the MENU screen.
1-19
BASIC SERVICE INFORMATION
EAS20010
BASIC SERVICE INFORMATION

EAS30014
ELECTRICAL SYSTEM
Electrical parts handling

ECA22611
NOTICE
• Do not perform angle adjustment of the IMU
and battery box by pinching the washer
and related parts.
• When installing the IMU, apply a thin coat of
silicone grease onto the washer where con-
tacting the IMU grommet.
• When installing the IMU, use only a genuine
bolt and washer, and tighten the bolt to the
specified torque.
• Pay attention not to expose the IMU to
strong shocks, such as striking or drop-
ping it.
• Do not place any foreign objects in and
around the battery box.
• Do not obstruct breather opening “a” of the
IMU.
• Do not clean the breather opening and do
not blow it with compressed air.
• When replacing the collar or grommet, re-
place all four collars and grommets.
1-20
SPECIAL TOOLS
EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
• For U.S.A. and Canada, use part numbers starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part numbers starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB 3-4, 3-12, 4-80,
90890-03267 4-81, 9-2, 9-31,
9-32
Yamaha diagnostic tool (A/I) 3-4, 3-12, 4-80,

90890-03264 4-81, 9-2, 9-31,
9-32
Thickness gauge 3-6, 3-7, 3-7, 3-7,

90890-03268 4-42, 4-51, 5-33,
Feeler gauge set 5-64
YU-26900-9
Vacuum gauge 3-10

90890-03094
Vacuummate
YU-44456
YU-44456
Carburetor angle driver 2 3-10

90890-03173
Steering nut wrench 3-20, 4-110

90890-01403
Exhaust flange nut wrench
YU-A9472
1-21
SPECIAL TOOLS
Reference
pages
Oil filter wrench 3-30
90890-01426
Oil filter wrench
YU-38411
Oil pressure gauge joint 18 mm 3-31

90890-04176
YU-04176
ø18
Oil pressure gauge set 3-31

90890-03120
Vacuum/pressure pump gauge set 4-30

90890-06945
Pressure/ vacuum tester
YB-35956-B
Wheel bearing ring nut tool 4-46, 4-48

90890-01574
YM-01574
Fork spring compressor 4-92, 4-97

90890-01441
Fork spring compressor
YM-01441
Rod holder 4-92, 4-97

90890-01434
Damper rod holder double ended
YM-01434
Damper rod holder (ø30) 4-93, 4-95

90890-01506
Damper rod holder
YM-01506
1-22
SPECIAL TOOLS
Reference
pages
Fork seal driver 4-95, 4-95, 4-96,
90890-01442 4-105, 4-105
Adjustable fork seal driver (36–46 mm)
YM-01442
Rod puller 4-96, 4-97

90890-01437
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Rod puller attachment (M10) 4-96, 4-97

90890-01436
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Front fork cap bolt wrench 42mm 4-102, 4-103,

90890-01575 4-107
YM-01575
ø42
Ring nut wrench 4-110

90890-01268
Spanner wrench
YU-01268
Ring nut wrench 4-122, 4-124

90890-01507
Ring nut wrench
YM-01507
Damper rod holder (ø22) 4-122, 4-124

90890-01365
1-23
SPECIAL TOOLS
Reference
pages
Drive chain cut & rivet tool 4-126, 4-128
90890-01550
Drive chain cut & rivet tool
YM-01550
Compression gauge 90890-03081 5-9

90890-03081
Engine compression tester
YU-33223
YU-33223
Pivot shaft wrench 5-15, 5-15

90890-01485
Frame mount insert wrench
YM-01485
Valve spring compressor 5-26, 5-29, 5-37,

90890-04019 5-42
Valve spring compressor
YM-04019
Valve spring compressor attachment (ø26) 5-37, 5-42

90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
Valve guide remover (ø4.5) 5-39

90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide remover (ø5) 5-39

90890-04097
YM-04097
Valve guide installer (ø4.5) 5-39

90890-04117
Valve guide installer (4.5 mm)
YM-04117
1-24
SPECIAL TOOLS
Reference
pages
Valve guide installer (ø5) 5-39
90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø4.5) 5-39

90890-04118
Valve guide reamer (4.5 mm)
YM-04118
Valve guide reamer (ø5) 5-39

90890-04099
YM-04099
15mm pin type rotor holding tool 5-45, 5-46

90890-04171
YM-04171
Crankshaft protector 5-45

90890-01382
Crankshaft protector
YM-01382
Flywheel puller 5-45

90890-01404
Flywheel puller
YM-01404
Yamaha bond No. 1215 5-46, 5-73

90890-85505
(Three bond No.1215®)
Sheave holder 5-48, 5-48

90890-01701
Primary clutch holder
YS-01880-A
Digital circuit tester (CD732) 5-51, 8-41, 8-42,

90890-03243 8-43, 8-44, 8-45,
Model 88 Multimeter with tachometer 8-45, 8-46, 8-47,
YU-A1927 8-47, 8-48, 8-49,
8-50, 8-51, 8-51,
8-51, 8-52, 8-52
1-25
SPECIAL TOOLS
Reference
pages
Universal clutch holder 5-63, 5-66
90890-04086
Universal clutch holder
YM-91042
Piston pin clip rotation tool 5-78

90890-04175
YM-04175
Piston pin puller set 5-79

90890-01304
Piston pin puller
YU-01304
YU-01304
Connecting rod big end bearing installer 5-82, 5-85

90890-04193 ø8.1 ø9.1
ø7
Connecting rod big end bearing installer
YM-04193
Piston pin clip insertion tool 5-87

90890-04173
YM-04173
Piston pin clip installer tool 5-87

90890-04174
YM-04174
1-26
SPECIAL TOOLS
Reference
pages
Radiator cap tester 6-5, 6-6
90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 6-5, 6-6

90890-01352
Pressure tester adapter
YU-33984
YU-33984
Mechanical seal installer (ø33) 6-16

90890-04132
Water pump seal installer (ø33)
YM-33221-A
Middle driven shaft bearing driver 6-16

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Pressure gauge 7-17, 7-17

90890-03153
Pressure gauge
YU-03153
Fuel injector pressure adapter 7-17

90890-03210
Fuel injector pressure adapter
YU-03210
Fuel pressure adapter 7-17

90890-03176
Fuel pressure adapter
YM-03176
1-27
SPECIAL TOOLS
Reference
pages
Ignition checker 8-45
90890-06754
Oppama pet–4000 spark checker
YM-34487
Test harness– speed sensor (3P) 8-50

90890-03208
Test harness– speed sensor (3P)
YU-03208
TIP
Yamaha diagnostic tool (A/I) 90890-03264
This special tool includes the YDT sub harness (6P) (90890-03266).
TIP
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.
1-28
SPECIAL TOOLS
1-29
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-7
ELECTRICAL SPECIFICATIONS .................................................................2-10
TIGHTENING TORQUES .............................................................................. 2-12

2
ENGINE TIGHTENING TORQUES......................................................... 2-12
CHASSIS TIGHTENING TORQUES.......................................................2-14
CABLE ROUTING ......................................................................................... 2-17

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model B3L5 (YZF1000L_AUS)
B3L7 (YZF1000_RUS)
B3L8 (YZF1000_ZAF)
B4S5 (YZF1000DL_AUS)
B4S6 (YZF1000D_RUS)
B4S7 (YZF1000D_ZAF)
Dimensions
Overall length 2055 mm (80.9 in)
Overall width 690 mm (27.2 in)
Overall height 1165 mm (45.9 in)
Wheelbase 1405 mm (55.3 in)
Ground clearance 130 mm (5.12 in)
Minimum turning radius 3.4 m (11.16 ft)
Weight
Curb weight 201 kg (443 lb) (YZF-R1)
202 kg (445 lb) (YZF-R1M)
Loading
Maximum load 185 kg (408 lb)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train DOHC
Displacement 998 cm³
Cylinder arrangement Inline
Number of cylinders 4-cylinder
Bore × stroke 79.0 × 50.9 mm (3.11 × 2.00 in)
Compression ratio 13.0 : 1
Compression pressure 1261–1624 kPa/210 r/min (12.6–16.2 kgf/cm²/
210 r/min, 179.4–231.0 psi/210 r/min)
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline (E10 acceptable)
(except for RUS)
Unleaded gasoline only. Minimum research
octane number 95 (for RUS)
Fuel tank capacity 17 L (4.5 US gal, 3.7 Imp.gal)
Fuel reserve amount 3.0 L (0.79 US gal, 0.66 Imp.gal)
Engine oil
Recommended brand YAMALUBE
Type Full synthetic
SAE viscosity grades 10W-40, 15W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Lubrication system Wet sump
Engine oil quantity
Oil change 3.90 L (4.12 US qt, 3.43 Imp.qt)
With oil filter removal 4.10 L (4.33 US qt, 3.61 Imp.qt)
Quantity (disassembled) 4.90 L (5.18 US qt, 4.31 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Oil pressure 200.0 kPa/5000 r/min (2.00 kgf/cm²/5000 r/min,
29.0 psi/5000 r/min)
Cooling system
Coolant quantity
Radiator (including all routes) 2.25 L (2.38 US qt, 1.98 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator cap valve opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9
psi)
Cooling system leak test pressure 137.3 kPa (1.37 kgf/cm², 19.9 psi)
Thermostat
Valve opening temperature 69.0–73.0 °C (156.20–163.40 °F)
2-2
Valve full open temperature 85.0 °C (185.00 °F)

Valve lift (full open) 8.0 mm (0.31 in)
Spark plug(s)
Manufacturer/model NGK/LMAR9E-J
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
Cylinder head
Warpage limit 0.10 mm (0.0039 in)
Camshaft
Camshaft cap inside diameter 25.500–25.521 mm (1.0039–1.0048 in)
Camshaft journal diameter 25.459–25.472 mm (1.0023–1.0028 in)
Camshaft-journal-to-camshaft-cap clearance 0.028–0.062 mm (0.0011–0.0024 in)
Limit 0.080 mm (0.0032 in)
Camshaft lobe dimensions
Lobe height (Intake) 35.291–35.391 mm (1.3894–1.3933 in)
Limit 35.191 mm (1.3855 in)
Lobe height (Exhaust) 34.745–34.845 mm (1.3679–1.3718 in)
Limit 34.645 mm (1.3640 in)
Camshaft runout limit 0.050 mm (0.0020 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter 7.987–8.002 mm (0.3144–0.3150 in)
Limit 8.017 mm (0.3156 in)
Rocker arm shaft outside diameter 7.967–7.979 mm (0.3137–0.3141 in)
Limit 7.936 mm (0.3124 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.09–0.17 mm (0.0035–0.0067 in)
Exhaust 0.18–0.23 mm (0.0071–0.0091 in)
Valve dimensions
Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in)
Limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) 1.10–1.30 mm (0.0433–0.0512 in)
Limit 1.8 mm (0.07 in)
Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)
Limit 4.960 mm (0.1953 in)
Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in)
Limit 4.425 mm (0.1742 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance
(exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Inner spring
Free length (intake) 34.52 mm (1.36 in)
2-3
Limit 32.79 mm (1.29 in)

Free length (exhaust) 36.94 mm (1.45 in)
Limit 35.09 mm (1.38 in)
Outer spring
Free length (intake) 35.72 mm (1.41 in)
Limit 33.93 mm (1.34 in)
Free length (exhaust) 36.85 mm (1.45 in)
Limit 35.01 mm (1.38 in)
Cylinder
Bore 79.000–79.010 mm (3.1102–3.1106 in)
Wear limit 79.060 mm (3.1126 in)
Piston
Diameter 78.961–78.994 mm (3.1087–3.1100 in)
Measuring point (from piston skirt bottom) 8.0 mm (0.31 in)
Piston-to-cylinder clearance 0.006–0.049 mm (0.0002–0.0019 in)
Piston pin bore inside diameter 17.002–17.013 mm (0.6694–0.6698 in)
Limit 17.043 mm (0.6710 in)
Piston pin outside diameter 16.991–17.000 mm (0.6689–0.6693 in)
Limit 16.971 mm (0.6681 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 1.15 mm (0.0453 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)
Connecting rod
Oil clearance 0.033–0.057 mm (0.0013–0.0022 in)
Bearing color code
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Code 6 Pink
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.025–0.043 mm (0.0010–0.0017 in)
Bearing color code
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
2-4
Code 6 Pink
Balancer
Balancer shaft runout limit 0.030 mm (0.0012 in)
Bearing color code
Code 0 White
Code 1 Blue
Code 2 Black
Code 3 Brown
Code 4 Green
Code 5 Yellow
Code 6 Pink
Balancer shaft journal to balancer shaft bearing
clearance 0.028–0.046 mm (0.0011–0.0018 in)
Clutch
Clutch type Wet, multiple-disc
Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)
Assembly width 48.3–49.3 mm (1.90–1.94 in)
Friction plate 1 thickness 2.72–2.88 mm (0.107–0.113 in)
Plate quantity 3 pcs
Friction plate 2 thickness 2.72–2.88 mm (0.107–0.113 in)
Clutch plate 1 thickness 2.46–2.74 mm (0.097–0.108 in)
Clutch plate 2 thickness 2.18–2.42 mm (0.086–0.095 in)
Clutch spring free length 47.36 mm (1.86 in)
Limit 44.99 mm (1.77 in)
Drivetrain
Primary reduction ratio 1.634 (67/41)
Transmission type Constant mesh 6-speed
Gear ratio
1st 2.600 (39/15)
2nd 2.176 (37/17)
3rd 1.842 (35/19)
4th 1.579 (30/19)
5th 1.381 (29/21)
6th 1.250 (30/24)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Secondary reduction ratio 2.563 (41/16)
Final drive Chain
Shifting mechanism
Installed shift rod length 258.5–260.5 mm (10.18–10.26 in)
2-5
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
Maximum consumption amperage 5.2 A
Fuel injector
Resistance 12.0 Ω
Throttle body
ID mark B3L1 00
Idling condition
Engine idling speed 1200–1400 r/min
AI system Inactive
O2 feedback control Inactive
Coolant temperature 90–110 °C (194–230 °F)
Intake vacuum 26.0 kPa (195 mmHg, 7.7 inHg)
Difference in vacuum pressure between the
cylinders 0 kPa-1.3 kPa (0 mmHg-10 mmHg, 0 inHg-0.4
inHg)
CO% 1.0–4.0 %
Fuel line pressure (at idle) 300–390 kPa (3.0–3.9 kgf/cm², 43.5–56.6 psi)
Air induction system

Solenoid resistance 18–22 Ω
2-6
CHASSIS SPECIFICATIONS
EAS20015
Chassis
Frame type Diamond
Caster angle 24.0 °
Trail 102 mm (4.0 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/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)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C X MT6.00
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)
Front tire
Type Tubeless
Size 120/70ZR17M/C (58W)
Manufacturer/model BRIDGESTONE/BATTLAX RACING STREET
RS11F
Rear tire
Type Tubeless
Size 190/55ZR17M/C (75W) (YZF-R1)
200/55ZR17M/C (78W) (YZF-R1M)
Manufacturer/model BRIDGESTONE/BATTLAX RACING STREET
RS11R
Tire air pressure (measured on cold tires)

1 person
Front 250 kPa (2.50 kgf/cm², 36 psi)
Rear 290 kPa (2.90 kgf/cm², 42 psi)
2 persons
Front 250 kPa (2.50 kgf/cm², 36 psi)
Rear 290 kPa (2.90 kgf/cm², 42 psi)
Front brake
Type Hydraulic dual disc brake
Disc outside diameter × thickness 320.0 × 5.0 mm (12.60 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on wheel) 0.10 mm (0.0039 in)
Brake pad lining thickness limit 0.5 mm (0.02 in)
Master cylinder inside diameter 15.87 mm (0.62 in)
Caliper cylinder inside diameter (Left) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Caliper cylinder inside diameter (Right) 30.23 mm, 27.00 mm (1.19 in, 1.06 in)
Specified brake fluid DOT 4
2-7
Rear brake
Type Hydraulic single disc brake
Disc outside diameter × thickness 220.0 × 5.0 mm (8.66 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 0.5 mm (0.02 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 30.23 mm (1.19 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper (YZF-R1)
Gas-hydraulic damper (YZF-R1M)
Wheel travel 120 mm (4.7 in)
Fork spring free length 219.5 mm (8.64 in) (YZF-R1)
260.0 mm (10.24 in) (YZF-R1M)
Limit 215.1 mm (8.47 in) (YZF-R1)
254.8 mm (10.03 in) (YZF-R1M)
Recommended oil Yamaha Suspension Oil 01 (YZF-R1)
Öhlins R&T 43 (YZF-R1M)
Inner tube bending limit 0.2 mm (0.01 in)
Quantity (left) 470.0 cm³ (15.89 US oz, 16.58 Imp.oz)
(YZF-R1)
263.0 cm³ (8.89 US oz, 9.26 Imp.oz) (YZF-R1M)
Quantity (right) 470.0 cm³ (15.89 US oz, 16.58 Imp.oz)
(YZF-R1)
263.0 cm³ (8.89 US oz, 9.26 Imp.oz) (YZF-R1M)
Level (left) 84 mm (3.3 in) (YZF-R1)
180 mm (7.1 in) (YZF-R1M)
Level (right) 84 mm (3.3 in) (YZF-R1)
180 mm (7.1 in) (YZF-R1M)
Spring preload
Adjusting system Mechanical adjustable type
Unit for adjustment Turn
Adjustment value (Soft) 0
Adjustment value (STD) 6 (YZF-R1)
3 (YZF-R1M)
Adjustment value (Hard) 15
Rebound damping
Adjusting system Mechanical adjustable type (YZF-R1)
Electronically adjustable type (YZF-R1M)
Unit for adjustment Click (YZF-R1)
Adjustment value from the start position (Soft) 14 (YZF-R1)
Adjustment value from the start position (STD) 7 (YZF-R1)
Adjustment value from the start position (Hard) 1 (YZF-R1)
Compression damping
Unit for compression damping adjustment Click (YZF-R1)
2-8

Rear suspension
Type Swingarm (link suspension)
Spring Coil spring
Shock absorber Gas-hydraulic damper
Wheel travel 120 mm (4.7 in)
Spring preload
Adjusting system Mechanical adjustable type
Adjustment value (Soft) 77.5 mm (3.05 in) (YZF-R1)
0.0 mm (0.00 in) (YZF-R1M)
Adjustment value (STD) 78.5 mm (3.09 in) (YZF-R1)
4.0 mm (0.16 in) (YZF-R1M)
Adjustment value (Hard) 85.5 mm (3.37 in) (YZF-R1)
9.0 mm (0.35 in) (YZF-R1M)
Rebound damping
Compression damping
Fast compression damping
Unit for adjustment Turn (YZF-R1)
Adjustment value from the start position (Soft) 5.5 (YZF-R1)
Slow compression damping
Drive chain
Size 525
Chain type Sealed type
Number of links 113
Drive chain slack 25.0–35.0 mm (0.98–1.38 in)
Drive chain slack (Maintenance stand) 25.0–35.0 mm (0.98–1.38 in)
15-link length limit 239.3 mm (9.42 in)
2-9
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Ignition timing (B.T.D.C.) 3.0–7.0 °s/1300 r/min
Engine control unit

Model TBDF4N
Ignition coil
Primary coil resistance 0.85–1.15 Ω
Secondary coil resistance 8.50–11.50 kΩ
Charging system
Charging system AC magneto
Standard output 14.0 V, 26.3 A at 5000 r/min
Stator coil resistance 0.112–0.168 Ω
Rectifier/regulator
Regulator type Three-phase
Regulated voltage (DC) 14.3–14.7 V
Battery
Model YTZ7S(F)
Voltage, capacity 12 V, 6.0 Ah (10 HR)
Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal light LED
Rear turn signal light LED
Auxiliary light LED
License plate light LED
Meter lighting LED
Indicator light
Neutral indicator light LED
Stability control indicator light LED
Oil pressure and coolant temperature warning
light LED
High beam indicator light LED
Turn signal indicator light LED
Fuel level warning light LED
Malfunction indicator light LED
ABS warning light LED
Auxiliary system warning light LED
Immobilizer system indicator light LED
Shift indicator light LED
2-10
Starter motor
Brush overall length limit 5.5 mm (0.22 in)
Brush spring force 4.80–7.20 N (489–734 gf, 17.28–25.92 oz)
Mica undercut (depth) 2.40 mm (0.09 in)
Solenoid
Steering damper solenoid resistance 49.82–56.18 Ω
Intake solenoid resistance 42.0–48.0 Ω
Fuel injection sensor

Crankshaft position sensor resistance 189–231 Ω
Cylinder identification sensor output voltage (ON) 4.8 V
Cylinder identification sensor output voltage
(OFF) 0.8 V
Intake air temperature sensor resistance 5400–6600 Ω at 0 °C (5400–6600 Ω at 32 °F)
Intake air temperature sensor resistance 289–391 Ω at 80 °C (289–391 Ω at 176 °F)
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)
Fuse(s)
Main fuse 50.0 A
Headlight fuse 7.5 A
Signaling system fuse 7.5 A
Ignition fuse 15.0 A
Radiator fan motor fuse 15.0 A
Sub radiator fan motor fuse 10.0 A
Hazard fuse 7.5 A
ABS ECU fuse 7.5 A
SCU fuse 7.5 A (YZF-R1M)
Fuel injection system fuse 15.0 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
Auxiliary fuse 2.0 A
Backup fuse 7.5 A
Electronic throttle valve fuse 7.5 A
2-11
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Exhaust pipe nut M8 8 20 N·m (2.0 kgf·m, 15 lb·ft)
Muffler protector bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
EXUP valve pulley cover bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Spark plug M10 4 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Spark plug (new) M10 4 18 N·m (1.8 kgf·m, 13 lb·ft)
Cylinder head cover bolt M6 6 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Generator rotor bolt M10 1 85 N·m (8.5 kgf·m, 63 lb·ft) E
Generator cover bolt M6 8 See TIP.

Stake.
Clutch boss nut M20 1 125 N·m (12.5 kgf·m, 92 lb·ft)
E
Clutch spring bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Clutch cover bolt M6 10 See TIP.
Oil filter cartridge M20 1 17 N·m (1.7 kgf·m, 13 lb·ft)
Oil filter cartridge union bolt M20 1 70 N·m (7.0 kgf·m, 52 lb·ft) E
Water pump drain bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Engine oil drain bolt M14 1 23 N·m (2.3 kgf·m, 17 lb·ft)
TIP
Generator cover bolt
1. Tighten the bolts to 6 N·m (0.6 kgf·m, 4.4 lb·ft) with a torque wrench following the tightening order.
2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in
the illustration.
a. Loosen the bolt.
b. Tighten the bolt to 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) with a torque wrench.
c. Tighten the bolt further to reach the specified angle 90°.
8
7
1
6
2
5 3
4
2-12
TIGHTENING TORQUES
TIP
Clutch cover bolt
1. Tighten the bolts to 6 N·m (0.6 kgf·m, 4.4 lb·ft) with a torque wrench following the tightening order.
2. Perform the following procedure to all the bolts one by one in the tightening sequence as shown in
the illustration.
a. Loosen the bolt.
b. Tighten the bolt to 3.0 N·m (0.30 kgf·m, 2.2 lb·ft) with a torque wrench.
c. Tighten the bolt further to reach the specified angle 180°.
1
10 2
9
3
8 4
7 5
6
2-13
TIGHTENING TORQUES
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Front wheel axle nut M24 1 115 N·m (11.5 kgf·m, 85 lb·ft)
Front wheel axle pinch bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft) See TIP.
Rear wheel sprocket nut M10 5 100 N·m (10 kgf·m, 74 lb·ft)
Rear wheel axle nut M24 1 190 N·m (19 kgf·m, 140 lb·ft)
Rear brake caliper bolt (front) M12 1 27 N·m (2.7 kgf·m, 20 lb·ft) LS
LS
Rear brake caliper bolt (rear) M8 1 12 N·m (1.2 kgf·m, 8.9 lb·ft)
LT
Brake caliper bleed screw M8 3 5 N·m (0.5 kgf·m, 3.7 lb·ft)

Front brake caliper bolt M10 4 35 N·m (3.5 kgf·m, 26 lb·ft)
Handlebar bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Handlebar pinch bolt M8 2 32 N·m (3.2 kgf·m, 24 lb·ft)
Clutch cable locknut M8 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Lower bracket pinch bolt M8 4 23 N·m (2.3 kgf·m, 17 lb·ft) See TIP.
Upper bracket pinch bolt M8 2 26 N·m (2.6 kgf·m, 19 lb·ft)
Lower ring nut M30 1 See TIP.
Stake.
Drive sprocket nut M22 1 140 N·m (14 kgf·m, 103 lb·ft)
E
Rear frame bolt M10 4 37 N·m (3.7 kgf·m, 27 lb·ft)
TIP
Lower ring nut
1. Tighten the ring nut to 52 N·m (5.2 kgf·m, 38 lb·ft) with a torque wrench, then loosen the lower ring
nut completely.
2. Tighten the lower ring nut to 14 N·m (1.4 kgf·m, 10 lb·ft).
TIP
Front wheel axle pinch bolt
1. Tighten the pinch bolt “2”, pinch bolt “1”, and pinch bolt “2” to 21 N·m (2.1 kgf·m, 15 lb·ft) in this order.
2. Check that the right end of the front axle is flush with the front fork. If necessary, manually push the
front axle or lightly tap it with a soft hammer until its end is flush with the front fork. However, if the
surface of the front axle end is not parallel to the surface of the front fork, align a point on the outer
edge of the axle with the fork, making sure that the axle does not protrude past the fork.
3. Tighten the pinch bolt “4”, pinch bolt “3”, and pinch bolt “4” to 21 N·m (2.1 kgf·m, 15 lb·ft) in this order.
4 3 2 1
2-14
TIGHTENING TORQUES
TIP
Lower bracket pinch bolt
Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft) in the order pinch bolt “1” → pinch bolt “2” → pinch bolt
“1” → pinch bolt “2”.
2-15
TIGHTENING TORQUES
2-16
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
1 A 2
3
6 4
I 1
5
6
H
C
12
D
11
8
10 G
7 J F 9 5 E
13 L 2 13 K
P 13 O
3
H N
2-17
CABLE ROUTING
1. Handlebar switch lead (right)

2. Clutch cable
3. Handlebar switch lead (left)
4. Clutch switch connector
5. Immobilizer unit lead
6. Main switch lead
7. Horn lead
8. Radiator bracket (left)
9. Intake solenoid vacuum hose
10. Horn
11. Steering damper solenoid lead
12. Front brake hose
13. Front fork stepping motor sub-wire harness
A. Route the handlebar switch lead (right) to the rear
of the front brake hose. Be sure not to pinch the
handlebar switch lead (right) between the front fork
and the front brake hose.
B. Make sure that the horn lead and clutch switch
lead do not cross.
C. Make sure that the leads do not cross within the
range shown in the illustration.
D. Fasten the immobilizer unit lead at the blue tape to
the radiator bracket with a plastic locking tie. Face
the buckle of the plastic locking tie outward.
E. Route the immobilizer unit lead to the front and to
the inside of the spring nut on the plate behind the
radiator, and above the guide behind the radiator.
F. Fasten the horn lead to the lower bracket with a
plastic locking tie. Position the plastic locking tie
between the outer tube and the steering lock
portion of the lower bracket. Face the buckle of the
plastic locking tie forward with the end pointing
upward, and then cut off the excess end of the tie
to 5 mm (0.2 in) or less.
G. To front wheel sensor
H. Route the clutch cable to the rear of the handlebar
switch lead (right).
I. Route the handlebar switch lead (right) to the front
of the main switch lead.
J. Route the horn lead to the front of the lower
bracket.
K. For YZF-R1M
L. Connect the front fork stepping motor coupler
(right), which is identified by the tape on the lead,
to the right front fork leg.
M. Route the front fork stepping motor sub-wire
harness to the rear of the clutch cable and
handlebar switch lead (left).
N. Insert the projection on the front fork stepping
motor sub-wire harness holder into the hole in the
cable guide from the bottom of the guide. Route
the front fork stepping motor sub-wire harness
under the clutch cable.
O. Connect the front fork stepping motor coupler (left/
right), and then slide the waterproof cover until it
contacts the front fork cap bolt (left/right).
P. Fasten the front fork stepping motor sub-wire
harness at the lower edge of the black tape to the
straight section of the brake fluid reservoir hose
with the holder. Face the catch of the holder
downward.
2-18
CABLE ROUTING
Frame (front right side view)
6
5 J
I 4
7
1
2
3
C
D
4
E
4
8
1
5
F 1
5 L
M
H G
9
2-19
CABLE ROUTING
1. Clutch cable
2. Front brake hose (front brake master cylinder to
hydraulic unit)
4. Front fork stepping motor sub-wire harness (for
YZF-R1M)
5. Coolant reservoir breather hose
6. Side cover (right)
7. Damper
8. Radiator stay
9. Radiator bracket
A. Fasten the clutch cable and front fork stepping
motor sub-wire harness (for YZF-R1M) at the
positioning tape (white) on the cable and lead to
the radiator stay with a plastic locking tie.
B. Route the front fork stepping motor sub-wire
harness to the inside of the clutch cable. (For
YZF-R1M)
C. Route the front fork stepping motor sub-wire
harness between the ribs on the SCU stay. (For
YZF-R1M)
D. Install the front fork stepping motor sub-wire
harness holder completely onto the tab on the
headlight stay. (For YZF-R1M)
E. Route the front fork stepping motor sub-wire
harness to the outside of the coolant reservoir. (For
YZF-R1M)
F. Cross the coolant reservoir breather hose and
clutch cable so that the hose is routed to the
outside of the cable.
G. Route the coolant reservoir breather hose along
the clutch cable.
H. Fasten the coolant reservoir breather hose at the
paint mark to the clutch cable with the holder.
Route the coolant reservoir breather hose above
the clutch cable.
I. Route the front fork stepping motor sub-wire
harness between the right side cover and the
radiator. Make sure that the front fork stepping
motor sub-lead does not protrude past the right
side cover. (For YZF-R1M)
J. Route the coolant reservoir breather hose between
the damper and the radiator filler neck.
K. Point the end of the plastic locking tie outward. Do
not cut off the excess end of the plastic locking tie.
L. Route the coolant reservoir breather hose to the
outside of the clutch cable.
M. Fasten the coolant reservoir breather hose at the
paint mark to the clutch cable with the holder.
Make sure that the end of the holder contacts the
radiator bracket as shown in the illustration.
2-20
CABLE ROUTING
Frame (rear right side view)
4 C 3 B 2 A
2 D
2-21
CABLE ROUTING
1. Muffler protector bracket (right)

2. O2 sensor lead
3. Rear wheel sensor lead
4. Rear brake light switch lead
5. EXUP cable
6. Frame
7. Clutch cover
A. Route the O2 sensor lead over the muffler
protector bracket (right).
B. Route the rear wheel sensor lead to the outside of
the EXUP cables and to the inside of the brake
hose.
C. Route the rear brake light switch lead to the
outside of the rear wheel sensor lead.
D. Push in the O2 sensor lead from the outside until it
is aligned with the mating surface of the clutch
cover.
2-22
CABLE ROUTING
Electrical components tray (left side view)
21
28 29 V 22
20
S
19
23
14 M R
P Q 18 24
O 25 T
26
N
27
14 U
16 17 A B C 1 D
L
K
15
14
J 13
I
H 12
H 11
10
2
9
G 8
G 7
G 6
F 5
33 X 4 F 3 F E
Y
34
30 31 32 X
W 30 31 32 X
32 X 31 X 30 X
2-23
CABLE ROUTING
1. Intake funnel servo motor lead E. Fasten the right handlebar switch leads, left
2. Main switch coupler handlebar switch leads and radiator fan motor
3. Handlebar switch coupler (right) (non-waterproof leads with a plastic locking tie. The leads may be
4-pole) fastened in any order. Do not fasten the rectifier/
regulator lead with the plastic locking tie. Face the
4. Handlebar switch coupler (left) (non-waterproof 2-
buckle of the plastic locking tie upward, and then
pole)
cut off the excess end of the tie to 5 mm (0.2 in) or
5. Handlebar switch coupler (right) (non-waterproof less.
6-pole)
F. Insert the projection on the coupler completely into
6. Handlebar switch coupler (left) (waterproof 10- the hole in the electrical components tray.
pole)
G. Install the coupler completely onto the tab on the
7. Handlebar switch coupler (right) (waterproof 4- electrical components tray.
pole)
H. Fasten the coupler with the holder on the electrical
8. Handlebar switch coupler (right) (waterproof 6- components tray.
pole)
I. The radiator fan motor leads may cross.
9. Headlight control unit coupler
J. Fasten the horn lead at the white tape with a
10. Headlight control unit plastic locking tie.
11. Radiator fan motor lead coupler (right) (black) K. 15–25 mm (0.59–0.98 in)
12. Radiator fan motor lead coupler (left) (white)
L. 90–100 mm (3.54–3.94 in)
13. Rectifier/regulator lead
M. Inward
14. Horn lead
N. Cut off the excess end of the plastic locking tie to 5
15. Main switch lead mm (0.20 in) or less.
16. Handlebar switch lead (left) O. 60°
17. Handlebar switch lead (right) Position the buckle of the plastic locking tie within
18. Secondary injector #1 the range shown in the illustration.
19. Secondary injector #2 P. Forward
20. Secondary injector #3 Q. 30°
21. Secondary injector #4 Position the horn lead within the range shown in
22. Fuel hose 2 (secondary injector fuel rail side) the illustration.
23. Fuel hose 3 (fuel hose 2 to throttle body) R. Fasten the secondary injector lead with the holders
on the air filter case. Make sure that the white tape
24. Rear shock absorber assembly stepping motor
on the lead is positioned between the holders.
lead (for YZF-R1M)
S. Fasten the secondary injector lead to the fuel rail
25. Coolant temperature sensor lead
with a plastic locking tie. Position the plastic locking
26. Crankcase breather hose tie at the narrow portion of the fuel rail.
27. Fuel hose 1 (fuel tank to fuel hose 2) T. Route the coolant temperature sensor lead under
28. Secondary injector lead the fuel hose.
29. Fuel rail U. Route the secondary injector lead to the rear of the
30. Handlebar switch lead (right) (non-waterproof 4- cross bar.
pole) V. Fasten the secondary injector lead to the fuel rail
31. Handlebar switch lead (left) (non-waterproof 2- with a plastic locking tie. Point the end of the plastic
pole) locking tie rearward. Do not cut off the excess end
32. Handlebar switch lead (right) (non-waterproof 6- of the plastic locking tie.
pole) W. Make sure that the leads do not protrude to the
33. Handlebar switch lead (left) (waterproof 10-pole) outside of the guide on the electrical components
tray.
34. Handlebar switch lead (right) (waterproof 4-pole)
A. Cut off the excess end of the plastic locking tie so X. The leads may be fastened in any order.
that the end is not on the frame boss. Also, check Y. Fasten the right handlebar switch leads and left
the position from the side view so that the plastic handlebar switch lead with a plastic locking tie.
locking tie is positioned above the wire harness. Face the buckle of the plastic locking tie forward,
B. Route the main switch leads under the wire and then cut off the excess end of the tie to 5 mm
harness. (0.2 in) or less.
C. Fasten the main switch leads at the white tape to
the wire harness with a plastic locking tie. Position
the plastic locking tie between the wire harness
holder and the wire harness protector. Face the
buckle of the plastic locking tie downward, and
then cut off the excess end of the tie to 5 mm (0.2
in) or less.
D. Connect the intake funnel servo motor coupler on
top of the frame, and then place it between the air
filter case and the frame.
2-24
CABLE ROUTING
Frame (left side view)
A F
G
1
2
3 13 3
4 B
5
10 I 9 I
6 C
7 D
H 11 I
8
11 I
9 I
12
10 I
4
9 I
11 E 10 9 I 10
14 J
M 15 I 16 I
K 11 I
L
4
7
21 17 I O
23
20 I 19 I 18 I
8
22
N 22 24
23
24
P 22
2-25
CABLE ROUTING
1. Secondary injector lead M. Position the coupler cover (stator coil coupler,
2. Throttle position sensor crankshaft position sensor coupler) to the inside of
3. Wire harness the thermostat assembly as shown in the
illustration.
4. Fuel tank drain hose
N. Route the shift sensor lead outside the fuel tank
5. Engine ground lead
drain hose.
6. Starter motor lead
O. Fasten the stator coil lead and the shift sensor lead
7. Gear position sensor lead to the thermostat assembly at the positioning tape
8. Shift sensor on the shift sensor lead with a plastic locking tie.
9. Sidestand switch lead Position the plastic locking tie to the inside of the
10. O2 sensor lead (left) protruding portion on the thermostat assembly.
Point the end of the plastic locking tie rearward and
11. Oil pressure switch lead upward. Do not cut off the excess end of the plastic
12. ECU (engine control unit) coupler locking tie.
13. Frame P. Route the shift sensor lead between the protruding
14. Grommet portions on the thermostat assembly.
15. Oil pressure switch connector
16. Sidestand switch coupler (black)
17. O2 sensor coupler
18. Shift sensor coupler (white)
19. Crankshaft position sensor coupler
20. Stator coil coupler
21. Thermostat assembly
22. Shift sensor lead
24. Stator coil lead
A. To secondary injector
B. Route the fuel tank drain hose over the boss for
the shift arm.
C. Route the starter motor lead under the engine
ground lead.
D. Route the gear position sensor lead to the inside of
the starter motor lead.
E. Position the cable holder below the oil level check
window.
F. Insert the plastic locking tie into the frame hole.
The position of the plastic locking tie may change
after installation; however, make sure that it does
not come off.
G. Fasten the wire harness with the plastic locking tie.
Face the buckle of the plastic locking tie upward,
and then cut off the excess end of the tie to 5 mm
(0.2 in) or less.
H. Fasten the sidestand switch lead, O2 sensor lead
(left), and oil pressure switch lead with the holder.
Position the holder between the coupler cover and
the drive sprocket cover. The catch of the holder
may be facing in any direction.
I. The leads may be routed in any order.
J. Make sure that the grommet does not protrude
from the sidestand switch cover. Face the slit in the
grommet inward. Make sure that the projection on
the sidestand switch cover is hooked onto the
groove in the grommet. Align the grommet with the
paint mark on the fuel tank drain hose.
K. Fasten the sidestand switch lead, O2 sensor lead
(left), and oil pressure switch lead with the holder.
The catch of the holder may be facing in any
direction.
L. Place the coupler cover behind the coupler cover
(stator coil side) and push it inside the projection
on the chain case cover.
2-26
CABLE ROUTING
Frame (top view)
11
P
9 8
1 A 2 B 3 B 4 C
K
10
14 9
J
5
D
I
H
7 F 6
I
D L
1
M
9
5
13 N 12
2-27
CABLE ROUTING
1. Auxiliary light lead

2. Steering damper solenoid coupler
3. Intake solenoid lead (sub-wire harness)
5. Front turn signal light lead (right)
6. Meter assembly
7. Meter assembly coupler
9. Front turn signal light lead (left)
10. Wire harness
11. Headlight assembly
12. Headlight cover
13. Fuse box 2
14. Front cowling
A. Route the auxiliary light lead under the wire
harness.
B. Place the steering damper solenoid lead and
intake solenoid lead (sub-wire harness) in the gap
between the front cowling and front cowling
assembly stay.
C. Route the front turn signal light lead (right) under
the steering damper solenoid lead and intake
solenoid lead (sub-wire harness).
D. To front turn signal light (right)
E. Install the holder on the steering damper solenoid
lead to the curved section of the slit used for
connecting the lead in the headlight assembly.
F. Install the meter assembly coupler and coupler
cover securely to the meter assembly. Make sure
that the edges of the coupler cover are not rolled
up.
G. Fasten the intake solenoid vacuum hose with the
holders on the wire harness (2 locations).
H. Insert the projection on the wire harness holder
into the hole in the side cover bracket from the
inside.
I. To front turn signal light (left)
J. Fasten the intake solenoid vacuum hose, front turn
signal light lead (left), and auxiliary light lead with
the holder. Position the holder to the outside of and
above the head light control unit holder. The catch
of the holder may be facing in any direction.
K. Face the holder on the steering damper solenoid
lead downward, and then install the holder
completely onto the rib of the headlight assembly.
L. Connect the front turn signal light coupler (right),
and then fasten the front turn signal light leads
(right) with the holder as shown in the illustration.
The leads may be routed in any order.
M. To intake solenoid
N. Install fuse box 2 onto the rib of the front side
cowling inner panel (left).
O. Insert the projection on the wire harness holder
into the hole in the front cowling from the inside.
P. Position the plastic locking tie to the outside of the
intake solenoid vacuum hose and front turn signal
light lead (left).
2-28
CABLE ROUTING
Frame (top view) (for YZF-R1M)
1 A 2 3 4 B C
5
11
10 6
10 6 H F
D
11
6
I
8 9
4
13 5 12
2-29
CABLE ROUTING
1. Steering damper solenoid coupler (Öhlins:

OPTION)
2. Steering damper solenoid coupler
3. Intake solenoid lead
4. Front turn signal light lead (right)
5. Sub-wire harness (front fork stepping motor)
6. Sub-wire harness (SCU, steering damper
solenoid, sub-wire harness)
9. Auxiliary light lead
10. Front turn signal light lead (left)
11. Wire harness
12. SCU (Suspension Control Unit)
A. The steering damper solenoid coupler (Öhlins:
OPTION) may be positioned in any place.
B. Route the front turn signal light lead (right) under
the intake solenoid lead, steering damper solenoid
lead, and sub-wire harness (front fork stepping
motor).
C. Connect the sub-wire harness (front fork stepping
motor) to the sub-wire harness (SCU, steering
damper solenoid, sub-wire harness).
D. To front turn signal light (left)
E. Connect the sub-wire harness (SCU, steering
damper solenoid, sub-wire harness) to the wire
harness.
F. After connecting the SCU coupler, install the
rubber cover completely until it contacts the SCU
(Suspension Control Unit). Make sure that the
edges of the coupler cover are not rolled up.
G. To front turn signal light (right)
H. Route the sub-wire harness (SCU, steering
damper solenoid, sub-wire harness) over the
intake solenoid vacuum hose.
I. To intake solenoid
2-30
CABLE ROUTING
Frame (top view)
7
G
22
7
H
7 5
19 E
20 21
2 3
4
Q
17
17 19
F
1 A 2 3
4
18
19
2
5
17 O
19 O
6
25
7
18
17
16
8 B
15
N
14
18 17
D 9
13 C 12 11 10
12 K
J
L
8
M 24 I
23
2-31
CABLE ROUTING
1. Horn lead M. The folded portion of the intake air temperature

2. Main switch lead sensor lead does not have to be wrapped with
3. Handlebar switch lead (left) insulating tape.
4. Handlebar switch lead (right) N. Fasten the immobilizer unit lead and wire harness
at the white tape on the lead and harness with a
5. Cylinder identification sensor coupler
plastic locking tie. Face the buckle of the plastic
6. Ignition coil #4 coupler locking tie upward with the end pointing forward.
7. Front wheel sensor lead Do not cut off the excess end of the plastic locking
8. Atmospheric pressure sensor coupler tie.
9. Intake air pressure sensor coupler O. Route the immobilizer unit lead and intake
10. Ignition coil #3 coupler solenoid vacuum hose over the guide and to the
outside of the projection on the guide.
11. Immobilizer unit coupler
P. Fasten the main switch lead and wire harness to
12. Intake air temperature sensor coupler
the guide with a plastic locking tie. Face the buckle
13. Ignition coil #2 coupler of the plastic locking tie downward, and then cut off
14. Intake funnel servo motor coupler the excess end of the tie to 5 mm (0.2 in) or less.
15. Air induction system solenoid coupler Q. Fasten the leads (right handlebar switch lead [blue
16. Ignition coil #1 coupler tape], left handlebar switch lead [gray tape], main
17. Immobilizer unit lead switch lead [white tape], and immobilizer unit lead
[white tape]) at the positioning tape on each lead to
18. Wire harness
the guide with a plastic locking tie. Face the buckle
19. Intake solenoid vacuum hose of the plastic locking tie rearward, and then cut off
20. Radiator bracket the excess end of the tie to 5 mm (0.2 in) or less.
21. Radiator fan motor lead
22. Front brake hose
23. Atmospheric pressure sensor hose
24. Intake air temperature sensor lead
25. Guide
A. Fasten the horn lead at the white tape with the
holder on the lower bracket cover as shown in the
illustration.
B. Identified by the mark “A” on the lead
C. Route the ignition coil #2 lead over the air
induction system solenoid lead.
D. Insert the projection on the wire harness holder
into the hole in the frame.
E. To front wheel sensor
F. Fasten the edge of the shrink-tubing portion of the
front wheel sensor lead to the brake pipe with a
plastic locking tie.
G. Fasten the front wheel sensor lead at the
positioning tape with the holder as shown in the
illustration.
H. Fasten the front wheel sensor lead at the bend in
the brake pipe with a plastic locking tie as shown in
the illustration. Point the end of the plastic locking
tie rearward. Do not cut off the excess end of the
I. Make sure that the end of the atmospheric
pressure sensor hose contacts the air filter case
duct. Point the ends of the hose clamp to the
rearward. Position the hose clamp 0–4 mm (0–0.2
in) from the end of the hose.
J. Make sure that the atmospheric pressure sensor
hose is coming out of the inside of the air filter case
duct.
K. Fold the intake air temperature sensor lead so that
it does not get on the lock part of the coupler as
shown in the illustration.
L. Wrap the insulating tape around the intake air
temperature sensor lead, wrapping it more than
once, then three wraps or more around the lead
and the coupler together.
2-32
CABLE ROUTING
Frame (top view)

1 2 3 4
D
A
B 6
16 17 M
10 C 9 8
11 F
J K 5
G
7
H
15 12
I
14 L 18 13
2-33
CABLE ROUTING
1. Primary injector #1
5. Coolant temperature sensor coupler (sub-wire
harness)
6. O2 sensor lead
7. Neutral switch coupler
8. Fuel pump lead
9. Engine ground lead
lead (for YZF-R1M)
12. Frame
13. Cooling system air bleed hose
14. Canister purge hose
15. Throttle servo motor coupler
16. Round terminal
17. Combination terminal
18. Coolant temperature sensor lead (sub-wire
harness)
A. To O2 sensor
B. To fuel pump
C. Route the starter motor lead under the wire
harness.
D. Insert the projection on the wire harness holder
into the hole in the frame.
E. For YZF-R1M
F. Route the rear shock absorber assembly stepping
motor lead (for YZF-R1M) to the outside of the fuel
hose.
G. Connect the rear shock absorber assembly
stepping motor leads (for YZF-R1M) according to
those with identification tape (yellow) and those
without identification tape, and then cover the
couplers with the coupler cover.
H. Fasten the rear shock absorber assembly stepping
motor leads (for YZF-R1M) to the lower portion of
the brake hose with a plastic locking tie. Position
the plastic locking tie between the front of the
frame and rear end of the coupler cover. Be sure to
fasten the plastic locking tie around the protective
sleeves of the leads, not the leads themselves.
Face the buckle of the plastic locking tie inward
with the end pointing downward. Do not cut off the
excess end of the plastic locking tie.
I. To rear shock absorber assembly
J. Fasten the wire harness to the cross bar with a
plastic locking tie at the concave portion of the air
filter case. Point the end of the plastic locking tie
downward. Do not cut off the excess end of the
K. Fasten the coolant temperature sensor lead and
wire harness to the cross bar with a plastic locking
tie at the concave portion of the air filter case. Point
the end of the plastic locking tie downward. Do not
cut off the excess end of the plastic locking tie.
L. Route the coolant temperature sensor lead to the
engine side of the canister purge hose and the
cooling system air bleed hose.
M. Fasten the engine ground leads with the bolt so
that the crimped section of the terminal is facing
upward.
2-34
CABLE ROUTING
Rear fender (top view)

1 B I 18 15 16
12 13 15 16 J
11
12 D 14 E
21
X 30 14 17
2 C
H 18
4
G 13 F 19
20 33 34 35 W
21 V 12
1 2
12 11 5
3
31 11 4 20 K
5
32 U
21 21 L
T 30 22 15 16
11
30 R
20 N
S 22
21 M
22
22 10
6
29 10
A
26 27 28
9
8 7 7 23 24 25 O
4
30 Q 29 P
2-35
CABLE ROUTING
1. Rear wheel sensor coupler I. Route the rear shock absorber assembly stepping
2. Rear brake light switch coupler motor lead to the outside of the EXUP cables, to
3. Hydraulic unit the inside of the rear brake light switch lead, and to
the inside of the brake hose. (For YZF-R1M)
4. Battery
J. Route the EXUP cables to the front of the rear
5. Joint coupler
shock absorber assembly gas cylinder.
6. Yamaha diagnostic tool coupler
K. Route the Yamaha diagnostic tool coupler lead
7. Tail/brake light lead under the joint coupler.
8. Rear turn signal light coupler L. Route the negative battery lead under the joint
9. EXUP servo motor coupler.
10. Starter relay M. Route the negative battery lead between the ribs.
11. Wire harness N. Route the Yamaha diagnostic tool coupler lead
12. Hydraulic unit tray outside of the negative battery lead.
13. Rear wheel sensor lead O. Fasten the tail/brake light lead, license plate light
14. Rear brake light switch lead lead with the holder. The leads may be routed in
any order.
15. EXUP cable 2
P. Route the positive battery lead over the EXUP
16. EXUP cable 1
servo motor lead and starter relay lead.
17. Brake hose
Q. Route the starter motor lead under the main fuse
18. Rear shock absorber assembly stepping motor lead.
lead (for YZF-R1M)
R. Route the starter motor lead into the space in the
19. Rear shock absorber assembly gas cylinder battery box.
20. Yamaha diagnostic tool coupler lead S. Insert the projection on the holder into the hole in
21. Negative battery lead the battery box.
22. Battery box T. Route the starter motor lead under the wire
23. License plate light lead harness and negative battery lead.
24. Rear turn signal light lead (left) U. Route the fuse box lead between the outer rib of
25. Rear turn signal light lead (right) the hydraulic unit tray and the rib for installing the
fuse box.
26. Positive battery lead
V. Route the negative battery lead under the other
27. Starter relay lead
leads.
28. EXUP servo motor lead
W. Route the Yamaha diagnostic tool coupler lead,
29. Main fuse lead joint coupler lead, IMU lead, and CCU lead to the
30. Starter motor lead inside of the rib on the hydraulic unit tray. The
31. Fuse box leads may be routed in any order.
32. Fuse box lead X. Route the starter motor lead under the negative
33. Joint coupler lead battery lead.
34. IMU lead
35. CCU lead (To sub-wire harness for YZF-R1M)
A. The rear turn signal light leads, license plate light
lead, and tail/brake light lead may be routed in any
order.
B. Insert the projection on the rear wheel sensor
coupler into the hole in the hydraulic unit tray.
C. Position the rear brake light switch coupler toward
the hydraulic unit.
D. Fasten the rear wheel sensor lead and rear brake
light switch lead to the hydraulic unit tray with a
plastic locking tie. Point the end of the plastic
locking tie upward, and then cut off the excess end
of the tie to 5 mm (0.2 in) or less.
E. Route the rear brake light switch lead to the
outside of the EXUP cables, and between the
brake hoses.
F. Fasten the rear wheel sensor lead and rear brake
light switch lead to the brake hose with a plastic
locking tie. Point the end of the plastic locking tie
downward.
G. Route the rear wheel sensor lead to the outside of
the EXUP cables, and between the brake hoses.
H. Route the rear shock absorber assembly stepping
motor lead to the inside of the brake hose and to
the inside of rear brake light switch lead. (For
YZF-R1M)
2-36
CABLE ROUTING
Rear fender (left side view)
9 10
3 2
C D
4 A
5 6 B
7 8
9 3 E 10
3 F
11
G
8 7
2-37
CABLE ROUTING
1. Rear fender
2. Mudguard assembly
3. License plate light lead
4. License plate light coupler
5. Rear turn signal light coupler (left)
6. Rear turn signal light coupler (right)
7. EXUP cable 2
8. EXUP cable 1
9. Rear turn signal light lead (left)
10. Rear turn signal light lead (right)
11. Hydraulic unit tray
A. Route the license plate light lead under the rear
turn signal light couplers.
B. Rear turn signal light (left): Connect the black
sections of the coupler. Rear turn signal light
(right): Connect the white sections of the coupler.
The rear turn signal light coupler (left) and rear turn
signal light coupler (right) may be positioned in any
order.
C. Insert the projection on each rear turn signal light
lead holder into the hole in the tail/brake light
bracket. The rear turn signal light lead holders may
be placed in any order.
D. Make sure that the license plate light lead is not
positioned on top of the nut on the mudguard
assembly.
E. Fasten the license plate light lead and rear turn
signal light leads with the holder. Position the
holder to the rear of the ends of the protective
sleeves of the rear turn signal light leads, making
sure that the protective sleeves are not rolled up.
F. Fasten the license plate light lead with the holders
on the mudguard assembly.
G. Route the EXUP cables through the guide on the
hydraulic unit tray.
2-38
CABLE ROUTING
Rear brake hose (right side view)
E
17
1
5
16 13
15 7 F 5
13
C
D
G 13
1 6 I H
2
3
18 13 P
15
16
14
O 13
8
13 4
12
6
8 7
A
9
11 B J
10
5
13
10 8
10 8 9 5
N 6 M 6 L 6 7
K 6
2-39
CABLE ROUTING
1. Hydraulic unit
2. Rear frame
3. Brake fluid reservoir
4. Frame
5. Brake hose (rear brake master cylinder to
hydraulic unit)
6. Rear wheel sensor lead
7. Rear brake master cylinder
8. Swingarm assembly
9. Rear wheel sensor lead cover
10. Rear wheel sensor protector
11. Rear wheel sensor
12. Rear brake caliper
13. Brake hose (hydraulic unit to rear brake caliper)
14. Brake fluid reservoir hose
15. Hydraulic unit brake pipe (hydraulic unit to rear
brake caliper)
16. Hydraulic unit brake pipe (rear brake master
cylinder to hydraulic unit)
17. Rear brake hose bracket
18. Rear fender
A. Make sure that the rear wheel sensor lead does
not protrude from the rear wheel sensor lead cover.
B. Route the rear wheel sensor lead between the
swingarm assembly and the rear wheel sensor
lead cover.
C. 59.3°
D. 57.3°
E. Install the holder 0–10 mm (0–0.39 in) from the slit
in the brake hose protector.
F. Position the holder as shown in the illustration.
G. Route the rear wheel sensor lead to the rear of the
brake hose (hydraulic unit to rear brake caliper).
H. Position the holder 0–10 mm (0–0.39 in) from the
top edge of the brake hose protector.
I. Fasten the rear wheel sensor lead under the white
tape on the lead with the holder.
J. Install the larger diameter side of the holder on the
metal fitting section of the brake hose (rear brake
master cylinder to hydraulic unit).
K. Fasten the grommet on the rear wheel sensor lead
with the holder.
L. Fasten the grommet on the rear wheel sensor lead
with the holder on the rear wheel sensor lead
cover.
M. Fasten the grommet on the rear wheel sensor lead
with the holder on the rear wheel sensor protector.
N. Fasten the rear wheel sensor lead with the holder
on the rear wheel sensor protector.
O. Route the brake hose (hydraulic unit to rear brake
caliper) between the rear brake hose holder and
the swingarm assembly.
P. Fasten the brake hose (hydraulic unit to rear brake
caliper) with the holder. Face the catch of the
holder upward.
2-40
CABLE ROUTING
Front brake hose (left side view)
M H I
P
7
N 1
O 1
7
G
1
1 8
L 1
2 2
J 3
2
F
6 9 3 K B A
9 1
2
5 9
B
C 2 3
3 D
6
4
2
E
5 4
6 3
5 6
2-41
CABLE ROUTING
1. Brake hose (front brake master cylinder to

hydraulic unit)
2. Brake hose (hydraulic unit to front brake calipers)
3. Front wheel sensor lead
4. Front brake caliper
5. Front wheel sensor
6. Front fork leg
7. Collar
8. Front brake master cylinder
9. Front wheel sensor protector
A. Point the open ends of the holder forward.
B. Fasten the front wheel sensor lead to the brake
hose (hydraulic unit to front brake calipers) with the
holder. Position the holder above the flange on the
brake hose (hydraulic unit to front brake calipers).
Route the front wheel sensor lead to the inside of
the brake hose (hydraulic unit to front brake
calipers).
C. Route the front wheel sensor lead along the left
hose of the brake hose (hydraulic unit to front
brake calipers) without any slack.
D. Route the front wheel sensor lead to the inside of
the brake hose (hydraulic unit to front brake
calipers).
E. Fasten the front wheel sensor lead at the white
tape with the holder.
F. Install the holder on the shrink-tubing portion of the
brake hose (hydraulic unit to front brake calipers).
G. Install the collar so that the edge of the collar is
positioned 1–2 mm (0.04–0.08 in) from the end of
the projection.
H. 90°
I. Install the collar so that its slit is positioned within
the range shown in the illustration.
J. For YZF-R1M
K. Route the front wheel sensor lead through the
guide on the front wheel sensor protector.
L. Fasten the brake hose (front brake master cylinder
to hydraulic unit) at the shrink-tubing portion of the
hose to the outer tube with a plastic locking tie.
Position the plastic locking tie below the flange on
the brake hose (front brake master cylinder to
hydraulic unit).
M. Rearward
N. Position the buckle of the plastic locking tie 10 mm
(0.39 in) or more from the brake hose (front brake
master cylinder to hydraulic unit).
O. Forward
P. Cut off the excess end of the plastic locking tie to 5
mm (0.2 in) or less. The end of the plastic locking
tie may be pointing in any direction.
2-42
CABLE ROUTING
Front brake hose (left side view)
4 2 3
1 2 1 3 A
2 4
3
3
4 1
4
2-43
CABLE ROUTING
1. Brake hose bracket

2. Frame
3. Brake hose (hydraulic unit to front brake calipers)
4. Brake hose (front brake master cylinder to
hydraulic unit)
A. Install the brake hose (front brake master cylinder
to hydraulic unit) so that it is on the inside relative
to the brake hose (hydraulic unit to front brake
calipers). There is an identifying white paint mark
on the upper surface of the pipe of the brake hose
(front brake master cylinder to hydraulic unit).
2-44
CABLE ROUTING
Hydraulic unit assembly (top and left side view)

3 4
A
1
5
11 B
7
8
C
10
4 3
7
8
11
10
2-45
CABLE ROUTING
1. Brake hose (front brake master cylinder to brake

hose joint)
2. Brake hose (front brake calipers to brake hose
joint)
3. Brake hose (front brake caliper side brake hose
joint to hydraulic unit)
4. Brake hose (front brake master cylinder side brake
hose joint to hydraulic unit)
5. Brake hose (rear brake master cylinder to
hydraulic unit)
6. Brake hose (hydraulic unit to rear brake caliper)
7. Hydraulic unit
8. Rear frame
9. Hydraulic tray
10. Rear brake hose bracket
11. Brake hose joint
A. 23 mm (0.91 in)
B. 54.8°
C. 17.2 mm (0.68 in)
Install the hydraulic unit brake pipe (front brake
master cylinder to hydraulic unit) and hydraulic unit
brake pipe (hydraulic unit to front brake calipers) so
that they are parallel to each other.
2-46
CABLE ROUTING
Fuel tank (top and left side view)
5 B 4 A 3 2
5 2
2-47
CABLE ROUTING
1. Fuel tank
2. Fuel pump
3. Fuel tank breather hose
5. Fuel hose 1 (fuel tank to fuel hose 2)
A. Point the end of the hose clamp outward.
B. Install the fuel tank drain hose with its white paint
mark facing outward.
2-48
CABLE ROUTING
Canister
1 2 3 4
B 10 B D 9 8 C 7 B
F
10
E
G
11 7
2-49
CABLE ROUTING

2. Canister
3. Canister holder
4. O2 sensor coupler
5. Neutral switch coupler
6. Fuel pump lead
7. Fuel tank breather hose (fuel tank to canister)
10. Canister purge hose (hose joint to canister)
11. Canister bracket
A. Route the neutral switch lead and O2 sensor lead
to the front of and under the fuel tank breather
hose (fuel tank to canister).
B. Point the ends of the hose clamp in the direction
C. Install the fuel tank breather hose (fuel tank to
canister) with its yellow paint mark facing upward.
D. Install the canister with its stamped mark facing
upward.
E. To throttle bodies
F. To fuel tank
G. Install the fuel tank breather hose (fuel tank to
canister) with its white paint mark facing outward.
H. Install the canister purge hose (hose joint to
canister) onto the canister so that the end of the
hose is pointing in the direction of the arrow shown.
2-50
CABLE ROUTING
Air filter case and throttle bodies (top and left side view)
1
4
A
5
7 6
10
11 B
12 6 C 4
2-51
CABLE ROUTING
1. Air filter case

2. Secondary injector
3. Fuel hose (fuel rail to fuel rail)
4. Crankcase breather hose
5. Fuel hose 2 (secondary injector fuel rail side)
6. Canister purge hose
7. Throttle body position sensor
10. Fuel hose 3 (fuel hose 2 to throttle body)
11. Service hose
A. To one-way valve (intake solenoid)
B. Route the service hose to the under the cooling
system air bleed hose.
C. Point the ends of the hose clamp to the right.
Position the hose clamp 0–5 mm (0–0.2 in) from
the end of the hose.
2-52
CABLE ROUTING
Air cut-off valve (right side view)
C
5 3
5
7
D
1 A
2-53
CABLE ROUTING
1. Air filter case

2. Air cut-off valve
3. Air induction system hose (air filter case to air cut-off
valve)
4. Cylinder head cover
5. Air induction system hose (air cut-off valve to reed
valve cover)
6. Cylinder identification sensor
7. Cylinder identification sensor lead
A. Point the end of the clamp to the right. Install the air
induction system hose (air filter case to air cut-off
valve) with its white paint mark facing outward. Make
sure that the clamp is not installed on the flange of the
hose fitting of the air filter case.
When installing the air induction system hose (air
filter case to air cut-off valve), may apply water to the
air induction system hose.
B. Point the end of the clamp to the left.
C. Point the end of the clamp upward.
D. Insert the air induction system hose (air cut-off valve
to reed valve cover) until it contacts the reed valve
cover. Make sure that the clamp is not installed on the
flange of the hose fitting of the reed valve cover.
E. Point the end of the clamp to the right.
2-54
CABLE ROUTING
Air duct (left and right side view)
1
C
2
8
6
G
F H 2
I
E 3 4
D 4
1
A
2
3
2 1
6
8
7
2-55
CABLE ROUTING
1. Air intake duct valve

2. Air intake duct
3. Surge tank
4. Surge tank hose
5. One-way valve
6. Intake solenoid vacuum hose (one-way valve to
intake solenoid)
7. Intake solenoid vacuum hose (intake solenoid to
air intake duct valve)
8. Intake solenoid
A. Install the surge tank hose onto the surge tank,
making sure that the end of the hose contacts the
tank.
B. Install the intake solenoid vacuum hoses onto the
intake solenoid, making sure that the end of each
hose contacts the solenoid.
C. Install the intake solenoid vacuum hose (intake
solenoid to air intake duct valve) up to the bend in
the hose fitting of the air intake duct valve.
D. Install the surge tank hose with its white paint mark
facing upward.
E. Position the hose holder 13 mm (0.51 in) or less
from the end of the one-way valve.
F. Install the surge tank hose onto the one-way valve,
valve.
G. Install the intake solenoid vacuum hose (one-way
valve to intake solenoid) onto the one-way valve,
valve.
H. Install the plastic locking tie completely onto the rib
on the air intake duct.
I. Cut off the excess end of the plastic locking tie to 5
mm (0.2 in) or less.
2-56
CABLE ROUTING
Radiator (left side view)

B C D
E
G F
5
2
A
6
4
3
7
2
H
O
2
8
D
J
9 I
G
N K
3
L
3 M
2-57
CABLE ROUTING

3. Hose clamp
4. Radiator inlet hose
5. Cylinder
6. Crankcase
7. Generator cover
8. Water pump outlet pipe
9. Radiator outlet hose
A. Align the white paint mark on the radiator inlet
hose, projection on the radiator pipe, and crimped
section of the hose clamp. Install the radiator inlet
hose up to the center of the projection on the
radiator pipe. After installing the hose clamp, the
end of the radiator inlet hose should cover the
projection on the radiator pipe.
B. Oval shaped projection on the hose clamp (2
locations)
C. Align the yellow paint mark on the radiator inlet
hose, projection on the thermostat assembly, and
oval shaped projections on the hose clamp. Install
the radiator inlet hose until it contacts the
projection on the thermostat assembly.
D. Hose clamp installation details
E. 2 mm (0.08 in) or more
F. Installed length: 20 mm (0.79 in)
G. Make sure not to install the hose clamp on the
raised portion of the hose fitting of the thermostat
assembly.
H. When installing the thermostat assembly, make
sure that the projection on the thermostat
assembly fits into the slot in the generator cover.
I. 3 mm (0.12 in) or more
J. Installed length
K. Make sure that the hose clamp is not installed in a
slanted position as shown in the illustration.
L. Make sure to hook the end of the hose clamp
securely onto the projection on the hose clamp.
(Do not install the hose clamp as shown in the
illustration.)
M. Install the hose clamp so that both edges are
parallel to each other.
N. Make sure that the projection on the center of the
hose clamp fits into the cutout in the clamp.
O. Face the crimped section of the hose clamp to the
left.
2-58
CABLE ROUTING
Radiator (right side view)
H I
F
9
G 1
2
K J
2
A B
4
5
E 6
L
5
8 7
N
H R
U
V O
T Q
W
P
S
X
Y
2-59
CABLE ROUTING
1. Air induction system hose U. 3 mm (0.12 in) or more

2. Cooling system air bleed hose V. Make sure not to install the hose clamp on the
3. Radiator raised portion of the hose fitting of the water pump
4. Radiator outlet hose inlet pipe.
5. Hose clamp cover W. Make sure that the hose clamp is not installed in a
slanted position as shown in the illustration.
6. Hose clamp
X. Make sure to hook the end of the hose clamp
7. Water pump inlet pipe
securely onto the projection on the hose clamp.
8. Water pump outlet pipe (Do not install the hose clamp as shown in the
9. Thermostat assembly illustration.)
A. Route the cooling system air bleed hose under the Y. Install the hose clamp so that both edges are
fuel rail. parallel to each other.
B. Route the cooling system air bleed hose to the
outside of the air induction system hose.
C. Point the ends of the hose clamp to the right. Make
sure not to install the hose clamp on the raised
portion of the hose fitting.
D. Install the radiator outlet hose onto the radiator
pipe until the end of the hose contacts the
projection on the pipe. Align the white paint mark
on the radiator outlet hose with the projection on
the radiator pipe. Align the white paint mark on the
radiator outlet hose with the outer ribs on the hose
fittings.
E. Align the yellow paint mark on the radiator outlet
hose, the black paint mark on the water pump inlet
pipe, and the crimped section of the hose clamp.
Insert the radiator outlet hose up to the center of
the white paint mark on the water pump inlet pipe.
F. Align the white paint mark on the cooling system
air bleed hose with the projection on the
thermostat housing. Install the cooling system air
bleed hose onto the thermostat housing until the
end of the hose contacts the projection on the pipe.
G. Point the ends of the hose clamp away from the
projection on the thermostat housing and toward
the bolt. Make sure not to install the hose clamp on
the raised portion of the hose fitting.
H. Hose clamp installation details
I. 2 mm (0.08 in) or more
J. Installed length: 20 mm (0.79 in)
K. Make sure not to install the hose clamp on the
raised portion of the hose fitting.
L. Install the hose clamp cover so that the end of the
cover is pointed to the right.
M. Position the yellow paint mark on the radiator
outlet hose within the range shown in the
illustration. Install the screw clamp with the screw
head facing to the right.
N. Face the fastener of the screw clamp to the right
within the 45° range shown in the illustration.
O. Detail of the hose fitting portion: Keep a hose
clamp interference of 0–1 mm (0– 0.04 in) with
respect to the basic diameter of the hose as
shown. The hose clamp interference refers to the
basic external hose diameter and excludes any
bulging at the end of the hose.
P. Make sure not to install the hose clamp on the
raised portion of the hose fitting.
Q. 3 mm (0.12 in) or more
R. Installed length
S. 0–1 mm (0–0.04 in)
T. Make sure that the projection on the center of the
hose clamp fits into the cutout in the clamp.
2-60
CABLE ROUTING
Muffler (top and left side view)
5 5 4
6 6
1 2
3 4
6 5
4
5
2-61
CABLE ROUTING
1. Exhaust chamber
2. EXUP valve pulley cover
3. Muffler
4. EXUP servo motor
5. EXUP cable 2
6. EXUP cable 1
A. Route EXUP cable 1 and EXUP cable 2 through
the guide. Route EXUP cable 1 above EXUP cable
2. Align the white paint mark on each cable with
the guide.
2-62
CABLE ROUTING
CCU (top and right side view) (for YZF-R1M)
A 1 B C 2 3
4
8 6
9
5 9
E F
10
H G
5
4
2-63
CABLE ROUTING
1. CCU (Communication Control Unit)

2. GPS unit lead
3. GPS unit coupler
4. Wire harness coupler cap
5. Wire harness coupler (to sub-wire harness)
6. Yamaha diagnostic tool coupler
7. CCU (Communication Control Unit) lead (sub-wire
harness)
8. Passenger seat cover
9. GPS unit
10. Rear cover
A. Fasten the CCU and CCU bracket with the plastic
locking tie.
B. Fasten the CCU and CCU bracket with the band.
C. Connect the CCU coupler (sub-wire harness) to
the CCU.
D. Fasten the sub-wire harness to the rear frame with
the clamp. Align the corrugated end of the sub-wire
harness with end of the clamp.
E. Route the GPS unit lead between the passenger
seat cover and the rear cover.
F. Route the GPS unit lead as shown in the
illustration.
G. Route the GPS unit lead to the inside of the vehicle
through the hole in the passenger seat cover.
H. Fasten the GPS unit lead with the clamp on the
passenger seat cover.
2-64
CABLE ROUTING
2-65
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 (Primary injector)........................................ 3-4
CHECKING THE FUEL LINE (Secondary injector) ...................................3-4
CHECKING THE SPARK PLUGS ............................................................. 3-5
ADJUSTING THE VALVE CLEARANCE .................................................. 3-6
CHECKING THE ENGINE IDLING SPEED ..............................................3-9
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-9
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-11
CHECKING THE CRANKCASE BREATHER HOSE ..............................3-11
CHECKING THE EXHAUST SYSTEM....................................................3-11
3
CHECKING THE CANISTER .................................................................. 3-11
ADJUSTING THE EXHAUST GAS VOLUME .........................................3-12
CHECKING THE AIR INDUCTION SYSTEM..........................................3-12
REPLACING THE AIR FILTER ELEMENT ............................................. 3-12
ADJUSTING THE CLUTCH LEVER FREE PLAY................................... 3-13
CHECKING THE BRAKE OPERATION .................................................. 3-13
CHECKING THE BRAKE FLUID LEVEL................................................. 3-13
ADJUSTING THE FRONT DISC BRAKE................................................ 3-14
CHECKING THE FRONT BRAKE PADS ................................................ 3-14
ADJUSTING THE REAR DISC BRAKE .................................................. 3-15
CHECKING THE REAR BRAKE PADS .................................................. 3-15
CHECKING THE FRONT BRAKE HOSES ............................................. 3-15
CHECKING THE REAR BRAKE HOSE .................................................. 3-16
BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)......................... 3-16
CHECKING THE WHEELS ..................................................................... 3-17
CHECKING THE TIRES..........................................................................3-17
CHECKING THE WHEEL BEARINGS ....................................................3-18
CHECKING THE SWINGARM OPERATION ..........................................3-18
LUBRICATING THE SWINGARM PIVOT ............................................... 3-19
DRIVE CHAIN SLACK............................................................................. 3-19
LUBRICATING THE DRIVE CHAIN ........................................................ 3-20
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-20
LUBRICATING THE STEERING HEAD.................................................. 3-21
CHECKING THE STEERING DAMPER.................................................. 3-21
CHECKING THE CHASSIS FASTENERS .............................................. 3-21
LUBRICATING THE BRAKE LEVER ......................................................3-21
LUBRICATING THE CLUTCH LEVER....................................................3-21
LUBRICATING THE PEDAL ................................................................... 3-21
CHECKING THE SIDESTAND................................................................3-21
LUBRICATING THE SIDESTAND........................................................... 3-21
CHECKING THE SIDESTAND SWITCH................................................. 3-21
CHECKING THE FRONT FORK ............................................................. 3-21
ADJUSTING THE FRONT FORK LEGS (for YZF-R1)............................ 3-22
ADJUSTING THE PRELOAD OF THE FRONT FORK LEGS
(for YZF-R1M) ........................................................................................ 3-23
ADJUSTING THE DAMPING FORCE OF THE FRONT FORK LEGS
AND REAR SHOCK ABSORBER ASSEMBLY (for YZF-R1M).............. 3-24
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-26
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
(for YZF-R1) ........................................................................................... 3-26
ADJUSTING THE PRELOAD OF THE REAR SHOCK ABSORBER
ASSEMBLY (for YZF-R1M) .................................................................... 3-28
CHECKING THE CONNECTING ARM AND RELAY ARM.....................3-29
CHECKING THE ENGINE OIL LEVEL....................................................3-29
CHANGING THE ENGINE OIL ...............................................................3-29
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-30
CHECKING THE COOLANT LEVEL.......................................................3-32
CHECKING THE COOLING SYSTEM ....................................................3-32
CHANGING THE COOLANT................................................................... 3-32
ADJUSTING THE EXUP CABLES .......................................................... 3-34
CHECKING THE FRONT BRAKE LIGHT SWITCH ................................3-35
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-35
CHECKING AND LUBRICATING THE CABLES .................................... 3-36
CHECKING THE THROTTLE GRIP........................................................ 3-36
CHECKING AND CHARGING THE BATTERY....................................... 3-36
CHECKING THE FUSES ........................................................................3-36
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-36
PERIODIC MAINTENANCE
EAS20022
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• Items marked with an asterisk should be performed by your Yamaha dealer because these items re-
quire special tools, data, and technical skills.
• From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
• The annual checks must be performed every year, except if a distance-based maintenance is
performed instead.
ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
NO. ITEM JOB CHECK
1000 km 10000 km 20000 km 30000 km 40000 km
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition.
• Adjust gap and clean. √ √
2 * Spark plugs
• Replace. √ √
3 * Valve clearance • Check and adjust. Every 40000 km (24000 mi)
• Check engine idle speed. √ √ √ √ √ √
4 * Fuel injection • Check and adjust synchroni- √ √ √ √ √
zation.
• Check for leakage.
5 * Exhaust system • Tighten if necessary. √ √ √ √ √
• Replace gaskets if necessary.
Evaporative emis- • Check control system for
6 * sion control sys- damage. √ √
tem • Replace if necessary.
• Check the air cut-off valve,
Air induction sys- reed valve, and hose for dam-
7 * age. √ √ √ √ √
tem • Replace any damaged parts if
necessary.
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• Items marked with an asterisk should be performed by your Yamaha dealer because these items re-
quire special tools, data, and technical skills.
• From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).
• The annual checks must be performed every year, except if a distance-based maintenance is
performed instead.
3-1
ODOMETER READING
NO. ITEM
JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
• Perform dynamic inspection

Diagnostic sys-
1 * tem check using Yamaha diagnostic tool. √ √ √ √ √ √
• Check the DTC.
2 * Air filter element • Replace. Every 40000 km (24000 mi)
• Check operation.
3 Clutch • Adjust. √ √ √ √ √
• Check operation, fluid level,

and for fluid leakage.
4 * Front brake • Replace brake pads if neces- √ √ √ √ √ √
sary.
• Check operation, fluid level,
and for fluid leakage.
5 * Rear brake √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check for cracks or damage. √ √ √ √ √
6 * Brake hoses
• Replace. Every 4 years
7 * Brake fluid • Change. Every 2 years
• Check runout and for dam-
8 * Wheels age. √ √ √ √
• Check tread depth and for
damage.
9 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
10 * Wheel bearings or damage. √ √ √ √
• Check operation and for ex- √ √ √ √

Swingarm pivot cessive play.
11 * bearings
• Lubricate with lithium-soap-
Every 50000 km (30000 mi)
based grease.
• Check chain slack, alignment
and condition.
Every 800 km (500 mi) and after washing the motorcycle, riding in the
12 Drive chain • Adjust and lubricate chain rain or riding in wet areas
with a special O-ring chain lu-
bricant thoroughly.
• Check bearing assemblies for √ √ √
looseness.
13 * Steering bearings
• Moderately repack with lithi-
√ √
um-soap-based grease.
• Check operation and for oil
14 * Steering damper leakage. √ √ √ √
• Make sure that all nuts, bolts

15 * Chassis fasteners and screws are properly tight- √ √ √ √ √
ened.
16 Brake lever pivot • Lubricate with silicone √ √ √ √ √

shaft grease.
Brake pedal pivot • Lubricate with lithium-soap-
17 √ √ √ √ √
shaft based grease.
Clutch lever pivot • Lubricate with lithium-soap-
18 shaft based grease. √ √ √ √ √
19 Shift pedal pivot • Lubricate with molybdenum √ √ √ √ √

shaft disulfide grease.
20 Sidestand • Lubricate with lithium-soap- √ √ √ √ √
based grease.
21 * Sidestand switch • Check operation and replace √ √ √ √ √ √

if necessary.
22 * Front fork leakage. √ √ √ √
3-2
ODOMETER READING
NO. ITEM
JOB 1000 km 10000 km 20000 km 30000 km 40000 km CHECK
(600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi)
Shock absorber
23 * assembly leakage. √ √ √ √
Rear suspension
relay arm and
24 * connecting arm • Check operation. √ √ √ √
pivoting points
• Change (warm engine before
draining).
25 Engine oil √ √ √ √ √ √
• Check oil level and vehicle for
oil leakage.
Engine oil filter
26 • Replace. √ √ √
cartridge
• Check coolant level and vehi-
cle for coolant leakage. √ √ √ √ √
27 * Cooling system
• Change. Every 3 years
• Check operation, cable free
28 * EXUP system play and pulley position. √ √ √
29 * Front and rear • Check operation. √ √ √ √ √ √

brake switches
Moving parts and
30 * • Lubricate. √ √ √ √ √
cables
31 * Throttle grip • Lubricate the throttle grip tube √ √ √ √ √
guides.
Lights, signals • Check operation.
32 * and switches • Adjust headlight beam. √ √ √ √ √ √
TIP
• Air filter
• This model’s air filter uses a disposable oil-coated paper element. This element cannot be cleaned
with compressed air, doing so will only damage it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• Hydraulic brake service
• Regularly check the front and rear brake fluid levels. Replenish if necessary.
• Every two years replace the rear brake master cylinder, the internal components of the front brake
master cylinder, and the brake calipers, and change the brake fluid.
• Replace the brake hoses every four years or sooner if cracked, damaged, or if any section of the
stainless steel brake hose has turned black.
3-3
EAS32024 EAS30619
CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE (Primary
YAMAHA DIAGNOSTIC TOOL injector)
Use the Yamaha diagnostic tool and check the The following procedure applies to all of the fuel,
vehicle according to the following procedure. drain and breather hoses.
1. Remove: 1. Remove:
• Rider seat • Rider seat
• Battery cover Refer to “GENERAL CHASSIS (1)” on page
Refer to “GENERAL CHASSIS (1)” on page 4-1.
4-1. • Fuel tank
2. Remove the protective cap, and then connect Refer to “FUEL TANK” on page 7-1.
the Yamaha diagnostic tool to the coupler. 2. Check:
• Fuel hose “1”
Yamaha diagnostic tool USB • Fuel tank drain hose “2”
90890-03267 • Fuel tank breather hose “3”
Yamaha diagnostic tool (A/I) Cracks/damage → Replace.
90890-03264
Loose connection → Connect properly.
ECA14940
TIP NOTICE
• Yamaha diagnostic tool (A/I) (90890-03264) in- Make sure the fuel tank breather hose is rout-
cludes YDT sub harness (6P) (90890-03266). ed correctly.
• If you already have Yamaha diagnostic tool (A/
I) (90890-03262), YDT sub harness (6P) TIP
(90890-03266) is separately required. Before removing the fuel hoses, place a few
rags in the area under where it will be removed.
Refer to “YDT” on page 9-2.
3. Check:
• DTC 1
TIP
Use the “Diagnosis of malfunction” function of
the Yamaha diagnostic tool to check the DTC.
For information about using the Yamaha diag-
nostic tool, refer to the operation manual that is
2 3
included with the tool.
DTC number is displayed → Check and re-
pair the probable cause of the malfunction.
3. Install:
Refer to “SELF-DIAGNOSTIC FUNCTION
• Fuel tank
AND DIAGNOSTIC CODE TABLE” on page
Refer to “FUEL TANK” on page 7-1.
9-40.
• Fuel tank cover
4. Perform:
• Rider seat
• Dynamic inspection
Refer to “GENERAL CHASSIS (1)” on page
TIP 4-1.
Use the “Dynamic inspection” function of the
Yamaha diagnostic tool version 3.0 and after to EAS31633
CHECKING THE FUEL LINE (Secondary

perform the dynamic inspection. For information
injector)
about using the Yamaha diagnostic tool, refer to
1. Remove:
the operation manual that is included with the
• Rider seat
tool.
5. Install: 4-1.
• Rider seat • Fuel tank cover
• Battery cover • Fuel tank
Refer to “GENERAL CHASSIS (1)” on page Refer to “FUEL TANK” on page 7-1.
4-1.
3-4
2. Check:
• Fuel hose “1” Manufacturer/model
Cracks/damage → Replace. NGK/LMAR9E-J
4. Check:
TIP • Electrode “1”
Before removing the fuel hose, place a few rags Damage/wear → Replace the spark plug.
in the area under where it will be removed. • Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
1 • Spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

3. Install: 0.6–0.7 mm (0.024–0.028 in)
• Fuel tank
• Rider seat
4-1.
EAS30620
CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Remove: G088880
• Rider seat
7. Install:
• Spark plugs
4-1.
• Ignition coils
• Fuel tank
Refer to “FUEL TANK” on page 7-1. Spark plug
• Air filter case 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
Refer to “AIR FILTER CASE” on page 7-5. Spark plug (new)

• Air cut-off valve 18 N·m (1.8 kgf·m, 13 lb·ft)
Refer to “AIR INDUCTION SYSTEM” on
page 7-19. TIP
2. Remove: • Before installing the spark plug, clean the
• Ignition coils spark plug and gasket surface.
• Spark plugs • If the spark plug is a new one, tighten it to 18
ECA13320
NOTICE
N·m (1.8 kgf·m, 13 lb·ft).
Before removing the spark plugs, blow away 8. Install:
any dirt accumulated in the spark plug wells • Air cut-off valve
with compressed air to prevent it from falling Refer to “AIR INDUCTION SYSTEM” on
into the cylinders. page 7-19.
• Air filter case
3. Check:
Refer to “AIR FILTER CASE” on page 7-5.
• Spark plug type
• Fuel tank
Incorrect → Change.
3-5
• Rider seat 4. Measure:

Refer to “GENERAL CHASSIS (1)” on page • Valve clearance
4-1. Out of specification → Adjust.
EAS30622
Valve clearance (cold)
ADJUSTING THE VALVE CLEARANCE Intake
The following procedure applies to all of the 0.09–0.17 mm (0.0035–0.0067 in)
valves. Exhaust
TIP 0.18–0.23 mm (0.0071–0.0091 in)
• Valve clearance adjustment should be made
on a cold engine, at room temperature. a. Turn the crankshaft counterclockwise.
• When the valve clearance is to be measured or b. When piston #1 is at TDC on the compres-
adjusted, the piston must be at top dead center sion stroke, align the TDC mark “a” on the
(TDC) on the compression stroke. generator rotor with the generator rotor
cover slot “b”.
1. Remove:
• Rider seat a b
4-1.
• Front panel cover
4-9.
• Front side cowling
4-16.
• Side cover
• Front side cowling inner panel TIP
Refer to “GENERAL CHASSIS (6)” on page TDC on the compression stroke can be found
4-23. when the camshaft lobes are turned away from
• Side cover bracket each other.
c. Measure the valve clearance #1 with a
4-32. thickness gauge.
• Electrical components tray
TIP
4-34. Measure the valve clearance between the cam
• Fuel tank lobe and rocker arm “c”.
• Air filter case Thickness gauge
Refer to “AIR FILTER CASE” on page 7-5. 90890-03268
• Air cut-off valve Feeler gauge set
Refer to “AIR INDUCTION SYSTEM” on YU-26900-9
page 7-19.
• Radiator
Refer to “RADIATOR” on page 6-3.
c
2. Remove:
• Ignition coils c
• Spark plugs
• Cylinder head cover
• Cylinder head cover gasket
Refer to “CAMSHAFTS” on page 5-17.
3. Remove:
• Timing mark accessing bolt
• Crankshaft end cover
Refer to “GENERATOR” on page 5-43.
3-6
TIP
e b
• If the valve clearance is incorrect, record the
measured reading.
• Measure the valve clearance in the following
sequence.
Valve clearance measuring sequence

Cylinder #1 → #3 → #2 → #4
i. Measure the valve clearance #2 with a

thickness gauge.
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
G088883
j. Turn the crankshaft counterclockwise.
k. When piston #4 is at TDC on the compres-
A. Front sion stroke, align the TDC mark “f” on the
d. Turn the crankshaft counterclockwise. generator rotor with the generator rotor
e. When piston #3 is at TDC on the compres- cover slot “b”.
sion stroke, align the TDC mark “d” on the
f b
generator rotor with the generator rotor
cover slot “b”.
d b
l. Measure the valve clearance #4 with a

thickness gauge.
Thickness gauge
f. Measure the valve clearance #3 with a 90890-03268
thickness gauge. Feeler gauge set
YU-26900-9
Thickness gauge
90890-03268 5. Remove:
Feeler gauge set • Camshaft
YU-26900-9
TIP
g. Turn the crankshaft counterclockwise. • Refer to “CAMSHAFTS” on page 5-17.
h. When piston #2 is at TDC on the compres- • When removing the timing chain and cam-
sion stroke, align the TDC mark “e” on the shafts, fasten the timing chain with a wire to re-
generator rotor with the generator rotor trieve it if it falls into the crankcase.
cover slot “b”. 6. Adjust:
• Valve clearance
a. Pull the rocker arm “1” up, and then re-
move the valve pad “2”.
3-7
d. Calculate the sum of the values obtained

in steps (b) and (c) to determine the re-
quired valve pad thickness and the valve
pad number.
2 Example:
1.60 mm (0.063 in) + 0.03 mm (0.001 in) =
1.63 mm (0.064 in)
The valve pad number is A63.
1 e. Round off the valve pad number according
to the following table, and then select the
TIP suitable valve pad.
• Cover the timing chain opening with a rag to Last digit Rounded value
prevent the valve pad from falling into the 0, 1, 2 0
crankcase. 3, 4, 5, 6 5
• Make a note of the position of each valve pad
7, 8, 9 10
so that they can be installed in the correct
place. TIP
b. Calculate the difference between the Refer to the following table for the available
specified valve clearance and the mea- valve pads.
sured valve clearance.
Example: Valve pad range No. A60–A99, B00–B40
Specified valve clearance = 0.09–0.17 Valve pad thickness
1.60–2.40 mm
mm (0.004–0.007 in) (0.0630–0.0944 in)
Measured valve clearance = 0.20 mm 17 thicknesses in 0.05
(0.008 in) Available valve pads mm (0.002 in) incre-
0.20 mm (0.008 in) - 0.17 mm (0.007 in) = ments
0.03 mm (0.001 in) Example:
c. Check the thickness of the current valve Valve pad number = A63
pad. Rounded value = A65
TIP New valve pad number = A65
• The letter and number “a” marked on the valve f. Install the new valve pad “3” and then,
pad indicate the valve pad thickness. push the rocker arm “1” down.
• The letter A marked on the valve pad indicates TIP
1 mm (0.04 in), while B indicates 2 mm (0.08 • Lubricate the valve pad with molybdenum di-
in). sulfide oil.
• The number marked on the valve pad indicates • Install the valve pad in the correct place.
hundredths of millimeters.
Example:
If the valve pad is marked “A60”, the pad
thickness is 1.60 mm (0.063 in).
If the valve pad is marked “B30”, the pad
3
thickness is 2.30 mm (0.091 in).
a 1
g. Install the exhaust and intake camshafts,

timing chain and camshaft caps.
G088886
3-8
Refer to “CHECKING AND CLEANING THE

Camshaft cap bolt THROTTLE BODIES” on page 7-14.
8 N·m (0.8 kgf·m, 5.9 lb·ft) a. Connect the Yamaha diagnostic tool.
T.
R.
Camshaft cap bolt (new) Use the diagnostic code number “67”.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
Refer to “SELF-DIAGNOSTIC FUNC-
TION AND DIAGNOSTIC CODE TABLE”
TIP
on page 9-40.
• Refer to “CAMSHAFTS” on page 5-17. b. Check the ISC (Idle Speed Control) lean-
• Lubricate the camshaft lobes and camshaft ing value.
journals.
• First, install the exhaust camshaft. EAS30797
• Align the camshaft sprocket marks with the cyl- SYNCHRONIZING THE THROTTLE BODIES
inder head surface. TIP
• If the camshaft cap bolt is a new one, it is not Before synchronizing the throttle bodies, check
necessary to apply engine oil onto the mating the following items:
surface and threads of the bolt. • Valve clearance
• If the camshaft cap bolt is a new one, tighten it • Spark plugs
to 10 N·m (1.0 kgf·m, 7.4 lb·ft). • Air filter element
• Turn the crankshaft counterclockwise several • Throttle body joints
full turns to seat the parts. • Fuel hose
• Exhaust system
h. Measure the valve clearance again.
• Breather hoses
i. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear- Checking the throttle body synchronization
ance is obtained. 1. Stand the vehicle on a level surface.
7. Install: TIP
• All removed parts Place the vehicle on a maintenance stand.
TIP
2. Remove:
For installation, reverse the removal procedure. • Rider seat
EAS31017
4-1.
CHECKING THE ENGINE IDLING SPEED
• Fuel tank
TIP Refer to “FUEL TANK” on page 7-1.
Prior to checking the engine idling speed, the • Air filter case
throttle body synchronization should be adjusted Refer to “AIR FILTER CASE” on page 7-5.
properly, the air filter element should be clean, 3. Remove:
and the engine should have adequate compres- • Caps “1”
sion. • Service hose cap “2”
1. Start the engine and let it warm up for several
minutes.
2. Check:
• Engine idling speed 1 1
Out of specification → Go to next step.
Engine idling speed 2

