Tmax xp500f 2015

2015
SERVICE MANUAL
XP500F
LIT-11616-28-54 2PW-28197-10
EAS20002
XP500F
SERVICE MANUAL
©2014 by Yamaha Motor Corporation, U.S.A.
First edition, November 2014
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-28-54
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.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION

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

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

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

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
7
4
5
6
2
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
TROUBLESHOOTING 9
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
MULTI-FUNCTION DISPLAY.................................................................... 1-4
IMPORTANT INFORMATION ......................................................................... 1-9

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-9
REPLACEMENT PARTS...........................................................................1-9
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-9
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-9
BEARINGS AND OIL SEALS .................................................................. 1-10
CIRCLIPS ................................................................................................1-10
RUBBER PARTS.....................................................................................1-10
BASIC SERVICE INFORMATION.................................................................1-11

QUICK FASTENERS............................................................................... 1-11
ELECTRICAL SYSTEM...........................................................................1-12
SPECIAL TOOLS .......................................................................................... 1-16

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the frame.
EAS30003
MODEL LABEL
The model label “1” is affixed to the storage box.
This information will be needed to order spare
parts.
1-1
FEATURES
EAS20008
FEATURES
EAS30005
OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system,
the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of
the intake air and the fuel that is metered by the jet used in the respective chamber. Despite the same
volume of intake air, the fuel volume requirement varies with the engine operating conditions, such as
acceleration, deceleration, or operation under a heavy load. Carburetors that meter the fuel through the
use of jets have been provided with various auxiliary devices, so that an optimum air-fuel ratio can be
achieved to accommodate the constant changes in the operating conditions of the engine.
As the requirements for engines to deliver more performance and cleaner exhaust gases increase, it
becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system in place
of a conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the
engine at all times by using a microprocessor that regulates the fuel injection volume according to the
engine operating conditions detected by various sensors.
Adoption of the FI system has resulted in a highly precise fuel supply, improved engine response, better
fuel economy, and reduced exhaust emissions.
17
1. Fuel injector 15. Spark plug
2. Lean angle sensor 16. Ignition coil
3. ECU (engine control unit) 17. Speed sensor
4. Intake air temperature sensor
5. Engine trouble warning light
6. Battery
7. Intake air pressure sensor
8. Fuel hose
9. O2 sensor
10. Fuel pump
11. Crankshaft position sensor
12. Fuel tank
13. Coolant temperature sensor
14. Throttle position sensor
1-2
FEATURES
EAS30617
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump)
maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the
energizing signal from the ECU (engine control unit) energizes the fuel injector, the fuel passage opens,
causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the
volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU (engine control unit). Signals
that are input from the throttle position sensor, crankshaft position sensor, intake air pressure sensor,
intake air temperature sensor, coolant temperature sensor, and O2 sensor enable the ECU (engine
control unit) to determine the injection duration. The injection timing is determined through the signals
from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can
be supplied at all times in accordance with the driving conditions.
Illustration is for reference only.
1. Fuel pump 13. Throttle position sensor

2. Fuel injector
A. Fuel system
3. Ignition coil
B. Air system
4. ECU (engine control unit)
C. Control system
5. Catalyst
6. O2 sensor
10. Throttle body
12. Air filter case
1-3
FEATURES
EAS30618
The multi-function display is equipped with the
MULTI-FUNCTION DISPLAY
EWA17650
following:
WARNING • a fuel meter
Be sure to stop the vehicle before making • a coolant temperature meter
any setting changes to the multi-function • an odometer
meter unit. Changing settings while riding • two tripmeters (which show the distance trav-
can distract the operator and increase the eled since they were last set to zero)
risk of an accident. • a fuel reserve tripmeter (which shows the dis-
tance traveled when the remaining fuel in the
fuel tank reaches approximately 3.0 L (0.79 US
4 gal, 0.66 Imp.gal))
3
• a self-diagnosis device
2 5 • a clock
1 6 7 • an ambient temperature display
• a fuel consumption display (average and in-
stantaneous consumption functions)
• an oil change tripmeter (which shows the dis-
tance traveled since the last engine oil change)
• a V-belt replacement tripmeter (which shows
1. “SELECT” button the distance traveled since the last V-belt re-
2. Fuel meter placement)
3. Fuel level warning indicator “ ” TIP
4. Odometer • Be sure to turn the vehicle power on before us-
5. Coolant temperature warning indicator “ ” ing the “SELECT” and “RESET” buttons.
6. Coolant temperature meter • When the vehicle power is turned on, all of the
7. “RESET” button display segments of the multi-function display
will appear one after the other and then disap-
pear, in order to test the electrical circuits.
1
Clock
1. Tripmeter/fuel reserve tripmeter

2. Ambient temperature/average fuel
consumption/instantaneous fuel consumption
1. Clock
1
[To set the clock]
1. Push the “SELECT” and “RESET” buttons to-
gether for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button to set the hours.
3. Push the “SELECT” button, and the minute
digits will start flashing.
1. Clock 4. Push the “RESET” button to set the minutes.
5. Push the “SELECT” button and then release
it to start the clock.
1-4
FEATURES
Odometer and tripmeter modes

1
1
1. Fuel reserve tripmeter

1. Odometer/tripmeters/fuel reserve tripmeter
To reset a tripmeter, select it by pushing the “SE-
LECT” button until “Trip F”, “Trip 1” or “Trip 2” is
displayed. While “Trip F”, “Trip 1” or “Trip 2” is
displayed, push the “SELECT” button for at least
one second. If you do not reset the fuel reserve
1 tripmeter manually, it will reset itself automatical-
ly and the display will return to the prior mode af-
ter refueling and traveling 5 km (3 mi).
TIP
The display cannot be changed back to “Trip F”
after resetting the fuel reserve tripmeter.
1. Oil change tripmeter
Fuel meter
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear towards “E” (Empty) as the fuel level
1 decreases. When the fuel level reaches the bot-
tom segment near “E”, the fuel level warning in-
dicator, “F”, “E”, and the bottom segment will
flash. Refuel as soon as possible.
1. V-belt replacement tripmeter

Pushing the “SELECT” button switches the dis-
play between the odometer mode and the trip-
meter modes in the following order:
Odo → Trip 1 → Trip 2 → V-Belt Trip → Oil Trip
→ Odo
When approximately 3.0 L (0.79 US gal, 0.66
Imp.gal) of fuel remains in the fuel tank, the dis-
Coolant temperature meter
play will automatically change to the fuel reserve
The coolant temperature meter indicates the
tripmeter mode “Trip F” and start counting the
temperature of the coolant. The coolant temper-
distance traveled from that point. In that case,
ature varies with changes in the weather and en-
pushing the “SELECT” button switches the dis-
gine load. If the top segment, “H”, “C”, and
play between the various tripmeter and odome-
coolant temperature warning indicator flash,
ter modes in the following order:
stop the vehicle and let the engine cool.
Odo → Trip 1 → Trip 2 → Trip F → V-Belt Trip
→ Oil Trip → Odo
1-5
FEATURES
3. If the oil change indicator does not come on,

check the electrical circuit.
(Refer to “SIGNALING SYSTEM” on page
8-19)
V-belt replacement indicator “V-Belt”
ECA20730
NOTICE 1
Do not continue to operate the engine if it is
overheating.
Oil change indicator “Oil”

1. V-belt replacement indicator “V-Belt”
This indicator flashes every 20000 km (12500
mi) when the V-belt needs to be replaced.
After changing the V-belt, reset the V-belt re-
1 placement indicator. To reset the V-belt replace-
ment indicator, select it by pushing the
“SELECT” button until “V-Belt Trip” is displayed,
and then push the “SELECT” button at least one
second. When pushing the “SELECT” button,
“V-Belt Trip” starts flashing. While “V-Belt Trip” is
1. Oil change indicator “Oil” flashing, push the “SELECT” button for at least
This indicator flashes at the initial 1000 km (600 three seconds.
mi), then at 5000 km (3000 mi) and every 5000 If the V-belt is changed before the V-belt re-
km (3000 mi) thereafter to indicate that the en- placement indicator “V-Belt” flashes (i.e. before
gine oil should be changed. the periodic V-belt change interval has been
After changing the engine oil, reset the oil reached), the indicator “V-Belt” must be reset af-
change indicator. To reset the oil change indica- ter the V-belt change for the next periodic V-belt
tor, select it by pushing the “SELECT” button un- change to be indicated at the correct time.
til “Oil Trip” is displayed, and then push the The electrical circuit of the indicator can be
“SELECT” button at least one second. When checked according to the following procedure.
pushing the “SELECT” button, “Oil Trip” starts 1. Turn the vehicle on and make sure that the
flashing. While “Oil Trip” is flashing, push the engine stop switch is set to “ ”.
“SELECT” button for at least three seconds. 2. Check that the V-belt replacement indicator
If the engine oil is changed before the oil change comes on for a few seconds and then goes
indicator “Oil” flashes (i.e. before the periodic oil off.
change interval has been reached), the indicator 3. If the V-belt replacement indicator does not
“Oil” must be reset after the oil change for the come on, check the electrical circuit.
next periodic oil change to be indicated at the (Refer to “SIGNALING SYSTEM” on page
correct time. 8-19)
The electrical circuit of the indicator can be
checked according to the following procedure.
1. Set the engine stop switch to “ ” and turn
the power of the vehicle on.
2. Check that the oil change indicator comes on
for a few seconds and then goes off.
1-6
FEATURES
Ambient temperature display, average fuel Average fuel consumption mode

consumption, and instantaneous fuel con-
sumption modes
1 1. Average fuel consumption display

The average fuel consumption is displayed
1. Ambient temperature/average fuel “AVE_ _._ MPG”.
consumption/instantaneous fuel consumption
Push the “RESET” button to switch the display This display shows the average fuel consump-
between the ambient temperature display “Air”, tion since it was last reset.
the average fuel consumption mode “AVE_ _._ When the display is set to “AVE_ _._ MPG”, the
MPG”, and the instantaneous fuel consumption average distance that can be traveled on 1.0
mode “MPG” in the following order: Imp.gal of fuel is shown.
To reset the average fuel consumption display,
Air → AVE_ _._ MPG → MPG → Air select it by pushing the “RESET” button, and
then push the “RESET” button for at least one
second.
Ambient temperature display
TIP
After resetting an average fuel consumption dis-
play, “_ _._” is shown for that display until the ve-
hicle has traveled 1 km (0.6 mi).
1
Instantaneous fuel consumption mode
1. Ambient temperature display

This display shows the ambient temperature
from 15 °F to 104 °F in 1 °F increments.
The temperature displayed may vary from the 1

ambient temperature. Pushing the “RESET” but-
ton switches the ambient temperature display to 1. Instantaneous fuel consumption display
the average fuel consumption and instanta-
The instantaneous fuel consumption is dis-
neous fuel consumption modes.
played “MPG”.
The distance that can be traveled on 1.0 Imp.gal

of fuel under the current riding conditions is
shown.
TIP
If traveling at speeds under 10 km/h (6.0 mi/h),
“_ _._” is displayed.
1-7
FEATURES
Self-diagnosis device
1. Fault code display

This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
If a problem is detected in any of those circuits,
the engine trouble warning light comes on and
the display indicates a fault code.
If the display indicates any fault codes, note the
code number, and check the fuel injection sys-
tem (Refer to “FUEL INJECTION SYSTEM” on
page 8-31).
ECA20220
NOTICE
If the display indicates a fault code, the vehi-
cle should be checked as soon as possible
in order to avoid engine damage.
1-8
IMPORTANT INFORMATION
EAS20009
EAS30006
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS30008
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-16.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS30009
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS30007
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-9
EAS30010 EAS30012
BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in-
manufacturer marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECA13300
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS30011
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-10
BASIC SERVICE INFORMATION
EAS20010

EAS30013
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out. Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 2. Install:
the pin in with a screwdriver. Make sure that the • Quick fastener
pin is flush with the fastener’s head.
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-11
ECA16760
EAS30014
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECA16600 tery lead connections could damage the
NOTICE electrical components.
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
ECA16771
NOTICE
When connecting the battery leads to the
ECA16751 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
When disconnecting the battery leads from If the negative battery lead is connected first
the battery, be sure to disconnect the nega- and a tool or similar item contacts the vehi-
tive battery lead first, then the positive bat- cle while the positive battery lead is being
tery lead. If the positive battery lead is connected, a spark could be generated,
disconnected first and a tool or similar item which is extremely dangerous.
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
ECA22370
NOTICE
TIP Push the OFF/steering lock switch before

disconnecting or connecting an electrical
If a battery lead is difficult to disconnect due to
component.
rust on the battery terminal, remove the rust us-
ing hot water.
1-12
ECA16620
NOTICE Checking the electrical system

Handle electrical components with special TIP
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.
ECA16630 ECA14371
NOTICE NOTICE
Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end “a” of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.
ECA16640
TIP
NOTICE
When resetting the ECU by pushing the
For waterproof couplers, never insert the
OFF/steering lock switch, be sure to wait ap-
tester probes directly into the coupler. When
proximately 5 seconds before pushing the
performing any checks using a waterproof
ON/start switch.
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-13
2. Check:
Checking the connections • Lead
Check the leads, couplers, and connectors for • Coupler
stains, rust, moisture, etc. • Connector
1. Disconnect: Moisture → Dry with an air blower.
• Lead Rust/stains → Connect and disconnect sev-
• Coupler eral times.
• Connector
ECA16780
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
3. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.
ECA16790
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
1-14
TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
°C (68 °F), the specified measuring conditions
will be shown.
Intake air temperature sensor re-

sistance
5400–6600 Ω@0 °C (5400–6600
4. Check: Ω@32 °F)
• Continuity Intake air temperature sensor re-
(with the pocket tester) sistance
290–390 Ω@80 °C (290–390
Pocket tester Ω@176 °F)
90890-03112
Analog pocket tester
YU-03112-C
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
5. Check:
• Resistance
Pocket tester
90890-03112
YU-03112-C
1-15
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
Rotor holding tool 5-63, 5-67
90890-01235
Universal magneto and rotor holder
YU-01235
Piston pin puller set 5-32

90890-01304
Piston pin puller
YU-01304
YU-01304
Radiator cap tester 6-3, 6-3

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Locknut wrench 5-46, 5-46, 5-49

90890-01348
Locknut wrench
YM-01348
1-16
SPECIAL TOOLS
Reference
pages
Radiator cap tester adapter 6-3, 6-3
90890-01352
Pressure tester adapter
YU-33984
YU-33984
Flywheel puller 5-56

90890-01362
Heavy duty puller
YU-33270-B
Steering nut wrench 3-24, 4-91

90890-01403
Exhaust flange nut wrench
YU-A9472
Damper rod holder 4-83, 4-86

90890-01423
Damping rod holder
YM-01423
Rod holder 4-82, 4-88

90890-01434
Damper rod holder double ended
YM-01434
Rod puller attachment (M10) 4-86

90890-01436
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
1-17
SPECIAL TOOLS
Reference
pages
Rod puller 4-86
90890-01437
Universal damping rod bleeding tool set
YM-A8703
YM-A8703
Fork spring compressor 4-82, 4-88

90890-01441
Fork spring compressor
YM-01441
Fork seal driver 4-85, 4-85, 4-85

90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Oil filter wrench 3-26, 6-7

90890-01469
Oil filter wrench
YM-01469
66.8
Sheave holder 5-46, 5-46, 5-49,

90890-01481 5-50, 5-50
Clutch spring compressor 5-63, 5-66

90890-01482
Sheave holder 5-56, 5-56, 5-57,

90890-01701 5-58
Primary clutch holder
YS-01880-A
1-18
SPECIAL TOOLS
Reference
pages
Compression gauge 90890-03081
5-1
90890-03081
Engine compression tester
YU-33223
YU-33223
Vacuum gauge 3-9