1200–1400 r/min
3. Check:
• ISC (Idle Speed Control) learning value 4. Install:
“00” or “01” → Check the intake system. • Vacuum gauge “1”
“02” → Clean the throttle bodies.
3-9
ECA21300
Vacuum gauge NOTICE

90890-03094 Do not turn the bypass air screw (white paint
Vacuummate mark) of the throttle body that is the stan-
YU-44456 dard. Otherwise, the engine may run roughly
at idle and the throttle bodies may not oper-
ate properly.
TIP
• Turn the bypass air screw using the carburetor
angle driver.
• After each step, rev the engine two or three
1 times, each time for less than a second, and
check the synchronization again.
• If a bypass air screw was removed, turn the
screw in fully and be sure to synchronize the
5. Install: throttle bodies.
• Air filter case • If the throttle body synchronization can not be
Refer to “AIR FILTER CASE” on page 7-5. adjusted using the bypass air screw, clean or
• Fuel tank replace the throttle bodies.
Refer to “FUEL TANK” on page 7-1. • The difference in vacuum pressure between
6. Check: the throttle bodies should not exceed 1.33 kPa
• Throttle body synchronization (10 mmHg).
a. Start the engine, warm it up for several
minutes, and then let it run at the specified
Carburetor angle driver 2
engine idling speed. 90890-03173
Engine idling speed
1200–1400 r/min
b. Check the vacuum pressure.
Difference in vacuum pressure

between the cylinders
0 kPa-1.3 kPa (0 mmHg-10
mmHg, 0 inHg-0.4 inHg)
If out of specification → Adjust the throttle 1

body synchronization. 2. Stop the engine and remove the measuring
equipment.
Adjusting the throttle body synchronization 3. Install:
1. Adjust: • Caps
• Throttle body synchronization • Service hose cap
a. Start the engine, warm it up for several 4. Install:
minutes, and then let it run at the specified • Air filter case
engine idling speed. Refer to “AIR FILTER CASE” on page 7-5.
Engine idling speed • Fuel tank
1200–1400 r/min Refer to “FUEL TANK” on page 7-1.
• Rider seat
b. Using the throttle body that has the bypass Refer to “GENERAL CHASSIS (1)” on page
air screw “1” with a white paint mark as the 4-1.
standard, adjust the other throttle bodies
by turning its bypass air screw in or out.
3-10
EAS31318
• Exhaust chamber “2”
CHECKING THE THROTTLE BODY JOINTS
• Muffler “3”
1. Remove:
Cracks/damage → Replace.
• Throttle bodies
• Gasket “4”
Refer to “THROTTLE BODIES” on page
Exhaust gas leaks → Replace.
7-11.
2. Check:
2. Check:
Tightening torque
• Throttle body joints
• Exhaust pipe nut “5”
• Exhaust pipe joint bolt “6”
• Exhaust chamber bolt “7”
7-11.
• Muffler bolt “8”
3. Install:
• Muffler joint bolt “9”
• Throttle bodies
Refer to “THROTTLE BODIES” on page Exhaust pipe nut
7-11. 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
EAS30800
Exhaust pipe joint bolt
CHECKING THE CRANKCASE BREATHER 20 N·m (2.0 kgf·m, 15 lb·ft)
HOSE Exhaust chamber bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
1. Remove:
Muffler bolt
• Rider seat 20 N·m (2.0 kgf·m, 15 lb·ft)
Refer to “GENERAL CHASSIS (1)” on page Muffler joint bolt
4-1. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
• Fuel tank
2. Check: 3
• Crankcase breather hose “1”
Loose connection → Connect properly. 4
ECA13450
NOTICE
9
Make sure the crankcase breather hose is
8
routed correctly. 7
1
7
2
6 (8)
4
1 5
3. Install:
• Fuel tank EAS30626
CHECKING THE CANISTER

1. Remove:
• Rider seat
• Rider seat
4-1.
4-1.
EAS30625 • Fuel tank
CHECKING THE EXHAUST SYSTEM Refer to “FUEL TANK” on page 7-1.
1. Check: 2. Check:
• Exhaust pipe “1” • Canister “1”
3-11
• Canister purge hose EAS30627
CHECKING THE AIR INDUCTION SYSTEM

• Fuel tank breather hose
Refer to “AIR INDUCTION SYSTEM” on page
7-19.
TIP EAS30628
REPLACING THE AIR FILTER ELEMENT

Make sure that the canister breather “a” is not
1. Remove:
blocked, and if necessary, clean it.
• Rider seat
4-1.
1 • Fuel tank
2. Remove:
a • Air filter case cover
• Air filter element
3. Check:
3. Install: • Air filter seal
• Fuel tank Damage → Replace.
Refer to “FUEL TANK” on page 7-1. TIP
• Rider seat • Replace the air filter element every 40000 km
Refer to “GENERAL CHASSIS (1)” on page (24000 mi) of operation.
4-1. • The air filter needs more frequent service if you
EAS30799 are riding in unusually wet or dusty areas.
ADJUSTING THE EXHAUST GAS VOLUME
4. Install:
TIP
• Be sure to set the CO density level to standard, • Air filter case cover
and then adjust the exhaust gas volume. ECA20710
• To adjust the exhaust gas volume, use the CO NOTICE

adjustment mode of the Yamaha diagnostic Never operate the engine without the air filter
tool. For more information, refer to the opera- element installed. Unfiltered air will cause
tion manual of the Yamaha diagnostic tool. rapid wear of engine parts and may damage
1. Connect the Yamaha diagnostic tool to the the engine. Operating the engine without the
coupler. For information about connecting the air filter element will also affect throttle body
Yamaha diagnostic tool, refer to “YDT” on synchronization, leading to poor engine per-
page 9-2. formance and possible overheating.
TIP
Yamaha diagnostic tool USB
90890-03267 • Align projections “a” of the air filter element to
Yamaha diagnostic tool (A/I) the slots “b” of the air filter case and install.
90890-03264 • When installing the air filter element into the air
filter case, make sure that the sealing surfaces
TIP are aligned to prevent any air leaks.
• Yamaha diagnostic tool (A/I) (90890-03264) in-
cludes YDT sub harness (6P) (90890-03266).
I) (90890-03262), YDT sub harness (6P)
(90890-03266) is separately required.
3-12
TIP
If the specified clutch lever free play cannot be
a obtained on the handlebar side of the cable, use
the adjusting nut on the engine side.
Engine side
b
a. Remove the front side cowling (right).
Refer to “GENERAL CHASSIS (5)” on
page 4-16.
b. Loosen the locknut “1”.
5. Install: c. Turn the adjusting nut “2” until the speci-
• Fuel tank fied clutch lever free play is obtained.
Refer to “FUEL TANK” on page 7-1. d. Tighten the locknut “1”.
• Rider seat
Refer to “GENERAL CHASSIS (1)” on page Clutch cable locknut
4-1. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
EAS30629
ADJUSTING THE CLUTCH LEVER FREE

PLAY
1. Check:
• Clutch lever free play “a”
Out of specification → Adjust.
Clutch lever free play

10.0–15.0 mm (0.39–0.59 in) 1
2
a e. Install the front side cowling (right).
page 4-16.
EAS30801
CHECKING THE BRAKE OPERATION

1. Check:
• Brake operation
G088887 Brake not working properly → Check the
2. Adjust: brake system.
• Clutch lever free play Refer to “FRONT BRAKE” on page 4-52 and
“REAR BRAKE” on page 4-63.
Handlebar side TIP
a. Turn the adjusting bolt “1” until the speci- Drive on the dry road, operate the front and rear
fied clutch lever free play is obtained. brakes separately and check to see if the brakes
are operating properly.
1
EAS30632
CHECKING THE BRAKE FLUID LEVEL

1. Stand the vehicle on a level surface.
TIP
• Place the vehicle on a maintenance stand.
• Make sure the vehicle is upright.
G088888
3-13
2. Check: b. Turn the adjusting dial “1” until the brake

• Brake fluid level lever is in the desired position.
Below the minimum level mark → Add the c. Align the appropriate setting on the adjust-
specified brake fluid to the proper level. ing dial with the mark “a” on the brake le-
ver.
Front brake
Specified brake fluid
DOT 4
Rear brake
DOT 4
1 a
EWA13090
WARNING
• Use only the designated brake fluid. Other
G088890
brake fluids may cause the rubber seals to
EWA17050
deteriorate, causing leakage and poor
WARNING
brake performance.
• Refill with the same type of brake fluid that • After adjusting the brake lever position,
is already in the system. Mixing brake fluids make sure the pin on the brake lever holder
may result in a harmful chemical reaction, is firmly inserted in the hole in the adjusting
leading to poor brake performance. dial.
• When refilling, be careful that water does • A soft or spongy feeling in the brake lever
not enter the brake fluid reservoir. Water can indicate the presence of air in the brake
will significantly lower the boiling point of system. Before the vehicle is operated, the
the brake fluid and could cause vapor lock. air must be removed by bleeding the brake
ECA13540
system. Air in the brake system will consid-
NOTICE erably reduce brake performance resulting
in loss of control and possibly cause an ac-
Brake fluid may damage painted surfaces
cident. Therefore, check and if necessary,
and plastic parts. Therefore, always clean up
bleed the brake system.
any spilt brake fluid immediately.
ECA13490
TIP NOTICE
In order to ensure a correct reading of the brake After adjusting the brake lever position,
fluid level, make sure the top of the brake fluid make sure there is no brake drag.
reservoir is horizontal.
EAS30633
EAS30630 CHECKING THE FRONT BRAKE PADS

ADJUSTING THE FRONT DISC BRAKE The following procedure applies to all of the
1. Adjust: brake pads.
• Brake lever position 1. Operate the brake.
(distance “a” from the throttle grip to the brake 2. Check:
lever) • Front brake pad
Wear indicators “a” almost touch the brake
disc → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-52.
a
G088889
a. Push the brake lever forward.
3-14
2. Adjust:
• Rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-35.
a a
EAS30634
CHECKING THE REAR BRAKE PADS

brake pads.
1. Operate the brake.
2. Check:
EAS30631
• Rear brake pad
ADJUSTING THE REAR DISC BRAKE Wear indicator grooves “a” almost disap-
1. Adjust: peared → Replace the brake pads as a set.
• Brake pedal position Refer to “REAR BRAKE” on page 4-63.
a. Loosen the locknut “1”.
b. Turn the adjusting bolt “2” until the speci-
fied brake pedal position is obtained.
EWA18830
WARNING
After adjusting the brake pedal position, a a
check that the end of the adjusting bolt “a” is
visible through the hole “b”.
c. Tighten the locknut “1” to specification.
Rear brake master cylinder lock-

nut EAS30635
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft) CHECKING THE FRONT BRAKE HOSES

EWA17030
brake hoses and brake hose holders.
WARNING 1. Check:
A soft or spongy feeling in the brake pedal • Brake hose “1”
can indicate the presence of air in the brake Cracks/damage/wear → Replace.
system. Before the vehicle is operated, the 2. Check:
air must be removed by bleeding the brake • Brake hose surface
system. Air in the brake system will consid- Partly blackened surface on the brake hose
erably reduce braking performance. → Replace.
ECA13510 3. Check:
NOTICE • Brake hose holder “2”
After adjusting the brake pedal position, Loose → Tighten the holder bolt.
make sure there is no brake drag.
1
1
2
a
2
b 1
3-15
4. Hold the vehicle upright and apply the brake • the brake fluid level is very low.
several times. • brake operation is faulty.
5. Check:
TIP
• Brake hose
Brake fluid leakage → Replace the damaged • Be careful not to spill any brake fluid or allow
hose. the brake fluid reservoir to overflow.
Refer to “FRONT BRAKE” on page 4-52. • When bleeding the ABS, make sure that there
is always enough brake fluid before applying
EAS30636
the brake. Ignoring this precaution could allow
CHECKING THE REAR BRAKE HOSE air to enter the ABS, considerably lengthening
1. Check: the bleeding procedure.
• Brake hose “1” • If bleeding is difficult, it may be necessary to let
Cracks/damage/wear → Replace. the brake fluid settle for a few hours.
2. Check: • Repeat the bleeding procedure when the tiny
• Brake hose holder “2” bubbles in the hose have disappeared.
Loose connection → Tighten the holder bolt.
1. Bleed:
2 • ABS
a. Fill the brake fluid reservoir to the proper
1 level with the specified brake fluid.
b. Install the diaphragm (brake fluid reser-
voir).
c. Connect a clear plastic hose “1” tightly to
2 the bleed screw “2”.
1
1
3. Hold the vehicle upright and apply the rear
brake several times.
4. Check: 2
• Brake hose
Brake fluid leakage → Replace the damaged
hose.
Refer to “REAR BRAKE” on page 4-63.
EAS30893
BLEEDING THE HYDRAULIC BRAKE

SYSTEM (ABS)
EWA14000
WARNING
Always bleed the brake system when the
brake related parts are removed.
ECA22640
NOTICE
• Bleed the brake system in the following or-
der.
• 1st step: Front brake master cylinder
• 2nd step: Front brake calipers
• 3rd step: Rear brake caliper
EWA16530
WARNING
Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
3-16
l. Tighten the bleed screw to specification.
Front brake master cylinder

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

1 2 level with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13.
1 EWA13110
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
EAS31428
CHECKING THE WHEELS

2
The following procedure applies to both of the
wheels.
1. Check:
A. Front brake master cylinder • Wheel
B. Front brake caliper (left/right) Damage/out-of-round → Replace.
C. Rear brake caliper EWA13260
WARNING
d. Place the other end of the hose into a con-
tainer. Never attempt to make any repairs to the
e. Slowly apply the brake several times. wheel.
f. Fully squeeze the brake lever or fully de- TIP
press the brake pedal and hold it in posi- After a tire or wheel has been changed or re-
tion. placed, always balance the wheel.
g. Loosen the bleed screw.
TIP EAS31429
Loosening the bleed screw will release the pres- CHECKING THE TIRES
sure and cause the brake lever to contact the The following procedure applies to both of the
throttle grip or the brake pedal to fully extend. tires.
1. Check:
h. Tighten the bleed screw and then release • Tire pressure
the brake lever or brake pedal. Out of specification → Regulate.
i. Repeat steps (e) to (h) until all of the air EWA13181
bubbles have disappeared from the brake WARNING

fluid in the plastic hose. • The tire pressure should only be checked
j. Check the operation of the hydraulic unit. and regulated when the tire temperature
Refer to “HYDRAULIC UNIT OPERA- equals the ambient air temperature.
TION TEST” on page 4-79. • The tire pressure and the suspension must
ECA17061
NOTICE
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
Make sure that the main switch is turned to cessories) and the anticipated riding
“OFF” before checking the operation of the speed.
hydraulic unit. • Operation of an overloaded vehicle could
k. After operating the ABS, repeat steps (e) cause tire damage, an accident or an injury.
to (i), and then fill the brake fluid reservoir NEVER OVERLOAD THE VEHICLE.
to the proper level with the specified brake
fluid.
3-17
Tire air pressure (measured on Rear tire

cold tires) Size
1 person 190/55ZR17M/C (75W) (YZF-R1)
Front 200/55ZR17M/C (78W)
250 kPa (2.50 kgf/cm², 36 psi) (YZF-R1M)
Rear Manufacturer/model
290 kPa (2.90 kgf/cm², 42 psi) BRIDGESTONE/BATTLAX RAC-
2 persons ING STREET RS11R
Front
250 kPa (2.50 kgf/cm², 36 psi) EWA13210
Rear WARNING
290 kPa (2.90 kgf/cm², 42 psi) New tires have a relatively low grip on the
Maximum load road surface until they have been slightly
185 kg (408 lb) worn. Therefore, approximately 100 km
* Total weight of rider, passenger, cargo should be traveled at normal speed before
and accessories any high-speed riding is done.
2. Check: TIP
• Tire surfaces For tires with a direction of rotation mark “1”:
Damage/wear → Replace the tire. • Install the tire with the mark pointing in the di-
EWA13190
rection of wheel rotation.
WARNING • Align the mark “2” with the valve installation
It is dangerous to ride with a worn-out tire. point.
When the tire tread reaches the wear limit, re-
place the tire immediately.
1
Wear limit (front)
1.6 mm (0.06 in) (for RUS, ZAF) 2
1.5 mm (0.06 in) (for AUS)
Wear limit (rear)
1.6 mm (0.06 in) (for RUS, ZAF)
1.5 mm (0.06 in) (for AUS)
EWA14090 G088891
WARNING EAS30641
After extensive tests, the tires listed below CHECKING THE WHEEL BEARINGS
have been approved by Yamaha Motor Co., The following procedure applies to all of the
Ltd. for this model. The front and rear tires wheel bearings.
should always be by the same manufacturer 1. Check:
and of the same design. No guarantee con- • Wheel bearings
cerning handling characteristics can be giv- Refer to “CHECKING THE FRONT WHEEL”
en if a tire combination other than one on page 4-38 and “CHECKING THE REAR
approved by Yamaha is used on this vehicle. WHEEL” on page 4-47.
EAS30802
Front tire CHECKING THE SWINGARM OPERATION
Size 1. Check:
120/70ZR17M/C (58W) • Swingarm operation
Manufacturer/model Swingarm not working properly → Check the
BRIDGESTONE/BATTLAX RAC-
swingarm.
ING STREET RS11F
Refer to “SWINGARM” on page 4-120.
2. Check:
• Swingarm excessive play
Refer to “SWINGARM” on page 4-120.
3-18
EAS30643 ECA20870
LUBRICATING THE SWINGARM PIVOT NOTICE

1. Lubricate: Improper drive chain slack will overload the
• Oil seals engine as well as other vital parts of the mo-
• Collars torcycle and can lead to chain slippage or
Recommended lubricant breakage. If the drive chain slack is more
Lithium-soap-based grease than the specified limit, the chain can dam-
age the frame, swingarm, and other parts. To
Refer to “INSTALLING THE SWINGARM” on prevent this from occurring, keep the drive
page 4-123. chain slack within the specified limits.
EAS31923
DRIVE CHAIN SLACK Adjusting the drive chain slack

EWA13120
WARNING
Checking the drive chain slack
EWA13120 Securely support the vehicle so that there is
WARNING no danger of it falling over.
Securely support the vehicle so that there is 1. Loosen:
no danger of it falling over. • Wheel axle nut
ECA13550
Refer to “REAR WHEEL” on page 4-43.
NOTICE 2. Adjust:
A drive chain that is too tight will overload • Drive chain slack
the engine and other vital parts, and one that a. Loosen both locknuts “1”.
is too loose can skip and damage the swing- b. Turn both adjusting bolts “2” until the spec-
arm or cause an accident. Therefore, keep ified drive chain slack is obtained.
the drive chain slack within the specified lim-
its. 2 1
1. Shift the transmission into the neutral posi-
tion.
2. Check:
• Drive chain slack “a”
Drive chain slack

25.0–35.0 mm (0.98–1.38 in)
Drive chain slack (Maintenance
stand) TIP
25.0–35.0 mm (0.98–1.38 in) • To maintain the proper wheel alignment, adjust
Limit both sides evenly.
35.0 mm (1.38 in) • There should be no clearance between the ad-
justing block and adjusting bolt.
c. Tighten the wheel axle nut to specification.
Rear wheel axle nut

190 N·m (19 kgf·m, 140 lb·ft)
T.
R.
d. Tighten the locknuts to specification.
a Chain puller adjusting bolt lock-

nut
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft)
3-19
EAS30803
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber
O-rings between each side plate. Steam clean-
ing, high-pressure washing, certain solvents, G088892
and the use of a coarse brush can damage
b. Loosen the lower ring nut “4” and then
these O-rings. Therefore, use only kerosene to
tighten it to specification with a steering
clean the drive chain. Wipe the drive chain dry
nut wrench “5”.
and thoroughly lubricate it with chain lubricant
TIP
that is suitable for O-ring chains. Do not use any
other lubricants on the drive chain since they • Set the torque wrench at a right angle to the
may contain solvents that could damage the O- steering nut wrench.
rings. • Move the steering to the left and right a couple
of times to check that it moves smoothly.
Recommended lubricant
Chain lubricant suitable for O-
ring chains
EAS30645
CHECKING AND ADJUSTING THE

STEERING HEAD
EWA13120
WARNING
G088893
Securely support the vehicle so that there is
no danger of it falling over.
Steering nut wrench
TIP 90890-01403
Place the vehicle on a maintenance stand so Exhaust flange nut wrench
that the front wheel is elevated. YU-A9472
2. Check:
• Steering head Lower ring nut (initial tightening
Grasp the bottom of the front fork legs and torque)
T.
R.
gently rock the front fork. 52 N·m (5.2 kgf·m, 38 lb·ft)

Blinding/looseness → Adjust the steering
head. c. Loosen the lower ring nut completely, then
3. Remove: tighten it to specification.
EWA13140
• Upper bracket WARNING
4. Adjust:
Do not overtighten the lower ring nut.
• Steering head
a. Remove the lock washer “1”, the upper
ring nut “2”, and the rubber washer “3”. Lower ring nut (final tightening
torque)
T.
R.
14 N·m (1.4 kgf·m, 10 lb·ft)
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.
3-20
Refer to “STEERING HEAD” on page

4-108. Recommended lubricant
e. Install the rubber washer “3”. Silicone grease
f. Install the upper ring nut “2”.
EAS30805
g. Finger tighten the upper ring nut, then LUBRICATING THE CLUTCH LEVER
align the slots of both ring nuts. If neces- Lubricate the pivoting point and metal-to-metal
sary, hold the lower ring nut and tighten moving parts of the lever.
the upper ring nut until their slots are
aligned. Recommended lubricant
h. Install the lock washer “1”. Lithium-soap-based grease
TIP
EAS30649
Make sure the lock washer tabs “a” sit correctly
LUBRICATING THE PEDAL
in the ring nut slots “b”.
Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.
Molybdenum disulfide grease
EAS30650
CHECKING THE SIDESTAND

1. Check:
• Sidestand operation
G088894
Check that the sidestand moves smoothly.
Rough movement → Repair or replace.
5. Install:
• Upper bracket EAS30651
Refer to “HANDLEBARS” on page 4-83. LUBRICATING THE SIDESTAND

Lubricate the pivoting point, metal-to-metal mov-
EAS30646
ing parts and spring contact point of the side-
LUBRICATING THE STEERING HEAD stand.
1. Lubricate:
• Upper bearing Recommended lubricant
• Lower bearing Lithium-soap-based grease
• Bearing race
EAS30652
Recommended lubricant CHECKING THE SIDESTAND SWITCH

Lithium-soap-based grease Refer to “ELECTRICAL COMPONENTS” on
page 8-38.
EAS31634
CHECKING THE STEERING DAMPER EAS30653
Refer to “CHECKING THE STEERING DAMP- CHECKING THE FRONT FORK

ER” on page 4-111. 1. Stand the vehicle on a level surface.
EWA13120
EAS31186 WARNING
CHECKING THE CHASSIS FASTENERS Securely support the vehicle so that there is
Make sure that all nuts, bolts, and screws are no danger of it falling over.
properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES” 2. Check:
on page 2-14. • Inner tube
Damage/scratches → Replace.
EAS30804 • Front fork leg
LUBRICATING THE BRAKE LEVER Oil leaks between inner tube and outer tube
Lubricate the pivoting point and metal-to-metal → Replace the oil seal.
moving parts of the lever. Refer to “FRONT FORK (for YZF-R1)” on
page 4-89 or refer to “FRONT FORK (for
YZF-R1M)” on page 4-100.
3-21
3. Hold the vehicle upright and apply the front

brake. Spring preload
4. Check: Minimum (soft)
• Front fork operation 0 turn(s) in direction “a”*
Push down hard on the handlebar several Standard
times and check if the front fork rebounds 6 turn(s) in direction “a”*
smoothly. Maximum (hard)
Rough movement → Repair. 15 turn(s) in direction “a”*
Refer to “FRONT FORK (for YZF-R1)” on * With the adjusting nut fully turned in di-
page 4-89 or refer to “FRONT FORK (for rection “b”
EAS30806
1
ADJUSTING THE FRONT FORK LEGS (for
YZF-R1)
b
front fork legs. a
EWA13120
WARNING
Spring preload Rebound damping

EWA17040
ECA13590
WARNING NOTICE
Always adjust both front fork legs evenly. Never go beyond the maximum or minimum
Uneven adjustment can result in poor han- adjustment positions.
dling and loss of stability.
ECA13590
1. Adjust:
NOTICE • Rebound damping
a. Turn the adjusting bolt “1” in direction “a”
Never go beyond the maximum or minimum
or “b”.
adjustment positions.
1. Adjust: Direction “a”
• Spring preload Rebound damping is increased (sus-
a. Turn the adjusting nut “1” in direction “a” or pension is harder).
“b”. Direction “b”
Rebound damping is decreased (sus-
Direction “a” pension is softer).
Spring preload is increased (suspen-
sion is harder).
Direction “b” Rebound damping
Spring preload is decreased (suspen- Minimum (soft)
sion is softer). 14 click(s) in direction “b”*
Standard
7 click(s) in direction “b”*
Maximum (hard)
1 click(s) in direction “b”*
* With the adjusting bolt fully turned in di-
rection “a”
TIP
• Although the total number of clicks of a damp-
ing force adjusting mechanism may not exactly
match the above specifications due to small
3-22
differences in production, the actual number of range. To obtain a precise adjustment, check
clicks always represents the entire adjusting the number of clicks and modify the minimum
range. To obtain a precise adjustment, check and standard specifications as necessary.
the number of clicks and modify the minimum • When turning the damping force adjusting bolt
and standard specifications as necessary. in direction “a”, the 0 click position and the 1
• When turning the damping force adjusting bolt click position may be the same.
in direction “a”, the 0 click position and the 1
click position may be the same.
1
1
a b
a b
EAS31635
ADJUSTING THE PRELOAD OF THE FRONT

FORK LEGS (for YZF-R1M)
Compression damping The following procedure applies to both of the
ECA13590
NOTICE front fork legs.

EWA13120
Never go beyond the maximum or minimum WARNING

adjustment positions. Securely support the vehicle so that there is
1. Adjust: no danger of it falling over.
• Compression damping
a. Turn the adjusting bolt “1” in direction “a” Spring preload
or “b”. EWA17040
WARNING
Direction “a” Always adjust both front fork legs evenly.
Compression damping is increased Uneven adjustment can result in poor han-
(suspension is harder).
dling and loss of stability.
Direction “b”
Compression damping is decreased ECA13590
(suspension is softer). NOTICE

adjustment positions.
Compression damping
Minimum (soft) 1. Adjust:
23 click(s) in direction “b”* • Spring preload
Standard a. Turn the main switch to “OFF”.
17 click(s) in direction “b”* b. Slide the rubber cover “1” back at each
Maximum (hard) coupler.
1 click(s) in direction “b”* c. Disconnect the coupler “2” on each front
* With the adjusting bolt fully turned in di- fork.
rection “a”
TIP
match the above specifications due to small
differences in production, the actual number of
clicks always represents the entire adjusting
3-23
EAS30941
ADJUSTING THE DAMPING FORCE OF THE

1
2 FRONT FORK LEGS AND REAR SHOCK
ABSORBER ASSEMBLY (for YZF-R1M)
1 T- 1
H
-2
H
+2
T- 2 8
R- 1 7
S S
BRAKE CORNER ACCEL FRONT REAR
SETTING
d. Turn the adjusting bolt “3” in direction “a” SUPPORT SUPPORT SUPPORT FIRM FIRM
or “b”.
2 3 4 5 6
Direction “a” 1. ERS mode
sion is harder).
3. Cornering support level
Direction “b”
Spring preload is decreased (suspen- 4. Acceleration support level
sion is softer). 5. Front overall damping level
6. Rear overall damping level
Spring preload 8. Current level
Minimum (soft)
The ERS consists of three semi-active automat-
0 turn(s) in direction “a”* ic modes (T-1, T-2 and R-1) and three manual
Standard
setting modes (M-1, M-2 and M-3). When an au-
3 turn(s) in direction “a”* tomatic mode is selected, the SCU will adjust the
Maximum (hard)
compression and rebound damping forces
15 turn(s) in direction “a”* based on running conditions. For all modes and
* With the adjusting nut fully turned in di- models, spring preload is physically adjusted by
rection “b” hand.
For track modes T-1 and T-2, the following set-
tings can be adjusted:
3 BRAKE SUPPORT: reduces nosedive (front-
CORNER SUPPORT: increases damping to ab-
b sorb chassis fluctuations for smooth cornering.
a Reduce this setting for increased rear wheel
grip.
ACCEL SUPPORT: reduces rear-end squat
(rear-end pitch due to acceleration)
FRONT FIRM: hardens “H” or softens “S” overall
e. Connect the coupler on each fork. damping of the front suspension
f. Slide the rubber cover to the original posi- REAR FIRM: hardens “H” or softens “S” overall
tion. damping of the rear suspension
3-24
TIP
• M-1 is preset for track use with racing slick
T- 1 -2 +2
H H tires.
T- 2
6 • M-2 is preset for track use with street tires.
1 R- 1
• M-3 is preset for street use with street tires.
5
S S
1. Adjust:
BRAKE FRONT REAR
SETTING
SUPPORT FIRM FIRM • Damping force
a. Turn the main switch to “ON”.
2 3 4 b. Long push the wheel switch to enter the
1. ERS mode MENU screen.
3. Front overall damping level
4. Rear overall damping level Display Mode
5. Factory preset level YRC Setting
6. Current level Lap Time
For the road mode R-1, the following settings Logging

can be adjusted: Maintenance
BRAKE SUPPORT: reduces nosedive (front- Unit
FRONT FIRM: hardens “H” or softens “S” overall c. Select “YRC Setting”.
damping of the front suspension
REAR FIRM: hardens “H” or softens “S” overall km/h MENU GPS 10 : 00
damping of the rear suspension
Display Mode
TIP
YRC Setting
• T-1 is preset for track use with racing slick tires. Lap Time
• T-2 is preset for track use with street tires.
Logging
• R-1 is preset for road use with street tires.
Maintenance
Unit
1 M-1 8 18 22 22 7 d. Select the “ ” mark located to the right of

M-2
M-3
ERS.
TIP
6 The ERS setting menu is divided into automatic

SETTING Fr COM Fr REB Rr COM Rr REB and manual setting modes, and the two types
are accessed separately. Before moving to the
2 3 4 5 ERS setting menu, make sure the current ERS
1. ERS mode
mode corresponds to the same type (automatic
2. Front compression damping force
or manual) that you’d like to adjust.
3. Front rebound damping force
4. Rear compression damping force
5. Rear rebound damping force A 1 1 1 1 1 ON 1 1 1 T-1
6. Factory preset level B 2 2 2 2 2 2 2 2 T-2 3

7. Current level setting C 3 3 3 3 3 R-1
D 4 4 4 M-1
For the manual setting modes M-1, M-2, and M- 5 OFF OFF OFF OFF OFF M-2
2
3, the following settings can be adjusted: YRC PWR TCS SCS LCS QS QS LIF EBM BC ERS
Fr COM: front compression damping
Fr REB: front rebound damping 1
Rr COM: rear compression damping
Rr REB: rear rebound damping 1. To ERS menu
3-25
2. Manual modes Spring preload

ECA13590
3. Automatic modes
NOTICE
e. The display will change to the relevant Never go beyond the maximum or minimum
suspension setting screen and the ERS adjustment positions.
mode selection box “SETTING” is high-
lighted. Short push the wheel switch to en- 1. Adjust:
ter the box and select the ERS mode that • Spring preload
you want to adjust. a. Loosen the locknut “1”.
b. Adjust the spring preload with the special
km/h YRC Setting 10 : 00 wrench included in the owner’s tool kit.
M-1 8 18 22 22 4 c. Turn the adjusting ring “2” in direction “a”
M-2 or “b”.
M-3
Direction “a”
SETTING Fr COM Fr REB Rr COM Rr REB sion is harder).
Direction “b”
1 2 3 Spring preload is decreased (suspen-
sion is softer).
1. To YRC Setting menu
2. ERS mode selection box “SETTING”
f. Select the suspension item that you want
to adjust, and then rotate the wheel switch
to adjust the setting level. 1
b
TIP
2
All ERS modes regardless of type are indepen-
dent. Offset level setting changes made in one a
mode are not transferred to another mode.
TIP
g. To adjust other ERS modes of the same
type, repeat from step (d). To switch types The spring preload setting is determined by
or when finished, select the “ ” mark to measuring distance “c”. The longer distance “c”
return to the main “YRC Setting” menu. is, the higher the spring preload; the shorter dis-
tance “c” is, the lower the spring preload.
EAS30808
CHECKING THE REAR SHOCK ABSORBER

c
ASSEMBLY
Refer to “CHECKING THE REAR SHOCK AB-
SORBER ASSEMBLY” on page 4-117.
EAS30655
ADJUSTING THE REAR SHOCK ABSORBER

ASSEMBLY (for YZF-R1)
EWA13120
WARNING
3-26
• When turning the damping force adjusting

Spring preload screw in direction “a”, the 0 click position and
Minimum the 1 click position may be the same.
77.5 mm (3.05 in)
Standard
78.5 mm (3.09 in) 1
a b
Maximum
85.5 mm (3.37 in)
d. Tighten the locknut to the specified torque.
Spring preload adjusting ring

locknut (for YZF-R1)
T.
R.
28 N·m (2.8 kgf·m, 21 lb·ft)
Rebound damping Compression damping (for fast compres-

ECA13590
NOTICE sion damping)

ECA13590
Never go beyond the maximum or minimum NOTICE

adjustment positions. Never go beyond the maximum or minimum
1. Adjust: adjustment positions.
• Rebound damping 1. Adjust:
a. Turn the adjusting screw “1” in direction • Compression damping (for fast compression
“a” or “b”. damping)
a. Turn the adjusting bolt “1” in direction “a”
Direction “a”
Rebound damping is increased (sus- or “b”.
pension is harder).
Direction “b” Direction “a”
Rebound damping is decreased (sus- Compression damping is increased
pension is softer). (suspension is harder).
Direction “b”
Compression damping is decreased
Rebound damping (suspension is softer).
Minimum (soft)
23 click(s) in direction “b”* Fast compression damping
Standard Minimum (soft)
12 click(s) in direction “b”* 5.5 turn(s) in direction “b”*
Maximum (hard) Standard
1 click(s) in direction “b”* 3 turn(s) in direction “b”*
* With the adjusting screw fully turned in Maximum (hard)
direction “a” 0 turn(s) in direction “b”*
* With the adjusting bolt fully turned in di-
TIP rection “a”
ing force adjusting mechanism may not exactly TIP
match the above specifications due to small Although the total number of turns of a damping
differences in production, the actual number of force adjusting mechanism may not exactly
clicks always represents the entire adjusting match the above specifications due to small dif-
range. To obtain a precise adjustment, check ferences in production, the actual number of
the number of clicks and modify the minimum turns always represents the entire adjusting
and standard specifications as necessary.
3-27
range. To obtain a precise adjustment, check • When turning the damping force adjusting
the number of turns and modify the minimum screw in direction “a”, the 0 click position and
and standard specifications as necessary. the 1 click position may be the same.
1 1
a b a b
EAS30942
Compression damping (for slow compres- ADJUSTING THE PRELOAD OF THE REAR
sion damping) SHOCK ABSORBER ASSEMBLY (for
ECA13590
NOTICE YZF-R1M)
EWA13120
Never go beyond the maximum or minimum WARNING

adjustment positions. Securely support the vehicle so that there is
1. Adjust: no danger of it falling over.
• Compression damping (for slow compression
damping) Spring preload
a. Turn the adjusting screw “1” in direction ECA13590
“a” or “b”. NOTICE

Direction “a” adjustment positions.
Compression damping is increased
(suspension is harder). 1. Adjust:
Direction “b” • Spring preload
Compression damping is decreased a. Loosen the locknut “1”.
(suspension is softer). b. Adjust the spring preload with the special
wrench included in the owner’s tool kit.
c. Turn the adjusting ring “2” in direction “a”
Slow compression damping or “b”.
Minimum (soft)
18 click(s) in direction “b”* Direction “a”
Standard Spring preload is increased (suspen-
12 click(s) in direction “b”* sion is harder).
Maximum (hard) Direction “b”
1 click(s) in direction “b”* Spring preload is decreased (suspen-
sion is softer).
* With the adjusting screw fully turned in
direction “a”
TIP 1
• Although the total number of clicks of a damp- 2 b
match the above specifications due to small a
differences in production, the actual number of
clicks always represents the entire adjusting
range. To obtain a precise adjustment, check
the number of clicks and modify the minimum
and standard specifications as necessary.
3-28
TIP
The spring preload setting is determined by
measuring distance “c”. The longer distance “c”
is, the higher the spring preload; the shorter dis-
tance “c” is, the lower the spring preload.
b
a
Recommended brand
YAMALUBE
Type
c Full synthetic
SAE viscosity grades
10W-40, 15W-50
Spring preload Recommended engine oil grade
Minimum API service SG type or higher,
0 mm (0.00 in) JASO standard MA
Standard ECA13361
4 mm (0.16 in) NOTICE
Maximum
9 mm (0.35 in) • Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
d. Tighten the locknut to the specified torque. clutch slippage. Therefore, do not add any
chemical additives or use engine oils with a
Spring preload adjusting ring grade of “CD” or higher and do not use oils
locknut (for YZF-R1M) labeled “ENERGY CONSERVING II”.
T.
R.
25 N·m (2.5 kgf·m, 18 lb·ft) • Do not allow foreign materials to enter the
crankcase.
EAS30809
CHECKING THE CONNECTING ARM AND TIP

RELAY ARM Before checking the engine oil level, wait a few
Refer to “CHECKING THE CONNECTING ARM minutes until the oil has settled.
AND RELAY ARM” on page 4-117.
4. Start the engine, warm it up for several min-
EAS30656
utes, and then turn it off.
CHECKING THE ENGINE OIL LEVEL
5. Check the engine oil level again.
TIP
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled.
2. Start the engine, warm it up for several min- EAS30657
utes, and then turn it off. CHANGING THE ENGINE OIL

3. Check: 1. Start the engine, warm it up for several min-
• Engine oil level utes, and then turn it off.
The engine oil level should be between the 2. Place a container under the engine oil drain
minimum level mark “a” and maximum level bolt.
mark “b”. 3. Remove:
Below the minimum level mark → Add the • Engine oil filler cap “1”
recommended engine oil to the proper level. • Engine oil drain bolt “2”
• Gasket “3”
3-29
ECA25890
NOTICE
1 Make sure the O-ring is positioned correctly
in the groove of the oil filter cartridge.
d. Tighten the new oil filter cartridge to spec-
ification with an oil filter wrench.
Oil filter cartridge

17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
e. Install the front side cowling (left).
page 4-16.
6. Install:
• Engine oil drain bolt
3 (along with the gasket New )
Engine oil drain bolt

2 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
7. Fill:
• Crankcase
4. Drain:
(with the specified amount of the recom-
• Engine oil
mended engine oil)
(completely from the crankcase)
5. If the oil filter cartridge is also to be replaced, Engine oil quantity
perform the following procedure. Oil change
a. Remove the front side cowling (left). 3.90 L (4.12 US qt, 3.43 Imp.qt)
Refer to “GENERAL CHASSIS (5)” on With oil filter removal
page 4-16. 4.10 L (4.33 US qt, 3.61 Imp.qt)
b. Remove the oil filter cartridge “1” with an Quantity (disassembled)
oil filter wrench “2”. 4.90 L (5.18 US qt, 4.31 Imp.qt)
Oil filter wrench 8. Install:

90890-01426 • Engine oil filler cap
Oil filter wrench (along with the O-ring New )
YU-38411 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
1 LEVEL” on page 3-29.
2 EAS30810
MEASURING THE ENGINE OIL PRESSURE

1. Check:
c. Lubricate the O-ring of the new oil filter • Engine oil level
cartridge with a thin coat of lithium-soap- Below the minimum level mark “a” → Add the
based grease. recommended engine oil to the proper level.
3-30
5. Install:
• Oil pressure gauge “1”
• Adapter C “2”
Oil pressure gauge set

90890-03120
2. Remove: 2
• Front side cowling (left)
3. Remove: 1
• Oil pressure switch joint bolt “1”
• Oil pressure switch joint (with the oil pressure
switch) “2”
EWA12980
WARNING 6. Start the engine, warm it up for several min-

The engine, muffler and engine oil are ex- utes.
ECA13410
tremely hot. NOTICE
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.
7. Measure:
• Engine oil pressure
2
(at the following conditions)
1
Oil pressure
4. Install: 200.0 kPa/5000 r/min (2.00 kgf/
• Oil pressure gauge joint 18 mm “1” cm²/5000 r/min, 29.0 psi/5000 r/
• Oil pressure switch joint bolt “2” min)
Oil pressure gauge joint 18 mm Engine oil pressure Possible causes

90890-04176
YU-04176 • Faulty oil pump
• Clogged oil filter
Below specification • Leaking oil passage
Oil pressure switch joint bolt • Broken or damaged
10 N·m (1.0 kgf·m, 7.4 lb·ft) oil seal
T.
R.
• Faulty oil filter

Above specification
• Oil viscosity too high
8. Remove:
1 • Oil pressure gauge
• Adapter C
• Oil pressure switch joint bolt
• Oil pressure switch joint (with the O-ring)
9. Install:
2
• O-ring “1” New
• Oil pressure switch joint (with the oil pressure
switch) “2”
3-31
• Oil pressure switch joint bolt “3” TIP

Before checking the coolant level, wait a few
Oil pressure switch joint bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft) minutes until it settles.
T.
R.
EAS30812
CHECKING THE COOLING SYSTEM

1. Check:
• Radiator “1”
1
2 • Radiator inlet hose “2”
3 • Radiator outlet hose “3”
• Water pump inlet pipe “4”
• Water pump outlet pipe “5”
• Oil cooler “6”
• Oil cooler outlet hose “7”
• Oil cooler inlet hose “8”
EAS30811
CHECKING THE COOLANT LEVEL

1. Stand the vehicle on a level surface. Refer to “RADIATOR” on page 6-3, “OIL
COOLER” on page 6-7, “THERMOSTAT” on
TIP
page 6-9 and “WATER PUMP” on page 6-13.
2. Check:
• Coolant level 1
The coolant level should be between the
maximum level mark “a” and minimum level
mark “b”. 4
Below the minimum level mark → Add the
2
recommended coolant to the proper level.
3
5
a
6 7
8
ECA21281
NOTICE EAS30813
• Adding water instead of coolant dilutes the CHANGING THE COOLANT

antifreeze concentration of the coolant. If 1. Remove:
water is used instead of coolant; check, • Front side cowling (right)
and if necessary, correct the antifreeze • Front muffler protector (right)
concentration of the coolant. Refer to “GENERAL CHASSIS (5)” on page
• Use only distilled water. However, if dis- 4-16.
tilled water is not available, soft water may • Radiator cap “1”
EWA13030
be used. WARNING
3. Start the engine, warm it up for several min- A hot radiator is under pressure. Therefore,
utes, and then turn it off. do not remove the radiator cap when the en-
4. Check: gine is hot. Scalding hot fluid and steam may
• Coolant level
3-32
be blown out, which could cause serious in-

jury. When the engine has cooled, open the
radiator cap as follows: 1
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.
6. Remove:
• Coolant reservoir bolt “1”
1 • Coolant reservoir “2”
2. Remove:
• Water pump drain bolt “1”
• Copper washer “2”
7. Drain:
• Coolant
(from the coolant reservoir)
8. Install:
2 • Coolant reservoir
• Coolant reservoir bolt
Coolant reservoir bolt

1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
9. Fill:
3. Drain: • Cooling system
• Coolant (with the specified amount of the recom-
(from the engine and radiator) mended coolant)
4. Install:
• Water pump drain bolt Recommended antifreeze
• Copper washer New High-quality ethylene glycol anti-
freeze containing corrosion
Water pump drain bolt inhibitors for aluminum engines
10 N·m (1.0 kgf·m, 7.4 lb·ft) Mixing ratio
T.
1 : 1 (antifreeze : water)
R.
5. Remove: Coolant quantity

• Coolant reservoir cap “1” Radiator (including all routes)
2.25 L (2.38 US qt, 1.98 Imp.qt)
Coolant reservoir (up to the maxi-
mum level mark)
0.25 L (0.26 US qt, 0.22 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
3-33
EWA13040
12.Loosen the water pump air bleed bolt “1” to
WARNING allow any trapped air to escape from the wa-
• If coolant splashes in your eyes, thorough- ter pump.
ly wash them with water and consult a doc-
tor. 1
• 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.
ECA21291
NOTICE
• Adding water instead of coolant dilutes the
antifreeze concentration of the coolant. If 13.When coolant begins to flow out, tighten the
water is used instead of coolant; check, water pump air bleed bolt to the specified
and if necessary, correct the antifreeze torque.
concentration of the coolant.
• Use only distilled water. However, if dis- Water pump air bleed bolt
tilled water is not available, soft water may 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
be used. R.
• If coolant comes into contact with painted 14.Pour the specified coolant into the radiator
surfaces, immediately wash them with wa- until it is full.
ter. 15.Install:
• Do not mix different types of antifreeze. • Radiator cap
16.Start the engine, warm it up for several min-
10.Fill: utes, and then turn it off.
• Coolant reservoir 17.Check:
(with the recommended coolant to the maxi- • Coolant level
mum level mark “a”) Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-32.
TIP
a
Before checking the coolant level, wait a few
minutes until the coolant has settled.
18.Install:
• Front muffler protector (right)
• Front side cowling (right)
4-16.
11.Install: EAS31389
• Coolant reservoir cap ADJUSTING THE EXUP CABLES
1. Remove:
• EXUP valve pulley cover “1”
3-34
2. Check: f. Turn the adjusting nut “5” until the tension

• EXUP system operation of the EXUP cable (white metal) “6” is the
a. Activate the diagnostic mode and select same as that of the EXUP cable (black
the diagnostic code number “53”. metal) “3”.
Refer to “FUEL INJECTION SYSTEM” on g. Tighten the locknut “4” to specification.
page 9-11.
b. Set the start/engine stop switch to “ ”. EXUP cable locknut
c. Check that the EXUP valve operates prop- 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
erly.
TIP
3
Check that the projection “a” on the EXUP valve
pulley contacts the stopper “b” (fully open posi-
tion). If the projection does not contact the stop-
per, adjust the EXUP cable free play.
b 5
4
6
4. Install:
• EXUP valve pulley cover
a
EXUP valve pulley cover bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
EAS31145
3. Adjust: CHECKING THE FRONT BRAKE LIGHT
• EXUP cable free play SWITCH
a. Turn the main switch to “ON”. Refer to “ELECTRICAL COMPONENTS” on
b. Loosen the locknut “1”. page 8-38.
c. Turn the adjusting nut “2” until the projec-
EAS31146
tion “a” on the EXUP valve pulley slightly
ADJUSTING THE REAR BRAKE LIGHT
contacts the stopper “b” and make sure
SWITCH
the EXUP cable (black metal) “3” is not
TIP
slack.
d. Tighten the locknut “1” to specification. The rear brake light switch is operated by the
movement of the brake pedal.
EXUP cable locknut Adjustment is correct when the brake light
6 N·m (0.6 kgf·m, 4.4 lb·ft) comes on by depressing the brake pedal 5.5–
T.
R.
12.0 mm (0.22–0.47 in) or more.

2 1. Check:
1
3 • Rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
• Rear brake light operation timing
b a. Hold the main body “1” of the rear brake
a light switch so that it does not rotate and
turn the adjusting nut “2” until the rear
brake light comes on at the proper time.
e. Loosen the locknut “4”.
3-35
Repeat this check with the handlebar turned all

1 the way to the left and right.
2 EAS30816
CHECKING AND CHARGING THE BATTERY

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-42.
EAS30662
CHECKING THE FUSES

Refer to “CHECKING THE FUSES” on page
EAS31147
8-41.
CHECKING AND LUBRICATING THE EAS30664
CABLES ADJUSTING THE HEADLIGHT BEAMS

The following procedure applies to all of the in- 1. Adjust:
ner and outer cables. • Headlight beam (vertically)
EWA13270
TIP
WARNING
To adjust the headlight beam (vertically), insert
Damaged outer cable may cause the cable to
a crosshead screwdriver into the holes “a” in the
corrode and interfere with its movement. Re-
headlight cover and turn the adjusting screw.
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate.
Engine oil or a suitable cable lu-
bricant
TIP a
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
EAS30815
CHECKING THE THROTTLE GRIP

1. Check:
• Throttle grip movement
Rough movement → Lubricate or replace the a. Turn the adjusting screws “1”.
defective part(s).
Suitable cable lubricant
TIP
With the engine stopped, turn the throttle grip
slowly and release it. Make sure that the throttle
1 1
grip turns smoothly and returns properly when
released.
3-36
2. Adjust:
• Headlight beam (horizontally)
TIP
To adjust the headlight beam (horizontally), in-
sert a crosshead screwdriver into the holes “a” in
the headlight cover and turn the adjusting screw.
a. Turn the adjusting screws “1”.
1 1
3-37
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE TAIL COVER ................................................................4-5
REMOVING THE REAR SIDE COVER.....................................................4-5
INSTALLING THE IMU..............................................................................4-5
INSTALLING THE REAR SIDE COVER ................................................... 4-6
INSTALLING THE TAIL COVER ............................................................... 4-6
GENERAL CHASSIS (2) ................................................................................. 4-7

REMOVING THE TAIL COVER ................................................................4-8
INSTALLING THE CCU (for YZF-R1M) .................................................... 4-8
CONNECTING TO THE CCU (for YZF-R1M) ...........................................4-8
INSTALLING THE TAIL COVER ............................................................... 4-8
GENERAL CHASSIS (3) ................................................................................. 4-9

REMOVING THE FRONT PANEL (LEFT) .............................................. 4-10
REMOVING THE FRONT PANEL COVER (LEFT).................................4-10
REMOVING THE FRONT PANEL (RIGHT) ............................................4-10
REMOVING THE FRONT PANEL COVER (RIGHT) ..............................4-11
INSTALLING THE FRONT PANEL COVER (LEFT) ...............................4-11
INSTALLING THE FRONT PANEL (LEFT) ............................................. 4-11
4
INSTALLING THE FRONT PANEL COVER (RIGHT)............................. 4-12
INSTALLING THE FRONT PANEL (RIGHT)...........................................4-12
GENERAL CHASSIS (4) ............................................................................... 4-13

REMOVING THE FRONT UPPER COWLING........................................ 4-14
INSTALLING THE FRONT UPPER COWLING ...................................... 4-14
GENERAL CHASSIS (5) ............................................................................... 4-16

REMOVING THE FRONT MUFFLER PROTECTOR (LEFT).................. 4-18
REMOVING THE FRONT MUFFLER PROTECTOR (RIGHT) ............... 4-18
REMOVING THE FRONT SIDE COWLING (LEFT) (for YZF-R1) ..........4-18
REMOVING THE FRONT SIDE COWLING (RIGHT) (for YZF-R1) ........ 4-19
REMOVING THE FRONT SIDE COWLING (LEFT) (for YZF-R1M) ....... 4-19
REMOVING THE FRONT SIDE COWLING (RIGHT) (for YZF-R1M) ..... 4-19
INSTALLING THE FRONT SIDE COWLING (RIGHT) (for YZF-R1)....... 4-20
INSTALLING THE FRONT SIDE COWLING (LEFT) (for YZF-R1) .........4-20
INSTALLING THE FRONT SIDE COWLING (RIGHT) (for YZF-R1M).... 4-20
INSTALLING THE FRONT SIDE COWLING (LEFT) (for YZF-R1M) ...... 4-21
INSTALLING THE FRONT MUFFLER PROTECTOR (LEFT) ................ 4-21
INSTALLING THE FRONT MUFFLER PROTECTOR (RIGHT).............. 4-21
GENERAL CHASSIS (6) ............................................................................... 4-23

REMOVING THE SIDE COVER (LEFT) ................................................. 4-26
REMOVING THE SIDE COVER (RIGHT) ............................................... 4-26
INSTALLING THE SIDE COVER (LEFT) ................................................ 4-26
INSTALLING THE SIDE COVER (RIGHT).............................................. 4-26
GENERAL CHASSIS (7) ............................................................................... 4-28
CHECKING THE AIR INTAKE DUCT VALVE.........................................4-30
CHECKING THE VACUUM LINE............................................................ 4-30
ASSEMBLING THE AIR INTAKE DUCT ASSEMBLY............................. 4-30
INSTALLING THE AIR INTAKE DUCT VALVE....................................... 4-31
GENERAL CHASSIS (8) ............................................................................... 4-32

REMOVING THE ECU (engine control unit) ...........................................4-33
INSTALLING THE ECU (engine control unit) ..........................................4-33
GENERAL CHASSIS (9) ............................................................................... 4-34
FRONT WHEEL............................................................................................. 4-35

REMOVING THE FRONT WHEEL.......................................................... 4-38
DISASSEMBLING THE FRONT WHEEL................................................ 4-38
CHECKING THE FRONT WHEEL .......................................................... 4-38
ASSEMBLING THE FRONT WHEEL......................................................4-39
MAINTENANCE OF THE FRONT WHEEL SENSOR
AND SENSOR ROTOR ..........................................................................4-40
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-40
INSTALLING THE FRONT WHEEL (DISC BRAKE) ...............................4-40
REAR WHEEL ...............................................................................................4-43

REMOVING THE REAR WHEEL ............................................................ 4-46
DISASSEMBLING THE REAR WHEEL .................................................. 4-46
CHECKING THE REAR WHEEL............................................................. 4-47
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-47
CHECKING AND REPLACING THE REAR WHEEL SPROCKET .........4-47
CHECKING THE REAR WHEEL SPROCKET BRACKET......................4-47
ASSEMBLING THE REAR WHEEL ........................................................ 4-48
MAINTENANCE OF THE REAR WHEEL SENSOR
AND SENSOR ROTOR ..........................................................................4-49
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-49
INSTALLING THE REAR WHEEL (DISC BRAKE) .................................4-49
FRONT BRAKE ............................................................................................. 4-52

INTRODUCTION .....................................................................................4-57
CHECKING THE FRONT BRAKE DISCS............................................... 4-57
REPLACING THE FRONT BRAKE PADS .............................................. 4-57
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-59
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-59
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-59
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-59
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-60
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-61
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-61
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-61
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-61
REAR BRAKE ...............................................................................................4-63
INTRODUCTION .....................................................................................4-68
CHECKING THE REAR BRAKE DISC....................................................4-68
REPLACING THE REAR BRAKE PADS................................................. 4-68
REMOVING THE REAR BRAKE CALIPER ............................................4-69
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-69
CHECKING THE REAR BRAKE CALIPER............................................. 4-70
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-70
INSTALLING THE REAR BRAKE CALIPER...........................................4-70
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-71
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-72
THE REAR BRAKE MASTER CYLINDER .............................................. 4-72
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-72
ABS (Anti-lock Brake System) .................................................................... 4-74

ABS COMPONENTS CHART .................................................................4-76
REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-77
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-78
CHECKING THE BRAKE PIPES............................................................. 4-78
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-78
HYDRAULIC UNIT OPERATION TEST .................................................. 4-79
CHECKING THE ABS WARNING LIGHT ............................................... 4-82
HANDLEBARS ..............................................................................................4-83
REMOVING THE HANDLEBARS ........................................................... 4-86
CHECKING THE HANDLEBARS ............................................................ 4-86
INSTALLING THE HANDLEBARS .......................................................... 4-86
FRONT FORK (for YZF-R1)..........................................................................4-89

REMOVING THE FRONT FORK LEGS (for YZF-R1)............................. 4-92
DISASSEMBLING THE FRONT FORK LEGS (for YZF-R1)................... 4-92
CHECKING THE FRONT FORK LEGS (for YZF-R1) ............................. 4-94
ASSEMBLING THE FRONT FORK LEGS (for YZF-R1)......................... 4-94
INSTALLING THE FRONT FORK LEGS (for YZF-R1) ........................... 4-98
FRONT FORK (for YZF-R1M).....................................................................4-100

HANDLING THE FRONT FORK (for YZF-R1M) ...................................4-102
DISPOSING OF FRONT FORK LEG (for YZF-R1M)............................4-102
REMOVING THE FRONT FORK LEGS (for YZF-R1M)........................4-102
DISASSEMBLING THE FRONT FORK LEGS (for YZF-R1M)..............4-103
CHECKING THE FRONT FORK LEGS (for YZF-R1M) ........................4-104
ASSEMBLING THE FRONT FORK LEGS (for YZF-R1M)....................4-104
INSTALLING THE FRONT FORK LEGS ..............................................4-106
STEERING HEAD........................................................................................4-108
REMOVING THE LOWER BRACKET...................................................4-110
CHECKING THE STEERING HEAD .....................................................4-110
INSTALLING THE STEERING HEAD ...................................................4-111
CHECKING THE STEERING DAMPER................................................4-111
REAR SHOCK ABSORBER ASSEMBLY ..................................................4-112
HANDLING THE REAR SHOCK ABSORBER ......................................4-116
DISPOSING OF A REAR SHOCK ABSORBER ...................................4-116
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY.................4-116
DISASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY.......4-117
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY .................4-117
CHECKING THE CONNECTING ARM AND RELAY ARM...................4-117
ASSEMBLING THE REAR SHOCK ABSORBER ASSEMBLY.............4-118
INSTALLING THE RELAY ARM............................................................4-118
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ...............4-119
SWINGARM.................................................................................................4-120
REMOVING THE SWINGARM..............................................................4-122
CHECKING THE SWINGARM ..............................................................4-122
INSTALLING THE SWINGARM ............................................................4-123
CHAIN DRIVE..............................................................................................4-125
REMOVING THE DRIVE CHAIN...........................................................4-126
CHECKING THE DRIVE CHAIN ...........................................................4-126
CHECKING THE DRIVE SPROCKET...................................................4-127
CHECKING THE REAR WHEEL SPROCKET......................................4-127
CHECKING THE REAR WHEEL DRIVE HUB ......................................4-127
INSTALLING THE DRIVE CHAIN .........................................................4-127
ADJUSTING THE SHIFT PEDAL..........................................................4-129
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the seats and battery
1.5 N・m (0.15 kgf・m, 1.1 lb・ft) 7 N・m (0.7 kgf・m, 5.2 lb・ft) 7 N・m (0.7 kgf・m, 5.2 lb・ft)
1 3
(4) 2
(4)
(4)
(4)
(4)
8
4
7
(4)
2.0 N・m (0.20 kgf・m, 1.5 lb・ft)
Order Job/Parts to remove Q’ty Remarks

1 Rider seat 1
2 Passenger seat 1
3 Battery cover 1
4 Negative battery lead 1 Disconnect.
5 Positive battery lead 1 Disconnect.
6 Battery 1
7 IMU coupler 1
8 IMU (Inertial Measurement Unit) 1
4-1
GENERAL CHASSIS (1)
Removing the rear side covers and rear fender (for YZF-R1)
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
14
.
(3)
5 2
LT 13
11
8
9
(3) 12
10 9
7
1
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
3 4
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

Rider seat/Passenger seat/Battery cover 4-1.
1 Tail cover 1
2 Seat lock bracket 1
3 Rear side inner cover (left) 1
4 Rear side outer cover (left) 1
5 Rear side inner cover (right) 1
6 Rear side outer cover (right) 1
7 Tail/brake light bracket 1
8 Tail/brake light coupler 1 Disconnect.
9 Rear turn signal light coupler 2 Disconnect.
10 License plate light coupler 1 Disconnect.
11 Special washer 1
12 Mudguard assembly 1
13 Rear fender 1
14 Tail/brake light 1
4-2
GENERAL CHASSIS (1)
Removing the rear side covers and rear fender (for YZF-R1M)
T.R
9 N•m (0.9 kgf•m, 6.6 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
.
12
(3)
2
LT 9 11
4
6 7
87
5 10
1 (3)
3 T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.

1 Tail cover 1
2 Seat lock bracket 1
3 Rear side cover (left) 1
4 Rear side cover (right) 1
5 Tail/brake light bracket 1
6 Tail/brake light coupler 1 Disconnect.
7 Rear turn signal light coupler 2 Disconnect.
8 License plate light coupler 1 Disconnect.
9 Special washer 1
10 Mudguard assembly 1
11 Rear fender 1
12 Tail/brake light 1
4-3
GENERAL CHASSIS (1)
Disassembling the mudguard assembly
FW
D 4
3
2
5
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.

1 Mudguard assembly cover 1
2 Clamp 1
3 Stay 2
4 Rear turn signal light 2
5 Cover 1
6 License plate light 1
7 Rear reflector 1
4-4
GENERAL CHASSIS (1)
EAS33139
REMOVING THE TAIL COVER b a

1. Remove:
• Tail cover “1”
1
1
EAS31636
INSTALLING THE IMU

ECA22611
NOTICE
a. Remove the quick fasteners. • Do not perform angle adjustment of the IMU
b. Unhook the projections “a” on the tail cov- and battery box by pinching the washer
er “1” from the holes “b” in the rear fender, and related parts.
and then remove the tail cover. • When installing the IMU, apply a thin coat of
silicone grease onto the washer where con-
b a tacting the IMU grommet.
• When installing the IMU, use only a genuine
bolt and washer, and tighten the bolt to the
1 specified torque.
• Pay attention not to expose the IMU to
strong shocks, such as striking or drop-
b ping it.
a • Do not place any foreign objects in and
around the battery box.
EAS31908
• Do not obstruct breather opening “a” of the
REMOVING THE REAR SIDE COVER IMU.
The following procedure applies to both of the • Do not clean the breather opening and do
rear side covers. not blow it with compressed air.
1. Remove: • When replacing the collar or grommet, re-
• Rear side inner covers and rear side outer place all four collars and grommets.
covers (YZF-R1) “1”
• Rear side covers (YZF-R1M) “1”
1 a
1. Install:
a. Remove the bolts and quick fastener. • IMU (Inertial Measurement Unit) “1”
b. Unhook the projection “a” on the rear side a. Connect the IMU coupler “2” to the IMU.
inner covers (YZF-R1)/rear side covers b. Install the IMU “1”, washers and IMU bolts,
(YZF-R1M) from the hole “b” in the rear and then tighten the bolts to specification.
fender, and then remove the rear side in- TIP
ner covers (YZF-R1)/rear side covers
Apply a thin coat of silicone grease onto the
(YZF-R1M).
washers where contacting the grommets.
4-5
GENERAL CHASSIS (1)
EAS33140
Recommended lubricant INSTALLING THE TAIL COVER

Silicone grease 1. Install:
• Tail cover “1”
IMU bolt
2.0 N·m (0.20 kgf·m, 1.5 lb·ft) 1
T.
R.
S
S
2
a. Fit the projections “a” on the tail cover “1”
1
into the holes “b” in the rear fender, and
then install the quick fasteners.
EAS31909
b a
INSTALLING THE REAR SIDE COVER
rear side covers.
1
1. Install:
• Rear side cover “1”
b
1 a
a. Fit the projection “a” on the rear side inner

covers (YZF-R1)/rear side covers
(YZF-R1M) into the hole “b” in the rear
fender, and then tighten the rear side cov-
er bolts.
Rear side cover bolt

9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.
R.
b a
4-6
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the CCU (for YZF-R1M)
7 N•m (0.7 kgf•m, 5.2 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
T.R
.
.
1
4 7
8
3
10
9
5
1 4
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)
12
T.R
.
13
11

1 Passenger seat cover 1
2 GPS unit coupler 1 Disconnect.
3 Cushion 1
4 GPS unit 1
5 Tail cover 1
6 CCU coupler (sub-wire harness) 1 Disconnect.
7 Band 1
8 CCU (Communication Control Unit) 1
9 CCU bracket 1 1
10 CCU bracket 2 1
11 Wire harness coupler 1 Disconnect.
12 Yamaha diagnostic tool coupler 1
13 Sub-wire harness 1
4-7
GENERAL CHASSIS (2)
EAS33363
REMOVING THE TAIL COVER a

EAS33371
INSTALLING THE CCU (for YZF-R1M)

TIP
When the passenger seat cover is attached, the
total number of occupants is reduced to one per-
son. Depending on your area’s regulations, it
may be necessary to change the vehicle’s regis-
tration to reflect this. Contact your local authori- c. Turn the main switch to “ON” and ap-
ties. proach the vehicle with a wireless capable
smartphone or tablet.
EAS31676 d. Connect to the wireless network “Yamaha
CONNECTING TO THE CCU (for YZF-R1M) Motor Network” by inputting the CCU seri-
The CCU (Communication Control Unit) con- al number as the password.
nects to the vehicle’s CAN (Controller Area Net- TIP
work) and has a GPS receiver to enable the Since all CCU-equipped models put out a simi-
recording of vehicle and riding data. (Refer to larly named wireless network, have only one ve-
“MENU SCREEN” on page 1-6.) Logging data hicle turned on at a time to avoid confusion.
and YRC setting data can be accessed when a
smartphone or tablet is connected to the CCU e. Install the passenger seat cover assembly
wireless network. to the original position, and then install the
TIP bolts.
From the Google© or Apple© application store, Passenger seat cover bolt (for
download the “Y-TRAC” application to make use YZF-R1M)
T.
R.
of the logging data and the “YRC Setting” appli- 7 N·m (0.7 kgf·m, 5.2 lb·ft)
cation to remotely adjust the YRC settings.
EAS33364
1. Connect: INSTALLING THE TAIL COVER
• CCU wireless network Refer to “GENERAL CHASSIS (1)” on page 4-1.
a. Remove the bolts “1” and then remove the
passenger seat cover assembly “2” as
shown.
1 2
b. Note down the CCU serial number “a”.
4-8
GENERAL CHASSIS (3)
EAS20156
GENERAL CHASSIS (3)

Removing the front panel covers
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
1 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
4
3
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

T.R
.

1 Front panel (left) 1
2 Front panel cover (left) 1
3 Front panel (right) 1 For YZF-R1
4 Front panel (right) 1 For YZF-R1M
5 Front panel cover (right) 1
6 Storage compartment 1
4-9
GENERAL CHASSIS (3)
EAS31352
c. Unhook the projections “e” on the front
REMOVING THE FRONT PANEL (LEFT)
panel cover (left) from the holes “f” on the
1. Remove:
front cowling.
• Front panel (left) “1”
d. Unhook the projections “g” on the front
panel cover (left) from the holes “h” on the
front upper cowling.
1
h g
e a c
a. Remove the quick fastener and bolt.

f
b. Slide the front panel (left) upward. Unhook b d
the projections “a” on the front panel (left)
EAS33346
“1” from the holes “b” in the front panel REMOVING THE FRONT PANEL (RIGHT)
cover (left). 1. Remove:
c. Slide the front panel (left) forward. Unhook • Front panel (right) “1”
the projections “c” on the front panel (left)
“1” from the holes “d” in the front panel
cover (left). 1
1
b
a
c
a. Remove the quick fastener and bolt.

d b. Slide the front panel (right) upward. Un-
hook the projections “a” on the front panel
EAS33347
(right) “1” from the holes “b” in the front
REMOVING THE FRONT PANEL COVER
panel cover (right).
(LEFT)
c. Slide the front panel (right) forward. Un-
1. Remove:
hook the projections “c” on the front panel
• Front panel cover (left) “1”
(right) “1” from the holes “d” in the front
panel cover (right).
1
1
b
a
c
a. Unhook the projection “a” on the front pan- d

el cover (left) from the grommet “b” on the
side cover bracket.
b. Unhook the projections “c” on the front
panel cover (left) from the holes “d” on the
side cover bracket.
4-10
GENERAL CHASSIS (3)
EAS33348
a. Fit the projections “a” on the front panel
REMOVING THE FRONT PANEL COVER
cover (left) into the holes “b” on the front
(RIGHT)
upper cowling.
1. Remove:
b. Insert the projections “c” on the front panel
• Front panel cover (right) “1”
cover (left) into the grommets “d” on the
side cover bracket.
c. Fit the projections “e” on the front panel
1 cover (left) into the holes “f” on the front
cowling.
d. Fit the projections “g” on the front panel
cover (left) into the grommets “h” on the
side cover bracket.
b a
a. Unhook the projection “a” on the front pan-
el cover (right) from the grommet “b” on e c g
the side cover bracket.
b. Unhook the projections “c” on the front
panel cover (right) from the holes “d” on
the side cover (right). f
c. Unhook the projections “e” on the front d h
panel cover (right) from the holes “f” on the
EAS31353
front cowling. INSTALLING THE FRONT PANEL (LEFT)
d. Unhook the projections “g” on the front 1. Install:
panel cover (right) from the holes “h” on • Front panel (left) “1”
the front upper cowling.
1
g h
c a e
d b f
a. Fit the projections “a” on the front panel

EAS33349
(left) “1” into the holes “b” in the front panel
INSTALLING THE FRONT PANEL COVER
cover (left). Slide the front panel (left) rear-
(LEFT)
ward.
1. Install:
b. Fit the projections “c” on the front panel
• Front panel cover (left) “1”
(left) “1” into the holes “b” in the front panel
cover (left). Slide the front panel (left)
downward.
1
c. Install the bolt and quick fastener.
Front panel bolt (left)

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
4-11
GENERAL CHASSIS (3)
1 1
d
c
a
b
EAS33350 a. Fit the projections “a” on the front panel
INSTALLING THE FRONT PANEL COVER (right) “1” into the holes “b” in the front pan-
(RIGHT) el cover (right). Slide the front panel (right)
1. Install: rearward.
• Front panel cover (right) “1” b. Fit the projections “c” on the front panel
(right) “1” into the holes “d” in the front pan-
el cover (right). Slide the front panel (right)
1 downward.
c. Install the bolt and quick fastener.
Front panel bolt (right)

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
1
a. Fit the projections “a” on the front panel d
cover (right) into the holes “b” on the front c
upper cowling. a
b. Insert the projections “c” on the front panel
cover (right) into the grommets “d” on the
side cover (right).
c. Fit the projections “e” on the front panel b
cover (right) into the holes “f” on the front
cowling.
d. Fit the projections “g” on the front panel
cover (right) into the grommets “h” on the
side cover (right).
a b
g c e
h d f
EAS33352
INSTALLING THE FRONT PANEL (RIGHT)

1. Install:
• Front panel (right) “1”
4-12
GENERAL CHASSIS (4)
EAS20157
GENERAL CHASSIS (4)

Removing the Rearview mirrors and windshield
0.4 N•m (0.04 kgf•m, 0.30 lb•ft) 4
T.R
.
1 2
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
3
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

T.R
.

Front panel cover 4-9.
1 Turn signal light coupler 2 Disconnect.
2 Rearview mirror 2
3 Front upper cowling 1
4 Windshield 1
4-13
GENERAL CHASSIS (4)
EAS31362
REMOVING THE FRONT UPPER COWLING

1. Remove: 7
7
• Front upper cowling “1”
e. Remove the front upper cowling “1”.

f. Unhook the projections “a” on the front up-
per cowling from the holes “b” on the front
cowling assembly. Unhook the projection
a. Remove the holder “2” from the turn signal
“c” on the front upper cowling from the
light lead (left) and auxiliary light lead. Dis-
grommets “d” in the front cowling assem-
connect the turn signal light coupler (left)
bly. Unhook the projections “e” on the front
“3”.
upper cowling from the holes “f” on the
front cowling assembly. Slide the front up-
per cowling upward and then, unhook the
holes “g” in the front upper cowling from
the projections “h” on the front cowling as-
2
sembly.
3
h
g
h
g c d
b. Disconnect the turn signal light coupler
(right) “4”. Remove the turn signal light
lead from the holder “5”. e f
c
a b
a d
b
EAS31363
5 INSTALLING THE FRONT UPPER COWLING

1. Install:
• Front upper cowling “1”
4
c. Remove the rearview mirror nuts, and

1
then remove the rearview mirrors “6”.
a. Install the front upper cowling “1”.

b. Fit the holes “a” in the front upper cowling
into the projections “b” on the front cowling
6 assembly and then, slide the front upper
cowling downward. Fit the projection “c”
on the front upper cowling into the grom-
d. Remove the front upper cowling bolts “7”.
4-14
GENERAL CHASSIS (4)
mets “d” in the front cowling assembly. Fit

the projections “e” on the front upper cowl-
ing into the holes “f” on the front cowling
assembly. Fit the projections “g” on the
front upper cowling into the holes “h” on 5
the front cowling assembly.
4
b
a
b
a c d
e f
c
g h 5
g d
h
c. Install the front upper cowling bolts “2”,
and then tighten the bolts to specification. 4
Front upper cowling bolt
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
2 2
d. Install the rearview mirrors “3” and rear-

view mirror nuts, and then tighten the nuts
to specification.
Rearview mirror nut

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
e. Connect the turn signal light couplers “4”.

Fasten the turn signal light leads to the
holders “5”.
4-15
GENERAL CHASSIS (5)
EAS20158
GENERAL CHASSIS (5)

Removing the front side cowlings (for YZF-R1)
T.R
T.R
9
.
.
8
6 7
5
2
7 N•m (0.7 kgf•m, 5.2 lb•ft) 1
T.R
.
T.R
T.R
.

1 Front muffler protector (left) 1
2 Front side cowling (left) 1
3 Front muffler protector (right) 1
4 Front side cowling (right) 1
5 Bottom cowling 1
6 Front side cowling bracket (front left) 1
7 Front side cowling bracket (rear left) 1
8 Front side cowling bracket (front right) 1
9 Front side cowling bracket (rear right) 1
4-16
GENERAL CHASSIS (5)
Removing the front side cowlings (for YZF-R1M)

T.R
T.R
8
.
.
7
3
5 6
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
T.R
T.R
.

1 Front muffler protector (left) 1
2 Front side cowling (left) 1
3 Front muffler protector (right) 1
4 Front side cowling (right) 1
5 Front side cowling bracket (front left) 1
6 Front side cowling bracket (rear left) 1
7 Front side cowling bracket (front right) 1
8 Front side cowling bracket (rear right) 1
4-17
GENERAL CHASSIS (5)
EAS33365
REMOVING THE FRONT MUFFLER

PROTECTOR (LEFT)
b b
1. Remove:
• Front muffler protector (left) “1”
a a
EAS31696
REMOVING THE FRONT SIDE COWLING

(LEFT) (for YZF-R1)
1 1. Remove:
• Front side cowling (left) “1”
a. Remove the front muffler protector bolts
(left).
b. Pull the front muffler protector (left) “1”
downward.
c. Unhook the projections “a” on the front
muffler protector (left) “1” from the holes
“b” of the front cowling (left).
b 1
b
a. Remove the quick fastener screws.
a b. Pull the front side cowling (left) “1” for-
a
ward, and then unhook the projection “a”
on the front side cowling (left) “1” from the
hole “b” of the front cowling.
1 c. Unhook the projections “c” on the front
side cowling (left) “1” from the slits “d” on
EAS33366
the front cowling.
REMOVING THE FRONT MUFFLER
d. Unhook the projections “e” on the front
PROTECTOR (RIGHT)
side cowling (left) “1” from the holes “f” on
1. Remove:
the bottom cowling.
• Front muffler protector (right) “1”
e. Unhook the projections “g” on the front
side cowling (left) “1” from the holes “h” on
the bottom cowling.
c
d
b a
1
a. Remove the front muffler protector bolts e
f
(right). h g
b. Pull the front muffler protector (right) “1”
downward.
c. Unhook the projections “a” on the front
muffler protector (right) “1” from the holes
“b” of the front cowling (right).
4-18
GENERAL CHASSIS (5)
EAS33340
a. Remove the front side cowling bolts, quick
fastener screws and quick fasteners.
(RIGHT) (for YZF-R1)
b. Pull the front side cowling (left) “1” for-
1. Remove:
ward, and then unhook the projection “a”
• Front side cowling (right) “1”
on the front side cowling (left) “1” from the
hole “b” of the front cowling.
c. Unhook the projection “c” on the front side
cowling (left) “1” from the slit “d” on the
front cowling.
d
b
c
1
a. Remove the quick fastener screws.
b. Pull the front side cowling (right) “1” for-
ward, and then unhook the projection “a” 1 a
on the front side cowling (right) “1” from
the hole “b” of the front cowling.
EAS33351
c. Unhook the projections “c” on the front REMOVING THE FRONT SIDE COWLING
side cowling (right) “1” from the slits “d” on (RIGHT) (for YZF-R1M)
the front cowling. 1. Remove:
d. Remove the projections “e” on the front • Front side cowling (right) “1”
side cowling (right) “1” from the holes “f”
on the bottom cowling.
e. Remove the projections “g” on the front
side cowling (right) “1” from the holes “h”
on the bottom cowling.
c d
a b
1
a. Remove the front side cowling bolts and
f quick fastener screws.
e b. Pull the front side cowling (right) “1” for-
h ward, and then unhook the projection “a”
g
on the front side cowling (right) “1” from
EAS33344
the hole “b” of the front cowling.
c. Unhook the projection “c” on the front side
(LEFT) (for YZF-R1M)
cowling (right) “1” from the hole “d” on the
1. Remove:
front cowling.
d
c
b
1
a
1
4-19
GENERAL CHASSIS (5)
EAS33341
a. Fit the projection “a” on the front side cowl-
INSTALLING THE FRONT SIDE COWLING
ing (left) “1” into the hole “b” on the front
(RIGHT) (for YZF-R1)
cowling.
1. Install:
b. Fit the projection “c” on the front side cowl-
ing (left) “1” into the slits “d” on the front
cowling.
c. Fit the projections “e” on the front side
cowling (left) “1” into the holes “f” on the
bottom cowling.
d. Fit the projections “g” on the front side
cowling (left) “1” into the holes “h” on the
bottom cowling.
c
1 d
ing (right) “1” into the hole “b” on the front
cowling and slide the front side cowling b a
(right) “1” backward.
ing (right) “1” into the slits “d” on the front e
f
cowling. h g
c. Fit the projections “e” on the front side
e. Install the quick fastener screws.
cowling (right) “1” into the holes “f” on the
bottom cowling. EAS33353
d. Fit the projections “g” on the front side INSTALLING THE FRONT SIDE COWLING
cowling (right) “1” into the holes “h” on the (RIGHT) (for YZF-R1M)
bottom cowling. 1. Install:
c d
a b
f
e
h
g
1
e. Install the quick fastener screws.
EAS31697
ing (right) “1” into the hole “b” on the front
INSTALLING THE FRONT SIDE COWLING
cowling.
(LEFT) (for YZF-R1)
1. Install:
ing (right) “1” into the hole “d” on the front
cowling.
4-20
GENERAL CHASSIS (5)
EAS33367
d INSTALLING THE FRONT MUFFLER
PROTECTOR (LEFT)
1. Install:
c
b • Front muffler protector (left) “1”
c. Install the front side cowling bolts, quick

fastener screws and quick fasteners.
Front side cowling bolt 1

9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.
R.
a. Fit the projections “a” on the front muffler

EAS33345 protector (left) “1” into the holes “b” of the
INSTALLING THE FRONT SIDE COWLING front cowling (left).
(LEFT) (for YZF-R1M) b. Tighten the front muffler protector bolt.
1. Install:
• Front side cowling (left) “1” Front muffler protector bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
b
b
a
a
a. Fit the projection “a” on the front side cowl- 1

ing (left) “1” into the hole “b” on the front
cowling. EAS33368
b. Fit the projection “c” on the front side cowl- INSTALLING THE FRONT MUFFLER
ing (left) “1” into the hole “d” on the front PROTECTOR (RIGHT)
cowling. 1. Install:
• Front muffler protector (right) “1”
d
b
c
1
c. Install the front side cowling bolts, quick
fastener screws and quick fasteners. a. Fit the projections “a” on the front muffler
protector (right) “1” into the holes “b” of the
Front side cowling bolt front cowling (right).
9 N·m (0.9 kgf·m, 6.6 lb·ft) b. Tighten the front muffler protector bolt.
T.
R.
4-21
GENERAL CHASSIS (5)
Front muffler protector bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
b b
a a
4-22
GENERAL CHASSIS (6)
EAS20159
GENERAL CHASSIS (6)

Removing the side covers and front cowling assembly
T.R
.
T.R
.
2
LT
6 3
4
1
5 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Windshield 4-13.
Front side cowling 4-16.
1 Side cover (left) 1
2 Side cover (right) 1
3 Fuse box 1
4 Front side cowling inner panel (right) 1
5 Front side cowling inner panel (left) 1
6 Steering damper solenoid coupler 1 Disconnect.
7 Intake solenoid coupler 1 Disconnect.
4-23
GENERAL CHASSIS (6)
Removing the side covers and front cowling assembly

T.R
.
T.R
.
16
LT
14
15 10
12
13
11
8
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

8 Auxiliary light coupler 1 Disconnect.
9 Headlight control unit coupler 1 Disconnect.
10 Meter assembly coupler 1 Disconnect.
Disconnect.
11 Sub-wire harness coupler 1 For YZF-R1M
Disconnect.
12 Front fork stepping motor coupler 1 For YZF-R1M
13 Intake solenoid vacuum hose 1 Disconnect.
14 Surge tank hose 1 Disconnect.
15 Front cowling assembly 1
16 Side cover bracket (right) 1
4-24
GENERAL CHASSIS (6)
Disassembling the front cowling assembly

1.5 N•m (0.15 kgf•m, 1.1 lb•ft) 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
5 N•m (0.5 kgf•m, 3.7 lb•ft)
4 7
T.R
.
6
11
5
9 10
5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
3 1.5 N•m (0.15 kgf•m, 1.1 lb•ft)

T.R
.
* When installing the auxiliary light onto the front cowling, tighten this screw last.

1 Meter assembly 1
2 Headlight control unit coupler 1 Disconnect.
3 Headlight 1
Disconnect.
4 SCU coupler 1 For YZF-R1M
5 SCU cover 1 For YZF-R1M
6 SCU (Suspension Control Unit) 1 For YZF-R1M
7 SCU bracket 1 For YZF-R1M
8 Auxiliary light (left) 1
9 Auxiliary light (right) 1
10 Front cowling assembly stay 1
11 Front cowling 1
4-25
GENERAL CHASSIS (6)
EAS33354
REMOVING THE SIDE COVER (LEFT)

1. Remove:
• Side cover (left) “1”
1
b
EAS33356
1 INSTALLING THE SIDE COVER (LEFT)

1. Install:
• Side cover (left) “1”
a. Remove the side cover bolt (right) and
quick fastener.
b. Pull the side cover (left) “1” rearward and
unhook the projections “a” on the side cov-
er (left) “1” from the holes “b” of the side
cover bracket.
b 1
a
a. Fit the projections “a” on the side cover
(left) into the holes “b” of the side cover
bracket “1” and slide the side cover (left)
forward.
1
EAS33355
REMOVING THE SIDE COVER (RIGHT)

b
1. Remove: a
• Side cover (right) “1”
b. Install the side cover bolt (left) and quick

fastener.
1 Side cover bolt (left)

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
a. Remove the side cover (left) bolts. EAS33357
b. Pull the side cover (right) “1” downward INSTALLING THE SIDE COVER (RIGHT)
and remove the hole “a” of the side cover 1. Install:
(right) “1” from the projection “b” on the • Side cover (right) “1”
side cover bracket (right).
4-26
GENERAL CHASSIS (6)
a. Fit the hole “a” in the side cover (right) “1”

onto the projection “b” on the side cover
bracket and slide the side cover (right) up-
ward.
TIP
• Position the front cowling assembly “2” on the
side cover (right) “1”.
• Make sure that there is projection “c” on the
side cover (right) “1” in the hole “d” in the front
cowling assembly “2”.
1
b
1
c d
b. Install the side cover bolt (right).
Side cover bolt (right)

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
4-27
GENERAL CHASSIS (7)
EAS20193
GENERAL CHASSIS (7)

Removing the air intake duct
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.
LT
LT
5
4
2 11 N•m (1.1 kgf•m, 8.1 lb•ft)
3
T.R
.
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.

Windshield 4-13.
Side cover/Front cowling assembly 4-23.
1 Intake solenoid vacuum hose 1
2 Surge tank hose 1
3 One-way valve 1
Intake solenoid vacuum hose (one-way valve to
4 1
intake solenoid)
Intake solenoid vacuum hose (intake solenoid to
5 1
air intake duct valve)
4-28
GENERAL CHASSIS (7)
Removing the air intake duct

11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.
12
13
LT
14
7 15
11
LT
8
13
10
6
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)
T.R
.

6 Intake solenoid lead (sub-wire harness) 1
7 Intake solenoid bracket 1
8 Intake solenoid 1
9 Air duct 1
10 Surge tank 1
11 Diaphragm 1
12 Air intake duct assembly 1
13 Air intake duct 1
14 Air intake duct guard 1
15 Air intake duct valve 1
4-29
GENERAL CHASSIS (7)
EAS31645
CHECKING THE AIR INTAKE DUCT VALVE

1. Check:
• Air intake duct valve operation
a. Connect the vacuum/pressure pump
gauge set “1” to the air intake duct valve
“2”.
Vacuum/pressure pump gauge

set
90890-06945
Pressure/ vacuum tester 4. Check:
YB-35956-B • Intake solenoid
Damage → Replace.
b. Check that the air intake duct valve oper- 5. Check:
ates when vacuum pressure is applied to • Intake solenoid
the valve using the vacuum/pressure Refer to “SELF-DIAGNOSTIC FUNCTION
pump gauge set. AND DIAGNOSTIC CODE TABLE” on page
Faulty → Replace the air intake duct 9-40.
valve. 6. Check:
• Surge tank
2 Cracks/damage → Replace.
EAS33358
ASSEMBLING THE AIR INTAKE DUCT

ASSEMBLY
1. Install:
1
• Air intake duct (left)
• Air intake duct (right) “1”
• Air intake duct valve “2”
• Air intake duct guard
EAS31646 • Rubber damper “3”
CHECKING THE VACUUM LINE
1. Check: Air intake duct assembly bolt
• Hoses 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
Loose connections → Connect properly.