90890-03094
Vacuummate
YU-44456
YU-44456
Pocket tester 1-15, 1-15, 8-89,

90890-03112 8-90, 8-90, 8-91,
Analog pocket tester 8-94, 8-97, 8-97,
YU-03112-C 8-98, 8-99, 8-99,
8-99, 8-100,
8-100, 8-102,
8-102, 8-103,
8-104, 8-104,
8-105, 8-106,
8-106, 8-107
Oil pressure gauge set 3-28
90890-03120
Oil pressure adapter B 3-28

90890-03124
Pressure gauge 3-28, 7-5

90890-03153
Pressure gauge
YU-03153
1-19
SPECIAL TOOLS
Reference
pages
Carburetor angle driver 2 3-10
90890-03173
Thickness gauge 4-30, 5-21, 5-64

90890-03180
Feeler gauge set
YU-26900-9
Fuel pressure adapter 7-5

90890-03181
Fuel pressure adapter
YM-03181
Digital circuit tester (CD–731a) 5-38, 8-101,

90890-03189 90890-03189 8-105
Model 88 Multimeter with tachometer
YU-A1927
YU-A1927
Test harness S– pressure sensor (3P) 8-105

90890-03207
Test harness S– pressure sensor (3P)
YU-03207
Test harness– speed sensor (3P) 8-103

90890-03208
Test harness– speed sensor (3P)
YU-03208
Test harness– lean angle sensor (6P) 8-100

90890-03209
Test harness– lean angle sensor (6P)
YU-03209
Tension gauge 3-21

90890-03226
1-20
SPECIAL TOOLS
Reference
pages
Yamaha diagnostic tool (US) 8-34
90890-03234
Valve spring compressor 5-24, 5-29

90890-04019
Valve spring compressor
YM-04019
Middle driven shaft bearing driver 6-15

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
Universal clutch holder 5-63, 5-66

90890-04086
Universal clutch holder
YM-91042
Valve lapper 90890-04101

3-6
90890-04101
Valve lapping tool
YM-A8998
YM-A8998
Valve guide remover (ø4) 5-26

90890-04111
Valve guide remover (4.0 mm)
YM-04111
Valve guide installer (ø4) 5-26

90890-04112
Valve guide installer (4.0 mm)
YM-04112
1-21
SPECIAL TOOLS
Reference
pages
Valve guide reamer (ø4) 5-26
90890-04113
Valve guide reamer (4.0 mm)
YM-04113
Valve spring compressor attachment 5-24, 5-29

90890-04114
Valve spring compressor adapter 19.5 mm
YM-04114
Mechanical seal installer 6-15

90890-04132
Water pump seal installer
YM-33221-A
Sheave spring compressor 5-46, 5-49

90890-04134
Sheave spring compressor
YM-04134
Sheave fixed block 5-46, 5-49

90890-04135
Sheave fixed bracket
YM-04135
1-22
SPECIAL TOOLS
Reference
pages
Plane bearing installer 5-78, 5-82
90890-04139
Ignition checker 8-100

90890-06754
Oppama pet–4000 spark checker
YM-34487
Digital tachometer 3-8, 3-9

90890-06760
Digital tachometer
YU-39951-B
Yamaha bond No. 1215 5-18, 5-49, 5-58,

90890-85505 5-74
(Three bond No.1215®)
1-23
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-7
ELECTRICAL SPECIFICATIONS .................................................................2-10
TIGHTENING TORQUES .............................................................................. 2-12

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-12
ENGINE TIGHTENING TORQUES......................................................... 2-13
CHASSIS TIGHTENING TORQUES.......................................................2-16
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-20

ENGINE................................................................................................... 2-20
CHASSIS.................................................................................................2-22
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-23

ENGINE OIL LUBRICATION CHART .....................................................2-23
LUBRICATION DIAGRAMS .................................................................... 2-25
COOLING SYSTEM DIAGRAMS .................................................................. 2-33
CABLE ROUTING ......................................................................................... 2-37

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model 2PWD
Dimensions
Overall length 2200 mm (86.6 in)
Overall width 775 mm (30.5 in)
Overall height (Lo/Hi) 1420/1475 mm (55.9/58.1 in)
Seat height 800 mm (31.5 in)
Wheelbase 1580 mm (62.2 in)
Ground clearance 125 mm (4.92 in)
Minimum turning radius 2800 mm (110.2 in)
Weight
Curb weight 220 kg (485 lb)
Maximum load 195 kg (430 lb)
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 530 cm³
Cylinder arrangement Inline 2-cylinder
Bore × stroke 68.0 × 73.0 mm (2.68 × 2.87 in)
Compression ratio 10.9 : 1
Standard compression pressure (at sea level) 1950 kPa/470 r/min (19.5 kgf/cm²/470 r/min,
277.3 psi/470 r/min)
Minimum–maximum 1697–2184 kPa/470 r/min (17.0–21.8
kgf/cm²/470 r/min, 241.4–310.6 psi/470 r/min)
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline (Gasohol (E10)
acceptable)
Fuel tank capacity 15.0 L (3.96 US gal, 3.30 Imp.gal)
Fuel reserve amount 3.0 L (0.79 US gal, 0.66 Imp.gal)
Engine oil
Lubrication system Dry sump
Recommended brand YAMALUBE
Type SAE 10W-30 or 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Quantity (disassembled) 3.50 L (3.70 US qt, 3.08 Imp.qt)
Without oil filter cartridge replacement 2.70 L (2.85 US qt, 2.38 Imp.qt)
With oil filter cartridge replacement 2.90 L (3.07 US qt, 2.55 Imp.qt)
Oil filter
Oil filter type Cartridge
Oil pump
Oil pump type Trochoid
Oil pressure 120.0 kPa/1200 r/min@70 °C (17.4 psi/1200
r/min@158 °F)
Bypass valve opening pressure 78.0–118.0 kPa (0.78–1.18 kgf/cm², 11.3–17.1
psi)
Relief valve operating pressure 450.0–550.0 kPa (4.50–5.50 kgf/cm², 65.3–79.8
psi)
Pressure check location MAIN GALLERY
Cooling system
Coolant quantity
Radiator (including all routes) 1.50 L (1.59 US qt, 1.32 Imp.qt)
Coolant reservoir (up to the maximum level mark) 0.27 L (0.29 US qt, 0.24 Imp.qt)
Radiator cap opening pressure 107.9–137.3 kPa (1.08–1.37 kgf/cm², 15.6–19.9
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)
Radiator core
Width 329.0 mm (12.95 in)
Height 149.8 mm (5.90 in)
Depth 24.0 mm (0.94 in)
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio 23/19 (1.210)
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug(s)
Manufacturer/model NGK/CR7E
Spark plug gap 0.7–0.8 mm (0.028–0.031 in)
Cylinder head
Combustion chamber volume 16.93–17.73 cm³ (1.03–1.08 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (left)
Camshaft cap inside diameter 23.000–23.021 mm (0.9055–0.9063 in)
Camshaft journal diameter 22.959–22.972 mm (0.9039–0.9044 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) 32.490–32.590 mm (1.2791–1.2831 in)
Limit 32.390 mm (1.2752 in)
Base circle diameter (Intake) 24.950–25.050 mm (0.9823–0.9862 in)
Limit 24.850 mm (0.9783 in)
Lobe height (Exhaust) 32.690–32.790 mm (1.2870–1.2909 in)
Limit 32.590 mm (1.2831 in)
Base circle diameter (Exhaust) 24.950–25.050 mm (0.9823–0.9862 in)
Limit 24.850 mm (0.9783 in)
Camshaft runout limit 0.030 mm (0.0012 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.15–0.22 mm (0.0059–0.0087 in)
Exhaust 0.25–0.32 mm (0.0098–0.0126 in)
Valve dimensions
Valve head diameter (intake) 25.90–26.10 mm (1.0197–1.0276 in)
Valve head diameter (exhaust) 21.90–22.10 mm (0.8622–0.8701 in)
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) 0.90–1.10 mm (0.0354–0.0433 in)
Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in)
Limit 3.945 mm (0.1553 in)
Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in)
Limit 3.930 mm (0.1547 in)
Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in)
Limit 4.050 mm (0.1594 in)
2-3
Valve guide inside diameter (exhaust) 4.000–4.012 mm (0.1575–0.1580 in)

Limit 4.050 mm (0.1594 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 0.040 mm (0.0016 in)
Valve spring
Free length (intake) 36.73 mm (1.45 in)
Limit 34.89 mm (1.37 in)
Free length (exhaust) 36.73 mm (1.45 in)
Limit 34.89 mm (1.37 in)
Installed length (intake) 30.60 mm (1.20 in)
Installed length (exhaust) 30.60 mm (1.20 in)
Spring rate K1 (intake) 16.95 N/mm (1.73 kgf/mm, 96.78 lbf/in)
Spring rate K2 (intake) 23.19 N/mm (2.36 kgf/mm, 132.41 lbf/in)
Spring rate K1 (exhaust) 16.95 N/mm (1.73 kgf/mm, 96.78 lbf/in)
Spring rate K2 (exhaust) 23.19 N/mm (2.36 kgf/mm, 132.41 lbf/in)
Installed compression spring force (intake) 96.60–111.20 N (9.85–11.34 kgf, 21.72–25.00
lbf)
Installed compression spring force (exhaust) 96.60–111.20 N (9.85–11.34 kgf, 21.72–25.00
lbf)
Spring tilt (intake) 1.6 mm (0.06 in)
Spring tilt (exhaust) 1.6 mm (0.06 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder
Bore 68.000–68.010 mm (2.6772–2.6776 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.010–0.035 mm (0.0004–0.0014 in)
Diameter 67.975–67.990 mm (2.6762–2.6768 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Offset 0.25 mm (0.0098 in)
Offset direction Intake side
Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in)
Limit 16.043 mm (0.6316 in)
Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in)
Limit 15.971 mm (0.6288 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.022 mm (0.0001–0.0009 in)
Piston ring
Top ring
Ring type Barrel
End gap (installed) 0.25–0.35 mm (0.0098–0.0138 in)
Limit 0.60 mm (0.0236 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Limit 0.100 mm (0.0039 in)
2-4
2nd ring
Ring type Taper
Limit 0.75 mm (0.0295 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Limit 0.100 mm (0.0039 in)
Oil ring
Connecting rod
Oil clearance 0.036–0.060 mm (0.0014–0.0024 in)
Bearing color code 1. Blue 2. Black 3. Brown 4. Green
Small end inside diameter 16.005–16.018 mm (0.6301–0.6306 in)
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Big end side clearance 0.160–0.262 mm (0.0063–0.0103 in)
Big end radial clearance 0.040–0.064 mm (0.0016–0.0025 in)
Crankshaft journal diameter 54.984-55.000 mm (2.1647-2.1654 in)
Journal oil clearance 0.040–0.087 mm (0.0016–0.0034 in)
Bearing color code 0. White 1.Blue 2.Black 3.Brown 4.Green
5.Yellow
Balancer
Balancer drive method Piston
Clutch
Clutch type Wet, multiple-disc automatic
Clutch release method Automatic
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.82 mm (0.111 in)
Plate quantity 6 pcs
Clutch plate 1 thickness 1.30–1.50 mm (0.051–0.059 in)
Clutch plate 2 thickness 1.80–2.00 mm (0.071–0.079 in)
Clutch spring free length 31.90 mm (1.26 in)
Limit 24.80 mm (0.98 in)
Spring quantity 6 pcs
Clutch damper spring height 3.50 mm (0.14 in)
Minimum height 3.10 mm (0.12 in)
Clutch spring plate height 4.70 mm (0.19 in)
Minimum height 4.40 mm (0.17 in)
Clutch-in revolution 1650–2250 r/min
Clutch-stall revolution 3500–4500 r/min
V-belt
V-belt width 32.9 mm (1.30 in)
Limit 31.4 mm (1.24 in)
2-5
Transmission
Transmission type V-belt automatic
Primary reduction ratio 1.000
Secondary reduction ratio 6.034 (52/32 x 36/22 x 59/26)
Final drive Belt
Gear ratio 2.041–0.758 : 1
Weight outside diameter 25.0 mm (0.98 in)
Limit 24.5 mm (0.96 in)
Drive axle runout limit 0.10 mm (0.0039 in)
Secondary shaft runout limit 0.12 mm (0.0047 in)
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
Maximum consumption amperage 1.7 A
Fuel injector
Model/quantity 0660/2
Resistance 12.0 Ω
Throttle body
Type/quantity ACW34/1
ID mark 59C1 00
Throttle position sensor

Resistance 2.64–6.16 kΩ
Output voltage (at idle) 0.63–0.73 V
Fuel injection sensor

Crankshaft position sensor resistance 284–372 Ω
Intake air pressure sensor output voltage 3.57–3.71 [email protected] kPa (3.57–3.71 [email protected]
kgf/cm², 3.57–3.71 [email protected] psi)
Intake air temperature sensor resistance 5400–6600 Ω@0 °C (5400–6600 Ω@32 °F)
Intake air temperature sensor resistance 290–390 Ω@80 °C (290–390 Ω@176 °F)
Coolant temperature sensor resistance 2320–2590 Ω@20 °C (2320–2590 Ω@68 °F)
Coolant temperature sensor resistance 310–329 Ω@80 °C (310–329 Ω@176 °F)
Idling condition
Engine idling speed 1100–1300 r/min
Intake vacuum 29.3–31.9 kPa (220–239 mmHg, 8.7–9.4 inHg)
Water temperature 85.0–105.0 °C (185.00–221.00 °F)
Oil temperature 60.0–80.0 °C (140.00–176.00 °F)
Fuel line pressure at idling 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-6
CHASSIS SPECIFICATIONS
EAS20015
Chassis
Frame type Diamond
Caster angle 25.00 °
Trail 92 mm (3.6 in)
Front wheel
Wheel type Cast wheel
Rim size 15M/C x MT3.50
Rim material Aluminum
Wheel travel 120 mm (4.7 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Rear wheel
Wheel type Cast wheel
Rim size 15M/C x MT5.00
Rim material Aluminum
Wheel travel 116 mm (4.6 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Front tire
Type Tubeless
Size 120/70R15 M/C 56H
Manufacturer/model DUNLOP/GPR-100F
Wear limit (front) 1.0 mm (0.04 in)
Rear tire
Type Tubeless
Size 160/60R15 M/C 67H
Manufacturer/model DUNLOP/GPR-100
Wear limit (rear) 1.0 mm (0.04 in)
Tire air pressure (measured on cold tires)

Loading condition 0–90 kg (0–198 lb)
Front 225 kPa (2.25 kgf/cm², 33 psi, 2.25 bar)
Rear 250 kPa (2.50 kgf/cm², 36 psi, 2.50 bar)
Loading condition 90–195 kg (198–430 lb)
Front 225 kPa (2.25 kgf/cm², 33 psi, 2.25 bar)
Rear 280 kPa (2.80 kgf/cm², 41 psi, 2.80 bar)
Front brake
Type Dual disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 267.0 × 4.0 mm (10.51 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
2-7
Brake pad lining thickness (inner) 4.0 mm (0.16 in)

Brake pad lining thickness (outer) 4.0 mm (0.16 in)
Master cylinder inside diameter 15.00 mm (0.59 in)
Caliper cylinder inside diameter 30.23 mm (1.19 in)
Specified brake fluid DOT 4
Rear brake
Type Single disc brake
Operation Left hand operation
Rear disc brake
Disc outside diameter × thickness 282.0 × 5.0 mm (11.10 × 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 (inner) 8.0 mm (0.31 in)
Brake pad lining thickness (outer) 8.0 mm (0.31 in)
Master cylinder inside diameter 14.0 mm (0.55 in)
Specified brake fluid DOT 4
Rear brake lock