Cracks/damage → Replace. TIP
2. Check: • Install the air intake duct valve within the range
• Surge tank of stopper portion “a” and projection “b” inside
Cracks/damage → Replace. the air intake duct.
3. Check: • Install the rubber damper “3” in the direction of
• One-way valve the illustration so that it makes contact with
Cracks/damage/faulty → Replace. stepped portion “c” of the air intake duct.
TIP • After installing the air intake duct, make sure
Check that air flows smoothly only in the direc- that there is no gap between the air intake duct
tion of the arrow shown in the illustration. (left) and the air intake duct (right).
4-30
GENERAL CHASSIS (7)
1 c 3
a 2
b 3
c c
EAS31647
INSTALLING THE AIR INTAKE DUCT VALVE

1. Install:
• Air intake duct valve
a. Hook the end of the shaft “a” onto the plate
“1” as shown.
a 1
a
b. Align the tabs “b” on the air intake duct
valve “2” with the cutouts “c” in the air in-
take duct “3”, and then turn the air intake
duct valve 90° clockwise.
2 b c 3
3 2
4-31
GENERAL CHASSIS (8)
EAS20194
GENERAL CHASSIS (8)

Removing the ECU and side cover bracket
6
5
7 N•m (0.7 kgf•m, 5.2 lb•ft) 3

T.R
.
1 2

Front panel cover (left) 4-9.
Front side cowling (left) 4-16.
Side cover (left) 4-23.
1 ECU cover 1
2 ECU coupler 3 Disconnect.
3 ECU (Engine Control Unit) 1
4 Wire harness holder 1
5 Side cover bracket 1
6 Side cover bracket damper 1
4-32
GENERAL CHASSIS (8)
EAS31641
REMOVING THE ECU (engine control unit)

1. Disconnect:
• ECU coupler “1”
TIP
While pushing the portion “a” of the ECU cou-
pler, move the lock lever “b” in the direction of
the arrow shown to disconnect the coupler.
a 1
EAS31642
INSTALLING THE ECU (engine control unit)

1. Connect:
• ECU coupler “1”
TIP
Connect the ECU coupler, and then push the
lock lever “a” of the coupler in the direction of the
arrow shown.
4-33
GENERAL CHASSIS (9)
EAS20195
GENERAL CHASSIS (9)

Removing the electrical components tray
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
4
2
3
2
6 3
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Front panel cover (left) 4-9.
Side cover (left)/Front side cowling inner panel Refer to “GENERAL CHASSIS (6)” on page
(left) 4-23.
1 Radiator fan motor coupler 2 Disconnect.
2 Handlebar switch coupler (right) 4 Disconnect.
3 Handlebar switch coupler (left) 2 Disconnect.
4 Rectifier/regulator coupler 1 Disconnect.
5 Electrical components tray 1
6 Rectifier/regulator 1
4-34
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake discs (for YZF-R1)
2 3 6 N・m (0.6 kgf・m, 4.4 lb・ft)
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft) 1 35 N・m (3.5 kgf・m, 26 lb・ft)
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
5
3
21 N・m (2.1 kgf・m, 15 lb・ft)
8
10
11
12 6
1
2
7
4 5
LT
115 N・m (11.5 kgf・m, 85 lb・ft)
LT
9
12 7 N・m (0.7 kgf・m, 5.2 lb・ft)
11
17 N・m (1.7 kgf・m, 13 lb・ft)
10
1 Reflector bracket 2
2 Reflector 2
3 Front brake hose holder 2
4 Front wheel sensor 1
5 Front brake caliper 2
6 Wheel axle pinch bolt 4 Loosen.
7 Front wheel axle nut 1
8 Front wheel axle 1
9 Front wheel 1
10 Collar 2
11 Front brake disc 2
12 Plate 2
4-35
FRONT WHEEL
Removing the front wheel and brake discs (for YZF-R1M)

2 3 6 N・m (0.6 kgf・m, 4.4 lb・ft)
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft) 1 35 N・m (3.5 kgf・m, 26 lb・ft)
3.8 N・m (0.38 kgf・m, 2.8 lb・ft)
6
3
21 N・m (2.1 kgf・m, 15 lb・ft)
9
11
12
13 7 1
2
8 5
6
4
7
LT
115 N・m (11.5 kgf・m, 85 lb・ft)
LT
10
13 7 N・m (0.7 kgf・m, 5.2 lb・ft)
12
17 N・m (1.7 kgf・m, 13 lb・ft)
11
1 Reflector bracket 2
2 Reflector 2
4 Front wheel sensor protector 1
5 Front wheel sensor 1
7 Wheel axle pinch bolt 4 Loosen.
8 Front wheel axle nut 1
9 Front wheel axle 1
10 Front wheel 1
11 Collar 2
12 Front brake disc 2
13 Plate 2
4-36
FRONT WHEEL
Disassembling the front wheel
2
4
8 N・m (0.8 kgf・m, 5.9 lb・ft)
5 LT
3
2
1

1 Front wheel sensor rotor 1
2 Oil seal 2
3 Wheel ring 1
4 Wheel bearing 2
5 Spacer 1
4-37
FRONT WHEEL
EAS30145
• Wheel bearings
REMOVING THE FRONT WHEEL
ECA20981
a. Clean the surface of the front wheel hub.
NOTICE b. Remove the oil seals “1” with a flat-head
• Keep any type of magnets (including mag- screwdriver.
netic pick-up tools, magnetic screwdrivers, TIP
etc.) away from the front wheel sensor or To prevent damaging the wheel, place a rag “2”
front wheel sensor rotor; otherwise, the between the screwdriver and the wheel surface.
sensor or rotor may be damaged, resulting
in improper performance of the ABS sys- 2
tem.
• Do not drop the front wheel sensor rotor or
subject it to shocks.
• If any solvent gets on the front wheel sen- 1
sor rotor, wipe it off immediately.
EWA13120
WARNING G088896
Securely support the vehicle so that there is c. Remove the wheel bearings with a gener-
no danger of it falling over. al bearing puller.
2. Remove: EAS30147
• Front brake caliper (left) CHECKING THE FRONT WHEEL

• Front brake caliper (right) 1. Check:
• Front wheel sensor • Wheel axle
ECA21440
Roll the wheel axle on a flat surface.
NOTICE Bends → Replace.
• Do not apply the brake lever when remov- EWA13460
ing the brake calipers. WARNING

• Be sure not to contact the sensor electrode Do not attempt to straighten a bent wheel ax-
to any metal part when removing the front le.
wheel sensor from the sensor housing. 2. Check:
3. Elevate: • Tire
• Front wheel • Front wheel
TIP Damage/wear → Replace.
Place the vehicle on a maintenance stand so Refer to “CHECKING THE TIRES” on page
that the front wheel is elevated. 3-17 and “CHECKING THE WHEELS” on
page 3-17.
4. Loosen: 3. Measure:
• Wheel axle pinch bolt • Radial wheel runout “1”
5. Remove: • Lateral wheel runout “2”
• Front wheel axle Over the specified limits → Replace.
• Front wheel
Radial wheel runout limit
EAS30146
1.0 mm (0.04 in)
DISASSEMBLING THE FRONT WHEEL
ECA21340
Lateral wheel runout limit
NOTICE 1.0 mm (0.04 in)
• 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.
1. Remove:
• Oil seals
4-38
FRONT WHEEL
TIP
2 Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
1
“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”.
G088897
4. Check:
• Wheel bearings
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
• Oil seals
Damage/wear → Replace.
G088899
EAS30151
d. Install the new oil seals.
ASSEMBLING THE FRONT WHEEL
ECA21340
2. Install:
NOTICE • Front wheel sensor rotor
• Do not drop the wheel sensor rotor or sub- Wheel sensor rotor bolt
ject it to shocks. 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
• If any solvent gets on the wheel sensor ro- LOCTITE®

ECA17200
1. Install: NOTICE
• Wheel bearings New Replace the wheel sensor rotor bolts with
• Oil seals New new ones.
a. Install the new wheel bearing (right side).
ECA18110 TIP
NOTICE Install the wheel sensor rotor with the stamped
Do not contact the wheel bearing inner race mark “1” facing outward.
“1” or balls “2”. Contact should be made
only with the outer race “3”.
TIP
1
Use a socket “4” that matches the diameter of
the wheel bearing outer race.
G088900
3. Measure:
• Wheel sensor rotor runout
Out of specification → Correct the wheel sen-
sor rotor runout or replace the wheel sensor
rotor.
G088898
Refer to “MAINTENANCE OF THE FRONT
b. Install the spacer. WHEEL SENSOR AND SENSOR ROTOR”
c. Install the new wheel bearing (left side). on page 4-40.
Wheel sensor rotor runout limit

0.25 mm (0.01 in)
4-39
FRONT WHEEL
EAS30155
a. Hold the dial gauge at a right angle against
MAINTENANCE OF THE FRONT WHEEL
the wheel sensor rotor surface.
SENSOR AND SENSOR ROTOR
ECA21070
b. Measure the wheel sensor rotor runout.
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 front wheel sensor cannot be disas-
sembled. Do not attempt to disassemble it.
If faulty, replace with a new one.
• Keep any type of magnets (including mag- G088902
netic pick-up tools, magnetic screwdrivers,
c. If the runout is above specification, re-
etc.) away from the front wheel sensor or
front wheel sensor rotor. move the sensor rotor from the wheel, ro-
• Do not drop or shock the wheel sensor or tate it by two or three bolt holes, and then
install it.
the wheel sensor rotor.
1. Check: Wheel sensor rotor bolt
• Front wheel sensor “1” T.
R.
8 N·m (0.8 kgf·m, 5.9 lb·ft)
Cracks/bends/distortion → Replace. LOCTITE®
Iron powder/dust → Clean. ECA17200
NOTICE
Replace the wheel sensor rotor bolts with
new ones.
d. If the runout is still above specification, re-
place the wheel sensor rotor.
EAS30152
ADJUSTING THE FRONT WHEEL STATIC

1 BALANCE
TIP
2. Check: • After replacing the tire, wheel or both, the front
• Front wheel sensor rotor wheel static balance should be adjusted.
Cracks/damage/scratches → Replace the • Adjust the front wheel static balance with the
front wheel sensor rotor. brake disc installed.
Iron powder/dust/solvent → Clean. • Be sure to use stick-on type balancing weights.
TIP
1. Remove:
• The wheel sensor rotor is installed on the inner • Balancing weight(s)
side of the wheel hub. 2. Find:
• When cleaning the wheel sensor rotor, be • Front wheel’s heavy spot
careful not to damage the surface of the sensor 3. Adjust:
rotor. • Front wheel static balance
3. Measure: 4. Check:
• Wheel sensor rotor runout • Front wheel static balance
Out of specification → Clean the installation EAS30154
surface of the wheel sensor rotor and correct INSTALLING THE FRONT WHEEL (DISC
the wheel sensor rotor runout, or replace the BRAKE)
wheel sensor rotor. 1. Install:
• Plate
Wheel sensor rotor runout limit • Front brake discs
0.25 mm (0.01 in)
4-40
FRONT WHEEL
TIP
Front brake disc bolt
17 N·m (1.7 kgf·m, 13 lb·ft) Apply lithium soap-based grease onto the mat-
T.
ing surface of the front wheel axle nut.

R.
LOCTITE®
ECA19150
6. Tighten:
NOTICE • Front wheel axle nut
Replace the brake disc bolts with new ones. Front wheel axle nut
115 N·m (11.5 kgf·m, 85 lb·ft)
T.
TIP
R.
Tighten the brake disc bolts in stages and in a ECA14140
crisscross pattern. NOTICE
2. Apply: Before tightening the wheel axle nut, push

• Sealant down hard on the handlebar(s) several times
and check if the front fork rebounds smooth-
TIP
ly.
Apply Three Bond No. 1215B® onto the corner
of brake disc and wheel. 7. Tighten:
• Front wheel axle pinch bolt
a. Tighten the pinch bolt “2”, pinch bolt “1”,
and pinch bolt “2” to the specified torque in
this order.
Front wheel axle pinch bolt

21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
b. Check that the right end “a” of the front

axle is flush with the front fork “b”. If nec-
essary, manually push the front axle or
lightly tap it with a soft hammer until its end
is flush with the front fork. However, if the
surface of the front axle end is not parallel
to the surface of the front fork, align a point
on the outer edge of the axle with the fork,
making sure that the axle does not pro-
trude past the fork.
b
a
3. Check:
• Front brake discs
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-57.
4. Lubricate:
• Oil seal lips
c. Tighten the pinch bolt “4”, pinch bolt “3”,
Recommended lubricant and pinch bolt “4” to the specified torque in
Lithium-soap-based grease
this order.
5. Install: Front wheel axle pinch bolt
• Collar 21 N·m (2.1 kgf·m, 15 lb·ft)
T.
• Front wheel
R.
• Front wheel axle

• Front wheel axle nut
4-41
FRONT WHEEL
Distance “a” (between the front

wheel sensor rotor and front
wheel sensor)
0.9–1.7 mm (0.035–0.067 in) (for
YZF-R1)
1.1–1.9 mm (0.043–0.075 in) (for
YZF-R1M)
4 3 2 1
TIP
Measure the distance between the front wheel
8. Install: sensor rotor and front wheel sensor in several
• Front wheel sensor places in one rotation of the front wheel. Do not
• Front wheel sensor protector (for YZF-R1M) turn the front wheel while the thickness gauge is
installed. This may damage the front wheel sen-
Front wheel sensor bolt sor rotor and the front wheel sensor.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
Front wheel sensor protector bolt

(for YZF-R1M) Thickness gauge
7 N·m (0.7 kgf·m, 5.2 lb·ft) 90890-03268
Feeler gauge set
ECA21020 YU-26900-9
NOTICE
Make sure there are no foreign materials in a
the front wheel sensor rotor and front wheel
sensor. Foreign materials cause damage to 1
the front wheel sensor rotor and front wheel
2
sensor. 2
TIP 1
• When installing the front wheel sensor, check
the front wheel sensor lead for twists.
G088903
• To route the front wheel sensor lead, refer to
“CABLE ROUTING” on page 2-17. 10.Install:
• Front brake calipers
9. Measure:
• Front brake hose holder
• Distance “a”
(between the front wheel sensor rotor “1” and Front brake caliper bolt
front wheel sensor “2”) 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
Out of specification → Check the wheel bear-

R.
Front brake hose holder bolt

ing for looseness, and the front wheel sensor 6 N·m (0.6 kgf·m, 4.4 lb·ft)
and sensor rotor installation conditions
EWA13500
(warpage caused by overtorque, wrong in-
WARNING
stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor, Make sure the brake hose is routed properly.
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.
4-42
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel
7 N・m (0.7 kgf・m, 5.2 lb・ft) 2 11
190 N・m (19 kgf・m, 140 lb・ft)
5
6
9
8
10
7
4 3 3 4
16 N・m (1.6 kgf・m, 12 lb・ft) 16 N・m (1.6 kgf・m, 12 lb・ft)

Rear brake caliper Refer to “REAR BRAKE” on page 4-63.
1 Rear wheel sensor protector 1
2 Rear wheel sensor 1
3 Locknut 2 Loosen.
4 Adjusting bolt 2 Loosen.
5 Rear wheel axle nut 1
6 Washer 1
7 Rear wheel axle 1
8 Adjusting block (left) 1
9 Adjusting block (right) 1
10 Rear wheel 1
11 Brake caliper bracket 1
4-43
REAR WHEEL
Removing the brake disc and rear wheel sprocket

8 N・m (0.8 kgf・m, 5.9 lb・ft) 30 N•m (3.0 kgf•m, 22 lb•ft)
T.R
.
1
(5) LT
3
7
2
(5) LT
(5)
LT
105 N・m (10.5 kgf・m, 77 lb・ft)

13
12
LT
28 N・m (2.8 kgf・m, 21 lb・ft)

14 (5)
4
11 9
10 8
5
6
100 N・m (10 kgf・m, 74 lb・ft) (5)

1 Rear wheel sensor rotor 1
2 Rear brake disc 1
3 Brake disc carrier 1
4 Rear wheel sprocket bracket 1
5 Rear wheel sprocket 1
6 Collar 1
7 Collar 1
8 Oil seal 1
9 Bearing 1
10 Rear wheel drive hub 1 1
11 Rear wheel drive hub damper 5
12 Rear wheel drive hub 2 1
13 Gasket 5
14 Rear wheel 1
4-44
REAR WHEEL
Disassembling the rear wheel
80 N・m (8.0 kgf・m, 59 lb・ft)
5 6 LT
LT

1 Collar 1
2 Oil seal 1
3 Wheel bearing 1
4 Spacer 1
5 Oil seal 1
6 Wheel bearing ring nut 1
7 Wheel bearing 1
4-45
REAR WHEEL
EAS30910 ECA21040
REMOVING THE REAR WHEEL NOTICE

ECA21030
NOTICE • Do not depress the brake pedal when re-

moving the brake caliper.
• Keep any type of magnets (including mag-
• Be sure not to contact the sensor electrode
to any metal part when removing the rear
etc.) away from the rear wheel sensor or
wheel sensor from the rear brake caliper
rear wheel sensor rotor; otherwise, the sen-
bracket.
sor or rotor may be damaged, resulting in
improper performance of the ABS system. 3. Loosen:
• Do not drop the rear wheel sensor rotor or • Locknuts
subject it to shocks. • Adjusting bolts
• If any solvent gets on the rear wheel sensor 4. Remove:
rotor, wipe it off immediately. • Rear wheel axle nut
• Washer
EWA13120
• Rear wheel axle
WARNING • Rear wheel
Securely support the vehicle so that there is • Brake caliper bracket
ECA21400
no danger of it falling over. NOTICE
TIP Be sure to remove the rear wheel sensor be-
Place the vehicle on a maintenance stand so fore removing the brake caliper bracket, oth-
that the rear wheel is elevated. erwise the sensor could be damaged.
TIP
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
EAS30158
DISASSEMBLING THE REAR WHEEL

ECA21340
NOTICE
ject it to shocks.
1. Remove:
• Wheel bearing ring nut “1”
TIP
Use the wheel bearing ring nut tool “2” to remove
the wheel bearing ring nut by turning it clockwise
“a”.
Wheel bearing ring nut tool

A. Recommended tool 90890-01574
Tool No.: 2CR-271A0-00 YM-01574
Tool name: STAND HOOK M1 Type
2. Remove:
• Rear brake caliper
• Rear wheel sensor protector
• Rear wheel sensor
4-46
REAR WHEEL
• Rear wheel drive hub dampers

1 Damage/wear → Replace.
EAS30161
CHECKING AND REPLACING THE REAR

WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth “a” wear → Replace the
drive sprocket, the rear wheel sprocket and
the drive chain as a set.
Bent teeth → Replace the drive sprocket, the
rear wheel sprocket and the drive chain as a
2 set.
2. Remove:
• Oil seal G088904
• Wheel bearings b. Correct

Refer to “DISASSEMBLING THE FRONT 1. Drive chain roller
WHEEL” on page 4-38. 2. Rear wheel sprocket
EAS30159
2. Replace:
CHECKING THE REAR WHEEL
• Rear wheel sprocket
1. Check:
a. Remove the rear wheel sprocket nuts,
• Wheel axle
rear wheel sprocket bracket and the rear
• Wheel bearings
wheel sprocket.
• Oil seals
b. Clean the rear wheel drive hub with a
Refer to “CHECKING THE FRONT WHEEL”
clean cloth, especially the surfaces that
on page 4-38.
contact the sprocket.
2. Check:
c. Install the new rear wheel sprocket and
• Tire
rear wheel sprocket bracket.
• Rear wheel
Damage/wear → Replace. Rear wheel sprocket nut
Refer to “CHECKING THE TIRES” on page 100 N·m (10 kgf·m, 74 lb·ft)
T.
R.
3-17 and “CHECKING THE WHEELS” on

page 3-17. TIP
3. Measure: Tighten the rear wheel sprocket nuts in stages
• Radial wheel runout and in a crisscross pattern.
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL” EAS33361
on page 4-38. CHECKING THE REAR WHEEL SPROCKET
EAS30160
BRACKET
CHECKING THE REAR WHEEL DRIVE HUB 1. Check:
1. Check: • Rear wheel sprocket bracket
• Rear wheel drive hub Cracks/damage → Replace.
4-47
REAR WHEEL
EAS30163
ASSEMBLING THE REAR WHEEL Wheel bearing ring nut tool

ECA21340
90890-01574
NOTICE
YM-01574
ject it to shocks.
• If any solvent gets on the wheel sensor ro- Wheel bearing ring nut
tor, wipe it off immediately. 80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
LOCTITE®
1. Install:
• Wheel bearings New
• Oil seal New 1
Refer to “ASSEMBLING THE FRONT
WHEEL” on page 4-39.
2. Install:
• Wheel bearing ring nut
TIP
Apply locking agent (LOCTITE®) onto the two
symmetric places on the circumference of the
threads of the wheel bearing ring nut.
a
a
4. Apply:
• Sealant
TIP
Apply Three Bond No. 1215B® between the
wheel bearing ring nut and the wheel surface.
LT LT
a. Width: two grooves of the threaded portion

b. Length: more than 40 mm (1.57 in)
3. Tighten:
• Wheel bearing ring nut “1”
TIP
Use the wheel bearing ring nut tool “2” to tighten
the wheel bearing ring nut by turning it counter-
clockwise “a”.
4-48
REAR WHEEL
• Be sure to use stick-on type balancing weights.

1. Adjust:
• Rear wheel static balance
Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-40.
EAS30165
INSTALLING THE REAR WHEEL (DISC

BRAKE)
1. Install:
• Rear brake disc
EAS30167 • Rear wheel sensor rotor
MAINTENANCE OF THE REAR WHEEL
SENSOR AND SENSOR ROTOR Rear brake disc bolt
ECA21060
30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
NOTICE LOCTITE®
• Handle the ABS components with care Rear wheel sensor bolt
since they have been accurately adjusted. 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Keep them away from dirt and do not sub- LOCTITE®
ject them to shocks. ECA21011
• The rear wheel sensor cannot be disassem- NOTICE
bled. Do not attempt to disassemble it. If
faulty, replace with a new one.
ject it to shocks.
• Keep any type of magnets (including mag-
etc.) away from the rear wheel sensor or
• Replace the brake disc bolts and wheel
rear wheel sensor rotor.
sensor rotor bolts with new ones.
• Do not drop or shock the wheel sensor or
the wheel sensor rotor. TIP
1. Check: • Tighten the brake disc bolts in stages and in a
• Rear wheel sensor crisscross pattern.
Refer to “MAINTENANCE OF THE FRONT • Install the wheel sensor rotor with the stamped
WHEEL SENSOR AND SENSOR ROTOR” mark “a” facing outward.
on page 4-40.
2. Check:
• Rear wheel sensor rotor a
WHEEL SENSOR AND SENSOR ROTOR”
on page 4-40.
3. Measure:
• Wheel sensor rotor runout
WHEEL SENSOR AND SENSOR ROTOR”
on page 4-40. 2. Check:
EAS30164
• Rear brake disc
ADJUSTING THE REAR WHEEL STATIC Refer to “CHECKING THE REAR BRAKE
BALANCE DISC” on page 4-68.
TIP 3. Lubricate:
• After replacing the tire, wheel or both, the rear • Oil seal lips
wheel static balance should be adjusted. Recommended lubricant
• Adjust the rear wheel static balance with the Lithium-soap-based grease
brake disc and rear wheel drive hub installed.
4-49
REAR WHEEL
4. Install: 6. Tighten:
• Collars • Rear wheel axle nut
• Brake caliper bracket • Rear brake caliper bolts
• Rear wheel
• Adjusting blocks Rear wheel axle nut
• Rear wheel axle 190 N·m (19 kgf·m, 140 lb·ft)
T.
R.
• Washer Rear brake caliper bolt (front)
27 N·m (2.7 kgf·m, 20 lb·ft)
• Rear wheel axle nut
Rear brake caliper bolt (rear)
TIP 12 N·m (1.2 kgf·m, 8.9 lb·ft)
• Do not install the brake caliper. LOCTITE®
• Align the slot “a” in the swingarm with the pro-
EWA13500
jection “b” of the brake caliper bracket.
WARNING
• Install the adjusting block (left) so that projec-
tion “c” faces to the front of the vehicle. Make sure the brake hose is routed properly.
• Install the adjusting block (right) so that cham- TIP
fered “d” portions become the top and bottom. When tightening the wheel axle nut, there
should be no clearance “a” between the adjust-
ing block “1” and adjusting bolt “2”.
b
a 1 a
2 2
d
A. Left side
c B. Right side
7. Install:
• Rear wheel sensor
• Rear wheel sensor protector
Rear wheel sensor bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
A. Left side Rear wheel sensor protector bolt

B. Right side 7 N·m (0.7 kgf·m, 5.2 lb·ft)
5. Adjust: ECA21080
• Drive chain slack NOTICE

Refer to “Adjusting the drive chain slack” on Make sure there are no foreign materials in
page 3-19. the rear wheel sensor rotor and rear wheel
sensor. Foreign materials cause damage to
Drive chain slack the rear wheel sensor rotor and rear wheel
25.0–35.0 mm (0.98–1.38 in) sensor.
stand) TIP
25.0–35.0 mm (0.98–1.38 in) When installing the rear wheel sensor, check the
Limit rear wheel sensor lead for twists.
35.0 mm (1.38 in)
4-50
REAR WHEEL
8. Measure:
• Distance “a”
(between the rear wheel sensor rotor “1” and
rear wheel sensor “2”)
Out of specification → Check the wheel bear-
ing for looseness, and the rear wheel sensor
and sensor rotor installation conditions
(warpage caused by overtorque, wrong in-
stallation direction, rotor decentering, LOC-
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
vice and caught foreign materials). If there is
any defective part, repair or replace the de-
fective part.
Distance “a” (between the rear

wheel sensor rotor and rear
wheel sensor)
1.3–2.1 mm (0.051–0.083 in)
TIP
Measure the distance between the rear wheel
sensor rotor and rear wheel sensor in several
places in one rotation of the rear wheel. Do not
turn the rear wheel while the thickness gauge is
installed. This may damage the rear wheel sen-
sor rotor and the rear wheel sensor.
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
1
2
1 2
4-51
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
6 N・m (0.6 kgf・m, 4.4 lb・ft)
5 N・m (0.5 kgf・m, 3.7 lb・ft)
5 6
3
7 4
2 1
FW
D
35 N・m (3.5 kgf・m, 26 lb・ft)

The following procedure applies to both of
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Reflector 1
8 Bleed screw 1
9 Bleed screw 1 Right brake caliper side.
4-52
FRONT BRAKE
Removing the front brake master cylinder
2 3.5 N・m (0.35 kgf・m, 2.6 lb・ft) D

FW
3 1.2 N・m (0.12 kgf・m, 0.88 lb・ft)
32 N・m (3.2 kgf・m, 24 lb・ft)

4
1
6 1.0 N・m (0.10 kgf・m, 0.73 lb・ft)
9
S
10
11 13
8
7
14
12
16 N・m (1.6 kgf・m, 12 lb・ft) 1.2 N・m (0.12 kgf・m, 0.88 lb・ft)
2.5 N・m (0.25 kgf・m, 1.8 lb・ft) 6 N・m (0.6 kgf・m, 4.4 lb・ft)

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM (ABS)” on page 3-16.
1 Brake fluid reservoir cap stopper 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7 Brake lever 1
8 Front brake light switch lead connector 2 Disconnect.
9 Brake hose union bolt 1
10 Brake hose gasket 2
11 Brake hose 1
12 Front brake master cylinder holder 1
13 Front brake master cylinder 1
14 Front brake light switch 1
4-53
FRONT BRAKE
Disassembling the front brake master cylinder
5 N・m (0.5 kgf・m, 3.7 lb・ft)
3
BF
4
1
BF

1 Brake master cylinder kit 1
2 Bleed screw 1
3 Cap 1
4 Brake master cylinder body 1
4-54
FRONT BRAKE
Removing the front brake calipers

6 N・m (0.6 kgf・m, 4.4 lb・ft)
1 2
4
3
32 N・m (3.2 kgf・m, 24 lb・ft)
FW
D
35 N・m (3.5 kgf・m, 26 lb・ft)

Drain.
1 Reflector 1
5 Brake hose 1
4-55
FRONT BRAKE
Disassembling the front brake calipers

5 N・m (0.5 kgf・m, 3.7 lb・ft)
FW
D 8
3
9
7
6
BF
2 5
1
6
7
S
S
7
6
5
BF
6
7

1 Brake pad clip 2
2 Brake pad pin 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston dust seal 4
7 Brake caliper piston seal 4
8 Bleed screw 1
9 Bleed screw 1 Right brake caliper side.
4-56
FRONT BRAKE
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 G098641
system is disconnected, the entire brake
system must be disassembled, drained, 3. Measure:
cleaned, properly filled, and bled after reas- • Brake disc thickness
sembly. Measure the brake disc thickness at a few dif-
• Never use solvents on internal brake com- ferent locations.
ponents. Out of specification → Replace.
• Use only clean or new brake fluid for clean- Brake disc thickness limit
ing brake components. 4.5 mm (0.18 in)
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean 4. Adjust:
up any spilt brake fluid immediately. • Brake disc runout
• Avoid brake fluid coming into contact with a. Remove the brake disc.
the eyes as it can cause serious injury. b. Rotate the brake disc by one bolt hole.
FIRST AID FOR BRAKE FLUID ENTERING c. Install the brake disc.
THE EYES:
• Flush with water for 15 minutes and get im- Front brake disc bolt
mediate medical attention. 17 N·m (1.7 kgf·m, 13 lb·ft)
T.
R.
LOCTITE®
EAS30169
ECA19150
CHECKING THE FRONT BRAKE DISCS
NOTICE
The following procedure applies to both brake
discs. Replace the brake disc bolts with new ones.
1. Check: TIP
• Front brake disc
Tighten the brake disc bolts in stages and in a
Damage/galling → Replace.
crisscross pattern.
2. Measure:
• Brake disc runout d. Measure the brake disc runout.
Out of specification → Correct the brake disc e. If out of specification, repeat the adjust-
runout or replace the brake disc. ment steps until the brake disc runout is
within specification.
Brake disc runout limit (as mea- f. If the brake disc runout cannot be brought
sured on wheel) within specification, replace the brake
0.10 mm (0.0039 in) disc.
a. Place the vehicle on a maintenance stand EAS30170
so that the front wheel is elevated. REPLACING THE FRONT BRAKE PADS
b. Remove the brake caliper. The following procedure applies to both brake
c. Hold the dial gauge at a right angle against calipers.
the brake disc surface. TIP
d. Measure the runout 1.5 mm (0.06 in) be- When replacing the brake pads, it is not neces-
low the edge of the brake disc. sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Remove:
• Brake pad clips “1”
4-57
FRONT BRAKE
• Brake pad pin “2” a. Connect a clear plastic hose “1” tightly to
• Brake pad spring “3” the bleed screw “2”. Put the other end of
the hose into an open container.
3 b. Loosen the bleed screw and push the
brake caliper pistons into the brake caliper
with your finger.
1
2
1
2
2. Remove:
• Brake pads “1”
c. Tighten the bleed screw.

T.
R.
5 N·m (0.5 kgf·m, 3.7 lb·ft)
d. Install the brake pads and brake pad

1 spring.
TIP
The arrow mark “a” on the brake pad spring
3. Measure: must point in the direction of disc rotation.
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness limit

0.5 mm (0.02 in)
a
6. Install:
• Brake pad pin
• Brake pad clips
• Front brake caliper
Front brake caliper bolt

4. Remove: 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
• Brake caliper
5. Install: 7. Check:
• Brake pads • Brake fluid level
• Brake pad spring Below the minimum level mark → Add the
TIP specified brake fluid to the proper level.
Always install new brake pads and new brake Refer to “CHECKING THE BRAKE FLUID
pad spring as a set. LEVEL” on page 3-13.
4-58
FRONT BRAKE
8. Check: c. Remove the brake caliper piston dust

• Brake lever operation seals and brake caliper piston seals.
Soft or spongy feeling → Bleed the brake sys- d. Repeat the previous steps to force out the
tem. right side pistons from the brake caliper.
Refer to “BLEEDING THE HYDRAULIC
EAS30173
BRAKE SYSTEM (ABS)” on page 3-16. CHECKING THE FRONT BRAKE CALIPERS
EAS30171 The following procedure applies to both of the
REMOVING THE FRONT BRAKE CALIPERS brake calipers.
The following procedure applies to both of the Recommended brake component
brake calipers. replacement schedule
TIP
Brake pads If necessary
Before removing the brake caliper, drain the
Piston seals Every two years
brake fluid from the entire brake system.
Piston dust seals Every two years
1. Remove:
Brake hoses Every four years
• Brake hose union bolts
• Brake hose gaskets Every two years and
Brake fluid whenever the brake is
• Brake hoses disassembled
TIP
Put the end of the brake hose into a container 1. Check:
and pump out the brake fluid carefully. • Brake caliper pistons
Rust/scratches/wear → Replace the brake
EAS30172
caliper pistons.
DISASSEMBLING THE FRONT BRAKE • Brake caliper cylinders
CALIPERS Scratches/wear → Replace the brake caliper
The following procedure applies to both of the assembly.
brake calipers. • Brake caliper body
1. Remove: Cracks/damage → Replace the brake caliper
• Brake caliper pistons assembly.
• Brake caliper piston dust seals • Brake fluid delivery passages
• Brake caliper piston seals (brake caliper body)
a. Secure the right side brake caliper pistons Obstruction → Blow out with compressed air.
EWA13611
with a piece of wood “a”.
WARNING
b. Blow compressed air into the brake hose
joint opening “b” to force out the left side Whenever a brake caliper is disassembled,
pistons from the brake caliper. replace the brake caliper piston dust seals
EWA17060 and brake caliper piston seals.
WARNING
• Never try to pry out the brake caliper pis- EAS30174
tons. ASSEMBLING THE FRONT BRAKE

• Do not loosen the bolts “4”. CALIPERS
EWA16560
WARNING
• Before installation, all internal brake com-
ponents should be cleaned and lubricated
4
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
a b seals to swell and distort.
• Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
4-59
FRONT BRAKE
• Brake pad spring

Specified brake fluid • Brake pad pin
DOT 4 • Brake pad clips
EAS30175
INSTALLING THE FRONT BRAKE CALIPERS Front brake caliper bolt

The following procedure applies to both of the 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
brake calipers.
R.
1. Install: Refer to “REPLACING THE FRONT BRAKE
• Front brake caliper “1” PADS” on page 4-57.
(temporarily) 4. Fill:
• Brake hose gaskets New • Brake master cylinder reservoir
• Brake hoses “2” (with the specified amount of the specified
• Brake hose union bolts “3” brake fluid)
Front brake hose union bolt Specified brake fluid

32 N·m (3.2 kgf·m, 24 lb·ft) DOT 4
T.
R.
EWA13531 EWA13090
WARNING WARNING
Proper brake hose routing is essential to in- • Use only the designated brake fluid. Other
sure safe vehicle operation. brake fluids may cause the rubber seals to
ECA14170 deteriorate, causing leakage and poor
NOTICE brake performance.
When installing the brake hose onto the • Refill with the same type of brake fluid that
brake caliper “1”, make sure the brake pipe is already in the system. Mixing brake fluids
“a” touches the projection “b” on the brake may result in a harmful chemical reaction,
caliper. leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
2 will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
b ECA13540
NOTICE
a and plastic parts. Therefore, always clean up
3 any spilt brake fluid immediately.
1
5. Bleed:
• Brake system
2 Refer to “BLEEDING THE HYDRAULIC
6. Check:
• Brake fluid level
a
specified brake fluid to the proper level.
b
3
7. Check:
1
• Brake lever operation
2. Remove: Soft or spongy feeling → Bleed the brake sys-
• Front brake caliper tem.
3. Install: Refer to “BLEEDING THE HYDRAULIC
• Brake pads BRAKE SYSTEM (ABS)” on page 3-16.
4-60
FRONT BRAKE
EAS30179
REMOVING THE FRONT BRAKE MASTER Specified brake fluid

CYLINDER DOT 4
TIP
Before removing the front brake master cylinder, EAS30182
INSTALLING THE FRONT BRAKE MASTER

drain the brake fluid from the entire brake sys-
CYLINDER
tem.
1. Install:
1. Disconnect: • Front brake master cylinder
• Brake light switch connectors • Front brake master cylinder holder
(from the front brake light switch)
2. Remove: Front brake master cylinder hold-
• Brake hose union bolt er bolt
T.
R.
• Brake hose gaskets 16 N·m (1.6 kgf·m, 12 lb·ft)
• Brake hose
TIP
TIP
• Install the front brake master cylinder holder
To collect any remaining brake fluid, place a
with the “UP” mark “a” facing up.
container under the master cylinder and the end
• Align the end of the front brake master cylinder
of the brake hose.
with the punch mark “b” on the handlebar.
• First, tighten the upper bolt, then the lower bolt.
EAS30725
CHECKING THE FRONT BRAKE MASTER

CYLINDER
1. Check: b
• 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 a
Damage/scratches/wear → Replace.
3. Check: 2. Install:
• Brake fluid reservoir • Brake hose gaskets New
• Brake fluid reservoir diaphragm holder • Brake hose
Cracks/damage → Replace. • Brake hose union bolt
• Brake fluid reservoir diaphragm
Damage/wear → Replace. Front brake hose union bolt
32 N·m (3.2 kgf·m, 24 lb·ft)
T.
4. Check:
R.
• Brake hoses EWA13531
Cracks/damage/wear → Replace. WARNING

EAS30181
Proper brake hose routing is essential to in-
ASSEMBLING THE FRONT BRAKE MASTER sure safe vehicle operation.
CYLINDER
EWA13520 TIP
WARNING • When installing the brake hose onto the master
• Before installation, all internal brake com- cylinder, make sure the projection “a” on the
ponents should be cleaned and lubricated brake hose touches the projection “b” on the
with clean or new brake fluid. master cylinder.
• Never use solvents on internal brake com- • While holding the brake hose, tighten the union
ponents. bolt as shown.
4-61
FRONT BRAKE
• Turn the handlebars to the left and right to 6. Check:

make sure the brake hose does not touch other • Brake lever operation
parts (e.g., wire harness, cables, leads). Cor- Soft or spongy feeling → Bleed the brake sys-
rect if necessary. tem.
b BRAKE SYSTEM (ABS)” on page 3-16.
3. Fill:
• Brake master cylinder reservoir
(with the specified amount of the specified
brake fluid)

DOT 4
EWA13540
WARNING
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
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
4. Bleed:
• Brake system
5. Check:
specified brake fluid to the proper level.
4-62
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads
D
FW
5 N・m (0.5 kgf・m, 3.7 lb・ft)
27 N・m (2.7 kgf・m, 20 lb・ft)
8 3
7 2
1
LT
5 17 N・m (1.7 kgf・m, 13 lb・ft)

6 2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
4 12 N・m (1.2 kgf・m, 8.9 lb・ft)
6
5
1 Screw plug 1
2 Brake pad retaining bolt 1
3 Rear brake caliper 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake pad insulator 2
8 Bleed screw 1
4-63
REAR BRAKE
Removing the rear brake master cylinder

32 N・m (3.2 kgf・m, 24 lb・ft)
D
3.8 N・m (0.38 kgf・m, 2.8 lb・ft) FW
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
1
2
3
8
7 N・m (0.7 kgf・m, 5.2 lb・ft)
13 N・m (1.3 kgf・m, 9.6 lb・ft)
4.4 N•m (0.44 kgf•m, 3.2 lb•ft)

T.R
.

Rider seat 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Brake fluid reservoir bracket 1
6 Brake fluid reservoir hose 1
9 Brake hose 1
4-64
REAR BRAKE
Removing the rear brake master cylinder

32 N・m (3.2 kgf・m, 24 lb・ft)
13 D
3.8 N・m (0.38 kgf・m, 2.8 lb・ft) FW
1.5 N・m (0.15 kgf・m, 1.1 lb・ft)
10
14
12
11 7 N・m (0.7 kgf・m, 5.2 lb・ft)
13 N・m (1.3 kgf・m, 9.6 lb・ft)
4.4 N•m (0.44 kgf•m, 3.2 lb•ft)

T.R
.

10 Footrest plate 1
11 Cable guide 1
Do not disassemble the rear brake master
12 Rear brake master cylinder assembly 1 cylinder assembly.
13 Rear brake light switch coupler 1 Disconnect.
14 Rear brake light switch 1
4-65
REAR BRAKE
Removing the rear brake caliper
D
FW
32 N・m (3.2 kgf・m, 24 lb・ft)
2 3
4
LT
12 N・m (1.2 kgf・m, 8.9 lb・ft)

27 N・m (2.7 kgf・m, 20 lb・ft)

Drain.
3 Brake hose 1
4 Rear brake caliper 1
4-66
REAR BRAKE
Disassembling the rear brake caliper
7 D
FW
8
9 5 N・m (0.5 kgf・m, 3.7 lb・ft)
10
BF
2
1
4
5
11
3
17 N・m (1.7 kgf・m, 13 lb・ft)

5
2.5 N・m (0.25 kgf・m, 1.8 lb・ft)
4

1 Screw plug 1
2 Brake pad retaining bolt 1
3 Brake pad 2
4 Brake pad shim 2
5 Brake pad insulator 2
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
10 Bleed screw 1
11 Caliper bolt boot 1
4-67
REAR BRAKE
EAS30183
4. Adjust:
INTRODUCTION
EWA14101
• Brake disc runout
WARNING Refer to “CHECKING THE FRONT BRAKE
Disc brake components rarely require disas- DISCS” on page 4-57.
sembly. Therefore, always follow these pre- Rear brake disc bolt
ventive measures: 27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
• Never disassemble brake components un- LOCTITE®
less absolutely necessary.
• If any connection on the hydraulic brake EAS30185
system is disconnected, the entire brake REPLACING THE REAR BRAKE PADS
system must be disassembled, drained, TIP
cleaned, properly filled, and bled after reas- When replacing the brake pads, it is not neces-
sembly. sary to disconnect the brake hose or disassem-
• Never use solvents on internal brake com- ble the brake caliper.
ponents.
• Use only clean or new brake fluid for clean- 1. Measure:
ing brake components. • Brake pad wear limit “a”
• Brake fluid may damage painted surfaces Out of specification → Replace the brake
and plastic parts. Therefore, always clean pads as a set.
up any spilt brake fluid immediately.
Brake pad lining thickness limit
• Avoid brake fluid coming into contact with 0.5 mm (0.02 in)
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.
a
EAS30184
CHECKING THE REAR BRAKE DISC

1. Check:
• Rear brake disc
Damage/galling → Replace.
2. Measure:
• Brake disc runout 2. Install:
Out of specification → Correct the brake disc • Brake pad insulators
runout or replace the brake disc. • Brake pad shims
Refer to “CHECKING THE FRONT BRAKE (onto the brake pads)
DISCS” on page 4-57. • Brake pad spring
(into the rear brake caliper)
Brake disc runout limit (as mea- • Brake pads
sured on wheel) TIP
0.15 mm (0.0059 in)
Always install new brake pads, brake pad insu-
3. Measure: lators, brake pad shims, and brake pad spring as
• Brake disc thickness a set.
Measure the brake disc thickness at a few dif- a. Connect a clear plastic hose “1” tightly to
ferent locations. the bleed screw “2”. Put the other end of
Out of specification → Replace. the hose into an open container.
Refer to “CHECKING THE FRONT BRAKE b. Loosen the bleed screw and push the
DISCS” on page 4-57. brake caliper piston into the brake caliper
with your finger.
Brake disc thickness limit
4.5 mm (0.18 in)
4-68
REAR BRAKE
• Remove any excess grease.

4. Install:
1 • Brake pad retaining bolts
• Screw plug
2 Rear brake caliper bolt (front)

27 N·m (2.7 kgf·m, 20 lb·ft)
T.
R.
12 N·m (1.2 kgf·m, 8.9 lb·ft)
LOCTITE®
c. Tighten the bleed screw. Rear brake pad retaining bolt
17 N·m (1.7 kgf·m, 13 lb·ft)
Rear brake caliper screw plug
5 N·m (0.5 kgf·m, 3.7 lb·ft)
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.
d. Install the brake pad insulators and brake

5. Check:
pad shims onto each brake pads.
TIP Below the minimum level mark → Add the
Apply silicone grease between the brake pad in- specified brake fluid to the proper level.
sulator and brake pad shim. Refer to “CHECKING THE BRAKE FLUID
ECA14150 LEVEL” on page 3-13.
NOTICE 6. Check:
• Do not allow grease to contact the brake • Brake pedal operation
pads. Soft or spongy feeling → Bleed the brake sys-
• Remove any excess grease. tem.
e. Install the brake pads and brake pad BRAKE SYSTEM (ABS)” on page 3-16.
spring.
EAS30186
TIP
REMOVING THE REAR BRAKE CALIPER
The longer tangs “a” of the brake pad spring
TIP
must point in the direction of the brake caliper
piston. Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
a 1. Remove:
• Brake hose union bolt
• Brake hose gaskets
• Brake hose
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
EAS30187
DISASSEMBLING THE REAR BRAKE

3. Lubricate: CALIPER
• Rear brake caliper bolts 1. Remove:
Recommended lubricant • Brake caliper piston
Silicone grease • Brake caliper piston dust seal
• Brake caliper piston seal
ECA14150 a. Blow compressed air into the brake hose
NOTICE joint opening “a” to force out the piston
• Do not allow grease to contact the brake from the brake caliper.
pads.
4-69
REAR BRAKE
EWA13550
2. Check:
WARNING • Rear brake caliper bracket
• Cover the brake caliper piston with a rag. Cracks/damage → Replace.
Be careful not to get injured when the pis- Refer to “REAR WHEEL” on page 4-43.
ton is expelled from the brake caliper.
EAS30189
• Never try to pry out the brake caliper pis-
ASSEMBLING THE REAR BRAKE CALIPER
ton. EWA17080
WARNING
• Before installation, all internal brake com-
a 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.
b. Remove the brake caliper piston dust seal
EAS30188 DOT 4
CHECKING THE REAR BRAKE CALIPER
Recommended brake component EAS30190
replacement schedule INSTALLING THE REAR BRAKE CALIPER

1. Install:
Brake pads If necessary
Piston seal Every two years (temporarily)
Piston dust seal Every two years • Brake hose gaskets New
Brake hoses Every four years • Brake hose
Every two years and • Brake hose union bolt
Brake fluid whenever the brake is
disassembled Rear brake hose union bolt
32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
1. Check:
EWA13531
• Brake caliper piston
WARNING
Rust/scratches/wear → Replace the brake
caliper piston. Proper brake hose routing is essential to in-
• Brake caliper cylinder sure safe vehicle operation.
Scratches/wear → Replace the brake caliper ECA19080
assembly. NOTICE
• Brake caliper body When installing the brake hose onto the
Cracks/damage → Replace the brake caliper brake caliper “1”, make sure the brake pipe
assembly. “a” passes between the projections “b” on
• Brake fluid delivery passages the brake caliper.
(brake caliper body)
EWA13601
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
4-70
REAR BRAKE

b not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
a ECA13540
NOTICE
1 and plastic parts. Therefore, always clean up
5. Bleed:
2. Remove: • Brake system
• Rear brake caliper Refer to “BLEEDING THE HYDRAULIC
3. Install: BRAKE SYSTEM (ABS)” on page 3-16.
• Brake pad insulators 6. Check:
• Brake pad shims • Brake fluid level
(onto the brake pads) Below the minimum level mark → Add the
• Brake pad spring specified brake fluid to the proper level.
(into the rear brake caliper) Refer to “CHECKING THE BRAKE FLUID
• Brake pads LEVEL” on page 3-13.
• Rear brake caliper 7. Check:
Refer to “REPLACING THE REAR BRAKE • Brake pedal operation
PADS” on page 4-68. Soft or spongy feeling → Bleed the brake sys-
tem.
Rear brake caliper bolt (front) Refer to “BLEEDING THE HYDRAULIC
27 N·m (2.7 kgf·m, 20 lb·ft) BRAKE SYSTEM (ABS)” on page 3-16.
T.
R.

12 N·m (1.2 kgf·m, 8.9 lb·ft) EAS30193
LOCTITE® REMOVING THE REAR BRAKE MASTER

Rear brake pad retaining bolt CYLINDER
17 N·m (1.7 kgf·m, 13 lb·ft) 1. Remove:
Rear brake caliper screw plug • Brake hose union bolt “1”
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) • Brake hose gaskets “2”
• Brake hose “3”
4. Fill:
TIP
• Brake fluid reservoir
(with the specified amount of the specified To collect any remaining brake fluid, place a
brake fluid) container under the master cylinder and the end
of the brake hose.
DOT 4
EWA13090
1
WARNING
• Use only the designated brake fluid. Other 2
brake fluids may cause the rubber seals to 3
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,
4-71
REAR BRAKE
EAS30194
CHECKING THE REAR BRAKE MASTER

CYLINDER
1. Check:
• Brake master cylinder
Damage/scratches/wear → Replace. a
• Brake fluid delivery passages
(brake master cylinder body)
2. Check:
2. Fill:
• Brake fluid reservoir diaphragm holder
(with the specified amount of the specified
• Brake fluid reservoir diaphragm
brake fluid)
3. Check: Specified brake fluid
• Brake hose DOT 4
• Brake fluid reservoir hose
Cracks/damage/wear → Replace. EWA13090
WARNING
EAS31743
THE REAR BRAKE MASTER CYLINDER
ECA23000 brake fluids may cause the rubber seals to
NOTICE deteriorate, causing leakage and poor
Do not disassemble the rear brake master brake performance.
cylinder. If the master cylinder malfunctions, • Refill with the same type of brake fluid that
replace the rear brake master cylinder as- is already in the system. Mixing brake fluids
sembly. may result in a harmful chemical reaction,
EAS30196
INSTALLING THE REAR BRAKE MASTER not enter the brake fluid reservoir. Water
CYLINDER will significantly lower the boiling point of
1. Install: the brake fluid and could cause vapor lock.
• Brake hose gaskets New ECA13540
• Brake hose NOTICE

• Brake fluid reservoir hose Brake fluid may damage painted surfaces
• Brake hose union bolt and plastic parts. Therefore, always clean up
Rear brake hose union bolt
32 N·m (3.2 kgf·m, 24 lb·ft) 3. Bleed:
T.
R.
• Brake system
EWA13531 Refer to “BLEEDING THE HYDRAULIC
WARNING BRAKE SYSTEM (ABS)” on page 3-16.
Proper brake hose routing is essential to in- 4. Check:
sure safe vehicle operation. • Brake fluid level
ECA14160 Below the minimum level mark “a” → Add the
NOTICE specified brake fluid to the proper level.
When installing the brake hose onto the Refer to “CHECKING THE BRAKE FLUID
brake master cylinder, make sure the brake LEVEL” on page 3-13.
pipe touches the projection “a” as shown. 5. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-15.
4-72
REAR BRAKE
6. Adjust:
• Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-35.
4-73
ABS (Anti-lock Brake System)
EAS20032

Removing the hydraulic unit assembly
T.R
T.R
.
.
1 2
LT 3
LT
32 N•m (3.2 kgf•m, 24 lb•ft) 4

T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
LT
5
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
New 6
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Rider seat/Battery cover/Battery 4-1.
Drain.
1 Fuel tank bracket 1
2 Fuse box 1 1
3 Radiator fan motor relay 1
4 Rear wheel sensor coupler 1
5 ABS ECU coupler 1 Disconnect.
6 Rear brake hose bracket 1
Hydraulic unit brake pipe (hydraulic unit to rear
7 1
brake caliper)
4-74
Removing the hydraulic unit assembly

T.R
T.R
.
.
LT
LT
32 N•m (3.2 kgf•m, 24 lb•ft) 18

T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
9 19
13
LT
13 15 10
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
16
17
11 14 New
12
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Hydraulic unit brake pipe (rear brake master cyl-
8 1
inder to hydraulic unit)
Hydraulic unit brake pipe (hydraulic unit to front
9 1
brake calipers)
Hydraulic unit brake pipe (front brake master
10 1
cylinder to hydraulic unit)
11 Rear brake light switch lead 1
12 Rear wheel sensor lead 1
14 Gasket 4
Brake hose (hydraulic unit to front brake cali-
15 1
pers)
Brake hose (front brake master cylinder to hy-
16 1
draulic unit)
17 Brake hose joint 1
18 Hydraulic unit tray 1
19 Hydraulic unit assembly 1
4-75
EAS30728
ABS COMPONENTS CHART
6,7
5
3,4
2
15,16
10
14
11
12
13
1. Meter assembly
2. Hydraulic unit assembly
3. Fuse box 1
4. ABS solenoid fuse
5. YDT coupler
6. Starter relay
7. ABS motor fuse
9. Rear wheel sensor rotor
11. Front brake caliper (left)
13. Front wheel sensor rotor
14. Front brake caliper (right)
15. Fuse box 2
16. Signaling system fuse
4-76
EAS30197
REMOVING THE HYDRAULIC UNIT

ASSEMBLY 1
ECA18230
NOTICE
Unless necessary, avoid removing and in-
stalling the brake pipes of the hydraulic unit
assembly.
EWA13930
WARNING a
Refill with the same type of brake fluid that is
already in the system. Mixing fluids may re- 2. Remove:
sult in a harmful chemical reaction, leading • Brake hoses
to poor braking performance. • Brake pipes
ECA19790 TIP
NOTICE • Do not operate the brake lever and brake pedal
• Handle the ABS components with care while removing the brake hoses and brake
since they have been accurately adjusted. pipes.
Keep them away from dirt and do not sub- • Do not bend the brake pipe when loosening the
ject them to shocks. brake pipe flare nuts.
• Do not set the main switch to “ON” when ECA19800
removing the hydraulic unit assembly. NOTICE

• Do not clean with compressed air. • When removing the brake hoses and brake
• Do not reuse the brake fluid. pipes, cover the area around the hydraulic
• Brake fluid may damage painted surfaces unit assembly to catch any spilt brake fluid.
and plastic parts. Therefore, always clean Do not allow the brake fluid to contact other
up any spilt brake fluid immediately. parts.
• Do not allow any brake fluid to contact the • Before disconnecting the brake pipes from
couplers. Brake fluid may damage the cou- the hydraulic unit assembly, do not lift up
plers and cause bad contacts. or move the brake pipes.
• If the brake pipe flare nuts for the hydraulic
3. Remove:
unit assembly have been removed, be sure
• Hydraulic unit assembly “1”
to tighten them to the specified torque and
bleed the brake system. TIP
To avoid brake fluid leakage and to prevent for-
1. Disconnect:
eign materials from entering the hydraulic unit
• ABS ECU coupler “1”
assembly, insert a rubber plug “a” or a bolt (M10
TIP × 1.00) into each flare nut hole.
While pushing the portion “a” of the ABS ECU ECA19810
coupler, pull the lock lever up to release the lock. NOTICE
ECA20080
When using a bolt, do not tighten the bolt un-
NOTICE til the bolt head touches the hydraulic unit.
Do not use a tool to disconnect the ABS ECU Otherwise, the brake pipe seating surface
coupler. could be deformed.
4-77
Hydraulic unit assembly bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
a LOCTITE®
1
1
2
EAS30198
CHECKING THE HYDRAULIC UNIT 3

ASSEMBLY
1. Check: 4
• Hydraulic unit assembly
2. Remove:
Cracks/damage → Replace the hydraulic unit
• Rubber plugs or bolts (M10 × 1.0)
assembly and the brake pipes that are con-
3. Install:
nected to the assembly as a set.
• Hydraulic unit brake pipe
EAS30199 4. Tighten:
CHECKING THE BRAKE PIPES • Hydraulic unit brake pipe flare nuts
brake pipes. Hydraulic unit brake pipe flare
1. Check: nut
T.
R.
• Brake pipe end (flare nut) 16 N·m (1.6 kgf·m, 12 lb·ft)

Damage → Replace the hydraulic unit as- ECA19820
sembly, brake pipes, and related parts as a NOTICE
set.
If the brake pipe flare nut does not turn easi-
EAS30200 ly, replace the hydraulic unit assembly,
INSTALLING THE HYDRAULIC UNIT brake pipes, and related parts as a set.
ASSEMBLY
1. Install: TIP
• Hydraulic unit assembly Do not bend the brake pipe when tightening the
ECA18260
brake pipe flare nuts.
NOTICE
5. Install:
Do not remove the rubber plugs or bolts
(M10 × 1.0) installed in the flare nut holes be- • Gaskets New
fore installing the hydraulic unit assembly. • Brake hose union bolts
• Brake hoses “1”
TIP
Do not allow any foreign materials to enter the Front brake hose union bolt
hydraulic unit assembly or the brake hoses or 32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
brake pipes when installing the hydraulic unit as- ECA22800

sembly. NOTICE
a. Install the hydraulic unit assembly “1” on When installing each brake hose onto the hy-
the hydraulic unit tray “2”. draulic unit brake pipe joint, make sure that
b. Temporarily tighten the hydraulic unit as- the brake pipe “a” touches the projection “b”
sembly bolts “3”, “4”. on the joint.
c. Tighten the hydraulic unit assembly bolt
“3”, and bolt “4” to the specified torque in
this order.
4-78
TIP • When refilling, be careful that water does

There is an identifying white paint mark “c” on not enter the brake master cylinder reser-
the upper surface of the pipe of the brake hose voir or brake fluid reservoir. Water will sig-
(front brake master cylinder to the hydraulic nificantly lower the boiling point of the
unit). brake fluid and could cause vapor lock.
ECA13540
NOTICE
b any spilt brake fluid immediately.
a 8. Bleed:
1 • Brake system
c BRAKE SYSTEM (ABS)” on page 3-16.
9. Check the operation of the hydraulic unit ac-
cording to the brake lever and the brake ped-
6. Connect:
al response. (Refer to “HYDRAULIC UNIT
• ABS ECU coupler “1”
OPERATION TEST” on page 4-79.)
TIP ECA14770
Connect the ABS ECU coupler, and then push NOTICE

the lock lever of the coupler in the direction of the Always check the operation of the hydraulic
arrow shown. unit according to the brake lever and the
brake pedal response.
1 10.Delete the DTC. (Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE
TABLE” on page 9-40.)
11.Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-82.)
EAS30201
HYDRAULIC UNIT OPERATION TEST

The reaction-force pulsating action generated in
the brake lever and brake pedal when the ABS
7. Fill: is activated can be tested when the vehicle is
• Brake fluid reservoir stopped.
(with the specified amount of the specified The hydraulic unit operation can be tested using
brake fluid) the following two methods.
• Brake line routing confirmation: this test
Specified brake fluid checks the function of the ABS after the sys-
DOT 4 tem was disassembled, adjusted, or serviced.
EWA17280
• ABS reaction-force confirmation: this test gen-
WARNING erates the same reaction-force pulsating action
that is generated in the brake lever and brake
pedal when the ABS is activated.
deteriorate, causing leakage and poor Brake line routing confirmation
brake performance. EWA13120
• Refill with the same type of brake fluid that WARNING

is already in the system. Mixing brake fluids Securely support the vehicle so that there is
may result in a harmful chemical reaction, no danger of it falling over.
4-79
TIP 6. Start the Yamaha diagnostic tool and display

• For the brake line routing confirmation, use the the diagnosis of function screen.
diagnosis of function of the Yamaha diagnostic 7. Select code No. 2, “Brake line routing confir-
tool. mation”.
• Before performing the brake line routing confir- 8. Click “Actuator Check”, and then operate the
mation, make sure that no malfunctions have brake lever “1” and brake pedal “2” simulta-
been detected in the ABS ECU and that the neously.
wheels are not rotating. TIP
• The hydraulic unit operates 1 second after the
1. Place the vehicle on a maintenance stand.
brake lever and brake pedal are operated si-
2. Turn the main switch to “OFF”.
multaneously and continues for approximately
3. Remove:
5 seconds.
• Rider seat
• The operation of the hydraulic unit can be con-
firmed using the indicator.
4-1.
On: The hydraulic unit is operating.
4. Check:
Flashing: The conditions for operating the hy-
• Battery voltage
draulic unit have not been met.
Lower than 12.8 V → Charge or replace the
Off: The brake lever and brake pedal are not
battery.
being operated.
Battery voltage
Higher than 12.8 V 1
TIP
If the battery voltage is lower than 12.8 V, charge
the battery, and then perform brake line routing
confirmation.
5. Removing the protective cap, and then con-
nect the Yamaha diagnostic tool to the G088909 2
Yamaha diagnostic tool coupler (6P).
9. Check:
Yamaha diagnostic tool USB • Hydraulic unit operation
90890-03267 Click “Actuator Check”, a single pulse will be
Yamaha diagnostic tool (A/I) generated in the brake lever “1”, brake pedal
90890-03264 “2”, and again in the brake lever “1”, in this or-
der.
TIP
• Yamaha diagnostic tool (A/I) (90890-03264) in- 1
cludes YDT sub harness (6P) (90890-03266).
(90890-03266) is separately required.
G088911 2
TIP
“ON” and “OFF” on the tool screen indicate
when the brakes are being applied and released
respectively.
4-80
ECA17371
5. Removing the protective cap, and then con-
NOTICE nect the Yamaha diagnostic tool to the
• Check that the pulse is felt in the brake le- Yamaha diagnostic tool coupler (6P).
ver, brake pedal, and again in the brake le-
ver, in this order. Yamaha diagnostic tool USB
• If the pulse is felt in the brake pedal before 90890-03267
it is felt in the brake lever, check that the Yamaha diagnostic tool (A/I)
brake hoses and brake pipes are connected 90890-03264
correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake TIP
lever or brake pedal, check that the brake • Yamaha diagnostic tool (A/I) (90890-03264) in-
hoses and brake pipes are connected cor- cludes YDT sub harness (6P) (90890-03266).
rectly to the hydraulic unit assembly. • If you already have Yamaha diagnostic tool (A/
10.If the operation of the hydraulic unit is normal, (90890-03266) is separately required.
delete all of the DTC.
ABS reaction-force confirmation 6. Start the Yamaha diagnostic tool and display
EWA13120
the diagnosis of function screen.
WARNING 7. Select code No. 1, “ABS reaction-force con-
Securely support the vehicle so that there is firmation”.
no danger of it falling over. 8. Click “Actuator Check”, and then operate the
brake lever “1” and brake pedal “2” simulta-
TIP
neously.
• For the ABS reaction-force confirmation, use
TIP
the diagnosis of function of the Yamaha diag-
nostic tool. For more information, refer to the • The hydraulic unit operates 1 second after the
operation manual of the Yamaha diagnostic brake lever and brake pedal are operated si-
tool. multaneously and continues for approximately
• Before performing the ABS reaction-force con- 5 seconds.
firmation, make sure that no malfunctions have • The operation of the hydraulic unit can be con-
been detected in the ABS ECU and that the firmed using the indicator.
wheels are not rotating. On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
1. Place the vehicle on a maintenance stand. draulic unit have not been met.
2. Turn the main switch to “OFF”. Off: The brake lever and brake pedal are not
3. Remove: being operated.
• Rider seat
Refer to “GENERAL CHASSIS (1)” on page 1
4-1.
4. Check:
• Battery voltage
Lower than 12.8 V → Charge or replace the
battery.
Battery voltage
Higher than 12.8 V
G088909 2
TIP 9. A reaction-force pulsating action is generated
If the battery voltage is lower than 12.8 V, charge in the brake lever “1” and continues for a few
the battery, and then perform ABS reaction- seconds.
force confirmation. TIP
• The reaction-force pulsating action consists of
quick pulses.
4-81
• Be sure to continue operating the brake lever ECA17371
and brake pedal even after the pulsating action NOTICE

has stopped. • Check that the pulse is felt in the brake le-
• “ON” and “OFF” on the tool screen indicate ver, brake pedal, and again in the brake le-
when the brakes are being applied and re- ver, in this order.
leased respectively. • If the pulse is felt in the brake pedal before
it is felt in the brake lever, check that the
brake hoses and brake pipes are connected
1 correctly to the hydraulic unit assembly.
• If the pulse is hardly felt in either the brake
lever or brake pedal, check that the brake
hoses and brake pipes are connected cor-
rectly to the hydraulic unit assembly.
12.Turn the main switch to “OFF”.
13.Remove the Yamaha diagnostic tool from the
G088913 Yamaha diagnostic tool coupler, and then in-
10.After the pulsating action has stopped in the stall the protective cap.
brake lever, it is generated in the brake pedal 14.Turn the main switch to “ON”.
“1” and continues for a few seconds. 15.Set the start/engine stop switch to “ ”.
TIP 16.Check for brake fluid leakage around the hy-
draulic unit.
Brake fluid leakage → Replace the hydraulic
quick pulses.
unit, brake pipes, and related parts as a set.
• Be sure to continue operating the brake lever
17.If the operation of the hydraulic unit is normal,
and brake pedal even after the pulsating action
delete all of the DTC.
has stopped.
• “ON” and “OFF” on the tool screen indicate EAS30202
when the brakes are being applied and re- CHECKING THE ABS WARNING LIGHT
leased respectively. After all checks and servicing are completed, en-
sure that the ABS warning light goes off by walk-
ing the vehicle at a speed of faster than 5 km/h
(3.1 mi/h) or performing a trial run.
1
G088914
11.After the pulsating action has stopped in the

brake pedal, it is generated in the brake lever
and continues for a few seconds.
TIP
quick pulses.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
4-82
HANDLEBARS
EAS20033
HANDLEBARS
Removing the handlebars
3.8 N•m (0.38 kgf•m, 2.8 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft) 115 N•m (11.5 kgf•m, 85 lb•ft)
T.R
T.R
T.R
.
.
16 N•m (1.6 kgf•m, 12 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
.
26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
LS
LS
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 2

T.R
.
4
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
3
T.R
.
T.R
.
T.R
.

Rider seat 4-1.
Side cover bracket damper 4-28.
Side cover (left) 4-23.
Air filter case Refer to “AIR FILTER CASE” on page 7-5.
1 Grip end (left) 1
2 Handlebar grip 1
3 Clutch switch connector 2 Disconnect.
4 Clutch switch 1
4-83
HANDLEBARS

T.R
T.R
T.R
.
.
16 N•m (1.6 kgf•m, 12 lb•ft) 13 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
.
16 26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
14
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
8
LS
LS
15 2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
11
8 9
12 10
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.
T.R
.
T.R
.
5 7

5 Handlebar switch coupler (left) 2 Disconnect.
6 Horn connector 2 Disconnect.
7 Horn 1
8 Handlebar switch (left) 1
9 Clutch cable 1 Disconnect.
10 Clutch lever holder 1
11 Front brake light switch connector 2 Disconnect.
12 Front brake light switch 1
13 Front brake master cylinder bracket 1
14 Front brake master cylinder holder 1
15 Front brake master cylinder assembly 1
16 Grip end (right) 1
4-84
HANDLEBARS

T.R
T.R
T.R
.
.
16 N•m (1.6 kgf•m, 12 lb•ft) 20 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
.
18 26 N•m (2.6 kgf•m, 19 lb•ft)
T.R
.
24 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
19 20
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
18 32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
26
LS
LS
23 25
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)
T.R
.
21
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.
T.R
.
T.R
.
17
22
17
17

17 Handlebar switch coupler (right) 4 Disconnect.
18 Handlebar switch (right) 1
19 Throttle grip 1
20 Front fork stepping motor coupler 2 Disconnect. (for YZF-R1M)
21 Immobilizer coupler 1 Disconnect.
22 Main switch coupler 1 Disconnect.
23 Main switch cover 1
24 Upper bracket 1
25 Handlebar (left) 1
26 Handlebar (right) 1
4-85
HANDLEBARS
EAS30203
REMOVING THE HANDLEBARS Steering stem nut

1. Stand the vehicle on a level surface. 115 N·m (11.5 kgf·m, 85 lb·ft)
T.
R.
EWA13120
Upper bracket pinch bolt
WARNING 26 N·m (2.6 kgf·m, 19 lb·ft)
Securely support the vehicle so that there is Handlebar bolt
no danger of it falling over. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Handlebar pinch bolt
2. Remove: 32 N·m (3.2 kgf·m, 24 lb·ft)
• Handlebar grip “1”
TIP 3. Install:
Blow compressed air between the left handlebar • Main switch cover “1”
and the handlebar grip, and gradually push the TIP
grip off the handlebar. • Pass the main switch cover “1” between the
projection “a” of the upper bracket and main
switch “b”, and hook the hook on one end of the
1
main switch cover into the hole on the other
end.
• Make sure that the main switch cover “1” cov-
ers the main switch bolt head “c”.
• The main switch cover may be facing in any di-
rection.
G088916
EAS30204
CHECKING THE HANDLEBARS a b

1. Check:
• Handlebar (left) 1
• Handlebar (right)
Bends/cracks/damage → Replace.
EWA13690
WARNING c
Do not attempt to straighten a bent handle-
4. Install:
bar as this may dangerously weaken it.
• Handlebar switch (right)
EAS30205
• Throttle grip
INSTALLING THE HANDLEBARS • Grip end (right)
EWA13120 Handlebar switch screw
WARNING 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
Grip end bolt

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
2. Install: a. Fit the slot “a” in the throttle grip “1” into the
• Handlebar (left) projection “b” in the handlebar switch
• Handlebar (right) (right, front side) “2” and the throttle grip
• Upper bracket “1” onto the handlebar “3”.
4-86
HANDLEBARS
2a
b 1
3 b
a
e
5
b. Make sure that the throttle grip “1” turns 5. Install:

smoothly. • Front brake master cylinder assembly
Refer to “INSTALLING THE FRONT BRAKE
MASTER CYLINDER” on page 4-61.
6. Install:
• Clutch lever holder “1”
1 • Clutch cable
Clutch lever holder pinch bolt

T.
R.
11 N·m (1.1 kgf·m, 8.1 lb·ft)
TIP
c. Install the handlebar switch (right, rear Align the center of slit on the clutch lever holder
side) “4”. with the punch mark “a” on the handlebar.
TIP
Align the projection “c” on the handlebar switch 1
(right, rear side) “4” with the hole “d” in the han-
dlebar “1”.
1 d
a
c
7. Install:
• Handlebar switch screw (left)
4
Handlebar switch screw
d. Install the grip end (right) “5”. 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
TIP
TIP
There should be 1–3 mm (0.04–0.12 in) of clear-
Align the projection “a” on the handlebar switch
ance “e” between the throttle grip and the grip
(left) with the hole “b” in the handlebar.
end.
4-87
HANDLEBARS
b a
8. Install:
• Handlebar grip “1”
• Grip end (left) “2”
Grip end bolt

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
a. Apply a thin coat of rubber adhesive onto

the end of the left handlebar.
b. Side the handlebar grip over the end of the
left handlebar.
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.
TIP
There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the handlebar grip and the grip
end.
G088918 1
9. Adjust:
• Clutch lever free play
Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-13.
Clutch lever free play

10.0–15.0 mm (0.39–0.59 in)
4-88
FRONT FORK (for YZF-R1)
EAS20034

Removing the front fork legs (for YZF-R1)
32 N・m (3.2 kgf・m, 24 lb・ft) 7 N・m (0.7 kgf・m, 5.2 lb・ft)
26 N・m (2.6 kgf・m, 19 lb・ft)

4
23 N・m (2.3 kgf・m, 17 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft)

the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-35.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Handlebar pinch bolt 1 Loosen.
4 Handlebar bolt 1 Loosen.
5 Cap bolt 1 Loosen.
6 Lower bracket pinch bolt 2 Loosen.
7 Front fork leg 1
4-89
Disassembling the front fork legs (for YZF-R1)

23 N・m (2.3 kgf・m, 17 lb・ft)
15 N・m (1.5 kgf・m, 11 lb・ft)
11 8
7
14
13
12
10
9
21 N・m (2.1 kgf・m, 15 lb・ft)

40 N・m (4.0 kgf・m, 30 lb・ft)

1 Cap bolt 1
2 O-ring 1
3 Guide 1
4 Spacer 1
5 Fork spring 1
6 Locknut 1
7 Damper adjusting rod 1 1
8 Damper adjusting rod 2 1
9 Dust seal 1
10 Oil seal clip 1
11 Outer tube 1
12 Oil seal 1
13 Washer 1
14 Outer tube bushing 1
4-90
Disassembling the front fork legs (for YZF-R1)

23 N・m (2.3 kgf・m, 17 lb・ft)
15 N・m (1.5 kgf・m, 11 lb・ft)
15
16
19
18
17
21 N・m (2.1 kgf・m, 15 lb・ft)

40 N・m (4.0 kgf・m, 30 lb・ft)

15 Inner tube bushing 1
16 Damper rod assembly 1
17 Base valve assembly 1
18 O-ring 1
19 Inner tube 1
4-91
EAS30206 EAS30207
REMOVING THE FRONT FORK LEGS (for DISASSEMBLING THE FRONT FORK LEGS
YZF-R1) (for YZF-R1)
The following procedure applies to both of the The following procedure applies to both of the
front fork legs. front fork legs.
1. Stand the vehicle on a level surface. 1. Turn the spring preload adjusting nut “1”
EWA13120
counterclockwise until it stops.
WARNING
no danger of it falling over. 1
TIP
Place the vehicle on a maintenance stand so
that the front wheel is elevated.
2. Remove:
Refer to “FRONT BRAKE” on page 4-52.
• Front wheel 2. Remove:
Refer to “FRONT WHEEL” on page 4-35. • Cap bolt “1”
3. Loosen: (from the damper rod assembly)
• Handlebar pinch bolt “1” • Guide “2”
• Upper bracket pinch bolt “2” • Spacer “3”
• Handlebar bolt “3” • Locknut “4”
• Cap bolt “4” a. Press down on the spacer with the fork
• Lower bracket pinch bolts “5” spring compressor “5”.
EWA13640
WARNING b. Install the rod holder “6” between the lock-

nut “4” and the guide “2”.
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg. Fork spring compressor
90890-01441
3 YM-01441
Rod holder
4
90890-01434
Damper rod holder double ended
YM-01434
2
TIP
1 Use the side of the rod holder that is marked “B”.
6
4
2
5 3
5
c. Hold the cap bolt “1” and loosen the lock-

4. Remove: nut “4”.
• Front fork leg
4-92
ECA17390
5. Remove:
NOTICE • Outer tube
When loosening the nut, be sure not to break a. Hold the front fork leg horizontally.
the projections on the cap bolt collar of the b. Securely clamp the brake caliper bracket
cap bolt. in a vise with soft jaws.
c. Separate the outer tube from the inner
1 tube by pulling the outer tube forcefully but
carefully.
ECA19880
NOTICE
4 Excessive force will damage the bushings.
Damaged bushings must be replaced.
d. Remove the cap bolt and guide.

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

90890-01506
Damper rod holder
YM-01506
G088919
4. Remove:
• Dust seal “1” 1
• Oil seal clip “2”
(with a flat-head screwdriver)
ECA19100
NOTICE
Do not scratch the outer tube.
1 7. Remove:
• Base valve assembly “1”
a. Secure straight part “a” of the base valve
assembly firmly in a vise with soft jaws.
b. Pull up the damper rod assembly “2” and
remove the base valve assembly “1”.
2
G088920
4-93
• When disassembling and assembling the

front fork leg, do not allow any foreign ma-
2 terial to enter the front fork.
4. Check:
1 • Cap bolt “1”
• Cap bolt collar projection “2”
a a
1
EAS30208
CHECKING THE FRONT FORK LEGS (for

YZF-R1)
front fork legs.
1. Check:
• Inner tube 2
• Outer tube
Bends/damage/scratches → Replace. EAS30209
EWA13650 ASSEMBLING THE FRONT FORK LEGS (for
WARNING YZF-R1)
Do not attempt to straighten a bent inner The following procedure applies to both of the
tube as this may dangerously weaken it. front fork legs.
EWA18360
2. Measure: WARNING
• Spring free length “a”
If both front fork legs are not filled with the
Out of specification → Replace.
specified amount of the fork oil, it may cause
Fork spring free length poor handling and a loss of stability.
219.5 mm (8.64 in) TIP
Limit
215.1 mm (8.47 in) • When assembling the front fork leg, be sure to
replace the following parts:
–Inner tube bushing
–Outer tube bushing
–Oil seal
–Oil seal clip
–Dust seal
–O-ring
• Before assembling the front fork leg, make
sure all of the components are clean.
G088921
1. Install:
• Base valve assembly
3. Check: • Damper rod assembly
• Damper rod ECA22560
Damage/wear → Replace. NOTICE

Obstruction → Blow out all of the oil passag- Allow the damper rod assembly to slide
es with compressed air. slowly down the inner tube. Be careful not to
ECA19110
damage the inner tube.
NOTICE
• The front fork leg has a very sophisticated 2. Tighten:
internal construction, which are particular- • Damper rod assembly
ly sensitive to foreign material. Front fork damper rod assembly
40 N·m (4.0 kgf·m, 30 lb·ft)
T.
R.
4-94
TIP
Tighten the damper rod assembly with the 3
damper rod holder “1”. 4
5
Damper rod holder (ø30) 6
90890-01506
Damper rod holder 1
YM-01506
2
G088922
3. Lubricate:
• Inner tube’s outer surface 5. Install:
• Outer tube
Recommended oil (to the inner tube)
Yamaha Suspension Oil 01 6. Install:
• Outer tube bushing “1”
4. Install:
• Washer “2”
• Dust seal “1” New (with the fork seal driver “3”)
• Oil seal clip “2” New
• Oil seal “3” New Fork seal driver
90890-01442
• Washer “4”
Adjustable fork seal driver (36–46
• Outer tube bushing “5” New mm)
• Inner tube bushing “6” New YM-01442
ECA19170
NOTICE
Make sure the numbered side of the oil seal
faces bottom side.
TIP 3
• Before installing the oil seal, lubricate its lips 2
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube 1
with fork oil.
• Before installing the oil seal, cover the top of G088923
the front fork leg with a plastic bag to protect 7. Install:

the oil seal during installation. • Oil seal “1”
(with the fork seal driver “2”)
Fork seal driver

90890-01442
mm)
YM-01442
4-95
Rod puller
90890-01437
Universal damping rod bleeding
2 tool set
YM-A8703
1 Rod puller attachment (M10)
90890-01436
tool set
G088924
YM-A8703
8. Install:
• Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
1
G088927
11.Fill:
• Front fork leg
mended fork oil)
G088925
9. Install: Recommended oil

• Dust seal “1” Yamaha Suspension Oil 01
(with the fork seal driver “2”) Quantity (left)
470.0 cm³ (15.89 US oz, 16.58
Fork seal driver Imp.oz)
90890-01442 Quantity (right)
Adjustable fork seal driver (36–46 470.0 cm³ (15.89 US oz, 16.58
mm) Imp.oz)
YM-01442
ECA14230
NOTICE
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
2 • When disassembling and assembling the
1 terial to enter the front fork.
12.After filling the front fork leg, slowly stroke the
damper rod “1” up and down (at least ten
G088926
times) to distribute the fork oil.
10.Install: TIP
• Rod puller “1”
Be sure to stroke the damper rod slowly be-
• Rod puller attachment (M10) “2”
cause the fork oil may spurt out.
(onto the damper rod “3”)
4-96
TIP
Install the fork spring with the smaller diameter
“a” facing up “A”.
G088929
13.Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
G088931
TIP
c. Install the locknut all the way onto the
Be sure to bleed the front fork leg of any residual
damper rod assembly.
air.
d. Install the rod puller and rod puller attach-
14.Measure: ment.
• Front fork leg oil level “a” e. Install the spacer and guide.
(from the top of the outer tube, with the outer f. Install the fork spring compressor.
tube fully compressed and without the fork g. Press down on the spacer with the fork
spring) spring compressor “1”.
Out of specification → Correct. h. Pull up the rod puller and install the rod
holder “2” between the locknut “3” and the
Level (left) guide “4”.
84 mm (3.3 in)
Level (right) Rod puller
84 mm (3.3 in) 90890-01437
tool set
YM-A8703
Rod puller attachment (M10)
a 90890-01436
tool set
YM-A8703
90890-01441
G088930 Fork spring compressor
YM-01441
15.Install: Rod holder
• Fork spring 90890-01434
• Spacer Damper rod holder double ended
• Locknut YM-01434
• Damper adjusting rod 2
• Damper adjusting rod 1 TIP
• Guide Use the side of the rod holder that is marked “B”.
• Cap bolt
(along with the O-ring New )
a. Remove the rod puller and rod puller at-
tachment.
b. Install the fork spring.
4-97
EAS30210
INSTALLING THE FRONT FORK LEGS (for

YZF-R1)
3
4 front fork legs.
2 1. Install:
• Front fork leg
1 Temporarily tighten the upper and lower
bracket pinch bolts.
EWA13680
WARNING
i. Remove the rod puller and rod puller at- Make sure the brake hoses are routed prop-
tachment. erly.
j. Install the damper adjusting rods and cap
TIP
bolt, and then finger tighten the cap bolt.
EWA13670 Align the outer tube with the position “a” as
WARNING shown in the illustration.
Always use a new cap bolt O-ring.
k. Hold the cap bolt “5” and tighten the lock-
nut “3” to specification. a
ECA17390
NOTICE
When loosening the nut, be sure not to break
the projections on the cap bolt collar of the
cap bolt.
Front fork cap bolt locknut

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

5 Lower bracket pinch bolt
4 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
TIP
3 Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft)

2 in the order pinch bolt “1” → pinch bolt “2” →
1 pinch bolt “1” → pinch bolt “2”.
l. Remove the rod holder and fork spring

compressor.
16.Install:
• Cap bolt
(to the outer tube) 1
TIP
• Temporarily tighten the cap bolt. 2
• When to tighten the cap bolt to the specified
torque is after installing the front fork leg to the
vehicle and tightening the lower bracket pinch 3. Tighten:
bolts. • Cap bolt “1”
Front fork cap bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
4-98
• Handlebar bolt “2”
Handlebar bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Handlebar pinch bolt “3”

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

26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
TIP
When installing the front fork legs, make sure
that the spring preload adjusting nuts are posi-
tioned at the angles shown in the illustration.
55-65° 55-65°
4. Check:
• Cable routing
TIP
Make sure the brake hose, throttle cables, clutch
cable, and handlebar switch leads are routed
properly. Refer to “CABLE ROUTING” on page
2-17.
5. Adjust:
• Spring preload
• Rebound damping
Refer to “ADJUSTING THE FRONT FORK
LEGS (for YZF-R1)” on page 3-22.
4-99
FRONT FORK (for YZF-R1M)
EAS20169

Removing the front fork legs (for YZF-R1M)
32 N・m (3.2 kgf・m, 24 lb・ft) 7 N・m (0.7 kgf・m, 5.2 lb・ft) 26 N・m (2.6 kgf・m, 19 lb・ft)
23 N・m (2.3 kgf・m, 17 lb・ft)
4 20 N・m (2.0 kgf・m, 15 lb・ft)
5
2
3
6
6 N・m (0.6 kgf・m, 4.4 lb・ft)

1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Handlebar pinch bolt 1 Loosen.
4 Handlebar bolt 1 Loosen.
5 Front fork stepping motor coupler 1 Disconnect.
6 Cap bolt (with front fork stepping motor) 1 Loosen.
7 Lower bracket pinch bolt 2 Loosen.
8 Front fork leg 1
4-100
Disassembling the front fork legs

20 N・m (2.0 kgf・m, 15 lb・ft) 19 N・m (1.9 kgf・m, 14 lb・ft)
13
8
12
11
10
9
21 N・m (2.1 kgf・m, 15 lb・ft)

1 Cap bolt (with front fork stepping motor) 1
2 O-ring 1
3 Damper adjusting rod 1
4 Locknut 1
5 Upper spring seat 1
6 Fork spring 1
7 Spacer 1
8 Outer tube 1
9 Dust seal 1
10 Oil seal clip 1
11 Oil seal 1
12 Washer 1
13 Inner tube 1
4-101
EAS33359
HANDLING THE FRONT FORK (for YZF-R1M) TIP

EWA20910 Place the vehicle on a maintenance stand so
WARNING that the front wheel is elevated.
This front fork contains highly compressed 2. Remove:
nitrogen gas. Before handling the front fork, • Front brake caliper
read and make sure you understand the fol- Refer to “FRONT BRAKE” on page 4-52.
lowing information. The manufacturer can- • Front wheel
not be held responsible for property damage Refer to “FRONT WHEEL” on page 4-35.
or personal injury that may result from im- 3. Disconnect:
proper handling of the front fork. • Front fork stepping motor coupler
• Do not tamper or attempt to open the front 4. Loosen:
fork. • Handlebar pinch bolt “1”
• Do not subject the front fork to an open • Upper bracket pinch bolt “2”
flame or any other source of high heat. High • Handlebar bolt “3”
heat can cause an explosion due to exces- • Cap bolt “4”
sive gas pressure. • Lower bracket pinch bolts “5”
• Do not deform or damage the front fork in EWA13640
any way. Front fork damage will result in WARNING

poor damping performance. Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
EAS33360
DISPOSING OF FRONT FORK LEG (for

YZF-R1M) 3
1. Gas pressure must be released before dis-
posing of a rear shock absorber. To release 4
the gas pressure, drill a 2–3 mm (0.08–0.12
in) hole through the rear shock absorber as
shown.
EWA13760
2
WARNING
Wear eye protection to prevent eye damage 1
from released gas or metal chips.
TIP
Loosen the cap bolt “4” using the front fork cap
bolt wrench “6”.
Front fork cap bolt wrench 42mm

90890-01575
YM-01575
EAS31648
REMOVING THE FRONT FORK LEGS (for 6

YZF-R1M)
front fork legs.
4
EWA13120
WARNING
4-102
5 1
5. Remove: b. Hold the spring preload adjusting bolt “5”

• Front fork leg and loosen the locknut.
EAS31649 5
DISASSEMBLING THE FRONT FORK LEGS
(for YZF-R1M)
front fork legs.
1. Turn the spring preload adjusting bolt “1”
counterclockwise until it stops.
TIP 2
3
Turn the spring preload adjusting bolt “1” before
removing the front fork from the vehicle. c. Remove the cap bolt, damper adjusting
rod, upper spring seat and fork spring.
3. Drain:
1 • Fork oil
TIP
Separately from the fork oil in the inner tube, fork
oil is in the inside cartridge of the lower part of
the inner tube. The fork oil of the cartridge in the
inner tube cannot be replaced.
4. Remove:
• Outer tube
• Cap bolt “1” • Dust seal
• Locknut “2” • Oil seal clip “1”
• Upper spring seat “3” (with a flat-head screwdriver)
• Damper adjusting rod • Oil seal
a. Loosen the cap bolt “1” using the front fork • Washer
cap bolt wrench “4” and then remove it
from the outer tube.
1
90890-01575
YM-01575
4-103
EAS31650
1. Lubricate:
CHECKING THE FRONT FORK LEGS (for
• Inner tube’s outer surface
YZF-R1M)
The following procedure applies to both of the Recommended oil
front fork legs. Öhlins R&T 43
1. Check:
• Inner tube 2. Install:
• Outer tube • Dust seal “1” New
Bends/damage/scratches → Replace. • Oil seal clip “2”
EWA13650
WARNING • Oil seal “3” New

Do not attempt to straighten a bent inner • Washer “4”
ECA19170
tube as this may dangerously weaken it. NOTICE
2. Measure: Make sure the numbered side of the oil seal
• Spring free length “a” faces bottom side.
TIP
Fork spring free length • Before installing the oil seal, lubricate its lips
260.0 mm (10.24 in) with lithium-soap-based grease.
Limit • Lubricate the outer surface of the inner tube
254.8 mm (10.03 in) 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.
3
4
G088921
1
3. Check:
• Cap bolt 2
EAS31651
ASSEMBLING THE FRONT FORK LEGS (for

YZF-R1M)
front fork legs.
EWA18360
WARNING
If both front fork legs are not filled with the
specified amount of the fork oil, it may cause
G088922
poor handling and a loss of stability.
3. Install:
TIP • Outer tube
• When assembling the front fork leg, be sure to (to the inner tube)
replace the following parts: 4. Install:
–Oil seal • Washer
–Dust seal • Oil seal “1”
–O-ring (with the fork seal driver “2”)
• Before assembling the front fork leg, make
sure all of the components are clean.
4-104
7. Fill:
Fork seal driver • Front fork leg
90890-01442 (with the specified amount of the recom-
Adjustable fork seal driver (36–46 mended fork oil)
mm)
YM-01442 Recommended oil
Öhlins R&T 43
Quantity (left)
263 cm³ (8.89 US oz, 9.26
Imp.oz)
2 Quantity (right)
263 cm³ (8.89 US oz, 9.26
Imp.oz)
1
ECA14230
NOTICE
G088924 • Be sure to use the recommended fork oil.
5. Install: Other oils may have an adverse effect on
• Oil seal clip “1” front fork performance.
• When disassembling and assembling the
TIP
Adjust the oil seal clip so that it fits into the outer terial to enter the front fork.
tube’s groove.
8. Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
9. Measure:
1 • Front fork leg oil level “a”
(from the top of the outer tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification → Correct.
G088925
Level (left)
6. Install: 180 mm (7.1 in)
• Dust seal “1” Level (right)
(with the fork seal driver “2”) 180 mm (7.1 in)
Fork seal driver

90890-01442
mm) a
YM-01442
G088930
2
10.Install:
• Spacer
1 • Fork spring
• Upper spring seat
G088926
• Locknut
• Damper adjusting rod
4-105
• Cap bolt d. Hold the spring preload adjusting bolt “3”

(along with the O-ring New ) and tighten the locknut “4” to specification.
a. Install the spacer and fork spring.
Front fork cap bolt locknut
TIP 19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
Install the fork spring with the marks “a” facing
up “A”.
3
a
A
11.Install:
• Cap bolt
b. Install the locknut “1”, upper spring seat
(to the outer tube)
“2” and damper adjusting rod.
TIP
TIP
• Temporarily tighten the cap bolt.
Touch the locknut “1” to the upper spring seat
• When to tighten the cap bolt to the specified
“2”, and install the locknut “1” until the upper
torque is after installing the front fork leg to the
spring seat “2” contacts with the width across
vehicle and tightening the lower bracket pinch
flats “b” of the inner tube.
bolts.
EAS31652
1 INSTALLING THE FRONT FORK LEGS

front fork legs.
2
1. Install:
b
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
EWA13680
WARNING
c. Install the cap bolt “3”.
EWA13670 Make sure the brake hoses are routed prop-
WARNING erly.
Always use a new cap bolt O-ring. TIP
TIP Align the outer tube with the position “a” as
Tighten the cap bolt “3” by hand while holding shown in the illustration.
the width across flats “b” of the inner tube.
a
4-106
2. Tighten: • Upper bracket pinch bolt “5”

• Lower bracket pinch bolts “1” and “2”
Lower bracket pinch bolt 26 N·m (2.6 kgf·m, 19 lb·ft)
T.
R.
23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
TIP 3
Tighten each bolt to 23 N·m (2.3 kgf·m, 17 lb·ft)
in the order pinch bolt “1” → pinch bolt “2” → 1
pinch bolt “1” → pinch bolt “2”.
1 TIP
When installing the front fork legs, make sure
2 that the front fork stepping motor couplers are
positioned at the angles shown in the illustration.
3. Tighten:
• Cap bolt “1”
TIP
Tighten the cap bolt “1” using the front fork cap
bolt wrench “2”.