Rear brake lock pad
Brake pad lining thickness 3.0 mm (0.12 in)
Steering
Center to lock angle (left) 38.5 °
Center to lock angle (right) 38.5 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 120.0 mm (4.72 in)
Fork spring free length 295.1 mm (11.62 in)
Limit 289.2 mm (11.39 in)
Collar length 100.0 mm (3.94 in)
Spring rate K1 16.27 N/mm (1.66 kgf/mm, 92.94 lbf/in)
Spring stroke K1 0.0–120.0 mm (0.00–4.72 in)
Inner tube outer diameter 41.0 mm (1.61 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Suspension oil 01 or equivalent
Quantity (left) 434.0 cm³ (14.67 US oz, 15.31 Imp.oz)
Quantity (right) 426.0 cm³ (14.40 US oz, 15.03 Imp.oz)
Level (left) 122 mm (4.8 in)
Level (right) 124 mm (4.9 in)
Rear suspension
Type Swingarm
Spring/shock absorber type Coil spring/gas-oil damper
2-8
Rear shock absorber assembly travel 43.0 mm (1.69 in)

Spring installed length 180.0 mm (7.09 in)
Enclosed gas/air pressure (STD) 4900 kPa (49.0 kgf/cm², 696.9 psi)
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 1.0 mm (0.04 in)
Drive belt
Drive belt slack 0.2 mm (0.01 in)
2-9
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0 °/1200 r/min
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 1.87–2.53 Ω
Secondary coil resistance 12.00–18.00 kΩ
Spark plug cap

Material Resin
Resistance 7.50–12.50 kΩ
Lean angle sensor output voltage

Less than 65° 0.4–1.4 V
More than 65° 3.7–4.4 V
AC magneto
Standard output 14.0 V, 350 W@5000 r/min
Stator coil resistance 0.224–0.336 Ω (W-W)
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.1–14.9 V
Rectifier capacity (DC) 22.0 A
Battery
Model YTZ12S
Voltage, capacity 12 V, 11.0 Ah
Specific gravity 1.310
Manufacturer GS YUASA
Ten hour rate charging current 1.10 A
Bulb voltage, wattage × quantity

Headlight LED
Auxiliary light LED
Tail/brake light LED
Front turn signal/position light 12 V, 5.0 W/21.0 W × 2
Rear turn signal light 12 V, 21.0 W × 2
License plate light 12 V, 5.0 W × 1
Meter lighting LED
Indicator light
Turn signal indicator light LED
High beam indicator light LED
Engine trouble warning light LED
2-10
Smart key system indicator light LED
Starter motor
Power output 0.70 kW
Armature coil resistance 0.0100–0.0200 Ω
Brush overall length 12.0 mm (0.47 in)
Limit 6.50 mm (0.26 in)
Brush spring force 6.02–6.51 N (614–664 gf, 21.69–23.45 oz)
Mica undercut (depth) 0.70 mm (0.03 in)
Starter relay
Amperage 180.0 A
Coil resistance 4.18–4.62 Ω
Horn
Horn type Plane
Quantity 1
Maximum amperage 3.0 A
Coil resistance 1.06–1.11 Ω
Turn signal/hazard relay

Built-in, self-canceling device No
Fuel sender unit

Sender unit resistance (full) 4.0–10.0 Ω
Sender unit resistance (empty) 93.0–100.0 Ω
Fuses
Main fuse 40.0 A
Headlight fuse 10.0 A
Signaling system fuse 15.0 A
Ignition fuse 7.5 A
Radiator fan motor fuse 15.0 A
Parking lighting fuse 10.0 A
Fuel injection system fuse 7.5 A
Terminal fuse 1 5.0 A
Backup fuse 7.5 A
Spare fuse 40.0 A
Spare fuse 5.0 A
Spare fuse 15.0 A
Spare fuse 10.0 A
Spare fuse 7.5 A
2-11
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30015
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening torques

A (nut) B (bolt)
Nm m·kgf ft·lbf
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-12
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Camshaft cap bolt M6 12 10 Nm (1.0 m·kgf, 7.2 ft·lbf) E
Engine oil check bolt M8 1 15 Nm (1.5 m·kgf, 11 ft·lbf)

Exhaust pipe stud bolt M8 4 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder head nut M9 6 See TIP. E
Cylinder head bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Cylinder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Spark plug M10 2 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head cover bolt M6 10 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner rod access-
M20 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
ing plug
Cylinder stud bolt M9 6 13 Nm (1.3 m·kgf, 9.4 ft·lbf) See TIP.
Connecting rod nut M7 4 See TIP. M
Balancer connecting rod nut M9 2 60 Nm (6.0 m·kgf, 43 ft·lbf) M
Balancer cylinder bolt M10 4 58 Nm (5.8 m·kgf, 42 ft·lbf) LT
Generator rotor nut M18 1 See TIP. E
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Timing chain guide bolt (intake side
M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
bolt)
Water pump housing cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump assembly bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump inlet pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Water pump outlet pipe M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Thermostat cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M12 1 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
Coolant reservoir bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Oil pump bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil strainer bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Oil filter cartridge union bolt M20 1 63 Nm (6.3 m·kgf, 46 ft·lbf)

Oil filter cartridge M20 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Oil delivery pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Intake manifold bolt M6 4 14 Nm (1.4 m·kgf, 10 ft·lbf)

Intake manifold joint clamp M5 2 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Throttle body joint clamp M5 2 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter case bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Exhaust assembly nut (front) M8 4 20 Nm (2.0 m·kgf, 14 ft·lbf)
Exhaust assembly nut (rear) M10 1 31 Nm (3.1 m·kgf, 22 ft·lbf)
Muffler protector bolt M6 5 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Muffler end bolt M6 5 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
2-13
TIGHTENING TORQUES
Thread
size
Muffler end bracket bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
L = 35 mm
Crankcase bolt M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
(1.38 in)
L = 50 mm
Crankcase bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
(1.97 in)
Crankcase bolt M8 8 24 Nm (2.4 m·kgf, 17 ft·lbf)
Engine oil pressure check point plug M20 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Engine oil check bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Engine oil drain bolt M14 1 43 Nm (4.3 m·kgf, 31 ft·lbf)
Oil tank bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stator coil base screw M6 3 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LT
Timing mark accessing plug M16 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf)

Generator cover bolt M6 19 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Outer V-belt case bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Outer V-belt case bolt M8 6 24 Nm (2.4 m·kgf, 17 ft·lbf)
Inner V-belt case plate bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
L = 25 mm
Inner V-belt case bolt M8 1 18 Nm (1.8 m·kgf, 13 ft·lbf)
(0.98 in)
Inner V-belt case bolt M8 1 24 Nm (2.4 m·kgf, 17 ft·lbf)
Outer V-belt case nut M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft end access cover screw M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
V-belt case air filter case screw M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Generator cover protector screw M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
V-belt case air filter case cover
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
screw
Generator cover protector cover
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
screw
V-belt case air filter element bolt (left
M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
side)
V-belt case air duct joint clamp M4 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
V-belt case air filter element joint
M4 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
clamp
Starter clutch bolt M8 3 30 Nm (3.0 m·kgf, 22 ft·lbf) LT
Clutch assembly nut M16 1 65 Nm (6.5 m·kgf, 47 ft·lbf)

Clutch boss nut M48 1 130 Nm (13 m·kgf, 94 ft·lbf)
Bearing housing bolt M8 3 30 Nm (3.0 m·kgf, 22 ft·lbf)
YAMAHA
GREASE
“G” (Shell
Primary sheave nut M20 1 160 Nm (16 m·kgf, 116 ft·lbf)
Sunlight
Grease
3®)
2-14
TIGHTENING TORQUES
Thread
size
YAMAHA
GREASE
Secondary sheave nut M18 1 90 Nm (9.0 m·kgf, 65 ft·lbf) “H” (Poly-
urea
Grease®)
Secondary sheave spring seat nut M36 1 90 Nm (9.0 m·kgf, 65 ft·lbf)
V-belt case bearing retainer screw M6 1 11 Nm (1.1 m·kgf, 8.0 ft·lbf) LT
Secondary shaft bearing retainer

M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf) LT
bolt
Stator coil bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Crankshaft position sensor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Starter motor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
O2 sensor M18 1 45 Nm (4.5 m·kgf, 33 ft·lbf)
Coolant temperature sensor M12 1 18 Nm (1.8 m·kgf, 13 ft·lbf)
TIP
Cylinder head nut
1. Tighten the nuts to 10 Nm (1.0 m·kgf, 7.2 ft·lbf).
2. Tighten the nuts to 20 Nm (2.0 m·kgf, 14 ft·lbf).
3. Tighten the nuts further to reach the specified angle 120°.
TIP
Cylinder head stud bolt
The tightening torque is for reference only. Install the cylinder head stud bolt so that it protrudes 150.2–
152.2 mm (5.91–5.99 in) from the crankcase.
TIP
Connecting rod nut
Tighten the connecting rod nuts to 16 Nm (1.6 m·kgf, 12 ft·lbf), and then tighten them further to reach
the specified angle 90°.
TIP
Generator rotor nut
Tighten the generator rotor nuts to 65 Nm (6.5 m·kgf, 47 ft·lbf), and then tighten them further to reach
the specified angle 120°.
Cylinder head tightening sequence:
2-15
TIGHTENING TORQUES
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting nut (front upper
M12 1 88 Nm (8.8 m·kgf, 64 ft·lbf)
side)
Engine mounting bolt (front right low-
M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf) LT
er side)
Engine mounting bolt (front left lower
M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf) LT
side)
Engine mounting nut (rear side) M12 1 105 Nm (10.5 m·kgf, 76 ft·lbf)
Rear frame bolt M12 2 83 Nm (8.3 m·kgf, 60 ft·lbf) LT
Windshield screw M5 4 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)

Windshield bracket bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Windshield inner panel bolt (top) M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Front cowling bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front cowling bolt (center) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rearview mirror bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Front cowling stay bolt M10 2 48 Nm (4.8 m·kgf, 35 ft·lbf)
Front turn signal/position light bolt M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Headlight bolt M6 4 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Radiator cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Side panel bolt M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Side cover bolt (front side) M6 4 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Side cover bolt (rear side) M6 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Center cover bolt M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Bottom side cowling bolt (top) M5 6 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Bottom side cowling bolt (front side) M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Bottom side cowling bolt (rear side) M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Side cover moulding screw M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Footboard bolt M6 6 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Footboard bolt (rear upper of right
M6 1 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) LT
side)
Inner panel center cover screw M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Inner panel cover screw (left side) M5 4 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Auxiliary DC jack assembly screw M5 3 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Battery box bolt (lower) M8 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
Battery box bolt (upper and center) M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Battery box bolt (air cleaner bracket) M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Meter panel assembly bolt M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Meter assembly bolt M5 5 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Seat lock assembly bolt M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rollover valve stay bolt M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Leg shield bolt M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Control switch assembly screw M5 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
2-16
TIGHTENING TORQUES
Thread
size
Seat nut M6 4 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank cover bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Fuel tank cover screw (top) M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Fuel tank cover screw (side) M5 6 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Grab bar bolt M8 4 16 Nm (1.6 m·kgf, 12 ft·lbf)
Seat hinge assembly bolt M8 4 16 Nm (1.6 m·kgf, 12 ft·lbf)
Rear cowling assembly bolt M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Tail/brake light bracket screw M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear turn signal light screw M5 6 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rear cowling screw M5 6 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Storage box bolt M6 10 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Front brake hose/lead holder bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Speed sensor bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front brake caliper bolt M10 4 35 Nm (3.5 m·kgf, 25 ft·lbf)
Front wheel axle pinch bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Front wheel axle M14 1 91 Nm (9.1 m·kgf, 66 ft·lbf)
Front brake disc bolt M8 10 23 Nm (2.3 m·kgf, 17 ft·lbf) LT
Front fender bolt (hexagon socket

M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
bolt)
Speed sensor rotor bolt M5 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT
Front wheel air valve nut M8 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Front wheel air valve locknut M8 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Rear brake caliper bolt M10 2 27 Nm (2.7 m·kgf, 20 ft·lbf)
Rear brake lock caliper bolt M8 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Drive belt guard bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Drive belt adjusting locknut M8 2 16 Nm (1.6 m·kgf, 12 ft·lbf)
Rear wheel axle nut M24 1 160 Nm (16 m·kgf, 116 ft·lbf)
Rear brake disc bolt M8 5 30 Nm (3.0 m·kgf, 22 ft·lbf) LT
Drive belt guide bolt M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Rear wheel pulley bolt M10 5 64 Nm (6.4 m·kgf, 46 ft·lbf) LT
Centerstand bracket nut M10 4 55 Nm (5.5 m·kgf, 40 ft·lbf)

Centerstand nut M10 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Sidestand nut M10 1 65 Nm (6.5 m·kgf, 47 ft·lbf)
Sidestand bolt M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Footboard bracket bolt (front side
M8 1 23 Nm (2.3 m·kgf, 17 ft·lbf)
left)
Passenger footrest bracket bolt M8 4 30 Nm (3.0 m·kgf, 22 ft·lbf)
Reflector nut (rear side) M5 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
License plate bracket nut M6 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Handlebar switch screw (right) M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
2-17
TIGHTENING TORQUES
Thread
size
Handlebar switch screw (left) M5 1 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Front brake caliper bleed screw M8 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Brake master cylinder reservoir cap
M4 4 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
screw
Brake lever screw M6 2 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
Brake hose union bolt (master cylin-
M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
der side)
Brake master cylinder holder bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake caliper bleed screw M7 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake hose union bolt M10 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Rear brake lock adjusting nut M8 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Lower handlebar cover screw M5 4 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Grip end M16 2 26 Nm (2.6 m·kgf, 19 ft·lbf)
Rear brake lock caliper piston lock- Left-hand
M16 1 22 Nm (2.2 m·kgf, 16 ft·lbf)
nut thread.
Throttle cable bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Brake hose union bolt (Brake joint
M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
side)
Upper handlebar holder bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Lower handlebar holder nut M10 2 34 Nm (3.4 m·kgf, 25 ft·lbf)
Rear brake lock caliper bracket bolt M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
Rear brake lock holder bolt M5 2 6 Nm (0.6 m·kgf, 4.3 ft·lbf)

Throttle cable adjusting locknut M8 1 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Rear brake lock caliper slide pin bolt M8 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Upper bracket pinch bolt M8 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Horn nut M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Horn lead coupler nut M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Horn bracket bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf) LT
Damper rod assembly bolt M10 2 23 Nm (2.3 m·kgf, 17 ft·lbf) LT
Damper rod locknut M10 2 15 Nm (1.5 m·kgf, 11 ft·lbf)