90890-01575 10° 10° 10° 10°
YM-01575
4. Check:
• Cable routing
Front fork cap bolt TIP
20 N·m (2.0 kgf·m, 15 lb·ft) Make sure the brake hose, throttle cables, clutch
T.
R.
cable, and handlebar switch leads are routed

properly. Refer to “CABLE ROUTING” on page
2-17.
5. Adjust:
2
• Spring preload
• Rebound damping
1 Refer to “ADJUSTING THE PRELOAD OF
THE FRONT FORK LEGS (for YZF-R1M)”
on page 3-23 and “ADJUSTING THE DAMP-
ING FORCE OF THE FRONT FORK LEGS
• Handlebar bolt “3”
AND REAR SHOCK ABSORBER ASSEM-
Handlebar bolt BLY (for YZF-R1M)” on page 3-24.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Handlebar pinch bolt “4”

32 N·m (3.2 kgf·m, 24 lb·ft)
T.
R.
4-107
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
LT
23 N・m (2.3 kgf・m, 17 lb・ft)
LT
11 N・m (1.1 kgf・m, 8.1 lb・ft) 1st 52 N・m (5.2 kgf・m, 38 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft) 2nd 14 N・m (1.4 kgf・m, 10 lb・ft)
* Loosen the lower ring nut completely, and then tighten it to specification.
Windshield 4-13.
Front cowling assembly 4-23.
Air intake duct 4-28.
Upper bracket/Handlebars Refer to “HANDLEBARS” on page 4-83.
Refer to “FRONT FORK (for YZF-R1)” on
Front fork legs page 4-89 or refer to “FRONT FORK (for
4-108
STEERING HEAD
Removing the lower bracket

6
5 7
11
8
9
14
13
4 LT 12
23 N・m (2.3 kgf・m, 17 lb・ft)
10
3
1 2
LT
7 N・m (0.7 kgf・m, 5.2 lb・ft) 2nd 14 N・m (1.4 kgf・m, 10 lb・ft)
* Loosen the lower ring nut completely, and then tighten it to specification.
1 Front brake hose 1
2 Horn bracket 1
3 Lower bracket cover 1
4 Steering damper solenoid coupler 1 Disconnect.
5 Steering damper solenoid 1
6 Lock washer 1
7 Upper ring nut 1
8 Rubber washer 1
9 Lower ring nut 1
10 Lower bracket 1
11 Bearing cover 1
12 Lower bearing dust seal 1
13 Upper bearing 1
14 Lower bearing 1
4-109
STEERING HEAD
EAS30213
• Bearing race
REMOVING THE LOWER BRACKET
Damage/pitting → Replace the bearings and
EWA13120
bearing races as a set.
WARNING 3. Replace:
Securely support the vehicle so that there is • Bearing
no danger of it falling over. • Bearing race
a. Remove the bearing races from the steer-
2. Remove: ing head pipe “1” with a long rod “2” and
• Upper ring nut “1” hammer.
• Rubber washer b. Remove the bearing race “3” from the low-
• Lower ring nut “2” er bracket with a floor chisel “4” and ham-
• Lower bracket mer.
EWA13730
c. Install a new dust seal and new bearing
WARNING
races.
Securely support the lower bracket so that ECA14270
there is no danger of it falling. NOTICE
TIP If the bearing race is not installed properly,

the steering head pipe could be damaged.
• Hold the lower ring nut with steering nut
wrench, and then remove the upper ring nut TIP
with the ring nut wrench “3”. • Always replace the bearings and bearing races
• Remove the lower ring nut with the steering nut as a set.
wrench “4”. • Whenever the steering head is disassembled,
replace the dust seal.
Ring nut wrench
90890-01268
Spanner wrench
YU-01268
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
4 3 G088933
G088932 2
EAS30214
CHECKING THE STEERING HEAD G088934

1. Wash:
4. Check:
• Bearing
• Upper bracket
• Bearing race
• Lower bracket
Recommended cleaning solvent (along with the steering stem)
Kerosene Bends/cracks/damage → Replace.
2. Check:
• Bearing
4-110
STEERING HEAD
EAS30216
INSTALLING THE STEERING HEAD

1. Lubricate:
• Upper bearing
• Lower bearing
Lithium-soap-based grease
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Upper ring nut “3”
• Lock washer “4”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-20.
G088935
3. Install:
• Upper bracket
• Steering stem nut
Refer to “HANDLEBARS” on page 4-83.
TIP
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
Refer to “FRONT FORK (for YZF-R1)” on
page 4-89 or “FRONT FORK (for YZF-R1M)”
on page 4-100.
TIP
Temporarily tighten the upper and lower bracket
pinch bolts.
EAS30215
CHECKING THE STEERING DAMPER

1. Check:
• Steering damper body
Damage/oil leaks → Replace the steering
damper assembly.
• Steering damper rod
Bends/scratch → Replace the steering
damper assembly.
• Bearing
Damage/pitting → Replace the steering
damper assembly.
4-111
REAR SHOCK ABSORBER ASSEMBLY
EAS20036

Removing the rear shock absorber assembly (for YZF-R1)
5 40 N・m (4.0 kgf・m, 30 lb・ft)
40 N・m (4.0 kgf・m, 30 lb・ft)
1
3 4
1
2
4
2
3
40 N・m (4.0 kgf・m, 30 lb・ft)

Rider seat 4-1.
Rear wheel Refer to “REAR WHEEL” on page 4-43.
Exhaust chamber Refer to “ENGINE REMOVAL” on page 5-11.
1 Connecting arm upper nut/Washer/Bolt 1/1/1
2 Rear shock absorber assembly lower nut/Bolt 1/1
3 Connecting arm lower nut/Washer/Bolt 1/1/1
4 Connecting arm 2
Rear shock absorber assembly upper nut/Col-
5 1/1/1
lar/Bolt
4-112
Removing the rear shock absorber assembly (for YZF-R1)

40 N・m (4.0 kgf・m, 30 lb・ft) 13
13
6 9 40 N・m (4.0 kgf・m, 30 lb・ft)
14
12
14
6
12
8
10 11 11
40 N・m (4.0 kgf・m, 30 lb・ft)

10

6 Relay arm nut/Bolt 1/1
7 Collar 1
8 Relay arm 1
9 Rear shock absorber assembly 1
10 Oil seal/Bearing 2/1
11 Collar/Oil seal/Bearing 1/2/2
13 Collar/Dust seal/Circlip/Bushing 2/2/1/1
4-113
Removing the rear shock absorber assembly (for YZF-R1M)

6 40 N・m (4.0 kgf・m, 30 lb・ft)
6 1
40 N・m (4.0 kgf・m, 30 lb・ft)
2
4
5 2
5
3
4
40 N・m (4.0 kgf・m, 30 lb・ft)

Rider seat 4-1.
Exhaust chamber Refer to “ENGINE REMOVAL” on page 5-11.
Rear shock absorber assembly stepping motor
1 2 Disconnect.
coupler
2 Connecting arm upper nut/Washer/Bolt 1/1/1
3 Rear shock absorber assembly lower nut/Bolt 1/1
4 Connecting arm lower nut/Washer/Bolt 1/1/1
5 Connecting arm 2
Rear shock absorber assembly upper nut/Col-
6 1/1/1
lar/Bolt
4-114
Removing the rear shock absorber assembly (for YZF-R1M)

40 N・m (4.0 kgf・m, 30 lb・ft)
14
14
40 N・m (4.0 kgf・m, 30 lb・ft)

7
15
10
13
15
7
13
9
12 12
11
40 N・m (4.0 kgf・m, 30 lb・ft)
11

7 Relay arm nut/Bolt 1/1
8 Collar 1
9 Relay arm 1
10 Rear shock absorber assembly 1
11 Oil seal/Bearing 2/1
14 Collar/Dust seal/Circlip/Bushing 2/2/2/1
4-115
EAS30826
HANDLING THE REAR SHOCK ABSORBER B

EWA13740
WARNING
This rear shock absorber contains highly
compressed nitrogen gas. Before handling
the rear shock absorber, read and make sure
you understand the following information.
The manufacturer cannot be held responsi-
ble for property damage or personal injury
that may result from improper handling of
the rear shock absorber. A. YZF-R1
• Do not tamper or attempt to open the rear B. YZF-R1M
shock absorber.
• Do not subject the rear shock absorber to EAS30219
an open flame or any other source of high REMOVING THE REAR SHOCK ABSORBER
heat. High heat can cause an explosion due ASSEMBLY
to excessive gas pressure. 1. Stand the vehicle on a level surface.
EWA13120
• Do not deform or damage the rear shock WARNING
absorber in any way. Rear shock absorber
damage will result in poor damping perfor- Securely support the vehicle so that there is
mance. no danger of it falling over.
TIP
EAS30729
DISPOSING OF A REAR SHOCK ABSORBER Place the vehicle on a maintenance stand so

1. Gas pressure must be released before dis- that the rear wheel is elevated.
posing of a rear shock absorber. To release 2. Remove:
the gas pressure, drill a 2–3 mm (0.08–0.12 • Connecting arm upper nut
in) hole through the rear shock absorber as • Connecting arm upper bolt “1”
shown. • Rear shock absorber assembly lower nut
EWA13760
• Rear shock absorber assembly lower bolt “2”
WARNING
• Connecting arm lower nut
Wear eye protection to prevent eye damage • Connecting arm lower bolt “3”
from released gas or metal chips. • Connecting arm “4”
TIP
When removing the bolt, hold the swingarm so
that it does not drop down.
2
4
3. Remove:
• Rear shock absorber assembly upper nut
• Rear shock absorber assembly upper bolt
4. Remove:
• Relay arm nut “1”
• Relay arm bolt “2”
4-116
• Collar “3”
• Relay arm “4”
TIP 2
Pull out the collar “3” from the left side of the ve-
hicle. 1
1 4. Remove:
• Oil seal
• Bearing “1”
3 4 TIP
2 Remove the bearing with a socket “2” that
matches its outside diameter.
5. Remove:
• Rear shock absorber assembly
EAS31653
DISASSEMBLING THE REAR SHOCK 2

ABSORBER ASSEMBLY
1. Remove:
• Collar 1
• Dust seal
2. Remove:
• Circlip “1”
(with a flat-head screwdriver)
EAS30220
CHECKING THE REAR SHOCK ABSORBER

1 ASSEMBLY
1. Check:
• Rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
Gas leaks/oil leaks → Replace the rear shock
absorber assembly.
3. Remove: • Spring
• Bushing “1” • Bushings
Damage/wear → Replace the bushings.
TIP
• Bolts
Remove the bushing with a socket “2” that Bends/damage/wear → Replace.
matches its outside diameter.
EAS30221
CHECKING THE CONNECTING ARM AND

RELAY ARM
1. Check:
• Connecting arms
• Relay arm
2. Check:
• Bearings
4-117
• Oil seals EAS30222
INSTALLING THE RELAY ARM

Damage/pitting → Replace.
1. Lubricate:
3. Check:
• Collars
• Collars
• Oil seals
Damage/scratches → Replace.
EAS31654 Recommended lubricant
ASSEMBLING THE REAR SHOCK Lithium-soap-based grease
ABSORBER ASSEMBLY
1. Install: 2. Install:
• Bearing “1” • Bearings “1”
(to the relay arm)
• Oil seal New
TIP
• Oil seals “2” New
(to the relay arm)
Install the bearing with a socket “2” that matches
its outside diameter. Installed depth “a”
4.5 mm (0.18 in)
Installed depth “a” Installed depth “b”
4.0 mm (0.16 in) 3.5 mm (0.14 in)
TIP
• When installing the oil seals “2” to the relay
arm, face the character stamp of the oil seals
2
outside.
a • Press in the oil seal so it does not protrude
from the end surface of the relay arm.
1
2 a
6
2. Install:
• Bushing “1” b 1 1 b
• Circlip New (for YZF-R1)
• Circlip (for YZF-R1M)
• Dust seal New
3
TIP 2
Install the bushing with a socket “2” that matches
its outside diameter.
4
Installed depth “a” 4
YZF-R1 6.0 mm (0.24 in)
YZF-R1M 3.0 mm (0.12 in) 5
a 3. Relay arm
4. Connecting arm
1 5. Rear shock absorber assembly
6. Frame
A. Left side
B. Right side
4-118
EAS30225
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Install:
• Relay arm
• Connecting arm
TIP
• Install the rear shock absorber assembly upper
bolt, relay arm bolt, connecting arm lower bolt
and connecting arm upper bolt from the left.
• When installing the rear shock absorber as-
sembly, lift up the swingarm.
2. Tighten:
• Relay arm nut
• Rear shock absorber assembly upper nut
• Connecting arm lower nut
• Rear shock absorber assembly lower nut
• Connecting arm upper nut
Relay arm nut

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

upper nut
40 N·m (4.0 kgf·m, 30 lb·ft)
Connecting arm lower nut
40 N·m (4.0 kgf·m, 30 lb·ft)
Rear shock absorber assembly
lower nut
40 N·m (4.0 kgf·m, 30 lb·ft)
Connecting arm upper nut
40 N·m (4.0 kgf·m, 30 lb·ft)
4-119
SWINGARM
EAS20037
SWINGARM
Removing the swingarm
65 N・m (6.5 kgf・m, 48 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)
6 2
7 N・m (0.7 kgf・m, 5.2 lb・ft) 16 N・m (1.6 kgf・m, 12 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)
3
105 N・m (10.5 kgf・m, 77 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)

Refer to “REAR SHOCK ABSORBER AS-
Rear shock absorber assembly SEMBLY” on page 4-112.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-125.
1 Drive chain guard 1
2 Rear fender 1
3 Drive chain guide 1
4 Rear wheel sensor lead cover 1
5 Pivot shaft nut/Washer 1/1
6 Pivot shaft ring nut/Washer 1/1
7 Pivot shaft 1
4-120
SWINGARM
Removing the swingarm

65 N・m (6.5 kgf・m, 48 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft)
7 N・m (0.7 kgf・m, 5.2 lb・ft) 16 N・m (1.6 kgf・m, 12 lb・ft)
10
9
8
12
14
11
7 N・m (0.7 kgf・m, 5.2 lb・ft)
105 N・m (10.5 kgf・m, 77 lb・ft)

13
7 N・m (0.7 kgf・m, 5.2 lb・ft)
11
14

8 Rear wheel sensor lead hook 1
9 Swingarm 1
10 Drive chain 1
11 Dust cover 2
12 Washer 1
13 Bushing 1
14 Bearing 2
4-121
SWINGARM
EAS30226
5. Remove:
REMOVING THE SWINGARM
• Pivot shaft nut
EWA13120
• Pivot shaft ring nut “1”
WARNING TIP
Securely support the vehicle so that there is Loosen the pivot shaft ring nut with the ring nut
no danger of it falling over. wrench “2”.
TIP
Ring nut wrench
Place the vehicle on a maintenance stand so 90890-01507
that the rear wheel is elevated. Ring nut wrench
2. Remove: YM-01507
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” on page 4-112.
3. Measure: 1
• Swingarm side play
• Swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut 2

105 N·m (10.5 kgf·m, 77 lb·ft)
T.
R.
Pivot shaft ring nut 6. Remove:

65 N·m (6.5 kgf·m, 48 lb·ft)
• Pivot shaft “1”
Pivot shaft
7 N·m (0.7 kgf·m, 5.2 lb·ft) TIP
Loosen the pivot shaft with the damper rod hold-
b. Check the swingarm side play “A” by mov- er “2”.
ing the swingarm from side to side.
If the swingarm has side-to-side play, Damper rod holder (ø22)
check the collars, bearings, and dust cov- 90890-01365
ers.
c. Check the swingarm vertical movement
“B” by moving the swingarm up and down.
2
If the swingarm vertical movement is not
smooth or if there is binding, check the piv- 1
ot shaft, collars, bearings, and dust cov-
ers.
B
A
7. Remove:
• Swingarm
EAS30227
CHECKING THE SWINGARM

G088936 1. Check:
4. Remove: • Swingarm
• Drive chain Bends/cracks/damage → Replace.
Refer to “REMOVING THE DRIVE CHAIN” 2. Check:
on page 4-126. • Pivot shaft
Roll the pivot shaft on a flat surface.
4-122
SWINGARM
Bends → Replace.
EWA13770 Recommended lubricant
WARNING Lithium-soap-based grease
Do not attempt to straighten a bent pivot
shaft. 2. Install:
• Bearings “1”
3. Wash: (to the swingarm)
• Pivot shaft
• Oil seals “2” New
• Dust covers
(to the swingarm)
• Collar
• Bushing Installed depth “a”
• Washer 0–1.0 mm (0–0.04 in)
Installed depth “b”
Recommended cleaning solvent 4.0 mm (0.16 in)
Kerosene
TIP
4. Check:
• Dust covers “1” • When installing the oil seals to the swingarm,
• Oil seals “2” face the character stamp of the oil seals out-
Damage/wear → Replace. side.
• Collar “3” • Press in the oil seal so it does not protrude
Damage/scratches → Replace. from the end surface of the swingarm.
• Bushing “5”
a 1 1a
1
4
5 2 1 2
24 4
1
3
42
b
A. Left side
B. Right side
3. Install:
EAS30228
• Swingarm
INSTALLING THE SWINGARM • Pivot shaft “1”
1. Lubricate:
Pivot shaft
• Dust covers
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
• Pivot shaft
R.
• Oil seals
• Collar
• Bushing
4-123
SWINGARM
TIP • Rear shock absorber assembly

Tighten the pivot shaft with the damper rod hold- Refer to “REAR SHOCK ABSORBER AS-
er “2”. SEMBLY” on page 4-112.
• Rear wheel
Refer to “REAR WHEEL” on page 4-43.
Damper rod holder (ø22)
7. Adjust:
90890-01365
• Drive chain slack
Refer to “Adjusting the drive chain slack” on
page 3-19.
2
1 Drive chain slack
25.0–35.0 mm (0.98–1.38 in)
stand)
25.0–35.0 mm (0.98–1.38 in)
Limit
35.0 mm (1.38 in)
4. Install:
• Pivot shaft ring nut “1”
Pivot shaft ring nut

65 N·m (6.5 kgf·m, 48 lb·ft)
T.
R.
TIP
Tighten the pivot shaft ring nut with the ring nut
wrench “2”.
Ring nut wrench

90890-01507
Ring nut wrench
YM-01507
2
1
5. Install:
• Pivot shaft nut
Pivot shaft nut

105 N·m (10.5 kgf·m, 77 lb·ft)
T.
R.
6. Install:
• Drive chain
Refer to “INSTALLING THE DRIVE CHAIN”
on page 4-127.
4-124
CHAIN DRIVE
EAS20038
CHAIN DRIVE
Removing the drive chain
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
1 5
6
2
LT
140 N•m (14 kgf•m, 103 lb•ft)
T.R
.
3
2
11
4
13 E 2
12
10 7
8
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
9
LT
6
LT M
10 N•m (1.0 kgf•m, 7.4 lb•ft) 28 N•m (2.8 kgf•m, 21 lb•ft)

T.R
T.R
.
.

1 Shift sensor coupler 1 Disconnect.
2 Locknut 3
3 Shift sensor 1
4 Shift rod 1
5 Shift arm 1
6 Shift rod joint 2
7 Shift pedal 1
8 Drive sprocket cover 1
9 Drive chain guide 1
10 Drive sprocket nut 1
11 Washer 1
12 Drive sprocket 1
13 Drive chain 1
4-125
CHAIN DRIVE
EAS30229
REMOVING THE DRIVE CHAIN

EWA13120
WARNING
TIP
Place the vehicle on a maintenance stand so
G088937
that the rear wheel is elevated.
b. Calculate the 15-link section length “c” of
2. Straighten the drive sprocket nut rib “a”. the drive chain using the following formula.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides +
length “b” between pin outer sides)/2
a TIP
• When measuring a 15-link section of the drive
a chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a different
location each time.
3. Remove:
• Drive chain
ECA17410
NOTICE
Be sure to put on safety goggles when work-
ing.
TIP
Cut the drive chain with the drive chain cut & riv- G088938
et tool. 2. Check:
• Drive chain
Drive chain cut & rivet tool Stiffness → Clean and lubricate or replace.
90890-01550
YM-01550
EAS30230
CHECKING THE DRIVE CHAIN

1. Measure:
• 15-link section length “a” of the drive chain
Out of specification → Replace the drive
chain. G088939
15-link length limit 3. Clean:

239.3 mm (9.42 in) • Drive chain
a. Wipe the drive chain with a clean cloth.
a. Measure the length “a” between the inner b. Put the drive chain in kerosene and re-
sides of the pins and the length “b” be- move any remaining dirt.
tween the outer sides of the pins on a 15- c. Remove the drive chain from the kerosene
link section of the drive chain as shown in and completely dry it.
the illustration.
4-126
CHAIN DRIVE
ECA19090
NOTICE
• This vehicle has a drive chain with small
rubber O-rings “1” between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean
the drive chain. High-pressure methods
could force dirt or water into the drive
chain’s internals, and solvents will deterio- G088943
rate the O-rings. A coarse brush can also 5. Lubricate:

damage the O-rings. Therefore, use only • Drive chain
kerosene to clean the drive chain.
• Do not soak the drive chain in kerosene for Recommended lubricant
more than ten minutes, otherwise the O- Chain lubricant suitable for O-
rings can be damaged. ring chains
EAS30231
CHECKING THE DRIVE SPROCKET

1. Check:
• Drive sprocket
More than 1/4 tooth “a” wear → Replace the
drive sprocket, the rear wheel sprocket and
the drive chain as a set.
Bent teeth → Replace the drive sprocket, the
rear wheel sprocket and the drive chain as a
G088940
set.
G088941 G088904
4. Check: b. Correct
• O-rings “1” 1. Drive chain roller
Damage → Replace the drive chain. 2. Drive sprocket
• Drive chain rollers “2”
Damage/wear → Replace the drive chain.
EAS30232
CHECKING THE REAR WHEEL SPROCKET

• Drive chain side plates “3” Refer to “CHECKING AND REPLACING THE
Damage/wear/cracks → Replace the drive REAR WHEEL SPROCKET” on page 4-47.
chain.
EAS30233
CHECKING THE REAR WHEEL DRIVE HUB

Refer to “CHECKING THE REAR WHEEL
DRIVE HUB” on page 4-47.
EAS30234
INSTALLING THE DRIVE CHAIN

1. Install:
• Drive chain
4-127
CHAIN DRIVE
ECA17410
NOTICE
Be sure to put on safety goggles when work-
ing.
TIP
Install the drive chain joint with the drive chain
cut & rivet tool.

90890-01550
Drive chain cut & rivet tool 2. Lubricate:
YM-01550 • Drive chain
a. When press fitting the connecting plate Recommended lubricant

“1”, make sure the space “a” between the Chain lubricant suitable for O-
end of the connecting pin “2” and the con- ring chains
necting plate is 1.3–1.4 mm (0.05–0.06
3. Install:
in).
• Drive sprocket
TIP • Washer “1”
Apply lithium soap-based grease onto the con- • Drive sprocket nut “2” New
necting pin “2”.
Drive sprocket nut
140 N·m (14 kgf·m, 103 lb·ft)
T.
R.
TIP
• While applying the rear brake, tighten the drive
sprocket nut.
• Install washer “1” with the “OUT” mark “a” fac-
ing out.
• Stake the drive sprocket nut “2” at cutouts “b”
in the drive axle.
b. After riveting, make sure the diameter be-

tween the edges “b” of the connecting pin 2
“2” is 5.5–5.8 mm (0.22–0.23 in).
1
1
b
4. Install:
• Shift arm “1”
TIP
c. After riveting, make sure the space “c”, Before installing, make sure to align the mark “a”
which is inside of the connecting link “3” of the shift shaft with the slot “b” of the shift arm.
and inside of the connecting plate “1”, is
15.10–15.30 mm (0.594–0.602 in). Shift arm bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
4-128
CHAIN DRIVE
6. Adjust:
1 • Installed shift rod length
Refer to “ADJUSTING THE SHIFT PEDAL”
on page 4-129.
7. Adjust:
• Drive chain slack
b Refer to “Adjusting the drive chain slack” on
page 3-19.
a
Drive chain slack
25.0–35.0 mm (0.98–1.38 in)
5. Install: Drive chain slack (Maintenance
• Shift rod joint “1” stand)
• Shift sensor “2” 25.0–35.0 mm (0.98–1.38 in)
• Shift rod “3”
ECA13550
TIP NOTICE
• Install the shift rod joint and shift sensor in the
A drive chain that is too tight will overload
direction shown in the illustration.
the engine and other vital parts, and one that
• The allowable twist of the shift rod joint and
is too loose can skip and damage the swing-
shift sensor is ±5°.
arm or cause an accident. Therefore, keep
• Install the shift rod so that the side “b” faces up-
the drive chain slack within the specified lim-
ward as shown in the illustration.
its.
Shift rod joint bolt EAS31729
10 N·m (1.0 kgf·m, 7.4 lb·ft) ADJUSTING THE SHIFT PEDAL

T.
R.
LOCTITE® TIP
Shift sensor locknut
The shift pedal position is determined by the in-
7 N·m (0.7 kgf·m, 5.2 lb·ft)
stalled shift rod length.
1. Measure:
a • Installed shift rod length “a”
Incorrect → Adjust.
1
Installed shift rod length
258.5–260.5 mm (10.18–10.26 in)
2 b
3 a
2. Adjust:
• Installed shift rod length
a. Loosen both locknuts “1”.
b. Turn the shift rod until the specified in-
a. 24 mm (0.94 in) stalled shift rod length is obtained.
c. Tighten both locknuts.
4-129
CHAIN DRIVE
TIP
Be sure to place the shift rod joints in parallel.
The allowable twist of the shift rod joints is ±5°.
Shift rod locknut

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
d. Make sure the installed shift rod length is

within specification.
4-130
CHAIN DRIVE
4-131
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

ENGINE OIL LUBRICATION CHART .......................................................5-1
LUBRICATION DIAGRAMS ...................................................................... 5-2
ENGINE INSPECTION .................................................................................... 5-9

MEASURE THE COMPRESSION PRESSURE........................................ 5-9
ENGINE REMOVAL ......................................................................................5-11

REMOVING THE ENGINE ...................................................................... 5-15
INSTALLING THE ENGINE..................................................................... 5-15
INSTALLING THE EXHAUST PIPE AND MUFFLER..............................5-16
CAMSHAFTS.................................................................................................5-17
REMOVING THE CAMSHAFTS..............................................................5-23
REMOVING THE ROCKER ARMS AND ROCKER ARM SHAFTS........ 5-23
CHECKING THE CAMSHAFTS ..............................................................5-23
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-25
CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET .........5-25
CHECKING THE TIMING CHAIN GUIDES............................................. 5-25
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-26
ASSEMBLING THE TIMING CHAIN COVER .........................................5-26
INSTALLING THE ROCKER ARMS AND ROCKER ARM SHAFTS ...... 5-26
INSTALLING THE TIMING CHAIN COVER............................................5-27
INSTALLING THE CAMSHAFTS ............................................................ 5-28 5
CYLINDER HEAD.......................................................................................... 5-32
REMOVING THE CYLINDER HEAD.......................................................5-33
CHECKING THE CYLINDER HEAD .......................................................5-33
INSTALLING THE CYLINDER HEAD .....................................................5-33
VALVES AND VALVE SPRINGS.................................................................. 5-35

REMOVING THE VALVES...................................................................... 5-37
CHECKING THE VALVES AND VALVE GUIDES ..................................5-37
CHECKING THE VALVE SEATS ............................................................ 5-39
CHECKING THE VALVE SPRINGS........................................................ 5-41
CHECKING THE VALVE SPRING SEAT................................................ 5-41
INSTALLING THE VALVES .................................................................... 5-41
GENERATOR ................................................................................................5-43
REMOVING THE GENERATOR ............................................................. 5-45
INSTALLING THE GENERATOR............................................................ 5-45
STARTER CLUTCH ......................................................................................5-47

REMOVING THE STARTER CLUTCH ...................................................5-48
CHECKING THE STARTER CLUTCH ....................................................5-48
INSTALLING THE STARTER CLUTCH .................................................. 5-48
ELECTRIC STARTER ...................................................................................5-49
CHECKING THE STARTER MOTOR .....................................................5-51
ASSEMBLING THE STARTER MOTOR................................................. 5-51
OIL PUMP...................................................................................................... 5-53

REMOVING THE OIL PAN...................................................................... 5-56
CHECKING THE SPROCKET AND CHAIN............................................5-56
CHECKING THE OIL PUMP ................................................................... 5-56
CHECKING THE RELIEF VALVE ........................................................... 5-56
CHECKING THE OIL DELIVERY PIPES ................................................ 5-56
CHECKING THE OIL STRAINER ........................................................... 5-56
ASSEMBLING THE OIL PUMP...............................................................5-56
INSTALLING THE OIL PUMP .................................................................5-57
INSTALLING THE OIL PAN .................................................................... 5-57
CLUTCH ........................................................................................................5-59
REMOVING THE CLUTCH ..................................................................... 5-63
CHECKING THE FRICTION PLATES.....................................................5-63
CHECKING THE CLUTCH PLATES .......................................................5-63
CHECKING THE CLUTCH SPRINGS.....................................................5-64
CHECKING THE CLUTCH HOUSING ....................................................5-64
CHECKING THE CLUTCH BOSS........................................................... 5-65
CHECKING THE PRESSURE PLATE ....................................................5-65
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-65
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-65
CHECKING THE PULL LEVER SHAFT AND PULL ROD ......................5-65
INSTALLING THE CLUTCH.................................................................... 5-65
SHIFT SHAFT................................................................................................5-68
CHECKING THE SHIFT SHAFT ............................................................. 5-69
CHECKING THE STOPPER LEVER ......................................................5-69
INSTALLING THE SHIFT SHAFT ........................................................... 5-69
CRANKCASE ................................................................................................5-70
DISASSEMBLING THE CRANKCASE....................................................5-73
CHECKING THE CRANKCASE ..............................................................5-73
ASSEMBLING THE CRANKCASE.......................................................... 5-73
INSTALLING THE CRANKCASE BREATHER COVER.......................... 5-75
INSTALLING THE OIL PRESSURE SWITCH.........................................5-76
INSTALLING THE GEAR POSITION SENSOR...................................... 5-76
CONNECTING RODS AND PISTONS .......................................................... 5-77

REMOVING THE CONNECTING RODS AND PISTONS.......................5-78
CHECKING THE CYLINDER AND PISTON ...........................................5-79
CHECKING THE PISTON RINGS........................................................... 5-80
CHECKING THE PISTON PIN ................................................................5-81
CHECKING THE CONNECTING RODS................................................. 5-81
INSTALLING THE CONNECTING ROD AND PISTON .......................... 5-85
CRANKSHAFT AND BALANCER SHAFT ...................................................5-90
REMOVING THE CRANKSHAFT AND BALANCER SHAFT.................. 5-91
CHECKING THE OIL NOZZLES ............................................................. 5-91
CHECKING THE CRANKSHAFT ............................................................ 5-91
CHECKING THE BALANCER SHAFT ....................................................5-93
INSTALLING THE CRANKSHAFT .......................................................... 5-94
INSTALLING THE THRUST BEARING...................................................5-95
INSTALLING THE BALANCER ASSEMBLY...........................................5-95
TRANSMISSION............................................................................................ 5-97
REMOVING THE TRANSMISSION ......................................................5-101
CHECKING THE SHIFT FORKS...........................................................5-101
CHECKING THE SHIFT DRUM ASSEMBLY........................................5-101
CHECKING THE TRANSMISSION .......................................................5-102
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ............................5-102
INSTALLING THE TRANSMISSION .....................................................5-103
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20298

EAS32362
ENGINE OIL LUBRICATION CHART
1. Oil strainer 17. Exhaust camshaft

2. Oil pump 18. Shift fork guide bar (upper)
3. Relief valve 19. Main axle
4. Oil cooler 20. Drive axle
5. Oil filter cartridge 21. Mission shower
6. Main gallery
7. Oil pressure switch
8. Crankshaft
9. Generator rotor
10. Balancer shaft
11. Oil nozzle
12. Sub gallery
13. Timing chain tensioner
14. Intake rocker arm
15. Intake camshaft
16. Exhaust rocker arm
5-1
EAS32363
LUBRICATION DIAGRAMS
Crankcase, cylinder, and cylinder head (left side view)
1. Intake camshaft
2. Oil nozzle
3. Oil delivery pipe 2
4. Oil filter cartridge
5. Crankshaft
6. Exhaust camshaft
7. Sub gallery
5-2
Crankcase and cylinder (right side view)
1. Timing chain tensioner

2. Intake camshaft
3. Exhaust camshaft
4. Crankshaft
5. Relief valve
6. Oil pipe 1
8. Oil pan
9. Oil strainer
10. Oil pump
11. Shift fork guide bar
12. Shift fork-C
13. Drive axle
5-3
Timing chain cover and oil pipe (right side view)
1. Timing chain cover

2. Oil pipe 3
3. Oil pipe 2
4. Crankshaft
5. Crankcase
5-4
Oil pump and oil cooler (bottom view)
1. Oil cooler
3. Oil cooler outlet hose
4. Oil filter cartridge
7. Oil strainer
8. Oil pump
9. Oil pipe 1
10. Main gallery
11. Relief valve
12. Oil pipe 2
13. Oil pipe 3
14. Oil cooler inlet hose
5-5
Camshaft and balancer shaft (top view)
1. Cylinder head
2. Exhaust camshaft
3. Intake camshaft
4. Balancer shaft
5-6
Crankshaft (rear view)
1. Oil nozzle
2. Oil pipe 3
3. Timing chain cover
4. Crankshaft
5. Oil pipe 2
7. Generator rotor
8. Shaft
5-7
Crankshaft and transmission (top view)
1. Oil pump
2. Main axle
3. Clutch housing
4. Drive axle
5-8
ENGINE INSPECTION
EAS20041
ENGINE INSPECTION 1
EAS30249
MEASURE THE COMPRESSION PRESSURE

The following procedure applies to all of the cyl-
inders.
TIP
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
5. Measure:
• Valve clearance
• Compression pressure
Out of specification → Refer to steps (c) and
Refer to “ADJUSTING THE VALVE CLEAR-
(d).
ANCE” on page 3-6.
2. Start the engine, warm it up for several min- Compression pressure
utes, and then turn it off. 1261–1624 kPa/210 r/min (12.6–
3. Remove: 16.2 kgf/cm²/210 r/min, 179.4–
• Rider seat 231.0 psi/210 r/min)
4-1. a. Set the main switch to “ON”.
• Fuel tank b. With the throttle wide open, crank the en-
Refer to “FUEL TANK” on page 7-1. gine until the reading on the compression
• Air filter case gauge stabilizes.
EWA17100
WARNING
• Air cut-off valve
Refer to “AIR INDUCTION SYSTEM” on To prevent sparking the plug, remove all ig-
page 7-19. nition coil couplers and fuel injector cou-
• Ignition coils plers before cranking the engine.
• Spark plugs TIP
ECA13340
The difference in compression pressure be-
NOTICE tween cylinders should not exceed 100 kPa (1
kgf/cm², 15 psi).
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumulat- c. If the compression pressure is above the
ed in the spark plug wells to prevent it from maximum specification, check the cylinder
falling into the cylinders. head, valve surfaces and piston crown for
4. Install: carbon deposits.
• Compression gauge “1” Carbon deposits → Eliminate.
d. If the compression pressure is below the
Compression gauge minimum specification, pour a teaspoonful
90890-03081 of engine oil into the spark plug bore and
Engine compression tester measure again.
YU-33223 Refer to the following table.
Compression pressure (with oil applied into the
cylinder)
Reading Diagnosis
Piston ring(s) wear or
Higher than without oil
damage → Repair.
Piston, valves, cylinder
Same as without oil head gasket possibly
defective → Repair.
5-9
ENGINE INSPECTION
6. Install:
• Spark plugs
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
Spark plug (new)

18 N·m (1.8 kgf·m, 13 lb·ft)
TIP
• Before installing the spark plug, clean the
spark plug and gasket surface.
• If the spark plug is a new one, tighten it to 18
N·m (1.8 kgf·m, 13 lb·ft).
7. Install:
• Ignition coils
page 7-19.
• Air filter case
• Fuel tank
• Rider seat
4-1.
5-10
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler and exhaust pipe
10 N・m (1.0 kgf・m, 7.4 lb・ft) 10 N・m (1.0 kgf・m, 7.4 lb・ft) 6 N・m (0.6 kgf・m, 4.4 lb・ft)
2.0 N・m (0.20 kgf・m, 1.5 lb・ft)

20 N・m (2.0 kgf・m, 15 lb・ft)
1
3
FW
D
LT
2
6 N・m (0.6 kgf・m, 4.4 lb・ft)
23 N•m (2.3 kgf•m, 17 lb•ft)

T.R
.
10 N・m (1.0 kgf・m, 7.4 lb・ft)

20 N・m (2.0 kgf・m, 15 lb・ft) (8) 20 N・m (2.0 kgf・m, 15 lb・ft)

Rider seat/Passenger seat/Battery cover/Tail Refer to “GENERAL CHASSIS (1)” on page
cover 4-1.
Side cover/Front side cowling inner panel 4-23.
Side cover bracket 4-32.
Electrical components tray 4-34.
Radiator Refer to “RADIATOR” on page 6-3.
Oil cooler Refer to “OIL COOLER” on page 6-7.
1 Muffler protector 1
2 Muffler joint 1
3 Muffler 1
5-11
ENGINE REMOVAL
Removing the muffler and exhaust pipe

10 N・m (1.0 kgf・m, 7.4 lb・ft) 10 N・m (1.0 kgf・m, 7.4 lb・ft) 6 N・m (0.6 kgf・m, 4.4 lb・ft)
2.0 N・m (0.20 kgf・m, 1.5 lb・ft)

14
20 N・m (2.0 kgf・m, 15 lb・ft) 15
16
17
5 FW
D
4 LT
6 N・m (0.6 kgf・m, 4.4 lb・ft) 8
23 N•m (2.3 kgf•m, 17 lb•ft) 7
T.R
.
9
9
12
6
11
10
10 N・m (1.0 kgf・m, 7.4 lb・ft)
20 N・m (2.0 kgf・m, 15 lb・ft) 13 (8) 20 N・m (2.0 kgf・m, 15 lb・ft)

4 Ring 1
5 Gasket 1
6 EXUP valve pulley cover 1
7 EXUP cable 2 1
8 EXUP cable 1 1
9 O2 sensor coupler 2 Disconnect.
10 Exhaust pipe 1
11 Exhaust chamber 1
12 Gasket 4
13 Gasket 2
14 EXUP servo motor coupler 1 Disconnect.
15 EXUP servo motor bracket 1
16 EXUP servo motor 1
17 EXUP servo motor cover 1
5-12
ENGINE REMOVAL
Disconnecting the leads and hoses
7 6 N・m (0.6 kgf・m, 4.4 lb・ft)

D
4 FW
10 3
9 2
4
8
7 N・m (0.7 kgf・m, 5.2 lb・ft)
6
5

Air filter case duct/Air cut-off valve page 7-19.
Canister Refer to “FUEL TANK” on page 7-1.
Throttle bodies 7-11.
Thermostat assembly Refer to “THERMOSTAT” on page 6-9.
Shift rod/Drive sprocket Refer to “CHAIN DRIVE” on page 4-125.
2 Starter motor lead 1 Disconnect.
3 Cylinder identification sensor coupler 1 Disconnect.
4 Ignition coil coupler 4 Disconnect.
Coolant temperature sensor coupler (sub-wire
5 1 Disconnect.
harness)
6 Neutral switch connector 1 Disconnect.
7 Stator coil coupler 1 Disconnect.
8 Crankshaft position sensor coupler 1 Disconnect.
9 Oil pressure switch connector 1 Disconnect.
10 Gear position sensor coupler 1 Disconnect.
5-13
ENGINE REMOVAL
Removing the engine
56 N・m (5.6 kgf・m, 41 lb・ft)
70 N・m (7.0 kgf・m, 52 lb・ft)
5
4
6
1 2
3
6
8
56 N・m (5.6 kgf・m, 41 lb・ft)
70 N・m (7.0 kgf・m, 52 lb・ft)

7
8
8 N・m (0.8 kgf・m, 5.9 lb・ft) FW
D

1 Engine mounting bolt (right front side) 1
2 Collar 2
3 Collar 1
4 Engine mounting bolt (left front side) 1
Engine mounting bolt (rear upper side)/Engine
5 1/1
mounting nut (rear upper side)
Engine mounting bolt (rear lower side)/Engine
6 1/1
mounting nut (rear lower side)
7 Engine 1
8 Engine mounting adjust bolt 2
5-14
ENGINE REMOVAL
EAS30250
6. Tighten:
REMOVING THE ENGINE
• Engine mounting adjust bolt “1”
1. Loosen:
• Engine mounting adjust bolt TIP
TIP
• Tighten the engine mounting adjust bolt to
specification with the pivot shaft wrench.
Loosen the engine mounting adjust bolt with the
• Make sure that the flange on the engine
pivot shaft wrench “1”.
mounting adjust bolt contacts the engine.
Pivot shaft wrench

Engine mounting adjust bolt
90890-01485
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
YM-01485
Pivot shaft wrench
90890-01485
YM-01485
7. Install:
• Engine mounting nut (rear lower side) “8”
1 • Engine mounting nut (rear upper side) “9”
8. Tighten:
• Engine mounting nut (rear lower side) “8”
Engine mounting nut

56 N·m (5.6 kgf·m, 41 lb·ft)
T.
R.
9. Tighten:
• Engine mounting nut (rear upper side) “9”
Engine mounting nut

56 N·m (5.6 kgf·m, 41 lb·ft)
T.
R.
1 10.Tighten:
• Engine mounting bolt (left front side) “4”
EAS30251
Engine mounting bolt
INSTALLING THE ENGINE 70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
1. Install:
• Engine mounting adjust bolt “1” 11.Tighten:
(temporarily tighten) • Engine mounting bolt (right front side) “7”
2. Install: Engine mounting bolt
• Engine 70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
3. Install:
• Engine mounting bolt (rear lower side) “2”
• Engine mounting bolt (rear upper side) “3”
4. Install:
• Engine mounting bolt (left front side) “4”
(temporarily tighten)
5. Install:
• Collar “5”
• Collar “6”
• Engine mounting bolt (right front side) “7”
(temporarily tighten)
5-15
ENGINE REMOVAL
9 4
75
2
6
8
EAS30252
INSTALLING THE EXHAUST PIPE AND

MUFFLER
1. Install:
• Exhaust pipe
• Gasket “1” New
(to exhaust chamber)
• Muffler
TIP
When installing the gasket, install it so that the
chamfered side “a” of the gasket faces the ex-
haust pipe side as shown in the illustration.
Installed depth of gasket “b”

5.0 mm (0.20 in)
5-16
CAMSHAFTS
EAS20043
CAMSHAFTS
Removing the cylinder head cover
13 N・m (1.3 kgf・m, 9.6 lb・ft)
(6)
LT
8 N・m (0.8 kgf・m, 5.9 lb・ft)

FW 10 N・m (1.0 kgf・m, 7.4 lb・ft)
D

Rider seat 4-1.
Air cut-off valve page 7-19.
5-17
CAMSHAFTS
Removing the cylinder head cover
13 N・m (1.3 kgf・m, 9.6 lb・ft)

1 2
3 (6)
5 LT
9
7
8 8 N・m (0.8 kgf・m, 5.9 lb・ft)

FW 10 N・m (1.0 kgf・m, 7.4 lb・ft)
D

1 Ignition coil coupler 4 Disconnect.
2 Ignition coil 4
If the spark plug is a new one, tighten it to 18
3 Spark plug 4
N·m (1.8 kgf·m, 13 lb·ft).
4 Cylinder identification sensor coupler 1 Disconnect.
5 Cylinder identification sensor 1
6 Cylinder head cover 1
7 Cylinder head cover gasket 1
8 Cylinder head cover gasket 1
9 Timing chain guide (top side) 1
5-18
CAMSHAFTS
Removing the camshafts
10 N・m (1.0 kgf・m, 7.4 lb・ft) 8 N・m (0.8 kgf・m, 5.9 lb・ft)
1 8 N・m (0.8 kgf・m, 5.9 lb・ft)
LT
E (4)
2
(4)
E
(4)
(4)
(4)
3
4
M
5
FW
6 M
D

Crankshaft end cover/Timing mark accessing Refer to “GENERATOR” on page 5-43.
bolt
1 Timing chain tensioner 1
2 Timing chain tensioner gasket 1
• If the camshaft cap bolt is a new one, it is
not necessary to apply engine oil onto the
3 Camshaft cap 1 4 mating surface and threads of the bolt.
• If the camshaft cap bolt is a new one, tight-
en it to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
• If the camshaft cap bolt is a new one, it is
not necessary to apply engine oil onto the
4 Camshaft cap 2 1 mating surface and threads of the bolt.
• If the camshaft cap bolt is a new one, tight-
en it to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
5 Intake camshaft 1
6 Exhaust camshaft 1
5-19
CAMSHAFTS
Removing the timing chain and timing chain guide
72 N・m (7.2 kgf・m, 53 lb・ft)
E 7
8 9 5
3
LT
(5) 6
4
2 1
LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)
1st 6 N・m (0.6 kgf・m, 4.4 lb・ft) FW

3.0 N・m (0.30 kgf・m, 2.2 lb・ft) D
2nd
Specified angle 90˚
*Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
Install the oil pipe to the timing chain cover,
1 Oil pipe 3 1 and then install them to the crankcase.
Install the oil pipe to the timing chain cover,
2 Timing chain cover 1 and then install them to the crankcase.
3 Timing chain cover gasket 1
4 Dowel pin 2
5 Timing chain guide (intake side) 1
6 Timing chain guide (exhaust side) 1
7 Timing chain 1
8 Timing chain sprocket bolt 1
9 Timing chain sprocket 1
5-20
CAMSHAFTS
Removing the timing chain and timing chain guide
72 N・m (7.2 kgf・m, 53 lb・ft)
11 10
13
12
LT
(5)
14
LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)

3.0 N・m (0.30 kgf・m, 2.2 lb・ft) D
2nd
torque.
10 Straight key 1
11 Circlip 1
12 Washer 1
13 Oil seal 1
When removing the oil pipe 2, also remove
14 Oil pipe 2 1 the water pump inlet pipe.
Refer to “WATER PUMP” on page 6-13.
5-21
CAMSHAFTS
Removing the rocker arms

10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
6 N・m (0.6 kgf・m, 4.4 lb・ft)
E
2
1 3
LT
3
E E
2
3
LT FW
D
10 N・m (1.0 kgf・m, 7.4 lb・ft)

Engine Refer to “ENGINE REMOVAL” on page 5-11.
Intake camshaft/Exhaust camshaft Refer to “CAMSHAFTS” on page 5-17.
1 Rocker arm shaft bolt 4
2 Straight plug (rocker arm shaft) 3
3 Rocker arm shaft 4
4 Rocker arm 16
5-22
CAMSHAFTS
EAS30256
REMOVING THE CAMSHAFTS

1. Remove:
2. Align:
• Mark “a” on the generator rotor
(with the generator rotor cover slot “b”)
a. Turn the crankshaft counterclockwise. 1
b. When piston #1 is at BTDC105° on the
compression stroke, align the BTDC105° EAS31655
mark “a” on the generator rotor with the REMOVING THE ROCKER ARMS AND
generator rotor cover slot “b”. ROCKER ARM SHAFTS
TIP 1. Remove:
• Rocker arm shaft bolt
BTDC105° on the compression stroke can be
• Straight plug
found when the camshaft lobes are turned away
• Rocker arm shaft
from each other.
• Rocker arm
b EAS30257
CHECKING THE CAMSHAFTS

1. Check:
• Camshaft lobes
a Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a”
Out of specification → Replace the camshaft.
3. Remove: Camshaft lobe dimensions

• Timing chain tensioner Lobe height (Intake)
35.291–35.391 mm (1.3894–
• Timing chain tensioner gasket
1.3933 in)
4. Remove: Limit
• Camshaft cap 35.191 mm (1.3855 in)
ECA13720
Lobe height (Exhaust)
NOTICE
34.745–34.845 mm (1.3679–
To prevent damage to the cylinder head, 1.3718 in)
camshafts or camshaft caps, loosen the Limit
camshaft cap bolts in stages and in a criss- 34.645 mm (1.3640 in)
cross pattern, working from the outside in.
5. Remove:
• Intake camshaft
• Exhaust camshaft
TIP
To prevent the timing chain from falling into the
crankcase, fasten it with a wire “1”.
G088946
3. Measure:
• Camshaft runout
5-23
CAMSHAFTS
Camshaft runout limit a b a b

0.050 mm (0.0020 in)
a. Camshaft cap bolt (black): 40 mm (1.57 in)

b. Camshaft cap bolt (silver): 35 mm (1.38 in)
A. Intake side
B. Exhaust side
4. Measure:
• Camshaft-journal-to-camshaft-cap clearance TIP
Out of specification → Measure the camshaft • If the camshaft cap bolt is a new one, it is not
journal diameter. necessary to apply engine oil onto the mating
Camshaft-journal-to-camshaft- surface and threads of the bolt.
cap clearance • If the camshaft cap bolt is a new one, tighten it
0.028–0.062 mm (0.0011–0.0024 to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
in) • Tighten the camshaft cap bolts in stages and in
Limit a crisscross pattern, working from the inner
0.080 mm (0.0032 in) caps out.
• Do not turn the camshaft when measuring the
a. Install the camshaft into the cylinder head camshaft journal-to-camshaft-cap clearance
(without the camshaft caps). with the Plastigauge®.
b. Position strip of Plastigauge® “1” onto the
camshaft journal as shown. Camshaft cap bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
Camshaft cap bolt (new)

1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge® “1”.
1
G088947
c. Install the dowel pins and camshaft caps.

ECA23010
NOTICE
There are two kinds of camshaft cap bolts
with different lengths. Be sure to install each
bolt onto the correct position. G088948
5. Measure:
• Camshaft journal diameter “a”
Out of specification → Replace the camshaft.
Within specification → Replace the cylinder
head and the camshaft caps as a set.
5-24
CAMSHAFTS
Camshaft journal diameter Rocker arm shaft outside diame-

25.459–25.472 mm (1.0023– ter
1.0028 in) 7.967–7.979 mm (0.3137–0.3141
in)
Limit
7.936 mm (0.3124 in)
G088949
EAS30259
CHECKING THE ROCKER ARMS AND

G088952
ROCKER ARM SHAFTS
The following procedure applies to all of the EAS30258
rocker arms and rocker arm shafts. CHECKING THE TIMING CHAIN AND
1. Check: CAMSHAFT SPROCKET
• Rocker arm 1. Check:
Damage/wear → Replace. • Timing chain
2. Check: Damage/stiffness → Replace the timing
• Rocker arm shaft chain and camshaft and camshaft sprocket
Blue discoloration/excessive wear/pitting/ as a set.
scratches → Replace or check the lubrication 2. Check:
system. • Camshaft sprocket
3. Measure: More than 1/4 tooth wear “a” → Replace the
• Rocker arm inside diameter “a” camshaft sprockets and the timing chain as a
Out of specification → Replace. set.
Rocker arm inside diameter

1
7.987–8.002 mm (0.3144–0.3150 a
in)
Limit b
8.017 mm (0.3156 in)
G088950
a a. 1/4 tooth
b. Correct
1. Timing chain
2. Camshaft sprocket
EAS30265
CHECKING THE TIMING CHAIN GUIDES

4. Measure:
camshaft sprockets and timing chain guides.
• Rocker arm shaft outside diameter “a”
1. Check:
• Timing chain guide (exhaust side)
• Timing chain guide (intake side)
5-25
CAMSHAFTS
• Timing chain guide (top side)

Damage/wear → Replace the defective 5
c
part(s).
d
EAS30266
CHECKING THE TIMING CHAIN TENSIONER 4

1. Check:
• Timing chain tensioner
Cracks/damage/rough movement → Re-
place.
a. Using the valve spring compressor “1”,
push and insert timing chain tensioner rod EAS31744
“2” into the timing chain tensioner housing. ASSEMBLING THE TIMING CHAIN COVER
TIP 1. Install:
Push the timing chain tensioner rod in direction • Oil seal “1” New
“a”, and turn the timing chain tensioner body “3” TIP
in direction “b” until it stops. Install the oil seal with a socket “2” that matches
90890-04019 Installed depth “a”
Valve spring compressor 4.0–4.5 mm (0.16–0.18 in)
YM-04019
a 1 2
1
a
2
b 3
2. Install:
• Washer
• Circlip New
1 EAS31657
INSTALLING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
1. Install:
• Rocker arm
• Rocker arm shaft “1”
• Rocker arm shaft bolt “2”
b. Keep pressing the timing chain tensioner • Straight plug “3”
rod, mount clip “4” into groove “5”, and TIP
lock the timing chain tensioner rod.
• Align the end surface “a” of the rocker arm
c. Push the timing chain tensioner rod in di-
shaft with the surface “b” of the cylinder head.
rection “c”.
• After installing the rocker arm shaft bolt, make
d. Make sure that the timing chain tensioner
sure that the rocker arm shaft turns smoothly.
rod can smoothly move out from the timing
chain tensioner housing in direction “d”. If
not smooth, replace the timing chain ten-
sioner assembly.
5-26
CAMSHAFTS
Rocker arm shaft bolt

6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
LOCTITE®
Straight plug (rocker arm shaft)
10 N·m (1.0 kgf·m, 7.4 lb·ft)
LOCTITE® 2
b 1
c. Install the oil pipe bolt “3” and tighten it

temporarily until there is no clearance at
a “a” (timing chain cover to oil pipe) and “b”
(oil pipe to oil pipe bolt).
1 2 1 3
TIP
Apply locking agent (LOCTITE®) onto the oil
pipe bolt.
a
b
3 1 2 1 3 3
EAS31715
INSTALLING THE TIMING CHAIN COVER d. Install the timing chain cover assembly
1. Install: and a new timing chain cover gasket.
• Timing chain cover e. Install new timing chain cover bolts and
• Oil pipe 3 tighten them.
a. Install new O-rings to the oil pipe.
TIP Timing chain cover bolt
Apply lithium-soap-based grease evenly on new 1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
*
O-rings. 2nd: 3.0 N·m (0.30 kgf·m, 2.2
lb·ft)
b. Install the oil pipe “1” to the timing chain Specified angle 90°
cover “2”.
TIP * Following the tightening order, loosen the
• While turning the oil pipe, install it to the timing bolt one by one and then retighten it to the
chain cover so that the grease applied to the O- specific torque and the specific angle.
rings is distributed. TIP
• If the oil pipe is not turned smoothly, the O- Tighten the timing chain cover bolts in the tight-
rings might be caught. ening sequence as shown.
5-27
CAMSHAFTS
a. Turn the crankshaft counterclockwise.

1 b. When piston #1 is at BTDC105°, align the
2
BTDC105° mark “a” on the generator rotor
with the generator rotor cover slot “b”.
b
3
5
a
4
f. Install the oil pipe bolts “4” and tighten
them temporarily.
TIP
Apply locking agent (LOCTITE®) onto the oil
pipe bolts. 3. Install:
• Exhaust camshaft “1”
• Intake camshaft “2”
TIP
• Hang the timing chain on the sprocket from the
exhaust camshaft to the intake camshaft.
• The intake camshaft sprocket timing mark “a”
and exhaust camshaft sprocket timing mark “b”
should align with the cylinder head surface “c”.
• Check the timing mark position of the camshaft
4 sprocket using a mirror.
• The timing chain (exhaust side) should be
g. Tighten the oil pipe bolts to the specified stretched and the timing chain (intake side)
torque following the tightening order should be sagged.
Oil pipe 3 bolt c a 2 1 b c

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
4. Install:
• Camshaft cap
1 2 TIP
3 Make sure each camshaft cap is installed in its
original place. Refer to the identification marks
EAS30269
as follows:
INSTALLING THE CAMSHAFTS
“1”: camshaft cap mark for cylinder #1
1. Remove:
2. Align:
• Mark “a” on the generator rotor
(with the generator rotor cover slot “b”)
5-28
CAMSHAFTS
4 3 2 1 a b a b
5. Tighten: a. Camshaft cap bolt (black): 40 mm (1.57 in)

• Camshaft cap bolts b. Camshaft cap bolt (silver): 35 mm (1.38 in)
A. Intake side
Camshaft cap bolt B. Exhaust side
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
Camshaft cap bolt (new) 6. Install:

10 N·m (1.0 kgf·m, 7.4 lb·ft) • Timing chain tensioner
• Timing chain tensioner gasket New
TIP a. Using the valve spring compressor “1”,
• If the camshaft cap bolt is a new one, it is not push and insert timing chain tensioner rod
necessary to apply engine oil onto the mating “2” into the timing chain tensioner housing.
surface and threads of the bolt. TIP
• If the camshaft cap bolt is a new one, tighten it
Push the timing chain tensioner rod in direction
to 10 N·m (1.0 kgf·m, 7.4 lb·ft).
“a”, and turn the timing chain tensioner body “3”
• Tighten the camshaft cap bolts in stages and in
in direction “b” until it stops.
a crisscross pattern, working from the inner
caps out.
ECA17430
90890-04019
NOTICE
• Lubricate the camshaft cap bolts with the YM-04019
engine oil.
• The camshaft cap bolts must be tightened
evenly or damage to the cylinder head, a
1
camshaft caps, and camshafts will result.
• Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing. 2
ECA23010
NOTICE
b 3
There are two kinds of camshaft cap bolts
with different lengths. Be sure to install each
bolt onto the correct position.
5-29
CAMSHAFTS
b. Keep pressing the timing chain tensioner

rod, mount clip “4” into groove “5”, and b
lock the timing chain tensioner rod.
5
a
d c c d
c. In the status of step (b), install the rod as-

sembly in the cylinder block.
TIP
Always use a new gasket.
Timing chain tensioner bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE® 9. Measure:
• Valve clearance
d. Unlock the timing chain tensioner by turn- Out of specification → Adjust.
ing the crankshaft clockwise, and tension Refer to “ADJUSTING THE VALVE CLEAR-
the timing chain. ANCE” on page 3-6.
7. Turn: 10.Install:
• Crankshaft • Timing mark accessing bolt
(several turns counterclockwise)
8. Check: Timing mark accessing bolt
• Mark “a” 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
Make sure the mark “a” on the generator rotor

is aligned with the generator rotor cover slot • Crankshaft end cover
“b”.
• Camshaft sprocket timing mark “c” Crankshaft end cover
Make sure the camshaft sprocket timing mark 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
“c” is aligned with the cylinder head mating

surface “d”.
11.Install:
Out of alignment → Adjust.
• Timing chain guide (top side)
Refer to the installation steps above.
• Cylinder head cover gasket “1” New
TIP
Check the timing mark position of the camshaft • Cylinder head cover gasket “2” New
sprocket using a mirror. • Cylinder head cover
Cylinder head cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Apply Three Bond No. 1541C® onto the mat-
ing surfaces of the cylinder head cover and cyl-
inder head cover gasket.
5-30
CAMSHAFTS
• After installing the cylinder head cover gasket

“2” to the cylinder head cover, cut off the “a”
section.
2
1
a
a
12.Install:
• Spark plugs
• Ignition coils “1”
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
Spark plug (new)

18 N·m (1.8 kgf·m, 13 lb·ft)
TIP
• Before installing the spark plug, clean the
spark plug and gasket surface.
• If the spark plug is a new one, tighten it to 18
N·m (1.8 kgf·m, 13 lb·ft).
• Install the ignition coils “1” in the direction
5-31
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
9 N•m (0.9 kgf•m, 6.6 lb•ft)
T.R
.
16 N•m (1.6 kgf•m, 12 lb•ft) 1
T.R
.
2
E
4
5
1st 10 N・m (1.0 kgf・m, 7.4 lb・ft)

2nd 25 N・m (2.5 kgf・m, 18 lb・ft)
3rd 45 N・m (4.5 kgf・m, 33 lb・ft)
15 N・m (1.5 kgf・m, 11 lb・ft)
4th
FW
D
torque.
Intake camshaft/Exhaust camshaft Refer to “CAMSHAFTS” on page 5-17.
1 Coolant temperature sensor 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
5 Oil delivery pipe 1
5-32
CYLINDER HEAD
EAS30276
REMOVING THE CYLINDER HEAD

1. Remove:
• Intake camshaft
Refer to “REMOVING THE CAMSHAFTS”
on page 5-23.
2. Remove:
• Cylinder head bolt (M6) (× 2)
• Cylinder head bolt (M9) (× 10) G088956
TIP a. Place a straightedge “1” and a thickness
• Loosen the bolts in the proper sequence as gauge “2” across the cylinder head.
shown.
• Loosen each bolt 1/2 of a turn at a time. After Thickness gauge
all of the bolts are fully loosened, remove them. 90890-03268
Feeler gauge set
YU-26900-9
5 7 11 9 3 1
1 2
4 6 2
10 12 8 2
10
EAS30277 G088957
CHECKING THE CYLINDER HEAD
1. Eliminate: b. Measure the warpage.
• Combustion chamber carbon deposits c. If the limit is exceeded, resurface the cylin-
(with a rounded scraper) der head as follows.
d. Place a 400–600 grit wet sandpaper on
TIP
the surface plate and resurface the cylin-
Do not use a sharp instrument to avoid damag- der head using a figure-eight sanding pat-
ing or scratching: tern.
• Spark plug bore threads
TIP
• Valve seats
To ensure an even surface, rotate the cylinder
2. Check: head several times.
• Cylinder head
Damage/scratches → Replace. EAS30282
• Cylinder head water jacket INSTALLING THE CYLINDER HEAD

Mineral deposits/rust → Eliminate. 1. Install:
3. Measure: • Cylinder head gasket New
• Cylinder head warpage • Dowel pins
Out of specification → Resurface the cylinder 2. Install:
head. • Cylinder head
• Cylinder head bolt (M6) (× 2)
Warpage limit
0.10 mm (0.0039 in) • Cylinder head bolt (M9) (× 10) New
TIP
• Pass the timing chain through the timing chain
cavity.
5-33
CYLINDER HEAD
• Lubricate the cylinder head bolt (M9) thread

and mating surface with engine oil.
3. Tighten:
• Cylinder head bolt “1”–“10”
• Cylinder head bolt “11”, “12”
Cylinder head bolt “1”–“10”

1st: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
2nd: 25 N·m (2.5 kgf·m, 18 lb·ft)

3rd: 45 N·m (4.5 kgf·m, 33 lb·ft)
*4th: 15 N·m (1.5 kgf·m, 11 lb·ft)
Specified angle 160°
Cylinder head bolt “11”, “12”
9 N·m (0.9 kgf·m, 6.6 lb·ft)
* Following the tightening order, loosen the

bolt one by one and then retighten it to the
specific torque and the specific angle.
TIP
Tighten the cylinder head bolts in the tightening
sequence as shown and torque them in 4 stag-
es.
8 6 2 4 10 12
9 7 11
3 1 5 2
10
4. Install:
• Intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”
on page 5-28.
5-34
VALVES AND VALVE SPRINGS
EAS20045

Removing the valves and valve springs
10
M
11
M
1
2
3
4
5
M
9
7
8
6
FW
D
M

Cylinder head Refer to “CYLINDER HEAD” on page 5-32.
1 Exhaust valve pad 8
2 Exhaust valve cotter 16
3 Exhaust valve spring retainer 8
4 Exhaust valve spring (outer) 8
5 Exhaust valve spring (inner) 8
6 Exhaust valve 8
7 Exhaust valve stem seal 8
8 Exhaust valve spring seat 8
9 Exhaust valve guide 8
10 Intake valve pad 8
11 Intake valve cotter 16
5-35
Removing the valves and valve springs
M
12
13
14
M
16
17
18
19
15
FW
D
M

12 Intake valve spring retainer 8
13 Intake valve spring (outer) 8
14 Intake valve spring (inner) 8
15 Intake valve 8
16 Intake valve stem seal 8
17 Intake valve spring seat 8
18 Circlip 8
19 Intake valve guide 8
5-36
EAS30283
REMOVING THE VALVES Valve spring compressor

The following procedure applies to all of the 90890-04019
valves and related components. Valve spring compressor
TIP YM-04019
Before removing the internal parts of the cylinder Valve spring compressor attach-
ment (ø26)
head (e.g., valves, valve springs, valve seats),
90890-01243
make sure the valves properly seal. Valve spring compressor adapt-
1. Remove: er (26 mm)
• Valve pad YM-01253-1
TIP
Make a note of the position of each valve pad so
that they can be reinstalled in their original place.
2. 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 5-39.
G088959
a. Pour a clean solvent “a” into the intake and
exhaust ports. 4. Remove:
b. Check that the valves properly seal. • Valve spring retainer
TIP • Valve spring (outer)
• Valve spring (inner)
There should be no leakage at the valve seat “1”.
• Valve
• Valve stem seal
• Valve spring seat
TIP
Identify the position of each part very carefully so
that it can be reinstalled in its original place.
EAS30284
CHECKING THE VALVES AND VALVE

GUIDES
G088958
3. Remove: valves and valve guides.
• Valve cotters 1. Measure:
TIP • Valve-stem-to-valve-guide clearance
Remove the valve cotters by compressing the Out of specification → Replace the valve
valve spring with the valve spring compressor guide.
“1” and the valve spring compressor attachment • Valve-stem-to-valve-guide clearance =
“2”. Valve guide inside diameter “a” -
Valve stem diameter “b”
5-37
b. Install the new valve guide with the valve

Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remov-
ance (intake) er “1”.
0.010–0.037 mm (0.0004–0.0015
in) Valve guide position (intake)
Limit 12.0–12.4 mm (0.47–0.49 in)
0.080 mm (0.0032 in) Valve guide position (exhaust)
Valve-stem-to-valve-guide clear- 17.5–17.9 mm (0.69–0.70 in)
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
G088963
a. Valve guide position

c. After installing the valve guide, bore the
G088960
valve guide with the valve guide reamer
“3” to obtain the proper valve-stem-to-
valve-guide clearance.
G088961
G088964
2. Replace:
• Valve guide TIP
TIP After replacing the valve guide, reface the valve
To ease valve guide removal and installation, seat.
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”.
G088962
5-38
Valve guide remover (ø4.5)

90890-04116
YM-04116
Valve guide remover (ø5)
90890-04097
YM-04097
Valve guide installer (ø4.5)
G088965
90890-04117
Valve guide installer (4.5 mm) EAS30285
YM-04117 CHECKING THE VALVE SEATS

Valve guide installer (ø5) The following procedure applies to all of the
90890-04098 valves and valve seats.
Valve guide installer (5.0 mm) 1. Eliminate:
YM-04098 • Carbon deposits
Valve guide reamer (ø4.5) (from the valve face and valve seat)
90890-04118
2. Check:
YM-04118 • Valve seat
Valve guide reamer (ø5) Pitting/wear → Replace the cylinder head.
90890-04099 3. Measure:
Valve guide reamer (5.0 mm) • Valve seat contact width “a”
YM-04099 Out of specification → Replace the cylinder
head.
3. Eliminate:
• Carbon deposits Valve seat contact width (intake)
(from the valve face and valve seat) 0.90–1.10 mm (0.0354–0.0433 in)
4. Check: Limit
• Valve face 1.6 mm (0.06 in)
Valve seat contact width (ex-
Pitting/wear → Grind the valve face.
haust)
• Valve stem end 1.10–1.30 mm (0.0433–0.0512 in)
Mushroom shape or diameter larger than the Limit
body of the valve stem → Replace the valve. 1.8 mm (0.07 in)
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 G088966

0.010 mm (0.0004 in)
a. Apply blue layout fluid “b” onto the valve
face.
5-39
G088967 G088968
b. Install the valve into the cylinder head. b. Apply molybdenum disulfide oil onto the
c. Press the valve through the valve guide valve stem.
and onto the valve seat to make a clear c. Install the valve into the cylinder head.
impression. d. Turn the valve until the valve face and
d. Measure the valve seat contact width. valve seat are evenly polished, then clean
TIP off all of the lapping compound.
Where the valve seat and valve face contacted TIP
one another, the blue layout fluid will have been For the best lapping results, lightly tap the valve
removed. seat while rotating the valve back and forth be-
tween your hands.
4. Lap:
• Valve face
• Valve seat
TIP
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
ECA22580
NOTICE
This model uses titanium intake valves. G088969
Titanium valves that have been used to lap e. Apply a fine lapping compound to the
the valve seats must not be used. Always re- valve face and repeat the above steps.
place lapped valves with new valves. f. After every lapping procedure, be sure to
TIP clean off all of the lapping compound from
the valve face and valve seat.
• When replacing the intake valves, replace the
g. Apply blue layout fluid “b” onto the valve
intake valves without lapping the valve seats
face.
and valve faces.
• When replacing the cylinder head or intake
valve guides, use new valves to lap the valve
seats, and then replace them with new intake
valves.
a. Apply a coarse lapping compound “a” to
the valve face.
ECA13790
NOTICE
Do not let the lapping compound enter the G088967
gap between the valve stem and the valve h. Install the valve into the cylinder head.
guide. i. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
5-40
j. Measure the valve seat contact width “c” 1. Check:

again. If the valve seat width is out of spec- • Valve spring seat
ification, reface and lap the valve seat. Damage/scratches → Replace the valve
spring seat.
EAS30288
INSTALLING THE VALVES

valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
G088970
EAS30286
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
spring. G088972
Inner spring 2. Lubricate:

Free length (intake) • Valve stem
34.52 mm (1.36 in) • Valve stem seal
Limit (with the recommended lubricant)
32.79 mm (1.29 in)
Free length (exhaust) Recommended lubricant
36.94 mm (1.45 in) Molybdenum disulfide oil
Limit
35.09 mm (1.38 in) 3. Install:
Outer spring • Valve spring seat “1”
Free length (intake) • Valve stem seal “2” New
35.72 mm (1.41 in) • Valve “3”
Limit • Valve spring (inner) “4”
33.93 mm (1.34 in) • Valve spring (outer) “5”
Free length (exhaust)
• Valve spring retainer “6”
36.85 mm (1.45 in)
Limit (into the cylinder head)
35.01 mm (1.38 in) TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
G088971
EAS31716
CHECKING THE VALVE SPRING SEAT

valve lifters.
5-41
3
6
2
1
G088975
b. Smaller pitch 6. Lubricate:

• Valve pad
4. Install: (with the recommended lubricant)
• Valve cotters
TIP Recommended lubricant
Install the valve cotters by compressing the Molybdenum disulfide oil
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment 7. Install:
“2”. • Valve pad
TIP
Valve spring compressor Each valve pad must be reinstalled in its original
90890-04019 position.
YM-04019
Valve spring compressor attach-
ment (ø26)
90890-01243
Valve spring compressor adapt-
er (26 mm)
YM-01253-1
G088959
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-42
GENERATOR
EAS20134
GENERATOR
Removing the stator coil and generator rotor
FW
D
10 N・m (1.0 kgf・m, 7.4 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft)
15 N・m (1.5 kgf・m, 11 lb・ft) LT 5
2 6
LT
1
LT 85 N・m (8.5 kgf・m, 63 lb・ft)

7
10 N・m (1.0 kgf・m, 7.4 lb・ft)
4
(8) 3
1st 6 N・m (0.6 kgf・m, 4.4 lb・ft)

*2nd 3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
15 N・m (1.5 kgf・m, 11 lb・ft)
torque.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
1 Stator coil coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Generator cover 1
4 Generator cover gasket 1
5 Dowel pin 2
6 Stator coil lead holder 1
Stator coil assembly (stator coil/crankshaft posi-
7 1
tion sensor)
5-43
GENERATOR
Removing the stator coil and generator rotor
FW
D
10 N・m (1.0 kgf・m, 7.4 lb・ft)
6 N・m (0.6 kgf・m, 4.4 lb・ft)
15 N・m (1.5 kgf・m, 11 lb・ft) LT

10
9
8
LT
11
LT 85 N・m (8.5 kgf・m, 63 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

12
(8)
1st 6 N・m (0.6 kgf・m, 4.4 lb・ft)

*2nd 3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
15 N・m (1.5 kgf・m, 11 lb・ft)
torque.
8 Shaft 1
9 Generator rotor 1
10 Woodruff key 1
11 Crankshaft end cover 1
12 Timing mark accessing bolt 1
5-44
GENERATOR
EAS30829
REMOVING THE GENERATOR Flywheel puller

1. Remove: 90890-01404
• Generator rotor bolt “1” Flywheel puller
• Washer YM-01404
TIP
While holding the generator rotor “2” with the
15mm pin type rotor holding tool “3”, loosen the
generator rotor bolt. 1
15mm pin type rotor holding tool

90890-04171
YM-04171 2
G088977
EAS30830
INSTALLING THE GENERATOR

2
1. Install:
• Woodruff key
• Generator rotor
• Washer “1”
• Shaft “2”
3 1 • Generator rotor bolt “3”
TIP
2. Install: • Clean the tapered portion of the crankshaft and
• Crankshaft protector “1” the generator rotor hub.
TIP • When installing the generator rotor, make sure
Install the crankshaft protector to the hole “a” of the woodruff key is properly seated in the key-
the crankshaft. way of the crankshaft.
• Lubricate the washer with engine oil.
Crankshaft protector • Install the shaft to the hole of the generator ro-
90890-01382 tor bolt.
Crankshaft protector • Lubricate the generator rotor bolt threads and
YM-01382 washer mating surfaces with engine oil.
1 3
1
2
a
3. Remove: 2. Tighten:
• Generator rotor “1” • Generator rotor bolt “1”
(with the flywheel puller “2”) Generator rotor bolt
• Woodruff key 85 N·m (8.5 kgf·m, 63 lb·ft)
T.
R.
TIP
Install the flywheel puller to the generator rotor.
5-45
GENERATOR
TIP TIP
While holding the generator rotor “2” with the Tighten the generator cover bolts in the tighten-
15mm pin type rotor holding tool “3”, tighten the ing sequence as shown.
generator rotor bolt.
8
15mm pin type rotor holding tool
90890-04171 7
1
YM-04171
6
2
2 5 3
4
5. Connect:
• Stator coil coupler
• Crankshaft position sensor coupler
3 1 TIP
To route the stator coil lead, refer to “CABLE
3. Apply: ROUTING” on page 2-17.
• Sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No. 1215

90890-85505
G088980
4. Install:
• Generator cover gasket New
• Generator cover
• Generator cover bolt New
Generator cover bolt

1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
*2nd: 3.0 N·m (0.30 kgf·m, 2.2

lb·ft)
*Following the tightening order, loosen the

5-46
STARTER CLUTCH
EAS20049
STARTER CLUTCH
Removing the starter clutch
E
14 N・m (1.4 kgf・m, 10 lb・ft)
1
2
LT
3
E
E 4
FW
D

Clutch housing assembly Refer to “CLUTCH” on page 5-59.
1 Starter clutch gear 1
2 Bearing 1
3 Starter clutch assembly 1
4 Circlip 1
5 Starter clutch idle gear 1
5-47
STARTER CLUTCH
EAS30305
c. When turning the starter clutch gear coun-
REMOVING THE STARTER CLUTCH
terclockwise “B”, it should turn freely, oth-
1. Remove:
erwise the starter clutch is faulty and must
• Starter clutch bolt “1”
be replaced.
TIP
• While holding the clutch housing assembly “2” A 1
with the sheave holder “3”, remove the starter
clutch bolt.
• Fix the flat surface of the clutch housing as-
sembly with the sheave holder.
B
Sheave holder
90890-01701
2
Primary clutch holder
YS-01880-A
EAS30309
INSTALLING THE STARTER CLUTCH

1 1. Install:
• Starter clutch
Starter clutch holder bolt

14 N·m (1.4 kgf·m, 10 lb·ft)
T.
2
R.
LOCTITE®
TIP
3 • Install the starter clutch so that the side of the
starter clutch roller assembly with the arrow
EAS30306 mark is toward the clutch housing.
CHECKING THE STARTER CLUTCH • While holding the clutch housing assembly “1”
1. Check: with the sheave holder “2”, tighten the starter
• Starter clutch rollers clutch holder bolt “3”.
Damage/wear → Replace. • Fix the flat surface of the clutch housing as-
2. Check: sembly with the sheave holder.
• Starter clutch gear
• Starter clutch idle gear Sheave holder
Burrs/chips/roughness/wear → Replace the 90890-01701
defective part(s). Primary clutch holder
3. Check: YS-01880-A
• Starter clutch gear’s contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
3
4. Check:
• Starter clutch operation
a. Install the starter clutch gear “1” onto the
clutch housing assembly “2” and hold the 1
clutch housing assembly.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the 2
starter clutch is faulty and must be re-
placed.
5-48
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor
6 N・m (0.6 kgf・m, 4.4 lb・ft)

1
10 N・m (1.0 kgf・m, 7.4 lb・ft)
FW
D

Rider seat 4-1.
Fuel tank cover 4-9.
1 Starter motor lead 1 Disconnect.
2 Starter motor 1
5-49
ELECTRIC STARTER
Disassembling the starter motor
D
6 FW
5
7 3
1
2
4.5 N・m (0.45 kgf・m, 3.3 lb・ft)

1 O-ring 1
2 Starter motor front cover 1
3 Starter motor yoke 1
4 Armature assembly 1
5 Gasket 2
6 Brush holder set 1
7 Starter motor rear cover 1
5-50
ELECTRIC STARTER
EAS30325
CHECKING THE STARTER MOTOR Brush overall length limit

1. Check: 5.5 mm (0.22 in)
• Commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• Mica undercut “a”
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth)

2.40 mm (0.09 in)
G088989
TIP 5. Measure:
The mica of the commutator must be undercut to • Brush spring force
ensure proper operation of the commutator. Out of specification → Replace the brush
holder set.
Brush spring force

4.80–7.20 N (489–734 gf, 17.28–
25.92 oz)
G088986
3. Check:
• Armature assembly
a. Connect the digital circuit tester and check
the continuity.
Digital circuit tester (CD732)

90890-03243 6. Check:
Model 88 Multimeter with ta- • Gear teeth
chometer Damage/wear → Replace the starter motor.
YU-A1927 7. Check:
• Bearing
b. If there is no continuity, replace the starter • Oil seal
motor. Damage/wear → Replace the starter motor
front cover.
EAS30326
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor rear cover “1”
• Starter motor yoke “2”
• Starter motor front cover “3”
TIP
Align the match mark “a” on the starter motor
4. Measure: yoke with the match mark “b” on the starter mo-
• Brush length “a” tor front cover.
Out of specification → Replace the brush
holder set.
5-51
ELECTRIC STARTER
a b
1 2 3
5-52
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pan and oil pump
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

E
10 N・m (1.0 kgf・m, 7.4 lb・ft)

LT
LT
FW
D
10 N・m (1.0 kgf・m, 7.4 lb・ft)
6
1
LT
LT
5
LT (10) LT 3
LT
23 N・m (2.3 kgf・m, 17 lb・ft) 10 N・m (1.0 kgf・m, 7.4 lb・ft) 10 N・m (1.0 kgf・m, 7.4 lb・ft)

Rider seat 4-1.
Front side cowling/Front panel/Side cover brack- Refer to “GENERAL CHASSIS (3)” on page
et/Front muffler protector/Fuel tank cover 4-9.
Drain.
page 3-29.
Exhaust pipe/Muffler Refer to “ENGINE REMOVAL” on page 5-11.
1 Oil pan 1
2 Oil pan gasket 1
3 Oil strainer 1
4 Oil delivery pipe 1 1
5 Oil pipe 1 1
6 Relief valve assembly 1
5-53
OIL PUMP
Removing the oil pan and oil pump

9 10 N・m (1.0 kgf・m, 7.4 lb・ft)
10
11 E
10 N・m (1.0 kgf・m, 7.4 lb・ft) 12

E 8
10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
LT
15
FW
D
10 N・m (1.0 kgf・m, 7.4 lb・ft)
7 14
13
LT
LT
LT (10) LT
LT
23 N・m (2.3 kgf・m, 17 lb・ft) 10 N・m (1.0 kgf・m, 7.4 lb・ft) 10 N・m (1.0 kgf・m, 7.4 lb・ft)

8 Oil pump drive chain guide 1
9 Collar 1
10 Oil pump drive sprocket 1
11 Washer 1
12 Oil pump drive chain 1
13 Oil pump 1
14 Dowel pin 2
15 Baffle plate 1
5-54
OIL PUMP
Disassembling the oil pump
3
7
1
10 N・m (1.0 kgf・m, 7.4 lb・ft)
E
FW
D

1 Oil pump cover 1
2 Dowel pin 2
3 Oil pump outer rotor 1
4 Oil pump inner rotor 1
5 Pin 1
6 Oil pump housing 1
7 Oil pump driven sprocket 1
5-55
OIL PUMP
EAS30333
REMOVING THE OIL PAN

1. Remove:
• Oil pan
• Gasket
• Dowel pins
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.
EAS30339
EAS30336
CHECKING THE SPROCKET AND CHAIN CHECKING THE OIL DELIVERY PIPES
1. Check: The following procedure applies to all of the oil
• Oil pump drive sprocket delivery pipes.
Cracks/damage/wear → Replace. 1. Check:
2. Check: • Oil delivery pipe 1
• Oil pump drive chain • Oil delivery pipe 2
Damage/stiffness → Replace the oil pump • Oil pipe 1
drive chain and oil pump drive sprocket as a Damage → Replace.
set. Obstruction → Wash and blow out with com-
pressed air.
EAS30337
CHECKING THE OIL PUMP EAS30340
1. Check: CHECKING THE OIL STRAINER

• Oil pump driven sprocket 1. Check:
• Oil pump housing • Oil strainer
• Oil pump inner rotor Damage → Replace.
• Oil pump outer rotor Contaminants → Clean with solvent.
• Oil pump cover EAS30342
Cracks/damage/wear → Replace the oil ASSEMBLING THE OIL PUMP

pump assembly. 1. Lubricate:
2. Check: • Inner rotor
• Oil pump operation • Outer rotor
Rough movement → Repeat steps (1) and • Oil pump shaft
(2) or replace the oil pump assembly. (with the recommended lubricant)
Engine oil
2. Install:
• Oil pump driven sprocket “1”
• Pin “2”
• Inner rotor “3”
• Outer rotor “4”
G088997 • Oil pump cover “5”
• Oil pump housing bolt
EAS30338
CHECKING THE RELIEF VALVE Oil pump housing bolt

1. Check: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
• Relief valve body “1”

R.
• Relief valve “2”

• Spring “3”
• Damage/wear → Replace the defective
part(s).
5-56
OIL PUMP
TIP
When installing the inner rotor, align the pin “2”
in the oil pump shaft with the groove in the inner 2
rotor “3”.
2
1
5
3. Install:
• Oil pump drive chain guide
3
1 Oil pump drive chain guide bolt
4
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
3. Check: LOCTITE®
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on 4. Install:
page 5-56. • O-ring New
• Oil pipe 1
EAS30343
INSTALLING THE OIL PUMP Oil pipe 1 bolt

1. Install: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• Dowel pin LOCTITE®

• Oil pump “1”
• Oil pump bolt “2” • O-ring New
• Oil delivery pipe 1
Oil pump bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft) • Oil strainer
T.
R.
Oil strainer bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
2
R.
LOCTITE®
• O-ring New
• Relief valve assembly
Relief valve assembly bolt

2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
1
5. Install:
2. Install:
• Washer • O-ring New
• Oil pump drive chain “1” • Oil delivery pipe 2
• Oil pump drive sprocket “2”
Oil delivery pipe 2 bolt
• Collar 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP LOCTITE®
Install the oil pump drive chain “1” onto the oil
pump drive sprocket “2”. EAS30345
INSTALLING THE OIL PAN

ECA22830
1. Install:
NOTICE
• Oil pan gasket New
After installing the oil pump drive chain and
• Oil pan
drive sprocket, make sure the oil pump turns
• Oil pan bolt (× 12)
smoothly.
5-57
OIL PUMP
• M6 × 25 mm (0.98 in) bolts: “1”–“6”, “9”–“12”

• M6 × 30 mm (1.18 in) bolts: “7”, “8”
6 7
8
9
5
10
4
11
3 12
2 1
2. Tighten:
• Oil pan bolt
Oil pan bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
3. Install:
• Engine oil drain bolt
• Gasket New
Engine oil drain bolt

23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
5-58
CLUTCH
EAS20055
CLUTCH
Removing the clutch cover
5
4
2
3
7 N・m (0.7 kgf・m, 5.2 lb・ft)
1
(10)
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
D
*2nd
torque.
Front side cowling (right) 4-9.
Drain.
page 3-29.
2 Clutch cover 1
3 Clutch cover gasket 1
4 Dowel pin 2
5 Oil filler cap 1
5-59
CLUTCH
Removing the pull lever shaft
10 N・m (1.0 kgf・m, 7.4 lb・ft) LT
LT
10
8
7
6
5
E
3
2
D
FW 1

1 Circlip 1
2 Pull lever 1
3 Pull lever spring 1
4 Circlip 1
5 Pull lever shaft 1
6 Oil seal 1
7 Bearing 1
8 Bearing 1
9 Clutch cover damper plate 1
10 Clutch cover damper 1
5-60
CLUTCH
Removing the clutch
FW
D
125 N・m (12.5 kgf・m, 92 lb・ft)
6
8 3
4
2 5
E 1
9
7
E E
6 E
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1 Pressure plate 1 1
2 Compression spring 3
3 Pressure plate 2 1
4 Pull rod 1
5 Bearing 1 Press the bearing into pressure plate 2.
6 Friction plate 1 3 Blackish shoe
7 Clutch plate 1 1 Inside diameter: 110.2 mm (4.34 in)
8 Clutch plate 2 8 Inside diameter: 103.5 mm (4.07 in)
9 Friction plate 2 7 Whitish shoe
5-61
CLUTCH
Removing the clutch
FW
D
125 N・m (12.5 kgf・m, 92 lb・ft)
E
10 11
18
17
13
16
12
15
14
11
10
E E
E
10 N・m (1.0 kgf・m, 7.4 lb・ft)

10 Clutch damper spring 1
11 Clutch damper spring seat 1
12 Clutch boss nut 1
13 Conical spring washer 1
14 Clutch boss 1
15 Thrust plate 1
16 Clutch housing assembly 1
17 Bearing 1
18 Washer 1
5-62
CLUTCH
EAS30346
REMOVING THE CLUTCH

1. Remove:
• Clutch cover 3 1
• Gasket
TIP
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
2
After all of the bolts are fully loosened, remove
them. G088993
• Compression spring bolts • Clutch boss nut
• Pressure plate 1 • Conical spring washer
• Compression springs • Clutch boss
• Pressure plate 2 • Thrust plate
• Pull rod • Clutch housing assembly
3. Remove: • Bearing
• Friction plates 1 • Washer
• Clutch plate 1 EAS30348
• Clutch plates 2 CHECKING THE FRICTION PLATES

• Friction plates 2 The following procedure applies to all of the fric-
• Clutch damper spring tion plates.
• Clutch damper spring seat 1. Check:
TIP • Friction plate 1 (blackish shoe)
Be sure to mark the friction plates and clutch • Friction plate 2 (whitish shoe)
plates or note the position of each part so that Damage/wear → Replace the friction plates
they are installed in their original positions. as a set.
2. Measure:
4. Straighten the clutch boss nut rib “a”. • Friction plate 1, 2 thickness
Out of specification → Replace the friction
a
plates as a set.
TIP
Measure the friction plate at four places.
Friction plate 1 thickness

2.72–2.88 mm (0.107–0.113 in)
Wear limit
G088991 2.62 mm (0.103 in)
Friction plate 2 thickness
5. Loosen: 2.72–2.88 mm (0.107–0.113 in)
• Clutch boss nut “1” Wear limit
TIP 2.62 mm (0.103 in)
• While holding the clutch boss “2” with the uni-
versal clutch holder “3”, loosen the clutch boss EAS30349
nut. CHECKING THE CLUTCH PLATES

• Do not use an impact wrench for removing the The following procedure applies to all of the
clutch boss nut. clutch plates.
1. Check:
• Clutch plate 1, 2
Universal clutch holder Damage → Replace the clutch plates as a
90890-04086
set.
YM-91042
5-63
CLUTCH
2. Measure: Clutch plate “1”

• Clutch plate 1, 2 warpage
(with a surface plate and thickness gauge) Part No. Thickness
Out of specification → Replace the clutch 2CR-16325-10 2.0 mm (0.079 in)
plates as a set.
2CR-16325-00 2.3 mm (0.091 in) STD
Thickness gauge 2CR-16325-20 2.6 mm (0.102 in)
90890-03268
Feeler gauge set 1
YU-26900-9
Clutch plate 1 thickness

2.46–2.74 mm (0.097–0.108 in)
Warpage limit
0.10 mm (0.004 in)
Clutch plate 2 thickness
2.18–2.42 mm (0.086–0.095 in)
Warpage limit
0.10 mm (0.004 in) EAS30351
CHECKING THE CLUTCH SPRINGS