Steering stem nut M28 1 115 Nm (11.5 m·kgf, 83 ft·lbf)
Front fork cap bolt M46 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Lower ring nut M30 1 See TIP.
Lower bracket pinch bolt M8 4 23 Nm (2.3 m·kgf, 17 ft·lbf)
Steering lock unit screw M8 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Rear brake hose holder bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake hose holder bolt (rear left
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
footrest)
Rear brake lock cable holder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear shock absorber assembly bolt
M16 1 68 Nm (6.8 m·kgf, 49 ft·lbf) LS
(front side)
Rear shock absorber assembly nut
M12 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
(rear side)
2-18
TIGHTENING TORQUES
Thread
size
L = 25 mm
(0.98 in), L
Drive pulley assembly bolt M10 5 48 Nm (4.8 m·kgf, 35 ft·lbf)
= 90 mm
(3.54 in)
Pivot shaft M22 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft nut M22 1 100 Nm (10 m·kgf, 72 ft·lbf)
Swingarm bolt M10 3 40 Nm (4.0 m·kgf, 29 ft·lbf)
Swingarm cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Drive pulley cover bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator bracket bolt M8 4 30 Nm (3.0 m·kgf, 22 ft·lbf)
Fuel tank bracket bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Fuel tank bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Fuel tank nut M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Fuel pump bolt M5 6 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Fuel rail screw M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Canister bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Canister bracket nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle position sensor screw M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
2-19
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20018

EAS30018
ENGINE
Lubrication point Lubricant
Oil seal lips LS
O-rings LS
Coolant hose insertion part Water or silicone fluid

Bearings and bushings E
Cylinder head nut seats and washers E
Camshaft cap bolt seats E
Crankshaft big ends E
Piston surfaces E
Piston pins E
Crankshaft journals E
Balancer piston surface E
Balancer piston pin E
Generator rotor nut E
Camshaft lobes and journals (intake and exhaust) M
Valve stem seals (intake and exhaust) Silicone fluid

Valve stems and stem ends (intake and exhaust) M
Valve lifter outer surface (intake and exhaust) E
Water pump impeller shaft M
O-ring (coolant pipe)

LS or silicone flu-
id
Oil pump shaft and rotors (inner and outer) E
Oil pump gaskets LS
V-belt case air filter case screw bushing Water

V-belt case air filter case cover screw bushing Water
Crankshaft end access cover screw bushing Water or silicone fluid
Generator cover protector cover screw bushing Water or silicone fluid
Generator cover protector screw bushing Water or silicone fluid
Starter clutch idle gear inner surface E
Starter clutch idle gear shaft E
Starter clutch and starter clutch gear E
Primary driven gear spline and main axle spline E
1st pinion gear spline and main axle spline E
1st wheel gear spline and drive axle spline E
YAMAHA GREASE “G”

Primary sheave spacer and o-ring (Shell Sunlight Grease
3®)
2-20

YAMAHA GREASE “G”
Primary sheave nut (Shell Sunlight Grease
3®)
YAMAHA GREASE “H”
Secondary sheave nut
(Polyurea Grease®)
Secondary shaft right end bearing LS
Pivot shaft taper roller bearing LS
Yamaha bond No.1215

Crankcase mating surface
Yamaha bond No.1215
Inner V-belt case seal mating surface
Yamaha bond No.1215
Crankshaft position sensor/stator lead grommet
2-21
EAS30019
CHASSIS
Steering bearings (upper and lower) LS
Upper bearing cover seal lip and lower bearing dust seal lip LS
Tube guide (throttle grip) inner surface and throttle cables LS
Rear brake lock cable end (lever end) YAMAHA GREASE “F”
Brake lever pivoting point and metal-to-metal moving parts S
YAMAHA GREASE “J”

Drive axle spline (Shell Alvania EP
Grease R0®)
YAMAHA GREASE “J”
Drive pulley assembly pivoting point (Shell Alvania EP
Grease R0®)
Rear shock absorber assembly bearing inner surface LS
Rear shock absorber assembly spacer and collar LS
Pivot shaft oil seal and collar LS
Rear shock absorber assembly bolt (front side) seats LS
Seat lock metal-to-metal moving parts LS
Seat hinge metal-to-metal moving parts LS
Seat lock cable LS
Passenger footrest pivoting point LS
Centerstand pivoting point and metal-to-metal moving parts LS
Centerstand hook and spring contact point LS
Sidestand pivoting point and metal-to-metal moving parts LS
Sidestand hook and spring contact point LS
Front wheel oil seal lip LS
Rear wheel oil seal lip LS
Fuel lid pivoting point LS
2-22
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20019

EAS30020
ENGINE OIL LUBRICATION CHART
2-23
1. Intake camshaft
2. Exhaust camshaft
3. Timing chain tensioner
4. Connecting rod
5. To piston
6. Starter clutch gear
7. Crankshaft
8. Balancer connecting rod
9. To balancer piston
10. Oil pipe
11. Check valve
12. Relief valve
13. Oil filter
14. Oil cooler
15. Oil tank
16. Oil strainer
17. Feed pump
18. Delivery pipe
19. Scavenge pump
20. Oil strainer
21. To starter idle gear
22. Clutch
23. Secondary shaft
24. To transmission
2-24
EAS30021
LUBRICATION DIAGRAMS
2-25
1. Exhaust camshaft
2. Intake camshaft
3. Delivery pipe
4. Oil pump assembly
5. Scavenge pump
6. Feed pump
7. Oil pipe
8. Oil cooler
9. Oil filter
10. Relief valve
11. Check valve
2-26
2-27
1. Crankshaft
2. Secondary shaft
3. Drive axle
4. Clutch
5. Generator cover
2-28
2-29
1. Oil strainer
2. Intake camshaft
3. Exhaust camshaft
2-30
2-31
1. Generator cover
2. Oil strainer
3. Main gallery
4. Crankcase (right)
A. Forward
2-32
COOLING SYSTEM DIAGRAMS
EAS20020
2-33
1. Radiator cap
2. Radiator filler hose
3. Radiator inlet hose
4. Cooling system air bleed hose
5. Coolant pipe
6. Thermostat outlet hose
7. Oil cooler outlet hose
8. Thermostat
9. Oil cooler
10. Coolant hose
11. Water pump inlet pipe
12. Water pump outlet pipe
13. Oil cooler inlet hose
14. Radiator outlet hose
15. Coolant reservoir hose
16. Fast idle plunger outlet coolant hose
17. Coolant reservoir
18. Coolant reservoir breather hose
19. Radiator
20. Water pump
2-34
2-35
1. Thermostat
2. Thermostat outlet hose
3. Cooling system air bleed hose
4. Radiator cap
5. Radiator filler pipe
6. Radiator filler hose
7. Coolant reservoir hose
8. Radiator
9. Radiator inlet hose
10. Coolant pipe
11. Oil cooler
12. Oil cooler outlet hose
2-36
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (top side, front side and left side view)
4 5
2 B 3 5
A
C 4 L
1
7 E
7 F
6
5 G 1 H
4 I
K 2
8 J
1
9 M
8
7
2-37
CABLE ROUTING
1. Rear brake hose

2. Speed sensor lead
3. Horn lead
4. Left handlebar switch lead
5. Right handlebar switch lead
6. Front brake hose
7. Throttle cables
8. Rear brake lock cable
9. Brake light switch connectors
A. Fasten the rear brake hose with the holder. Face
the catch of the holder downward.
B. Fasten the front brake hose, speed sensor lead,
and horn lead with the holder. Face the catch of the
holder to the left.
C. Fasten the front brake hose with the holder. Face
the catch of the holder downward.
D. Fasten the rear brake hose with the holder.
E. Route the throttle cables over the front brake hose.
F. Route the throttle cables to the rear of the
handlebar switch leads and to the front of the rear
brake lock cable.
G. Route the right handlebar switch lead to the front
of the throttle cables, and then route it through the
opening in the lower handlebar holder toward the
front of the vehicle.
H. Route the rear brake hose to the front of the
handlebar, and then route it through the opening in
the lower handlebar holder toward the rear of the
vehicle.
I. Route the left handlebar switch lead to the front of
the rear brake lock cable, and then route it through
the opening in the lower handlebar holder toward
the front of the vehicle.
J. Route the rear brake lock cable to the rear of the
handlebar switch leads and throttle cables.
K. Route the speed sensor lead over the handlebar
switch leads.
L. Face the catch of the holder to the right.
M. Install the brake light switch connectors so that the
leads are routed inward.
2-38
CABLE ROUTING
Front brake (left side and front view)
2
1 3
I
1
A
2 3
H
B 2
K
1
M
N 2
L
D
O 1
F E C
2-39
CABLE ROUTING
1. Front brake hose

2. Horn lead
A. Make sure that there is no slack in the horn lead
and speed sensor lead in the area shown in the
illustration.
B. Align the holder with the paint mark on the front
brake hose.
C. Route the speed sensor lead to the front of the
front brake hose and horn lead.
D. 20–30 mm (0.79–1.18 in)
E. Fasten the front brake hose and speed sensor lead
with the holder at the location shown in the
illustration. Align the holder with the end of the
protective sleeve of the speed sensor lead. Make
sure that the speed sensor lead is routed within the
range to the left and to the rear of the front brake
hose.
F. Pass the speed sensor lead through the hole in the
lower bracket cover.
G. Fasten the grommet on the speed sensor lead with
the holder.
H. Forward
I. Position the holder 0–5 mm (0–0.20 in) from the
bend in the brake hose.
J. 0–5 mm (0–0.20 in)
K. Face the catch of the holder rearward.
L. Route the horn lead under the brake hose between
the holders. The lead may be routed as shown in
either illustration.
M. Position the white tape on the horn lead between
the flanges of the brake hose grommet.
N. White tape
O. Area between the flanges of the brake hose
grommet
2-40
CABLE ROUTING
Frame (front side view)
N 9
13
1 A B C
2 3
A
4
6
E
7 F
12
8 G
11
10
A
9
A H
13 M
9
I
L
2-41
CABLE ROUTING

2. Meter lead
3. Intake air temperature sensor lead
4. Turn signal/hazard relay 1
5. Steering lock relay
6. Starter relay
7. Handlebar switch coupler (right side)
8. Handlebar switch coupler (left side)
9. Wire harness
10. Fuse box lead
11. Lean angle sensor lead
12. ECU (engine control unit) lead
13. Handlebar switch leads
A. Insert the projection on the wire harness holder
into the hole in the front cowling stay.
B. Fasten the speed sensor lead with the holder by
inserting the projections on the holder into the hole
in the front cowling stay.
C. Route the meter lead to the front of the intake air
temperature sensor lead.
D. Install the steering lock relay and turn
signal/hazard relay 1 onto the tabs of the front
cowling stay. The relays may be positioned in any
order.
E. Fasten the starter relay lead and handlebar switch
leads with the holder by inserting the projection on
the holder into the hole in the plastic stay. Route
the handlebar switch leads to the inside of the
starter relay lead.
F. Insert the projection on the right handlebar switch
coupler into the hole in the plastic stay.
G. Insert the projection on the left handlebar switch
coupler into the hole in the plastic stay.
H. Insert the projection on the wire harness holder
(white tape) into the hole in the front cowling stay.
I. Secure the holder by inserting the projection on
the holder into the hole in the front cowling stay,
and then fasten the handlebar switch leads with the
holder. The catch of the holder may be facing in
any direction.
J. Fasten the handlebar switch leads with the holder.
The catch of the holder may be facing in any
direction.
K. Route the handlebar switch leads through the
opening in the front cowling stay.
L. Position the holder between the wire harness
holder and the meter lead. The catch of the holder
may be facing in any direction.
M. The handlebar switch leads may be routed in any
order.
N. Route the wire harness to the inside of the front
cowling stay.
O. Insert the projection on the wire harness holder
into the hole in the front cowling stay from the
inside of the stay.
2-42
CABLE ROUTING
Frame (left side view)
Y X
17
19
Q R
S
5 1
17
16 9 T
O 17
P
N 1
2 A
M 18
B U 8 5
6
L 3
K 15
V
4 C 7
D 8
J 14 7
E 5 6 9
I
13
12
F
11
H
11
W 10 10
8 G
2-43
CABLE ROUTING
1. Battery T. 60 mm (2.36 in)

2. Sidestand switch coupler U. Fasten the leads with the plastic band. The leads
3. Auxiliary DC jack lead may be routed in any order.
4. Battery negative lead coupler V. Face the buckle of the plastic band downward.
5. Battery negative lead Point the end of the plastic band downward along
the frame. Do not cut off the excess end of the
6. Starter motor lead
plastic band.
7. AC magneto lead
W. Fasten the cylinder-#1 spark plug lead with the
8. Sidestand switch lead holder. Point the open ends of the holder
9. Rear brake hose downward.
10. Cylinder-#1 spark plug lead X. Secure the plastic locking tie by inserting the
11. Cylinder-#2 spark plug lead projection on the tie into the hole in the battery box
12. Ignition coil leads rib, and then fasten the battery positive lead with
the tie. Face the buckle of the plastic locking tie
13. Rectifier/regulator
upward. Insert the end of the plastic locking tie into
14. Stator coil coupler the hole in the battery box so that the end is
15. Crankshaft position sensor coupler pointing to the left as shown in the illustration.
16. Fuel injection system relay Y. Position the plastic locking tie 0–2 mm (0–0.079
17. Battery positive lead in) from the edge of the hole in the battery box.
18. Frame
19. Battery box
A. Fasten the sidestand switch coupler with the
holder on the battery box.
B. Fasten the auxiliary DC jack lead at the tape with a
plastic locking tie. Face the buckle of the plastic
locking tie upward. Point the end of the plastic
locking tie upward, along the battery, and then cut
off the excess end of the tie.
C. Fasten the battery negative lead coupler with the
holder on the battery box.
D. Fasten the sidestand switch lead and rear brake
hose with the holder.
E. Fasten the AC magneto lead, starter motor lead,
and battery negative lead with the holder. The
leads may be routed in any order.
F. To the starter motor and AC magneto
G. Fasten the sidestand switch lead at the positioning
tape.
H. Fasten the spark plug leads with the holder.
I. Remove the rectifier/regulator, and then fasten the
battery negative lead, starter motor lead, and wire
harness with the holder on the battery box. The
leads may be routed in any order.
J. Install the stator coil coupler to the battery box.
K. Install the crankshaft position sensor coupler to the
battery box.
L. Route the starter motor lead to the outside of the
wire harness.
M. Route the battery negative lead to the inside of the
wire harness.
N. Route the battery negative lead through the hole in
the battery box.
O. The starting circuit cut-off relay and sidestand
relay may be installed to either tab.
P. Insert the projections on the plastic locking ties into
the holes so that the cut end of each tie points
downward.
Q. Fasten the battery negative lead with the holder on
the battery box.
R. Fasten the auxiliary DC jack lead at the tape and
the battery positive lead with a plastic locking tie as
shown in the illustration.
S. 25 mm (0.98 in)
2-44
CABLE ROUTING
Frame (right side view)
M N M
19 20 21 5
N O O N
1 P 18
22
24 23
2
1 A 3 4
17 5 B
C
Q
L
D
17 7
K
1
R J
8
16 I
9
15 11 10
12 E
F
H G
D
13
14
S
25
2-45
CABLE ROUTING
1. Control switch assembly lead Q. Pass a plastic locking tie through the hole in the
2. Rear brake lock cable steering lock unit bracket, and then fasten the
3. Smart key unit lead control switch assembly lead and steering lock unit
lead with the tie. Face the buckle of the plastic
4. ECU (engine control unit) lead
locking tie upward, and then cut off the excess end
5. Headlight sub-wire harness coupler of the tie. The leads may be routed in any order.
6. Turn signal/hazard relay 2 R. The leads may be routed in any order.
7. Couplers
S. Applicable unit range: SJ13Y-0000635 and after.
8. Seat open relay
9. Radiator fan motor relay
10. Headlight relay
11. Smart key system relay
12. Buzzer lead
13. Wire harness
14. Throttle position sensor sub-wire harness coupler
15. Fuel pump lead
16. Seat lock cable
17. Steering lock unit lead
18. Front turn signal/position light coupler (left)
19. Headlight sub-wire harness
20. Auxiliary light coupler (left)
21. Auxiliary light coupler (right)
22. Front turn signal/position light coupler (right)
23. Headlight coupler (right)
24. Headlight coupler (left)
25. Throttle position sensor sub-wire harness
A. Insert the projection on the control switch
assembly coupler into the hole in the control switch
assembly bracket.
B. Insert the projection on the headlight sub-wire
harness coupler into the hole in the plastic stay.
C. Route the headlight sub-wire harness to the
outside of the fuse box.
D. Insert the projection on the wire harness holder
into the hole in the bracket.
E. Route the buzzer lead between the wire harness
and the headlight relay/smart key system relay
lead.
F. Route the wire harness along the frame as shown
in the illustration.
G. Route the buzzer lead over the control switch
assembly lead.
H. Insert the projection on the wire harness holder
into the hole in the frame.
I. Fasten the seat lock cable with the holders on the
bracket.
J. Route the rear brake lock cable to the inside of the
bracket.
K. Route the steering lock unit lead to the outside of
the control switch assembly lead.
L. Route the steering lock unit lead and control switch
assembly lead through the guide on the bracket.
M. Fasten the headlight sub-wire harness with the
holders (three locations) on the headlight body.
N. Insert the projection on the headlight sub-wire
harness holder into the hole in the headlight body.
O. Fasten the headlight lead with the holders (two
locations) on the headlight body.
P. Fasten the control switch assembly lead and
steering lock unit lead at the tape on each lead with
a plastic locking tie.
2-46
CABLE ROUTING
Rear frame (right side view)
A
M
1
4
A
B 3
2
C
3 4
D
5
6
I
J
H
7
K
G
N F
8
9
2-47
CABLE ROUTING
1. Wire harness
2. Seat lock cable
3. Seat lock solenoid lead
4. Fuel tank breather hose
6. Radiator fan motor lead
7. O2 sensor lead
8. Tail/brake light lead
9. Rear turn signal light lead
A. Insert the projection on the wire harness holder
into the hole in the rear frame.
B. Route the fuel tank breather hose and seat lock
solenoid lead between the storage box and the fuel
tank. Make sure that the seat lock solenoid lead is
routed to the outside of the fuel tank breather hose.
C. Fasten the seat lock cable with the holder on the
fuel tank.
D. Route the seat lock solenoid lead to the inside of
the rear brake lock cable.
E. Fasten the radiator fan motor lead with the plastic
band. Point the end of the plastic band outward. Do
not cut off the excess end of the plastic band.
F. Fasten the wire sub-lead coupler to the wire
harness.
G. Insert the projection on the wire harness holder
H. Route the coolant temperature sensor lead under
the rear brake lock cable.
I. Position the paint mark on the fuel tank breather
hose between the edges of the holder.
J. Insert the projection on the wire harness holder
into the hole in the bracket.
K. Install the holder so that the O2 sensor lead is
routed under the portion of the holder that is
inserted into the hole.
L. Fasten the O2 sensor lead with the holder on the
side cover.
M. Fasten the seat lock solenoid lead and fuel tank
breather hose with the holder. Make sure that the
seat lock solenoid lead is routed under the fuel
tank breather hose.
N. Taillight routing diagram
2-48
CABLE ROUTING
Frame (top side view)
2 4
3 5 B
6 C
A
D
1 E
10 7
8
17
H I
11 12
J
16
L
15 13
K
K
14
2-49
CABLE ROUTING