3. Measure: The following procedure applies to all of the
• Assembly width “a” of the friction plates and clutch springs.
clutch plates 1. Check:
Out of specification → Adjust. • Clutch spring
Damage → Replace the clutch springs as a
Assembly width
48.3–49.3 mm (1.90–1.94 in) set.
2. Measure:
TIP
• Clutch spring free length
Out of specification → Replace the clutch
• Perform the thickness measurement without
springs as a set.
applying the oil.
• This step should be performed only if the fric- Clutch spring free length
tion plates and clutch plates were replaced. 47.36 mm (1.86 in)
• To measure the total width of the friction plates Limit
and clutch plates, combine 10 friction plates 44.99 mm (1.77 in)
and 9 clutch plates as shown.
EAS30352
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing dogs
a Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
a TIP
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
a. Assembly width adjusted by clutch plate

“1”.
b. Select the clutch plate from the following
table.
5-64
CLUTCH
EAS30357
CHECKING THE PRIMARY DRIVEN GEAR

1. Check:
• Primary driven gear
Damage/wear → Replace the clutch housing
and crankshaft as a set.
Excessive noise during operation → Replace
the clutch housing and crankshaft as a set.
EAS30358
G088994 CHECKING THE PULL LEVER SHAFT AND
2. Check: PULL ROD
• Bearing 1. Check:
Damage/wear → Replace the bearing and • Pull lever shaft pinion gear teeth
clutch housing. • Pull rod teeth
Damage/wear → Replace the pull rod and
EAS30353
pull lever shaft as a set.
CHECKING THE CLUTCH BOSS
2. Check:
1. Check:
• Pull rod bearing
• Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss. EAS30363
TIP INSTALLING THE CLUTCH

Pitting on the clutch boss splines will cause er- TIP
ratic clutch operation. After assembling the clutch assembly, the noise
like a dry-type clutch might occur with the gear
position in neutral and half clutch. This is due to
the clutch dragging by engine oil when assem-
bled. The pressure plate makes chattering by
the clutch dragging and noise occurs between
pressure plate cam and clutch boss cam. This
noise will disappeared after riding few mileage
as engine oil between clutch plate and friction
plate will be reduced to optimum condition by
G088995 clutch operation.
EAS30354
1. Install:
CHECKING THE PRESSURE PLATE • Washer
1. Check: • Bearing
• Pressure plate 1 • Clutch housing assembly “1”
ECA22570
• Pressure plate 2
NOTICE
• Bearing Make sure to fit the projections “a” of the oil
Damage/wear → Replace. pump drive sprocket to the concave “b” of
the clutch housing assembly.
EAS30356
CHECKING THE PRIMARY DRIVE GEAR TIP

1. Check: When installing the clutch housing assembly,
• Primary drive gear turn the crankshaft so that the crankshaft web “c”
Damage/wear → Replace the crankshaft and cannot be seen.
clutch housing as a set.
Excessive noise during operation → Replace
the crankshaft and clutch housing as a set.
5-65
CLUTCH
2
1
a
a b
4 3 2 1
2. Install: 3. Lubricate:
• Thrust plate • Friction plates
• Clutch boss “1” • Clutch plates
• Conical spring washer “2” (with the recommended lubricant)
• Clutch boss nut “3” New
Clutch boss nut Engine oil
125 N·m (12.5 kgf·m, 92 lb·ft)
T.
4. Install:
R.
TIP
• Clutch damper spring seat
• Clutch damper spring
• Install the conical spring washer on the main
• Friction plates 1
axle with the “OUT” mark “a” facing away from
• Clutch plates 2
the vehicle.
• Friction plates 2
• While holding the clutch boss “1” with the uni-
• Clutch plate 1
versal clutch holder “4”, tighten the clutch boss
nut. TIP
• Do not use an impact wrench for installing the • First, install a friction plate and then alternate
clutch boss nut. between a clutch plate and a friction plate.
• Stake the clutch boss nut at cutouts “b” in the • Install the last friction plate “1” offset from the
main axle. other friction plates “2”, making sure to align a
projection on the friction plate with the punch
mark “a” on the clutch housing.
90890-04086
YM-91042
1
5-66
CLUTCH
5. Install:
• Pull rod 1
10 2
• Pressure plate 2
• Clutch springs 9
• Pressure plate 1 3
• Clutch spring bolts
8 4
Clutch spring bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
5
R.
7 6
TIP
• Tighten the clutch spring bolts in stages and in 8. Install:
a crisscross pattern. • Pull lever spring “1”
• Apply lithium-soap-based grease onto the pull • Pull lever “2”
rod. • Washer
• Position the pull rod so that the teeth “a” face • Circlip New
towards the rear of the vehicle. Then, install the TIP
clutch cover. • The end of the pull lever should be closest to
the clutch cover match mark “a” when there is
no free play of the pull lever.
• Make sure that the pull rod teeth and pull lever
shaft pinion gear are engaged.
a 2
6. Install:
• Dowel pins
• Clutch cover gasket New
• Clutch cover a
• Clutch cover bolt New 9. Adjust:
7. Tighten: • Clutch lever free play
• Clutch cover bolt Refer to “ADJUSTING THE CLUTCH LEVER
FREE PLAY” on page 3-13.
Clutch cover bolt
1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft) Clutch lever free play
T.
R.
*
2nd: 3.0 N·m (0.30 kgf·m, 2.2 10.0–15.0 mm (0.39–0.59 in)
lb·ft)
*
Following the tightening order, loosen the
TIP
Tighten the clutch cover bolts in the tightening
sequence as shown.
5-67
SHIFT SHAFT
EAS20057
SHIFT SHAFT
Removing the shift shaft and stopper lever
12
5 4
E
6
9
E 10 8
3
LT
7 11
E
22 N・m (2.2 kgf・m, 16 lb・ft)
13
14
2
1
FW
D

Clutch assembly Refer to “CLUTCH” on page 5-59.
Shift arm Refer to “CHAIN DRIVE” on page 4-125.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Washer 1
5 Circlip 1
6 Washer 1
7 Stopper lever 1
8 Stopper lever spring 1
9 Collar 1
10 Shift shaft spring 1
11 Shift shaft spring stopper 1
12 Bearing 1
13 Oil seal 1
14 Bearing 1
5-68
SHIFT SHAFT
EAS30377
CHECKING THE SHIFT SHAFT TIP

1. Check: Lubricate the oil seal lips with lithium-soap-
• Shift shaft based grease.
Bends/damage/wear → Replace.
• Shift shaft spring
• Collar
EAS30378
CHECKING THE STOPPER LEVER

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

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

22 N·m (2.2 kgf·m, 16 lb·ft)
T.
R.
LOCTITE®
TIP
• Hook the end of the shift shaft spring “3” onto
the shift shaft spring stopper “1”.
• Hook the ends of the stopper lever spring “2”
onto the stopper lever “4” and the crankcase
boss “5”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
1
3
4 5
2. Install:
• Bearing
• Oil seal New
• Washer
• Circlip New
5-69
CRANKCASE
EAS20059
CRANKCASE
Removing the crankcase breather cover and switches
1st 6 N・m (0.6 kgf・m, 4.4 lb・ft) (8) 12 N・m (1.2 kgf・m, 8.9 lb・ft)
FW *2nd 3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
D Specified angle 90˚ LT
LT LT
17 N・m (1.7 kgf・m, 13 lb・ft)
70 N・m (7.0 kgf・m, 52 lb・ft)
**
E
17 N・m (1.7 kgf・m, 13 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
1.8 N・m (0.18 kgf・m, 1.3 lb・ft) 4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
** Apply Three Bond No. 1215B®

Cylinder head cover/Intake camshaft/Exhaust Refer to “CAMSHAFTS” on page 5-17.
camshaft
Cylinder head Refer to “CYLINDER HEAD” on page 5-32.
Generator rotor Refer to “GENERATOR” on page 5-43.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-49.
Water pump Refer to “WATER PUMP” on page 6-13.
Clutch housing assembly Refer to “CLUTCH” on page 5-59.
Oil strainer/Oil pump/Relief valve assembly Refer to “OIL PUMP” on page 5-53.
5-70
CRANKCASE
Removing the crankcase breather cover and switches

1st 6 N・m (0.6 kgf・m, 4.4 lb・ft) (8) 12 N・m (1.2 kgf・m, 8.9 lb・ft)
FW *2nd 3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
D Specified angle 90˚ LT
6
8
7 LT LT
17 N・m (1.7 kgf・m, 13 lb・ft)
70 N・m (7.0 kgf・m, 52 lb・ft)
**
E
5 11 10
17 N・m (1.7 kgf・m, 13 lb・ft)

4
2 10 N・m (1.0 kgf・m, 7.4 lb・ft)
3 1
LT
1.8 N・m (0.18 kgf・m, 1.3 lb・ft) 4.0 N・m (0.40 kgf・m, 3.0 lb・ft)
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific
torque.
** Apply Three Bond No. 1215B®

1 Gear position sensor 1
2 Oil pressure switch 1
3 Oil pressure switch joint 1
4 Oil filter cartridge 1
5 Oil filter cartridge union bolt 1
6 Crankcase breather cover 1
7 Crankcase breather cover gasket 1
8 Damper plate (upper crankcase) 1
9 Clutch cable holder 1
10 Neutral switch 1
11 Gasket 1
5-71
CRANKCASE
Separating the crankcase

*2nd 15 N・m (1.5 kgf・m, 11 lb・ft)
4 24 N・m (2.4 kgf・m, 18 lb・ft)
3rd Specified angle 75˚
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)
(10)
(2)
E
4 (2)
4 E
(6)
2 E (2)
LT (5)
(4)
E
3
2 (8)
1
10 N・m (1.0 kgf・m, 7.4 lb・ft) E
24 N・m (2.4 kgf・m, 18 lb・ft)

FW
D
8 N・m (0.8 kgf・m, 5.9 lb・ft)
torque.
1 Plug (oil gallery) 2
2 Plug (balancer shaft end) 2
3 Lower crankcase 1
4 Dowel pin 4
5-72
CRANKCASE
EAS30389
DISASSEMBLING THE CRANKCASE TIP

1. Place the engine upside down. Identify the position of each part very carefully so
2. Remove: that it can be reinstalled in its original place.
• Crankcase bolt (× 40)
EAS30390
TIP
CHECKING THE CRANKCASE
• Loosen each bolt 1/4 of a turn at a time, in stag- 1. Thoroughly wash the crankcase halves in a
es and in a crisscross pattern. After all of the mild solvent.
bolts are fully loosened, remove them. 2. Thoroughly clean all the gasket surfaces and
• Loosen the bolts in the proper sequence as crankcase mating surfaces.
shown. 3. Check:
• The numbers embossed on the crankcase in- • Crankcase
dicate the crankcase tightening sequence. Cracks/damage → Replace.
• Oil delivery passages
20 7 EAS30397
10 ASSEMBLING THE CRANKCASE

26 9 8 1. Lubricate:
24 30 28
• Crankshaft journal bearing inner surface
23 25 18 29 27 6 (with the recommended lubricant)
11
34 36 40 38 32
12 Engine oil
31 37 39 35 33
13 15 17 19 2. Apply:
16 22 • Sealant
14
(onto the crankcase mating surfaces)
3 21 Yamaha bond No. 1215
1 90890-85505
2 4 5
TIP
40
• Do not allow any sealant to come into contact
3. Remove: with the oil gallery or crankshaft journal bear-
• Lower crankcase ings, or balancer shaft journal bearings.
ECA13900
• Remove the sealant from the area “a” as
NOTICE
Tap on one side of the crankcase with a soft- • Make sure that the sealant does not get into
face hammer. Tap only on reinforced por- the groove “b” in the crankcase.
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
4. Remove:
• Dowel pins
5. Remove:
• Crankshaft journal lower bearing
• Balancer shaft journal bearing
(from the lower crankcase)
5-73
CRANKCASE
• Lubricate the bolts “28”, “40” mating surfaces

a a with engine oil.
• Apply the bolts “28”, “40” thread with LOC-
TITE®.
• M9 × 100 mm (3.94 in) bolts with washers:
“1”–“10” New
• M8 × 58 mm (2.28 in) bolts with new O-rings:
“11”–“18”
• M8 × 60 mm (2.36 in) bolts: “19”, “20”
• M6 × 65 mm (2.56 in) bolts: “21”, “22”
• M6 × 70 mm (2.76 in) bolt: “23”
• M6 × 60 mm (2.36 in) bolts: “24”–“27”, “35”,
“38”
• M6 × 50 mm (1.97 in) bolts: “31”–“34”
• M6 × 50 mm (1.97 in) bolts (LOCTITE®):
“28”, “40”
• M6 × 40 mm (1.57 in) bolts: “29”, “30”, “36”,
“37”, “39”
b
3. Install:
• Dowel pins 21 34
4. Set the shift drum assembly and transmission 31
15 32 33
gears in the neutral position. 17 11 13
5. Install: 18 16 23 14
12 35
• Lower crankcase “1” 30
(onto the upper crankcase “2”) 7 5 1 3 9
ECA13980
NOTICE 29 10 4 2 6 8
Before tightening the crankcase bolts, make 28 26 24 22
sure the transmission gears shift correctly 25 19
when the shift drum assembly is turned by 27
hand.
38 20
40
39 37 36
1
40
7. Tighten:
• Crankcase bolts “1”–“10”
2
Crankcase bolts “1”–“10”
1st: 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
6. Install: *2nd: 15 N·m (1.5 kgf·m, 11 lb·ft)

• Crankcase bolt (× 40) 3rd: Specified angle 75°
TIP *
Following the tightening order, loosen the
• Lubricate the bolts “1”–“10” thread, mating sur- bolt one by one and then retighten it to the
faces and washers with engine oil. specific torque.
• Lubricate the bolts “11”–“18” thread, mating
surfaces and O-rings with engine oil.
• Lubricate the bolts “19”–“27”, “29”–“39” thread
and mating surfaces with engine oil.
5-74
CRANKCASE
EWA16610
WARNING
If the bolt is tightened more than the speci-
fied angle, do not loosen the bolt and then re- 21 34
31
tighten it. Instead, replace the bolt with a new 15 32 33
one and perform the procedure again. 17 11 13
ECA20890 18 16 23 12 14 35
NOTICE 30
Do not use a torque wrench to tighten the
bolt to the specified angle. 29
TIP 28 26 24 22
25 19
Tighten the bolts in the tightening sequence cast 27
on the crankcase.
38 20
40
39 37 36
30
EAS31718
INSTALLING THE CRANKCASE BREATHER

7 5 1 3 9
COVER
1. Install:
10 4 2 6 8
• Crankcase breather cover
• Crankcase breather cover bolt New
2. Tighten:
• Crankcase breather cover bolt
Crankcase breather cover bolt

1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
*2nd: 3.0 N·m (0.30 kgf·m, 2.2

lb·ft)
10 Specified angle 90°
8. Tighten: *Following the tightening order, loosen the

• Crankcase bolts “11”–“40” bolt one by one and then retighten it to the
Crankcase bolts “11”–“20”
24 N·m (2.4 kgf·m, 18 lb·ft) TIP
T.
R.
Crankcase bolts “21”–“40” Tighten the crankcase breather cover bolts in

10 N·m (1.0 kgf·m, 7.4 lb·ft) the tightening sequence as shown.
TIP 2
Tighten the bolts “11”–“18” in the tightening se- 1 3
quence cast on the crankcase.
4
8
7 5
6
5-75
CRANKCASE
EAS31071
INSTALLING THE OIL PRESSURE SWITCH Gear position sensor bolt

1. Install: 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
• Oil pressure switch “1” LOCTITE®
• Oil pressure switch lead “2”
TIP
Oil pressure switch
• Lubricate the O-ring with lithium-soap-based
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
grease.
R.
Oil pressure switch lead bolt

1.8 N·m (0.18 kgf·m, 1.3 lb·ft) • Fit the end “a” of the shift drum assembly into
the opening “b” in the gear position sensor “1”.
TIP
• Apply Three Bond No. 1215B® to the threads 1
“a” of the oil pressure switch. However, do not
apply Three Bond No. 1215B® to the portion
“b” of the oil pressure switch.
• Install the oil pressure switch lead so that it is
routed within the range shown in the illustra-
tion. a
b
a
b
53˚
EAS31658
INSTALLING THE GEAR POSITION SENSOR

ECA22630
NOTICE
To prevent damage to the gear position sen-
sor, keep magnets (including any pickup tool
with a magnet, magnetized screwdrivers,
etc.) away from the gear position sensor.
1. Install:
• O-ring New
• Gear position sensor “1”
5-76
CONNECTING RODS AND PISTONS
EAS20132

Removing the connecting rods and pistons
1st 25 N・m (2.5 kgf・m, 18 lb・ft)

2nd Specified angle 180˚
(8)
1
2
E
3
4
13 E
5
13
6
12 5
7
E
10
E
9
11 E 8 FW
D

Lower crankcase Refer to “CRANKCASE” on page 5-70.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Big end upper bearing 4
4 Connecting rod 4
5 Piston pin clip 8
6 Piston pin 4
7 Piston 4
8 Top ring 4
9 2nd ring 4
10 Oil ring 4
11 Cylinder 1
12 Cylinder gasket 1
13 Dowel pin 2
5-77
EAS30745
REMOVING THE CONNECTING RODS AND Piston pin clip rotation tool
PISTONS 90890-04175
The following procedure applies to all of the con- YM-04175
necting rods and pistons.
1. Remove:
• Connecting rod cap e
• Connecting rod
• Big end bearings
TIP
• Identify the position of each big end bearing so
that it can be reinstalled in its original place.
• After removing the connecting rods and con- d 2
necting rod caps, care should be taken not to
damage the mating surfaces of the connecting
rods and connecting rod caps. c. Turn the piston pin clip rotation tool “2” so
that the piston pin clip ends are positioned
2. Remove:
at “a” or “b”.
• Piston pin clip “1”
a. Make sure that the piston pin clip ends are
in either the “a” or “b” position in relation to
the cutout “c”.
TIP
If the piston pin clip ends are not positioned at
“a” or “b”, adjust the piston pin clip ends position 2
by following steps (b) to (c).
1 1
c a b c
a b
1
d. Remove the piston pin clip “1” using long-
nose pliers or a similar tool.
TIP
When removing the piston pin clip, hold the pis-
ton pin clip in place with your fingers because it
can easily spring.
b. Install the piston pin clip rotation tool “2” to

the piston pin clip.
TIP
When installing the piston pin clip rotation tool,
align the projection “d” on the piston pin clip ro-
tation tool with the clip ends “e”.
5-78
G088999
EAS30747
3. Remove:
CHECKING THE CYLINDER AND PISTON
• Piston pin “1”
1. Check:
• Piston “2”
ECA13810
• Piston wall
NOTICE • Cylinder wall
Do not use a hammer to drive the piston pin Vertical scratches → Replace the cylinder
out. block, and replace the pistons and piston
rings as a set.
TIP 2. Measure:
• For reference during installation, put identifica- • Piston-to-cylinder clearance
tion marks on the piston crown. a. Measure cylinder bore “C” with the cylin-
• Before removing the piston pin, deburr the pis- der bore gauge.
ton pin clip groove and the piston pin bore ar- TIP
ea. If both areas are deburred and the piston Measure cylinder bore “C” by taking side-to-side
pin is still difficult to remove, remove it with the and front-to-back measurements of the cylinder.
piston pin puller set “3”.
Bore
Piston pin puller set 79.000–79.010 mm (3.1102–
90890-01304 3.1106 in)
Piston pin puller Wear limit
YU-01304 79.060 mm (3.1126 in)
“C” = maximum of D1, D2, D3, D4, D5, D6

2 1
G088998 3
4. Remove:
• Top ring G089000
• 2nd ring b. If out of specification, replace the cylinder,

• Oil ring and replace the piston and piston rings as
TIP a set.
When removing a piston ring, open the end gap c. Measure piston skirt diameter “P” with the
with your fingers and lift the other side of the ring micrometer.
over the piston crown.
5-79
Piston Piston ring

Diameter Top ring
78.961–78.994 mm (3.1087– Ring side clearance
3.1100 in) 0.030–0.065 mm (0.0012–
0.0026 in)
Side clearance limit
0.115 mm (0.0045 in)
a 2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–
P 0.0022 in)
Side clearance limit
0.115 mm (0.0045 in)
a. 8.0 mm (0.31 in) from the bottom edge of the

piston
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 “C” - G089002
Piston skirt diameter “P”
2. Install:
• Piston ring
Piston-to-cylinder clearance (into the cylinder)
0.006–0.049 mm (0.0002–0.0019 TIP
in)
Use the piston crown to level the piston ring near
bottom of cylinder “a”, where cylinder wear is
f. If out of specification, replace the cylinder,
lowest.
and replace the piston and piston rings as
a set. 3. Measure:
EAS30748
• Piston ring end gap
CHECKING THE PISTON RINGS Out of specification → Replace the piston
1. Measure: ring.
• Piston ring side clearance TIP
Out of specification → Replace the piston The oil ring expander spacer’s end gap cannot
and piston rings as a set. be measured. If the oil ring rail’s gap is exces-
TIP sive, replace all three piston rings.
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston Top ring
ring grooves and piston rings. End gap limit
0.50 mm (0.0197 in)
2nd ring
End gap limit
1.15 mm (0.0453 in)
5-80
b b
G089005
3. Calculate:
b. Upper of cylinder
• Piston-pin-to-piston-pin-bore clearance
EAS30749 Out of specification → Replace the piston pin
CHECKING THE PISTON PIN and piston as a set.
The following procedure applies to all of the pis- Piston-pin-to-piston-pin-bore clearance = Piston
ton pins. pin bore inside diameter “b” - Piston pin outside
1. Measure: diameter “a”
• Piston pin outside diameter “a”
Out of specification → Replace the piston pin. Piston-pin-to-piston-pin-bore
clearance
Piston pin outside diameter
0.002–0.022 mm (0.0001–0.0009
16.991–17.000 mm (0.6689–
in)
0.6693 in)
Limit
EAS30750
16.971 mm (0.6681 in) CHECKING THE CONNECTING RODS
1. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.
Oil clearance
0.033–0.057 mm (0.0013–0.0022
in)

G089004
connecting rods.
2. Measure: ECA13930
• Piston pin bore inside diameter “b” NOTICE

Out of specification → Replace the piston. Do not interchange the big end bearings and
connecting rods. To obtain the correct
Piston pin bore inside diameter crankshaft-pin-to-big-end-bearing clear-
17.002–17.013 mm (0.6694– ance and prevent engine damage, the big
0.6698 in) end bearings must be installed in their origi-
Limit nal positions.
17.043 mm (0.6710 in)
a. Clean the big end bearings, crankshaft
pins, and the connecting rods with oil
cleaner.
TIP
When cleaning the connecting rod, clean the
bearing surface “a” of the connecting rod bolt
and threads “b”.
5-81
a
b
1
a b
b. Wait five minutes to dry the remaining oil

cleaner component.
c. Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap with
the connecting rod big end metal installer
1
“1”.
TIP
2
• From the 3 types, choose the connecting rod
big end metal installer “1” that fits exactly, and
install it to the connecting rod and connecting d. Put a piece of Plastigauge® “1” on the
rod cap as shown in the illustration. crankshaft pin.
• Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rod
1
and connecting rod cap.
• Push the big end bearing “2” down and install it
to the connecting rod and connecting rod cap.
Connecting rod big end bearing

installer
90890-04193 G089008
installer e. Assemble the connecting rod halves.
ECA18390
YM-04193
NOTICE
Tighten the connecting rod bolts using the
plastic-region tightening angle method. Al-
1
ways install new bolts.
TIP
• Install the new connecting rod bolt without
cleaning and without any oil.
• Make sure that the projection “a” on the con-
necting rod cap faces the same direction as the
1
“ ” mark “b” on the connecting rod.
• After installing the big end bearing, assemble
the connecting rod and connecting rod cap
without installing them onto the crankshaft.
5-82
• Make sure the “ ” marks “b” on the connecting

b rods face towards the left side of the crank-
shaft.
a • Install the connecting rod so that the Plasti-
gauge® is in position “c” or “d”.
b
a
TIP
Install by carrying out the following procedures in
order to assemble in the most suitable condition.
f. Tighten the connecting rod bolt while
checking that the sections shown “a” and
“b” are flush with each other by touching
the surface.
Connecting rod bolt

30 N·m (3.0 kgf·m, 22 lb·ft) d
T.
R.
c
TIP
To install the connecting rod cap, care should be
taken not to install it at an angle and the position
should not be out of alignment.
h. Tighten the connecting rod bolts with a
b torque wrench.
Connecting rod bolt (1st)

25 N·m (2.5 kgf·m, 18 lb·ft)
T.
R.
i. Put a mark “1” on the corner of the con-

necting rod bolt “2” and the connecting rod
a cap “3”.
a. Side machined face

b. Thrusting faces
g. Loosen the connecting rod bolt, remove
the connecting rod and connecting rod
cap and install these parts to the crank-
shaft with the big end bearing kept in the
current condition.
TIP
• Do not move the connecting rod or crankshaft j. Tighten the connecting rod bolts further to
until the clearance measurement has been reach the specified angle 175°–185° with
completed. torque wrench, and then confirm that the
• Make sure that the projection “a” on the con- torque value is within the range of 40 N·m
necting rod cap faces the same direction as the (4.0 kgf·m, 30 lb·ft) to 85 N·m (8.5 kgf·m,
“ ” mark “b” on the connecting rod. 63 lb·ft) with keeping the torque wrench
5-83
175°–185°. If torque is out of range, re- 2. Select:

place the connecting rod bolt to new one • Big end bearings (P1–P4)
and repeat from step (h). TIP
Connecting rod bolt (final) • The numbers “A” stamped into the crankshaft
Specified angle 175°–185° web and the numbers “1” on the connecting
T.
R.
rods are used to determine the replacement

big end bearings sizes.
• “P1”–“P4” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P1” and
the crankshaft web “P1” numbers are 6 and 2
respectively, then the bearing size for “P1” is:
“P1” (connecting rod) - “P1” (crankshaft web) = 6 -
180˚
2 = 4 (green)
EWA16610
WARNING Bearing color code

If the bolt is tightened more than the speci- Code 1
fied angle, do not loosen the bolt and then re- Blue
Code 2
tighten it. Instead, replace the bolt with a new
Black
one and perform the procedure again. Code 3
k. After the installation, check that the sec- Brown
tion shown “a” is flush with each other by Code 4
touching the surface. Green
Code 5
Yellow
Code 6
Pink
a P3
P1 P4
l. Remove the connecting rod and big end P2
bearings.
m. Measure the compressed Plastigauge®
width on the crankshaft pin. If the crank-
shaft-pin-to-big-end-bearing clearance is
out of specification, select replacement P1 P2 P3 P4
big end bearings.
5-84
a b
1
EAS30751
INSTALLING THE CONNECTING ROD AND

1
PISTON
The following procedure applies to all of the con-
necting rods and pistons.
1. Install:
• Big end bearings
• Connecting rod cap
(onto the connecting rod) 1
TIP
• Clean the big end bearings, crankshaft pins,
and the connecting rods with oil cleaner, and c
then wait five minutes to dry the remaining oil
d
cleaner component.
• When cleaning the connecting rod, clean the
bearing surface “a” of the connecting rod bolt
and threads “b”.
• Be sure to reinstall each big end bearing in its
original place.
• From the 3 types, choose the connecting rod
big end metal installer “1” that fits exactly, and
install it to the connecting rod and connecting
rod cap as shown in the illustration.
• Align the projections “c” on the big end bear-
ings with the notches “d” in the connecting rods
and connecting rod caps.
• Push the big end bearing “2” down and install it 1
to the connecting rod and connecting rod cap.
• Make sure that the projection “e” on the con- 2
“ ” mark “f” on the connecting rod.
f
installer e
90890-04193
installer
YM-04193
5-85
2. Tighten: 3. Install:
• Connecting rod bolts New • Top ring “1”
ECA18390 (into the piston)
NOTICE • 2nd ring “2”
Tighten the connecting rod bolts using the • Upper oil ring rail “3”
plastic-region tightening angle method. Al- • Oil ring expander “4”
ways install new bolts. • Lower oil ring rail “5”
TIP
TIP
Be sure to install the piston rings so that the
• Install by carrying out the following procedures
manufacturer’s marks or numbers “a” face up.
in order to assemble in the most suitable con-
dition.
• Install the new connecting rod bolt without
cleaning and without any oil.
a. Replace the connecting rod bolts with new
ones.
b. After installing the big end bearing, as-
semble the connecting rod and connecting
rod cap without installing them onto the
crankshaft. G089011
c. Tighten the connecting rod bolt while
4. Install:
checking that the sections shown “a” and
• Piston “1”
“b” are flush with each other by touching
(onto the respective connecting rod “2”)
the surface.
• Piston pin “3”
Connecting rod bolt TIP
30 N·m (3.0 kgf·m, 22 lb·ft) • Apply engine oil onto the piston pin.
T.
R.
• Make sure that the “ ” mark “a” on the connect-

TIP ing rod faces left when the punch mark “b” on
To install the connecting rod cap, care should be the piston is pointing up as shown.
taken not to install it at an angle and the position • Reinstall each piston into its original cylinder.
should not be out of alignment.
a b
b
1
2
3
a
5. Install:
a. Side machined face • Piston pin clip “1” New
b. Thrusting faces a. Install the piston pin clip “1” in the piston as
d. Loosen the connecting rod bolt, remove
the connecting rod and connecting rod TIP
cap and install these parts to the crank- When installing the first piston pin clip, place oth-
shaft with the big end bearing kept in the er piston pin “2” under the piston pin as shown in
current condition. the illustration.
5-86
3
2
TIP d. Make sure the piston pin clip “1” is posi-

Align the piston pin clip end with the position “a”. tioned as shown in the illustration.
a 1
1
e. Install the piston pin clip installer tool “4”

b. Push the piston pin clip insertion tool “3” in onto the piston.
the direction as shown in the illustration
and place the piston pin clip into the piston Piston pin clip installer tool
pin bore. 90890-04174
TIP YM-04174
Push in the piston pin clip insertion tool while f. While holding the piston clip installer tool,
holding it parallel with the upper surface of the turn it counterclockwise “c”, to completely
piston and rear surface of the piston pin clip in- install the piston pin clip in the piston.
sertion tool.
Piston pin clip insertion tool 4

90890-04173
c
YM-04173
g. Make sure that the piston pin clip “1” is in

the groove “d”.
c. Install the piston pin clip to the piston by

pressing the portion “b” on the piston pin
clip insertion tool “3” in the direction shown
in the illustration.
5-87
TIP
d 1 • While holding the piston rings with the hand, in-
stall the piston assembly into the cylinder from
underneath.
• Install the piston assembly into the cylinder so
that the piston ring end gap is aligned with the
cylinder skirt “a”.
1
6. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant) a
Recommended lubricant 2
Engine oil
10.Install:
7. Offset:
• Cylinder gasket New
• Piston ring end gaps
• Dowel pins
• Cylinder assembly
d • Connecting rod caps
• Connecting rod bolts
TIP
• Make sure the “ ” marks “a” on the connecting
b,e a,c rods face towards the left side of the crank-
shaft.
• Make sure that the projection “b” on the con-
“ ” mark “a” on the connecting rod.
a. Top ring
b. 2nd ring
a
c. Upper oil ring rail
d. Oil ring expander b
e. Lower oil ring rail
A. Exhaust side
8. Lubricate:
• Crankshaft pins
• Connecting rod big end bearing inner surface
and side surface
(with the recommended lubricant)
11.Tighten:
Recommended lubricant • Connecting rod bolts “1”
Engine oil
9. Install:
• Piston assemblies “1”
(into the cylinder “2”)
5-88
180˚
EWA16610
WARNING
TIP If the bolt is tightened more than the speci-
Tighten the connecting rod bolts using the fol- fied angle, do not loosen the bolt and then re-
lowing procedure. tighten it. Instead, replace the bolt with a new
a. Tighten the connecting rod bolts with a one and perform the procedure again.
torque wrench. d. After the installation, check that the sec-
tion shown “a” is flush with each other by
Connecting rod bolt (1st) touching the surface.
25 N·m (2.5 kgf·m, 18 lb·ft) EWA17120
T.
R.
WARNING
b. Put a mark “1” on the corner of the con- If the connecting rod and cap are not flush
necting rod bolt “2” and the connecting rod with each other, remove the connecting rod
cap “3”. bolts and big end bearing and restart from
step (1). In this case, make sure to replace
the connecting rod bolts.
c. Tighten the connecting rod bolts further to

a
reach the specified angle 175°–185° with
torque wrench, and then confirm that the
torque value is within the range of 40 N·m
(4.0 kgf·m, 30 lb·ft) to 85 N·m (8.5 kgf·m,
63 lb·ft) with keeping the torque wrench
175°–185°. If torque is out of range, re-
place the connecting rod bolt to new one
and repeat from step (a).
Connecting rod bolt (final)

Specified angle 175°–185°
T.
R.
5-89
CRANKSHAFT AND BALANCER SHAFT
EAS20178

Removing the crankshaft and balancer shaft
9 5
3.0 N・m (0.30 kgf・m, 2.2 lb・ft)
9
4
E
2
1
E LT
6
2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
8 E 3
E
FW
D

Refer to “REMOVING THE CONNECTING
Connecting rod RODS AND PISTONS” on page 5-78.
1 Balancer shaft 1
2 Balancer shaft journal lower bearing 4
3 Balancer shaft journal upper bearing 4
4 Crankshaft 1
5 Crankshaft journal lower bearing 5
6 Crankshaft journal upper bearing 5
7 Thrust bearing 2
8 Oil nozzle 1 4
9 Oil nozzle 2 5
5-90
EAS31171
2. Check:
REMOVING THE CRANKSHAFT AND
• Crankshaft journal surfaces
BALANCER SHAFT
• Crankshaft pin surfaces
1. Remove:
Scratches/wear → Replace the crankshaft.
• Balancer shaft “1”
• Bearing surfaces
• Balancer shaft journal bearing
Scratches/wear → Replace the crankshaft
• Crankshaft assembly “2”
journal bearing.
• Crankshaft journal bearings
3. Measure:
TIP • Crankshaft-journal-to-crankshaft-journal-
Identify the position of each balancer shaft jour- bearing clearance
nal bearings and crankshaft journal bearings so Out of specification → Replace the crank-
that it can be reinstalled in its original place. shaft journal bearings.
Journal oil clearance

0.025–0.043 mm (0.0010–0.0017
in)
ECA13920
NOTICE
2 Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
1
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
EAS31174
CHECKING THE OIL NOZZLES their original positions.

The following procedure applies to all of the oil a. Clean the crankshaft journal bearings,
nozzles. crankshaft journals, and bearing portions
1. Check: of the crankcase.
• Oil nozzle 1 b. Place the upper crankcase upside down
• Oil nozzle 2 on a bench.
Damage/wear → Replace the oil nozzle. c. Install the crankshaft journal upper bear-
• Oil passage ings “1” and the crankshaft into the upper
Obstruction → Blow out with compressed air. crankcase.
EAS31075
TIP
CHECKING THE CRANKSHAFT Align the projections “a” on the crankshaft jour-
1. Measure: nal upper bearings with the notches “b” in the up-
• Crankshaft runout per crankcase.
Out of specification → Replace the crank-
shaft.
Runout limit 1
0.030 mm (0.0012 in) a
b
G089019
d. Put a piece of Plastigauge® “1” on each

crankshaft journal.
TIP
G089018
Do not put the Plastigauge® over the oil hole in
the crankshaft journal.
5-91
4. Select:
1 • Crankshaft journal bearings (J1–J5)
TIP
• The numbers “A” stamped into the crankshaft
web and the numbers “B” stamped into the
lower crankcase are used to determine the re-
placement crankshaft journal bearing sizes.
• “J1”–“J5” refer to the bearings shown in the
G089020 crankshaft and lower crankcase illustration.
e. Install the crankshaft journal lower bear- For example, if the crankcase “J1” and crank-
ings “1” into the lower crankcase and as- shaft web “J1” numbers are 5 and 2 respec-
semble the crankcase halves. tively, then the bearing size for “J1” is:
TIP
“J1” (crankcase) - “J1” (crankshaft web) + 4 = 5 - 2
• Align the projections “a” of the crankshaft jour-
+ 4 = 7 (red)
nal lower bearings with the notches “b” in the
lower crankcase.
• Do not move the crankshaft until the clearance Bearing color code
measurement has been completed. Code 0
White
Code 1
Blue
Code 2
1
Black
a Code 3
b Brown
Code 4
Green
Code 5
G089019 Yellow
Code 6
f. Tighten the bolts to specification in the Pink
tightening sequence cast on the crank-
case.
Refer to “CRANKCASE” on page 5-70.
g. Remove the lower crankcase and the
crankshaft journal lower bearings.
h. Measure the compressed Plastigauge®
width “a” on each crankshaft journal. J1 J2 J3 J4 J5
If the crankshaft-journal-to-crankshaft-
journal-bearing clearance is out of specifi-
cation, select replacement crankshaft
journal bearings.
J1 J2 J3 J4 J5
a
G089021
5-92
ing clearance and prevent engine damage,

the balancer shaft journal bearings must be
installed in their original positions.
a. Clean the balancer shaft journal bearings,
balancer shaft journals, and bearing por-
tions of the crankcase.
b. Place the upper crankcase upside down
on a bench.
c. Install the balancer shaft journal upper
J1 J2 J3 J4 J5 bearings “1” and the balancer shaft into
EAS31076
the upper crankcase.
CHECKING THE BALANCER SHAFT TIP
1. Measure: Align the projections “a” on the balancer shaft
• Balancer shaft runout journal upper bearings with the notches “b” in the
Out of specification → Replace the balancer upper crankcase.
shaft.
Balancer shaft runout limit

0.030 mm (0.0012 in) 1
a
b
G089019
d. Put a piece of Plastigauge® “1” on each

balancer shaft journal.
TIP
Do not put the Plastigauge® over the oil hole in
2. Check: the balancer shaft journal.
• Balancer shaft journal surfaces
Scratches/wear → Replace the balancer 1
shaft.
• Bearing surfaces
Scratches/wear → Replace the balancer
shaft journal bearing.
3. Measure:
• Balancer shaft journal-to-balancer shaft jour-
nal bearing clearance
Out of specification → Replace the balancer G089020
shaft journal bearings. e. Install the balancer shaft journal lower
Balancer shaft journal to balanc- bearings “1” into the lower crankcase and
er shaft bearing clearance assemble the crankcase halves.
0.028–0.046 mm (0.0011–0.0018 TIP
in) • Align the projections “a” of the balancer shaft
ECA18400
journal lower bearings with the notches “b” in
NOTICE the crankcase.
• Do not move the balancer shaft until the clear-
Do not interchange the balancer shaft jour- ance measurement has been completed.
nal bearings. To obtain the correct balancer
shaft-journal-to-balancer shaft-journal-bear-
5-93
Bearing color code

Code 0
1 White
a Code 1
Blue
b Code 2
Black
Code 3
Brown
G089019
Code 4
f. Tighten the bolts to specification in the Green
tightening sequence cast on the crank- Code 5
case. Refer to “CRANKCASE” on page Yellow
5-70. Code 6
g. Remove the lower crankcase and the bal- Pink
ancer shaft journal lower bearings.
h. Measure the compressed Plastigauge®
width “a” on each balancer shaft journal. If
the balancer shaft-journal-to-balancer
shaft-journal-bearing clearance is out of
specification, select replacement balancer
J1 J2 J3 J4
shaft journal bearings.
J1 J2 J3 J4
G089021
4. Select:
• Balancer shaft journal bearing (J1–J4)
TIP
• The numbers “A” stamped into the balancer
shaft web and the numbers “B” stamped into
the lower crankcase are used to determine the
replacement balancer shaft journal bearing siz-
es.
• “J1”–“J4” refer to the bearings shown in the bal-
ancer shaft and lower crankcase illustration.
For example, if the crankcase “J1” and bal-
ancer shaft web “J1” numbers are 6 and 2 re-
spectively, then the bearing size for “J1” is:
J1 J2 J3 J4
“J1” (crankcase) - “J1” (balancer shaft web) - 1 =
EAS31077
6 - 2 - 1 = 3 (brown)
INSTALLING THE CRANKSHAFT
1. Install:
• Crankshaft journal upper bearings
(into the upper crankcase)
5-94
• Crankshaft journal lower bearings TIP

(into the lower crankcase) When installing the thrust bearing, shift the
• Crankshaft crankshaft to the left to widen the gap between
TIP the crankshaft and the crankcase.
• Align the projections “a” on the crankshaft jour-
nal bearings “1” with the notches “b” in the 1
crankcase.
• Be sure to install each crankshaft journal bear-
ings in its original place.
1
a
b b. Insert the thrust bearing “2” into the slot of
the upper crankcase as shown in the illus-
tration and slide it in the direction of the ar-
G089019 row.
TIP
EAS31799
INSTALLING THE THRUST BEARING When installing thrust bearing “2”, shift the
1. Install: crankshaft to the right to widen the gap between
• Thrust bearing “1” the crankshaft and the crankcase.
TIP
• Install the thrust bearings to the both side of the 2
journal #4 of the upper crankcase.
• The thickness of the thrust bearing is only one.
No need to adjust the clearance between the
thrust bearing and the crankshaft.
• Install the thrust bearing with the grooves “a”
side is facing the crankshaft.
• Apply engine oil on the grooves “a” side of the
thrust bearing.
c. Check that the thrust bearing is inserted
1 a properly into the groove of the crankcase.
a. Insert the thrust bearing “1” into the slot of

the upper crankcase as shown in the illus-
tration and slide it in the direction of the ar- EAS31172
row. INSTALLING THE BALANCER ASSEMBLY

1. Install:
• Balancer shaft journal upper bearings
(into the upper crankcase)
5-95
• Balancer shaft journal lower bearings

(into the lower crankcase)
TIP
• Align the projections “a” on the balancer shaft
journal bearings “1” with the notches “b” in the
crankcases.
• Be sure to install each balancer shaft journal
bearing in its original place.
1
a
b
G089019
2. Install:
• Balancer shaft
TIP
Install by aligning the crankshaft match mark “a”
and the balancer shaft match marks “b”.
a
b
5-96
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
5
E
1 6
E
13 8
E
9
LT
LT
12 N・m (1.2 kgf・m, 8.9 lb・ft) E
13
7
3
10 N・m (1.0 kgf・m, 7.4 lb・ft)
4
E
3
4 2
LT
12
10
D LT
FW 11
LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1 Drive axle assembly 1
2 Shift drum retainer 2
3 Spring 2
4 Shift fork guide bar 2
5 Shift fork-L 1
6 Shift fork-R 1
7 Shift drum assembly 1
8 Shift fork-C 1
9 Main axle assembly 1
11 O-ring 3
12 Oil baffle plate 1
13 Bearing 2
5-97
TRANSMISSION
Disassembling the main axle assembly
1
2
3
4
5
M
9
6
7 M
8 M
10 15
M 11
12 14
13
D
FW
E

Make sure the chamfered side of the pinion
1 2nd pinion gear 1 gear faces to the left.
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Collar 1
6 Washer 1
7 Circlip 1
8 3rd pinion gear 1
9 Circlip 1
10 Washer 1
11 5th pinion gear 1
12 Collar 1
13 Bearing housing 1
14 Bearing 1
15 Main axle 1
5-98
TRANSMISSION
Disassembling the drive axle assembly
12 M
11
10
9 M
8
7
6
5
M M
4
3
2
M
M
D
FW
E
M
1

1 Circlip 1
2 Bearing 1
3 Washer 1
4 1st wheel gear 1
5 Collar 1
6 5th wheel gear 1
7 Circlip 1
8 Washer 1
9 3rd wheel gear 1
10 Collar 1
11 Toothed lock washer 1
12 Toothed lock washer retainer 1
5-99
TRANSMISSION
Disassembling the drive axle assembly

22
23
25
E
26
21
16 24 20
15 19
14 18
13 17
M
M M
M
D
FW
E
M

13 4th wheel gear 1
14 Collar 1
15 Washer 1
16 Circlip 1
17 6th wheel gear 1
18 Circlip 1
19 Washer 1
20 2nd wheel gear 1
21 Collar 1
22 Collar 1
23 Oil seal 1
24 Circlip 1
25 Bearing 1
26 Drive axle 1
5-100
TRANSMISSION
EAS30430 EAS30431
REMOVING THE TRANSMISSION CHECKING THE SHIFT FORKS

1. Remove: The following procedure applies to all of the shift
• Drive axle assembly “1” forks.
• Shift drum retainers “2” 1. Check:
• Shift fork guide bars • Shift fork cam follower “1”
• Shift fork-L • Shift fork pawl “2”
• Shift fork-R Bends/damage/scoring/wear → Replace the
• Shift drum assembly shift fork.
• Shift fork-C
1
G089022
2
2. Check:
2. Remove: • Shift fork guide bar
• Bearing housing “1” Roll the shift fork guide bar on a flat surface.
• Main axle assembly “2” Bends → Replace.
a. Insert two bolts “3” of the proper size, as EWA12840
shown in the illustration, into the main axle WARNING

assembly bearing housing. Do not attempt to straighten a bent shift fork
guide bar.
1 2 3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
b. Tighten the bolts until they contact the

crankcase surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
3. Remove: G089023
• Oil delivery pipe 3 “1” 4. Check:

• Bearings “2” • Shift fork guide bar (for the shift fork-C) oil
passage
2 Clogging/damage → Replace the shift fork
1 guide bar (for the shift fork-C).
EAS30432
CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
• Shift drum groove
Damage/scratches/wear → Replace the shift
drum assembly.
5-101
TRANSMISSION
• Shift drum segment “1” 3. Check:

Damage/wear → Replace the shift drum as- • Transmission gears
sembly. Blue discoloration/pitting/wear → Replace
• Shift drum bearing “2” the defective gear(s).
Damage/pitting → Replace the shift drum as- • Transmission gear dogs
sembly. Cracks/damage/rounded edges → Replace
the defective gear(s).
G089024
G089025
EAS30433
CHECKING THE TRANSMISSION 4. Check:

1. Measure: • Transmission gear engagement
• Main axle runout (each pinion gear to its respective wheel
(with a centering device and dial gauge “1”) gear)
Out of specification → Replace the main axle. Incorrect → Reassemble the transmission
axle assemblies.
Main axle runout limit 5. Check:
0.08 mm (0.0032 in) • Transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
1
• Circlips
Bends/damage/looseness → Replace.
EAS30435
ASSEMBLING THE MAIN AXLE AND DRIVE

AXLE
1. Install:
• Toothed washer “1”
2. Measure: • Circlip “2” New
• Drive axle runout TIP
(with a centering device and dial gauge “1”) • Be sure the circlip sharp-edged corner “a” is
Out of specification → Replace the drive axle. positioned opposite side to the toothed washer
and gear.
Drive axle runout limit • Install the circlip so that a spline “b” is in the
0.08 mm (0.0032 in) center of the gap between the circlip ends “c”
as shown.
5-102
TRANSMISSION
B c
1 b
2 2
1
a
b
A. Main axle
c
B. Drive axle
EAS30438
INSTALLING THE TRANSMISSION

1. Install:
• Oil delivery pipe 3 “2”
TIP
b
Face the seal side of bearing to the outside.
2. Install:
• Toothed lock washer retainer “1”
Oil delivery pipe 3 bolt
• Toothed lock washer “2” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP LOCTITE®
• With the toothed lock washer retainer in the
groove “a” in the axle, align the projection on
the retainer with an axle spline, and then install 1
the toothed lock washer. 2
• Be sure to align the projection on the toothed
lock washer that is between the alignment
marks “b” with the alignment mark “c” on the re-
tainer.
A
c 1
2 b
2. Install:
2 • Main axle assembly “1”
1
• Bearing housing “2”
Main axle bearing housing bolt

a 12 N·m (1.2 kgf·m, 8.9 lb·ft)
T.
R.
LOCTITE®
b
2 1
5-103
TRANSMISSION
3. Install: • Oil seal New

• Shift fork-C “1”
• Circlip “4” New
• Shift drum assembly “2”
• Drive axle assembly “5”
• Shift fork guide bar “3”
TIP Shift drum retainer bolt
• The embossed marks on the shift forks should 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
face towards the right side of the engine and be LOCTITE®
in the following sequence: “R”, “C”, “L”.
• Carefully position the shift forks so that they TIP
are installed correctly into the transmission • Install shift fork-R into the groove “a” in the 5th
gears. wheel gear and shift fork-L into the groove “b”
• Install shift fork-C into the groove “a” in the 3rd in the 6th wheel gear on the drive axle.
pinion gear on the main axle. • Install the shift drum retainer with its “OUT”
• Install the shift fork guide bar “3” in the crank- mark “c” facing outward.
case with the cap “b” facing toward the direc- • Make sure that the projection “d” on the drive
tion shown in the illustration. axle assembly is inserted into the slot in the
crankcase.
• Make sure that the drive axle bearing circlip “4”
is inserted into the groove “e” in the upper
a crankcase.
a b 5
2 3
1
4
1 2 e
d
3
c
3
b
3 5. Check:
b
• Transmission
Rough movement → Repair.
TIP
Oil each gear, shaft, and bearing thoroughly.
4. Install:
• Shift fork-R “1”
• Shift fork-L “2”
• Shift fork guide bar
• Shift drum retainers “3”
• Bearing
5-104
TRANSMISSION
5-105
COOLING SYSTEM
COOLING SYSTEM DIAGRAMS .................................................................... 6-1
RADIATOR ...................................................................................................... 6-3

REMOVING THE RADIATOR ...................................................................6-5
CHECKING THE RADIATOR.................................................................... 6-5
INSTALLING THE RADIATOR..................................................................6-5
OIL COOLER...................................................................................................6-7
CHECKING THE OIL COOLER ................................................................6-8
INSTALLING THE OIL COOLER .............................................................. 6-8
THERMOSTAT ................................................................................................6-9
REMOVING THE THERMOSTAT ASSEMBLY....................................... 6-11
CHECKING THE THERMOSTAT............................................................ 6-11
ASSEMBLING THE THERMOSTAT ASSEMBLY................................... 6-11
INSTALLING THE THERMOSTAT ASSEMBLY ..................................... 6-11
WATER PUMP...............................................................................................6-13
DISASSEMBLING THE WATER PUMP.................................................. 6-15
CHECKING THE WATER PUMP ............................................................ 6-15
ASSEMBLING THE WATER PUMP........................................................ 6-15
INSTALLING THE WATER PUMP .......................................................... 6-16
6
COOLING SYSTEM DIAGRAMS
EAS20299

5. Radiator
7. Water pump
6-1

2. Radiator
7. Water pump
6-2
RADIATOR
EAS20063
RADIATOR
Removing the radiator
8 N・m (0.8 kgf・m, 5.9 lb・ft)
8 N・m (0.8 kgf・m, 5.9 lb・ft)
FW
D

Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
6-3
RADIATOR
Removing the radiator

8 N・m (0.8 kgf・m, 5.9 lb・ft)
8 10
7 10
9
3
8 N・m (0.8 kgf・m, 5.9 lb・ft)
FW
D
7 N・m (0.7 kgf・m, 5.2 lb・ft) 2 10 N・m (1.0 kgf・m, 7.4 lb・ft)

1 Coolant reservoir hose 1 Disconnect.
2 Coolant reservoir 1
3 Coolant reservoir cap 1
4 Radiator cap 1
5 Radiator fan motor coupler 2 Disconnect.
6 Cooling system air bleed hose 1 Disconnect.
7 Radiator outlet hose 1 Disconnect.
8 Radiator inlet hose 1 Disconnect.
9 Radiator 1
10 Radiator fan 2
6-4
RADIATOR
EAS31659
3. Measure:
REMOVING THE RADIATOR
• Radiator cap valve opening pressure
1. Remove:
Below the specified pressure → Replace the
• Hose clamp (Clic-R) “1”
radiator cap.
TIP
• Remove the hose clamp using the hose clamp Radiator cap valve opening pres-
pliers “2”. sure
• When removing the hose clamp, make sure 107.9–137.3 kPa (1.08–1.37 kgf/
that the thick tip “a” of the hose clamp pliers is cm², 15.6–19.9 psi)
directed as shown in the illustration.
a. Install the radiator cap tester “1” and radi-
ator cap tester adapter “2” to the radiator
a cap “3”.
Radiator cap tester

90890-01325
YU-24460-A
Radiator cap tester adapter
1 90890-01352
G089027 2 Pressure tester adapter
YU-33984
2. Disconnect:
• Radiator inlet hose
• Radiator outlet hose
3. Remove:
• Radiator
EAS30439
CHECKING THE RADIATOR

1. Check:
• Radiator fins
Obstruction → Clean.
G089029
Apply compressed air to the rear of the radia-
tor. b. Apply the specified pressure for ten sec-
Damage → Repair or replace. onds and make sure there is no drop in
TIP pressure.
4. Check:
Straighten any flattened fins with a thin, flat-head
• Radiator fan
screwdriver.
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” on page 8-27.
EAS30440
INSTALLING THE RADIATOR

1. Install:
• Radiator
2. Connect:
G089028
• Radiator outlet hose
3. Install:
2. Check:
• Hose clamp (Clic-R) “1” New
• Radiator hoses
Cracks/damage → Replace. TIP
• Install the hose clamp using the hose clamp pli-
ers “2”.
6-5
RADIATOR
• When installing the hose clamp, make sure Refer to “CHECKING THE RADIATOR” on
that the thin tip “a” of the hose clamp pliers is page 6-5.
directed as shown in the illustration.
• For more information about installing the hose,
refer to “CABLE ROUTING” on page 2-17.
New 1
G089030 2
4. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-32.
5. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
a. Attach the radiator cap tester “1” and radi-
ator cap tester adapter “2” to the radiator.
Radiator cap tester

90890-01325
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
G089031 1
b. Apply 137.3 kPa (1.37 kgf/cm², 19.9 psi) of
pressure.
c. Measure the indicated pressure with the
gauge.
6. Measure:
radiator cap.
6-6
OIL COOLER
EAS20064
OIL COOLER
Removing the oil cooler
10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
10 N・m (1.0 kgf・m, 7.4 lb・ft) 4

10 N・m (1.0 kgf・m, 7.4 lb・ft)
LT
LT
2
5
3 1
LT
2
FW
D
10 N・m (1.0 kgf・m, 7.4 lb・ft)

Drain.
page 3-29.
1 Oil cooler cover 1
2 Damper 2
Disconnect.
When removing the oil cooler inlet hose,
3 Oil cooler inlet hose 1 also remove the water pump inlet pipe.
Refer to “WATER PUMP” on page 6-13.
4 Oil cooler outlet hose 1
5 Oil cooler 1
6-7
OIL COOLER
EAS30441
CHECKING THE OIL COOLER

1. Check:
• Oil cooler
• Oil cooler fins
Apply compressed air to the rear of the oil
cooler.
Damage → Repair or replace. 2
TIP
Straighten any flattened fins with a thin, flat-head 2
screwdriver. 4
1
3
2. Tighten:
• Oil cooler bolt (upper) “2”
G089028
2. Check: Oil cooler bolt

• Oil cooler inlet hose 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• Oil cooler outlet hose

3. Tighten:
Cracks/damage/wear → Replace.
• Oil cooler bolt (lower) “3”
EAS30442
INSTALLING THE OIL COOLER Oil cooler bolt

1. Install: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• Oil cooler “1”

4. Tighten:
• O-ring New
• Radiator bolt “4”
• Oil cooler bolt (upper) “2”
• Oil cooler bolt (lower) “3” Radiator bolt
• Radiator bolt “4” 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
Apply lithium-soap-based grease to the O-ring. 5. Fill:
• Crankcase
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” on
page 3-29.
6. Measure:
• Engine oil pressure
Refer to “MEASURING THE ENGINE OIL
PRESSURE” on page 3-30.
6-8
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat
FW
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Rider seat 4-1.
Fuel tank/Canister Refer to “FUEL TANK” on page 7-1.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-32.
6-9
THERMOSTAT
Removing the thermostat
FW
D
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
4 5
1
6
3
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

1 Cooling system air bleed hose 1 Disconnect.
2 Radiator inlet hose 1
3 Thermostat housing cover 1
4 O-ring 1
5 Thermostat 1
6 Thermostat housing 1
7 O-ring 1
6-10
THERMOSTAT
EAS31660
2. Check:
REMOVING THE THERMOSTAT ASSEMBLY
• Thermostat housing
1. Remove:
• Thermostat housing cover
• Hose clamp (Clic-R)
Refer to “REMOVING THE RADIATOR” on
page 6-5. EAS30444
• Radiator inlet hose ASSEMBLING THE THERMOSTAT

2. Remove: ASSEMBLY
• Thermostat assembly 1. Install:
• Thermostat housing “1”
EAS30443
• Thermostat “2”
CHECKING THE THERMOSTAT
1. Check: • O-ring “3” New
• Thermostat • Thermostat housing cover “4”
Does not open at 69–73 °C (156–163 °F) →
Thermostat housing cover nut
Replace. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
a. Suspend the thermostat “1” in a container
R.
“2” filled with water. TIP
b. Slowly heat the water “3”.
Install the thermostat with its breather hole “a”
c. Place a thermometer “4” in the water.
facing up.
d. While stirring the water, observe the ther-
mostat and thermometer’s indicated tem- a
perature.
1
2
4
3 2
EAS30445
G089032
INSTALLING THE THERMOSTAT
ASSEMBLY
1. Install:
B • Thermostat assembly
2. Install:
E
• Hose clamp (Clic-R) New
Refer to “INSTALLING THE RADIATOR” on
A page 6-5.
TIP
G089033 C D
For more information about installing the hose,
A. Fully closed refer to “CABLE ROUTING” on page 2-17.
B. Fully open
C. 71 °C (159.8 °F) 3. Fill:
D. 85 °C (185.0 °F) • Cooling system
E. 8 mm (0.31 in) (with the specified amount of the recom-
mended coolant)
TIP Refer to “CHANGING THE COOLANT” on
If the accuracy of the thermostat is in doubt, re- page 3-32.
place it. A faulty thermostat could cause serious 4. Check:
overheating or overcooling. • Cooling system
Leaks → Repair or replace any faulty part.
6-11
THERMOSTAT
Refer to “INSTALLING THE RADIATOR” on

page 6-5.
5. Measure:
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-5.
6-12
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
FW
D
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

4 2.0 N・m (0.20 kgf・m, 1.5 lb・ft)
3
1
4
4
2
LT
10 N・m (1.0 kgf・m, 7.4 lb・ft)

Rider seat 4-1.
Muffler/Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-11.
1 Water pump inlet pipe 1
2 Water pump outlet pipe 1
3 Water pump assembly 1
4 Oil cooler stay 3
6-13
WATER PUMP
Disassembling the water pump
3
D
6 FW
7
4 2
10 N・m (1.0 kgf・m, 7.4 lb・ft)
10 N・m (1.0 kgf・m, 7.4 lb・ft)

1 Water pump housing cover 1
2 O-ring 1
3 Circlip 1
4 Impeller shaft 1
5 Mechanical seal 1
6 Bearing 1
7 Oil seal 1
6-14
WATER PUMP
EAS30446 EAS30447
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Mechanical seal (housing side) “1” • Water pump housing cover
TIP • Impeller shaft
Remove the mechanical seal (housing side) Cracks/damage/wear → Replace.
from the inside of the water pump housing “2”. • Water pump housing
Cracks/damage/wear → Replace the water
pump assembly.
2. Check:
• Bearing
Rough movement → Replace.
1 2 3. Check:
• Water pump inlet pipe
• Water pump outlet pipe
Cracks/damage/wear → Replace.
EAS30448
ASSEMBLING THE WATER PUMP

2. Remove: 1. Install:
• Bearing “1” • Oil seal “1” New
• Oil seal “2”
• Bearing “2” New
TIP (into the water pump housing “3”)
Remove the oil seal and bearing from the out-
side of the water pump housing “3”. Installed depth “a”
0.5–1.0 mm (0.02–0.04 in)
1 TIP
2 Install the oil seal with a socket “4” that matches
3
3
3. Remove:
• Mechanical seal (impeller side) “1” 1
a
(from the impeller, with a thin, flat-head 2
screwdriver)
TIP
Do not scratch the impeller shaft. 2. Install:
• Mechanical seal (housing side) “1” New
ECA20330
NOTICE
Never lubricate the mechanical seal (hous-
ing side) surface with oil or grease.
TIP
Use the special tools and a press to press the
mechanical seal (housing side) straight in until it
G089034
touches the water pump housing.
6-15
WATER PUMP
Mechanical seal installer (ø33)

90890-04132
Water pump seal installer (ø33)
YM-33221-A
Middle driven shaft bearing driv-
er
90890-04058 b
Middle drive bearing installer 40
& 50 mm
1 a
YM-04058
2. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-32.
3. Check:
1 • Cooling system
Leaks → Repair or replace the faulty part.
4. Measure:
2. Water pump housing Below the specified pressure → Replace the
3. Mechanical seal installer radiator cap.
4. Middle driven shaft bearing driver Refer to “CHECKING THE RADIATOR” on
A. Push down page 6-5.
3. Install:
• Mechanical seal (impeller side) “1” New
TIP
• Before installing the mechanical seal (impeller
side), apply tap water or coolant onto its outer
surface.
• If the top of the mechanical seal is dirty, clean
it.
G089035
EAS30449
INSTALLING THE WATER PUMP

1. Install:
• Water pump assembly “1”
TIP
Align the slit “a” on the impeller shaft with the
projection “b” on the oil pump driven sprocket.
6-16
WATER PUMP
6-17
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 FUEL PUMP OPERATION............................................7-3
INSTALLING THE FUEL PUMP................................................................7-4
INSTALLING THE FUEL TANK.................................................................7-4
AIR FILTER CASE .......................................................................................... 7-5

CHECKING THE SECONDARY INJECTORS (BEFORE REMOVING) ...7-7
REMOVING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE
AND SECONDARY INJECTOR JOINT SIDE) ......................................... 7-7
REMOVING THE SECONDARY INJECTORS.......................................... 7-7
REMOVING THE AIR FILTER CASE........................................................7-7
REMOVING THE INTAKE FUNNEL ASSEMBLY ..................................... 7-8
CHECKING THE SECONDARY INJECTORS .......................................... 7-8
CHECKING THE AIR FILTER CASE SEAL ..............................................7-8
CHECKING THE INTAKE FUNNEL .......................................................... 7-8
INSTALLING THE INTAKE FUNNEL AND AIR FILTER CASE ................ 7-8
CHECKING THE INTAKE FUNNEL OPERATION....................................7-9
INSTALLING THE SECONDARY INJECTORS ........................................ 7-9
INSTALLING THE AIR FILTER CASE COVER ........................................ 7-9
INSTALLING THE FUEL HOSE (PRIMARY INJECTOR JOINT SIDE
AND SECONDARY INJECTOR JOINT SIDE) ....................................... 7-10
THROTTLE BODIES .....................................................................................7-11

CHECKING THE PRIMARY INJECTORS (BEFORE REMOVING)........ 7-14
REMOVING THE PRIMARY INJECTORS .............................................. 7-14
CHECKING THE PRIMARY INJECTORS............................................... 7-14
CHECKING AND CLEANING THE THROTTLE BODIES.......................7-14
REPLACING THE THROTTLE BODIES ................................................. 7-16
INSTALLING THE PRIMARY INJECTORS............................................. 7-16
CHECKING THE INJECTOR PRESSURE.............................................. 7-16
CHECKING THE FUEL PRESSURE ......................................................7-17
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-18 7
AIR INDUCTION SYSTEM ............................................................................7-19
CHECKING THE AIR INDUCTION SYSTEM..........................................7-22
INSTALLING THE AIR INDUCTION SYSTEM........................................ 7-23
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank
5 N•m (0.5 kgf•m, 3.7 lb•ft) 4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
T.R
.
.
4.0 N•m (0.40 kgf•m, 3.0 lb•ft) 2 12 5 N•m (0.5 kgf•m, 3.7 lb•ft)
T.R
.
T.R
.
T.R
.
T.R
.
*
*
* 7
8
*
1
New
LS
3
13
11
9
10
(4)
4
0.4 N•m (0.04 kgf•m, 0.30 lb•ft)

T.R
.
5
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
6
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
* Hook-and-loop fastener

Rider seat 4-1.
1 Fuel tank side cover (left) 1
2 Fuel tank side cover (right) 1
3 Fuel hose connector 1 Disconnect.
4 Fuel pump coupler 1 Disconnect.
5 Fuel tank breather hose 1 Disconnect.
6 Fuel tank drain hose 1 Disconnect.
7 Fuel tank 1
8 Fuel tank top cover (rear) 1
9 Fuel tank top cover (front) 1
10 Fuel pump bracket 1
11 Fuel pump 1
12 Fuel tank cap 1
13 Fuel tank protector 1
7-1
FUEL TANK
Removing the rollover valve and canister
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Rider seat 4-1.
1 Canister purge hose (hose joint to canister) 1
2 Fuel tank breather hose (fuel tank to canister) 1
3 Canister holder 1
4 Canister 1
5 Canister bracket 1
7-2
FUEL TANK
EAS30450
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the 1 c
fuel tank cap with a pump.
2. Remove:
• Rider seat
4-1.
• Fuel tank cover
4-9.
3. Disconnect:
• Fuel hose (fuel tank side) a
• Fuel pump coupler b
• Fuel tank drain hose
• Fuel tank breather hose
EWA17320
WARNING
b
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 hose. 4. Remove:
ECA17490
• Fuel tank
NOTICE TIP
Be sure to disconnect the fuel hose by hand. Do not set the fuel tank down so that the instal-
Do not forcefully disconnect the hose with lation surface of the fuel pump is directly under
tools. the tank. Be sure to lean the fuel tank in an up-
right position.
TIP
• While pushing the ends “a” of the fuel hose EAS30451
connector cover “1” in direction “b”, slide the REMOVING THE FUEL PUMP
fuel hose connector cover in direction “c”, and 1. Remove:
then remove the hose from the fuel pump. • Fuel pump
ECA14721
• Before removing the hose, place a few rags in
NOTICE
the area under where it will be removed.
• It is prohibited to wear the cotton work gloves • Do not drop the fuel pump or give it a
or equivalent coverings. strong shock.
• Do not touch the base section of the fuel
sender.
EAS30454
CHECKING THE FUEL PUMP BODY

1. Check:
• Fuel pump body
Cracks/damage → Replace fuel pump as-
sembly.
EAS30455
CHECKING THE FUEL PUMP OPERATION

1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PRES-
SURE” on page 7-17.
7-3
FUEL TANK
EAS30456
INSTALLING THE FUEL PUMP TIP

1. Install: • Install the fuel hose onto the fuel pump secure-
ly, and slide the fuel hose connector cover “1”
• Fuel pump gasket New
in the direction shown in the illustration.
• Fuel pump
• It is prohibited to wear the cotton work gloves
• Fuel pump bracket
or equivalent coverings.
• Fuel pump bolts
Fuel pump bolt

4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
1
TIP
• Do not damage the installation surfaces of the
fuel tank when installing the fuel pump.
• Always use a new fuel pump gasket.
• Install the fuel pump gasket so that the lip side
turns to the inside of the fuel tank.
• Install the fuel pump as shown in the illustra-
tion. 3. Connect:
• Align the projection “a” on the fuel pump with • Fuel tank breather hose
the slot in the fuel pump bracket. • Fuel tank drain hose
• Tighten the fuel pump bolts in the proper tight- • Fuel pump coupler
ening sequence as shown. 4. Tighten:
• Front fuel tank bolt
a Front fuel tank bolt
1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
4 5. Tighten:
• Rear fuel tank bolt
3 Rear fuel tank bolt
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
A. Forward
EAS30457
INSTALLING THE FUEL TANK

1. Install:
• Fuel tank
• Rear fuel tank bolt
• Fuel tank nut
TIP
Temporarily tighten the rear fuel tank bolt.
2. Connect:
• Fuel hose (fuel tank side)
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.
7-4
AIR FILTER CASE
EAS20068
AIR FILTER CASE

Removing the air filter case and secondary injectors
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
5
.
(4) 1 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
3 3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
2
6 23 N•m (2.3 kgf•m, 17 lb•ft)
8
T.R
.
7 (6)
(10)
LT
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

T.R
.

Rider seat 4-1.
1 Fuel hose 2 (secondary injector fuel rail side) 1
2 Fuel hose 1 (fuel tank to fuel hose 2) 1
3 Fuel hose 3 (fuel hose 2 to throttle body) 1 Disconnect.
4 Secondary injector coupler 4 Disconnect.
5 Fuel rail/Secondary injector joint 2/1
6 Secondary injector 4
7 Air filter case cover 1
8 Air filter element 1
9 Crankcase breather hose 1 Disconnect.
7-5
AIR FILTER CASE
Removing the air filter case and secondary injectors

3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
(4) 15 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
12 3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
(6)
14
(10)
17
20 18
19
13
16 LT
2.0 N•m (0.20 kgf•m, 1.5 lb•ft)

10
T.R
.
11

10 Air induction system hose 1 Disconnect.
11 Intake funnel servo motor coupler 1 Disconnect.
12 Intake funnel assembly bolt 6 Loosen.
13 Air filter case 1
14 Intake funnel servo motor rod assembly 1
15 Intake funnel assembly 1
16 Intake funnel servo motor 1
Rear shock absorber assembly stepping motor
17 1 for YZF-R1M
lead
18 Coolant temperature sensor lead 1
19 Throttle servo motor lead 1
20 Cross bar 1
7-6
AIR FILTER CASE
EAS30458
CHECKING THE SECONDARY INJECTORS

(BEFORE REMOVING) 1 c
1. Check:
• Injectors
Use the diagnostic code numbers “40”–“43”.
9-40.
EAS30459
REMOVING THE FUEL HOSE (PRIMARY

INJECTOR JOINT SIDE AND SECONDARY
a
INJECTOR JOINT SIDE)
1. Remove: b
• Fuel hose (primary injector joint side and sec-
ondary injector joint side)
EWA17320
WARNING
b
EAS30460
spurt out when removing the hose.
REMOVING THE SECONDARY INJECTORS
ECA17490 EWA17330
NOTICE WARNING
Be sure to disconnect the fuel hose by hand. • Check the injectors in a well-ventilated area
Do not forcefully disconnect the hose with free of combustible materials. Make sure
tools. that there is no smoking or use of electric
tools in the vicinity of the injectors.
TIP
• Be careful when disconnecting the fuel
• While pushing the ends “a” of the fuel hose hose. Any remaining pressure in the fuel
connector cover “1” in direction “b”, slide the hose may cause the fuel to spray out. Place
fuel hose connector cover in direction “c”, and a container or rag under the hose to catch
then remove the hose from the fuel pump. any fuel that spills. Always clean up any
• Before removing the hose, place a few rags in spilt fuel immediately.
the area under where it will be removed. • Turn the main switch to “OFF” and discon-
• It is prohibited to wear the cotton work gloves nect the negative battery lead from the bat-
or equivalent coverings. tery terminal before removing the injectors.
1. Remove:
• Fuel tank
• Fuel hose
Refer to “REMOVING THE FUEL TANK” on
page 7-3.
2. Remove:
• Fuel rail screw
• Fuel rail
• Secondary injector joint
• Secondary injector
EAS31663
REMOVING THE AIR FILTER CASE

1. Remove:
• Air filter case cover
7-7
AIR FILTER CASE
2. Loosen: Damage → Replace.

• Intake funnel assembly bolt “1” 2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJEC-
TORS” on page 8-51.
EAS31664
CHECKING THE AIR FILTER CASE SEAL

1. Check:
1 1
• Air filter case seal
Damage → Replace.
EAS30463
3. Disconnect: CHECKING THE INTAKE FUNNEL

• Crankcase breather hose 1. Check:
• Air induction system hose • Intake funnel servo motor rod assembly
• Intake funnel servo motor coupler Damage/scratches → Replace.
4. Remove: • Intake funnel assembly
• Air filter case Cracks/damage → Replace.
2. Check:
EAS30461 • Intake funnel movement
REMOVING THE INTAKE FUNNEL Sticks → Replace the intake funnel assem-
ASSEMBLY bly.
1. Remove: ECA17550
• Intake funnel servo motor rod assembly NOTICE

• Intake funnel servo motor • Make sure that the intake funnel smoothly
2. Remove: moves to the contacting surface between
• Intake funnel assembly upper stopper and lower seating position
ECA26860
when it is moved by hand.
NOTICE
• Make sure that the intake funnel smoothly
• Do not disassemble the intake funnel as- strokes from the upper position to the seat-
sembly. ing position by its own weight.
• Do not remove the intake funnel bolts from
the intake funnel joint.
a. Keep the two tabs “a” pushed in the direc-
tion shown in the illustration and separate
the intake funnel assembly from air filter
case.
A. Upper
B. Lower
EAS31665
INSTALLING THE INTAKE FUNNEL AND AIR

a FILTER CASE
EAS30462
1. Install:
CHECKING THE SECONDARY INJECTORS • Cross bar “1”
1. Check: • Intake funnel servo motor
• Injectors • Intake funnel servo motor rod assembly
Obstruction → Replace and check the fuel • Air filter case “2”
pump/fuel supply system. • Intake funnel assembly “3”
Deposit → Replace. a. Install the cross bar “1”.
7-8
AIR FILTER CASE
b. Temporary tighten the cross bar bolts “a”.

c. Install the intake funnel assembly and air
filter case.
d. Tighten the Intake funnel assembly bolt
“b” and air filter case bolt “c”.
b
Intake funnel assembly bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
Air filter case bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft) a
e. Tighten the cross bar bolt “a”. A. Upper

B. Lower
Cross bar bolt
EAS30466
23 N·m (2.3 kgf·m, 17 lb·ft) INSTALLING THE SECONDARY INJECTORS
T.
R.
ECA21550
NOTICE
2 • Always use new O-rings.
3 • When installing the injectors, do not allow
any foreign material to enter or adhere to
the injectors, fuel rails, or O-rings.
b b • Be careful not to twist or pinch the O-rings
when installing the injectors.
• When installing the injector, install it at the
a c 1 c a
same position as the removed cylinder.
• If an injector is subject to strong shocks or
EAS30465
excessive force, replace it.
CHECKING THE INTAKE FUNNEL
• If installing the original fuel rail and bolts,
OPERATION
remove the white paint marks using a
1. Check:
cleaning solvent. Otherwise, paint chips on
• Intake funnel servo motor operation
the bolt seats could prevent the bolts from
a. Activate the diagnostic mode and select
being tightened to the specified torque.
the diagnostic code number “34”.
Refer to “SELF-DIAGNOSTIC FUNC- 1. Install a new seal onto the end of each injec-
TION AND DIAGNOSTIC CODE TABLE” tor.
on page 9-40. 2. Install the injectors to the fuel rails.
b. Set the start/engine stop switch to “ ”. 3. Install the secondary injector joint, making
c. Check that the stopper lever “a” contacts sure to install them in the correct direction.
the lever “b” (figure “A”). 4. Install the injector assemblies to the air filter
d. Check that the intake funnel seal mates case cover.
with the fixed intake funnel (figure “B”).
Fuel rail screw (secondary injec-
TIP
tor)
T.
R.
The intake funnels should move smoothly and 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
should not make any unusual sound.
5. Check the injector pressure after the injectors
are installed.
Refer to “CHECKING THE INJECTOR
PRESSURE” on page 7-16.
EAS31731
INSTALLING THE AIR FILTER CASE COVER

1. Install:
• Air filter case cover
7-9
AIR FILTER CASE
Air filter case cover screw

2.0 N·m (0.20 kgf·m, 1.5 lb·ft)
T.
R.
EAS30468
INSTALLING THE FUEL HOSE (PRIMARY

INJECTOR JOINT SIDE AND SECONDARY
INJECTOR JOINT SIDE)
1. Connect:
• Fuel hose (primary injector joint side and sec-
ondary injector joint side)
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
• While pushing the ends “a” of the fuel hose
connector cover “1” in direction “b”, slide the
fuel hose connector cover in direction “c”, and
then remove the hose from the fuel pump.
• Before removing the hose, place a few rags in
the area under where it will be removed.
• It is prohibited to wear the cotton work gloves
or equivalent coverings.
1 c
a
b
7-10
THROTTLE BODIES
EAS20070
THROTTLE BODIES
Removing the throttle bodies
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
LT
2
3
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.

Rider seat 4-1.
Side cover 4-23.
1 Throttle position sensor coupler 1 Disconnect.
2 Intake air pressure sensor coupler 1 Disconnect.
3 Coupler holder 1
7-11
THROTTLE BODIES
Removing the throttle bodies

8
12
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
13 6
6 10
5
11 6
LT 6
13
7
4
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)

T.R
.

4 Throttle servo motor coupler 1 Disconnect.
5 Fuel hose 3 (fuel hose 2 to throttle body) 1
6 Primary injector coupler 4 Disconnect.
7 Intake solenoid vacuum hose 1 Disconnect.
Coolant temperature sensor coupler (sub-wire
8 1 Disconnect.
harness)
9 Throttle body joint clamp screw 4 Loosen.
10 Throttle body assembly 1
11 Neutral switch connector 1 Disconnect.
12 Heat protector 1
13 Throttle body joint 2
7-12
THROTTLE BODIES
Removing the primary injectors

3.5 N•m (0.35 kgf•m, 2.6 lb•ft) New
8
T.R
.
New 3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
New 5
New 9 6
New
3 3
4
8 New 10
10
4 3
10 10
New 3
3
2 1
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)

T.R
.
1
7 2
1
2 1
1 1

1 Canister purge hose 6
2 Hose joint 3
3 Negative pressure hose 5
4 Hose joint 2
5 Service hose 1
6 Intake air pressure sensor 1
7 Throttle position sensor 1
8 Fuel rail 2
9 Primary injector joint 1
10 Primary injector 4
7-13
THROTTLE BODIES
EAS31666
• Throttle body joints
CHECKING THE PRIMARY INJECTORS
• Fuel hoses
(BEFORE REMOVING)
• Air induction system
1. Check:
• Exhaust system
• Injectors
• Crankcase breather hose
Use the diagnostic code numbers “36”–“39”.
• Vacuum hose
EWA17340
WARNING
9-40.
If the throttle bodies are subjected to strong
EAS31667
shocks or dropped during cleaning, replace
REMOVING THE PRIMARY INJECTORS
EWA17330
them as a set.
WARNING 1. Check:
• Check the injectors in a well-ventilated area • Throttle bodies
free of combustible materials. Make sure Cracks/damage → Replace the throttle bod-
that there is no smoking or use of electric ies as a set.
tools in the vicinity of the injectors. 2. Clean:
• Be careful when disconnecting the fuel • Throttle bodies
hose. Any remaining pressure in the fuel ECA21540
hose may cause the fuel to spray out. Place NOTICE

a container or rag under the hose to catch • Observe the following precautions; other-
any fuel that spills. Always clean up any wise, the throttle bodies may not operate
spilt fuel immediately. properly.
• Turn the main switch to “OFF” and discon- • Do not subject the throttle bodies to exces-
nect the negative battery lead from the bat- sive force.
tery terminal before removing the injectors. • Clean the throttle bodies in the recom-
mended cleaning solvent.
1. Remove:
• Do not use any caustic carburetor cleaning
• Fuel rail
solution.
a. Remove the fuel rail screws.
• Do not apply cleaning solvent directly to
EAS31668 any plastic parts, sensors, or seals.
CHECKING THE PRIMARY INJECTORS • Be careful not to remove the white paint
1. Check: mark that identifies the standard throttle
• Injectors body.
Obstruction → Replace and check the fuel • Do not turn the bypass air screws “a”; oth-
pump/fuel supply system. erwise, the throttle body synchronization
Deposit → Replace. will be affected.
Damage → Replace.
2. Check: Recommended cleaning solvent
• Injector resistance Yamaha Oil & Brake Cleaner
Refer to “CHECKING THE FUEL INJEC-
TORS” on page 8-51.
EAS30769
CHECKING AND CLEANING THE THROTTLE

BODIES
TIP
Clean the throttle bodies only if they cannot be
synchronized using the bypass air screws. Be-
a
fore cleaning the throttle bodies, check the fol-
lowing items: a
• Valve clearance
a. Place the throttle bodies on a flat surface
• Spark plugs
with the air filter case side facing up.
7-14
THROTTLE BODIES
b. Install the caps (895-14169-00) onto the ECA17590
hose fittings “a”. NOTICE

• Do not use a tool, such as a wire brush, to
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
aged.
• Do not allow carbon deposits or other for-
eign materials to enter any of the passages
a in each throttle body or in the space be-
tween the throttle valve shaft and the throt-
a tle body.
f. After removing the carbon deposits, clean
c. Hold the throttle valves in the open posi- the inside of the throttle bodies with the
tion. recommended cleaning solvent, and then
EWA15940
WARNING dry the throttle bodies using compressed

air.
When cleaning the throttle bodies, be careful
g. Make sure that there are no carbon de-
not to injure yourself on the throttle valves or posits or other foreign materials in any of
other components of the throttle bodies. the passages “a” in each throttle body or in
ECA20380
the space “b” between the throttle valve
NOTICE shaft and the throttle body.
• Do not open the throttle valves by supply-
ing electrical power to the throttle bodies.
• Do not use tools to open the throttle valves b
or to keep them in the open position.
• Do not open the throttle valves quickly. a
3. Install the throttle bodies.

4. Connect the intake air pressure sensor cou-
pler “1”.
G089040
TIP
After connecting intake air pressure sensor cou-
d. Apply the recommended cleaning solvent
pler “1”, press corner portion “a” of coupler cover
to the throttle valves and the inside of the
“2”, then make sure that the intake air pressure
throttle bodies to remove any carbon de-
sensor is not exposed.
posits.
TIP
a
• Do not allow any cleaning solvent to enter the 2
1
opening for the injectors.
• Do not apply any cleaning solvent to the por-
tions of the throttle valve shafts between the
throttle bodies.
e. Remove the carbon deposits from the in-
side of each throttle body in a downward
direction, from the air filter case side of the
throttle body to the engine side. 5. Reset:
• ISC (Idle Speed Control) learning values
Use the diagnostic code number “67”.
7-15
THROTTLE BODIES
Refer to “SELF-DIAGNOSTIC FUNCTION • Be careful not to twist or pinch the O-rings

AND DIAGNOSTIC CODE TABLE” on page when installing the injectors.
9-40. • When installing the injector, install it at the
6. Reset: same position as the removed cylinder.
• A/F control learning value • If an injector is subject to strong shocks or
Use the DTC number “87”. excessive force, replace it.
Refer to “SELF-DIAGNOSTIC FUNCTION • If installing the original fuel rail and bolts,
AND DIAGNOSTIC CODE TABLE” on page remove the white paint marks using a
9-40. cleaning solvent. Otherwise, paint chips on
7. Adjust: the bolt seats could prevent the bolts from
• Throttle bodies synchronizing being tightened to the specified torque.
Out of specification → Replace the throttle 1. Install primary injector joint “1” so that damper
bodies. part “a” faces the rib “b” side of fuel rail “2” as
Refer to “SYNCHRONIZING THE THROT- shown in the illustration.
TLE BODIES” on page 3-9.
EAS31160
1,a
REPLACING THE THROTTLE BODIES
1. Remove the throttle bodies from the vehicle.
2. Install a new throttle bodies to the vehicle. 2
3. Reset: 2
• ISC (Idle Speed Control) learning values
Use the diagnostic code number “67”. b
9-40. 2. Install a new seal onto the end of each injec-
4. Reset: tor.
• A/F control learning value 3. Install the injectors to the fuel rails.
Use the diagnostic code number “87”. 4. Install the primary injector joint, making sure
Refer to “SELF-DIAGNOSTIC FUNCTION to install them in the correct direction.
AND DIAGNOSTIC CODE TABLE” on page 5. Install the injector assemblies to the throttle
9-40. bodies.
5. Adjust:
• Throttle bodies synchronizing Fuel rail screw (throttle body)
Refer to “SYNCHRONIZING THE THROT- 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
TLE BODIES” on page 3-9.

6. Place the vehicle on a maintenance stand so 6. Check the injector pressure after the injectors
that the rear wheel is elevated. are installed.
7. Check: Refer to “CHECKING THE INJECTOR
• Engine idling speed PRESSURE” on page 7-16.
Start the engine, warm it up, and then mea- EAS30481
sure the engine idling speed. CHECKING THE INJECTOR PRESSURE

TIP
Engine idling speed
• After installing the injectors, perform the follow-
1200–1400 r/min
ing steps to check the injector pressure.
EAS31669
• Do not allow any foreign materials to enter the
INSTALLING THE PRIMARY INJECTORS fuel lines.
ECA21550
NOTICE 1. Check:
• Injector pressure
• Always use new O-rings.
a. Connect the fuel injector pressure adapter
• When installing the injectors, do not allow
“1” to the injector joint “2”, and then con-
any foreign material to enter or adhere to
nect an air compressor “3” to the adapter.
the injectors, fuel rails, or O-rings.
7-16
THROTTLE BODIES
b. Connect the pressure gauge “4” to the fuel • Fuel tank cover
injector pressure adapter “1”. Refer to “FUEL TANK” on page 7-1.
2. Check:
Pressure gauge • Fuel pressure
90890-03153 a. Remove the fuel tank bolts and hold up the
Pressure gauge fuel tank.
YU-03153
b. Disconnect the fuel hose “1” from the fuel
Fuel injector pressure adapter
90890-03210 pump.
Fuel injector pressure adapter Refer to “FUEL TANK” on page 7-1.
EWA17320
YU-03210
WARNING
spurt out when removing the hose.
ECA17490
NOTICE
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with
tools.
G089041
c. Close the valve on the injector pressure

adapter.
1
d. Apply air pressure with the air compres-
sor.
e. Open the valve on the injector pressure
adapter until the specified pressure is
reached.
Specified air pressure

490 kPa (5.0 kgf/cm², 71.1 psi)
ECA17600
c. Connect the pressure gauge “2” and fuel
NOTICE pressure adapter “3” to the fuel hose.
Never exceed the specified air pressure or Pressure gauge
damage could occur. 90890-03153
f. Close the valve on the injector pressure Pressure gauge
adapter. YU-03153
Fuel pressure adapter
g. Check that the specified air pressure is
90890-03176
held at least one minute. Fuel pressure adapter
Pressure drops → Check the pressure YM-03176
gauge and adapter.
Check the seals and O-rings and then re-
install. 2
Out of specification → Replace the fuel in- 3
jectors.
EAS30482
CHECKING THE FUEL PRESSURE

1. Remove:
• Rider seat
4-1.
d. Start the engine.
7-17
THROTTLE BODIES
e. Measure the fuel line pressure. f. Adjust the position of the throttle position
Faulty → Replace the fuel pump. sensor angle so that 11–21 can appear in
the Yamaha diagnostic tool screen.
Fuel line pressure (at idle) g. After adjusting the throttle position sensor
300–390 kPa (3.0–3.9 kgf/cm², angle, tighten the throttle position sensor
43.5–56.6 psi) bolts “1”.
3. Install: Throttle position sensor bolt
• Fuel tank 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
• Fuel tank cover
• Rider seat
4-1.
EAS30485
ADJUSTING THE THROTTLE POSITION

SENSOR 1
ECA17540
NOTICE 1
• Handle the throttle position sensor with
special care.
• Never subject the throttle position sensor
to strong shocks. If the throttle position
sensor is dropped, replace it.
1. Check:
• Throttle position sensor
Refer to “DIAGNOSTIC CODE: SENSOR
OPERATION TABLE” on page 9-69.
2. Adjust:
• Throttle position sensor angle
TIP
Before adjusting the throttle position sensor, the
throttle bodies must be removed.
a. Temporary tighten the throttle position
sensor screws.
b. Check that the throttle valves are fully
closed.
c. Connect the throttle position sensor to the
wire harness.
d. Remove the protective cap, and then con-
nect the Yamaha diagnostic tool to cou-
pler.
TIP
For information about using the Yamaha diag-
nostic tool, refer to the operation manual that is
included with the tool.
Refer to “SELF-DIAGNOSTIC FUNC-
TION AND DIAGNOSTIC CODE TABLE”
on page 9-40.
e. Diagnostic code number “01” is selected.
7-18
AIR INDUCTION SYSTEM
EAS20071
1. Air filter case

2. Air cut-off valve
3. Air induction system hose (air filter case to air
cut-off valve)
4. Cylinder head cover
5. Air induction system hose (air cut-off valve to
reed valve cover)
7-19
Removing the air cut-off valve assembly and reed valves

9 N•m (0.9 kgf•m, 6.6 lb•ft) 5 0.3 N•m (0.03 kgf•m, 0.22 lb•ft)
T.R
T.R
.
.
6 1
3
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
4
8
7 2
LT
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

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

Rider seat 4-1.
1 Atmospheric pressure sensor coupler 1 Disconnect.
2 Intake air temperature sensor coupler 1 Disconnect.
3 Air filter case duct 1
4 Atmospheric pressure sensor hose 1
5 Atmospheric pressure sensor 1
6 Damper 1
7 Intake air temperature sensor holder 1
8 Intake air temperature sensor 1
7-20
Removing the air cut-off valve assembly and reed valves

9 N•m (0.9 kgf•m, 6.6 lb•ft) 0.3 N•m (0.03 kgf•m, 0.22 lb•ft)
T.R
T.R
.
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
11
LT 14 15
2.5 N•m (0.25 kgf•m, 1.8 lb•ft) 13

T.R
.
10 16
12
9
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
14 LT
15
16

9 Air cut-off valve coupler 1 Disconnect.
Air induction system hose (air cut-off valve to
10 1
reed valve cover)
Air induction system hose (air filter case to air
11 1
cut-off valve)
Air induction system hose (air cut-off valve to
12 1
reed valve cover)
13 Air cut-off valve 1
14 Reed valve cover 2
15 Reed valve assembly 2
16 Reed valve plate 4
7-21
EAS30488
Air injection
The air induction system burns unburned ex-
haust gases by injecting fresh air (secondary air)
into the exhaust port, reducing the emission of
hydrocarbons. When there is negative pressure
at the exhaust port, the reed valve opens, allow-
ing secondary air to flow into the exhaust port.
The required temperature for burning the un-
burned exhaust gases is approximately 600 to
700 °C (1112 to 1292 °F).
Air cut-off valve

The air cut-off valve is controlled by the signals
from the ECU in accordance with the combus-
tion conditions. Ordinarily, the air cut-off valve
opens to allow the air to flow during idle and
closes to cut-off the flow when the vehicle is be-
ing driven. However, if the coolant temperature
is below the specified value, the air cut-off valve
remains open and allows the air to flow into the
exhaust pipe until the temperature becomes
higher than the specified value.
A. From the air filter case

B. To the cylinder head
1. Check:
• Hoses
Loose connections → Connect properly.
2. Check:
• Reed valve
• Reed valve stopper
• Reed valve seat
Cracks/damage → Replace the reed valve
assembly.
3. Measure:
• Reed valve bending limit “a”
Out of specification → Replace the reed
valve assembly.
Reed valve bending limit

0.4 mm (0.02 in)
7-22
3. Install:
• Reed valve cover
Reed valve cover bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
LOCTITE®
G089044
4. Check:
5. Check:
• Air induction system solenoid
Refer to “CHECKING THE AIR INDUCTION
SYSTEM SOLENOID” on page 8-49.
EAS30489
INSTALLING THE AIR INDUCTION SYSTEM

1. Install:
• Reed valve plate
TIP
Align the projection “a” on the cylinder head cov-
er “1” with the hole “b” in the reed valve plate.
2. Install:
• Reed valve assembly
TIP
Install the reed valve assembly so that the open
side turns to the exhaust side of the engine.
G089045
A. Exhaust side
7-23
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
ENGINE STOPPING DUE TO SIDESTAND OPERATION.......................8-3
TROUBLESHOOTING ..............................................................................8-4
ELECTRIC STARTING SYSTEM .................................................................... 8-7

CIRCUIT DIAGRAM .................................................................................. 8-7
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-9
TROUBLESHOOTING ............................................................................8-10
CHARGING SYSTEM....................................................................................8-12
CIRCUIT DIAGRAM ................................................................................ 8-12
LIGHTING SYSTEM ......................................................................................8-15

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

CIRCUIT DIAGRAM ................................................................................ 8-19
COOLING SYSTEM....................................................................................... 8-27

CIRCUIT DIAGRAM ................................................................................ 8-27
FUEL PUMP SYSTEM...................................................................................8-31

CIRCUIT DIAGRAM ................................................................................ 8-31
COMMUNICATION CONTROL SYSTEM (for YZF-R1M) ............................ 8-35

CIRCUIT DIAGRAM ................................................................................ 8-35
8
ELECTRICAL COMPONENTS...................................................................... 8-38
CHECKING THE SWITCHES .................................................................8-40
CHECKING THE FUSES ........................................................................8-41
REPLACING THE ECU (Engine Control Unit) ........................................ 8-41
CHECKING AND CHARGING THE BATTERY....................................... 8-42
CHECKING THE RELAYS ...................................................................... 8-42
CHECKING THE RELAY UNIT (DIODE) ................................................ 8-43
CHECKING THE IGNITION COILS......................................................... 8-44
CHECKING THE IGNITION SPARK GAP............................................... 8-45
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 8-45
CHECKING THE STARTER MOTOR OPERATION ...............................8-46
CHECKING THE STATOR COIL ............................................................ 8-46
CHECKING THE RECTIFIER/REGULATOR ..........................................8-46
CHECKING THE HORN..........................................................................8-47
CHECKING THE FUEL SENDER ........................................................... 8-47
CHECKING THE FUEL LEVEL WARNING LIGHT .................................8-48
CHECKING THE RADIATOR FAN MOTORS.........................................8-48
CHECKING THE COOLANT TEMPERATURE SENSOR.......................8-48
CHECKING THE THROTTLE SERVO MOTOR ..................................... 8-49
CHECKING THE AIR INDUCTION SYSTEM SOLENOID ......................8-49
CHECKING THE CYLINDER IDENTIFICATION SENSOR ....................8-50
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................8-50
CHECKING THE STEERING DAMPER SOLENOID ..............................8-51
CHECKING THE FUEL INJECTORS......................................................8-51
CHECKING THE WHEEL SWITCH ........................................................ 8-52
EAS30490
EAS20072
R/W R/W
R/W
R
R
RR
4 R/W
R R R R R R/W
R R/W R/W
R R/W R/W
R
51
O
3 O R/W
ON 50 (B)
OFF 19
R R/W
O 52
Br/L Gy/R Gy/R
B R/W Gy/R R/W
O/G
R Br/L 30 50
CIRCUIT DIAGRAM
Gy/G
(B)
Br/L
B Br/W L/W R/W L R/L
B R/W
L/R L/W R/W L/B L/Y Sb B/Y Sb/W 53
Sb L/Y L/B O/G
O/G R/W
18 R/W R/G 50
23 (B)
IGNITION SYSTEM
B R/W
L/Y R/W
26 R/W R/W
54
L/B Gy/G
R/W R/W R/W R/W Gy/G R/W
R/L R/B 50
L/Y B (B)
R L/Y 34
9 28 B B
R/G
(B)
B
R/W L L/W R/B Sb
L/B B
R/W L/W L/R R/L
(B)
B
33
12 R/W B
R/W
Br/L
Br/L Br/L
L L L
R/G L/Y L
R/G 44 W W/B W/B
B/L
49
L W/B W L/Y
B/L B/L
(B) (B)
Gy Gy Gy Gy
8-1
B/L Gy B Gy 46 B B/L
B/L
B/L B/L L/B Y/L P/W P V L L/R Gy

B/L
L/W B/Y Gy/G Br/W B/L W W/B
L/Y L/W Gy/Y G/W G Gy/B W/L
(B)
B
B
Y/R P/W P/B Gy/G O/G Gy/R O L/Y L Y/B R/W

Lg/R L/R O/B L/B G/B R/B B W W L/G B/R
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B B/G B B/G
R/W B/W R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y
(B) (B)
L/B
71
L/W
L/W L/B
B/W L/W L/B R/W
B/W B
(B) B/W B
L/W L/W L/B L/B
23 B/W B/W
B B/W BB
* L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B
** L/W L/W L/W L/W L/W L/W L/W
L/B L/B L/B L/B L/B L/B L/B
IGNITION SYSTEM
IGNITION SYSTEM
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
18.Engine ground
19.Battery
23.Joint coupler
26.Handlebar switch (right)
28.Start/engine stop switch
30.Relay unit
33.Neutral switch
34.Sidestand switch
44.Cylinder identification sensor
46.Crankshaft position sensor
49.ECU (Engine Control Unit)
50.Spark plug
51.Ignition coil #1
52.Ignition coil #2
53.Ignition coil #3
54.Ignition coil #4
71.IMU (Inertial Measurement Unit)
*. Joint coupler for YZF-R1
**. Joint coupler for YZF-R1M
8-2
IGNITION SYSTEM
EAS30491
ENGINE STOPPING DUE TO SIDESTAND OPERATION

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

(Main, ignition and backup)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-41.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-42.
OK ↓
3. Check the spark plugs. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug(s).
PLUGS” on page 3-5.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE SPARK Ignition system is OK.
PLUGS” on page 3-5.
NG ↓
5. Check the ignition coils. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil(s).
TION COILS” on page 8-44.
OK ↓
6. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on
page 8-45.
OK ↓
7. Check the cylinder identification NG →
sensor.
Refer to “CHECKING THE CYLIN- Replace the cylinder identification sensor.
DER IDENTIFICATION SENSOR”
on page 8-50.
OK ↓
8-4
IGNITION SYSTEM
8. Check the main switch. NG →

Refer to “CHECKING THE Replace the main switch/immobilizer unit.
SWITCHES” on page 8-40.
OK ↓
9. Check the start/engine stop switch. NG →
Refer to “CHECKING THE Replace the handlebar switch (right).
OK ↓
10.Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
11.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
12.Check the relay unit (diode). NG →
Refer to “CHECKING THE RELAY Replace the relay unit.
UNIT (DIODE)” on page 8-43.
OK ↓
13.Check the entire ignition system’s NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 8-1.
OK ↓
Replace the ECU or IMU.
Refer to “REPLACING THE ECU (En-
gine Control Unit)” on page 8-41.
8-5
IGNITION SYSTEM
8-6
EAS30493
EAS20073
R/W R/W R/W
R
R
RR
4 R/W
R R R R R R/W
R R/W
R
R
20 L/W L/W
L/W
3 L/R
B R/W
ON
OFF 19 R/W L/W
R 22 (B) R/W
Br/L L/R L/W
B R/W
R Br/L 30
CIRCUIT DIAGRAM
Br/L 31
B Br/W L/W R/W L R/L
B
L/R L/W R/W L/B L/Y Sb B/Y Sb/W
R/W L Sb L/Y L/B
18 R/W B/Y
R/W R/G
23 R/W
B
L/Y
B/Y
26 R/W R/W L
L/B
R/W R/W R/W R/W
R/L R/B L/W
L/Y B
R L/Y 34
L/Y
9 28 B B
R/G
(B)
B
R/W L L/W R/B Sb
L/B B
R/W L/W B/Y
L/R R/L
B/Y (B)
B/Y B
B 33
12 R/W B
R/W
Br/L
Br/L Br/L
ELECTRIC STARTING SYSTEM
R/G
R/G
49
B
B/W
8-7
91 B/Y L/Y
L/W
L/W B/Y
B L/R
L/B Y/L P/W P V L L/R Gy
B/Y L/Y L/W B/Y Gy/G Br/W B/L W W/B
L/W B/W L/Y L/W Gy/Y G/W G Gy/B W/L
(B)
B
B
99

R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y
(B) (B)
B/W
B/W
B/W B/W
B B/W
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
18.Engine ground
19.Battery
20.Starter relay
22.Starter motor
23.Joint coupler
30.Relay unit
31.Starting circuit cut-off relay
33.Neutral switch
34.Sidestand switch
91.Handlebar switch (left)
99.Clutch switch
8-8
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to “ON” and the “ ” side of the start/engine stop switch is pushed, the starter
motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the
sidestand switch is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the
starter motor. When at least one of the above conditions has been met, the starting circuit cut-off relay
is closed and the engine can be started by pressing the “ ” side of the start/engine stop switch.
12
11
4
6 6
10
6
6
7 a
6
8 9 10
b
a. WHEN THE TRANSMISSION IS IN NEUTRAL

b. WHEN THE SIDESTAND IS UP AND THE
CLUTCH LEVER IS PULLED TO THE
HANDLEBAR
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Starting circuit cut-off relay
6. Relay unit (diode)
7. Clutch switch
8. Sidestand switch
9. Neutral switch
11. Starter relay
12. Starter motor
8-9
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Front side cowling/Front panel/Side cover
2. Rider seat
3. Fuel tank cover
4. Fuel tank
5. Air filter case
6. Throttle bodies

ES” on page 8-41.
OK ↓
page 8-42.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step (5).
8-46.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-51.
OK ↓
5. Check the relay unit (starting circuit NG →
cut-off relay).
Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 8-42.
OK ↓
6. Check the relay unit (diode). NG →
OK ↓
7. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
8-10

OK ↓
9. Check the neutral switch. NG →
OK ↓
10.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
11.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
12.Check the start/engine stop switch. NG →
OK ↓
13.Check the entire starting system’s NG →
wiring. Properly connect or repair the starting sys-
page 8-7.
OK ↓
Replace the ECU.
8-11
CHARGING SYSTEM
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
RR
B
B
18
19
R
4
R
R
R
R
R
B W R
W W
(Dgy)
R
R
R
R
2
B
W
W
W
W W W
W W W
1
1. AC magneto
2. Rectifier/regulator
4. Main fuse
18.Engine ground
19.Battery
8-12
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Front side cowling/Front panel/Side cover bracket/Electrical components tray
2. Rider seat
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 8-41.
OK ↓
page 8-42.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator coil assembly.
COIL” on page 8-46.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 8-46.
OK ↓
5. Check the entire charging system’s NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 8-12.
OK ↓
The charging system circuit is OK.
8-13
CHARGING SYSTEM
8-14
EAS30498
EAS20075
R/W R/W
R
R
RR
4
R R R R R
R
R
R
3
ON
OFF 19
R
Br/L
B R/W
R Br/L
CIRCUIT DIAGRAM
Br/L
B B
B
18 R/G
23 R/W
B R/W
LIGHTING SYSTEM
R/W R/W R/W R/W
R
9
R/G
12 R/W
R/W
Br/L 13
Br/L Br/L
Br/L L/R
16 R/Y R/G
Br/L R/Y R/G
R/G 49
B/W 72
B/W
L/R
L/R
L/R
91 R/W
8-15
L/R
93 94
Y L/Y G/B G/Y G 78

B/G Y/B B W/B W/Y
(B)
Y/B Y
G G/Y G/B L/Y Y L/W B/Y Gy/G Br/W B/L W W/B
W/Y W/L B Y/B Br/Y L/Y L/W Gy/Y G/W G Gy/B W/L
(B)
(B)
B
B/W
B Y/B
B
B
Y/B
Y/B Lg/R L/R O/B L/B G/B R/B B W W L/G B/R
Y
L/R Y
R/G 110 L/R 109 108 L/R 84 R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y
(B) (B) Y/B
Y
B/R 86
B/Y
Y
B B R/Y R/Y Y/B Y
B L/R
104 B/W
B B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W B/W
B/Y B B/R L/R B R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
(Gy)
B 106 105
R/G B L/R
B
(B) B Y L/R R/Y B Y/B Y B R/Y
(B) (B)
B
B
B
B/W B/W
B B/W
LIGHTING SYSTEM
LIGHTING SYSTEM
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
13.Signaling system fuse
16.Headlight fuse
18.Engine ground
19.Battery
23.Joint coupler
72.Meter assembly
78.Multi-function meter
84.Meter light
86.High beam indicator light
93.Pass/LAP switch
94.Dimmer switch
104.Headlight control unit
105.Headlight (high beam)
106.Headlight (low beam)
108.Tail/brake light
109.License plate light
110.Auxiliary light
8-16
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, auxiliary light, high beam indicator light, tail/brake light, li-
cense plate light or meter light.
TIP
2. Passenger seat/Rider seat/Tail cover/Rear side cover
3. Headlight assembly

(Main, headlight, backup, ignition
and signaling system) Replace the fuse(s).
ES” on page 8-41.
OK ↓
page 8-42.
OK ↓
OK ↓
4. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
Refer to “CHECKING THE
handlebar switch (left).
OK ↓
5. Check the Pass/LAP switch. NG →
The Pass/LAP switch is faulty. Replace the
Refer to “CHECKING THE
handlebar switch (left).
OK ↓
6. Check the entire lighting system’s NG →
wiring. Properly connect or repair the lighting sys-
page 8-15.
OK ↓
Replace the ECU, meter assembly,
headlight assembly, tail/brake light, li-
cense plate light or auxiliary light.
8-17
LIGHTING SYSTEM
8-18
EAS30500
EAS20076
R/W R/W
R
R
RR
4
R R R R R
R
R
R
3
ON
OFF 19
R
Br/L Sb/W
BB R/W
R Br/L 30
CIRCUIT DIAGRAM
W W
Br/L L/R G W G G
B B Br/W L/W R/W L R/L 38 L/R L/R
B (Dl)
Sb
18 R/G
23 R/W
B R/W
26 25
R/W R/W R/W R/W
SIGNALING SYSTEM
R G/W
9 B
R/G
B 35
Sb
R/W L L/W R/B
R/W L/W L/R R/L B Y B
L/R
B R/L B G/W B R W B R L
L/W Y 33 W V V
Y B 41 B B/L
12 R/W B (B) (B)
R/W
Br/L 13
Br/L Br/L L/W
14 L/R
Br/R R/B
15 L
Br/R L/Y
L L
R/G
R/G
R/G
49
R/G
L/W
L/W B/W 72
B/W
L/W L/W L/W 23 L/W

74
L/R
L/R 76
91 L/W L/Y R/W Sb/W
8-19
L/R
95 L/R 97 77 G/W B G/W G/W
Br G/W B/L 47 B/L B B/L
107 (B)
96
Br Y Y L/Y G/B G/Y G G/W
R/G 78 B/L
B/G Y/B B W/B W/Y R/G
Y L/W B/Y L/W
Y L/R B L/R B W/B B/G L/B
(B)
B/W W/L W/Y Br/Y B/L B/L B/L
G G/Y G/B L/Y Y B/Y L/Y G/L L/W B/Y Gy/G Br/W B/L W W/B
W/Y W/L B Y/B Br/Y L/W B/W 80 L/Y L/W Gy/Y G/W G Gy/B W/L
(B)
(B)
B
B B/W
B/W 98
W/Y
Y W/L 82
B Br/Y
B Y Y
Y Y/R P/W P/B Gy/G O/G Gy/R O L/Y L Y/B R/W
Br/B 83 Lg/R L/R O/B L/B G/B R/B B W W L/G B/R Gy/B Gy/B
Br/W
Ch R/L G/Y Br/R Br/B Br/Y Sb/W W/L B B/G B B/G W/L W/L
Dg
108 Y R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y
102 Br/W 100 Dg G/L
(B) (B) W W
G G E B B 69
L/B
G/L 67
Br/W G
Dg B B G L/W B W W B
B B
(B) (B) G/L
B/W
B B B/W
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W Y R/B
Br/B 103 Ch 101 R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
Br Br
90
(Gy)
B Br Ch B
Br Br/B
B B B (B)
(B)
B Y L/R (Gy) (Gy) B/W B
(B) B B
B L/W Gy/B L Y G R/B B L/W B/W
B
B B R/W G/O W/L L B W W L/B B
L/W L/W L/B L/B
(B)
23 B/W B/W
B B/W B/W
B E ** L/W L/W L/W L/W L/W L/W L/W
B/L G/W G/W B/L

G/L G/L
A C A F
SIGNALING SYSTEM
SIGNALING SYSTEM
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
14.ABS ECU fuse
15.Hazard lighting fuse
18.Engine ground
19.Battery
23.Joint coupler
25.Front brake light switch
30.Relay unit
33.Neutral switch
35.Fuel sender
38.Gear position sensor
41.Shift sensor
47.Coolant temperature sensor
67.Hydraulic unit assembly (ABS ECU)
69.Rear wheel sensor
72.Meter assembly
74.Fuel level warning light
76.Neutral indicator light
77.Shift indicator light
80.Oil pressure and coolant temperature warning
light
82.Turn signal indicator light (right)
83.Turn signal indicator light (left)
90.Oil pressure switch
95.Horn switch
96.Turn signal switch
97.Hazard switch
98.Horn
100.Rear turn signal light (right)
101.Rear turn signal light (left)
102.Front turn signal light (right)
103.Front turn signal light (left)
107.Rear brake light switch
A. Wire harness
C. Sub-wire harness (coolant temperature sensor)
F. Sub-wire harness (oil pressure switch)
8-20
SIGNALING SYSTEM
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• The speedometer fails to operate.
TIP
2. Passenger seat/Rider seat/Tail cover/Rear side cover
3. Fuel tank cover
4. Fuel tank
5. Air filter case
6. Throttle bodies
7. Drive sprocket cover

(Main, ignition, signaling system,
backup, ABS ECU and hazard light-
ing)
ES” on page 8-41.
OK ↓
page 8-42.
OK ↓
OK ↓
4. Check the entire signaling sys- NG →
tem’s wiring. Properly connect or repair the signaling
page 8-19.
OK ↓
Check the condition of each of the sig-
naling system circuits.
Refer to “Checking the signaling sys-
tem”.
Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
Refer to “CHECKING THE Replace the handlebar switch (left).
OK ↓
8-21
SIGNALING SYSTEM
2. Check the horn. NG →

Refer to “CHECKING THE HORN” Replace the horn.
on page 8-47.
OK ↓
page 8-19.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
page 8-19.
OK ↓
Replace the tail/brake light.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal switch. NG →
OK ↓
2. Check the hazard switch. NG →
OK ↓
8-22
SIGNALING SYSTEM

page 8-19.
OK ↓
Replace the meter assembly or turn
signal light.
The neutral indicator light fails to come on.

1. Check the neutral switch. NG →
OK ↓
2. Check the relay unit (diode). NG →
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The oil pressure and coolant temperature warning light fails to come on, or the oil pressure warning icon
flashes when the main switch is set to “ON”.
tem’s wiring. Properly connect or replace the wiring har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-19.
OK ↓
2. Disconnect the oil pressure switch NG →
lead from the oil pressure switch,
and then check whether the oil
pressure and coolant temperature Replace the meter assembly.
warning light comes on when the
lead is connected to the engine
ground.
OK ↓
Replace the oil pressure switch.
8-23
SIGNALING SYSTEM
The oil pressure and coolant temperature warning light remains on after the engine is started.
page 8-19.
OK ↓
2. Measure the engine oil pressure. NG →
Refer to “MEASURING THE EN- Check the engine oil leakage, oil viscosity,
GINE OIL PRESSURE” on page oil seal, oil filter, or oil pump.
3-30.
OK ↓
Replace the oil pressure switch.
The fuel level warning light fails to come on.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 8-47.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The oil pressure and coolant temperature warning light fails to come on.
1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-48.
OK ↓
page 8-19.
OK ↓
Replace the ECU or meter assembly.
8-24
SIGNALING SYSTEM
QSS (Quick Shift System) does not operate.

1. Check that the malfunction indicator NG →
Repair the faulty parts.
light does not come on.
OK ↓
2. Check that the QSS is working un- NG → Check the QSS operating conditions ex-
der normal QSS operating condi- plained in the owner’s manual and operate
tions. the QSS accordingly.
OK ↓
3. Make sure that the QSS is effective. NG →
Activate the QSS. (Set the QSS to a set-
(Check whether the “QS ” icon
ting other than “OFF”.)
is displayed at the top of the meter.)
OK ↓
4. Are you operating while the NG →
Operate while the “QS ” icon is lit.
“QS ” icon is lit?
OK ↓
5. Is the transmission gear display NG →
Repair the gear position sensor.
normal?
OK ↓
6. Check the connection of the cou- NG →
pler between the gear position sen- Connect the gear position sensor coupler.
sor and the ECU.
OK ↓
7. Are the clutch and neutral switches NG →
Repair the switch if it is not normal.
normal?
OK ↓
8. Check the shift sensor value in the NG →
DIAG mode.
2.5 V when the shift pedal is not be-
ing operated.
Replace the shift sensor.
4.5 V when the shift pedal is
pressed fully in.
0.5 V when the shift pedal is
pushed fully up.
OK ↓
page 8-19.
OK ↓
Replace the ECU.
8-25
SIGNALING SYSTEM
The speedometer fails to operate.

1. Check the rear wheel sensor. NG →
Refer to “MAINTENANCE OF THE
Replace the rear wheel sensor.
REAR WHEEL SENSOR AND
SENSOR ROTOR” on page 4-49.
OK ↓
2. Check the entire wheel sensor wir- NG →
Properly connect or repair the wheel sen-
ing.
sor wiring.
Refer to TIP.
OK ↓
Replace the hydraulic unit assembly,
ECU, meter assembly.
TIP
Repair or replace if there is an open or short circuit.
• Between rear wheel sensor coupler and ABS ECU coupler.
(white–white)
(black–black)
• Between ABS ECU coupler and ECU coupler.
(gray/black–gray/black)
(white/blue–white/blue)
• Between joint coupler and ECU coupler.
(blue/white–blue/white)
(blue/black–blue/black)
• Between joint coupler and meter assembly coupler.
(blue/white–blue/white)
(blue/black–blue/black)
8-26
EAS30502
EAS20077
R/W R/W
R/W
R
R
RR
4
R R R R R
R
RR
R
3
ON
OFF 19
R
Br/L
B R/W
R Br/L
CIRCUIT DIAGRAM
Br/L
B
B
18 R/G
B
R
COOLING SYSTEM
R/W
5
R
G/Y
R R/B 9
R/G
R/B
R/W G/Y
10
L
R/B 11
L/W
12
R/W
Br/L
Br/L Br/L
R/G
R/G
49
L/W L
8-27
113 112
G/W B G/W G/W
G/W B/L 47 B/L B B/L
B B
(B)
L L
(B) B/L
B
B B
B L
L/W
(B) L/B Y/L P/W P V L L/R Gy
B/L B/L
B
B
(B)
B

R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y G/Y
(B) (B)
B/W
B/W
B/W
B B/W
B/L G/W G/W B/L
A C
COOLING SYSTEM
COOLING SYSTEM
3. Main switch
4. Main fuse
5. Radiator fan motor relay
9. Backup fuse
10.Sub radiator fan motor fuse
11.Radiator fan motor fuse
12.Ignition fuse
18.Engine ground
19.Battery
112.Sub radiator fan motor (right)
113.Radiator fan motor (left)
A. Wire harness
C. Sub-wire harness (coolant temperature sensor)
8-28
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
TIP
1. Front side cowling/Front panel/Side cover bracket/Electrical components tray
2. Rider seat
3. Fuel tank cover
4. Fuel tank
5. Air filter case
6. Throttle bodies

(Main, ignition, backup, radiator fan
motor and sub radiator fan motor) Replace the fuse(s).
ES” on page 8-41.
OK ↓
page 8-42.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTORS” on page 8-48.
OK ↓
5. Check the radiator fan motor relay. NG →
Refer to “CHECKING THE RE- Replace the radiator fan motor relay.
OK ↓
6. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-48.
OK ↓
8-29
COOLING SYSTEM
7. Check the entire cooling system’s NG →

wiring. Properly connect or repair the cooling sys-
page 8-27.
OK ↓
Replace the ECU.
8-30
EAS30513
EAS20081
R/L R/L
R/W R/W R/L
R
R
RR
4 R/W
R R R R R R/W
R
R
R
3
ON
OFF 19
R R/W
Br/L Br/W
B R/W
R Br/L 30
CIRCUIT DIAGRAM
Br/L
Br/W L/W R/W L R/L
32
B
B
L/W
L/W
18 R/L
R/W R/G
23 R/W R/L
B
7 26 R/W R/W
Br/W R/W R/W R/W R/W
R/L R/B
FUEL PUMP SYSTEM
R R/L
9 28
R/G
36
R/W L L/W R/B
R/W L/W L/R R/L B
R/L B G/W B
B
12 R/W B (B)
R/W
Br/L
Br/L Br/L
R/G
R/G
49
8-31
(B)
B
B

(B) (B)
B/W
B/W
B/W
B B/W
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
3. Main switch
4. Main fuse
7. Fuel injection system fuse
9. Backup fuse
12.Ignition fuse
18.Engine ground
19.Battery
23.Joint coupler
30.Relay unit
32.Fuel pump relay
36.Fuel pump
8-32
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Front side cowling/Front panel
2. Rider seat
3. Fuel tank cover
4. Fuel tank

(Main, ignition, backup and fuel in-
jection system) Replace the fuse(s).
ES” on page 8-41.
OK ↓
page 8-42.
OK ↓
OK ↓
4. Check the start/engine stop switch. NG →
OK ↓
5. Check the relay unit (fuel pump re- NG →
lay).
Replace the relay unit.
Refer to “CHECKING THE RE-
OK ↓
6. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PUMP OPERATION” on page 7-3.
OK ↓
8-33
FUEL PUMP SYSTEM
7. Check the entire fuel pump sys- NG →

tem’s wiring. Properly connect or repair the fuel pump
page 8-31.
OK ↓
Replace the ECU.
8-34
EAS31671
EAS20212
R/W R/W
R/W
R
R
RR
4
R R R R R
R
R
R
3
ON
OFF 19
R
Br/L
B R/W
R Br/L
CIRCUIT DIAGRAM
Br/L
B
B
18 R/G
23 R/W
R/W
7
R/W R/W R/W R/W
R/G
R
9
R/G
R/G
12 R/W
R/W
Br/L
Br/L Br/L
R/G
R/G
49
B/W 72
B/W
R/W
8-35
78
L/W
L/B

(B)
B/W

(B) (B)
L/B
COMMUNICATION CONTROL SYSTEM (for YZF-R1M)
71
L/W
L/W L/B
B/W L/W L/B R/W
B/W
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W (B) B/W
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
(Gy)
L/W D L/W
L/B D L/B
W B B/W D B/W
L/W B/W R/G D R/G
Y O
OWY B B YWO L/B R/G
R GW
B G 88
R W
89 L/W L/W L/W L/W L/B L/B L/B L/B
R/G B/W L/B L/W
L/W L/B
O W Y B
(B) 23 B/W B/W B/W B/W

B B/W B/W
R/G
L/W B/W B/W
87 L/B
R/G L/B L/W
D
L/W L/W L/W L/W L/W L/W L/W
(R)
L/W L/B L/B L/W
R/G B/W B/W R/G
A E
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
18.Engine ground
19.Battery
23.Joint coupler
72.Meter assembly
87.YDT coupler
88.CCU (Communication Control Unit)
89.GPS unit
A. Wire harness
E. Sub-wire harness (CCU (Communication
Control Unit))
8-36
EAS31672
TROUBLESHOOTING
The communication control system failed to function.
TIP
2. Rider seat/Passenger seat/Battery cover/Tail cover

ES” on page 8-41.
OK ↓
page 8-42.
OK ↓
OK ↓
4. Check the entire communication NG →
control system’s wiring. Properly connect or repair the communica-
Refer to “CIRCUIT DIAGRAM” on tion control system’s wiring.
page 8-35.
OK ↓
Replace the ECU, CCU, GPS unit,
IMU or meter assembly.
8-37
ELECTRICAL COMPONENTS
EAS20089
5
4
2 7 8
1
3 6 9
26
10
25
24 11
23
22
12
21
13
20
17 14
19
15
16
18
1. Accelerator position sensor 18. ECU (Engine Control Unit)
2. Intake funnel servo motor 19. Radiator fan motor
3. Throttle position sensor 20. Horn
4. Primary injector 21. Headlight control unit
5. Intake air pressure sensor 22. Steering damper solenoid
6. Throttle servo motor 23. SCU (Suspension Control Unit) (for YZF-R1M)
7. Secondary injector 24. Front brake light switch
8. Fuel pump 25. Clutch switch
9. Battery 26. Main switch/Immobilizer unit
10. GPS unit (for YZF-R1M)
11. CCU (Communication Control Unit) (for
YZF-R1M)
12. EXUP servo motor
13. IMU (Inertial Measurement Unit)
14. Hydraulic unit assembly (ABS ECU)
15. Shift sensor
16. Stator coil
17. Crankshaft position sensor
8-38
3 4 5 6
2 7
8
25 9
24
10
23
11
22
12
21
20 13
19 14
18 15
16
17
1. Intake solenoid 20. Front wheel sensor
2. Front fork stepping motor (for YZF-R1M) 21. Cylinder identification sensor
3. Air induction system solenoid 22. Fuse box 3 (SCU fuse) (for YZF-R1M)
4. Ignition coil 23. Rectifier/regulator
5. Atmospheric pressure sensor 24. Intake air temperature sensor
6. Coolant temperature sensor 25. Fuse box 2
7. Neutral switch
(for YZF-R1M)
9. Main fuse
10. Starter relay
11. Relay unit
12. Fuse box 1
15. Rear brake light switch
16. Gear position sensor
18. O2 sensor
8-39
EAS30549
CHECKING THE SWITCHES

Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
2 1
MODE
DOWN
3
10
6 11
12
8
9 13

2. Mode switch
3. Pass/LAP switch
4. Dimmer switch
5. Horn switch
6. Turn signal switch
7. Hazard switch
8. Main switch
9. Sidestand switch
10. Clutch switch
11. Front brake light switch
12. Neutral switch
13. Rear brake light switch
8-40
EAS30551
CHECKING THE FUSES Amperage

Fuses Q’ty
The following procedure applies to all of the fus- rating
es. ABS ECU 7.5 A 1
ECA13680
ABS solenoid 15 A 1
NOTICE
Auxiliary 2A 1
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing Backup 7.5 A 1
a fuse. Electronic throttle valve 7.5 A 1
1. Remove: SCU (for YZF-R1M) 7.5 A 1
• Passenger seat/Rider seat Spare 30 A 1
Refer to “GENERAL CHASSIS (1)” on page Spare 15 A 1
4-1.
Spare 10 A 1
• Front panel (left)
Refer to “GENERAL CHASSIS (3)” on page Spare 7.5 A 1
4-9. Spare 2A 1
2. Check: EWA13310
• Fuse WARNING
a. Connect the digital circuit tester to the fuse
Never use a fuse with an amperage rating
and check the continuity.
other than that specified. Improvising or us-
TIP ing a fuse with the wrong amperage rating
Set the digital circuit tester selector to “ Ω ”. may cause extensive damage to the electri-
cal system, cause the lighting and ignition
Digital circuit tester (CD732) systems to malfunction and could possibly
90890-03243 cause a fire.
Model 88 Multimeter with ta-
4. Install:
chometer
YU-A1927 • Rider seat/Passenger seat
b. If the digital circuit tester indicates “O.L”, 4-1.
replace the fuse. • Front panel (left)
3. Replace: Refer to “GENERAL CHASSIS (3)” on page
• Blown fuse 4-9.
a. Set the main switch to “OFF”. EAS31006
b. Install a new fuse of the correct amperage REPLACING THE ECU (Engine Control Unit)
rating. 1. Turn the main switch to “OFF”.
c. Set on the switches to verify if the electri- 2. Replace the ECU (Engine Control Unit).
cal circuit is operational. 3. Clean the throttle bodies and reset the ISC
d. If the fuse immediately blows again, check (Idle Speed Control) learning value.
the electrical circuit. Refer to “CHECKING AND CLEANING THE
Amperage THROTTLE BODIES” on page 7-14.
Fuses Q’ty 4. Check:
rating
• Engine idling speed
Main 50 A 1
Start the engine, warm it up, and then mea-
Headlight 7.5 A 1 sure the engine idling speed.
Signaling system 7.5 A 1
Engine idling speed
Ignition 15 A 1
1200–1400 r/min
Radiator fan motor 15 A 1
Sub radiator fan motor 10 A 1
Hazard 7.5 A 1
Fuel injection system 15 A 1
ABS motor 30 A 1
8-41
EAS30552
CHECKING AND CHARGING THE BATTERY

TIP
2
Refer to “CHECKING AND CHARGING THE
BATTERY” in “BASIC INFORMATION” (sepa- 1
rate volume).
1. Remove:
• Rider seat/Battery cover
4-1.
2. Disconnect: TIP
• Battery leads Route the positive battery lead “1” to the outside
(from the battery terminals) of the EXUP servo motor lead “3” and starter re-
ECA13640
lay lead “4”.
NOTICE
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”. 4
3
1
1
2
8. Check:
• Battery terminals
3. Remove: Dirt → Clean with a wire brush.
• Battery Loose connection → Connect properly.
Refer to “GENERAL CHASSIS (1)” on page 9. Lubricate:
4-1. • Battery terminals
4. Check: Recommended lubricant
• Battery charge Dielectric grease
5. Charge:
• Battery 10.Install:
6. Install: • Battery cover/Rider seat
• Battery Refer to “GENERAL CHASSIS (1)” on page
4-1.
EAS30553
7. Connect:
CHECKING THE RELAYS
• Battery leads
Check each switch for continuity with the digital
(to the battery terminals)
ECA13630
circuit tester. If the continuity reading is incor-
NOTICE rect, replace the relay.
First, connect the positive battery lead “1”, Digital circuit tester (CD732)
and then the negative battery lead “2”. 90890-03243
chometer
YU-A1927
8-42
1. Disconnect the relay from the wire harness. Relay unit (fuel pump relay)
2. Connect the digital circuit tester (Ω) and bat-
tery (12 V) to the relay terminal as shown.
Check the relay operation. 3 2 1 4
Starter relay
Br/W L/W R/W L R/L
3 L/R L/W R/W L/B L/Y Sb B/Y Sb/W
R/W 1. Positive battery terminal

R/W L/W 2. Negative battery terminal
3. Positive tester probe
1 2 4. Negative tester probe
4
Result
1. Positive battery terminal Continuity
2. Negative battery terminal (between “3” and “4”)
4. Negative tester probe
Radiator fan motor relay
Relay operation
Continuity
(between “3” and “4”) R
R/B
Relay unit (starting circuit cut-off relay) R/W G/Y
1. Positive battery terminal

2. Negative battery terminal
Br/W L/W R/W L R/L 3. Positive tester probe
4. Negative tester probe
Result
1. Positive battery terminal Continuity
2. Negative battery terminal (between “3” and “4”)
4. Negative tester probe EAS30795
CHECKING THE RELAY UNIT (DIODE)

Result 1. Check:
Continuity • Relay unit (diode)
(between “3” and “4”) Out of specification → Replace.

90890-03243
chometer
YU-A1927
8-43
TIP a. Disconnect the relay unit coupler from the

The digital circuit tester readings are shown in wire harness.
the following table. b. Connect the digital circuit tester (Ω) to the
relay unit terminal as shown.
c. Check the relay unit (diode) for continuity.
Continuity
d. Check the relay unit (diode) for no continu-
Positive tester probe
sky blue “1” ity.
Negative tester probe EAS30558
black/yellow “2” CHECKING THE IGNITION COILS

No continuity The following procedure applies to all of the igni-
Positive tester probe tion coils.
black/yellow “2” 1. Check:
Negative tester probe • Primary coil resistance
sky blue “1”
Continuity
Positive tester probe Primary coil resistance
sky blue “1” 0.85–1.15 Ω
Negative tester probe
blue/yellow “3” a. Disconnect the ignition coil coupler from
No continuity
the ignition coil.
blue/yellow “3” b. Connect the digital circuit tester (Ω) to the
Negative tester probe ignition coil as shown.
sky blue “1”
Continuity Digital circuit tester (CD732)
Positive tester probe 90890-03243
sky blue “1” Model 88 Multimeter with ta-
Negative tester probe chometer
sky blue/white “4” YU-A1927
No continuity
Positive tester probe • Positive tester probe
sky blue/white “4” Ignition coil terminal “1”
Negative tester probe • Negative tester probe
Ignition coil terminal “2”
sky blue “1”
Continuity
Positive tester probe 1
blue/black “5” 2
blue/yellow “3”
No continuity
blue/yellow “3”
blue/black “5”
c. Measure the primary coil resistance.

2. Check:
• Secondary coil resistance
Secondary coil resistance

Br/W L/W R/W L R/L 8.50–11.50 kΩ
a. Connect the digital circuit tester (Ω) to the
ignition coil as shown.
8-44

90890-03243
chometer
YU-A1927
• Negative tester probe

Ignition coil terminal “1”
• Positive tester probe
Spark plug terminal “2”
2. Ignition coil
c. Turn the main switch to “ON”.
1
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the “ ” side
of the start/engine stop switch and gradu-
ally increase the spark gap until a misfire
occurs.
EAS30560
2 CHECKING THE CRANKSHAFT POSITION

SENSOR
b. Measure the secondary coil resistance. 1. Disconnect:
EAS30556
• Crankshaft position sensor coupler
CHECKING THE IGNITION SPARK GAP (from the wire harness)
1. Check: 2. Check:
• Ignition spark gap • Crankshaft position sensor resistance
Out of specification → Perform the ignition Out of specification → Replace the crank-
system troubleshooting, starting with step (5). shaft position sensor.
Refer to “TROUBLESHOOTING” on page
8-4. Crankshaft position sensor resis-
tance
Minimum ignition spark gap 189–231 Ω
6.0 mm (0.24 in)
a. Connect the digital circuit tester (Ω) to the
TIP crankshaft position sensor coupler as
shown.
If the ignition spark gap is within specification,
the ignition system circuit is operating normally. Digital circuit tester (CD732)
a. Remove the ignition coil from the spark 90890-03243
plug. Model 88 Multimeter with ta-
b. Connect the ignition checker “1” as chometer
YU-A1927
shown.
Ignition checker • Positive tester probe

90890-06754 black “1”
Oppama pet–4000 spark checker • Negative tester probe
gray “2”
YM-34487
8-45
2. Check:
• Stator coil resistance
Out of specification → Replace the stator coil.
Stator coil resistance

0.112–0.168 Ω
B Gy a. Connect the digital circuit tester to the sta-

tor coil coupler as shown.

b. Measure the crankshaft position sensor 90890-03243
resistance. Model 88 Multimeter with ta-
EAS30562
chometer
CHECKING THE STARTER MOTOR YU-A1927
OPERATION
1. Check: • Positive tester probe
white “1”
• Starter motor operation • Negative tester probe
Does not operate → Perform the electric white “2”
starting system troubleshooting, starting with
step (4). • Positive tester probe
Refer to “TROUBLESHOOTING” on page white “1”
8-10. • Negative tester probe
a. Connect the positive battery terminal “1” white “3”
and starter motor lead “2” with a jumper
lead “3”. white “2”
EWA13810
WARNING white “3”
• A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn. 1 2 3
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
W W W
fluid is in the vicinity.
b. Measure the stator coil resistance.

EAS30680
CHECKING THE RECTIFIER/REGULATOR

1. Check:
• Rectifier/regulator input voltage
Out of specification → Correct the stator coil
condition.
b. Check the starter motor operation. Refer to “CHECKING THE STATOR COIL”
EAS30566 on page 8-46.
CHECKING THE STATOR COIL
1. Disconnect: Rectifier/regulator input voltage
• Stator coil coupler above 14 V at 5000 r/min
(from the wire harness)
a. Connect the digital circuit tester (AC V) to
the rectifier/regulator coupler as shown.
8-46

90890-03243
2
chometer 1
YU-A1927

white “1”
white “2”
b. Start the engine and let it run at approxi-
• Positive tester probe mately 5000 r/min.
white “1” c. Measure the charging voltage.
white “3” EAS30569
CHECKING THE HORN

• Positive tester probe 1. Check:
white “2” • Horn sound
• Negative tester probe Faulty sound → Replace.
white “3”
EAS30573
CHECKING THE FUEL SENDER

1. Disconnect:
1 2 3 • Fuel pump coupler
(from the wire harness)
• Fuel hose
W W W (from the fuel tank)
2. Remove:
• Fuel tank
3. Remove:
b. Start the engine and let it run at approxi- • Fuel pump
mately 5000 r/min. (from the fuel tank)
c. Measure the rectifier/regulator input volt- 4. Connect:
age. • Fuel pump coupler
2. Check: • Fuel hose
• Rectifier/regulator output voltage 5. Turn the main switch to “ON”.
Out of specification → Replace the rectifier/ 6. Check:
regulator. • Fuel level warning light
Out of specification → Replace the fuel
Regulated voltage (DC) pump.
14.3–14.7 V
• Fuel pump is atmosphere “A”
a. Connect the digital circuit tester (DC V) to → Fuel level warning light is come on
• Fuel pump is soaked in fuel “B”
the battery as shown. → Fuel level warning light is goes off
90890-03243
chometer
YU-A1927

positive battery terminal “1”
negative battery terminal “2”
8-47
EAS30574 c. Measure the radiator fan motor move-

CHECKING THE FUEL LEVEL WARNING ment.
LIGHT
EAS30578
This model is equipped with a self-diagnosis de- CHECKING THE COOLANT TEMPERATURE
vice for the fuel level detection circuit. SENSOR
1. Check: 1. Remove:
• Fuel level warning light “1” • Coolant temperature sensor
(Turn the main switch to “ON”.) Refer to “CYLINDER HEAD” on page 5-32.
Warning light comes on for a few seconds, EWA14130
then goes off → Warning light is OK. WARNING

Warning light does not come on → Replace • Handle the coolant temperature sensor
the meter assembly. with special care.
Warning light flashes eight times, then goes • Never subject the coolant temperature sen-
off for 3 seconds in a repeated cycle (mal- sor to strong shocks. If the coolant tem-
function detected in fuel sender) → Replace perature sensor is dropped, replace it.
the fuel pump assembly.
2. Check:
• Coolant temperature sensor resistance
1
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)
EAS30577
CHECKING THE RADIATOR FAN MOTORS a. Connect the digital circuit tester (Ω) to the
1. Check: coolant temperature sensor as shown.
• Radiator fan motor
Faulty/rough movement → Replace. Digital circuit tester (CD732)
a. Disconnect the radiator fan motor coupler 90890-03243
from the wire harness. Model 88 Multimeter with ta-
b. Connect the battery (DC 12 V) as shown. chometer
• Positive tester probe YU-A1927
blue “1”
• Negative tester probe b. Immerse the coolant temperature sensor
black “2” “1” in a container filled with coolant “2”.
TIP
Make sure the coolant temperature sensor ter-
minals do not get wet.
c. Place a thermometer “3” in the coolant.
8-48
2
3
1 1
2 1
3V
d. Heat the coolant or let it cool down to the 2
specified temperatures.
e. Measure the coolant temperature sensor
1
resistance.
3. Install:
• Coolant temperature sensor
Coolant temperature sensor 1

16 N·m (1.6 kgf·m, 12 lb·ft) 3V
T.
R.
EAS30592 A. Check that the throttle valves “2” open.

CHECKING THE THROTTLE SERVO MOTOR B. Check that the throttle valves “2” fully close.
1. Remove:
EAS30587
• Air filter case
SOLENOID
2. Check:
1. Check:
• Throttle valve operation
• Air induction system solenoid resistance
Throttle valves do not fully close → Replace
the throttle bodies.
a. Connect two C-size batteries to the throttle Solenoid resistance
servo motor terminals “1” as shown. 18–22 Ω
ECA17660
NOTICE a. Remove the air induction system solenoid

Do not use a 12 V battery to operate the throt- coupler from the air induction system sole-
tle servo motor. noid.
b. Connect the digital circuit tester (Ω) to the
TIP
air induction system solenoid terminal as
Do not use old batteries to operate the throttle shown.
servo motor.
90890-03243
chometer
YU-A1927

orange “1”
green “2”
8-49

white/black (wire harness color)
black/blue (wire harness color)
O G 1
c. Measure the air induction system solenoid

resistance.
EAS30589
CHECKING THE CYLINDER

IDENTIFICATION SENSOR c. Turn the main switch to “ON”.
1. Remove: d. Rotate the crankshaft.
• Fuel tank e. Measure the voltage. With each full rota-
Refer to “FUEL TANK” on page 7-1. tion of the crankshaft, the voltage reading
• Air filter case should cycle from 0.8 V to 4.8 V to 0.8 V to
Refer to “AIR FILTER CASE” on page 7-5. 4.8 V.
• Air filter case duct
EAS30594
Air cut-off valve CHECKING THE INTAKE AIR
Refer to “AIR INDUCTION SYSTEM” on TEMPERATURE SENSOR
page 7-19. 1. Remove:
2. Check: • Intake air temperature sensor
• Cylinder identification sensor output voltage EWA14110
Out of specification → Replace. WARNING

• Handle the intake air temperature sensor
Cylinder identification sensor
with special care.
output voltage (ON)
4.8 V • Never subject the intake air temperature
Cylinder identification sensor sensor to strong shocks. If the intake air
output voltage (OFF) temperature sensor is dropped, replace it.
0.8 V 2. Check:
• Intake air temperature sensor resistance
a. Connect the test harness– speed sensor
(3P) “1” to the rear speed sensor coupler
and wire harness as shown. Intake air temperature sensor re-
b. Connect the digital circuit tester (DC V) to sistance
the test harness– speed sensor (3P). 5400–6600 Ω at 0 °C (5400–6600
Ω at 32 °F)
Digital circuit tester (CD732) Intake air temperature sensor re-
90890-03243 sistance
Model 88 Multimeter with ta- 289–391 Ω at 80 °C (289–391 Ω
chometer at 176 °F)
YU-A1927
Test harness– speed sensor (3P) a. Connect the digital circuit tester (Ω) to the
90890-03208 intake air temperature sensor terminal as
Test harness– speed sensor (3P) shown.
YU-03208
8-50
Digital circuit tester (CD732) Digital circuit tester (CD732)

90890-03243 90890-03243
Model 88 Multimeter with ta- Model 88 Multimeter with ta-
chometer chometer
YU-A1927 YU-A1927
b. Immerse the intake air temperature sen- • Positive tester probe

sor “1” in a container filled with water “2”. black “1”
TIP • Negative tester probe
black “2”
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.
3
1
B B
1 2
2
c. Measure the steering damper solenoid re-
sistance.
d. Slowly heat the water, then let it cool down
EAS30681
to the specified temperature. CHECKING THE FUEL INJECTORS
e. Measure the intake air temperature sen- The following procedure applies to all of the fuel
sor resistance. injectors.
3. Install: 1. Remove:
• Intake air temperature sensor • Fuel injector
EAS30598 Refer to “THROTTLE BODIES” on page 7-11
CHECKING THE STEERING DAMPER or “AIR FILTER CASE” on page 7-5.
SOLENOID 2. Check:
1. Remove: • Fuel injector resistance
• Front upper cowling Out of specification → Replace the fuel injec-
Refer to “GENERAL CHASSIS (4)” on page tor.
4-13.
2. Check: Resistance
• Steering damper solenoid resistance 12.0 Ω
Out of specification → Replace the steering
a. Disconnect the fuel injector coupler from
damper assembly.
the fuel injector.
Steering damper solenoid resis- b. Connect the digital circuit tester (Ω) to the
tance fuel injector coupler as shown.
49.82–56.18 Ω
a. Disconnect the steering damper lead cou- 90890-03243
pler from wire harness. Model 88 Multimeter with ta-
b. Connect the digital circuit tester (Ω) to the chometer
YU-A1927
steering damper lead coupler.
Injector terminal “1”
Injector terminal “2”
8-51

white/black “4”
black/yellow “3”
e. When turning the wheel switch in direction

“a”, check that the output voltage is within
the specified values.
Output voltage
More than 5 V
c. Measure the fuel injector resistance.
f. When turning the wheel switch in direction
EAS31673
CHECKING THE WHEEL SWITCH “b”, check that the output voltage is within
1. Check: the specified values.
• Wheel switch “1” output voltage Output voltage
Out of specification → Replace the handlebar Less than 0.5 V
switch (right).
a. Connect the digital circuit tester (DC V) to
the handlebar switch coupler (right) as 2
shown.
Digital circuit tester (CD732) a

90890-03243
chometer
YU-A1927 4 3 b
• Positive tester probe 1

white/green “2”
black/yellow “3”
b. Turn the main switch to “ON”.

c. When turning the wheel switch in direction
“a” and “b”, check that the output voltage is
within the specified values.
Output voltage reading cycle

More than 5 V to less than 0.5 V
then back to more than 5 V to
less than 0.5 V
d. Connect the digital circuit tester (DC V) to

the handlebar switch coupler (right) as
shown.

90890-03243
chometer
YU-A1927
8-52
8-53
SELF DIAGNOSTIC
SELF-DIAGNOSTIC FUNCTION..................................................................... 9-1

GLOSSARY............................................................................................... 9-1
OUTLINE ...................................................................................................9-1
CHECKING THE WARNING LIGHT .........................................................9-1
YDT ...........................................................................................................9-2
PARTS CONNECTED TO THE ECU ........................................................9-3
PARTS CONNECTED TO THE SCU (for YZF-R1M)................................9-3
PARTS CONNECTED TO THE ABS ECU................................................ 9-4
PRECAUTIONS FOR ROAD TEST .......................................................... 9-4
SYSTEM DIAGRAM ........................................................................................9-5

ECU CIRCUIT DIAGRAM..........................................................................9-5
ECU COUPLER LAYOUT ......................................................................... 9-8
FUEL INJECTION SYSTEM..........................................................................9-11

CIRCUIT DIAGRAM ................................................................................ 9-11
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-13
[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS
NOT NORMAL........................................................................................ 9-14
[B] THE MIL DOES NOT COME ON, BUT THE ENGINE OPERATION
IS NOT NORMAL ...................................................................................9-14
IMMOBILIZER SYSTEM................................................................................ 9-15

CIRCUIT DIAGRAM ................................................................................ 9-15
SYSTEM OUTLINE ................................................................................. 9-17
PART REPLACEMENT AND KEY CODE REGISTRATION
REQUIREMENTS...................................................................................9-17
HOW TO CHECK DTC............................................................................9-22
ABS (Anti-lock Brake System) .................................................................... 9-23

CIRCUIT DIAGRAM ................................................................................ 9-23
ABS COMPONENTS CHART .................................................................9-25
ABS COUPLER LOCATION CHART ......................................................9-26
MAINTENANCE OF THE ABS ECU .......................................................9-27
ABS TROUBLESHOOTING OUTLINE....................................................9-27
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 9-28
[A] CHECKING THE ABS WARNING LIGHT..........................................9-30
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............. 9-30
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................9-30
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 9-30
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE ........................ 9-30
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE ........................ 9-31
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................... 9-31
[B-2] DIAGNOSIS USING THE DTC .......................................................9-31
9
[B-3] DELETING THE DTC ..................................................................... 9-32
[C-1] FINAL CHECK ................................................................................ 9-32
STEERING DAMPER SYSTEM .................................................................... 9-33
CIRCUIT DIAGRAM ................................................................................ 9-33
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM

(for YZF-R1M) ..............................................................................................9-37
CIRCUIT DIAGRAM ................................................................................ 9-37
MAINTENANCE OF THE SCU (suspension control unit) .......................9-39
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........9-40

DTC TABLE............................................................................................. 9-40
SELF-DIAGNOSTIC FUNCTION TABLE
(FOR FUEL INJECTION SYSTEM)........................................................ 9-46
SELF-DIAGNOSTIC FUNCTION TABLE
(FOR IMMOBILIZER SYSTEM) ............................................................. 9-60
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake
System)) .................................................................................................9-61
SELF-DIAGNOSTIC FUNCTION TABLE (FOR STEERING DAMPER
SYSTEM)................................................................................................9-65
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ELECTRONICALLY
ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M)).......................9-66
COMMUNICATION ERROR WITH THE METER ................................... 9-68
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 9-69
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................9-72
DIAGNOSTIC CODE TABLE (SCU) (for YZF-R1M) ...............................9-74
EVENT CODE TABLE...................................................................................9-75
30_EVENT ..................................................................................................... 9-77

70_EVENT ..................................................................................................... 9-79

C0044 ............................................................................................................9-80
C0520 (FI) ...................................................................................................... 9-81

C0520 (SCU).................................................................................................. 9-85

C1000 ............................................................................................................9-86
C1002 ............................................................................................................9-89
C1003 ............................................................................................................9-90
C1007 ............................................................................................................9-96
P0030............................................................................................................. 9-97
P0050...........................................................................................................9-101
TROUBLESHOOTING ..........................................................................9-101
P0069...........................................................................................................9-105
P00D1, P2195..............................................................................................9-107
P00D3, P2197..............................................................................................9-111
P0107, P0108 ..............................................................................................9-115

P0112, P0113 ..............................................................................................9-119

P0117, P0118 ..............................................................................................9-123

P0122, P0123, P0222, P0223, P2135 .........................................................9-127

P0132...........................................................................................................9-131
P0152...........................................................................................................9-134
P0201...........................................................................................................9-137
P0202...........................................................................................................9-140
P0203...........................................................................................................9-143
P0204...........................................................................................................9-146
P0335...........................................................................................................9-149
P0340...........................................................................................................9-152
P0351...........................................................................................................9-155
P0352...........................................................................................................9-159
P0353...........................................................................................................9-163
P0354...........................................................................................................9-167
P0475, P0476, P048B .................................................................................9-171

P0480...........................................................................................................9-175
P048D, P048E .............................................................................................9-178

P0500 (FI), P1500........................................................................................9-181

P0500 (SCU)................................................................................................9-193
P0560 (FI), P0563........................................................................................9-194

P0560 (SCU)................................................................................................9-195
P0601...........................................................................................................9-196
P0606...........................................................................................................9-197
P062F ..........................................................................................................9-198
P0638...........................................................................................................9-200
P0657...........................................................................................................9-204
P0916, P0917 ..............................................................................................9-208

P1400...........................................................................................................9-212
P1600...........................................................................................................9-216
P1601...........................................................................................................9-220
P1602...........................................................................................................9-224
P1806, P1807 ..............................................................................................9-228

P2122, P2123, P2127, P2128, P2138 .........................................................9-232

P2158 (FI) ....................................................................................................9-236

P2158 (SCU)................................................................................................9-240
P21CF ..........................................................................................................9-241
P21D0 ..........................................................................................................9-244
P21D1 ..........................................................................................................9-247
P21D2 ..........................................................................................................9-250
P2228, P2229 ..............................................................................................9-253

U0100 ..........................................................................................................9-257
U0121 ..........................................................................................................9-260
U0125 (FI) ....................................................................................................9-263

U0125 (SCU)................................................................................................9-267
U0155 or Err (FI) .........................................................................................9-270

U0155 or Err (SCU).....................................................................................9-274

51_IMMOBILIZER .......................................................................................9-277
52_IMMOBILIZER .......................................................................................9-278
53_IMMOBILIZER .......................................................................................9-279
54_IMMOBILIZER .......................................................................................9-280
55_IMMOBILIZER .......................................................................................9-281
56_IMMOBILIZER .......................................................................................9-282
11_ABS .......................................................................................................9-283
12_ABS .......................................................................................................9-284
13, 26_ABS .................................................................................................9-285

14, 27_ABS .................................................................................................9-286

15_ABS .......................................................................................................9-287
16_ABS .......................................................................................................9-289
21_ABS .......................................................................................................9-291
31_ABS .......................................................................................................9-292
33_ABS .......................................................................................................9-294
34_ABS .......................................................................................................9-296
41_ABS .......................................................................................................9-297
42_ABS .......................................................................................................9-298
43, 45_ABS .................................................................................................9-299

44, 46_ABS .................................................................................................9-300
51_ABS .......................................................................................................9-301
53_ABS .......................................................................................................9-302
55_ABS .......................................................................................................9-304
56_ABS .......................................................................................................9-305
57_ABS .......................................................................................................9-306
62_ABS .......................................................................................................9-310
68_ABS .......................................................................................................9-311
89_ABS .......................................................................................................9-312
90_ABS .......................................................................................................9-315
91_ABS .......................................................................................................9-318
SELF-DIAGNOSTIC FUNCTION
EAS20437
EAS33142
GLOSSARY
Word Description
MIL
MIL is an indicator light that comes on when a control unit determines a malfunc-
(Malfunction indicator
tion.
light)
DTC
DTC is a code that is saved within a control unit’s memory when the control unit
(Diagnostic trouble
determines a malfunction.
code)
Current malfunction A DTC for an unrecovered, current malfunction.
Recovered malfunc-
A DTC for a previously determined but now recovered malfunction.
tion
OBD
Self-diagnostic system is equipped in a control unit for the emission control sys-
(On-board diagnos-
tem.
tics)
GST
Generic diagnostic tool that complies with OBD standards.
(Generic scan tool)
YDT
(Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles.
tool)
EAS32858
OUTLINE
The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat-
ing normally. If this function detects a malfunction in the system, it immediately operates the system
under substitute characteristics and illuminates the warning light to alert the rider that a malfunction has
occurred in the system. Once a malfunction has been detected, a DTC is stored in the memory of the
control unit.
EAS32859
CHECKING THE WARNING LIGHT

The warning light comes on after the main switch has been set 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. Therefor, 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 ECU software.
• Using the electrical accessory which may affect the ECU.
• Using the incorrect specification of spark plug and fuel injector. Using the third party accessories such
as suspension and exhaust system.
• Change of specifications of drive chain, sprocket, wheel and tire.
• Removing or modifying the O2 sensor, the air induction system, the exhaust system part (catalyst, EX-
UP, etc.).
• Poor maintenance of the drive chain and tire air pressure.
• Incorrect brake pedal height, rear brake dragging.
• Excessive opening and closing of the throttle grip, frequently used of burnout, wheelie and half clutch.
• Air mixture by fuel supply badness.
9-1
4 3 2 1
System Lighting up warning light Lighting time

FUEL INJECTION SYSTEM MIL “2” 2.0 seconds
About 0.15 sec-
IMMOBILIZER SYSTEM Immobilizer system indicator light “3”
onds
ABS (Anti-lock Brake System) ABS warning light “1” *
STEERING DAMPER SYS-
Auxiliary system warning light “4” 2.0 seconds
TEM
ELECTRONICALLY ADJUST-
ABLE SUSPENSION SYS- Auxiliary system warning light “4” 2.0 seconds
TEM (for YZF-R1M)
TIP
*: The ABS warning light goes off when the vehicle is judged to normal with running.
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.

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.
9-2
Connecting the YDT

Remove the protective cap “1”, and then connect the YDT to the coupler.
EAS32864
PARTS CONNECTED TO THE ECU

The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Fuel pump
• Primary injector #1 • Auxiliary light
• Primary injector #2 • O2 sensor 2 (right side)
• Primary injector #3 • Hydraulic unit assembly (ABS ECU)
• Primary injector #4 • Air induction system solenoid
• Secondary injector #1 • Throttle servo motor
• Secondary injector #2 • Relay unit
• Secondary injector #3 • Starter relay
• Secondary injector #4 • Radiator fan motor relay
• Ignition coil #1 • Meter assembly
• Ignition coil #2 • Immobilizer unit
• Ignition coil #3 • Steering damper solenoid
• Ignition coil #4 • EXUP servo motor
• Throttle position sensor • Cylinder identification sensor
• Accelerator position sensor • Intake funnel servo motor
• Intake air pressure sensor • Intake solenoid
• Atmospheric pressure sensor • Headlight control unit
• Coolant temperature sensor • Handlebar switch (left and right)
• Gear position sensor • IMU (Inertial Measurement Unit)
• Shift sensor • SCU (Suspension Control Unit) (YZF-R1M)
• Intake air temperature sensor • CCU (Communication Control Unit) (YZF-R1M)
• O2 sensor 1 (left side)
EAS32865
PARTS CONNECTED TO THE SCU (for YZF-R1M)

The following parts are connected to the SCU.
parts beforehand.
• Front fork stepping motor (left) • Sub radiator fan motor
• Front fork stepping motor (right) • Auxiliary DC connector
9-3
• Rear shock absorber assembly stepping motor • Sidestand switch

(compression damping)
• Rear shock absorber assembly stepping motor (re- • Fuel sender
bound damping)
• Steering damper solenoid (OPTION) • Fuel pump
• ECU (Engine Control Unit) • Handlebar switch (left)
• Hydraulic unit assembly (ABS ECU) • Headlight control unit
• Meter assembly • Auxiliary light
• IMU (Inertial Measurement Unit) • Front turn signal light (right and left)
• CCU (Communication Control Unit) • Steering damper solenoid
• Radiator fan motor
EAS32918
PARTS CONNECTED TO THE ABS ECU

The following parts are connected to the hydraulic unit assembly (ABS ECU).
parts beforehand.
• SCU (Suspension Control Unit) (YZF-R1M) • Rear wheel sensor
• Meter assembly • Immobilizer unit
• IMU (Inertial Measurement Unit) • Handlebar switch (right and left)
• ECU (Engine Control Unit) • Rear brake light switch
• CCU (Communication Control Unit) (YZF-R1M) • Tail/brake light
• Front wheel sensor
EAS33137
PRECAUTIONS FOR ROAD TEST

EWA20860
WARNING
When test riding the vehicle, always comply with local traffic regulations.
9-4
SYSTEM DIAGRAM
EAS20387
SYSTEM DIAGRAM
EAS32920
ECU CIRCUIT DIAGRAM

A
29 16
2. Electronic throttle valve fuse B 34. Primary injector #1
26
10. Fuel pump 15
3. Backup fuse relay 35. Primary injector #2
32
14
4. Fuel injection 9. Start/engine 36. Primary injector #3
system fuse stop switch 11. Fuel pump
13
13. Neutral 41 37. Primary injector #4
5. Ignition fuse 12. Starter
relay indicator 24
light 38. Secondary injector #1
6. Main switch 96
23
7. Main fuse 15. Starter 39. Secondary injector #2
M
motor
C 22
40. Secondary injector #3
8. Battery
14. Starting circuit 21
cut-off relay
95
19. Rectifier/regulator 1. ECU (Engine
16. Clutch Control Unit)
switch 64 42. Immobilizer unit
80 18 A
9. Start/engine
stop switch 43. Throttle servo motor
17. Sidestand 18. Neutral 1
switch switch 10
34
33
B 44. Ignition
coil #1
72 9
92 45. Ignition
coil #2
21. Crankshaft 8
76
position
sensor 46. Ignition
coil #3
7
22. EXUP servo motor 60
47. Ignition
23. Atmospheric coil #4
pressure sensor 69 6
24. Intake air pressure 17
sensor 68 25
25. Coolant temperature sensor

102
26. Intake air temperature sensor
86
27. Shift sensor 71
9-5
SYSTEM DIAGRAM
73 30
48. Intake funnel servo motor
28. Gear position sensor 103
89 31
29. O2 sensor 1 84 53
(left side) 22. EXUP servo motor
5
30. O2 sensor 2 100 47

(right side)
4
49. Steering damper solenoid
88 39
37
31. Throttle position
43 50. Intake solenoid
sensor 11
31. Throttle position
sensor 56
49 51. Air induction system
solenoid
20
45
52. Radiator fan
35 motor relay
32. Accelerator position
42 C
sensor
19
32. Accelerator position
51
sensor
54 28
57 54. Pass/LAP
53. Dimmer switch
33. Hydraulic unit assembly 105 switch
(ABS ECU)
107
55. Headlight
control unit
56. Meter assembly
77
57. CAN communication
61 circuit
9-6
SYSTEM DIAGRAM
1. ECU (Engine Control Unit) 54. Pass/LAP switch

2. Electronic throttle valve fuse 55. Headlight control unit
3. Backup fuse 56. Meter assembly
4. Fuel injection system fuse 57. CAN communication circuit
5. Ignition fuse
6. Main switch
7. Main fuse
8. Battery
10. Fuel pump relay
11. Fuel pump
12. Starter relay
13. Neutral indicator light
14. Starting circuit cut-off relay
15. Starter motor
16. Clutch switch
18. Neutral switch
19. Rectifier/regulator
21. Crankshaft position sensor
22. EXUP servo motor
23. Atmospheric pressure sensor
24. Intake air pressure sensor
25. Coolant temperature sensor
26. Intake air temperature sensor
27. Shift sensor
28. Gear position sensor
29. O2 sensor 1 (left side)
30. O2 sensor 2 (right side)
31. Throttle position sensor
32. Accelerator position sensor
42. Immobilizer unit
43. Throttle servo motor
44. Ignition coil #1
48. Intake funnel servo motor
49. Steering damper solenoid
50. Intake solenoid
51. Air induction system solenoid
53. Dimmer switch
9-7
SYSTEM DIAGRAM
EAS33369
ECU COUPLER LAYOUT
1 2 3 4 5 6 7 8 9 35 36 37 38 39 40 41
10 11 12 13 14 15 16 17 42 43 44 45 46 47 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76
18 19 20 21 22 23 24 25 48 49 50 51 52 53 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92
26 27 28 29 30 31 32 33 34 54 55 56 57 58 59 60 93 94 95 96 97 98 99 100101102103104105106107108
Wire harness Wire harness

No. Connected parts No. Connected parts
color color
1 Throttle servo motor Y/R Pass/LAP switch, dim-
2 — — 28 mer switch, headlight Y/B
control unit
3 — —
29 Fuel pump relay L/W
O2 sensor 2 (right Intake funnel servo
4 P/W 30 Y/L
side) motor
Intake funnel servo
5 O2 sensor 1 (left side) P/B 31 Sb
motor
6 Ignition coil #4 Gy/G 32 Fuel pump relay R/L
7 Ignition coil #3 O/G 33 Ground B/W
8 Ignition coil #2 Gy/R 34 Ground B/W
9 Ignition coil #1 O Accelerator position

35 L/Y
sensor
10 Throttle servo motor Lg/R
36 — —
11 Intake solenoid L/R
Throttle position sen-
12 — — 37 L
sor
13 Primary injector #4 O/B 38 — —
14 Primary injector #3 L/B Steering damper sole-
39 Y/B
15 Primary injector #2 G/B noid
16 Primary injector #1 R/B 40 — —
17 Ground B 41 Ignition fuse R/W
Electronic throttle Accelerator position
18 R/L 42 W
valve fuse sensor
Radiator fan motor re- Throttle position sen-
19 G/Y 43 W
lay sor
Air induction system 44 — —
20 Br/R
solenoid Accelerator position
45 L/G
21 Secondary injector #4 Br/B sensor
22 Secondary injector #3 Br/Y 46 — —
23 Secondary injector #2 Sb/W 47 EXUP servo motor B/R
24 Secondary injector #1 W/L 48 — —
25 Ground B Throttle position sen-
49 B/G
sor
26 Backup fuse R/G
50 — —
27 — —
Accelerator position
51 B
sensor
9-8
SYSTEM DIAGRAM
Wire harness Wire harness

No. Connected parts No. Connected parts
color color
52 — — 83 — —
53 EXUP servo motor B/G
84 O2 sensor 1 (left side) Gy/G
Accelerator position
54 B/L
sensor 85 — —
55 — — Intake air tempera-
86 Br/W
ture sensor
Throttle position sen-
56 B
sor 87 — —
Accelerator position Cylinder identification
57 B/Y
sensor sensor, crankshaft po-
sition sensor, EXUP
58 — —
servo motor, atmo-
59 — — spheric pressure sen-
60 EXUP servo motor W/Y sor, intake air
88 pressure sensor, cool- B/L
CAN communication ant temperature sen-
61 L/B
circuit sor, intake air
62 — — temperature sensor,
shift sensor, O2 sen-
63 — — sor 1 (left side), O2
64 Immobilizer unit Y/L sensor 2 (right side)
65 — — 89 Gear position sensor W
66 — — 90 — —
67 — — 91 — —
Intake air pressure Cylinder identification
68 P/W 92 W/B
sensor sensor
Atmospheric pres- 93 — —
69 P
sure sensor
94 — —
70 — —
Clutch switch, relay
71 Shift sensor V 95 L/Y
unit
Cylinder identification Starter relay, relay
sensor, EXUP servo 96 L/W
unit
motor, atmospheric
72 L 97 — —
pressure sensor, in-
take air pressure sen- 98 — —
sor, shift sensor
99 — —
73 Gear position sensor L/R
O2 sensor 2 (right
74 — — 100 Gy/Y
side)
75 — —
Crankshaft position 101 — —
76 Gy
sensor Coolant temperature
102 G/W
CAN communication sensor
77 L/W
circuit 103 Gear position sensor G
78 — — 104 — —
79 — — Hydraulic unit assem-
105 Gy/B
Starting circuit cut-off bly (ABS ECU)
80 B/Y
relay, clutch switch 106 — —
81 — — Hydraulic unit assem-
107 W/L
82 — — bly (ABS ECU)
108 — —
9-9
SYSTEM DIAGRAM
9-10
EAS32871
EAS20440
R/L R/L R/L R/L R/L R/L R/L
R/W R/W R/W R/W R/L R/L R/L R/L
R/W R/W R/W R/W
R
R
RR
4 R/W
R R R R R R/W R/W
R R/W A R/W L/R A L/R R/W R/W
R R/W R/W
R 37 51
L/R O
3 L/R R/W O R/W
ON (B)
50 (B)
OFF 19
R R/W R/W
Br/W O 52
Br/L Gy/R Gy/R
BB R/W Gy/R R/W
O/G
R Br/L 30 50
CIRCUIT DIAGRAM
W W Gy/G
32 L/R G W (B)
Br/L 31 38 G G
B Br/W L/W R/W L R/L L/R L/R
B (Dl) R/W
L/W
Sb L/Y L/B L/W O/G
R/L O/G R/W
18 B/Y R/L
R/W R/G 50 (B)
23 R/W
B R/W R/L
L/Y R/W
R/W B/Y 54
7 26 R/W R/W Gy/G
Br/W Y/G W/R L/Y B L/B R/W B B P/B P/B Gy/G R/W
R/W R/W R/W R/W
R/G R/L R/B Y/R W/B B/L L/G B/L W L Gy/G Gy/G 50
5 8 Y/B W/G W B/Y L/Y B (B)
R R/L L/Y 34 R/L
R/W P/W B B 39 B B R/W P/B
G/Y B (B)
(B) L/Y 40 Br/R Br/R G O R/W
9 B B Gy/Y B/L W L W L Gy/G B/L
R 28
R/G (B) (B)
R/B B (B) (B) (B) 55 O G Br/R R/W
29 36 R/W B B P/W P/W
R/W G/Y B
R/W L L/W R/B Sb L/B B B/L W L Gy/Y Gy/Y
Y/G W/G R/B R/B R/L
R/W L/W B/Y
L/R R/L Y/B Y/R W/B W/R B
B/Y (B)
B/Y B R/L B G/W B R L R/LR/B 56 R/L G/B
B/Y L/G B/L L/Y 33 B/L V L R W B W V V 57
B 41
B W B B/L G/B G/B R/L
B (B) (B)
FUEL INJECTION SYSTEM
12 R/W (B)
R/W L/B L/B R/L
Br/L L
B/L P/W L B/L R/L L/B 58 R/L O/B
Br/L Br/L 42 P/W P/W 59
(Dl) O/B O/B R/L
14 L
R/B W/L W/L R/L
B/L
B/L P L 43 P P Sb/W
Br/Y
LLL Br/B
60 Sb/WR/L
(Dl) W/L R/L
L L L
R/G L/Y L L (Gy) 61 (Gy)
R/G 44 W W/B W/B Sb/W R/L
B/L
49 Br/Y R/L
L W/B W L/Y
B/L B/L L W/Y B/L 62
B/W 72 Br/Y R/L Br/B R/L
B/W (B) (B) G B/G B/R
(Gy) 63 (Gy)
(B) Br/B R/L
L W/Y W/Y
45 B/G B/G Y/L Y/L R
B/L B/R B/R Sb Sb B 64 R B Sb Y/L
75
Gy Gy Gy Gy
B/L Gy B Gy 46 Lg/R Lg/R
91 B/Y L/Y R/W B B/L Y/R Y/R 65 Lg/R Y/R
9-11
L/W (B)
G/W B G/W G/W
G/W B/L 47 B/L B B/L Y/B Y/B B B
(B)
66 B B Y/B B
Br/W C Br/W Br/W
Br/W B/L 48 B/L C B/L
78 B/L
L/W B/Y L/W (B)
B L/R L/B
B/L B/L B/L B/L B/L L/B Y/L P/W P V L L/R Gy
B/L B/L B/L B/L B/L B/L
B/Y L/Y L/W B/Y Gy/G Br/W B/L W W/B
L/W B/W L/Y L/W Gy/Y G/W G Gy/B W/L
L/Y
B/L (B)
B 81 L/G
B B/W B/Y
B
99
W
B
B
Y/B
B Y/R P/W P/B Gy/G O/G Gy/R O L/Y L Y/B R/W B W W B
Y/B Lg/R L/R O/B L/B G/B R/B B W W L/G B/R Gy/B Gy/B
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B B/G B B/G W/L W/L W W
B B 68
R/W B/W R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y G/Y
(B) (B) Y/B W W
B/G B/G B B 69
L/B
71 W W 67
B B Y/B W B/G L B 70 B B
L/W B W W B
L L
L/W L/B (B)
B/W L/W L/B R/W
104 B/W B
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W (B) B/W B
R/B
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y L/B
(Gy) L/W
R/Y B Y/B Y B R/Y B/W B

(B)
L/W Gy/B L Y G R/B B L/W B/W
R/W G/O W/L L B W W L/B B
L/W L/W L/W L/W L/B L/B L/B L/B
(B)
L/W L/B
23 B/W B/W B/W B/W

B B/W BB B/W
R/G
L/W B/W B/W
87 L/B
R/G L/B L/W
A B C ** L/W L/W L/W L/W L/W L/W L/W
(R)
R/W L/R L/R R/W B/L G/W G/W B/L Br/W B/L B/L Br/W
(B) (B) (B) (B)
A B A C A D
3. Main switch 70.Throttle position sensor

4. Main fuse 71.IMU (Inertial Measurement Unit)
5. Radiator fan motor relay 72.Meter assembly
7. Fuel injection system fuse 75.MIL (Malfunction indicator light)
8. Electronic throttle valve fuse 78.Multi-function meter
9. Backup fuse 81.Auxiliary system warning light
12.Ignition fuse 87.YDT coupler
14.ABS ECU fuse 91.Handlebar switch (left)
18.Engine ground 99.Clutch switch
19.Battery 104.Headlight control unit
23.Joint coupler
A. Wire harness
B. Sub-wire harness (Intake solenoid)
C. Sub-wire harness (Coolant temperature
29.Accelerator position sensor sensor)
30.Relay unit D. Sub-wire harness (Intake air temperature
31.Starting circuit cut-off relay sensor)
32.Fuel pump relay *. Joint coupler for YZF-R1
33.Neutral switch **. Joint coupler for YZF-R1M
34.Sidestand switch
36.Fuel pump
37.Intake solenoid
38.Gear position sensor
39.O2 sensor 1 (left side)
40.O2 sensor 2 (right side)
41.Shift sensor
42.Intake air pressure sensor
43.Atmospheric pressure sensor
44.Cylinder identification sensor
45.EXUP servo motor
46.Crankshaft position sensor
48.Intake air temperature sensor
50.Spark plug
51.Ignition coil #1
52.Ignition coil #2
53.Ignition coil #3
54.Ignition coil #4
55.Air induction system solenoid
56.Primary injector #1
60.Secondary injector #1
64.Intake funnel servo motor
65.Throttle servo motor
66.Steering damper solenoid
68.Front wheel sensor
9-12
EAS32917
BASIC PROCESS FOR TROUBLESHOOTING

This section describes the basic process about fuel injection system troubleshooting.
But because a work procedure varies depending to symptom and DTC, check and repair it according
to applicable troubleshooting.
When turning the main switch to No Does the MIL (LED) work No
Check the MIL (LED).
“ON”, does the MIL come on? properly?
Yes Yes
Yes [B] Perform the checking with the

The MIL goes off after 2 seconds?
diagnostic mode.
No
Still on/flash.
[A] Check the DTC.
Do the troubleshooting according

to the DTCs of “malfunction”.
Check the DTCs of “malfunction”

are not displayed on the screen.
Finished.
9-13
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 from “OFF” to “ON”, and then check the DTC of “malfunction” is not displayed.
TIP
• If another DTC is displayed, repeat steps (1) to (4) until no DTC is displayed.
• Turning 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 9-69 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-72.
D01: Throttle position sensor signal 1 (throttle angle)
D13: Throttle position sensor signal 2 (throttle angle)
D14: Accelerator position sensor signal 1 (throttle angle)
D15: Accelerator position sensor signal 2 (throttle angle)
D30: Cylinder-#1 ignition coil
D36: Primary injector #1
D40: Secondary injector #1
D48: Air induction system solenoid
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
9-14
EAS32885
EAS20442
R/G B B R/G
24 R/W Lg Y/L Y/L Lg R/W R/W R/W R/W
R Lg R/G R/W B Y/L

R
RR
4
R R R R R
R
R
R
3
ON
OFF 19 Y/L
R
Br/L
B R/W
R Br/L
CIRCUIT DIAGRAM
Br/L
B
B
18 R/G
23 R/W
R/W
R/W R/W R/W R/W
R
9
R/G
IMMOBILIZER SYSTEM
12 R/W
R/W
Br/L
Br/L Br/L
R/G
R/G R/G
R/G
49
R/G
Lg
B/W 72
B/W 73
R/W
9-15
R/G
R/G
78

(B)
B/W

(B) (B)
B/W
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W B/W
(Gy)
B/W B/W
B B B/W
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
18.Engine ground
19.Battery
23.Joint coupler
24.Immobilizer unit
72.Meter assembly
73.Immobilizer system indicator light
9-16
IMMOBILIZER SYSTEM
EAS32886
SYSTEM OUTLINE
This vehicle is equipped with an immobilizer system to help prevent theft by re-registering codes in the
standard keys. This system consists of the following:
• A code re-registering key (with a red bow)
• Two standard keys (with a black bow) that can be re-registered with new codes
• A transponder (installed in the red key bow)
• An immobilizer unit
• The ECU
• An immobilizer system indicator light
The key with the red bow is used to register codes in each standard key. Do not use the key with the
red bow for driving. It should only be used for re-registering new codes in the standard keys. The im-
mobilizer system cannot be operated with a new key until the key registered with a code. If you lose the
code re-registering key, the ECU and main switch (equipped with the immobilizer unit) need to be re-
placed.
Therefore, always use a standard key for driving. (See NOTICE.)
TIP
Each standard key is registered during production, therefore re-registering at purchase is not neces-
sary.
ECA14971
NOTICE
• DO NOT LOSE THE CODE RE-REGISTERING KEY! If the code re-registering key is lost, regis-
tering new codes in the standard keys is impossible. The standard keys can still be used to
start the vehicle. However, if code re-registering is required (e.g., if a new standard key is made
or all keys are lost) the entire immobilizer system must be replaced. Therefore, it is highly rec-
ommended to use either standard key for driving, and to keep the code re-registering key in a
safe place.
• Do not submerse the keys in water.
• Do not expose the keys to excessively high temperatures.
• Do not place the keys close to magnets (this includes, but is not limited to, products such as
speakers, etc.).
• Do not place heavy items on the keys.
• Do not grind the keys or alter their shape.
• Do not disassemble the key bows.
• Do not put two keys of any immobilizer system on the same key ring.
• Keep the standard keys as well as other immobilizer system keys away from the code re-reg-
istering key.
• Keep other immobilizer system keys away from the main switch as they may cause signal in-
terference.
EAS32887
PART REPLACEMENT AND KEY CODE REGISTRATION REQUIREMENTS

In the course of use, you may encounter the following cases where replacement of parts and registra-
tion of code re-registering/standard keys are required.
TIP
Each standard key is registered during production, therefore re-registering at purchase is not neces-
sary.
9-17
IMMOBILIZER SYSTEM
Parts to be replaced
Main switch/
Accessory Key registration re-
immobilizer unit Standard
ECU lock* and quirement
Main Immobilizer key
key
switch unit
Standard key is lost √ New standard key
All keys have been lost
Code re-registering
(including code re-reg- √ √ √ √
key and standard keys
istering key)
Code re-registering
ECU is defective √
Immobilizer unit is de- Code re-registering
√
fective key and standard keys
Code re-registering
Main switch is defective √ √ √ √
Accessory lock* is de-
√ Not required
fective
* Accessory locks mean the seat lock and fuel tank cap.
Code re-registering key registration:

When the immobilizer unit or ECU is replaced, the code re-registering key must be registered to the
unit.
To register a code re-registering key:
1. Turn the main switch to “ON” with the code re-registering key.
TIP
Check that the immobilizer system indicator light comes on for one second, then goes off. When the
immobilizer system indicator light goes off, the code re-registering key has been registered.
2. Check that the engine can be started.
3. Register the standard key, following the instructions in the section below.
Standby mode:
To enable the immobilizer system, turn the ignition key to “OFF”. 30 seconds later, the indicator light
will start flashing continuously in the standby flashing mode pattern for up to 24 hours. After that time,
the indicator light will stop flashing, but the immobilizer system is still enabled.
Standby mode
a. Main switch “ON” d. LED off

b. Main switch “OFF” e. Standby mode on
c. LED on f. Standby mode off
9-18
IMMOBILIZER SYSTEM
Standard key registration:

Standard key registration is required when a standard key is lost and needs to be replaced, or when
the code re-registering key is re-registered after the immobilizer unit or ECU are replaced.
TIP
Do not start the engine with a standard key that has not been registered. If the main switch is turned
“ON” with a standard key that has not been registered, the immobilizer system indicator light flashes to
indicate DTC “52”. (Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR IMMOBILIZER SYS-
TEM)” on page 9-60).
1. Check that the immobilizer system indicator light signals the standby mode.
2. Using the code re-registering key, turn the main switch to “ON”, then “OFF”, and then remove the
key within 5 seconds.
3. Insert the first standard key to be registered into the main switch, then turn the key to “ON” within 5
seconds to activate the key registration mode.
TIP
The existing standard key code is erased from the memory when the key registration mode is activated.
When the key registration mode is activated, the immobilizer system indicator light flashes rapidly.
4. While the indicator light is flashing, turn the main switch to “OFF”, remove the key, and within 5 sec-
onds, insert the second standard key to be registered into the main switch.
TIP
If the immobilizer system indicator light stops flashing 5 seconds after the first standard key is regis-
tered, the registration mode is deactivated. If this occurs, the second standard key cannot be registered,
and steps (2) to (4) need to be repeated to register both standard keys.
5. Turn the main switch to “ON”.
TIP
When the indicator light goes off, the registration is complete.
6. Check that the engine can be started with the two registered standard keys.
Standard key registration
a. Main switch “ON” B. Immobilizer system indicator light stops flashing

b. Main switch “OFF” when the registration of the second standard
c. LED on key is complete.
d. LED off
e. Less than 5.0 s
f. Code re-registering key
g. First standard key
h. Second standard key
i. Registration mode
A. Registration of the second standard key is
complete.
9-19
IMMOBILIZER SYSTEM
Voiding the standard key code:

If a standard key has been lost, it is possible to disable its use by re-registering the remaining standard
key. Standard key registration erases the stored standard key code from the memory, thus disabling
the lost standard key. To re-register, refer to “Standard key registration”.
Standard key code voiding method
a. Main switch “ON”

b. Main switch “OFF”
c. LED on
d. LED off
e. Less than 5.0 s
f. Code re-registering key
g. Remaining standard key
h. Registration mode
A. If the immobilizer system indicator light stops
flashing 5 seconds after the first standard key is
registered, the second standard key cannot be
registered.
9-20
IMMOBILIZER SYSTEM
EAS32888
TROUBLESHOOTING
When the main switch is turned to “ON”, the immobilizer system indicator light does not come on nor
flashes.
(Main, ignition, fuel injection sys-
tem, and backup) Replace the fuse(s).
ES” on page 8-41.
OK ↓
page 8-42.
OK ↓
OK ↓
4. Check the entire immobilizer sys- NG →
tem wiring. Properly connect or repair the immobilizer
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 9-15.
OK ↓
• Check the condition of the each im-
mobilizer system circuits.
• Refer to “SELF-DIAGNOSTIC
FUNCTION TABLE (FOR IMMOBI-
LIZER SYSTEM)” on page 9-60.
9-21
IMMOBILIZER SYSTEM
EAS32889
HOW TO CHECK DTC

When a system malfunction occurs, the DTC is indicated in the meter display and the immobilizer sys-
tem indicator light flashes at the same time. The pattern of flashing also shows the DTC.
Immobilizer system indicator light DTC indication

Digit of 10: Cycles of 1 sec. ON and 1.5 sec. OFF.
Digit of 1: Cycles of 0.5 sec. ON and 0.5 sec. OFF.
Example: DTC 52
a. Light on
b. Light off
9-22
EAS32890
EAS20443
R/W R/W
R/W
R
R
RR
4 R/W
R R R R R 21
R
RR
R
3
ON R/W
OFF 19 R/W L/W
R (B)
Br/L
BB R/W
R Br/L
CIRCUIT DIAGRAM
Br/L
B B
B
18 R/G
23 R/W
R 6 R/W
L/W
7 26 25
R/W R/W R/W R/W
R/G
R
9 B
R/G
B
R/W L L/W R/B

R/W L/W L/R R/L B Y
L/R
L/W Y
Y B
12 R/W
R/W
Br/L 13
Br/L Br/L L/W
14 L/R
R/B
R/G
R/G
49
L/W
L/W B/W 72
B/W
L/W L/W L/W 23
L/R
L/R
R/W
9-23
L/R
Br
107
Br Y
78
Y L/W
Y L/R L/B

(B)
B/W
R/W
Y L
Y Y L
Y/R P/W P/B Gy/G O/G Gy/R O L/Y L Y/B R/W B W W B
Y
Lg/R L/R O/B L/B G/B R/B B W W L/G B/R Gy/B Gy/B
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B B/G B B/G W/L W/L W W
B B 68
108 Y
(B) (B) W W
85 B B 69
L/B G/O
G/O 71 67
L/W B W W B
L/W L/B
B/W L/W L/B R/W
B/W L/W
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W (B) B/W Y R/B
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y L/B
(Gy) L/W
B
B Y L/R
B/W B
(B)
B L/W Gy/B L Y G R/B B L/W B/W
B R/W G/O W/L L B W W L/B B
L/W L/W L/W L/W L/B L/B L/B L/B
(B)
L/W L/B
23 B/W B/W B/W B/W

B B/W B/W
R/G
L/W B/W B/W
87 L/B
R/G L/B L/W
(R)
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
14.ABS ECU fuse
18.Engine ground
19.Battery
21.ABS motor fuse
23.Joint coupler
25.Front brake light switch
68.Front wheel sensor
72.Meter assembly
85.ABS warning light
87.YDT coupler
107.Rear brake light switch
9-24
EAS32891
ABS COMPONENTS CHART
6,7
5
3,4
2
15,16
10
14
11
12
13
1. Meter assembly
3. Fuse box 1
5. YDT coupler
6. Starter relay
7. ABS motor fuse
9. Rear wheel sensor rotor
11. Front brake caliper (left)
13. Front wheel sensor rotor
14. Front brake caliper (right)
15. Fuse box 2
16. Signaling system fuse
9-25
EAS32892
ABS COUPLER LOCATION CHART
1 2
L/W B/W
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W R/G L/B
(R)
(Gy)
B W W B
3
4
(B)
W B B W

2. YDT coupler
3. ABS ECU coupler
4. Rear wheel sensor coupler
5. Front wheel sensor coupler
9-26
EAS32893
MAINTENANCE OF THE ABS ECU
Checking the ABS ECU

1. Check:
• Terminals “1” of the hydraulic unit assembly (ABS ECU)
Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off → Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
1 2
EAS33284
ABS TROUBLESHOOTING OUTLINE

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 9-32.
ABS operation when the ABS warning light comes on

1. The ABS warning light remains on → ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 10 km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h)). → ABS operation is normal.
3. The ABS warning light flashes → ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-39.
Self-diagnosis with 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 YDT when the ABS
ECU has entered the self-diagnosis mode.
9-27
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 under the seat,
and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and
pedal, but these do not indicate a malfunction.
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 DTC when the service is
finished. (This is because the past DTC will be displayed again if another malfunction occurs.)
EAS32895
BASIC INSTRUCTIONS FOR TROUBLESHOOTING

TIP
4. Do the final check.
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.
9-28
Fails to
[A] Turn the main switch to “ON”, come on [A-1] Does only the ABS Yes • The ABS warning light (LED) is
and check the ABS warning warning light fail to defective. Return to [A].
light. come on? • The wire harness is grounded
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly is defective.
• The hydraulic unit assembly is
defective.
No
• The main switch is defective.
[A-2] Do all indicator lights Yes • The battery voltage is low. Return to [A].
fail to come on? • The main fuse is blown.
Cannot
[A-3] The ABS warning light comes communicate • The ABS ECU fuse is blown.
[A-4] Only the ABS ECU Yes
on. • The ABS ECU coupler is Return to [A].
fails to communicate.
Connect the YDT, and then disconnected.
execute functional diagnosis. • The wire harness is defective.
Can the YDT communicate • The hydraulic unit assembly
with the ABS ECU? is defective.
Can communicate
No
[A-5] ABS ECU and FI ECU Yes • The connection with the YDT is
defective. Return to [A].
fail to communicate.
• The wire harness is defective.
[B-1] Check for ABS DTC in the Yes [B-2] Diagnose by the DTC. [B-3] Delete the DTC.
screen for the YDT. Return to [A].
Execute diagnosis of
malfunction.
Are DTC displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect. Refer to
“[C-1] FINAL CHECK”.
[C-1] Perform the final checks. • The brake hoses and brake
No
Were all of the final checks pipes are not connected Return to [A].
completed normally? correctly.
The ABS warning light does
Yes not go off when the light is
(The ABS warning light checked. Refer to “[C-1]
goes off when the light is FINAL CHECK”.
checked.) • The malfunction is not
corrected.
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The ABS warning light circuit in
the hydraulic unit assembly is
defective.
Finished.
9-29
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 green/orange terminal of the ABS ECU coupler
and green/orange terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
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 8-40.
• If there is no continuity, replace the main switch/immobilizer unit.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-42.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Main fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-41.
• If the main fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 9-23.
• If the meter assembly circuit is open, replace the wire harness.
EAS32900
[A-3] THE ABS WARNING LIGHT COMES ON

Connect the YDT to the YDT coupler and execute functional diagnosis. (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.)
EAS32901
[A-4] ONLY THE ABS ECU FAILS TO COMMUNICATE

1. ABS ECU fuse
• Check the ABS ECU fuse for continuity.
• If the ABS ECU fuse is blown, replace the fuse.
9-30
2. ABS ECU coupler

• Check that the ABS ECU coupler is connected properly.
For information about connecting the ABS ECU coupler properly, refer to “INSTALLING THE HY-
DRAULIC UNIT ASSEMBLY” on page 4-78.
3. Wire harness
• Open circuit between the main switch and the ABS ECU, or between the ABS ECU and the ground.
Check for continuity between brown/blue terminal of the main switch coupler and red/black terminal
of the ABS ECU coupler.
Check for continuity between black terminal of the ABS ECU coupler and the ground.
If there is no continuity, the wire harness is defective. Replace the wire harness.
• Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler.
Check for continuity between blue/white terminal of the ABS ECU coupler and blue/white terminal
of the YDT coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the YDT coupler. (CANL)
4. ABS ECU malfunction
Replace the hydraulic unit assembly.
EAS32902
[A-5] ABS ECU AND FI ECU FAIL TO COMMUNICATE

1. YDT
Check that the YDT is properly connected.
2. Wire harness
• Open circuit in the wire harness between the ABS ECU coupler and the YDT coupler.
Check for continuity between blue/white terminal of the ABS ECU coupler and blue/white terminal
of the YDT coupler. (CANH)
Check for continuity between blue/black terminal of the ABS ECU coupler and blue/black terminal
of the YDT coupler. (CANL)
EAS32903
[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the YDT is connected to the YDT coupler, the DTC will be displayed on the computer screen.
• A DTC is displayed. [B-2]
• A DTC is not displayed. [C-1]
EAS32904
[B-2] DIAGNOSIS USING THE DTC

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.