2. Throttle cables
3. Control switch assembly lead
4. Steering lock unit lead
6. Seat lock cable
7. Fuel injector #2
8. Fuel pump coupler
9. AC magneto lead
10. Fuel injector #1
11. Tail/brake light coupler
12. License plate light coupler
13. Rear right turn signal light coupler
14. Storage box light switch lead
15. Rear left turn signal light coupler
16. Tail/brake light lead
17. Storage box
A. Route the wire harness under the fuel tank
mounting bracket, and then route it through the
hole in the storage box.
B. Route the rear brake lock cable between the
bracket and the frame.
C. Fasten the seat lock cable with the holders on the
bracket.
D. Insert the projection on the wire harness holder
into the hole in the fuel tank mounting bracket.
Route the wire harness under the seat lock cable
and rear brake lock cable.
E. Secure the holder by inserting the projection on
the holder into the hole in the fuel tank mounting
bracket, and then fasten the seat lock cable and
rear brake lock cable with the holder.
F. Insert the projection on the wire harness holder
G. Insert the projection on the wire harness holder
into the hole in the fuel tank mounting bracket from
the bottom of the bracket.
H. Route the AC magneto lead so that it does not
contact the rear frame.
I. Fasten the leads with the holder on the storage
box.
J. Install the connectors all the way onto the storage
box light.
K. Fasten the leads with the holders on the tail/brake
light lead cover. Route the rear right turn signal
light lead and storage box light switch lead on the
right side of the vehicle. Route the rear left turn
signal light lead and tail/brake light lead on the left
side of the vehicle. Route the leads to the inside of
the turn signal light mounting portions.
L. Fasten the tail/brake light lead, license plate light
lead, and rear left turn signal light lead with the
holder after the leads branch off from the wire
harness. The leads may be routed in any order.
2-50
CABLE ROUTING
Rear brake (top side and left side view)
2-51
CABLE ROUTING
1. Rear brake hose

2. Fuel tank mounting bracket
3. Footboard
4. Rear frame
5. Rear cowling (left)
6. Rear brake hose holder (left)
7. Swingarm
8. Drive pulley cover
9. Passenger footrest
10. Rear brake lock cable holder bracket
11. Crankcase
12. Frame
13. Sidestand switch lead
14. Stay
15. Brake hose holder
16. Side cover (left)
17. Seat lock cable
19. Rear brake lock cable holder (crankcase)
20. Rear brake lock adjusting nut
21. Rear brake hose bracket
22. Rear brake hose holder (right)
23. Rear brake lock caliper
24. Rear brake lock cable holder (swingarm)
25. Rear brake caliper
26. Rear brake disc
A. Install the brake hose holder, aligning the stopper
of the brake hose holder with the hole of the
passenger footrest. To prevent kinks, install the
rear brake hose holder (left) first and then the
brake hose holder.
B. Face the opening of the brake hose holder upward.
C. Route the brake hose along the concave face of
the left rear cowling.
D. Install the cap, pushing it against the nut and
washer.
E. Route the rear brake lock cable under the brake
hose.
F. Face the opening of the cable holder to the inside
of the vehicle.
G. Install the rear brake lock cable holder
(crankcase), inserting the projection of the cable
holder into the hole of the rear brake lock cable
holder bracket.
H. Install the rear brake hose holder (left), inserting
the projection of the rear brake hose holder (left)
into the hole of the rear brake hose bracket.
I. Tighten the union bolt, pushing the brake pipe
against the projection of the brake caliper.
J. Install the rear brake hose holder (right), inserting
the projection of the rear brake hose holder (right)
into the hole of the rear brake hose bracket.
2-52
CABLE ROUTING
Throttle body (left side view)
2-53
CABLE ROUTING
1. Fast idle plunger inlet coolant hose W. Position the clip 1–4 mm (0.04–0.16 in) away from
2. Intake manifold the end of the cylinder head breather hose. The
3. Radiator clip may be rotated to any direction.
4. Fast idle plunger outlet coolant hose X. Position the clip at least 1 mm (0.04 in) away from
5. Throttle body assembly the end of the hose, making sure that it does not
run on the spool. Face the clip to the bottom of the
6. Air filter case vehicle.
7. Intake air pressure sensor Y. Insert the fast idle plunger intake hose until it does
A. Insert the throttle body into the intake manifold not move any further. Face the yellow paint mark to
until it does not move any further. Engine oil may the front of the vehicle.
be applied.
B. Insert the coolant hose until it does not move any
further. Face the pink paint mark to the rear of the
vehicle.
C. Position the clip at least 1 mm (0.04 in) away from
the end of the hose, making sure that it does not
run on the spool. Face the clip to the rear of the
vehicle.
D. Position the clip at least 1 mm (0.04 in) away from
run on the spool. Face the clip to the left of the
vehicle.
E. Insert the fast idle plunger inlet coolant hose until
the bending part of the pipe.
F. Insert the fast idle plunger outlet coolant hose until
the bending part of the pipe. Face the white paint
mark to the left of the vehicle.
G. Insert the fast idle plunger outlet coolant hose until
the bending part of the pipe. Face the yellow paint
mark to the top the vehicle.
H. Position the clip at least 1 mm (0.04 in) away from
run on the spool. Turn the clip, so that it does not
interfere with the spark plug leads and radiator
(should be turned downwards slightly to the front).
I. Insert the air filter case until it touches the throttle
body. Engine oil may be applied.
J. 8°
K. 3°
L. 30°
M. 65°
N. Insert the intake air pressure sensor hose until it
does not move any further.
O. Position the clip 1–4 mm (0.04–0.16 in) away from
the end of the cylinder head breather hose. Face
the clip to the left of the vehicle.
P. Insert the cylinder head breather hose until it does
not move any further. Face the white paint mark to
the top of the vehicle.
Q. To the cylinder head cover
R. To the throttle body assembly
S. Insert the fast idle plunger intake hose until it does
not move any further. Face the blue paint mark to
the right of the vehicle.
T. Position the clip 1–4 mm (0.04–0.16 in) away from
the end of the fast idle plunger intake hose. Face
the clip to the right of the vehicle.
U. Fasten the cylinder head breather hose to the air
filter case.
V. Insert the cylinder head breather hose until it does
not move any further. Face the yellow paint mark to
the right of the vehicle.
2-54
CABLE ROUTING
Fuel tank (top side and right side view)
J 14
13 2
A
5
E 1 2
2
2 B 15
4
D
K
8
C L
M
15 N
3 P O
16 6 7
11
G 8
12
11
10
2-55
CABLE ROUTING
1. Fuel hose
2. Fuel tank breather hose
4. Holder
5. Canister
6. Filler cover
7. Fuel tank cap
8. Fuel tank
9. Bottom center cowling
10. Radiator outlet hose
11. Fuel tank overflow hose
12. Throttle body assembly
13. Canister purge hose (3-way joint to canister)
14. Hose guide on the canister bracket
15. Spacer
16. Fuel tank fitting bracket
A. Fit the grommet securely into the fuel tank. Soapy
water or silicone fluid may be used.
B. When inserting the fuel tank breather hose into the
fuel tank, 2-stroke engine oil may be applied.
C. Route the canister purge hose (3-way joint to
canister) under the intake air pressure sensor lead.
D. Route the canister purge hose (3-way joint to
canister) over the fuel pump lead.
E. Route the canister purge hose (3-way joint to
canister) under the seat lock cable and rear brake
lock cable.
F. White paint mark
G. Install the fuel tank overflow hose and filler cover,
making sure that they contact the connector boss.
H. Route the fuel tank overflow hose so that the end
of the hose protrudes past the bottom center
cowling.
I. Route the fuel tank overflow hose to the inside of
the frame.
J. Route the fuel tank breather hose and canister
purge hose (3-way joint to canister) through the
hose guide on the canister bracket.
K. Install the fuel tank breather hose until it contacts
the end of the spacer.
L. Install the spacer until it contacts the raised portion
of the hose fitting on the fuel tank.
M. End of the fuel tank breather hose
N. Position the end of the fuel tank breather hose
within the range shown in the illustration.
O. Inward
P. Outward
2-56
CABLE ROUTING
Fuel tank (left side view)
I L
1
M
I
7 1 8
N
K
3
J 1
P 9 L Q
1 3 L 10
A R
T R
1 11
2 S N S N
4
3 4
U 12
V
4 W
H B
C
G
F D
1
5
8 6
E
I
1
2-57
CABLE ROUTING
1. Fuel tank breather hose W. 0–3 mm (0–0.12 in)

2. Fuel hose X. Install the fuel tank breather hose and canister
3. Canister purge hose (3-way joint to canister) purge hose (3-way joint to canister) onto the hose
4. Throttle body assembly fittings of the canister, making sure that each hose
5. Canister bracket contacts the canister.
6. Fuel tank
7. Rollover valve
8. Fuel tank fitting bracket
9. 3-way joint
10. Canister purge hose (throttle body #1 to 3-way
joint)
11. Canister purge hose (throttle body #2 to 3-way
joint)
A. Affix the holder to the fuel tank so that the catch of
the holder is facing upward or downward. Make
sure that the holder is aligned with the upper edge
of the damper and that the holder is not installed
on the curved portions of the fuel tank.
B. Route the canister purge hose (3-way joint to
canister) outside the cooling system air bleed
hose.
C. Route the canister purge hose (3-way joint to
canister) outside the frame. Install the canister
purge hose (3-way joint to canister) protector so
that the protector is close to the throttle body.
D. Route the canister purge hose (3-way joint to
canister) inside of the wire harness.
E. Point the ends of the hose clamp outward.
F. Route the fuel tank breather hose inside of the wire
harness.
G. Route the fuel tank breather hose inside of the
frame.
H. Install the fuel tank breather hose, holding the
positioning protector behind the holder.
I. Make sure that the fuel tank breather hose
contacts the rollover valve.
J. Route the fuel tank breather hose through the slot
in the storage box.
K. Install the rollover valve stay so that it contacts the
projection on the storage box.
L. Point the ends of the hose clamp rearward.
M. Install the fuel tank breather hose with its paint
mark facing upward.
N. Make sure not to install the hose clamp on the
raised portion of the hose fitting.
O. Fasten the fuel tank breather hose with the holder
on the storage box.
P. Install the canister purge hoses completely onto
the 3-way joint.
Q. Install the canister purge hose (throttle body #1 to
3-way joint) with its paint mark facing upward.
R. Point the ends of the hose clamp forward.
S. Install the canister purge hose onto the hose fitting
of the throttle body, making sure that the hose
contacts the throttle body.
T. Position the hose clamp 1–4 mm (0.04–0.16 in)
from the end of the canister purge hose.
U. Intake air pressure sensor hose installing diagram
V. Install the intake air pressure sensor hose onto the
intake air pressure sensor, making sure that the
hose contacts the sensor.
2-58
CABLE ROUTING
2-59
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUGS ............................................................. 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-5
ADJUSTING THE ENGINE IDLING SPEED .............................................3-8
SYNCHRONIZING THE THROTTLE BODY .............................................3-9
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-10
CHECKING THE CYLINDER HEAD BREATHER HOSE .......................3-10
CHECKING THE EXHAUST SYSTEM....................................................3-11
CHECKING THE CANISTER .................................................................. 3-11
REPLACING THE AIR FILTER ELEMENT ............................................. 3-11
CLEANING THE V-BELT CASE AIR FILTER ELEMENT .......................3-12
3
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
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-15
CHECKING THE FRONT BRAKE HOSES ............................................. 3-16
CHECKING THE REAR BRAKE HOSE .................................................. 3-16
ADJUSTING THE REAR BRAKE LOCK CABLE .................................... 3-17
CHECKING THE REAR BRAKE LOCK .................................................. 3-17
CHECKING THE REAR BRAKE LOCK PADS........................................ 3-18
CHECKING THE WHEELS ..................................................................... 3-18
CHECKING THE TIRES..........................................................................3-18
CHECKING THE WHEEL BEARINGS ....................................................3-19
CHECKING THE SWINGARM ................................................................3-20
CHECKING THE DRIVE BELT ...............................................................3-20
ADJUSTING THE DRIVE BELT SLACK ................................................. 3-20
LUBRICATING THE DRIVE PULLEY AND DRIVE AXLE.......................3-22
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-23
CHECKING THE CHASSIS FASTENERS .............................................. 3-24
LUBRICATING THE LEVERS .................................................................3-24
CHECKING THE SIDESTAND................................................................3-24
LUBRICATING THE SIDESTAND........................................................... 3-24
CHECKING THE CENTERSTAND ......................................................... 3-25
LUBRICATING THE CENTERSTAND ....................................................3-25
CHECKING THE SIDESTAND SWITCH................................................. 3-25
CHECKING THE FRONT FORK ............................................................. 3-25
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-25
CHECKING THE ENGINE OIL LEVEL....................................................3-25
CHANGING THE ENGINE OIL ...............................................................3-26
MEASURING THE ENGINE OIL PRESSURE ........................................ 3-27
CHECKING THE COOLANT LEVEL.......................................................3-28
CHECKING THE COOLING SYSTEM ....................................................3-29
CHANGING THE COOLANT................................................................... 3-29
REPLACING THE V-BELT ...................................................................... 3-31
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-31
CHECKING AND LUBRICATING THE CABLES .................................... 3-31
LUBRICATING THE REAR SUSPENSION............................................. 3-32
CHECKING THE THROTTLE GRIP........................................................ 3-32
CHECKING AND CHARGING THE BATTERY....................................... 3-33
CHECKING THE FUSES ........................................................................3-33
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-33
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 long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.
INITIAL ODOMETER READINGS
NO. ITEM ROUTINE 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi

(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
• Check fuel hoses for cracks or
1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition.
2 * Spark plugs • Adjust gap and clean. √ Replace. √
• Replace every 12000 mi
3 * Valve clearance • Check and adjust valve clear- Every 26600 mi (42000 km)
ance when engine is cold.
• Check breather hose for
Crankcase
4 * breather system cracks or damage. √ √ √
5 * Fuel injection • Adjust synchronization. √ √ √ √ √ √
Evaporative emis- • Check control system for
6 * sion control sys- damage. √ √
tem • Replace if necessary.
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.
No. ITEM ROUTINE 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi

(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
1 month 6 month 12 month 18 month 24 month 30 month
1 Air filter element • Replace. Every 12000 mi (19000 km)

V-belt case air fil-
2 * ter elements • Clean. √ √ √ √ √
• Check operation, fluid level,

and for fluid leakage.
3 * Front brake • Replace brake pads if neces- √ √ √ √ √ √
sary.
3-1

(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
• Check operation, fluid level,

and for fluid leakage.
4 * Rear brake • Replace brake pads if neces- √ √ √ √ √ √
sary.
• Check for cracks or damage.
• Check for correct routing and √ √ √ √ √
5 * Brake hoses clamping.
• Replace. Every 4 years
6 * Brake fluid • Replace. Every 2 years
7 Rear brake lock • Check cable length. √ √ √ √ √ √

cable • Adjust if necessary.
• Check operation.
8 * Rear brake lock • Check rubber boot. √ √ √ √ √ √
• Check wear indicator.
• Adjust if necessary.
• Check runout and for dam-
9 * Wheels age. √ √ √ √ √
• Check tread depth and for
damage.
10 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearings for smooth
11 * Wheel bearings operation. √ √ √ √ √
• Check belt condition.
12 * Drive belt • Replace if damaged. √ √ √ √ √ √
• Check belt tension.
• Adjust if necessary.
Drive pulley and
13 * drive axle • Lubricate. Every 12000 mi (19000 km)
• Check bearing assemblies for √ √ √ √ √ √

looseness.
14 * Steering bearings
• Moderately repack with lithi-
Every 12000 mi (19000 km)
um-soap-based grease.
• Check all chassis fitting and
15 * Chassis fasteners fasteners. √ √ √ √ √
• Correct if necessary.
Front brake lever
16 pivot shaft • Apply silicone grease lightly. √ √ √ √ √
17 Rear brake lever • Apply silicone grease lightly. √ √ √ √ √

pivot shaft
Centerstand and
18 sidestand pivots • Apply lithium-soap-based √ √ √ √ √
grease lightly.
• Check operation and replace
19 * Sidestand switch √ √ √ √ √ √
if necessary.
• Check operation and for oil
20 * Front fork leakage. √ √ √ √ √
• Check operation and for oil
21 * Shock absorber leakage. √ √ √ √ √
assembly
• Change. √ When the oil change indicator flashes
22 Engine oil • Check oil level and vehicle for
√ √ √ √ √ √
oil leakage.
Engine oil filter At 12500 mi (20000 km) and thereafter every 12500 mi
23 cartridge • Replace. √ (20000 km)
3-2

(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
• Check coolant level and vehi- √ √ √ √ √

24 * Cooling system cle for coolant leakage.
• Change coolant. Every 3 years
25 * V-belt • Replace. When the V-belt replacement indicator flashes (every 12500 mi (20000
km)).
Front and rear
26 * • Check operation. √ √ √ √ √ √
brake switches
• Apply Yamaha cable lubri-
27 Control cables cant or other suitable cable lu- √ √ √ √ √
bricant thoroughly.
• Check throttle grip free play,
28 * Throttle grip and adjust if necessary. √ √ √ √ √
• Lubricate cable and grip
housing.
TIP
• Engine air filter and V-belt air filters
• This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not
be cleaned with compressed air to avoid damaging it.
• The engine air filter element needs to be replaced and the V-belt air filter elements need to be serviced
more frequently when riding in unusually wet or dusty areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check
the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
EAS30619
1. Remove:
CHECKING THE FUEL LINE
• Radiator cover
The following procedure applies to all of the fuel
Refer to “GENERAL CHASSIS (2)” on page
and breather hoses.
4-8.
1. Remove:
2. Disconnect:
• Center cover
• Spark plug cap
3. Remove:
4-8.
• Spark plug
• Side covers ECA13320
Refer to “GENERAL CHASSIS (2)” on page NOTICE

4-8. Before removing the spark plugs, blow away
• Footboards any dirt accumulated in the spark plug wells
Refer to “GENERAL CHASSIS (2)” on page with compressed air to prevent it from falling
4-8. into the cylinders.
• Storage box
Refer to “GENERAL CHASSIS (5)” on page 4. Check:
4-20. • Spark plug type
2. Check: Incorrect → Change.
• Fuel hose “1”
Manufacturer/model
• Fuel tank breather hose “2” NGK/CR7E
Cracks/damage → Replace.
Loose connection → Connect properly. 5. Check:
ECA14940
NOTICE • Electrode “1”

Damage/wear → Replace the spark plug.
Make sure the fuel tank breather hose is rout- • Insulator “2”
ed correctly. Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

3. Install: 0.7–0.8 mm (0.028–0.031 in)
• Storage box
4-20.
• Footboards
4-8.
• Side covers
4-8.
• Center cover
8. Install:
4-8.
• Spark plug
EAS30620
CHECKING THE SPARK PLUGS Spark plug

The following procedure applies to all of the 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
spark plugs.
3-4
TIP
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
• Spark plug cap
10.Install:
• Radiator cover
4-8.
EAS30622
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
8. Measure:
1. Remove: • Valve clearance
• Radiator cover Out of specification → Adjust.
4-8. Valve clearance (cold)
2. Remove: Intake
• Radiator bracket 0.15–0.22 mm (0.0059–0.0087 in)
Refer to “RADIATOR” on page 6-1. Exhaust
3. Remove: 0.25–0.32 mm (0.0098–0.0126 in)
• Storage box
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “GENERAL CHASSIS (5)” on page a. Turn the crankshaft clockwise.
4-20.
4. Remove:
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
5. Remove:
• Air filter case
• Throttle body
• Intake manifold
Refer to “THROTTLE BODY” on page 7-6.
6. Remove:
• Spark plugs b. When piston #1 is at TDC on the compres-
• Cylinder head cover sion stroke, align the “I” mark “a” on the gen-
• Cylinder head cover gasket erator rotor with the mark “b” on the generator
Refer to “CAMSHAFTS” on page 5-10. cover.
7. Remove:
TIP
• Timing mark accessing plug “1”
• Crankshaft end access cover “2” • TDC on the compression stroke can be found
when the cylinder #1 camshaft lobes are
turned away from each other.
• In order to be sure that the piston is at TDC, the
alignment mark “c” on the intake camshaft
sprocket and the alignment mark “d” on the ex-
3-5
haust camshaft sprocket must align with the

#2 #1
cylinder head mating surface as shown in the
illustration.
A
a A. Front
d. To measure the valve clearances of the other
cylinders, starting with cylinder #1 at TDC,
turn the crankshaft clockwise as specified in
the following table.
A 0˚ 360˚ 720˚
#1 C
B
#2 C
c. Measure the valve clearance with a thickness
gauge “1”.
A. Degrees that the crankshaft is turned
clockwise
B. Cylinder
C. Combustion cycle
Cylinder #2 360°
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Remove:
• Camshafts
TIP
TIP
• Refer to “CAMSHAFTS” on page 5-10.
• If the valve clearance is incorrect, record the
• When removing the timing chain and cam-
measured reading.
shafts, fasten the timing chain with a wire to re-
• Measure the valve clearance in the following
trieve it if it falls into the crankcase.
sequence.
10.Adjust:
Valve clearance measuring sequence • Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Cylinder #1 → #2
a. Remove the valve lifter “1” and the valve pad
“2” with a valve lapper “3”.
Valve lapper
90890-04101
Valve lapping tool
YM-A8998
3-6
TIP
• Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
• Make a note of the position of each valve lifter
“1” and valve pad “2” so that they can be in-
stalled in the correct place.
d. Calculate the sum of the values obtained in

steps (b) and (c) to determine the required
valve pad thickness and the valve pad num-
ber.
Example:
1.55 mm (0.061 in) + 0.03 mm (0.001 in) =
1.58 mm (0.062 in)
The valve pad number is 158.
e. Round off the valve pad number according to
the following table, and then select the suit-
able valve pad.
Last digit Rounded value
0, 1, 2 0
3, 4, 5, 6 5
7, 8, 9 10
TIP
b. Calculate the difference between the speci- Refer to the following table for the available
fied valve clearance and the measured valve valve pads.
clearance.
Example: Valve pad range Nos. 120–240
Specified valve clearance = 0.15–0.22 mm 1.20–2.40 mm (0.047–
Valve pad thickness
(0.0059–0.0087 in) 0.094 in)
Measured valve clearance = 0.25 mm 25 thicknesses in 0.05
(0.0098 in) Available valve pads mm (0.002 in) incre-
0.25 mm (0.0098 in) - 0.22 mm (0.0087 in) = ments
0.03 mm (0.001 in)
Example:
c. Check the thickness of the current valve pad.
Valve pad number = 158
TIP Rounded value = 160
The thickness “a” of each valve pad is marked in New valve pad number = 160
hundredths of millimeters on the side that touch- f. Install the new valve pad “1” and the valve lift-
es the valve lifter. er “2”.
Example: TIP
If the valve pad is marked “155”, the pad • Lubricate the valve pad with molybdenum dis-
thickness is 1.55 mm (0.061 in). ulfide oil.
• Lubricate the valve lifter (Top side) with molyb-
denum disulfide oil.
• Lubricate the valve lifter (Outer side) with en-
gine oil.
• The valve lifter must turn smoothly when rotat-
ed by hand.
3-7
• Install the valve lifter and the valve pad in the 1. Start the engine and let it warm up for several
correct place. minutes.
2. Remove:
2 • Radiator cover
4-8.
• Side cover (right)
1 Refer to “GENERAL CHASSIS (2)” on page
4-8.
3. Install:
• Digital tachometer
(onto the spark plug lead of cylinder #1)
g. Install the exhaust and intake camshafts, tim- Digital tachometer
ing chain and camshaft caps. 90890-06760
Digital tachometer
Camshaft cap bolt YU-39951-B
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
4. Check:
TIP • Engine idling speed
• Refer to “CAMSHAFTS” on page 5-10. Out of specification → Adjust.
• Lubricate the camshaft lobes and camshaft
journals with molybdenum disulfide oil. Engine idling speed
• First, install the exhaust camshaft. 1100–1300 r/min
• Turn the crankshaft clockwise several full turns
to seat the parts. 5. Adjust:
• Engine idling speed
h. Measure the valve clearance again. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
i. If the valve clearance is still out of specifica- a. Turn the idling speed adjusting screw “1” in
tion, repeat all of the valve clearance adjust- direction “a” or “b” until the specified engine
ment steps until the specified clearance is idling speed is obtained.
obtained.
Direction “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Engine idling speed is increased.
11.Install: Direction “b”
• All removed parts Engine idling speed is decreased.
TIP
For installation, reverse the removal procedure.
12.Adjust:
• Throttle grip free play
Refer to “CHECKING THE THROTTLE
GRIP” on page 3-32.
EAS30624
ADJUSTING THE ENGINE IDLING SPEED

TIP
Prior to adjusting the engine idling speed, the
throttle body synchronization should be adjusted ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
properly, the air filter element should be clean, 6. Install:
and the engine should have adequate compres- • Side cover (right)
sion. Refer to “GENERAL CHASSIS (2)” on page
4-8.
• Radiator cover
4-8.
3-8
EAS31424
• Vacuum gauge hose for cylinder #1 “4”
SYNCHRONIZING THE THROTTLE BODY
• Vacuum gauge hose for cylinder #2 “5”
TIP • Vacuum gauge
Prior to synchronizing the throttle body, the • Digital tachometer
valve clearance and the engine idling speed (onto the spark plug lead of cylinder #1)
should be properly adjusted and the ignition tim-
ing should be checked. Vacuum gauge
90890-03094
1. Stand the vehicle on a level surface. Vacuummate
TIP YU-44456
Place the vehicle on a centerstand. Digital tachometer
90890-06760
2. Remove: Digital tachometer
• Radiator cover YU-39951-B
4-8.
• Center cover
4-8.
• Side covers
4-8.
• Footboards
4-8.
3. Remove:
• Intake air pressure sensor hose for cylinder
#1 “1”
• Synchronizing pipe cap for cylinder #2 “2”
5. Start the engine and let it warm up for several

minutes.
6. Check:
• Engine idling speed
Out of specification → Adjust.
Refer to “ADJUSTING THE ENGINE IDLING
SPEED” on page 3-8.
Engine idling speed

1100–1300 r/min
7. Adjust:
• Throttle body synchronization
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the cylinder #1 air screw “1” and cylinder
4. Install: #2 air screw “2” using the carburetor angle
• Hose “1” (Parts No.: 5JW-24311-00) driver 2 “3”.
• 3-Way joint “2” (Parts No.: 68V-24376-00)
• Cylinder #1 intake air pressure sensor hose
“3”
3-9
EAS31318
CHECKING THE THROTTLE BODY JOINTS

1. Remove:
• Center cover
4-8.
2. Check:
• Throttle body joints “1”
TIP
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
• If the air screw is removed, turn the screw is ful-
ly, and then turn it out 3/4 turn. Then, synchro-
nize the throttle body.
Carburetor angle driver 2 3. Install:

90890-03173 • Center cover
4-8.
Intake vacuum
29.3–31.9 kPa (220–239 mmHg, EAS30623
8.7–9.4 inHg) CHECKING THE CYLINDER HEAD

BREATHER HOSE
TIP 1. Remove:
The difference in vacuum pressure between two • Center cover
cylinders should not exceed 1.33 kPa (10 mm Refer to “GENERAL CHASSIS (2)” on page
Hg). 4-8.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Refer to “GENERAL CHASSIS (2)” on page
8. Measure: 4-8.
• Engine idling speed • Footboard (right)
Out of specification → Adjust. Refer to “GENERAL CHASSIS (2)” on page
Make sure that the vacuum pressure is within 4-8.
specification. 2. Check:
9. Stop the engine and remove the measuring • Cylinder head breather hose “1”
equipment. Cracks/damage → Replace.
10.Adjust: Loose connection → Connect properly.
• Throttle grip free play ECA14920
Refer to “CHECKING THE THROTTLE NOTICE