90890-03267
90890-03264
TIP
Details about the displayed DTCs are shown in the following chart. Refer to this chart and check the
vehicle.
Once all the work is complete, delete the DTCs. [B-3]
TIP
Do the final check after terminating the connection with the YDT and turning the main switch off. [C-1]
9-31
EAS33339
[B-3] DELETING THE DTC

To delete the DTCs, use the YDT. For information about deleting the DTCs, refer to the operation man-
ual of the YDT.
Check that all the displayed DTCs are deleted.

90890-03267
90890-03264
TIP
EAS32905
[C-1] FINAL CHECK

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.
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
cylinder reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-13.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (DISC BRAKE)” on page 4-40 and “INSTALLING THE
REAR WHEEL (DISC BRAKE)” on page 4-49.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TEST” on page 4-79.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the DTCs.
Refer to “[B-3] DELETING THE DTC” on page 9-32.
5. Checking the ABS warning light.
Confirm the ABS warning light go off.
If the ABS warning light does not come on or does not go off, refer to “[A] CHECKING THE ABS
WARNING LIGHT” on page 9-30.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between green/orange terminal of the ABS ECU coupler and green/orange ter-
minal of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.
9-32
EAS32912
EAS20445
R/W R/W
R
R
RR
4
R R R R R
R
R
R
3
ON
OFF 19
R
Br/L
B R/W
R Br/L
CIRCUIT DIAGRAM
Br/L
B
B
18 R/G
23 R/W
B R/W
7
R/W R/W R/W R/W
R/G
R
9
R/G
12 R/W
R/W
Br/L
Br/L Br/L
STEERING DAMPER SYSTEM
R/G
R/G
49
B/W 72
B/W
R/W
9-33
Y/B Y/B B B
66 B B Y/B B
78
L/W
L/B

(B)
B 81
B/W
B Y/R P/W P/B Gy/G O/G Gy/R O L/Y L Y/B R/W

(B) (B)
L/B
L/W
B/W B
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W B/W B
(Gy)
L/W L/W L/B L/B

L/W L/B
23 B/W B/W B/W

B B/W BB
R/G
L/W B/W B/W
87 L/B
R/G L/B L/W
(R)
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
18.Engine ground
19.Battery
23.Joint coupler
66.Steering damper solenoid
72.Meter assembly
81.Auxiliary system warning light
87.YDT coupler
9-34
EAS32913
The auxiliary system warning light comes on.

TIP
9-35
9-36
EAS32914
EAS20446
R/W R/W
R/W
R
R
RR
4
R R R R R
R
R
R
3
ON
OFF 19
R
Br/L
B R/W
R Br/L
CIRCUIT DIAGRAM
Br/L
B
B
18 R/G
23 R/W
B R/W
7
R/W R/W R/W R/W
R/G
R
9
R/G
12 R/W
R/W
Br/L
Br/L Br/L
Br/L
R/G
R/G
Br/L
49
B/W 72
114 B/W
Br/W
P/W G/R Y Br/W
P G Y/R Gy/G Gy B
L/B P/L G/B Y/G Gy/B Gy/R
L/W P/B G/L Y/B W W/R W/B W/G
(B)
R/W
9-37
Br/W F Br/W
B F B
G G G
G/B G G/B
G/R G G/R 116
G/L G G/L
78
L/W
G/R G G/B G/L L/B

P G P B
P/B G P/B L/Y L/W Gy/Y G/W G Gy/B W/L
P/W G P/W 117
P/L G P/L (B)
B 81
B/W
P/W P P/B P/L

W F W Lg/R L/R O/B L/B G/B R/B B W W L/G B/R
W/B F W/B R/L G/Y Br/R Br/B Br/Y Sb/W W/L B B/G B B/G
115 W/R F W/R 118 R/W B/W R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y
W/G F W/G
(B) (B)
L/B
W/R W W/B W/G 71
L/W
L/W L/B
Y F Y B/W L/W L/B R/W
B/W
Y/B F Y/B
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W (B) B/W
Y/R F Y/R 119
Y/G F Y/G R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
(Gy)
Y/R Y Y/B Y/G
Gy H Gy
Gy/B H Gy/B
Gy/R H Gy/R 120
Gy/G H Gy/G
L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B
L/W
L/B L/W L/B
L/W L/B
L/B L/W Gy/G Gy Gy/B Gy/R
F F 23 B/W B/W B/W B/W
L/B L/W B B/W
R/G
L/W B/W B/W
87 L/B
R/G L/B L/W
F G H
L/W L/W L/W L/W L/W L/W L/W
(R)
L/W Y/B Y W/B W Br/W Br/W W W/B Y Y/B L/W G G/B G/R G/L G/L G/R G/B G
Gy/R Gy Gy/B Gy/G
L/B Y/G Y/R W/G W/R B B W/R W/G Y/R Y/G L/B P P/B P/W P/L P/L P/W P/B P Gy/G Gy Gy/B Gy/R
(B) (B) (B) (B)
G A G H G I
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for YZF-R1M)
ELECTRONICALLY ADJUSTABLE SUSPENSION SYSTEM (for
YZF-R1M)
YZF-R1M)
3. Main switch
4. Main fuse
9. Backup fuse
12.Ignition fuse
18.Engine ground
19.Battery
23.Joint coupler
72.Meter assembly
81.Auxiliary system warning light
87.YDT coupler
114.SCU fuse
115.SCU (Suspension Control Unit)
116.Front fork stepping motor (left)
117.Front fork stepping motor (right)
118.Rear shock absorber assembly stepping
motor (compression damping)
119.Rear shock absorber assembly stepping
motor (rebound damping)
120.Steering damper solenoid (OPTION)
A. Wire harness
G. Sub-wire harness (SCU, steering damper
solenoid, sub-wire harness)
H. Sub-wire harness (front fork stepping motor)
I. Sub-wire harness (Steering damper
solenoid), (OPTION)
9-38
YZF-R1M)
EAS32915
MAINTENANCE OF THE SCU (suspension control unit)
Checking the SCU (suspension control unit)

1. Check:
• Terminals “1” of the SCU
Cracks/damages → Replace the SCU.
• Terminals “2” of the SCU couplers
Connection defective, contaminated, come-off → Replace or clean.
TIP
If the SCU couplers are clogged with mud or dirt, clean with compressed air.
1 2
EAS32916

TIP
9-39
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20551

EAS33149
DTC TABLE
Fail-safe system
Diagnostic
DTC Symptom Starting the Driving the code
engine vehicle
Front wheel sensor (intermittent pulses or no
“11_ABS” — — —
pulses)
Rear wheel sensor (intermittent pulses or no
“12_ABS” — — —
pulses)
“13,
Front wheel sensor (abnormal pulse period) — — —
26_ABS”
“14,
Rear wheel sensor (abnormal pulse period) — — —
27_ABS”
“15_ABS” Front wheel sensor (open or short circuit) — — —
“16_ABS” Rear wheel sensor (open or short circuit) — — —
Hydraulic unit assembly (defective solenoid
“21_ABS” — — —
drive circuit)
“30_EVENT” Latch up detected. Unable Unable D17
Hydraulic unit assembly (defective ABS sole-
“31_ABS” — — —
noid power circuit)
Hydraulic unit assembly (abnormal ABS mo-
“33_ABS” — — —
tor power supply)
Hydraulic unit assembly (short circuit in ABS
“34_ABS” — — —
motor power supply circuit)
Front wheel ABS (intermittent wheel speed
“41_ABS” — — —
pulses or incorrect depressurization)
Rear wheel ABS (intermittent wheel speed
“42_ABS” — — —
pulses or incorrect depressurization)
“43,
Front wheel sensor (missing pulses) — — —
45_ABS”
“44,
Rear wheel sensor (missing pulses) — — —
46_ABS”
Vehicle system power supply (voltage of
“51_ABS” — — —
ABS ECU power supply is high)
“51_IMMO- Code cannot be transmitted between the key
Unable Unable —
BILIZER” and the immobilizer unit.
“52_IMMO- Codes between the key and immobilizer unit
Unable Unable —
BILIZER” do not match.
Vehicle system power supply (voltage of
“53_ABS” — — —
ABS ECU power supply is low)
“53_IMMO- Codes cannot be transmitted between the
Unable Unable —
BILIZER” ECU and the immobilizer unit.
“54_IMMO- Codes transmitted between the ECU and the
Unable Unable —
BILIZER” immobilizer unit do not match.
Hydraulic unit assembly (defective ABS
“55_ABS” — — —
ECU)
“55_IMMO-
Key code registration malfunction. Unable Unable —
BILIZER”
9-40
Fail-safe system
Diagnostic
engine vehicle
Hydraulic unit assembly (abnormal internal
“56_ABS” — — —
circuit)
“56_IMMO-
Unidentified code is received. Unable Unable —
BILIZER”
Vehicle CAN communication line or power
“57_ABS” — — —
source of vehicle system
Power supply voltage failure in pressure sen-
“62_ABS” — — —
sor
Defective hydraulic unit assembly (defective
“68_ABS” — — —
front pressure sensor)
Engine forcibly stops when the vehicle is left
“70_EVENT” Unable Unable —
idling for a long period.
CAN communication (between meter as-
“89_ABS” — — —
sembly and hydraulic unit assembly)
CAN communication (between ECU and hy-
“90_ABS” — — —
draulic unit assembly)
CAN communication (between IMU and hy-
“91_ABS” — — —
draulic unit assembly)
“C0044” Abnormal ABS Able Able —
“C0520 (FI)” Abnormal IMU Able/Unable Able/Unable —
“C0520
Abnormal IMU Unable Able/Unable —
(SCU)”
Steering damper solenoid: open or short cir-
“C1000” Able Able D47
cuit detected.
“C1002” Abnormal SCU EEPROM Able Able —
Stepping motor: open or short circuit detect-
“C1003” Able Able —
ed.
“C1007” Abnormality inside SCU Able Able —
O2 sensor 1 heater: defective heater control-
“P0030” Able Able —
ler detected.
O2 sensor 2 heater: defective heater control-
ler detected.
Intake air pressure sensor or atmospheric
pressure sensor: when the main switch is
“P0069” turned to “ON”, the intake air pressure sen- Able Able D02, D03
sor voltage and atmospheric pressure sen-
sor voltage differ greatly.
[P00D1] O2 sensor 1: heater performance
“P00D1,
deterioration Able Able —
P2195”
[P2195] O2 sensor 1: open circuit detected.
[P00D3] O2 sensor 2: heater performance
“P00D3,
deterioration Able Able —
P2197”
[P2197] O2 sensor 2: open circuit detected.
[P0107] Intake air pressure sensor: ground
“P0107, short circuit detected.
Able Able D03
P0108” [P0108] Intake air pressure sensor: open or
power short circuit detected.
9-41
Fail-safe system
Diagnostic
engine vehicle
[P0112] Intake air temperature sensor:
“P0112, ground short circuit detected.
Able Able D05
P0113” [P0113] Intake air temperature sensor: open
or power short circuit detected.
[P0117] Coolant temperature sensor: ground
“P0117, short circuit detected.
Able Able D06
P0118” [P0118] Coolant temperature sensor: open
[P0122] Throttle position sensor: ground
short circuit detected.
[P0123] Throttle position sensor: open or
“P0122,
power short circuit detected.
P0123,
[P0222] Throttle position sensor: open or
P0222, Able/Unable Able/Unable D01, D13
ground short circuit detected.
P0223,
[P0223] Throttle position sensor: power
P2135”
[P2135] Throttle position sensor: output volt-
age deviation error.
O2 sensor 1: short circuit detected (power
short circuit).
O2 sensor 2: short circuit detected (power
short circuit).
Able Able
(depending on (depending on
Primary injector #1: malfunction in primary
“P0201” the number of the number of D36
injector #1.
faulty cylin- faulty cylin-
ders) ders)
Able Able
injector #2.
ders) ders)
Able Able
injector #3.
ders) ders)
Able Able
injector #4.
ders) ders)
Crankshaft position sensor: no normal sig-
“P0335” nals are received from the crankshaft posi- Unable Unable —
tion sensor.
Cylinder identification sensor: no normal sig-
“P0340” nals are received from the cylinder identifica- Unable Able —
tion sensor.
9-42
Fail-safe system
Diagnostic
engine vehicle
Able Able
Cylinder-#1 ignition coil: open or short circuit (depending on (depending on
“P0351” detected in the primary lead of the cylinder- the number of the number of D30
#1 ignition coil. faulty cylin- faulty cylin-
ders) ders)
Able Able
ders) ders)
Able Able
ders) ders)
Able Able
ders) ders)
[P0475] EXUP servo motor: performance
“P0475, deterioration
P0476, [P0476] EXUP servo motor: stuck EXUP Able Able D53
P048B” servo motor is detected.
[P048B] EXUP servo motor: signal stuck
Radiator fan motor relay: open or short cir-
“P0480” Able Able D51
cuit detected.
[P048D] EXUP servo motor: open or ground
“P048D, short circuit detected.
Able Able D53
P048E” [P048E] EXUP servo motor: power short cir-
cuit detected.
[P0500 (FI)] Rear wheel sensor: no normal
signals are received from the rear wheel
sensor.
“P0500 (FI),
[P1500] Neutral switch: open or short circuit Able Able D07, D21
P1500”
is detected.
Clutch switch: open or short circuit is detect-
ed.
“P0500
Abnormal rear wheel sensor Able Able —
(SCU)”
[P0560 (FI)] Charging voltage is abnormal.
“P0560 (FI),
[P0563] Vehicle system power voltage out of Able Able —
P0563”
range
“P0560
Abnormal SCU power supply voltage Able Able D09
(SCU)”
Internal malfunction in ECU. (When this mal-
“P0601” function is detected in the ECU, the DTC Unable Unable —
might not appear on the tool display.)
Internal malfunction in ECU. (When this mal-
“P0606” function is detected in the ECU, the DTC Able/Unable Able/Unable —
might not appear on the tool display.)
9-43
Fail-safe system
Diagnostic
engine vehicle
EEPROM DTC: an error is detected while
“P062F” Able/Unable Able/Unable D60
reading or writing on EEPROM.
“P0638” YCC-T drive system: malfunction detected. Able/Unable Able/Unable —
Fuel system voltage: incorrect voltage sup-
“P0657” Able Able D09, D50
plied to the fuel injector and fuel pump.
[P0916] Gear position sensor: open or
Able Able —
P0917” [P0917] Gear position sensor: power short
circuit detected.
Air induction system solenoid: open or short
“P1400” Able Able D48
circuit detected.
Lean angle sensor: open or short circuit de-
“P1600” Unable Unable D17
tected.
Sidestand switch: open or short circuit of the
“P1601” Unable Unable D20
blue/yellow lead of the ECU is detected.
Malfunction in ECU internal circuit (malfunc-
“P1602” Able/Unable Able/Unable —
tion of ECU power cut-off function).
[P1806] Shift sensor: open or ground short
“P1806, circuit detected.
Able Able D95
P1807” [P1807] Shift sensor: power short circuit de-
tected.
[P2122] Accelerator position sensor: open or
ground short circuit detected.
“P2122, [P2123] Accelerator position sensor: power
P2123, short circuit detected.
P2127, [P2127] Accelerator position sensor: open or Able/Unable Able/Unable D14, D15
P2128, ground short circuit detected.
P2138” [P2128] Accelerator position sensor: power
[P2138] Deviation error
Front wheel sensor: no normal signals are
“P2158 (FI)” Able Able D16
received from the front wheel sensor.
“P2158 Front wheel sensor: no normal signals are
Able Able —
(SCU)” received from the front wheel sensor.
Able Able
Secondary injector #1: malfunction in sec-
“P21CF” the number of the number of D40
ondary injector #1.
ders) ders)
Able Able
“P21D0” the number of the number of D41
ondary injector #2.
ders) ders)
Able Able
ondary injector #3.
ders) ders)
9-44
Fail-safe system
Diagnostic
engine vehicle
Able Able
ondary injector #4.
ders) ders)
[P2228] Atmospheric pressure sensor:
Able Able D02
P2229” [P2229] Atmospheric pressure sensor: open
Abnormal CAN communication (between
“U0100” Able Able —
ECU and SCU)
Abnormal CAN communication (between
“U0121” Able Able —
ABS ECU and SCU)
Signals cannot be transmitted between the
“U0125 (FI)” Unable Able/Unable —
ECU and the IMU.
“U0125 Abnormal CAN communication (between
Able Able —
(SCU)” IMU and SCU)
Multi-function meter: signals cannot be
“U0155 or
transmitted between the ECU and the multi- Able Able —
Err (FI)”
function meter.
“U0155 or Abnormal CAN communication (between
Able Able —
Err (SCU)” meter assembly and SCU)
9-45
EAS33028
SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)

TIP
For details of the DTC, refer to “BASIC PROCESS FOR TROUBLESHOOTING” on page 9-13.
Probable cause of Fail-safe system op-

DTC Item Vehicle symptom
malfunction eration
30_EVEN Latch up detected. • The vehicle has – –
T overturned.
• Installed condition of
IMU.
• Defective IMU.
• Malfunction in ECU.
70_EVEN Engine forcibly stops • Allow to idle for a – –
T when the vehicle is long period of time.
left idling for a long • Malfunction in ECU.
period.
C0520 Abnormal IMU • Defective IMU cou- Engine cannot be Engine cannot be
pler or ECU coupler. started (depending on started (depending on
• Open or short cir- the circumstances). the circumstances).
cuit in wire harness
between IMU and
ECU.
• Improperly installed
IMU.
• Malfunction in IMU.
P0030 O2 sensor 1 heater: • Open or short cir- (When the O2 sensor Display only (If the O2
defective heater con- cuit in wire harness. 1 does not operate sensor 1 does not op-
troller detected. • Disconnected cou- because the exhaust erate, O2 feedback is
pler. temperature is low) not carried out.)
• Defective O2 sensor Increased exhaust
1 heater controller emissions.
(Malfunction in Fuel learning cannot
ECU). be carried out.
• Broken or discon-
nected lead in O2
sensor 1 heater.
P0050 O2 sensor 2 heater: • Open or short cir- (When the O2 sensor Display only (If the O2
defective heater con- cuit in wire harness. 2 does not operate sensor 2 does not op-
troller detected. • Disconnected cou- because the exhaust erate, O2 feedback is
pler. temperature is low) not carried out.)
• Defective O2 sensor Increased exhaust
2 heater controller emissions.
(Malfunction in Fuel learning cannot
ECU). be carried out.
• Broken or discon-
nected lead in O2
sensor 2 heater.
9-46

malfunction eration
P0069 Intake air pressure • Malfunction in ECU. Engine is difficult to Intake air pressure is
sensor or atmospher- • Intake air pressure start. fixed to 101.3 [kPa].
ic pressure sensor: sensor hose is dis- Engine idling speed is Intake air pressure
when the main switch connected, clogged, unstable. difference is fixed to 0
is turned to “ON”, the kinked, or pinched. Increased exhaust [kPa].
intake air pressure • Defective intake air emissions. Atmospheric pres-
sensor voltage and at- pressure sensor or Loss of engine power. sure is fixed to 101.3
mospheric pressure atmospheric pres- [kPa].
sensor voltage differ sure sensor. α–N is fixed.
greatly. Fuel is not cut off due
to the intake air pres-
sure difference.
Atmospheric pres-
sure sensor output
correction value is
fixed to 0.
O2 feedback is not
carried out.
ISC feedback is not
carried out.
ISC learning is not
carried out.
QSS is not carried
out.
P00D1 O2 sensor 1: heater • Improperly installed Increased exhaust O2 feedback is not
performance deterio- O2 sensor 1. emissions. carried out.
ration • Defective coupler O2 learning is not car-
between O2 sensor ried out.
1 and ECU. Air induction system
• Open or short cir- solenoid is turned on
cuit in wire harness all the time (air induc-
between O2 sensor tion system air cut
1 and ECU. off).
• Incorrect fuel pres- QSS is not carried
sure. out.
• Defective O2 sensor
1.
P00D3 O2 sensor 2: heater • Improperly installed Increased exhaust O2 feedback is not
performance deterio- O2 sensor 2. emissions. carried out.
ration • Defective coupler O2 learning is not car-
between O2 sensor ried out.
2 and ECU. Air induction system
• Open or short cir- solenoid is turned on
cuit in wire harness all the time (air induc-
between O2 sensor tion system air cut
2 and ECU. off).
• Incorrect fuel pres- QSS is not carried
sure. out.
2.
9-47

malfunction eration
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure
P0108 pressure sensor: of the intake air pres- unstable. difference is fixed to 0
ground short circuit sure sensor circuit Engine response is [kPa].
detected. (0.5 V or less) poor. α–N is fixed.
[P0108] Intake air [P0108] High voltage Loss of engine power. Fuel is not cut off due
pressure sensor: of the intake air pres- Increased exhaust to the intake air pres-
open or power short sure sensor circuit emissions. sure difference.
circuit detected. (4.8 V or more) Atmospheric pres-
• Defective coupler sure sensor output
between intake air correction value is
pressure sensor and fixed to 0.
ECU. Intake air pressure is
• Open or short cir- fixed to 101.3 [kPa].
cuit in wire harness O2 feedback is not
between intake air carried out.
pressure sensor and ISC feedback is not
ECU. carried out.
• Defective intake air ISC learning is not
pressure sensor. carried out.
• Malfunction in ECU. QSS is not carried
out.
P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tem-
P0113 temperature sensor: of the intake air tem- start. perature is fixed to 20
ground short circuit perature sensor circuit Increased exhaust [°C].
detected. (0.1 V or less) emissions. O2 sensor heater driv-
[P0113] Intake air [P0113] High voltage Engine idling speed is ing is not carried out.
temperature sensor: of the intake air tem- unstable. O2 feedback is not
open or power short perature sensor circuit carried out.
circuit detected. (4.8 V or more) ISC feedback is not
• Defective coupler carried out.
between intake air ISC learning is not
temperature sensor carried out.
and ECU. QSS is not carried
• Open or short cir- out.
between intake air
temperature sensor
and ECU.
intake air tempera-
ture sensor.
• Defective intake air
temperature sensor.
9-48

malfunction eration
P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to The radiator fan motor
P0118 perature sensor: of the coolant tem- start. relay is on only when
ground short circuit perature sensor circuit Increased exhaust the vehicle is traveling
detected. (0.1 V or less) emissions. at low speeds.
[P0118] Coolant tem- [P0118] High voltage Engine idling speed is O2 feedback is not
perature sensor: open of the coolant tem- unstable. carried out.
or power short circuit perature sensor circuit ISC feedback is not
detected. (4.9 V or more) carried out.
• Defective coupler ISC learning is not
between coolant carried out.
temperature sensor The coolant tempera-
and ECU. ture is fixed to 60 [°C].
• Open or short cir- QSS is not carried
cuit in wire harness out.
between coolant Engine brake man-
temperature sensor agement: control val-
and ECU. ue is fixed.
coolant temperature
sensor.
• Defective coolant
temperature sensor.
P0122 [P0122] Throttle posi- [P0122, P0222] Low Engine idling speed is Change in the throttle
P0123 tion sensor: ground voltage of the throttle high. opening is 0 (transient
P0222 short circuit detected. position sensor circuit Engine idling speed is control is not carried
P0223 [P0123] Throttle posi- (0.25 V or less) unstable. out).
P2135 tion sensor: open or [P0123, P0223] High Engine response is D–j is fixed.
power short circuit de- voltage of the throttle poor. Throttle opening is
tected. position sensor circuit Loss of engine power. fixed to 125 [°].
[P0222] Throttle posi- (4.75 V or more) Deceleration is poor. O2 feedback is not
tion sensor: open or [P2135] Difference in Increased exhaust carried out.
ground short circuit output voltage 1 and emissions. Fuel is not cut off due
detected. output voltage 2 of the Vehicle cannot be to the throttle open-
[P0223] Throttle posi- throttle position sen- driven. ing.
tion sensor: power sor Output is restricted.
short circuit detected. • Defective coupler Air induction system
[P2135] Throttle posi- between throttle po- solenoid is turned on
tion sensor: output sition sensor and all the time (air induc-
voltage deviation er- ECU. tion system air cut
ror. • Open or short cir- off).
cuit in wire harness ISC feedback is not
between throttle po- carried out.
sition sensor and ISC learning is not
ECU. carried out.
• Improperly installed O2 sensor heater driv-
throttle position sen- ing is not carried out.
sor. QSS is not carried
• Defective throttle po- out.
sition sensor. Engine brake man-
• Malfunction in ECU. agement: control
mode is fixed.
9-49

malfunction eration
P0132 O2 sensor 1: short cir- [P0132] High voltage Increased exhaust O2 feedback is not
cuit detected (power of the O2 sensor 1 cir- emissions. carried out.
short circuit). cuit (4.8 V or more) O2 feedback learning
• Improperly installed is not carried out.
O2 sensor 1. Air induction system
• Defective coupler solenoid is turned on
between O2 sensor all the time (air induc-
1 and ECU. tion system air cut
• Open or short cir- off).
cuit in wire harness QSS is not carried
between O2 sensor out.
1 and ECU.
• Incorrect fuel pres-
sure.
1.
P0152 O2 sensor 2: short cir- [P0152] High voltage Increased exhaust O2 feedback is not
cuit detected (power of the O2 sensor 2 cir- emissions. carried out.
short circuit). cuit (4.8 V or more) O2 feedback learning
• Improperly installed is not carried out.
O2 sensor 2. Air induction system
• Defective coupler solenoid is turned on
between O2 sensor all the time (air induc-
2 and ECU. tion system air cut
• Open or short cir- off).
cuit in wire harness QSS is not carried
between O2 sensor out.
2 and ECU.
sure.
2.
P0201 [P0201] Primary injec- • Defective coupler Loss of engine power. O2 feedback is not
P0202 tor #1: malfunction in between primary in- Engine is difficult to carried out.
P0203 primary injector #1. jector and ECU. start. Air induction system
P0204 [P0202] Primary injec- • Open or short cir- Engine cannot be solenoid is turned on
tor #2: malfunction in cuit in wire harness started. all the time (air induc-
primary injector #2. between primary in- Engine stops. tion system air cut
[P0203] Primary injec- jector and ECU. Engine idling speed is off).
tor #3: malfunction in • Defective primary in- unstable. ISC feedback is not
primary injector #3. jector. Increased exhaust carried out.
[P0204] Primary injec- • Malfunction in ECU. emissions. ISC learning is not
tor #4: malfunction in • Improperly installed carried out.
primary injector #4. primary injector. Injection to the appli-
cable cylinder group
(cylinders #1 and #2
or cylinders #3 and
#4) is cut off.
QSS is not carried
out.
9-50

malfunction eration
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor: no normal between crankshaft started. ISC feedback is not
signals are received position sensor and carried out.
from the crankshaft ECU. ISC learning is not
position sensor. • Open or short cir- carried out.
between crankshaft
position sensor and
ECU.
crankshaft position
sensor.
• Malfunction in gen-
erator rotor.
• Defective crank-
shaft position sen-
sor.
P0340 Cylinder identification • Defective coupler Engine cannot be The vehicle is operat-
sensor: no normal between cylinder started. ed using only the cyl-
signals are received identification sensor inder identification
from the cylinder iden- and ECU. information stored
tification sensor. • Open or short cir- during operation.
cuit in wire harness ISC feedback is not
between cylinder carried out.
identification sensor ISC learning is not
and ECU. carried out.
cylinder identifica-
tion sensor.
• Defective pickup ro-
tor.
• Defective cylinder
identification sensor.
9-51

malfunction eration
P0351 [P0351] Cylinder-#1 • Defective coupler Engine stops. Injection to the appli-
P0352 ignition coil: open or between ignition coil Loss of engine power. cable cylinder group
P0353 short circuit detected and ECU. Engine is difficult to (cylinders #1 and #4
P0354 in the primary lead of • Open or short cir- start. or cylinders #2 and
the cylinder-#1 igni- cuit in wire harness Engine cannot be #3) is cut off.
tion coil. between ignition coil started. Air induction system
[P0352] Cylinder-#2 and ECU. Engine idling speed is solenoid is turned on
ignition coil: open or • Improperly installed unstable. all the time (air induc-
short circuit detected ignition coil. Increased exhaust tion system air cut
in the primary lead of • Defective ignition emissions. off).
the cylinder-#2 igni- coil. O2 feedback is not
tion coil. • Malfunction in ECU. carried out.
[P0353] Cylinder-#3 ISC feedback is not
ignition coil: open or carried out.
short circuit detected ISC learning is not
in the primary lead of carried out.
the cylinder-#3 igni- QSS is not carried
tion coil. out.
[P0354] Cylinder-#4
ignition coil: open or
short circuit detected
in the primary lead of
the cylinder-#4 igni-
tion coil.
P0475 EXUP servo motor: • Defective coupler Loss of engine power. Learning values for
performance deterio- between EXUP ser- fully closed EXUP are
ration vo motor and ECU. fixed.
• Open or short cir- Learning values for
cuit in wire harness fully open EXUP are
between EXUP ser- fixed.
vo motor and ECU. O2 feedback is not
• Improperly installed carried out.
EXUP servo motor
and cables.
• Defective EXUP ser-
vo motor.
• Stuck EXUP servo
motor (mechanism
or motor).
P0476 EXUP servo motor: • Defective coupler Loss of engine power. Learning values for
stuck EXUP servo between EXUP ser- fully closed EXUP are
motor is detected. vo motor and ECU. fixed.
EXUP servo motor
and cables.
vo motor.
motor (mechanism
or motor).
9-52

malfunction eration
P0480 Radiator fan motor re- • Open or short cir- Engine is difficult to Radiator fan motor re-
lay: open or short circuit in wire harness. start. lay is off all the time.
cuit detected. • Disconnected cou- Loss of engine power. O2 feedback is not
pler. Engine overheats. carried out.
• Defective radiator Increased exhaust ISC feedback is not
fan motor relay. emissions. carried out.
• Defective radiator ISC learning is not
fan motor relay con- carried out.
troller (Malfunction
in ECU).
P048B EXUP servo motor: • Defective coupler Loss of engine power. Learning values for
signal stuck between EXUP ser- fully closed EXUP are
vo motor and ECU. fixed.
EXUP servo motor
and cables.
vo motor.
motor (mechanism
or motor).
P048D [P048D] EXUP servo • Defective coupler Loss of engine power. Learning values for
P048E motor: open or ground between EXUP po- fully closed EXUP are
short circuit detected. sition sensor and fixed.
[P048E] EXUP servo ECU. Learning values for
motor: power short • Open or short cir- fully open EXUP are
circuit detected. cuit in wire harness fixed.
between EXUP po- O2 feedback is not
sition sensor and carried out.
ECU.
• Defective EXUP po-
sition sensor.
9-53

malfunction eration
P0500 [P0500] Rear wheel • Open or short cir- Vehicle speed is not Vehicle speed dis-
P1500 sensor: no normal cuit in wire harness displayed on the me- played on the meter =
signals are received between rear wheel ter. 0 [km/h]
from the rear wheel sensor and ABS Indication of the neu- O2 feedback is not
sensor. unit. tral indicator light is in- carried out.
[P1500] Neutral • Open or short cir- correct. Fuel cut-off control
switch: open or short cuit in wire harness Engine idling speed is when the rear wheel
circuit is detected. between ABS unit unstable. sensor or neutral
[P1500] Clutch switch: and ECU. Traction control does switch malfunctions is
open or short circuit is • Open or short cir- not work. carried out.
detected. cuit in wire harness ISC feedback is not
between neutral carried out.
switch and ECU. ISC learning is not
• Open or short cir- carried out.
cuit in wire harness Traction control does
between clutch not work.
switch and ECU. QSS is not carried
• Defective rear wheel out.
sensor.
• Defective neutral
switch.
• Defective clutch
switch.
• Improper adjust-
ment of clutch lever.
P0560 Charging voltage is • Battery over-dis- Engine is difficult to O2 feedback is not
abnormal. charging (broken or start. carried out.
disconnected lead in Increased exhaust
charging system). emissions.
• Battery over-dis- Battery performance
charging (defective has deteriorated or
rectifier/regulator). battery is defective.
P0563 Vehicle system power • Battery overcharg- Engine is difficult to O2 feedback is not
voltage out of range ing (defective rectifi- start. carried out.
er/regulator). Increased exhaust
• Battery overcharg- emissions.
ing (broken or dis- Battery performance
connected lead in has deteriorated or
rectifier/regulator battery is defective.
wire harness).
P0601 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be
ECU. (When this mal- started. started.
function is detected in
the ECU, the DTC
might not appear on
the tool display.)
9-54

malfunction eration
P0606 Internal malfunction in • Malfunction in ECU. Engine cannot be Engine cannot be
ECU. (When this mal- started. started.
function is detected in Engine response is Ignition and injection
the ECU, the DTC poor. are not carried out.
might not appear on Loss of engine power. Judgment for other
the tool display.) DTCs is not carried
out.
Load control is not
carried out. (The relay
unit, radiator fan mo-
tor relay, and other re-
lays are all turned off.)
The CO adjustment
mode and diagnostic
mode cannot be acti-
vated.
Output is restricted.
P062F EEPROM DTC: an er- • CO adjustment val- Increased exhaust CO adjustment value
ror is detected while ue is not properly emissions. for the faulty cylinder
reading or writing on written. Engine cannot be = 0 (default value)
EEPROM. • ISC learning value is started or is difficult to ISC learning values =
not properly written. start. Default values.
• O2 feedback learn- Engine idling speed is OBD memory value is
ing value is not unstable. initialized.
properly written. OBD memory value is Initialization of O2
• OBD memory value not correct. feedback learning val-
is not properly writ- ue.
ten.
P0638 YCC-T drive system: • Defective coupler Engine response is O2 feedback is not
malfunction detected. between throttle ser- poor. carried out.
vo motor and ECU. Loss of engine power. YCC-T evacuation is
• Open or short cir- Engine idling speed is activated.
cuit in wire harness unstable. Output is restricted.
between throttle ser- ISC feedback is not
vo motor and ECU. carried out.
• Defective throttle ISC learning is not
servo motor. carried out.
• Throttle servo mo- QSS is not carried
tor is stuck (mecha- out.
nism or motor).
• Blown electric throt-
tle valve fuse.
P0657 Fuel system voltage: • Open or short cir- Engine is difficult to Monitor voltage = 12
incorrect voltage sup- cuit in wire harness start. [V]
plied to the fuel injec- between relay unit Increased exhaust O2 feedback is not
tor and fuel pump. and ECU. emissions. carried out.
• Open circuit in wire
harness between
battery and ECU.
• Defective relay unit.
9-55

malfunction eration
P0916 [P0916] Gear posi- [P0916] Low voltage Improper display for Maintains the gear
P0917 tion sensor: open or of the gear position position. position value at the
ground short circuit sensor circuit (0.2 V Engine response is previous value.
detected. or less) poor. QSS is not carried
[P0917] Gear posi- [P0917] High voltage out.
tion sensor: power of the gear position Engine brake man-
short circuit detected. sensor circuit (4.8 V agement: control
or more) mode is fixed.
• Defective coupler Engine brake man-
between gear posi- agement: control val-
tion sensor and ue is fixed.
ECU.
• Open or power short
circuit in wire har-
ness between gear
position sensor and
ECU.
gear position sen-
sor.
• Defective gear posi-
tion sensor.
P1400 Air induction system • Open or short cir- Increased exhaust Electric current in air
solenoid: open or cuit in wire harness. emissions. induction system so-
short circuit detected. • Disconnected cou- lenoid is prohibited
pler. (air induction system
• Defective air induc- air in).
tion system sole- O2 feedback is not
noid. carried out.
• Defective air induc-
tion system sole-
noid controller.
(malfunction in
ECU)
P1600 Lean angle sensor: • Open or short cir- Engine cannot be Engine cannot be
open or short circuit cuit in wire harness. started. started.
detected. • Malfunction in IMU.
P1601 Sidestand switch: • Defective coupler Engine cannot be Engine is forcefully
open or short circuit of between relay unit started. stopped (the injector
the blue/yellow lead of and ECU. output is stopped).
the ECU is detected. • Open or short cir-
between relay unit
and ECU.
• Defective coupler
between sidestand
switch and relay
unit.
• Open or short cir-
between sidestand
switch and relay
unit.
• Defective sidestand
switch.
9-56

malfunction eration
P1602 Malfunction in ECU • Open or short cir- Engine idling speed is O2 feedback learning
internal circuit (mal- cuit in wire harness unstable. is not carried out.
function of ECU pow- between ECU and Engine idling speed is O2 feedback learning
er cut-off function). battery. high. value is not written.
• Open or short cir- Increased exhaust
cuit in wire harness emissions.
between ECU and Engine is difficult to
main switch. start.
• Blown backup fuse.
P1806 [P1806] Shift sensor: • Defective coupler Unable to carry out QSS is not carried
P1807 open or ground short between shift sensor QSS. out.
circuit detected. and ECU. (If this abnormality oc-
[P1807] Shift sensor: • Open or power short curs during actual
power short circuit de- circuit in wire har- shifting, the operation
tected. ness between shift will be carried out until
sensor and ECU. the process is com-
• Improperly installed pleted.)
shift sensor.
• Defective shift sen-
sor.
P2122 [P2122] Accelerator [P2122, P2127] Low Engine response is No change in acceler-
P2123 position sensor: open voltage of the acceler- poor. ator opening (tran-
P2127 or ground short cir- ator position sensor Loss of engine power. sient control is not
P2128 cuit detected. circuit (0.25 V or less) Engine idling speed is carried out).
P2138 [P2123] Accelerator [P2123, P2128] High unstable. Accelerator opening is
position sensor: pow- voltage of the acceler- fixed to 0[°].
er short circuit detect- ator position sensor O2 feedback is not
ed. circuit (4.75 V or carried out.
[P2127] Accelerator more) YCC-T evacuation is
position sensor: open [P2138] Difference in activated.
or ground short cir- output voltage 1 and Fuel cut is prohibited
cuit detected. output voltage 2 of the by accelerator open-
[P2128] Accelerator accelerator position ing.
position sensor: pow- sensor Output is restricted.
er short circuit detect- • Defective coupler ISC feedback is not
ed. between accelera- carried out.
[P2138] Deviation er- tor position sensor ISC learning is not
ror and ECU. carried out.
• Open or short cir- QSS is not carried
cuit in wire harness out.
between accelera-
tor position sensor
and ECU.
accelerator position
sensor.
• Defective accelera-
tor position sensor.
9-57

malfunction eration
P2158 Front wheel sensor: • Open or short cir- Traction control does Traction control does
no normal signals are cuit in wire harness not work. not work.
received from the between front wheel Traction control sys-
front wheel sensor. sensor and ABS tem indicator on the
ECU. meter comes on.
• Open or short cir- Traction control sys-
cuit in wire harness tem switch is dis-
between ABS ECU abled. (Traction
and ECU. control system indica-
• Defective front tor on the meter goes
wheel sensor. OFF.)
• Malfunction in ABS
ECU.
P2195 O2 sensor 1: open cir- • Signal voltage is Increased exhaust O2 feedback is not
cuit detected. 0.18–0.49 V. emissions. carried out.
• Improperly installed O2 feedback learning
O2 sensor 1. is not carried out.
• Defective coupler Air induction system
between O2 sensor solenoid is turned on
1 and ECU. all the time (air induc-
• Open or short cir- tion system air cut
cuit in wire harness off).
between O2 sensor QSS is not carried
1 and ECU. out.
sure.
1.
P2197 O2 sensor 2: open cir- • Signal voltage is Increased exhaust O2 feedback is not
cuit detected. 0.18–0.49 V. emissions. carried out.
• Improperly installed O2 feedback learning
O2 sensor 2. is not carried out.
• Defective coupler Air induction system
between O2 sensor solenoid is turned on
2 and ECU. all the time (air induc-
• Open or short cir- tion system air cut
cuit in wire harness off).
between O2 sensor QSS is not carried
2 and ECU. out.
sure.
2.
9-58

malfunction eration
P21CF [P21CF] Secondary • Defective coupler Loss of engine power. O2 feedback is not
P21D0 injector #1: malfunc- between secondary carried out.
P21D1 tion in secondary in- injector and ECU. Air induction system
P21D2 jector #1. • Open or short cir- solenoid is turned on
[P21D0] Secondary cuit in wire harness all the time (air induc-
injector #2: malfunc- between secondary tion system air cut
tion in secondary in- injector and ECU. off).
jector #2. • Defective second- ISC feedback is not
[P21D1] Secondary ary injector. carried out.
injector #3: malfunc- • Malfunction in ECU. ISC learning is not
tion in secondary in- • Improperly installed carried out.
jector #3. secondary injector. Injection to the appli-
[P21D2] Secondary cable cylinder group
injector #4: malfunc- (cylinders #1 and #2
tion in secondary in- or cylinders #3 and
jector #4. #4) is cut off.
QSS is not carried
out.
P2228 [P2228] Atmospheric [P2228] Low voltage Engine is difficult to α–N is fixed.
P2229 pressure sensor: of the atmospheric start. Intake air pressure
ground short circuit pressure sensor cir- Increased exhaust difference is fixed to 0
detected. cuit (0.5 V or less) emissions. [kPa].
[P2229] Atmospheric [P2229] High voltage Insufficient power at Atmospheric pres-
pressure sensor: of the atmospheric high altitudes. sure is fixed to 101.3
open or power short pressure sensor cir- Engine idling speed is [kPa].
circuit detected. cuit (4.8 V or more) unstable. Atmospheric pres-
• Defective coupler sure sensor output
between atmospher- correction value is
ic pressure sensor fixed to 0.
and ECU. Fuel is not cut off due
• Open or short cir- to the intake air pres-
cuit in wire harness sure difference.
between atmospher- O2 feedback is not
ic pressure sensor carried out.
and ECU. ISC feedback is not
atmospheric pres- ISC learning is not
sure sensor. carried out.
• Defective atmo- QSS is not carried
spheric pressure out.
sensor.
U0125 Signals cannot be • Defective IMU cou- Engine cannot be Engine cannot be
transmitted between pler or ECU coupler. started. started.
the ECU and the IMU. • Open or short cir-
between IMU and
ECU.
9-59
EAS33029
SELF-DIAGNOSTIC FUNCTION TABLE (FOR IMMOBILIZER SYSTEM)

TIP
For details of the DTC, refer to “HOW TO CHECK DTC” on page 9-22.
DTC Item
51 Immobilizer unit: Code cannot be transmitted between the key and the immobilizer unit.
52 Immobilizer unit: Codes between the key and immobilizer unit do not match.
53 Immobilizer unit: Codes cannot be transmitted between the ECU and the immobilizer unit.
54 Immobilizer unit: Codes transmitted between the ECU and the immobilizer unit do not match.
55 Immobilizer unit: Key code registration malfunction.
56 ECU: Unidentified code is received.
9-60
EAS33286
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))

TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-28.
DTC Item Symptom Check point

11 Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the front wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
12 Rear wheel sensor (intermit- Rear wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the rear wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) rear wheel
rotor
• Defective rear wheel sen-
of the sensor
13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
front wheel
rotor
of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered
27* mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
rear wheel
rotor
of the sensor
9-61

15 Front wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the front wheel sen- the front wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
sor or hydraulic unit as-
sembly
16 Rear wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the rear wheel sen- the rear wheel sensor and
sor. the hydraulic unit assembly
rear wheel sensor and the
sor or hydraulic unit as-
sembly
21 Hydraulic unit assembly (de- Solenoid drive circuit in the • Defective hydraulic unit as-
fective solenoid drive circuit) hydraulic unit assembly is sembly
open or short-circuited.
31 Hydraulic unit assembly (de- Power is not supplied to the • Blown ABS solenoid fuse
fective ABS solenoid power solenoid circuit in the hy- • Defective coupler between
circuit) draulic unit assembly. the battery and the hydrau-
lic unit assembly
battery and the hydraulic
unit assembly
• Defective hydraulic unit as-
sembly
33 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS motor fuse
normal ABS motor power motor circuit in the hydraulic • Defective coupler between
supply) unit assembly. the battery and the hydrau-
lic unit assembly
unit assembly
sembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS motor the motor power supply cir- sembly
power supply circuit) cuit in the hydraulic unit as-
sembly.
41 Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- front wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. front wheel
• Front wheel will not recover • Front brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
9-62

42 Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- rear wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. rear wheel
• Rear wheel will not recover • Rear brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
43* Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
45* pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) front wheel
rotor
of the sensor
44* Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
46* pulses) not received properly. (Miss- around the rear wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) rear wheel
rotor
of the sensor
51 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Disconnected battery ter-
supply is high) lic unit assembly is too high. minal
• Defective charging system
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lic unit assembly is too low. the battery and the hydrau-
lic unit assembly
unit assembly
55 Hydraulic unit assembly (de- Abnormal data is detected in • Defective hydraulic unit as-
fective ABS ECU) the hydraulic unit assembly. sembly
56 Hydraulic unit assembly (ab- Abnormality detected in of • Defective hydraulic unit as-
normal internal circuit) hydraulic unit assembly. sembly
9-63

57 Vehicle CAN communication Short-circuit in CAN commu- • Short-circuit in CAN com-
line or power source of vehi- nication line or the voltage munication line
cle system that supplies the hydraulic • Defective battery
unit assembly is too low. • Defective coupler between
battery and hydraulic unit
assembly
• Wire harness between bat-
tery and hydraulic unit is in-
terrupted or has short-
circuited
62 Power supply voltage failure Abnormality detected in • Defective hydraulic unit as-
in pressure sensor pressure sensor power sup- sembly
ply circuit of hydraulic unit
assembly.
68 Defective hydraulic unit as- Abnormality detected in In case of electrical interlock-
sembly (defective front pres- pressure sensor circuit at ing brake
sure sensor) front caliper side of hydrau- • Defective front brake line
lic unit assembly. • Defective hydraulic unit as-
sembly
89 CAN communication (be- Transmitted data from the • Defective coupler between
tween meter assembly and meter cannot be normally re- meter assembly and hy-
hydraulic unit assembly) ceived. draulic unit assembly
• Harness is broken or short-
circuit between meter as-
sembly and hydraulic unit
assembly
• Defective meter assembly
sembly
90 CAN communication (be- Transmitted data from the FI • Defective coupler between
tween ECU and hydraulic ECU cannot be normally re- FI ECU and hydraulic unit
unit assembly) ceived. assembly
circuit between FI ECU and
• Defective FI ECU
sembly
91 CAN communication (be- Transmitted data from the • Defective coupler between
tween IMU and hydraulic unit IMU cannot be normally re- IMU and hydraulic unit as-
assembly) ceived. sembly
circuit between IMU and
• Defective IMU
sembly
* The DTC number varies according to the vehicle conditions.
9-64
EAS33287
SELF-DIAGNOSTIC FUNCTION TABLE (FOR STEERING DAMPER SYSTEM)

TIP

malfunction eration
C1000 Steering damper sole- • Defective coupler Steering damper does Solenoid fixed at OFF.
noid: open or short between steering not work.
circuit detected. damper solenoid
and ECU.
• Open or short cir-
between steering
damper solenoid
and ECU.
• Defective steering
damper solenoid.
9-65
EAS33288
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ELECTRONICALLY ADJUSTABLE SUSPENSION

SYSTEM (for YZF-R1M))
TIP
Probable cause of
DTC Item Vehicle symptom Fail-safe system operation
malfunction
• ERS adjustments can-
not be performed.
• Defective front and
• The damping preset
rear brake line.
C0044 Abnormal ABS value is fixed at the —
• Defective hydraulic
prescribed position
unit assembly.
(automatic setting
modes).
• Defective IMU cou-
pler or ECU coupler.
• Open or short circuit
not be performed.
in wire harness be-
tween IMU and
C0520 Abnormal IMU value is fixed at the —
ECU.
prescribed position
(automatic setting
IMU.
modes).
• SCU abnormal data
Abnormal SCU • ERS adjustments can-
C1002 writing error. —
EEPROM not be performed.
• Malfunction in SCU.
• Defective connec-
tion of stepping mo-
tor and SCU
couplers.
not be performed.
Stepping motor: tion of sub-wire har-
value is fixed on the de-
C1003 open or short cir- ness coupler. —
fective side (front fork
cuit detected. • Short circuit in wire
or RCU) at the current
harness or wire har-
value (automatic set-
ness continuity.
ting modes).
• Defective stepping
motor.
Abnormality in- • ERS adjustments can-
C1007 • Malfunction in SCU. —
side SCU not be performed.
• Open or short circuit
in wire harness be-
tween rear wheel
sensor and ABS
not be performed.
unit.
Abnormal rear • Open or short circuit
P0500 value is fixed at the —
wheel sensor in wire harness be-
prescribed position
tween ABS unit and
(automatic setting
ECU.
modes).
• Defective rear
wheel sensor.
9-66
Probable cause of
malfunction
• Battery overcharg-
ing (defective rectifi-
er/regulator).
• Battery overcharg-
ing (broken or dis-
connected lead in
Abnormal SCU rectifier/regulator
P0560 power supply volt- wire harness). —
not be performed.
age • Battery over-dis-
charging (broken or
disconnected lead
in charging system).
• Battery over-dis-
charging (defective
rectifier/regulator).
• Open or short circuit • ERS adjustments can-
Front wheel sen-
in wire harness be- not be performed.
sor: no normal
tween front wheel • The damping preset
signals are re-
P2158 sensor and ECU. value is fixed at the —
ceived from the
• Defective front prescribed position
front wheel sen-
wheel sensor. (automatic setting
sor.
• Malfunction in ECU. modes).
tion of wire harness,
not be performed.
Abnormal CAN ECU, and SCU cou-
communication plers.
U0100 value is fixed at the —
(between ECU • Wire harness conti-
prescribed position
and SCU) nuity.
(automatic setting
modes).
tion of wire harness, • ERS adjustments can-
ABS ECU, and SCU not be performed.
Abnormal CAN
couplers. • The damping preset
communication
U0121 • Wire harness conti- value is fixed at the —
(between ABS
nuity. prescribed position
ECU and SCU)
• Malfunction in SCU. (automatic setting
• Malfunction in ABS modes).
ECU.
tion of wire harness,
not be performed.
Abnormal CAN IMU, and SCU cou-
communication plers.
U0125 value is fixed at the —
(between IMU • Wire harness conti-
prescribed position
and SCU) nuity.
(automatic setting
modes).
tion of wire harness, • ERS adjustments can-
Abnormal CAN meter assembly, not be performed.
communication and SCU couplers. • The damping preset
U0155 (between meter • Wire harness conti- value is fixed at the —
assembly and nuity. prescribed position
SCU) • Malfunction in SCU. (automatic setting
• Malfunction in meter modes).
assembly.
9-67
Probable cause of
malfunction
not be performed.
Abnormality in-
— • Malfunction in SCU. • The “Err” and ERS —
side SCU
icons are displayed on
the meter display.
tion of stepping mo- • ERS adjustments can-
tor and SCU not be performed.
Steering damper couplers. • The damping preset
stepping motor • Defective connec- value is fixed at the cur-
(manufactured by tion of sub-wire har- rent value.
— Öhlins: optional): ness coupler. • The auxiliary system —
open circuit or • Short circuit in wire warning light comes on
short-circuit de- harness or wire har- on the meter and the
tected. ness continuity. steering damper warn-
• Defective stepping ing icon is displayed on
motor. the meter display.
EAS33030
COMMUNICATION ERROR WITH THE METER

malfunction eration
U0155 [U0155 (FI)] Multi- Communication be- Defective meter dis- MAP changeover:
(YDT) function meter: sig- tween the ECU and play. State is fixed.
Err (multi- nals cannot be trans- the meter is not possi- Traction control does Traction control does
function mitted between the ble not work. not work.
meter dis- ECU and the multi- • Defective meter cou- Meter switch input:
play) function meter. pler and ECU cou- OFF is fixed.
[U0155 (SCU)] Abnor- pler QSS is not carried
mal CAN communica- • Open or short cir- out.
tion (between meter cuit in the wire har- Engine brake man-
assembly and SCU) ness between the agement: control
meter and the ECU mode is fixed.
• Defective meter
• Defective ECU
9-68
EAS33031
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
D01 Throttle position sensor sig-
nal 1
• Fully closed position 11–21 Check with throttle valves ful-
ly closed.
• Fully open position 96–107 Check with throttle valves ful-
ly open.
D02 Atmospheric pressure Displays the atmospheric Compare the actually mea-
pressure. sured atmospheric pressure
with the tool display value.
D03 Intake air pressure Displays the intake air pres- Operate the throttle while
sure. pushing the “ ” side of the
start/engine stop switch. (If
the display value changes,
the performance is OK.)
D05 Intake air temperature Displays the intake air tem- Compare the actually mea-
perature. sured air temperature with
the tool display value.
D06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
air temperature. with the tool display value.
When engine is hot: Displays
current coolant temperature.
D07 Rear wheel vehicle speed Rear wheel speed pulse Check that the number in-
pulses 0–999 creases when the rear wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
D09 Fuel system voltage Fuel system voltage Set the start/engine stop
(battery voltage) Approximately 12.0 switch to “ ”, and then com-
pare the actually measured
battery voltage with the tool
display value. (If the actually
measured battery voltage is
low, recharge the battery.)
D13 Throttle position sensor sig-
nal 2
• Fully closed position 9–23 Check with throttle valves ful-
ly closed.
• Fully open position 93–109 Check with throttle valves ful-
ly open.
D14 Accelerator position sensor
signal 1
• Fully closed position 9–23 Check with throttle grip fully
closed position.
• Fully open position 71–87 Check with throttle grip fully
open position.
9-69
Diagnostic
code No.
D15 Accelerator position sensor
signal 2
• Fully closed position 7–25 Check with throttle grip fully
closed position.
• Fully open position 69–89 Check with throttle grip fully
open position.
D16 Front wheel vehicle speed Front wheel speed pulse Check that the number in-
pulses 0–999 creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
D17 Bank angle display Displays the bank angle in in- Check that 0–5° is displayed
crements of 5° when the vehicle is vertical
• 0–5° (vehicle is vertical) and that the displayed value
• Less than 30° (when the increases as the vehicle con-
sidestand is used) tinues to incline.
D20 Sidestand switch Extend and retract the side-
stand (with the transmission
• Sidestand retracted ON
in gear).
• Sidestand extended OFF
D21 Neutral switch and clutch Operate the transmission,
switch clutch lever, and sidestand.
• Transmission is in neutral ON
• Transmission is in gear or OFF
the clutch lever released
• Clutch lever is squeezed ON
with the transmission in
gear and when the side-
stand is retracted
• Clutch lever is squeezed OFF
with the transmission in
gear and when the side-
stand is extended
D60 EEPROM DTC display —
• No history 00
• No malfunctions detected
(If the DTC P062F is indi-
cated, the ECU is defec-
tive.)
• History exists 01–04 (CO adjustment val-
ue)
• (If more than one cylinder is
defective, the display alter-
nates every two seconds to
show all the detected cylin-
der numbers.
When all cylinder numbers
are shown, the display re-
peats the same process.)
Except 00-04 (EEPROM
data error for corresponding
learning/memory values)
9-70
Diagnostic
code No.
D67 ISC (Idle Speed Control) 00 To erase the ISC (Idle Speed
learning condition display ISC (Idle Speed Control) Control) learning data, push
ISC (Idle Speed Control) learning data has been the “Operation” button 3
learning data erasure erased. times in 5 seconds.
01
It is not necessary to erase
the ISC (Idle Speed Control)
learning data.
02
It is necessary to erase the
ISC (Idle Speed Control)
learning data.
D70 Control number 0–254 [-] —
D87 O2 feedback learning data 00 To erase the O2 feedback
erasure O2 feedback learning data learning data, push the “Op-
has been erased. eration” button 3 times in 5
01 seconds.
O2 feedback learning data
has not been erased.
D95 Shift sensor Check the sensor condition
• Shift sensor output voltage 0.2–4.8 [V] by operating the shift pedal.
display
• With no shift weighting in- Approx. 2.5 [V]
put
• Shift up weighting Changes to the low side
• Shift down weighting Changes to the high side
9-71
EAS33032
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
D30 Cylinder-#1 ignition coil Actuates the cylinder-#1 igni- Check that a spark is gener-
tion coil five times at one- ated five times.
second intervals. • Connect an ignition check-
The “check” indicator on the er.
YDT screen come on each
time the ignition coil is actu-
ated.
ated.
ated.
ated.
D34 Intake funnel servo motor Actuates the intake funnels Check the operating of the
(up position down, position intake funnel servo motor.
for each six seconds).
Illuminates the “check” indi-
cator
D36 Primary injector #1 Actuates the primary injec- Disconnect the fuel pump
tor #1 five times at one-sec- coupler before doing this
ond intervals. procedure.
The “check” indicator on the Check that primary injector
YDT screen come on each #1 is actuated five times by
time the fuel injector is actu- listening for the operating
ated. sound.
ated. sound.
ated. sound.
9-72
Diagnostic
code No.
ated. sound.
D40 Secondary injector #1 Actuates the secondary in- Disconnect the fuel pump
jector #1 five times at one- coupler before doing this
second intervals. procedure.
The “check” indicator on the Check that secondary injec-
YDT screen come on each tor #1 is actuated five times
time the fuel injector is actu- by listening for the operating
ated. sound.
ated. sound.
ated. sound.
ated. sound.
D47 Steering damper solenoid When the start/engine stop Check the operating of the
switch is “ON”, the steering steering damper.
damper solenoid is on.
When the start/engine stop
switch is “OFF”, the steering
damper solenoid is off.
The “check” indicator on the
time the steering damper so-
lenoid is actuated.
D48 Air induction system sole- Actuates the air induction Check that the air induction
noid system solenoid five times at system solenoid is actuated
one-second intervals. five times by listening for the
The “check” indicator on the operating sound.
time the air induction system
solenoid is actuated.
9-73
Diagnostic
code No.
D49 Intake solenoid Actuates the intake solenoid Check that the intake sole-
five times at one-second in- noid is actuated five times by
tervals. listening for the operating
The “check” indicator on the sound.
time the intake solenoid is
actuated.
D50 Relay unit Actuates the relay unit five Check that the relay unit is
times at one-second inter- actuated five times by listen-
vals. ing for the operating sound.
time the relay is actuated.
D51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
seconds intervals. times by listening for the op-
The “check” indicator on the erating sound.
time the relay is actuated.
D52 Headlight relay Actuates the headlight five Check that the headlight
times at five-seconds inter- comes on five times.
vals.
time the headlight is actuat-
ed.
D53 EXUP servo motor After the EXUP is fully Check the operating sound.
closed, it stops at the open-
ing base position (intermedi-
ate position).
This operation takes approxi-
mately 3 seconds during
which the “check” indicator is
displayed on the YDT.
EAS33289
DIAGNOSTIC CODE TABLE (SCU) (for YZF-R1M)

Diagnostic
code No.
D09 Monitor voltage Displays the SCU power Check the displayed SCU
supply voltage. power supply voltage.
Approximately 12.0 V
9-74
EVENT CODE TABLE
EAS20707
EVENT CODE TABLE

TIP
The event code numbers listed below cannot be displayed on the meter. To display the event code
numbers, use the YDT.
No. Item Symptom Possible causes Note

192 Intake air pres- Brief abnormality de- Same as for DTC num- Perform the inspection
sure sensor tected in the intake air ber P0107 and P0108 items listed for DTC num-
pressure sensor ber P0107 and P0108.
193 Throttle position Brief abnormality de- Same as for DTC num- Perform the inspection
sensor tected in the throttle ber P0122, P0123, items listed for DTC num-
position sensor P0222 and P0223 ber P0122, P0123, P0222
and P0223.
194 EXUP servo mo- Brief abnormality de- Same as for DTC num- Perform the inspection
tor circuit tected in EXUP servo ber P048D and P048E items listed for DTC num-
motor circuit ber P048D and P048E.
195 Sidestand switch Brief abnormality de- Same as for DTC num- Perform the inspection
tected in the ECU ber P1601 items listed for DTC num-
(blue/yellow) input ber P1601.
line
196 Coolant tempera- Brief abnormality de- Same as for DTC num- Perform the inspection
ture sensor tected a in the coolant ber P0117 and P0118 items listed for DTC num-
temperature sensor ber P0117 and P0118.
197 Intake air tem- Brief abnormality de- Same as for DTC num- Perform the inspection
perature sensor tected in the intake air ber P0112 and P0113 items listed for DTC num-
temperature sensor ber P0112 and P0113.
198 Atmospheric Brief abnormality de- Same as for DTC num- Perform the inspection
pressure sensor tected in atmospher- ber P2228 and P2229 items listed for DTC num-
ic pressure sensor ber P2228 and P2229.
207 Accelerator posi- Brief abnormality de- Same as for DTC num- Perform the inspection
tion sensor tected in the acceler- ber P2122, P2123, items listed for DTC num-
ator position sensor P2127 and P2128 ber P2122, P2123, P2127
and P2128.
220 Gear position Brief abnormality de- Same as for DTC num- Perform the inspection
sensor tected in the gear po- ber P0916 and P0917 items listed for DTC num-
sition sensor ber P0916 and P0917.
240 O2 sensor During O2 feedback, • Open or short circuit in • If a DTC is occurring, re-
(Stuck at the up- the adjustment is the wire harness be- spond to that first.
per limit for ad- maintained at the up- tween the sensor and * Rarely, Code 240 occurs
justment) per limit ECU even when the system is
• Drop in fuel pressure functioning properly.
• Clogged fuel injector
• Fault in sensor
• Malfunction in ECU
• Malfunction in the fuel
injection system
9-75
EVENT CODE TABLE
No. Item Symptom Possible causes Note

241 O2 sensor During O2 feedback, • Open or short circuit in • If a DTC is occurring, re-
(Stuck at the low- the adjustment is the wire harness be- spond to that first.
er limit for adjust- maintained at the low- tween the sensor and * Rarely, Code 241 occurs
ment) er limit ECU even when the system is
• Drop in fuel pressure functioning properly.
• Clogged fuel injector
• Fault in sensor
• Malfunction in the fuel
injection system
242 ISC During idling, the ad- Idling engine speed is • Implement diagnosis
(Stuck at the up- justment is main- slow mode D67, and check the
per limit for ad- tained at the upper • Clogged throttle body ISC maintenance request.
justment) limit • Poorly adjusted clutch • If a DTC is occurring, re-
cable spond to that first.
• Malfunction in the fuel * Rarely, Code 242 occurs
injection system even when the system is
• Dirty or worn spark functioning properly.
plug
• Malfunction in the bat-
tery
243 ISC During idling, the ad- Idling engine speed is • If a DTC is occurring, re-
(Stuck at the low- justment is main- fast spond to that first.
er limit for adjust- tained at the lower • Poorly adjusted clutch * Rarely, Code 243 occurs
ment) limit cable even when the system is
• Malfunction in the fuel functioning properly.
injection system
• Dirty or worn spark
plug
tery
244 Poor starting/in- Poor starting/inability • No gasoline • If a DTC is occurring, re-
ability to start to start detected • Malfunction in the fuel spond to that first.
injection system * Rarely, Code 244 occurs
• Dirty or worn spark even when the system is
plug functioning properly.
tery
245 Engine stop Engine stop detected • No gasoline • If a DTC is occurring, re-
• Poorly adjusted clutch spond to that first.
cable * Rarely, Code 245 occurs
• Malfunction in the fuel even when the system is
injection system functioning properly.
• Dirty or worn spark
plug
tery
251 Shift sensor Brief abnormality de- Same as for DTC num- Perform the inspection
tected in the shift sen- ber P1806 and P1807 items listed for DTC num-
sor ber P1806 and P1807.
9-76
30_EVENT
EAS20552
30_EVENT
EAS33033
TROUBLESHOOTING
Item
Latch up detected.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle
Procedure
1. The vehicle has overturned.
• Raise the overturned vehicle vertically and check again.
• Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.
Is the MIL on?

YES
→ Go to step 2.
NO
→ Service is completed.
2. Installed condition of IMU.
• Check the installed direction and condition of the sensor.
• Check the grommet for cracks.
Is check result OK?

YES
→ Go to step 3.
NO
a. Fix the IMU installation condition.
b. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.
Is the MIL on?

YES
→ Go to step 3.
NO
3. Defective IMU.
• Execute the diagnostic mode. (Code D17)
• Check that 0°–5° is displayed when the vehicle is vertical and that the displayed value increases as
the vehicle continues to incline.
Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the IMU.
b. Turn the main switch to “ON”, then to “OFF”, and then back to “ON”.
Is the MIL on?

YES
→ Go to step 4.
9-77
30_EVENT
NO
4. Malfunction in ECU.
• Replace the ECU, and complete the service.
Refer to “REPLACING THE ECU (Engine Control Unit)” on page 8-41.
9-78
70_EVENT
EAS20554
70_EVENT
EAS33034
TROUBLESHOOTING
Item
Engine forcibly stops when the vehicle is left idling for a long period.
Procedure
TIP
If another error code is displayed at the same time, check the other error code first and repair it.
1. Allow to idle for a long period.
• Turn the main switch to “OFF”.
• Check whether it is possible to start the engine.
Can the engine starting?

YES
NO
→ Go to step 2.
9-79
C0044
EAS20559
C0044
EAS33039
TROUBLESHOOTING
Item
Abnormal ABS
Fail-safe system
• Able to start engine
• Able to drive vehicle
Procedure
1. Abnormal ABS
• Check the items of DTCs 62 and 68 for the ABS.
Refer to “[B-2] DIAGNOSIS USING THE DTC” on page 9-31.
• Turn the main switch to “OFF” and back to “ON”, and then check the condition of the DTC using the
malfunction mode of the YDT.
Is it in the “Recovered” condition?

YES
NO
→ Refer to the item corresponding to the DTC.
9-80
C0520 (FI)
EAS20689
C0520 (FI)
EAS33319
TROUBLESHOOTING
Item
Abnormal IMU
Fail-safe system
• Able/Unable to start engine
• Able/Unable to drive vehicle
Procedure
1. Connection of IMU coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).
Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

YES
→ Go to step 7, and complete the service.
NO
→ Go to step 2.
2. Connection of ECU coupler.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
3. Wire harness continuity.
• Disconnect the ECU coupler “1”, joint coupler “2”, IMU coupler “3” and ignition fuse “4”.
• Open circuit check
blue/white–blue/white
Between ECU coupler and joint coupler
blue/black–blue/black
9-81
C0520 (FI)
Between joint coupler and IMU coupler
Between IMU coupler and ignition fuse holder red/white–red/white
Between IMU coupler and ECU coupler black/white–black/white
4 1
3 Y/R P/W P/B Gy/G O/G Gy/R O
Lg/R L/R O/B L/B G/B R/B B
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B
R/G Y/B L/W Y/L Sb R/L B/W B/W
2 1
* L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/B Y/L P/W P V L L/R Gy

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.
of the YDT.

YES
NO
• Short circuit check
TIP
Disconnect the ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3.
Ground short circuit check “A”
blue/white–ground
Between ECU coupler “1” and ground
blue/black–ground
blue/white–ground
Between IMU coupler “3” and ground blue/black–ground
red/white–ground
Lines short circuit check “B”

blue/white–any other coupler terminal
ECU coupler
blue/black–any other coupler terminal
9-82
C0520 (FI)

Joint coupler “2”
IMU coupler blue/black–any other coupler terminal
red/white–any other coupler terminal
A B
1 1
L/B Y/L P/W P V L L/R Gy L/B Y/L P/W P V L L/R Gy

L/W B/Y Gy/G Br/W B/L W W/B L/W B/Y Gy/G Br/W B/L W W/B
L/Y L/W Gy/Y G/W G Gy/B W/L L/Y L/W Gy/Y G/W G Gy/B W/L
2

Is resistance ∞ Ω?
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO
9-83
C0520 (FI)

of the YDT.

YES
NO
→ Go to step 5.
5. Defective IMU.
• Replace the IMU.
• Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction mode
of the YDT.

YES
NO
→ Go to step 6.
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.
9-84
C0520 (SCU)
EAS20664
C0520 (SCU)
EAS33290
TROUBLESHOOTING
Item
Abnormal IMU
Fail-safe system
Procedure
1. Abnormal front wheel sensor
• Check the item of DTC C0520 for the ECU.
Refer to “SELF-DIAGNOSTIC FUNCTION TABLE (FOR FUEL INJECTION SYSTEM)” on page
9-46.

YES
NO
→ Refer to the item corresponding to DTC.
9-85
C1000
EAS20561
C1000
EAS33041
TROUBLESHOOTING
Item
Steering damper solenoid: open or short circuit detected.
Fail-safe system
Procedure
1. Connection of steering damper solenoid coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the ECU coupler “1 ” and steering damper solenoid coupler “2”.
Between steering damper solenoid coupler and
yellow/black–yellow/black
ECU coupler
9-86
C1000
Between steering damper solenoid coupler and en-

black–black
gine ground
1 2
L/Y L Y/B R/W
W W L/G B/R
B/G B B/G
B/L B B/Y W/Y
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
Between ECU coupler “1” and ground yellow/black–ground

ECU coupler yellow/black–any other coupler terminal
Steering damper solenoid coupler “2” yellow/black–any other coupler terminal
A B
1
L/Y L Y/B R/W
W W L/G B/R
1
B/G B B/G
B/L B B/Y W/Y L/Y L Y/B R/W
L/G
W W
B/G B
B/R
B/G
2
B/L B B/Y W/Y
YES
→ Go to step 4.
9-87
C1000
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective steering damper solenoid.
• Check the steering damper solenoid.
Refer to “CHECKING THE STEERING DAMPER SOLENOID” on page 8-51.
of the YDT.

YES
NO
→ Go to step 5.
9-88
C1002
EAS20562
C1002
EAS33042
TROUBLESHOOTING
Item
Abnormal SCU EEPROM
Fail-safe system
Procedure
1. Confirmation after correction of abnormality.
• Turn the main switch to “OFF” and back to “ON”.
• Check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
2. Malfunction in SCU.
• Replace the SCU.
• Make sure confirm the “Recovered” condition, and complete the service.
9-89
C1003
EAS20563
C1003
EAS33043
TROUBLESHOOTING
Item
Stepping motor: open or short circuit detected.
Fail-safe system
Procedure
1. Connection of front fork stepping motor coupler.
–Front fork stepping motor (left)
–Front fork stepping motor (right)
–Rear shock absorber assembly stepping motor (×2)
pins).

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 “OFF” and back to “ON”, and then check the condition of the DTC using the

YES
NO
→ Go to step 2.
2. Connection of SCU coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
3. Connection of front fork stepping motor sub-wire harness coupler.
9-90
C1003
pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
green–green
Between SCU coupler “1” and front fork stepping green/black–green/black
motor (left) “2” green/red–green/red
green/blue–green/blue
1 2
pink–pink
Between SCU coupler “1” and front fork stepping pink/black–pink/black
motor (right) “2” pink/white–pink/white
pink/blue–pink/blue
1 2
white–white
Between SCU coupler “1” and rear shock absorber
white/black–white/black
assembly stepping motor (compression damping)
white/red–white/red
“2”
white/green–white/green
9-91
C1003
1 2
yellow–yellow
Between SCU coupler “1” and rear shock absorber yellow/black–yellow/black
assembly stepping motor (rebound damping) “2” yellow/red–yellow/red
yellow/green–yellow/green
1 2
Is resistance 0 Ω?
YES
NO
a. Replace the wire harness and/or sub-wire harness.

YES
NO
TIP
Disconnect the SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for YZF-R1M)” on page 9-3.
green–black
Between front fork stepping motor (left) “1” and pow- green/black–black
er ground “2” green/red–black
green/blue–black
pink–black
Between front fork stepping motor (right) “3” and pink/black–black
power ground “2” pink/white–black
pink/blue–black
9-92
C1003
white–black
Between rear shock absorber assembly stepping
white/black–black
motor (compression damping) “4” and power ground
white/red–black
“2”
white/green–black
yellow–black
Between rear shock absorber assembly stepping yellow/black–black
motor (rebound damping) “5” and power ground “2” yellow/red–black
yellow/green–black
green–brown/white
Between front fork stepping motor (left) “1” and pow- green/black–brown/white
er battery “6” green/red–brown/white
green/blue–brown/white
pink–brown/white
Between front fork stepping motor (right) “3” and pink/black–brown/white
power battery “6” pink/white–brown/white
pink/blue–brown/white
white–brown/white
Between rear shock absorber assembly stepping
white/black–brown/white
motor (compression damping) “4” and power battery
white/red–brown/white
“6”
white/green–brown/white
yellow–brown/white
Between rear shock absorber assembly stepping yellow/black–brown/white
motor (rebound damping) “5” and power battery “6” yellow/red–brown/white
yellow/green–brown/white
3 1 5 2 6
P/W G/R Y Br/W

P G Y/R Gy/G Gy B
4
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Malfunction in stepping motor.
a. Connect the digital circuit tester (Ω) to the stepping motor.
• Positive tester probe “1”
• Negative tester probe “2”
9-93
C1003
A B
1 3
1 2 3 4 2 4
A. Stepping motor coupler

B. Connection wiring diagram
b. Measure the resistance of the stepping motor between “1” and “2”.
14.8–18.2 Ω (When the motor is cold at 20 °C (68 °F))?

YES
→ Go to step c.
NO
a. Replace the stepping motor.
Refer to “FRONT FORK (for YZF-R1M)” on page 4-100 and “REAR SHOCK ABSORBER ASSEM-
BLY” on page 4-112.
b. Turn the main switch to “ON”. Check the condition of the DTC using the malfunction mode of the
YDT.

YES
NO
→ Go to step c.
c. Connect the digital circuit tester (Ω) to the stepping motor.
• Positive tester probe “3”
• Negative tester probe “4”
d. Measure the resistance of the stepping motor between “3” and “4”.
14.8–18.2 Ω (When the motor is cold at 20 °C (68 °F))?

YES
→ Go to step 6.
NO
a. Replace the stepping motor.
Refer to “FRONT FORK (for YZF-R1M)” on page 4-100 and “REAR SHOCK ABSORBER ASSEM-
BLY” on page 4-112.
b. Turn the main switch to “ON”. Check the condition of the DTC using the malfunction mode of the
YDT.

YES
NO
→ Go to step 6.
9-94
C1003

YES
NO
9-95
C1007
EAS20566
C1007
EAS33046
TROUBLESHOOTING
Item
Abnormality inside SCU
Fail-safe system
Procedure
• Make sure confirm the“Recovered”condition, and complete the service.
9-96
P0030
EAS20397
P0030
EAS33134
TROUBLESHOOTING
Item
O2 sensor 1 heater: defective heater controller detected.
Fail-safe system
Procedure
TIP
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0112, P0113, P0122, P0123, P0222, P0223, P2135
1. Connection of O2 sensor 1 coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Start the engine, and then check the condition of the DTC.

YES
NO
→ Go to step 2.
TIP
For this check, also set the start/engine stop switch to “ON”.
pins).

YES
→ Go to step 3.
NO
9-97
P0030

of the YDT.

YES
NO

YES
NO
→ Go to step 3.
TIP
• Disconnect the O2 sensor 1 coupler “1”, ECU coupler “2”, ignition fuse “3” and main switch coupler
“4”.
Between O2 sensor 1 coupler and ECU coupler pink/black–pink/black
Between O2 sensor 1 coupler and ignition fuse hold-
red/white–red/white
er
Between main switch coupler and ignition fuse hold-
brown/blue–brown/blue
er
4 3 1 2
Y/R P/W P/B Gy/G O/G Gy/R O
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
9-98
P0030

YES
NO
TIP
TIP
Between O2 sensor 1 coupler “1” and ground red/white–ground
pink/black–ground
Between main switch coupler “4” and ground brown/blue–ground

O2 sensor 1 coupler red/white–any other coupler terminal
pink/black–any other coupler terminal
ECU coupler “2” pink/black–any other coupler terminal
Main switch coupler brown/blue–any other coupler terminal
A B
1
1 4 2
YES
→ Go to step 4.
NO
of the YDT.

YES
NO

YES
NO
9-99
P0030
→ Go to step 4.
TIP
4. Defective O2 sensor 1.
• Replace the O2 sensor 1.
Refer to “ENGINE REMOVAL” on page 5-11.
of the YDT.

YES
NO

YES
NO
→ Go to step 5.
TIP
9-100
P0050
EAS20398
P0050
EAS33135
TROUBLESHOOTING
Item
O2 sensor 2 heater: defective heater controller detected.
Fail-safe system
Procedure
TIP
• P0112, P0113, P0122, P0123, P0222, P0223, P2135
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO

YES
NO
→ Go to step 2.
TIP
pins).

YES
→ Go to step 3.
NO
9-101
P0050

of the YDT.

YES
NO

YES
NO
→ Go to step 3.
TIP
• Disconnect the O2 sensor 2 coupler “1”, ECU coupler “2”, ignition fuse “3” and main switch coupler
“4”.
Between O2 sensor 2 coupler and ECU coupler pink/white–pink/white
er
er
4 3 1 2
R/W P/W Lg/R L/R O/B L/B G/B R/B B
Gy/Y B/L R/L G/Y Br/R Br/B Br/Y Sb/W W/L B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
9-102
P0050

YES
NO
TIP
TIP
Between O2 sensor 2 coupler “1” and ground red/white–ground
pink/white–ground

O2 sensor 2 coupler red/white–any other coupler terminal
pink/white–any other coupler terminal
ECU coupler “2” pink/white–any other coupler terminal
A B
1
1 4 R/W P/W 2
Gy/Y B/L
R/W P/W Y/R P/W P/B Gy/G O/G Gy/R O
Gy/Y B/L Lg/R L/R O/B L/B G/B R/B B
YES
→ Go to step 4.
NO
of the YDT.

YES
NO

YES
NO
9-103
P0050
→ Go to step 4.
TIP
• Replace the O2 sensor 2.
of the YDT.

YES
NO

YES
NO
→ Go to step 5.
TIP
9-104
P0069
EAS20390
P0069
EAS33136
TROUBLESHOOTING
Item
Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the
intake air pressure sensor voltage and atmospheric pressure sensor voltage differ greatly.
Fail-safe system
Procedure
TIP
• P0107, P0108, P0335, P2228, P2229
1. Defective intake air pressure sensor.
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
0 m above sea level Approx. 101 kPa (757.6 mmHg, 29.8 inHg)
3000 m (9800 ft) above sea level Approx. 70 kPa (525.0 mmHg, 20.7 inHg)
Is check result OK?

YES
→ Go to step 2.
NO
a. Replace the intake air pressure sensor.
Refer to “THROTTLE BODIES” on page 7-11.
of the YDT.

YES
NO
→ Go to step 2.
2. Defective atmospheric pressure sensor.
dicated.
0 m above sea level Approx. 101 kPa (757.6 mmHg, 29.8 inHg)
3000 m (9800 ft) above sea level Approx. 70 kPa (525.0 mmHg, 20.7 inHg)
Is check result OK?

YES
→ Go to step 3.
NO
9-105
P0069
a. Replace the atmospheric pressure sensor.

Refer to “AIR INDUCTION SYSTEM” on page 7-19.
of the YDT.

YES
NO
→ Go to step 3.
9-106
P00D1, P2195
EAS20660
P00D1, P2195
EAS33115
TROUBLESHOOTING
Item
• [P00D1] O2 sensor 1: heater performance deterioration
• [P2195] O2 sensor 1: open circuit detected.
Fail-safe system
Procedure
TIP
• P0030
1. Installed condition of O2 sensor 1.
• Check for looseness or pinching.
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the O2 sensor 1.
b. Start the engine and let it idle for approximately 1 minute.
c. Check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-107
P00D1, P2195

pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor 1 coupler “1”, ECU coupler “2” and ignition fuse “3”.
gray/green–gray/green
Between O2 sensor 1 coupler and ECU coupler pink/black–pink/black
black/blue–black/blue
er
3
2 2
Lg/R L/R O/B L/B G/B R/B B L/B Y/L P/W P V L L/R Gy
1 R/L G/Y Br/R Br/B Br/Y Sb/W W/L B L/W B/Y Gy/G Br/W B/L W W/B
R/G Y/B L/W Y/L Sb R/L B/W B/W L/Y L/W Gy/Y G/W G Gy/B W/L
Is resistance 0 Ω?
YES
NO

YES
NO
9-108
P00D1, P2195
TIP
gray/green–ground
Between O2 sensor 1 coupler “1” and ground pink/black–ground
black/blue–ground
red/white–ground

gray/green–any other coupler terminal
O2 sensor 1 coupler pink/black–any other coupler terminal
black/blue–any other coupler terminal
ECU coupler “2” pink/black–any other coupler terminal
A B
1
2

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Check fuel pressure.
• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-17.
Is check result OK?

YES
→ Go to step 6.
9-109
P00D1, P2195
NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-3.

YES
NO
→ Go to step 6.
• Check the O2 sensor 1.
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the O2 sensor 1.

YES
NO
→ Go to step 7.
9-110
P00D3, P2197
EAS20661
P00D3, P2197
EAS33338
TROUBLESHOOTING
Item
• [P00D3] O2 sensor 2: heater performance deterioration
• [P2197] O2 sensor 2: open circuit detected.
Fail-safe system
Procedure
TIP
• P0050
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the O2 sensor 2.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-111
P00D3, P2197

pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor 2 coupler “1”, ECU coupler “2” and ignition fuse “3”.
gray/yellow–gray/yellow
Between O2 sensor 2 coupler and ECU coupler pink/white–pink/white
er
3
2 2
Lg/R L/R O/B L/B G/B R/B B L/B Y/L P/W P V L L/R Gy
1 R/L G/Y Br/R Br/B Br/Y Sb/W W/L B L/W B/Y Gy/G Br/W B/L W W/B
R/W P/W R/G Y/B L/W Y/L Sb R/L B/W B/W L/Y L/W Gy/Y G/W G Gy/B W/L
Gy/Y B/L
Is resistance 0 Ω?
YES
NO

YES
NO
9-112
P00D3, P2197
TIP
gray/yellow–ground
Between O2 sensor 2 coupler “1” and ground pink/white–ground
black/blue–ground
red/white–ground

gray/yellow–any other coupler terminal
O2 sensor 2 coupler pink/white–any other coupler terminal
A B
1
2
R/W P/W
1 Gy/Y B/L
R/W P/W Lg/R L/R O/B L/B G/B R/B B
Gy/Y B/L R/L G/Y Br/R Br/B Br/Y Sb/W W/L B

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Check fuel pressure.
• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-17.
Is check result OK?

YES
→ Go to step 6.
9-113
P00D3, P2197
NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-3.

YES
NO
→ Go to step 6.
Is check result OK?

YES
→ Go to step 7.
NO

YES
NO
→ Go to step 7.
9-114
P0107, P0108
EAS20567
P0107, P0108
EAS33047
TROUBLESHOOTING
Item
• [P0107] Intake air pressure sensor: ground short circuit detected.
• [P0108] Intake air pressure sensor: open or power short circuit detected.
Fail-safe system
Procedure
1. Connection of intake air pressure sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the intake air pressure sensor coupler “1” and ECU coupler “2”.
9-115
P0107, P0108
blue–blue
Between intake air pressure sensor coupler and
pink/white–pink/white
ECU coupler
2
1
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
Between intake air pressure sensor coupler “1” and blue–ground
ground pink/white–ground

blue–any other coupler terminal
Intake air pressure sensor coupler pink/white–any other coupler terminal
A B
1 1 2
B/L P/W L B/L P/W L
9-116
P0107, P0108
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of intake air pressure sensor.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the sensor.
of the YDT.

YES
NO
→ Go to step 5.
5. Defective intake air pressure sensor.
dicated.
Approx. 101 kPa (757.6 mmHg, 29.8 inHg), approx.
At sea level
3.64 V
1000 m (3300 ft) above sea level
3.30 V
3.00 V
2.70 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 intake air pressure sensor.
of the YDT.
9-117
P0107, P0108

YES
NO
→ Go to step 6.
9-118
P0112, P0113
EAS20568
P0112, P0113
EAS33048
TROUBLESHOOTING
Item
• [P0112] Intake air temperature sensor: ground short circuit detected.
• [P0113] Intake air temperature sensor: open or power short circuit detected.
Fail-safe system
Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of intake air temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
2. Connection of wire harness coupler and sub-wire harness coupler.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
9-119
P0112, P0113
pins).

YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the intake air temperature sensor coupler “1”, sub-wire harness coupler (wire harness
side) “2”, wire harness coupler (sub-wire harness side) “3” and ECU coupler “4”.
Between intake air temperature sensor coupler and brown/white–brown/white
sub-wire harness coupler (wire harness side) black/blue–black/blue
Between wire harness coupler (sub-wire harness brown/white–brown/white
side) and ECU coupler black/blue–black/blue
4
1 3
2 L/B Y/L P/W P V L L/R Gy
Br/W B/L B/L Br/W Br/W B/L L/W B/Y Gy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
9-120
P0112, P0113

Between intake air temperature sensor coupler “1”
brown/white–ground
and ground
Between wire harness coupler (sub-wire harness
side) “3” and ground

brown/white–any other coupler terminal
Intake air temperature sensor coupler
Wire harness coupler (sub-wire harness side)
ECU coupler “4”
A B
1 3 1 3
Br/W B/L Br/W B/L Br/W B/L Br/W B/L

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
5. Installed condition of intake air temperature sensor.
Is check result OK?

YES
→ Go to step 6.
NO
9-121
P0112, P0113
a. Reinstall the sensor.

of the YDT.

YES
NO
→ Go to step 6.
6. Defective intake air temperature sensor.
• When engine is cold: Displayed temperature is close to the ambient temperature.
• The displayed temperature is not close to the ambient temperature → Check the intake air tempera-
ture sensor.
Refer to “CHECKING THE INTAKE AIR TEMPERATURE SENSOR” on page 8-50.
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the intake air temperature sensor.
of the YDT.

YES
NO
→ Go to step 7.
9-122
P0117, P0118
EAS20569
P0117, P0118
EAS33049
TROUBLESHOOTING
Item
• [P0117] Coolant temperature sensor: ground short circuit detected.
• [P0118] Coolant temperature sensor: open or power short circuit detected.
Fail-safe system
Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of coolant temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
2. Connection of wire harness coupler and sub-wire harness coupler.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
9-123
P0117, P0118
pins).

YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the coolant temperature sensor coupler “1”, sub-wire harness coupler (wire harness
side) “2”, wire harness coupler (sub-wire harness side) “3” and ECU coupler “4”.
Between coolant temperature sensor coupler and green/white–green/white
sub-wire harness coupler (wire harness side) black/blue–black/blue
Between wire harness coupler (sub-wire harness green/white–green/white
side) and ECU coupler black/blue–black/blue
4
1 3
2 L/B Y/L P/W P V L L/R Gy
G/W B/L G/W B/L B/L G/W L/W B/Y Gy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
→ Go to step “Short circuit check”.
NO
of the YDT.

YES
NO
→ Go to step “Short circuit check”.
TIP
9-124
P0117, P0118

Between coolant temperature sensor coupler “1”
green/white–ground
and ground
Between wire harness coupler (sub-wire harness
green/white–ground
side) “3” and ground

green/white–any other coupler terminal
Coolant temperature sensor coupler
Wire harness coupler (sub-wire harness side)
ECU coupler “4”
A B
1 3 1 3
G/W B/L B/L G/W G/W B/L B/L G/W

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
5. Installed condition of coolant temperature sensor.
Refer to “CYLINDER HEAD” on page 5-32.
Is check result OK?

YES
→ Go to step 6.
NO
9-125
P0117, P0118

of the YDT.

YES
NO
→ Go to step 6.
6. Defective coolant temperature sensor.
• 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 8-48.
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the coolant temperature sensor.
Refer to “CYLINDER HEAD” on page 5-32.
of the YDT.

YES
NO
→ Go to step 7.
9-126
P0122, P0123, P0222, P0223, P2135
EAS20570
P0122, P0123, P0222, P0223, P2135

EAS33050
TROUBLESHOOTING
Item
• [P0122] Throttle position sensor: ground short circuit detected.
• [P0123] Throttle position sensor: open or power short circuit detected.
• [P0222] Throttle position sensor: open or ground short circuit detected.
• [P0223] Throttle position sensor: power short circuit detected.
• [P2135] Throttle position sensor: output voltage deviation error.
Fail-safe system
Procedure
TIP
If a DTC other than P2135 (P0122, P0123, P0222, P0223) is detected, perform troubleshooting first.
1. Connection of throttle position sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
9-127
P0122, P0123, P0222, P0223, P2135
→ Go to step 3.
• Disconnect the throttle position sensor coupler “1” and ECU coupler “2”.
white–white
Between throttle position sensor coupler and ECU black/green–black/green
coupler blue–blue
black–black
1 2
L/Y L Y/B R/W
W W L/G B/R
W B/G L B
B/G B B/G
B/L B B/Y W/Y
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
white–ground
Between throttle position sensor coupler “1” and
blue–ground
ground
black–ground

white–any other coupler terminal
black/green–any other coupler terminal
Throttle position sensor coupler
black–any other coupler terminal
ECU coupler “2”
9-128
P0122, P0123, P0222, P0223, P2135
A B
1 1 2
W B/G L B L/Y L Y/B R/W
W B/G L B
W W L/G B/R
B/G B B/G
B/L B B/Y W/Y
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of throttle position sensor.
Refer to “ADJUSTING THE THROTTLE POSITION SENSOR” on page 7-18.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or adjust the sensor.
of the YDT.

YES
NO
→ Go to step 5.
5. Defective throttle position sensor.
• Check throttle position sensor signal 1.
When the throttle valves are fully closed 11–21
When throttle valves are fully open 96–107
Is check result OK?

YES
→ Go to step 6.
NO
9-129
P0122, P0123, P0222, P0223, P2135
a. Replace the throttle position sensor.

of the YDT.

YES
NO
→ Go to step 6.
6. Defective throttle position sensor.
• Check throttle position sensor signal 2.
When throttle valves are fully open 93–109
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the throttle position sensor.
of the YDT.

YES
NO
→ Go to step 7.
9-130
P0132
EAS20571
P0132
EAS33051
TROUBLESHOOTING
Item
O2 sensor 1: short circuit detected (power short circuit).
Fail-safe system
Procedure
Is check result OK?

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
pins).
9-131
P0132
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor 1 coupler “1” and ECU coupler “2”.
Between O2 sensor 1 coupler and ECU coupler black/blue–black/blue
2
1
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
Between O2 sensor 1 coupler “1” and ground gray/green–ground

O2 sensor 1 coupler black/blue–any other coupler terminal
9-132
P0132

ECU coupler “2”
A B
1 1 2

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO
of the YDT.

YES
NO
→ Go to step 6.
9-133
P0152
EAS20572
P0152
EAS33052
TROUBLESHOOTING
Item
O2 sensor 2: short circuit detected (power short circuit).
Fail-safe system
Procedure
Is check result OK?

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
pins).
9-134
P0152
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor 2 coupler “1” and ECU coupler “2”.
Between O2 sensor 2 coupler and ECU coupler black/blue–black/blue
gray/yellow–gray/yellow
2
1
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
Between O2 sensor 2 coupler “1” and ground gray/yellow–ground

O2 sensor 2 coupler black/blue–any other coupler terminal
9-135
P0152

ECU coupler “2”
A B
1 1 2

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO
of the YDT.

YES
NO
→ Go to step 6.
9-136
P0201
EAS20574
P0201
EAS33054
TROUBLESHOOTING
Item
Primary injector #1: malfunction in primary injector #1.
Fail-safe system
• Able to start engine (depending on the number of faulty cylinders)
• Able to drive vehicle (depending on the number of faulty cylinders)
Procedure
1. Connection of primary injector #1 coupler.
pins).

YES
→ Go to step 2.
NO
b. Execute the diagnostic mode. (Code D36)
Is it hear operating sound?

YES
→ Go to step 6.
NO
→ Go to step 2.
2. Defective primary injector #1.
• Measure the primary injector resistance.
Refer to “CHECKING THE FUEL INJECTORS” on page 8-51.
Is check result OK?

YES
→ Go to step 3.
NO
a. Replace the primary injector #1.

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-137
P0201
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
• Disconnect the primary injector #1 coupler “1”, ECU coupler “2” and relay unit coupler “3”
Between primary injector #1 coupler and ECU cou-
red/black–red/black
pler
Between primary injector #1 coupler and relay unit
red/blue–red/blue
coupler
1
R/LR/B
2 3
Y/R P/W P/B Gy/G O/G Gy/R O Br/W L/W R/W L R/L
Lg/R L/R O/B L/B G/B R/B B L/R L/W R/W L/B L/Y Sb B/Y Sb/W
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
red/black–ground
Between primary injector #1 coupler “1” and ground
red/blue–ground

red/black–any other coupler terminal
Primary injector #1 coupler
red/blue–any other coupler terminal
9-138
P0201
ECU coupler “2” red/black–any other coupler terminal

Relay unit coupler “3” red/blue–any other coupler terminal
A B
1 1 2
R/LR/B R/LR/B
3
Br/W L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
• 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.
9-139
P0202
EAS20575
P0202
EAS33055
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-140
P0202
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
green/black–green/black
pler
red/blue–red/blue
coupler
1
R/LG/B
2 3
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
green/black–ground
red/blue–ground

green/black–any other coupler terminal
9-141
P0202
ECU coupler “2” green/black–any other coupler terminal

A B
1 1 2
R/LG/B R/LG/B
3
Br/W L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-142
P0203
EAS20576
P0203
EAS33056
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-143
P0203
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
pler
red/blue–red/blue
coupler
1
R/L L/B
2 3
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
blue/black–ground
red/blue–ground

9-144
P0203
ECU coupler “2” blue/black–any other coupler terminal

A B
1 1 2
R/L L/B R/L L/B
3
Br/W L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-145
P0204
EAS20577
P0204
EAS33057
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-146
P0204
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
orange/black–orange/black
pler
red/blue–red/blue
coupler
1
R/LO/B
2 3
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
orange/black–ground
red/blue–ground

orange/black–any other coupler terminal
9-147
P0204
ECU coupler “2” orange/black–any other coupler terminal

A B
1 1 2
R/LO/B R/LO/B
3
Br/W L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-148
P0335
EAS20578
P0335
EAS33058
TROUBLESHOOTING
Item
Crankshaft position sensor: no normal signals are received from the crankshaft position sensor.
Fail-safe system
Procedure
1. Connection of crankshaft position sensor coupler.
pins).

YES
→ Go to step 2.
NO
b. Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
2. Connection of wire harness ECU coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Disconnect the crankshaft position sensor coupler “1” and ECU coupler “2”.
Between crankshaft position sensor coupler and black/blue–black/blue
ECU coupler gray–gray
9-149
P0335
2
1
B/L Gy L/W B/Y Gy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between crankshaft position sensor coupler “1” and
gray–ground
ground

Crankshaft position sensor coupler
gray–any other coupler terminal
ECU coupler “2”
gray–any other coupler terminal
A B
1 1 2
B/L Gy
B/L Gy
YES
→ Go to step 4.
NO
9-150
P0335


YES
NO
→ Go to step 4.
4. Installed condition of crankshaft position sensor.
• Check the gap (0.75 mm (0.03 in)) between the crankshaft position sensor and the generator rotor.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective crankshaft position sensor.
• Check the crankshaft position sensor.
Refer to “CHECKING THE CRANKSHAFT POSITION SENSOR” on page 8-45.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the crankshaft position sensor.

YES
NO
→ Go to step 6.
9-151
P0340
EAS20579
P0340
EAS32839
TROUBLESHOOTING
Item
• Cylinder identification sensor: no normal signals are received from the cylinder identification sensor.
Fail-safe system
Procedure
TIP
• P0335
1. Connection of cylinder identification sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Disconnect the cylinder identification sensor coupler “1” and ECU coupler “2”.
9-152
P0340
white/black–white/black
Between cylinder identification sensor coupler and
blue–blue
ECU coupler
2
1
L W/B L/B Y/L P/W P V L L/R Gy
B/L
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder identification sensor coupler “1” white/black–ground
and ground blue–ground

white/black–any other coupler terminal
Cylinder identification sensor coupler blue–any other coupler terminal
white/black–any other coupler terminal
ECU coupler “2” blue–any other coupler terminal
A B
1 1 2
L W/B
B/L L W/B
B/L L/B Y/L P/W P V L L/R Gy
9-153
P0340
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of cylinder identification sensor.
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the cylinder identification sensor.

YES
NO
→ Go to step 5.
5. Defective cylinder identification sensor.
• Replace the cylinder identification sensor.
• Crank the engine, and then check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 6.
9-154
P0351
EAS20580
P0351
EAS33060
TROUBLESHOOTING
Item
Cylinder-#1 ignition coil: open or short circuit detected in the primary lead of the cylinder-#1 ignition coil.
Fail-safe system
Procedure
1. Connection of cylinder-#1 ignition coil coupler.
pins).

YES
→ Go to step 2.
NO
b. Start the engine and let it idle for approximately 5 seconds.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Disconnect the cylinder-#1 ignition coil coupler “1”, ECU coupler “2” and handlebar switch (right)
coupler “3”.
9-155
P0351
Between cylinder-#1 ignition coil coupler and ECU

orange–orange
coupler
Between cylinder-#1 ignition coil coupler and han-
dlebar switch (right) coupler “3”
2 3
Y/R P/W P/B Gy/G O/G Gy/R O 1
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder-#1 ignition coil coupler “1” and orange–ground
ground red/white–ground

orange–any other coupler terminal
Cylinder-#1 ignition coil coupler
ECU coupler “2” orange–any other coupler terminal
Handlebar switch (right) coupler “3” red/white–any other coupler terminal
A B
1 1
2 3
9-156
P0351
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of cylinder-#1 ignition coil.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the ignition coil.

YES
NO
→ Go to step 5.
5. Defective cylinder-#1 ignition coil.
• Measure the primary coil resistance of the cylinder-#1 ignition coil.
Refer to “CHECKING THE IGNITION COILS” on page 8-44.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the cylinder-#1 ignition coil.

YES
NO
→ Go to step 6.
• Confirm that spark plug does not sparking.
9-157
P0351

9-158
P0352
EAS20581
P0352
EAS33061
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
coupler “3”.
9-159
P0352

gray/red–gray/red
coupler
dlebar switch (right) coupler
2 3
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B Gy/R
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder-#2 ignition coil coupler “1” and gray/red–ground

gray/red–any other coupler terminal
ECU coupler “2” gray/red–any other coupler terminal
A B
1 1
Gy/R Gy/R 2 3
9-160
P0352
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
9-161
P0352

9-162
P0353
EAS20582
P0353
EAS33062
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3
NO

YES
NO
→ Go to step 3.
coupler “3”.
9-163
P0353

orange/green–orange/green
coupler
2 3
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B O/G
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder-#3 ignition coil coupler “1” and orange/green–ground

orange/green–any other coupler terminal
ECU coupler “2” orange/green–any other coupler terminal
A B
1 1
O/G O/G 2 3
9-164
P0353
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
9-165
P0353

9-166
P0354
EAS20583
P0354
EAS33063
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
coupler “3”.
9-167
P0354

coupler
2 3
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B Gy/G
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between cylinder-#4 ignition coil coupler “1” and gray/green–ground

ECU coupler “2” gray/green–any other coupler terminal
A B
1 1
Gy/G Gy/G 2 3
9-168
P0354
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
Is check result OK?

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
9-169
P0354

9-170
P0475, P0476, P048B
EAS20672
P0475, P0476, P048B

EAS32841
TROUBLESHOOTING
Item
• [P0475] EXUP servo motor: performance deterioration
• [P0476] EXUP servo motor: stuck EXUP servo motor is detected.
• [P048B] EXUP servo motor: signal stuck
Fail-safe system
Procedure
TIP
• P048D, P048E
1. Connection of EXUP servo motor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
9-171
P0475, P0476, P048B

• Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”.
Between EXUP servo motor coupler and ECU cou- black/green–black/green
pler black/red–black/red
2 1
L/Y L Y/B R/W
W W L/G B/R L W/Y B/L
B/G B B/G G B/G B/R
B/L B B/Y W/Y
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
black/green–ground
Between EXUP servo motor coupler “1” and ground
black/red–ground

EXUP servo motor coupler
black/red–any other coupler terminal
ECU coupler “2”
black/red–any other coupler terminal
9-172
P0475, P0476, P048B
A B
1 1 2
L W/Y B/L
G B/G B/R L/Y L Y/B R/W
L W/Y B/L
W W L/G B/R
G B/G B/R
B/G B B/G
B/L B B/Y W/Y
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective EXUP servo motor.
• Disconnect the cables and execute the diagnostic code. (Code D53)
• Check the operating sound of the motor.
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the EXUP servo motor.
of the YDT.

YES
NO
→ Go to step 5.
5. Defective EXUP valve, pulley, and cables.
• Turn the EXUP valve manually with the cables disconnected.
Is check result OK?

YES
• Check the cables.
Is check result OK?
YES
→ Go to step 6.
NO
9-173
P0475, P0476, P048B
a. Replace the cables.

b. Turn the main switch to “ON”, and then check the condition of the DTC using the malfunction
mode of the YDT.

YES
NO
→ Go to step 6.
NO
a. Replace the EXUP servo motor.
of the YDT.

YES
NO
→ Go to step 6.
9-174
P0480
EAS20585
P0480
EAS33065
TROUBLESHOOTING
Item
Radiator fan motor relay: open or short circuit detected.
Fail-safe system
Procedure
1. Connection of radiator fan motor relay coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the radiator fan motor relay “1”, ECU coupler “2” and ignition fuse “3”.
Between radiator fan motor relay and ignition fuse
holder
9-175
P0480
Between radiator fan motor relay and ECU coupler green/yellow–green/yellow
1
3 R
R/B
R/W G/Y
2
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
green/yellow–ground
Between radiator fan motor relay “1” and ground
red/white–ground

green/yellow–any other coupler terminal
Radiator fan motor relay
ECU coupler “2” green/yellow–any other coupler terminal
A B
1 R
1
R/B R 2
R/W G/Y R/B
R/W G/Y Y/R P/W P/B Gy/G O/G Gy/R O
YES
→ Go to step 4.
9-176
P0480
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective radiator fan motor relay.
• Replace the radiator fan motor relay.
of the YDT.

YES
NO
→ Go to step 5.
9-177
P048D, P048E
EAS20586
P048D, P048E
EAS33066
TROUBLESHOOTING
Item
• [P048D] EXUP servo motor: open or ground short circuit detected.
• [P048E] EXUP servo motor: power short circuit detected.
Fail-safe system
Procedure
TIP
If “P048D/P048E” and “P0476” are both indicated, take the actions specified for “P048D/P048E” first.
1. Connection of EXUP servo motor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the EXUP servo motor coupler “1” and ECU coupler “2”.
9-178
P048D, P048E

blue–blue
Between EXUP servo motor coupler and ECU cou-
white/yellow–white/yellow
pler
2 2
L/Y L Y/B R/W
1
W W L/G B/R L W/Y B/L L/B Y/L P/W P V L L/R Gy
B/G B B/G G B/G B/R L/W B/Y Gy/G Br/W B/L W W/B
B/L B B/Y W/Y L/Y L/W Gy/Y G/W G Gy/B W/L
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
white/yellow–ground
Between EXUP servo motor coupler “1” and ground
blue–ground

white/yellow–any other coupler terminal
EXUP servo motor coupler blue–any other coupler terminal
white/yellow–any other coupler terminal
ECU coupler “2” blue–any other coupler terminal
9-179
P048D, P048E
A B
1 1 2 2
L W/Y B/L
G B/G B/R L/Y L Y/B R/W
L W/Y B/L L/B Y/L P/W P V L L/R Gy
W W L/G B/R
G B/G B/R L/W B/Y Gy/G Br/W B/L W W/B
B/G B B/G
B/L B B/Y W/Y
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective EXUP servo motor.
• Replace the EXUP servo motor.
of the YDT.

YES
NO
→ Go to step 5.
9-180
P0500 (FI), P1500
EAS20674
P0500 (FI), P1500

EAS33303
TROUBLESHOOTING
Item
• Rear wheel sensor: no normal signals are received from the rear wheel sensor.
• Neutral switch: open or short circuit is detected.
• Clutch switch: open or short circuit is detected.
Fail-safe system
Procedure
TIP
• In case P0500 is detected, or both P0500 and P1500 are detected, proceed from step 1.
• If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0335
1. Locate the malfunction.
• DTCs P0500 or P0500 and P1500 detected.
a. Execute the diagnostic mode. (Code D07)
b. Rotate the rear wheel by hand and check that the indicated value increases.
Is that value increased?

YES
→ Go to step 21.
NO
→ Go to step 2.
TIP
Perform the procedure from step 2 to step 7 and step 21.
• DTC P1500 detected.
a. Execute the diagnostic mode. (Code D21)
When the transmission is in neutral ON

When the transmission is in gear with the clutch lever released OFF
Is check result OK?

YES
→ Go to step b.
NO
→ Go to step 8.
TIP
Perform the procedure from step 8 to step 14 and step 21.
When the transmission is in gear with the clutch lever squeezed and the side-
ON
stand retracted
9-181
P0500 (FI), P1500
Is check result OK?

YES
→ Go to step 21.
NO
→ Go to step 15.
TIP
Perform the procedure from step 15 to step 21.
2. Connection of rear wheel sensor coupler.
pins).

YES
→ Go to step 3.
NO
c. Rotate the rear wheel by hand and check that the indicated value increases.

YES
→ Go to step 21.
NO
→ Go to step 3.
3. Connection of ABS ECU coupler.
pins).

YES
→ Go to step 4.
NO

YES
→ Go to step 21.
NO
→ Go to step 4.
pins).

YES
→ Go to step 5.
9-182
P0500 (FI), P1500
NO

YES
→ Go to step 21.
NO
→ Go to step 5.
• Disconnect the rear wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
Between rear wheel sensor coupler and ABS ECU black–black
coupler white–white
Between ABS ECU coupler and ECU coupler white/blue–white/blue
3
2
1
L/W Gy/B L Y G R/B B L/W B/W L/B Y/L P/W P V L L/R Gy
B W
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 21.
NO
TIP
black–ground
Between ABS ECU coupler “2” and ground white–ground
white/blue–ground
9-183
P0500 (FI), P1500

Rear wheel sensor coupler “1”
ABS ECU coupler white–any other coupler terminal
white/blue–any other coupler terminal
ECU coupler “3” white/blue–any other coupler terminal
A B
1
2 B W

2

YES
→ Go to step 6.
NO

YES
→ Go to step 21.
NO
→ Go to step 6.
• Replace the ECU.
• Rotate the rear wheel by hand and check that the indicated value increases.

YES
9-184
P0500 (FI), P1500
→ Go to step 21.
NO
→ Go to step 7.
7. Malfunction in ABS ECU.
• Replace the ABS ECU and go to step 21.
8. Connection of neutral switch coupler.
pins).

YES
→ Go to step 9.
NO

Is it correct indication?
YES
→ Go to step 21.
NO
→ Go to step 9.
pins).

YES
→ Go to step 10.
NO

YES
→ Go to step 21.
NO
→ Go to step 10.
10.Wire harness continuity.
• Disconnect the relay unit coupler “1”, ECU coupler “2” and neutral switch coupler “3”.
Between relay unit coupler and ECU coupler black/yellow–black/yellow
9-185
P0500 (FI), P1500
Between relay unit coupler and neutral switch cou-

sky blue–sky blue
pler
1 Br/W L/W R/W L R/L

3 2
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 21.
NO
TIP
black/yellow–ground
Between relay unit coupler “1” and ground
sky blue–ground

black/yellow–any other coupler terminal
Relay unit coupler
sky blue–any other coupler terminal
ECU coupler “2” black/yellow–any other coupler terminal
Neutral switch coupler “3” sky blue–any other coupler terminal
9-186
P0500 (FI), P1500
A B
L/R L/W R/W L/B L/Y Sb B/Y Sb/W L/R L/W R/W L/B L/Y Sb B/Y Sb/W
2
3
YES
→ Go to step 11.
NO

YES
→ Go to step 21.
NO
→ Go to step 11.
11.Defective relay unit.
• Check the relay unit.
Refer to “CHECKING THE RELAY UNIT (DIODE)” on page 8-43.
Is check result OK?

YES
→ Go to step 12.
NO
a. Replace the relay unit.

YES
→ Go to step 21.
NO
→ Go to step 12.
12.Defective neutral switch.
• Check the neutral switch.
9-187
P0500 (FI), P1500
• Refer to “CHECKING THE SWITCHES” on page 8-40.
Is check result OK?

YES
→ Go to step 13.
NO
a. Replace the neutral switch.

YES
→ Go to step 21.
NO
→ Go to step 13.
13.Faulty shift drum (neutral detection area).
• Check the shift drum.
Refer to “CHECKING THE SHIFT DRUM ASSEMBLY” on page 5-101.
Is check result OK?

YES
→ Go to step 14.
NO
→ Replace the shift drum and go to step 21.
Refer to “TRANSMISSION” on page 5-97.
14.Malfunction in ECU.
15.Clutch lever adjustment.
• Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13.
When the clutch lever is released with the transmission in gear and when the
OFF
sidestand is retracted
When the clutch lever is squeezed with the transmission in gear and when the
ON
YES
→ Go to step 21.
NO
→ Go to step 16.
16.Connection of clutch switch coupler.
pins).
9-188
P0500 (FI), P1500

YES
→ Go to step 17.
NO
OFF
ON
YES
→ Go to step 21.
NO
→ Go to step 17.
17.Connection of ECU coupler.
pins).

YES
→ Go to step 18.
NO
OFF
ON
YES
→ Go to step 21.
NO
→ Go to step 18.
18.Wire harness continuity.
• Disconnect the ECU coupler “2”, relay unit coupler “1” and clutch switch coupler “3”.
Between ECU coupler and relay unit coupler black/yellow–black/yellow
black/yellow–black/yellow
Between clutch switch coupler and relay unit coupler
blue/yellow–blue/yellow
9-189
P0500 (FI), P1500
1
Br/W L/W R/W L R/L
3
B/Y L/Y L/B Y/L P/W P V L L/R Gy
L/W B/W L/W B/Y Gy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO
OFF
ON
YES
→ Go to step 21.
NO
TIP
black/yellow–ground
blue/yellow–ground

Relay unit coupler
blue/yellow–any other coupler terminal
ECU coupler “2” black/yellow–any other coupler terminal
Clutch switch coupler “3”
9-190
P0500 (FI), P1500
A B
2 3
L/B Y/L P/W P V L L/R Gy B/Y L/Y
L/W B/Y Gy/G Br/W B/L W W/B L/W B/W
YES
→ Go to step 19.
NO
OFF
ON
YES
→ Go to step 21.
NO
→ Go to step 19.
19.Defective clutch switch.
• Check the clutch switch.
Refer to “CHECKING THE SWITCHES” on page 8-40.
Is check result OK?

YES
→ Go to step 20.
NO
a. Replace the clutch switch.
OFF
ON
YES
→ Go to step 21.
9-191
P0500 (FI), P1500
NO
→ Go to step 20.
20.Malfunction in ECU.
21.Delete the DTC and check that the MIL goes off.
• Turn the main switch to “ON”, and then rotate the rear wheel by hand.
• Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (12
to 19 mph).
then delete the DTC. Delete this DTC even if it has a condition of “Detected”.
9-192
P0500 (SCU)
EAS20588
P0500 (SCU)
EAS33068
TROUBLESHOOTING
Item
Abnormal rear wheel sensor
Fail-safe system
Procedure
1. Abnormal rear wheel sensor
• Check the item of DTC P0500 for the ECU.
9-46.

YES
NO
9-193
P0560 (FI), P0563
EAS20675
P0560 (FI), P0563

EAS33304
TROUBLESHOOTING
Item
• [P0560 (FI)] Charging voltage is abnormal.
• [P0563] Vehicle system power voltage out of range
Fail-safe system
Procedure
TIP
• P0335
1. Malfunction in charging system.
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-12.
Is check result OK?

YES
→ Repeat step 1.
NO
a. Defective rectifier/regulator or AC magneto → Replace.
b. Defective connection in the charging system circuit → Properly connect or replace the wire har-
ness.
c. Start the engine and let it idle for approximately 5 seconds.
d. Check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Repeat step 1.
9-194
P0560 (SCU)
EAS20593
P0560 (SCU)
EAS33073
TROUBLESHOOTING
Item
Abnormal SCU power supply voltage
Fail-safe system
Procedure
1. Malfunction in charging system.
Is check result OK?

YES
→ Repeat step 1.
NO
a. Defective rectifier/regulator or AC magneto → Replace.
b. Defective connection in the charging system circuit → Properly connect or replace the wire har-
ness.
c. Start the engine and let it idle for approximately 5 seconds.
d. Check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Repeat the maintenance job.
9-195
P0601
EAS20676
P0601
EAS33305
TROUBLESHOOTING
Item
Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear
on the tool display.)
Fail-safe system
Procedure
• Turn the main switch to “ON”.
• Check that the MIL does not come on.
9-196
P0606
EAS20677
P0606
EAS33306
TROUBLESHOOTING
Item
Internal malfunction in ECU. (When this malfunction is detected in the ECU, the DTC might not appear
on the tool display.)
Fail-safe system
Procedure
1. Check and repair for simultaneous malfunction.
• Check the items of DTCs P0122, P0123, P0222, P0223 and P2135, if they are detected at the same
time, correct the P0122, P0123, P0222, P0223 and P2135 first.
of the YDT.

YES
NO
→ Go to step 2.
• Check that the MIL does not come on.
9-197
P062F
EAS20598
P062F
EAS33078
TROUBLESHOOTING
Item
EEPROM DTC: an error is detected while reading or writing on EEPROM.
Fail-safe system
Procedure
• Execute the diagnostic mode (Code D60)
00
Go to step 7.
01
Go to step 2.
02
Go to step 3.
03
Go to step 4.
04
Go to step 5.
Except 00–04
Go to step 6.
2. “01” is indicated in diagnostic mode (code D60). EEPROM data error for adjustment of CO concen-
tration of cylinder #1.
• Change the CO concentration of cylinder #1, and rewrite in EEPROM.
Refer to “ADJUSTING THE EXHAUST GAS VOLUME” on page 3-12.
• After this adjustment is made, turn the main switch to “OFF”.
of the YDT.

YES
NO
a. Repeat step 1.
b. If the same number is indicated, go to item 7.
of the YDT.

YES
NO
a. Repeat step 1.
9-198
P062F
of the YDT.

YES
NO
a. Repeat step 1.
of the YDT.

YES
NO
a. Repeat step 1.
6. Except “00-04” is indicated in diagnostic mode (Code D60). EEPROM data error for corresponding
learning/memory values.
• Turn the main switch to “OFF”.
of the YDT.

YES
NO
a. Repeat step 1.
9-199
P0638
EAS20599
P0638
EAS33079
TROUBLESHOOTING
Item
YCC-T drive system: malfunction detected.
Fail-safe system
Procedure
1. Connection of throttle servo motor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
3. Check the electronic throttle valve fuse.
Is check result OK?

YES
→ Go to step 4.
9-200
P0638
NO
a. Replace the electronic throttle valve fuse.
of the YDT.

YES
NO
→ Go to step 4.
• Disconnect the throttle servo motor coupler “1”, ECU coupler “2” and electronic throttle valve fuse
“3”.
Between throttle servo motor coupler and ECU cou- yellow/red–yellow/red
pler light green/red–light green/red
Between ECU coupler and electronic throttle valve
red/blue–red/blue
fuse holder
1
3 Lg/R Y/R
2
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
yellow/red–ground
Between ECU coupler “2” and ground light green/red–ground
red/blue–ground
9-201
P0638

yellow/red–any other coupler terminal
Throttle servo motor coupler “1”
light green/red–any other coupler terminal
yellow/red–any other coupler terminal
ECU coupler light green/red–any other coupler terminal
A B
2 1
Y/R P/W P/B Gy/G O/G Gy/R O Lg/R Y/R
2
YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
5. Defective throttle servo motor.
• Check the throttle servo motor.
Refer to “CHECKING THE THROTTLE SERVO MOTOR” on page 8-49.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the throttle bodies.
Refer to “REPLACING THE THROTTLE BODIES” on page 7-16.
of the YDT.

YES
NO
→ Go to step 6.
6. Defective throttle bodies.
• Check the throttle bodies.
Refer to “CHECKING THE THROTTLE SERVO MOTOR” on page 8-49.
9-202
P0638
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the throttle bodies.
Refer to “REPLACING THE THROTTLE BODIES” on page 7-16.
of the YDT.

YES
NO
→ Go to step 7.
9-203
P0657
EAS20601
P0657
EAS33081
TROUBLESHOOTING
Item
Fuel system voltage: incorrect voltage supplied to the fuel injector and fuel pump.
Fail-safe system
Procedure
TIP
• P0335
1. Connection of relay unit coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
2. Connection of handlebar switch (right) coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-204
P0657
pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the fuel injection system fuse “1”, relay unit coupler “2”, ignition fuse “3”, handlebar
switch (right) coupler “4” and ECU coupler “5”.
Between fuel injection system fuse holder and relay
brown/white–brown/white
unit coupler
Between ignition fuse holder and handlebar switch
(right) coupler
Between handlebar switch (right) coupler and relay
unit coupler
red/blue–red/blue
Between relay unit coupler and ECU coupler
1 2
Br/W L/W R/W L R/L
5
4
3 Y/R
Lg/R L/R
P/W P/B Gy/G O/G Gy/R O
O/B L/B G/B R/B B
Is resistance 0 Ω?
YES
NO

YES
NO
9-205
P0657

TIP
blue/white–ground
red/white–ground
red/blue–ground
Between handlebar switch (right) coupler “4” and
red/white–ground
ground

Relay unit coupler
Handlebar switch (right) coupler red/white–any other coupler terminal
ECU coupler “5”
A B
2 2
Br/W L/W R/W L R/L Br/W L/W R/W L R/L
4 5
4 Lg/R L/R O/B L/B G/B R/B B

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective relay unit.
• Check the operating sound of the relay.
9-206
P0657
Is check result OK?

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
6. Defective relay unit.
Is the Fuel system voltage less than 3V?

YES

YES
NO
→ Go to step 7.
NO
→ Go to step 7.
9-207
P0916, P0917
EAS20611
P0916, P0917
EAS33091
TROUBLESHOOTING
Item
• [P0916] Gear position sensor: open or ground short circuit detected.
• [P0917] Gear position sensor: power short circuit detected.
Fail-safe system
Procedure
1. Connection of gear position sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the gear position sensor coupler “1” and ECU coupler “2”.
9-208
P0916, P0917
white–white
Between gear position sensor coupler and ECU
green–green
coupler
blue/red–blue/red
2
1
L/R G W L/W B/Y Gy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
Between gear position sensor coupler “1” and green–ground
ground blue/red–ground

Gear position sensor coupler green–any other coupler terminal
blue/red–any other coupler terminal
ECU coupler “2” green–any other coupler terminal
blue/red–any other coupler terminal
A B
1 1 2
L/R G W L/R G W
9-209
P0916, P0917
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of gear position sensor.
Is check result OK?

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
5. Defective gear position sensor.
• Make sure that the position of each gear is correctly displayed on the meter.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the gear position sensor.
of the YDT.

YES
NO
→ Go to step 6.
9-210
P0916, P0917
9-211
P1400
EAS20612
P1400
EAS33092
TROUBLESHOOTING
Item
Air induction system solenoid: open or short circuit detected.
Fail-safe system
Procedure
1. Connection of air induction system solenoid coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Start the engine and check the status of the DTC.

YES
NO
→ Go to step 2.
TIP
Check that the start/engine stop switch is turned to “ON” then.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
9-212
P1400

NO

YES
NO
→ Go to step 3.
TIP
• Disconnect the air induction system solenoid coupler “1”, ECU coupler “2” and ignition fuse “3”.
Between air induction system solenoid coupler and
brown/red–brown/red
ECU coupler
Between air induction system solenoid coupler and
ignition fuse holder
2 1
Br/R R/W
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO

YES
NO
TIP
9-213
P1400

TIP
Between air induction system solenoid coupler “1” brown/red–ground
and ground red/white–ground

brown/red–any other coupler terminal
Air induction system solenoid coupler
ECU coupler “2” brown/red–any other coupler terminal
A B
1 1 2
Br/R R/W Br/R R/W
YES
→ Go to step 4.
NO
of the YDT.

YES
NO

YES
NO
→ Go to step 4.
TIP
4. Defective air induction system solenoid.
• Check the air induction system solenoid.
Refer to “CHECKING THE AIR INDUCTION SYSTEM SOLENOID” on page 8-49.
of the YDT.
9-214
P1400

YES
NO

YES
NO
→ Go to step 5.
TIP
9-215
P1600
EAS20613
P1600
EAS33093
TROUBLESHOOTING
Item
Lean angle sensor: open or short circuit detected.
Fail-safe system
Procedure
TIP
• U0125
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, then to “OFF”, and back to “ON”.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-216
P1600

Between ECU coupler and IMU coupler black/white–black/white
Between ignition fuse holder and IMU coupler red/white–red/white
4 1
2 1

Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Disconnect the ECU and IMU related connectors before checking.
blue/white–ground
blue/black–ground
blue/white–ground
red/white–ground
9-217
P1600

ECU coupler
black/black–any other coupler terminal
black/black–any other coupler terminal
A B
1 1

2

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?
9-218
P1600
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective IMU.
• Turn the main switch to “ON”, then to “OFF”, and back to “ON”.
• Check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 6.
9-219
P1601
EAS20614
P1601
EAS33094
TROUBLESHOOTING
Item
Sidestand switch: open or short circuit of the blue/yellow lead of the ECU is detected.
Fail-safe system
Procedure
1. Connection of sidestand switch coupler.
pins).

YES
→ Go to step 2.
NO
b. Turn the main switch to “ON”, and then extend and retract the sidestand.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
3. Connection of relay unit coupler.
pins).
9-220
P1601

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the relay unit coupler “1”, ECU coupler “2” and sidestand switch coupler “3”.
Between relay unit coupler and ECU coupler blue/yellow–blue/yellow
Between relay unit coupler and sidestand switch
coupler
2
3 1
Br/W L/W R/W L R/L L/B Y/L P/W P V L L/R Gy
L/B B L/R L/W R/W L/B L/Y Sb B/Y Sb/W L/W B/Y Gy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO

YES
NO
TIP
blue/yellow–ground
blue/black–ground
9-221
P1601

Relay unit coupler
ECU coupler “2” blue/yellow–any other coupler terminal
Sidestand switch coupler “3” blue/black–any other coupler terminal
A B
2 3
L/B B

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
5. Defective sidestand switch.
• Shift the transmission into gear.
Sidestand retracted ON
Sidestand extended OFF
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the sidestand switch.

YES
NO
9-222
P1601
→ Go to step 6.
9-223
P1602
EAS20615
P1602
EAS33095
TROUBLESHOOTING
Item
Malfunction in ECU internal circuit (malfunction of ECU power cut-off function).
Fail-safe system
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.
of the YDT.

YES
NO
→ Go to step 2.
2. Connection of starter relay coupler.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
3. Connection of main switch coupler.
pins).

YES
9-224
P1602
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Check the backup fuse.
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the fuse.
of the YDT.

YES
NO
→ Go to step 5.
• Disconnect the battery “1”, backup fuse “2”, ECU coupler “3”, main switch coupler “4” and ignition
fuse “5”.
Between battery and backup fuse holder red–red
Between backup fuse holder and ECU coupler red/green–red/green
er
Between ignition fuse holder and ECU coupler red/white–red/white
1
3
2 Lg/R L/R O/B L/B G/B R/B B
4
5
3
L/Y L Y/B R/W
W W L/G B/R
B/G B B/G
B/L B B/Y W/Y
Is resistance 0 Ω?
9-225
P1602
YES
NO
of the YDT.

YES
NO
TIP
Between battery “1” and ground red–ground
red/green–ground
red/white–ground

red/green–any other coupler terminal
ECU coupler
A B
1 3 3 3
Y/R P/W P/B Gy/G O/G Gy/R O Y/R P/W P/B Gy/G O/G Gy/R O L/Y L Y/B R/W
Lg/R L/R O/B L/B G/B R/B B Lg/R L/R O/B L/B G/B R/B B W W L/G B/R
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B R/L G/Y Br/R Br/B Br/Y Sb/W W/L B B/G B B/G
R/G Y/B L/W Y/L Sb R/L B/W B/W R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y
4 3
L/Y L Y/B R/W 4
W W L/G B/R
B/G B B/G
B/L B B/Y W/Y
YES
→ Go to step 6.
NO
of the YDT.

YES
9-226
P1602
NO
→ Go to step 6.
9-227
P1806, P1807
EAS20623
P1806, P1807
EAS33103
TROUBLESHOOTING
Item
• [P1806] Shift sensor: open or ground short circuit detected.
• [P1807] Shift sensor: power short circuit detected.
Fail-safe system
Procedure
1. Connection of shift sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
3. Wire harness continuity
• Disconnect the shift sensor coupler “1” and ECU coupler “2”.
9-228
P1806, P1807
Between shift sensor coupler and ECU coupler violet–violet
blue–blue
2
1
B/L V L L/W B/Y Gy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
violet–ground
Between shift sensor coupler “1” and ground
blue–ground

Shift sensor coupler violet–any other coupler terminal
ECU coupler “2” violet–any other coupler terminal
A B
1 1 2
B/L V L B/L V L
9-229
P1806, P1807
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of shift sensor.
Is check result OK?

YES
→ Go to step 5.
NO
Refer to “CHAIN DRIVE” on page 4-125.
of the YDT.

YES
NO
→ Go to step 5.
5. Defective shift sensor.
Shift sensor output voltage display 0.2–4.8 [V]
With no shift weighting input Approx. 2.5 [V]
Shift up weighting Changes to the low side
Shift down weighting Changes to the high side
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the shift sensor.
Refer to “CHAIN DRIVE” on page 4-125.
of the YDT.

YES
NO
9-230
P1806, P1807
→ Go to step 6.
9-231
P2122, P2123, P2127, P2128, P2138
EAS20632
P2122, P2123, P2127, P2128, P2138

EAS33112
TROUBLESHOOTING
Item
• [P2122] Accelerator position sensor: open or ground short circuit detected.
• [P2123] Accelerator position sensor: power short circuit detected.
• [P2127] Accelerator position sensor: open or ground short circuit detected.
• [P2128] Accelerator position sensor: power short circuit detected.
• [P2138] Deviation error
Fail-safe system
• Able/unable to start engine
• Able/unable to drive vehicle
Procedure
TIP
If a DTC other than P2138 (P2122, P2123, P2127, or P2128) is indicated, perform troubleshooting first.
1. Connection of accelerator position sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
9-232
P2122, P2123, P2127, P2128, P2138
→ Go to step 3.
• Disconnect the accelerator position sensor coupler “1” and ECU coupler “2”.
white–white
Between accelerator position sensor coupler and black/blue–black/blue
ECU coupler blue/green–blue/green
black–black
black/yellow–black/yellow
1 2
L/Y L Y/B R/W
L/Y B
W W L/G B/R
B/L L/G
B/G B B/G
W B/Y
B/L B B/Y W/Y
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
Between accelerator position sensor coupler “1” and white–white
ground blue/green–blue/green
black–black
9-233
P2122, P2123, P2127, P2128, P2138

Accelerator position sensor coupler
blue/green–any other coupler terminal
ECU coupler “2”
blue/green–any other coupler terminal
A B
1 1 2
L/Y B L/Y B L/Y L Y/B R/W
B/L L/G B/L L/G W W L/G B/R

B/G B B/G
W B/Y W B/Y
B/L B B/Y W/Y
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective accelerator position sensor.
• Execute the diagnostic mode. (Code D14) (Accelerator position sensor signal 1.)
When the throttle valves are fully open 71–87
• Execute the diagnostic mode. (Code D15) (Accelerator position sensor signal 2.)
When the throttle valves are fully open 69–89
Is check result OK?

YES
→ Go to step 5.
NO
→ Replace the handlebar switch (right).
9-234
P2122, P2123, P2127, P2128, P2138

YES
NO
→ Go to step 5.
9-235
P2158 (FI)
EAS20633
P2158 (FI)
EAS33113
TROUBLESHOOTING
Item
Front wheel sensor: no normal signals are received from the front wheel sensor.
Fail-safe system
Procedure
• Check the ABS warning light.
Is the ABS warning light on?

YES
→ Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-28.
NO
→ Go to step 2.
2. Execute the diagnostic mode.
• Rotate the front wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 3.
3. Connection of front wheel sensor coupler.
pins).

YES
→ Go to step 4.
NO
c. Rotate the front wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 4.
pins).
9-236
P2158 (FI)

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
pins).

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
• Disconnect the front wheel sensor coupler “1”, ABS ECU coupler “2” and ECU coupler “3”.
Between front wheel sensor coupler and ABS ECU black–black
coupler white–white
Between ABS ECU coupler and ECU coupler gray/black–gray/black
3
2
1
L/W Gy/B L Y G R/B B L/W B/W L/B Y/L P/W P V L L/R Gy
B W
Is resistance 0 Ω?
YES
NO
9-237
P2158 (FI)


YES
NO
TIP
Disconnect the ECU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE ABS
ECU” on page 9-4.
black–ground
Between ABS ECU coupler “2” and ground white–ground
gray/black–ground

Front wheel sensor coupler “1”
ABS ECU coupler white–any other coupler terminal
gray/black–any other coupler terminal
ECU coupler “3” gray/black–any other coupler terminal
A B
1
2 B W

2

YES
9-238
P2158 (FI)
→ Go to step 7.
NO

YES
NO
→ Go to step 7.
7. Defective 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 4-35.

YES
NO
→ Go to step 8.
• Rotate the front wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 9.
• Replace the ABS ECU.
Refer to “REMOVING THE HYDRAULIC UNIT ASSEMBLY” on page 4-77.
• Go to step 10, and complete the service.
10.Delete the DTC and check that the MIL goes off.
• Turn the main switch to “ON”, and then rotate the front wheel by hand.
• Start the engine, and input the vehicle speed signals by operating the vehicle at 20 to 30 km/h (12
to 19 mph).
• Delete this DTC even if it has a condition of “Detected”.
9-239
P2158 (SCU)
EAS20634
P2158 (SCU)
EAS33114
TROUBLESHOOTING
Item
Front wheel sensor: no normal signals are received from the front wheel sensor.
Fail-safe system
Procedure
1. Abnormal front wheel sensor
• Check the item of DTC P2158 for the ECU.
9-46.

YES
NO
9-240
P21CF
EAS20637
P21CF
EAS33117
TROUBLESHOOTING
Item
Secondary injector #1: malfunction in secondary injector #1.
Fail-safe system
Procedure
1. Connection of secondary injector #1 coupler.
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
2. Defective secondary injector #1.
• Measure the secondary injector resistance.
Is check result OK?

YES
→ Go to step 3.
NO
a. Replace the secondary injector #1.

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-241
P21CF
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
• Disconnect the secondary injector #1 coupler “1”, ECU coupler “2” and relay unit coupler “3”.
Between secondary injector #1 coupler and ECU
white/blue–white/blue
coupler
Between secondary injector #1 coupler and relay
red/blue–red/blue
unit coupler
2
Y/R P/W P/B Gy/G O/G Gy/R O 1 3
Lg/R L/R O/B L/B G/B R/B B Br/W L/W R/W L R/L
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B W/L R/L
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
Between secondary injector #1 coupler “1” and white/blue–ground
ground red/blue–ground

white/blue–any other coupler terminal
Secondary injector #1 coupler
9-242
P21CF
ECU coupler “2” white/blue–any other coupler terminal

A B
1 1 2
W/L R/L W/L R/L
3
Br/W L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-243
P21D0
EAS20638
P21D0
EAS33118
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-244
P21D0
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
sky blue/white–sky blue/white
coupler
red/blue–red/blue
unit coupler
2
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B Sb/WR/L
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
Between secondary injector #2 coupler “1” and sky blue/white–ground

sky blue/white–any other coupler terminal
9-245
P21D0
ECU coupler “2” sky blue/white–any other coupler terminal

A B
1 1 2
Sb/WR/L Sb/WR/L
3
Br/W L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-246
P21D1
EAS20639
P21D1
EAS33119
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-247
P21D1
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
brown/yellow–brown/yellow
coupler
red/blue–red/blue
unit coupler
2
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B Br/Y R/L
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
Between secondary injector #3 coupler “1” and brown/yellow–ground

brown/yellow–any other coupler terminal
9-248
P21D1
ECU coupler “2” brown/yellow–any other coupler terminal

A B
1 1 2
Br/Y R/L Br/Y R/L
3
Br/W L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-249
P21D2
EAS20640
P21D2
EAS33120
TROUBLESHOOTING
Item
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
→ Go to step 6.
NO
→ Go to step 2.
Is check result OK?

YES
→ Go to step 3.
NO

YES
→ Go to step 6.
NO
→ Go to step 3.
pins).

YES
9-250
P21D2
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
brown/black–brown/black
coupler
red/blue–red/blue
unit coupler
2
R/L G/Y Br/R Br/B Br/Y Sb/W W/L B Br/B R/L
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
TIP
Between secondary injector #4 coupler “1” and brown/black–ground

brown/black–any other coupler terminal
9-251
P21D2
ECU coupler “2” brown/black–any other coupler terminal

A B
1 1 2
Br/B R/L Br/B R/L
3
Br/W L/W R/W L R/L
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
9-252
P2228, P2229
EAS20641
P2228, P2229
EAS33121
TROUBLESHOOTING
Item
• [P2228] Atmospheric pressure sensor: ground short circuit detected.
• [P2229] Atmospheric pressure sensor: open or power short circuit detected.
Fail-safe system
Procedure
1. Connection of atmospheric pressure sensor coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the atmospheric pressure sensor coupler “1” and ECU coupler “2”.
9-253
P2228, P2229
blue–blue
Between atmospheric pressure sensor coupler and
pink–pink
ECU coupler
2
1
B/L P L L/W B/Y Gy/G Br/W B/L W W/B
Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
Between atmospheric pressure sensor coupler “1” blue–ground
and ground pink–ground

Atmospheric pressure sensor coupler pink–any other coupler terminal
ECU coupler “2” pink–any other coupler terminal
A B
1 1 2
B/L P L B/L P L
9-254
P2228, P2229
YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Installed condition of atmospheric pressure sensor.
Is check result OK?

YES
→ Go to step 5.
NO
of the YDT.

YES
NO
→ Go to step 5.
5. Defective atmospheric pressure sensor.
dicated.
At sea level
3.64 V
3.30 V
3.00 V
2.70 V
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the atmospheric pressure sensor.
of the YDT.
9-255
P2228, P2229

YES
NO
→ Go to step 6.
9-256
U0100
EAS20644
U0100
EAS33124
TROUBLESHOOTING
Item
Abnormal CAN communication (between ECU and SCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, joint coupler “2” and ECU coupler “3”.
Between SCU coupler and joint coupler
Between the joint coupler and ECU coupler
9-257
U0100
1
P/W G/R Y Br/W
P G Y/R Gy/G Gy B
2 3

Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Disconnect the ECU and SCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ECU” on page 9-3 and “PARTS CONNECTED TO THE SCU
(for YZF-R1M)” on page 9-3.
blue/white–ground
Between SCU coupler “1” and ground
blue/black–ground
blue/white–ground
blue/black–ground

SCU coupler
ECU coupler
9-258
U0100
A B
1 1
P/W G/R Y Br/W
P G Y/R Gy/G Gy B P/W G/R Y Br/W
L/B P/L G/B Y/G Gy/B Gy/R P G Y/R Gy/G Gy B
L/W P/B G/L Y/B W W/R W/B W/G L/B P/L G/B Y/G Gy/B Gy/R
3 3

2

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-259
U0121
EAS20646
U0121
EAS33126
TROUBLESHOOTING
Item
Abnormal CAN communication (between ABS ECU and SCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
Between the joint coupler and ABS ECU coupler
9-260
U0121
1
P/W G/R Y Br/W
P G Y/R Gy/G Gy B
3
2

Is resistance 0 Ω?
YES
→ Go to “Short circuit check”
NO

YES
NO
TIP
Disconnect the SCU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SCU (for YZF-R1M)” on page 9-3 and “PARTS CONNECTED
TO THE ABS ECU” on page 9-4.
blue/white–ground
blue/black–ground
blue/white–ground
Between ABS ECU coupler “3” and ground
blue/black–ground

SCU coupler
ABS ECU coupler
9-261
U0121
A B
1 1
P/W G/R Y Br/W
3 3
L/W Gy/B L Y G R/B B L/W B/W L/W Gy/B L Y G R/B B L/W B/W
R/W G/O W/L L B W W L/B B R/W G/O W/L L B W W L/B B
2

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Replace the ABS ECU, and complete the service.
Refer to “REMOVING THE HYDRAULIC UNIT ASSEMBLY” on page 4-77.
9-262
U0125 (FI)
EAS20647
U0125 (FI)
EAS33127
TROUBLESHOOTING
Item
Signals cannot be transmitted between the ECU and the IMU.
Fail-safe system
Procedure
TIP
• P1600
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-263
U0125 (FI)

Between IMU coupler and ignition fuse holder red/white–red/white
Between IMU coupler and ECU coupler black/white–black/white
4 1
2 1

Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Disconnect the ECU and IMU related connectors before checking.
blue/white–ground
blue/black–ground
blue/white–ground
red/white–ground
9-264
U0125 (FI)

ECU coupler
A B
1 1

2

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Malfunction in IMU.
9-265
U0125 (FI)

YES
NO
→ Go to step 5.
9-266
U0125 (SCU)
EAS20648
U0125 (SCU)
EAS33128
TROUBLESHOOTING
Item
Abnormal CAN communication (between IMU and SCU)
Fail-safe system
Procedure
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, joint coupler “2” and IMU coupler “3”.
Between the joint coupler and IMU coupler
9-267
U0125 (SCU)
1
P/W G/R Y Br/W 3
P G Y/R Gy/G Gy B
2

Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Disconnect the SCU and IMU related connectors before checking.
blue/white–ground
blue/black–ground
blue/white–ground
Between IMU coupler “3” and ground
blue/black–ground

SCU coupler
IMU coupler
9-268
U0125 (SCU)
A B
1 1
P/W G/R Y Br/W
3 3
2

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
3. Replace the IMU.
• Replace the IMU, and complete the service.
9-269
U0155 or Err (FI)
EAS20649
U0155 or Err (FI)

EAS33129
TROUBLESHOOTING
Item
Multi-function meter: signals cannot be transmitted between the ECU and the multi-function meter.
Fail-safe system
Procedure
TIP
“Err” is displayed on the clock display of the multi-function meter, but the MIL does not come on.
1. Connection of meter assembly coupler.
pins).

YES
→ Go to step 2.
NO
of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
of the YDT.

YES
NO
→ Go to step 3.
• Disconnect the meter assembly coupler “1”, joint coupler “2” and ECU coupler “3”.
9-270
U0155 or Err (FI)
Between meter assembly coupler and joint coupler
Between joint coupler and ECU coupler
1
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W
2 3

Is resistance 0 Ω?
YES
NO
of the YDT.

YES
NO
TIP
blue/white–ground
Between meter assembly coupler “1” and ground
blue/black–ground
blue/white–ground
blue/black–ground

Meter assembly coupler
9-271
U0155 or Err (FI)

ECU coupler
A B
1 1
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W
R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
3 3

2

YES
→ Go to step 4.
NO
of the YDT.

YES
NO
→ Go to step 4.
4. Defective meter assembly.
• Replace the meter assembly.
of the YDT.

YES
NO
→ Go to step 5.
9-272
U0155 or Err (FI)
9-273
U0155 or Err (SCU)
EAS20650
U0155 or Err (SCU)

EAS33130
TROUBLESHOOTING
Item
Abnormal CAN communication (between meter assembly and SCU)
Fail-safe system
Procedure
1. Connection of meter assembly coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
• Disconnect the SCU coupler “1”, joint coupler “2” and meter assembly coupler “3”.
Between the joint coupler and meter assembly cou- blue/white–blue/white
pler blue/black–blue/black
9-274
U0155 or Err (SCU)
1 3
P/W G/R Y Br/W
P G Y/R Gy/G Gy B
L/B P/L G/B Y/G Gy/B Gy/R B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W
L/W P/B G/L Y/B W W/R W/B W/G R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y
2

Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Disconnect the SCU related connectors before checking.
blue/white–ground
blue/black–ground
blue/white–ground
blue/black–ground

SCU coupler
9-275
U0155 or Err (SCU)
A B
1 1
P/W G/R Y Br/W
3 3
2

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
3. Defective meter assembly.
• Replace the meter assembly, and complete the service.
9-276
51_IMMOBILIZER
EAS20680
51_IMMOBILIZER
EAS33309
TROUBLESHOOTING
Item
Code cannot be transmitted between the key and the immobilizer unit.
Cause
• Radio wave interference caused by objects around the keys and antennas.
• Immobilizer unit malfunction.
• Key malfunction.
Procedure
TIP
When a system malfunction occurs, the DTC number is indicated in the meter display and the immobi-
lizer system indicator light flashes at the same time. The pattern of flashing also shows the DTC. Refer
to “HOW TO CHECK DTC” on page 9-22.
1. Keep magnets, metal objects, and other immobilizer system keys away from the keys and antennas.
Is DTC displayed?
YES
→ Go to step 2.
NO
2. Replace the main switch/immobilizer unit.
Is DTC displayed?
YES
→ Go to step 3.
NO
3. Key malfunction.
• Replace the key, and complete the service.
9-277
52_IMMOBILIZER
EAS20679
52_IMMOBILIZER
EAS33308
TROUBLESHOOTING
Item
Codes between the key and immobilizer unit do not match.
Cause
• Signal received from other transponder (failed to recognize code after ten consecutive attempts).
• Signal received from unregistered standard key.
Procedure
TIP
1. Place the immobilizer unit at least 50 mm away from the transponder of other vehicles.
Is DTC displayed?
YES
→ Go to step 2.
NO
2. Register the standard key, and complete the service.
9-278
53_IMMOBILIZER
EAS20681
53_IMMOBILIZER
EAS33310
TROUBLESHOOTING
Item
Codes cannot be transmitted between the ECU and the immobilizer unit.
Cause
• Noise interference or disconnected lead/cable.
• Interference due to radio wave noise.
• Disconnected communication harness.
• ECU malfunction.
Procedure
TIP
1. Check the wire harness and connector.
Is DTC displayed?
YES
→ Go to step 2.
NO
Is DTC displayed?
YES
→ Go to step 3.
NO
3. Replace the ECU, and complete the service.
9-279
54_IMMOBILIZER
EAS20682
54_IMMOBILIZER
EAS33311
TROUBLESHOOTING
Item
Codes transmitted between the ECU and the immobilizer unit do not match.
Cause
• Interference due to radio wave noise.
• Disconnected communication harness.
• ECU failure. (The ECU or immobilizer unit was replaced with a used unit from another vehicle.)
Procedure
TIP
1. Register the code re-registering key.
Is DTC displayed?
YES
→ Go to step 2.
NO
Is DTC displayed?
YES
→ Go to step 3.
NO
Is DTC displayed?
YES
→ Go to step 4.
NO
9-280
55_IMMOBILIZER
EAS20683
55_IMMOBILIZER
EAS33312
TROUBLESHOOTING
Item
Key code registration malfunction.
Cause
• Same standard key was attempted to be registered two consecutive times.
Procedure
TIP
1. Register another standard key, and complete the service.
9-281
56_IMMOBILIZER
EAS20684
56_IMMOBILIZER
EAS33313
TROUBLESHOOTING
Item
Unidentified code is received.
Cause
Procedure
TIP
Is DTC displayed?
YES
→ Go to step 2.
NO
Is DTC displayed?
YES
→ Go to step 3.
NO
9-282
11_ABS
EAS20685
11_ABS
EAS33314
TROUBLESHOOTING
Item
Front wheel sensor (intermittent pulses or no pulses)
Procedure
TIP
If the rear wheel continues to turn for more than 20 seconds after the front wheel has stopped, this will
be recorded.
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 4-38.
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
4-40.
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.
4-40.
Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.
9-283
12_ABS
EAS20686
12_ABS
EAS33315
TROUBLESHOOTING
Item
Rear wheel sensor (intermittent pulses or no pulses)
Procedure
1. Foreign material adhered around the rear wheel sensor
Is check result OK?

YES
→ Go to step 2.
NO
2. Incorrect installation of the rear wheel
Refer to “CHECKING THE REAR WHEEL” on page 4-47.
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR” on page
4-49.
Is check result OK?

YES
→ Go to step 4.
NO
4. Defective rear wheel sensor or incorrect installation of the sensor
4-49.
Is check result OK?

YES
NO
9-284
13, 26_ABS
EAS20687
13, 26_ABS
EAS33316
TROUBLESHOOTING
Item
Front wheel sensor (abnormal pulse period)
Procedure
TIP
• If the front brake ABS operates continuously for 20 seconds or more, DTC No. 26 will be recorded. If
the front brake ABS operates continuously for 36 seconds or more, DTC No. 13 will be recorded.
• Vehicle possibly ridden on uneven roads.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
4-40.
Is check result OK?

YES
→ Go to step 4.
NO
4-40.
Is check result OK?

YES
NO
9-285
14, 27_ABS
EAS20688
14, 27_ABS
EAS33317
TROUBLESHOOTING
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.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
4-49.
Is check result OK?

YES
→ Go to step 4.
NO
4-49.
Is check result OK?

YES
NO
9-286
15_ABS
EAS20662
15_ABS
EAS33040
TROUBLESHOOTING
Item
Front wheel sensor (open or short circuit)
Procedure
1. Defective coupler between the front wheel sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
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.
• Disconnect the ABS ECU coupler “1” and front wheel sensor coupler “2”.
Between ABS ECU coupler and front wheel sensor white–white
coupler black–black
1
2
B W
Is resistance 0 Ω?
YES
NO
→ Replace the wire harness.
TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
white–ground
black–ground
9-287
15_ABS

ABS ECU coupler
A B
1 1
YES
→ Go to step 3.
NO
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 4-35 and “ABS (Anti-lock Brake System)” on page 4-74.
9-288
16_ABS
EAS20663
16_ABS
EAS33285
TROUBLESHOOTING
Item
Rear wheel sensor (open or short circuit)
Procedure
1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the ABS ECU coupler “1” and rear wheel sensor coupler “2”.
Between ABS ECU coupler and rear wheel sensor white–white
coupler black–black
1
2
B W
Is resistance 0 Ω?
YES
NO
TIP
white–ground
black–ground
9-289
16_ABS

ABS ECU coupler
A B
1 1
YES
→ Go to step 3.
NO
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 4-43 and “ABS (Anti-lock Brake System)” on page 4-74.
9-290
21_ABS
EAS20690
21_ABS
EAS33320
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective solenoid drive circuit)
Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-74.
9-291
31_ABS
EAS20691
31_ABS
EAS33321
TROUBLESHOOTING
Hydraulic unit assembly (defective ABS solenoid power circuit)
Procedure
1. Blown ABS solenoid fuse
• Check the ABS solenoid fuse.
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
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS solenoid fuse “1” and ABS ECU coupler “2”.
Between ABS solenoid fuse holder and ABS ECU
coupler
1 2
Is resistance 0 Ω?
YES
NO
9-292
31_ABS
TIP
Between ABS ECU coupler “1” and ground blue/white–ground

ABS ECU coupler blue/white–any other coupler terminal
A B
1 1
YES
→ Go to step 4.
NO
9-293
33_ABS
EAS20692
33_ABS
EAS33322
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal ABS motor power supply)
Procedure
1. Blown ABS motor fuse
• Check the ABS motor fuse.
Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the starter relay coupler (ABS motor fuse) “1” and ABS ECU coupler “2”.
Between starter relay coupler (ABS motor fuse) and
ABS ECU coupler
1 2
R/W L/W Gy/B L Y G R/B B L/W B/W
R/W L/W R/W G/O W/L L B W W L/B B
Is resistance 0 Ω?
YES
NO
9-294
33_ABS
TIP
Between ABS ECU coupler “1” and ground red/white–ground

ABS ECU coupler red/white–any other coupler terminal
A B
1 1
YES
→ Go to step 4.
NO
9-295
34_ABS
EAS20693
34_ABS
EAS33323
TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS motor power supply circuit)
Procedure
9-296
41_ABS
EAS20694
41_ABS
EAS33331
TROUBLESHOOTING
Item
Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization)
Procedure
1. Incorrect installation of the front wheel sensor
4-40.
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 4-38 and “CHECKING THE FRONT BRAKE
DISCS” on page 4-57.
Is check result OK?

YES
→ Go to step 3.
NO
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 DISCS” on page 4-57.
Is check result OK?

YES
→ Go to step 4.
NO
9-297
42_ABS
EAS20695
42_ABS
EAS33324
TROUBLESHOOTING
Item
Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization)
Procedure
1. Incorrect installation of the rear wheel sensor
4-49.
Is check result OK?

YES
→ Go to step 2.
NO
2. Incorrect rotation of the rear wheel
• Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE REAR WHEEL” on page 4-47 and “CHECKING THE REAR BRAKE
DISC” on page 4-68.
Is check result OK?

YES
→ Go to step 3.
NO
3. Rear brake dragging
• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake pedal
is operated and that the pressure decreases when the pedal is released.
Refer to “CHECKING THE REAR BRAKE DISC” on page 4-68.
Is check result OK?

YES
→ Go to step 4.
NO
9-298
43, 45_ABS
EAS20696
43, 45_ABS
EAS33330
TROUBLESHOOTING
Item
Front wheel sensor (missing pulses)
Procedure
TIP
After the DTC 45 is recorded, DTC 43 will be recorded if a certain speed and time are exceeded.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
4-40.
Is check result OK?

YES
→ Go to step 4.
NO
4-40.
Is check result OK?

YES
NO
9-299
44, 46_ABS
EAS20697
44, 46_ABS
EAS33325
TROUBLESHOOTING
Item
Rear wheel sensor (missing pulses)
Procedure
TIP
After the DTC 46 is recorded, DTC 44 will be recorded if a certain speed and time are exceeded.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
4-49.
Is check result OK?

YES
→ Go to step 4.
NO
4-49.
Is check result OK?

YES
NO
9-300
51_ABS
EAS20698
51_ABS
EAS33326
TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is high)
Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
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
Is check result OK?

YES
NO
→ Confirm the cause of the problem and repair it, and check again.
9-301
53_ABS
EAS20699
53_ABS
EAS33327
TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is low)
Procedure
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS ECU fuse “1” and ABS ECU coupler “2”.
Between ABS ECU fuse holder and ABS ECU cou-
pler
2
Is resistance 0 Ω?
YES
NO
TIP
Between ABS ECU coupler “1” and ground red/black–ground
9-302
53_ABS

ABS ECU coupler red/black–any other coupler terminal
A B
1 1
YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
9-303
55_ABS
EAS20700
55_ABS
EAS33328
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS ECU)
Procedure
9-304
56_ABS
EAS20701
56_ABS
EAS33329
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal internal circuit)
Procedure
9-305
57_ABS
EAS20666
57_ABS
EAS33292
TROUBLESHOOTING
Item
Vehicle CAN communication line or power source of vehicle system
Procedure
• Disconnect the ECU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
Between the joint coupler and ABS ECU coupler
1
3
2

Is resistance 0 Ω?
YES
NO
TIP
ECU” on page 9-4.
blue/white–ground
blue/black–ground
9-306
57_ABS
blue/white–ground
blue/black–ground
ECU coupler
ABS ECU coupler
A B
1 1

3 3
2

YES
→ Go to step 2.
NO
TIP
Is check result OK?

YES
9-307
57_ABS
→ Go to step 4.
NO
• Disconnect the ABS ECU fuse “1”, ABS solenoid fuse “2” and ABS ECU coupler “3”.
Between ABS ECU fuse holder and ABS ECU cou-
pler
Between ABS solenoid fuse holder and ABS ECU
coupler
2 3
Is resistance 0 Ω?
YES
NO
TIP
red/black–ground
blue/white–ground

red/black–any other coupler terminal
ABS ECU coupler
A B
1 1
YES
9-308
57_ABS
→ Go to step 5.
NO
YES
NO
9-309
62_ABS
EAS20702
62_ABS
EAS33333
TROUBLESHOOTING
Item
Power supply voltage failure in pressure sensor
Procedure
9-310
68_ABS
EAS20705
68_ABS
EAS33336
TROUBLESHOOTING
Item
Defective hydraulic unit assembly (defective front pressure sensor)
Procedure
1. Defective front brake line
• Check the front brake line.
Is check result OK?

YES
→ Go to step 2.
NO
→ If there is bending or blocking, replace the front brake line.
9-311
89_ABS
EAS20669
89_ABS
EAS33299
TROUBLESHOOTING
Item
CAN communication (between meter assembly and hydraulic unit assembly)
Procedure
1. Defective coupler between the meter assembly and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the meter assembly coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
Between meter assembly coupler and joint coupler
Between joint coupler and ABS ECU coupler
1
B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W
3
2
* L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/W Gy/B L Y G R/B B L/W B/W


Is resistance 0 Ω?
YES
NO
9-312
89_ABS

TIP
blue/white–ground
blue/black–ground
blue/white–ground
blue/black–ground

ABS ECU coupler
A B
1 1
3 3
2

YES
→ Go to step 3.
NO
9-313
89_ABS
3. Defective meter assembly

• Replace the meter assembly, and check again.
9-314
90_ABS
EAS20670
90_ABS
EAS33300
TROUBLESHOOTING
Item
CAN communication (between ECU and hydraulic unit assembly)
Procedure
1. Defective coupler between the ECU and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the ECU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
1
3
2

Is resistance 0 Ω?
YES
9-315
90_ABS
NO
TIP
ECU” on page 9-4.
blue/white–ground
blue/black–ground
blue/white–ground
blue/black–ground

ECU coupler
ABS ECU coupler
A B
1 1

3 3
2

YES
→ Go to step 3.
NO
9-316
90_ABS
3. Defective ECU
• Replace the ECU, and check again.
9-317
91_ABS
EAS20671
91_ABS
EAS33301
TROUBLESHOOTING
Item
CAN communication (between IMU and hydraulic unit assembly)
Procedure
1. Defective coupler between the IMU and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the IMU coupler “1”, joint coupler “2” and ABS ECU coupler “3”.
Between IMU coupler and joint coupler
3
2
* L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B L/W Gy/B L Y G R/B B L/W B/W


Is resistance 0 Ω?
YES
NO
9-318
91_ABS

TIP
blue/white–ground
Between IMU coupler “1” and ground
blue/black–ground
blue/white–ground
blue/black–ground

IMU coupler
ABS ECU coupler
A B
1 1
3 3
2

YES
→ Go to step 3.
NO
3. Defective IMU
• Replace the IMU, and check again.
9-319
91_ABS

9-320
EAS20091
57. Primary injector #2 112.Sub radiator fan motor (right)
WIRING DIAGRAM 58. Primary injector #3 113.Radiator fan motor (left)
YZF1000L/YZF1000/YZF1000DL/ 59. Primary injector #4 114.SCU fuse (for YZF-R1M)
YZF1000D 2020 60. Secondary injector #1 115.SCU (Suspension Control
1. AC magneto 61. Secondary injector #2 Unit) (for YZF-R1M)
2. Rectifier/regulator 62. Secondary injector #3 116.Front fork stepping motor (left)
3. Main switch 63. Secondary injector #4 (for YZF-R1M)
4. Main fuse 64. Intake funnel servo motor 117.Front fork stepping motor
5. Radiator fan motor relay 65. Throttle servo motor (right) (for YZF-R1M)
6. ABS solenoid fuse 66. Steering damper solenoid 118.Rear shock absorber assem-
7. Fuel injection system fuse 67. Hydraulic unit assembly (ABS bly stepping motor (compres-
8. Electronic throttle valve fuse ECU) sion damping) (for YZF-R1M)
9. Backup fuse 68. Front wheel sensor 119.Rear shock absorber assem-
10. Sub radiator fan motor fuse 69. Rear wheel sensor bly stepping motor (rebound
11. Radiator fan motor fuse 70. Throttle position sensor damping) (for YZF-R1M)
12. Ignition fuse 71. IMU (Inertial Measurement 120.Steering damper solenoid
13. Signaling system fuse Unit) (OPTION) (for YZF-R1M)
14. ABS ECU fuse 72. Meter assembly *. Joint coupler for YZF-R1
15. Hazard lighting fuse 73. Immobilizer system indicator **. Joint coupler for YZF-R1M
16. Headlight fuse light A. Wire harness
17. Auxiliary fuse 74. Fuel level warning light B. Sub-wire harness (Intake sole-
18. Engine ground 75. MIL (Malfunction indicator light) noid)
19. Battery 76. Neutral indicator light C. Sub-wire harness (Coolant
20. Starter relay 77. Shift indicator light temperature sensor)
21. ABS motor fuse 78. Multi-function meter D. Sub-wire harness (Intake air
22. Starter motor 79. Stability control indicator light temperature sensor)
23. Joint coupler 80. Oil pressure and coolant tem- E. Sub-wire harness (CCU (Com-
24. Immobilizer unit perature warning light munication Control Unit)) (for
25. Front brake light switch 81. Auxiliary system warning light YZF-R1M)
26. Handlebar switch (right) 82. Turn signal indicator light (right) F. Sub-wire harness (Oil pressure
27. Wheel switch 83. Turn signal indicator light (left) switch)
28. Start/engine stop switch 84. Meter light G. Sub-wire harness (SCU, steer-
29. Accelerator position sensor 85. ABS warning light ing damper solenoid, sub-wire
30. Relay unit 86. High beam indicator light harness) (for YZF-R1M)
31. Starting circuit cut-off relay 87. YDT coupler H. Sub-wire harness (front fork
32. Fuel pump relay 88. CCU (Communication Control stepping motor) (for YZF-R1M)
33. Neutral switch Unit) (for YZF-R1M) I. Sub-wire harness (Steering
34. Sidestand switch 89. GPS unit (for YZF-R1M) damper solenoid), (OPTION)
35. Fuel sender 90. Oil pressure switch (for YZF-R1M)
36. Fuel pump 91. Handlebar switch (left)
37. Intake solenoid 92. Mode switch
38. Gear position sensor 93. Pass/LAP switch
39. O2 sensor 1 (left side) 94. Dimmer switch
40. O2 sensor 2 (right side) 95. Horn switch
41. Shift sensor 96. Turn signal switch
42. Intake air pressure sensor 97. Hazard switch
43. Atmospheric pressure sensor 98. Horn
44. Cylinder identification sensor 99. Clutch switch
45. EXUP servo motor 100.Rear turn signal light (right)
46. Crankshaft position sensor 101.Rear turn signal light (left)
47. Coolant temperature sensor 102.Front turn signal light (right)
48. Intake air temperature sensor 103.Front turn signal light (left)
49. ECU (Engine Control Unit) 104.Headlight control unit
50. Spark plug 105.Headlight (high beam)
51. Ignition coil #1 106.Headlight (low beam)
52. Ignition coil #2 107.Rear brake light switch
53. Ignition coil #3 108.Tail/brake light
54. Ignition coil #4 109.License plate light
55. Air induction system solenoid 110.Auxiliary light
56. Primary injector #1 111.Auxiliary DC connector
EAS30613
COLOR CODE Y/R Yellow/Red

B Black
Br Brown
Ch Chocolate
Dg Dark green
Dl Dark blue
G Green
Gy Gray
L Blue
Lg Light green
O Orange
P Pink
R Red
Sb Sky blue
V Violet
W White
Y Yellow
B/G Black/Green
B/L Black/Blue
B/R Black/Red
B/W Black/White
B/Y Black/Yellow
Br/B Brown/Black
Br/L Brown/Blue
Br/R Brown/Red
Br/W Brown/White
Br/Y Brown/Yellow
G/B Green/Black
G/L Green/Blue
G/O Green/Orange
G/R Green/Red
G/W Green/White
G/Y Green/Yellow
Gy/B Gray/Black
Gy/G Gray/Green
Gy/R Gray/Red
Gy/Y Gray/Yellow
L/B Blue/Black
L/G Blue/Green
L/R Blue/Red
L/W Blue/White
L/Y Blue/Yellow
Lg/R Light green/Red
O/B Orange/Black
O/G Orange/Green
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/B White/Black
W/G White/Green
W/L White/Blue
W/R White/Red
W/Y White/Yellow
Y/B Yellow/Black
Y/G Yellow/Green
Y/L Yellow/Blue
YZF1000L/YZF1000/YZF1000DL/YZF1000D 2020
WIRING DIAGRAM
W W
R/G R/G
B W R 24 B B
R/L R/L R/L R/L R/L R/L R/L
1 (Dgy)
R/W Lg Y/L Y/L Lg R/W R/W R/W
R/W
R/W
R/W
R/W R/W R/W
R/W R/W
R/L R/L R/L R/L
W R Lg R/G R/W B Y/L
W
W 2 R
R
RR
R
W W W
B R 4 R/W
R/W
W W W
R R R R R 21 R/W R/W
R R/W R/W A R/W L/R A L/R R/W R/W
RRR
R
20 L/W L/W L/W 37
R/W R/W
51
3 L/W
L/R L/R R/W L/R O
O R/W
ON
B R/W
(B)
50 (B)
OFF 19 R/W L/W Y/L
R
Br/L
22 (B)
L/R
R/W
L/W Sb/W Br/W L/W O
R/W
52
BB R/W Gy/R Gy/R
Gy/R R/W
R Br/L 30 O/G
50
Br/L
Br/W L/W R/W L R/L
31 32 L/R G W
38 L/R
W
G G
W
L/R
Gy/G
(B)
B B
B B
L/R L/W R/W L/B L/Y Sb B/Y Sb/W (Dl)
L/W
R/W
53
R/W L Sb L/Y L/B L/W O/G
O/G R/W
18 R/W B/Y R/L
R/L
50
R 6 23 R/W
R/W
R/W
R/G
R/L
(B)
B
R L/W
R/W
7 26 25 W/G W/B W R/W R/W L
L/Y
B/Y
R/W
54
Y/G W/R L/B Gy/G
Br/W R/W R/W R/W R/W L/Y B R/W B B P/B P/B Gy/G R/W
5 8 R/G R W/B R/L R/B L/W Y/R W/B B/L L/G B/L W L Gy/G Gy/G 50
27 Y/B W/G W B/Y L/Y B
34 39
(B)
R R/L W/B W/G W/G R
L/Y
L/Y G/W R/L
R/W P/W B B 40 B B R/W P/B
Br/R Br/R G O R/W
R R/B
G/Y
9 B B/W W W/B B/Y
(B) 28 (B)
(B)
B B Gy/Y B/L W L W L Gy/G B/L
R/B
R/G
R/G B
(B)
29 (B)
35 36 (B)
(B) (B)
(B) 55 O G Br/R R/W
R/W G/Y
10 B R/W B B P/W P/W
L R/W L L/W R/B Sb L/B B B/L W L Gy/Y Gy/Y
Y/G W/G R/B R/B R/L
B/Y
R/B 11 R/W L/W L/R R/L
L/R B/Y B Y Y/B Y/R W/B W/R B/Y (B) B B
56
L/W
L/W Y B/W B B/Y L/G B/L L/Y
B/Y
33 B
B
B
R/L B G/W B B/L V L R W B
41
R
W
L
V V
R/LR/B
57 R/L G/B
Y B
12 R/W
B W
B (B) (B)
(B)
B B/L G/B
L/B L/B
G/B
R/L
R/L
R/W
Br/L 13 42
L 58
Br/L
Br/L Br/L L/W
B/L P/W L B/L
P/W P/W
R/L L/B
59 R/L O/B
Br/L
Br/R
14 L/R
(Dl)
L
O/B O/B R/L
R/B
B/L P L 43 B/L W/L
Sb/W
W/L R/L
15 (Dl)
P
LLL
P
Br/Y
Br/B W/L R/L
60 Sb/WR/L
Br/R L/Y
16 R/G
L
L
L L
(Gy) 61 (Gy)
Br/L
R/Y
R/Y R/G R/G 44 L/Y
W
L
W/B W/B Sb/W R/L
Br/L 17 R/G
R/G
B/L
49 Br/Y R/L
B/W B R/G L W/B W L/Y
L/W
Br/Y
L/W 72 Lg
B/L B/L L W/Y B/L 62
114 Br/Y
B/W
B B/W
73 (B) (B) G B/G B/R
Br/Y R/L
63
Br/B R/L
111 B 23 (B)
(Gy)
Br/B R/L
(Gy)
P/W G/R Y Br/W

Br/W
B Br/Y
L/W L/W L/W L/W
74 L W/Y W/Y
P G Y/R Gy/G Gy B (Gy)
G 45 B/G B/G Y/L Y/L R
64
L/B P/L G/B Y/G Gy/B Gy/R 75 B/L B/R B/R Sb Sb B R B Sb Y/L
L/W P/B G/L Y/B W W/R W/B W/G L/W L L/R

Gy Gy Gy Gy
(B)
L
L/R L/R
91 76 B/L Gy B Gy 46 Lg/R Lg/R
65
Br/W F Br/W
113 112 L/R
L/R L/R
G G/Y G/B L/W B/Y L/Y L/Y R/W Sb/W B B/L Y/R Y/R Lg/R Y/R
B F B
93 94 95 L/R L/W
97 77 47 G/W B G/W G/W
(B)
UP G/W B/L B/L B B/L
G G G B B
Br
107 MODE Y/B Y/B B B
G/B G G/B DOWN 96 (B)
66
G/R G G/R 116 L L B B Y/B B
G/L G G/L (B) Br Y 92 Y L/Y G/B G/Y G G/W 78 Br/W B/L 48 Br/W C Br/W
B/L C B/L
Br/W
B/L
B R/G
B B/G Y/B B W/B W/Y R/G (B)
B Y L/W B/Y L/W
B L L/B
G/R G G/B G/L Y L/R (B) B L/R B W/B B/G
L/W
(B) B Y/B Y B/W W/L W/Y Br/Y
79 B/L
B/L B/L B/L B/L B/L
B/L B/L B/L B/L B/L
G G/Y G/B L/Y Y B/Y L/Y G/L L/W B/Y Gy/G Br/W B/L W W/B
W
P
P/B
G P
G P/B
B W/Y W/L B Y/B Br/Y L/W B/W
W/G
W/B 80 L/Y L/W Gy/Y G/W G Gy/B W/L
P/W G P/W 117 B
B (B) G/B L/Y
P/L G P/L B
B
G/Y
G 81 B/L
L/G
(B)
B
B/W
B
98 99 B/W B/Y
Y/B W R/W
P/W P P/B P/L B W/Y G
B
B
Y
Y
Y Y/B
W/L
Br/Y 82 B L
L
B B W W B
B Y/R P/W P/B Gy/G O/G Gy/R O L/Y L Y/B R/W
W F W
Y
Y/B
Y
Br/W
Br/B 83 Lg/R L/R O/B L/B G/B R/B B W W L/G B/R Gy/B Gy/B
115
W/B F W/B
118 Ch R/L G/Y Br/R Br/B Br/Y Sb/W W/L B B/G B B/G W/L W/L W W
B 68
W/R
W/G
F W/R
F W/G
L/R
R/G 110 L/R 109 108 L/R Y Y
102 Br/W 100 Dg G/L
Dg
84 R/W B/W R/G Y/B L/W Y/L Sb R/L B/W B/W B/L B B/Y W/Y G/Y B
(B) (B) Y/B W

Y W
B/R G G E
86 85 B/G B/G B B 69
W/R W W/B W/G
B/Y
B B R/Y R/Y Y/B Y Br/W G
G/L Y G/O 71 W B/G L B 70 W W
L/B G/O 67
Dg B B G B B B W W B
B B L/W
L L
B L/R (B) G/L L/W L/B (B)
(B)
Y F Y B/W L/W L/B R/W
Y/B F Y/B 104 B B
B/W B L/W
Y/R F Y/R 119 B
Br/B 103 Ch 101 B/W R/W Br/W Br/B Dg Ch W/L W/Y Br/Y Lg L/W L/B G/W (B) B/W B Y R/B
Y/G F Y/G B/Y B B/R L/R B
Br Br
90 R/GR/G Sb/W G/L G/Y G G/B W/B W/G W G/O Y L/B
B 106 105 Br/B B Br Ch B

(Gy)
L/W D L/W
L/W
R/G B L/R Br
Y/R Y Y/B Y/G B L/B D L/B
B B (B) (B) B/W D B/W
W B
(B) B Y L/R R/Y B Y/B Y B R/Y (Gy) (Gy) L/W B/W R/G D R/G
Y O B/W B
(B) OWY B B YWO L/B R/G
Gy H Gy (B) B B
Gy/B H Gy/B B L/W Gy/B L Y G R/B B L/W B/W
Gy/R H Gy/R 120 B
B
B
B R GW
88
Gy/G H Gy/G
B G
R W
89 L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B
L/W R/G B/W L/B L/W (B)

L/B L/W L/B
O W Y B L/W L/B
L/B L/W Gy/G Gy Gy/B Gy/R
F F (B) 23 B/W B/W B/W B/W
L/B L/W
R/G
* L/W L/W L/W L/W L/W L/W L/B L/B L/B L/B L/B L/B B B B/W B/W BB B/W
L/W B/W
87 B/W
L/B
A B C D E F G H
R/G L/B L/W
(R)
L/W Y/B Y W/B W Br/W Br/W W W/B Y Y/B L/W G G/B G/R G/L
L/W L/B L/B L/W G/L G/R G/B G Gy/R Gy Gy/B Gy/G
R/W L/R L/R R/W B/L G/W G/W B/L Br/W B/L B/L Br/W B W/R W/G Y/R Y/G L/B P P/B P/W P/L Gy/G Gy Gy/B Gy/R
L/B Y/G Y/R W/G W/R B P/L P/W P/B P
R/G B/W B/W R/G
(B) (B) (B) (B) G/L G/L
(B) (B) (B) (B)
A B A C A D A E A F G A G H G I
YZF1000L/YZF1000/YZF1000DL/YZF1000D 2020
WIRING DIAGRAM
24
1 (Dgy)
2
4
21
A A
20 37 51
3
ON (B)
50 (B)
OFF 19
22 (B) 52
30 50
31 32 38 (B)
(Dl)
53
18 50
6 23 (B)
7 26 25 54
5 8 50
27 34 39
(B)
40
9 (B) 28 (B)
(B)
(B)
29 (B)
35 36 (B)
(B) (B)
(B) 55
10
11 (B)
56
33 41 57
12 (B) (B)
(B)
13 42 58 59
14 (Dl)
43
15 (Dl)
60
16 (Gy) 61 (Gy)
44
17 49
72 62
114 73 (B) (B) 63
111 23 (B)
(Gy) (Gy)
74
(Gy) 45 64
75
(B)
91 76 46 65
F
113 112
F
93 94 95 97 77 47 B
(B)
UP B
G 107 MODE
G DOWN 96 (B)
66
G 116
G (B) 92 78 48 C
C
(B)
(B)
(B)
79
G
G 80
G 117 (B)
G
81 (B)
98 99
82
F 83
115
F
118 68
F
F 110 109 108 102 100 84
(B) (B)
E
86 85 69
71 70 67
(B) (B) (B)
F
F 104
F 119 103 101 (B)
F 90
106 105 (Gy)
D
(B) D
(B) D
(B) (Gy) (Gy) D
H (B) (B)
H
H 120 88
H 89
(B)
F F (B) 23
*
87
A B C D E F G H **
(R)
(B) (B) (B) (B) G/L G/L

(B) (B) (B) (B)
A B A C A D A E A F G A G H G I

B3L-28197-20 Yamaha YZF R1 2020 Service Manual EU

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2020

IMPORTANT MANUAL INFORMATION

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

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

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

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

BASIC SERVICE INFORMATION.................................................................1-20

SPECIAL TOOLS .......................................................................................... 1-21

VEHICLE IDENTIFICATION NUMBER

• YRC setting display MODE/PWR/TCS/SCS/

TCS 3 SCS 2 EBM

• Logging indicator (CCU - equipped models)

9. YRC items MODE/PWR/TCS/SCS/EBM TIP

Transmission gear display

YRC items MODE/PWR/TCS/SCS/EBM • When a YRC item is highlighted but cannot be

pendently for each group. These groups of set- GEAR

TCS 3 SCS 2 EBM

TIP To turn off the traction control system select TCS

TCS 3 SCS 2 EBM

SCU trouble warning (YZF-R1M)

Auxiliary system warning

Coolant temperature warning EAS31708

2. Select “STREET MODE” or “TRACK MODE”

EBM 2. The “YRC Setting” screen is displayed, and

4 3 YRC PWR TCS SCS LCS QS QS LIF EBM BC ERS

gagement may come on sooner than expected

ERS (YZF-R1M) 3. Front overall damping level

The ERS consists of three semi-active automat- 1 M-1 8 18 22 22 7

SETTING Fr COM Fr REB Rr COM Rr REB

[To view the lap time record data]

4. Current level setting

[To start and stop logging]

1 FASTEST / LAP 12 02:34.56 km/h MENU GPS 10 : 00

km/h Lap Time GPS

km/h Logging GPS 10 : 00

“Maintenance” [To set the distance or fuel consumption

km/h MENU GPS 10 : 00 Maintenance

Display Mode Unit

2. Select the item you want to reset.

km/h Maintenance GPS 10 : 00

2. Select the mode you want to adjust (select Wallpaper

STREET MODE (day)

Shift IND Setting

km/h Wallpaper GPS

STREET MODE (day)

2. Select “IND Mode”. tional range is 8500–15000 r/min.

Shift IND Setting

km/h Shift Indicator GPS 10 : 00

4. Select “IND Start”. Shift IND Brightness