GRIP” on page 3-32. Make sure the cylinder head breather hose is
routed correctly.
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in)
11.Install:
• All removed parts
3-10
EAS30626
CHECKING THE CANISTER

1. Remove:
• Storage box
4-20.
• Fuel tank
2. Check:
• Canister “1”
• Canister purge hoses “2”
3. Install:
EAS30625
CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the ex-
haust pipes and gaskets.
1. Remove:
4-8.
2. Check:
• Exhaust assembly “1”
• Gasket “2”
Exhaust gas leaks → Replace.
3. Check:
Tightening torque
• Exhaust assembly nut (front) “3”
• Exhaust assembly nut (rear) “4”
• O2 sensor “5”
Exhaust assembly nut (front)

20 Nm (2.0 m·kgf, 14 ft·lbf) 3. Install:
T.
R.
Exhaust assembly nut (rear) • Fuel tank

31 Nm (3.1 m·kgf, 22 ft·lbf)
O2 sensor
• Storage box
45 Nm (4.5 m·kgf, 33 ft·lbf)
4-20.
EAS30628
REPLACING THE AIR FILTER ELEMENT

1. Remove:
• Center cover
4-8.
2. Remove:
• Air filter case cover “1”
4. Install:
4-8.
3-11
EAS31181
CLEANING THE V-BELT CASE AIR FILTER

ELEMENT
1. Remove:
• Center cover
4-8.
• Footboards
4-8.
2. Remove:
3. Check:
• V-belt case air filter element (left) “1”
• Air filter element “1”
Damage → Replace.
TIP
• Replace the air filter element every 12000 mi
(19000 km) of operation.
• The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.
1
3. Remove:
• V-belt case air filter case cover “1”
• V-belt case air filter case “2”
• V-belt case air filter element (right) “3”
4. Install:
• Air filter case cover
ECA20710
NOTICE
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
synchronization, leading to poor engine per-
formance and possible overheating.
TIP
When installing the air filter element into the air
filter case cover, make sure that the sealing sur-
faces are aligned to prevent any air leaks.
5. Install:
• Center cover 4. Clean:
Refer to “GENERAL CHASSIS (2)” on page • V-belt case air filter elements
4-8. Blow the compressed air to the outer surface
of the V-belt case air filter element.
3-12
EAS30801
CHECKING THE BRAKE OPERATION

1. Check:
• Brake operation
Brake not working properly → Check the
brake system.
Refer to “FRONT BRAKE” on page 4-39 and
“REAR BRAKE” on page 4-53.
TIP
Drive on the road, operate the front and rear
brakes separately and check to see if the brakes
are operating properly.
EAS30632
CHECKING THE BRAKE FLUID LEVEL

1. Stand the vehicle on a level surface.
TIP
• Place the vehicle on the centerstand.
• Make sure the vehicle is upright.
2. Check:
5. Check: • Brake fluid level
• V-belt case air filter elements Below the minimum level mark “a”→ Add the
Damage → Replace. specified brake fluid to the proper level.
ECA13440
NOTICE Specified brake fluid

Since the V-belt case air filter element is a DOT 4
dry type, do not let grease or water contact it.
6. Install:
• V-belt case air filter element (right)
• V-belt case air filter case
• V-belt case air filter case cover
V-belt case air filter case screw

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
V-belt case air filter case cover

screw
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
7. Install:
• V-belt case air filter element (left)
V-belt case air filter element bolt

(left side)
T.
R.
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
8. Install:
• Footboards
4-8. A. Front brake
• Center cover B. Rear brake
4-8.
3-13
EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does EWA13060
not enter the brake master cylinder reser- WARNING

voir. Water will significantly lower the boil- • After adjusting the brake lever position,
ing point of the brake fluid and could cause make sure the pin on the brake lever holder
vapor lock. is firmly inserted in the hole in the adjusting
ECA13540 dial.
NOTICE • A soft or spongy feeling in the brake lever
Brake fluid may damage painted surfaces can indicate the presence of air in the brake
and plastic parts. Therefore, always clean up system. Before the vehicle is operated, the
any spilt brake fluid immediately. air must be removed by bleeding the brake
system. Air in the brake system will consid-
TIP erably reduce in loss of control and possi-
In order to ensure a correct reading of the brake bly an accident. Therefore, check and if
fluid level, make sure the top of the brake master necessary, bleed the brake system.
cylinder reservoir is horizontal. ECA13490
NOTICE
EAS30630
After adjusting the brake lever position,
ADJUSTING THE FRONT DISC BRAKE
make sure there is no brake drag.
1. Adjust:
• Brake lever position EAS30633
(distance “a” from the throttle grip to the brake CHECKING THE FRONT BRAKE PADS
lever) The following procedure applies to all of the
TIP brake pads.
• While pushing the brake lever forward, turn the 1. Operate the brake.
adjusting dial “1” until the brake lever is in the 2. Check:
desired position. • Front brake pad
• Be sure to align the setting on the adjusting dial Wear indicators “1” almost touch the brake
with the arrow mark “2” on the brake lever. disc → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-39.
Position #1
Distance “a” is the largest.
Position #5
Distance “a” is the smallest.
3-14
EAS30631
1. Operate the brake.
ADJUSTING THE REAR DISC BRAKE
2. Check:
1. Adjust:
• Rear brake pad
• Brake lever position
Wear indicators “1” almost touch the brake
(distance “a” from the left side grip to the
disc → Replace the brake pads as a set.
brake lever)
Refer to “REAR BRAKE” on page 4-53.
TIP
• While pushing the brake lever forward, turn the
adjusting dial “1” until the brake lever is in the
desired position.
• Be sure to align the setting on the adjusting dial
with the arrow mark “2” on the brake lever hold-
er.
Position #1
Distance “a” is the largest.
Position #5 EAS30637
Distance “a” is the smallest. BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA13100
WARNING
Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
TIP
EWA13060 • Be careful not to spill any brake fluid or allow
WARNING the brake master cylinder reservoir or brake
• After adjusting the brake lever position, fluid reservoir to overflow.
make sure the pin on the brake lever holder • When bleeding the hydraulic brake system,
is firmly inserted in the hole in the adjusting make sure there is always enough brake fluid
dial. before applying the brake. Ignoring this pre-
• A soft or spongy feeling in the brake lever caution could allow air to enter the hydraulic
can indicate the presence of air in the brake brake system, considerably lengthening the
system. Before the vehicle is operated, the bleeding procedure.
air must be removed by bleeding the brake • If bleeding is difficult, it may be necessary to let
system. Air in the brake system will consid- the brake fluid settle for a few hours. Repeat
erably reduce in loss of control and possi- the bleeding procedure when the tiny bubbles
bly an accident. Therefore, check and if in the hose have disappeared.
necessary, bleed the brake system. 1. Bleed:
ECA13490 • Hydraulic brake system
NOTICE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
After adjusting the brake lever position, a. Fill the brake fluid reservoir to the proper level
make sure there is no brake drag. with the specified brake fluid.
b. Install the diaphragm (brake master cylinder
EAS30634
reservoir or brake fluid reservoir).
CHECKING THE REAR BRAKE PADS c. Connect a clear plastic hose “1” tightly to the
The following procedure applies to all of the bleed screw “2”.
brake pads.
3-15
EWA13110
A WARNING
After bleeding the hydraulic brake system,
check the brake operation.
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 EAS30635
CHECKING THE FRONT BRAKE HOSES

brake hoses and brake hose holders.
1. Check:
• Brake hose “1”
Cracks/damage/wear → Replace.
A. Front
B. Rear
2. Check:
d. Place the other end of the hose into a con-
• Brake hose holder
tainer.
Loose → Tighten the holder bolt.
e. Slowly apply the brake several times.
3. Hold the vehicle upright and apply the front
f. Fully pull the brake lever and hold it in posi-
brake several times.
tion.
4. Check:
g. Loosen the bleed screw.
• Brake hose
TIP Brake fluid leakage → Replace the damaged
Loosening the bleed screw will release the pres- hose.
sure and cause the brake lever to contact the Refer to “FRONT BRAKE” on page 4-39.
throttle grip or handlebar grip.
EAS30636
h. Tighten the bleed screw and then release the CHECKING THE REAR BRAKE HOSE
brake lever. 1. Check:
i. Repeat steps (e) to (h) until all of the air bub- • Brake hose “1”
bles have disappeared from the brake fluid in Cracks/damage/wear → Replace.
the plastic hose.
j. Tighten the bleed screw to specification.
Front brake caliper bleed screw

5 Nm (0.5 m·kgf, 3.6 ft·lbf)
T.
R.
Rear brake caliper bleed screw

6 Nm (0.6 m·kgf, 4.3 ft·lbf)
k. Fill the brake fluid reservoir to the proper level

with the specified brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-13. 2. Check:
• Brake hose holders
Loose connection → Tighten the holder bolt.
3-16
3. Hold the vehicle upright and apply the rear 3. Adjust:

brake several times. • Clearance between the brake pad and brake
4. Check: disc.
• Brake hose ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Brake fluid leakage → Replace the damaged a. Remove the cap of the rear brake lock adjust-
hose. ing nut.
Refer to “REAR BRAKE” on page 4-53. b. Loosen the rear brake lock adjusting nut “1”
slightly.
EAS31425
c. Adjust the piston adjusting bolt “2” so that the
ADJUSTING THE REAR BRAKE LOCK
wear indicator “3” is placed within the width of
CABLE
EWA18100
the wear indicator groove “4” when the rear
WARNING brake lock is activated.
Do not use the rear brake lock lever while Recommended procedure:
driving. Tighten the piston adjusting bolt to 3.0 Nm
(0.30 m·kgf, 2.2 ft·lbf) and then loosen the
TIP bolt 1-1/2 turn.
Place the vehicle on the centerstand. d. Tighten the rear brake lock adjusting nut
while holding the piston adjusting bolt so as
1. Measure: not to turn the bolt.
• Rear brake lock cable length “a”
Out of specification → Adjust. Rear brake lock adjusting nut
TIP 15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
Measure while the rear brake lock lever is re- R.
leased. e. Make sure that the tire can be turned by hand

when the rear brake lock is deactivated.
f. Make sure that the wear indicator is placed
Rear brake lock cable length within the width of the wear indicator groove
43–45 mm (1.69–1.77 in)
when the rear brake lock is activated.
2. Adjust:
• Rear brake lock cable length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the rear brake lock cable adjusting nut
“1” in direction “b” or “c” until the specified
rear brake lock cable free play is obtained.
Direction “b”
Rear brake lock cable length in-
creased.
Direction “c” g. Install the cap of the rear brake lock adjusting
Rear brake lock cable length de- nut.
creased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31426
CHECKING THE REAR BRAKE LOCK

1. Check:
• Rear brake lock operation
Apply the rear brake lock, and then pushing
the vehicle for properly locks the rear brake
lock.
Rear brake lock not working properly →
Check the rear brake lock cable and rear
brake lock pads.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-17
Refer to “ADJUSTING THE REAR BRAKE EAS31428
CHECKING THE WHEELS

LOCK CABLE” on page 3-17 and “CHECK-
The following procedure applies to both of the
ING THE REAR BRAKE LOCK PADS” on
wheels.
page 3-18.
1. Check:
2. Check:
• Wheel
Damage/out-of-round → Replace.
Out of specification → Adjust. EWA13260
Refer to “ADJUSTING THE REAR BRAKE WARNING

LOCK CABLE” on page 3-17. Never attempt to make any repairs to the
3. Check: wheel.
• Wear indicator “1”
Check the position of the indicator while ap- TIP
plying the rear brake lock lever. After a tire or wheel has been changed or re-
Passed the wear indicator groove “2” → Ad- placed, always balance the wheel.
just the rear brake lock cable length.
Refer to “ADJUSTING THE REAR BRAKE EAS31429
LOCK CABLE” on page 3-17. CHECKING THE TIRES

tires.
1. Check:
• Tire pressure
Out of specification → Regulate.
4. Check:
• Rear brake lock caliper boots
Refer to “REAR BRAKE” on page 4-53.
EAS31427 EWA13181
CHECKING THE REAR BRAKE LOCK PADS WARNING
• The tire pressure should only be checked
brake pads.
and regulated when the tire temperature
1. Operate the rear brake lock.
equals the ambient air temperature.
2. Check:
• The tire pressure and the suspension must
• Rear brake lock pad
be adjusted according to the total weight
Wear indicators “1” almost touch the brake
(including cargo, rider, passenger and ac-
disc → Replace the brake pads as a set.
cessories) and the anticipated riding
Refer to “REPLACING THE REAR BRAKE
speed.
LOCK PADS” on page 4-67.
• Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
3-18
EWA14090
Tire air pressure (measured on WARNING

cold tires) After extensive tests, the tires listed below
Loading condition have been approved by Yamaha Motor Co.,
0–90 kg (0–198 lb) Ltd. for this model. The front and rear tires
Front should always be by the same manufacturer
225 kPa (2.25 kgf/cm², 33 psi,
and of the same design. No guarantee con-
2.25 bar)
Rear cerning handling characteristics can be giv-
250 kPa (2.50 kgf/cm², 36 psi, en if a tire combination other than one
2.50 bar) approved by Yamaha is used on this vehicle.
Loading condition
90–195 kg (198–430 lb) Front tire
Front Size
225 kPa (2.25 kgf/cm², 33 psi, 120/70R15 M/C 56H
2.25 bar) Manufacturer/model
Rear DUNLOP/GPR-100F
280 kPa (2.80 kgf/cm², 41 psi,
2.80 bar)
Maximum load Rear tire
195 kg (430 lb) Size
* Total weight of rider, passenger, cargo 160/60R15 M/C 67H
and accessories Manufacturer/model
DUNLOP/GPR-100
EWA13190
EWA13210
WARNING
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re- New tires have a relatively low grip on the
place the tire immediately. road surface until they have been slightly
worn. Therefore, approximately 100 km
2. Check: should be traveled at normal speed before
• Tire surfaces any high-speed riding is done.
Damage/wear → Replace the tire.
TIP
For tires with a direction of rotation mark “1”:
• Install the tire with the mark pointing in the di-
rection of wheel rotation.
• Align the mark “2” with the valve installation
point.
1. Tire tread depth

2. Side wall
3. Wear indicator
Wear limit (front)

1.0 mm (0.04 in)
Wear limit (rear) EAS30641
1.0 mm (0.04 in) CHECKING THE WHEEL BEARINGS
wheel bearings.
3-19
1. Check:
C D
• Wheel bearings
Refer to “FRONT WHEEL” on page 4-22 and
“REAR WHEEL” on page 4-31.
EAS31430
CHECKING THE SWINGARM

1. Check:
• Swingarm operation
Swingarm not working properly → Check the
swingarm.
Refer to “REMOVING THE SWINGARM” on
E F
page 4-101.
2. Check:
• Swingarm excessive play
Refer to “REMOVING THE SWINGARM” on
page 4-101.
EAS31431
CHECKING THE DRIVE BELT

1. Remove:
• Drive belt upper guard and lower guard
Refer to “REAR WHEEL” on page 4-31.
G H
2. Check:
• Drive belt
External tooth cracks “A” → Replace.
Missing teeth “B” → Replace.
Hook wear “C” → Replace.
Stone damage “D” → Replace if damage is
on the edge.
Internal tooth cracks (hairline) “E” → OK to
run, but monitor condition.
Chipping (not serious) “F” → OK to run, but 3. Install:
monitor condition. • Drive belt upper guard and lower guard
Fuzzy edge cord “G” → OK to run, but moni- Refer to “REAR WHEEL” on page 4-31.
tor condition
Bevel wear (outboard edge only) “H” → OK to
EAS31432
ADJUSTING THE DRIVE BELT SLACK

run, but monitor condition. 1. Reading method of tension gauge.
Refer to “BELT DRIVE” on page 4-93. The tension gauge indicators are located on
A B both side; the read side “A” and belt side.
Each side has own indicator number size.

They need to be read as follows.
Read side “A”
3-20
Read side indicator number’s character “c” is c. Read the read side scale at over lap point and
smaller than on the belt side. record it on paper etc.
Read the small number character “d” on the In this explanation should be read “13.2”.
handle for Read side “A”. Its value is “calibration value” of the tension
Belt side “B” gauge.
Belt side indicator number’s character “e” is d. Loosen the tension gauge enough until you
larger than on the Read side. can remove the calibration plate without any
Read the large number character “f” on the force.
handle for the Belt side “B”.
2. Calibrate the tension gauge.

TIP
• Belt tension gauge calibration must be done by
the same person who measure and adjust the
vehicle drive belt. It must be done every time
before each drive belt slack measurement.
• Though indicators are located on both sides of
the tension gauge, calibration should only be
done by read side indicator “a”.
TIP
Tension gauge Both small and large characters are printed on
90890-03226 the handle of the actual gauge.
However, the illustrations in this manual are
shown with only one size character to simplify
the illustrations.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure the drive belt slack.
ECA14950
NOTICE
A drive belt that is too tight will overload the
engine and other vital parts, and one that is
too loose can skip and damage the swing-
A. Read side view arm or cause an accident. Therefore, keep
the drive belt slack within the specified lim-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ its.
a. Fully loosen the handle “a”, and set the cali-
bration plate “1”. TIP
b. Turn the handle of the tension gauge until in- Measure the drive belt slack when the drive belt
dicator “b” and edge of handle “c” to lap over. is at room temperature, and when the drive belt
is dry.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Stand the vehicle on a level surface.
3-21
EWA13120
b. Turn both adjusting bolts “2” in direction “b”
WARNING and push the rear wheel forward.
Securely support the vehicle so that there is c. Turn both left and right adjusting bolts “2” in
no danger of it falling over. direction “a” to move the puller backward till
distance “c” of both left and right side will be
TIP
around 14 mm (0.55 in).
Place the vehicle on the centerstand.
d. Turn both left and right adjusting bolts “2” in
b. Remove the drive belt upper guard or lower direction “a” equivalently till aligning both indi-
guard. cator and edge of handle with calibrated val-
c. Align the rear wheel pulley bolt and center ue.
line of the swingarm as shown in the illustra- e. Check the difference in the distance “c” be-
tion. tween the left and right sides should be 0.8
mm (0.03 in) or less.
d. Set the tension gauge “1” to upside or down-

side of the drive belt. f. Tighten the wheel axle nut to specification.
TIP
Rear wheel axle nut
To set correctly between protruding portion “2” 160 Nm (16 m·kgf, 116 ft·lbf)
T.
of the tension gauge and teeth “3” of cog when

R.
scaling drive belt slack. g. Tighten the locknuts to specification.

e. Measure:
Drive belt adjusting locknut
• Drive belt slack 16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
(The scale position “a” on the tension gauge.)

R.
Out of specification → Adjust. h. Check the difference in the distance “c” be-
tween the left and right sides is within 0.8 mm
Drive belt slack (scale position)
(0.03 in).
Within calibration value +/- 0.2
mm (0.008 in) i. Put the tension gauge back onto the drive belt
and measure the drive belt slack again.
j. Measure and adjust until proper drive belt
slack “within calibration value +/- 0.2 mm
(0.008 in)” is obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31433
LUBRICATING THE DRIVE PULLEY AND

DRIVE AXLE
1. Remove:
• Drive belt upper guard and lower guard
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Remove:
4. Adjust the drive belt slack. • Drive belt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “BELT DRIVE” on page 4-93.
a. Loosen the wheel axle nut and both left and 3. Remove:
right locknuts “1”. • Drive pulley cover
3-22
• Dust cover
• Drive pulley assembly
4. Clean:
• Drive axle “1”
• Drive pulley assembly inner part “2”
5. Lubricate:
• Drive axle “1”
Recommended lubricant
YAMAHA GREASE “J” (Shell Al-
vania EP Grease R0®)
6. Lubricate:
• Drive pulley assembly inner part “2”
YAMAHA GREASE “J” (Shell Al-
vania EP Grease R0®)
7. Install:
8. Adjust:
• Drive belt slack
Refer to “ADJUSTING THE DRIVE BELT
SLACK” on page 3-20.
EAS30645
CHECKING AND ADJUSTING THE

STEERING HEAD
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
front wheel is elevated.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
• Upper bracket
Refer to “STEERING HEAD” on page 4-89.
4. Adjust:
• Steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer “1”, the upper ring
nut “2”, and the rubber washer “3”.
3-23

e. Install the rubber washer “3”.
f. Install the upper ring nut “2”.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.
h. Install the lock washer “1”.
TIP
Make sure the lock washer tabs “a” sit correctly
b. Loosen the lower ring nut “4” and then tighten in the ring nut slots “b”.
it to specification with a steering nut wrench
“5”.
TIP
• Set a torque wrench at a right angle to the
steering nut wrench.
• Move the steering to the left and right a couple
of time to check that it moves smoothly.
5
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Upper bracket
4 EAS31186
CHECKING THE CHASSIS FASTENERS

Make sure that all nuts, bolts, and screws are
Steering nut wrench properly tightened.
90890-01403 Refer to “CHASSIS TIGHTENING TORQUES”
Exhaust flange nut wrench on page 2-16.
YU-A9472
EAS30648
LUBRICATING THE LEVERS

Lower ring nut (initial tightening Lubricate the pivoting point and metal-to-metal
torque) moving parts of the levers.
T.
R.
52 Nm (5.2 m·kgf, 38 ft·lbf)

c. Loosen the lower ring nut completely, then Silicone grease
tighten it to specification.
EWA13140 EAS30650
WARNING CHECKING THE SIDESTAND

1. Check:
Do not overtighten the lower ring nut.
• Sidestand operation
Check that the sidestand moves smoothly.
Lower ring nut (final tightening Rough movement → Repair or replace.
torque)
T.
R.
14 Nm (1.4 m·kgf, 10 ft·lbf) EAS30651
LUBRICATING THE SIDESTAND

d. Check the steering head for looseness or Lubricate the pivoting point, metal-to-metal mov-
binding by turning the front fork all the way in ing parts and spring contact point of the side-
both directions. If any binding is felt, remove stand.
the lower bracket and check the upper and
lower bearings.
3-24
Lithium-soap-based grease
EAS30856
CHECKING THE CENTERSTAND

1. Check:
• Centerstand operation
Check that the centerstand moves smoothly.
Rough movement → Repair or replace.
EAS30857
EAS30808
LUBRICATING THE CENTERSTAND CHECKING THE REAR SHOCK ABSORBER
Lubricate the pivoting point, metal-to-metal mov- ASSEMBLY
ing parts and spring contact point of the center- 1. Check:
stand. • Rear shock absorber assembly operation
Push down hard on the seat several times
and check if the rear shock absorber rebound
smoothly.
EAS30652
Rough movement → Replace.
CHECKING THE SIDESTAND SWITCH Refer to “REAR SHOCK ABSORBER AS-
Refer to “CHECKING THE SWITCHES” on SEMBLY” on page 4-96.
page 8-87. 2. Check:
• Rear shock absorber assembly
EAS30653
Gas leaks/oil leaks → Replace.
CHECKING THE FRONT FORK
Refer to “REAR SHOCK ABSORBER AS-
EWA13120 SEMBLY” on page 4-96.
WARNING EAS30656
Securely support the vehicle so that there is CHECKING THE ENGINE OIL LEVEL
no danger of it falling over. 1. Stand the vehicle on a level surface.
2. Check: TIP
• Inner tube • Place the vehicle on the centerstand.
Damage/scratches → Replace. • Make sure the vehicle is upright.
• Front fork leg 2. Start the engine, warm it up for several min-
Oil leaks between inner tube and outer tube utes, and then turn it off.
→ Replace the oil seal. 3. Check:
3. Hold the vehicle upright and apply the front • Engine oil level
brake. The engine oil level should be between the
4. Check: maximum level mark “a” and minimum level
• Front fork operation mark “b”.
Push down hard on the handlebar several Below the minimum level mark → Add the
times and check if the front fork rebounds recommended engine oil to the proper level.
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” on page 4-78.
3-25
Recommended brand
YAMALUBE
Type
SAE 10W-30 or 10W-40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
ECA13361
NOTICE
• Engine oil also lubricates the clutch and the 4. Drain:
wrong oil types or additives could cause • Engine oil
clutch slippage. Therefore, do not add any (completely from the crankcase)
chemical additives or use engine oils with a 5. If the oil filter cartridge is also to be replaced,
grade of “CD” or higher and do not use oils perform the following procedure.
labeled “ENERGY CONSERVING II”. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Do not allow foreign materials to enter the a. Remove the oil filter cartridge “1” with an oil
crankcase. filter wrench “2”.
TIP Oil filter wrench
Before checking the engine oil level, wait a few 90890-01469
minutes until the oil has settled. Oil filter wrench
YM-01469
4. Start the engine, warm it up for several min-
utes, and then turn it off.
5. Check the engine oil level again.
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled.
EAS30657
CHANGING THE ENGINE OIL

2. Place a container under the engine oil drain b. Lubricate the O-ring “3” of the new oil filter
bolt. cartridge with a thin coat of lithium-soap-
3. Remove: based grease.
• Engine oil filler cap “1” ECA13390
(along with the O-ring) NOTICE

• Engine oil drain bolt “2” Make sure the O-ring “3” is positioned cor-
(along with the gasket) rectly in the groove of the oil filter cartridge.
3-26
11.Check:
• Engine oil level
3 Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-25.
12.Check:
• Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bottom side cowling and bottom
center cowling.
c. Tighten the new oil filter cartridge to specifi- 4-8.
cation with an oil filter wrench. b. Slightly loosen the oil check bolt “1”.
Oil filter cartridge

17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Engine oil drain bolt
(along with the gasket New )
TIP
Lubricate the O-ring of the engine oil drain bolt c. Start the engine and keep it idling until engine
with a thin coat of lithium-soap-based grease. oil starts to seep from the oil check bolt. If no
engine oil comes out after one minute, turn
Engine oil drain bolt the engine off so that it will not seize.
43 Nm (4.3 m·kgf, 31 ft·lbf) d. Check the engine oil passages, the oil filter
T.
R.
cartridge and the oil pump for damage or

7. Fill: leakage.
• Crankcase Refer to “OIL PUMP” on page 5-68.
(with the specified amount of the recom- e. Start the engine after solving the problem(s)
mended engine oil) and check the engine oil pressure again.
Engine oil quantity f. Tighten the oil check bolt to specification.
Quantity (disassembled)
Engine oil check bolt
3.50 L (3.70 US qt, 3.08 Imp.qt)
15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
Without oil filter cartridge re-

R.
placement
g. Install the bottom side cowling and bottom
2.70 L (2.85 US qt, 2.38 Imp.qt)
With oil filter cartridge replace- center cowling.
ment Refer to “GENERAL CHASSIS (2)” on page
2.90 L (3.07 US qt, 2.55 Imp.qt) 4-8.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install: EAS30810
• Engine oil filler cap MEASURING THE ENGINE OIL PRESSURE

(along with the O-ring New ) 1. Check:
9. Start the engine, warm it up for several min- • Engine oil level
utes, and then turn it off. Below the minimum level mark → Add the
10.Check: recommended engine oil to the proper level.
• Engine
(for engine oil leaks)
3-27

utes, and then turn it off. Oil pressure
ECA13410 120.0 kPa/1200 r/min@70 °C
NOTICE (17.4 psi/1200 r/min@158 °F)
When the engine is cold, the engine oil will
have a higher viscosity, causing the engine Out of specification → Adjust.
oil pressure to increase. Therefore, be sure Engine oil pressure Possible causes
to measure the engine oil pressure after • Faulty oil pump
warming up the engine. • Clogged oil filter
Below specification • Leaking oil passage
3. Remove:
• Broken or damaged
• Engine oil pressure check point plug “1” oil seal
(Bottom of the crankcase)
EWA12980 • Leaking oil passage
WARNING Above specification • Faulty oil filter
• Oil viscosity too high
The engine, muffler and engine oil are ex-
tremely hot. 6. Install:
• Engine oil pressure check point plug
TIP
Lubricate the O-ring of the engine oil pressure
check point plug with a thin coat of lithium-soap-
based grease.
Engine oil pressure check point

plug
T.
R.
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
• Oil pressure gauge “1” CHECKING THE COOLANT LEVEL

• Adapter “2” 1. Stand the vehicle on a level surface.
TIP
Oil pressure gauge set • Place the vehicle on the centerstand.
90890-03120 • Make sure the vehicle is upright.
Oil pressure adapter B
90890-03124 2. Check:
Pressure gauge • Coolant level
90890-03153 The coolant level should be between the
Pressure gauge maximum level mark “a” and minimum level
YU-03153 mark “b”.
Below the minimum level mark → Remove
the left footboard mat, coolant reservoir cap
access panel “1”, and coolant reservoir cap,
and then add the recommended coolant to
the proper level.
5. Measure:
• Engine oil pressure
(at the following conditions)
3-28
• Radiator filler hose “12”

• Coolant pipe “13”
Refer to “RADIATOR” on page 6-1, “THER-
MOSTAT” on page 6-8 and “WATER PUMP”
on page 6-11.
ECA13470
NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
4. Check:
• Coolant level
TIP
Before checking the coolant level, wait a few
minutes until it settles. 3. Install:
• Footboards
EAS30812 Refer to “GENERAL CHASSIS (2)” on page
CHECKING THE COOLING SYSTEM 4-8.
1. Remove: • Side covers
• Center cover Refer to “GENERAL CHASSIS (2)” on page
Refer to “GENERAL CHASSIS (2)” on page 4-8.
4-8. • Center cover
• Side covers Refer to “GENERAL CHASSIS (2)” on page
Refer to “GENERAL CHASSIS (2)” on page 4-8.
4-8.
• Footboards EAS30813
Refer to “GENERAL CHASSIS (2)” on page CHANGING THE COOLANT

4-8. 1. Remove:
2. Check: • Center cover
• Radiator “1” Refer to “GENERAL CHASSIS (2)” on page
• Radiator inlet hose “2” 4-8.
• Radiator outlet hose “3” • Side cover (left)
• Oil cooler inlet hose “4” Refer to “GENERAL CHASSIS (2)” on page
• Oil cooler outlet hose “5” 4-8.
• Oil cooler “6” • Footboard (left)
• Thermostat outlet hose “7” Refer to “GENERAL CHASSIS (2)” on page
• Water pump “8” 4-8.
• Water pump inlet pipe “9” 2. Disconnect:
• Water pump outlet pipe “10” • Coolant reservoir hose “1”
• Radiator filler pipe “11”
3-29
3. Drain: 6. Drain:
• Coolant • Coolant
(from the coolant reservoir) (from the engine and radiator)
4. Remove: 7. Install:
• Radiator cap “1” • Coolant drain bolt
EWA13030
WARNING (along with the O-ring New )

A hot radiator is under pressure. Therefore, Coolant drain bolt
do not remove the radiator cap when the en- 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
T.
R.
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in- 8. Connect:
jury. When the engine has cooled, open the • Coolant reservoir hose
radiator cap as follows: 9. Fill:
Place a thick rag or a towel over the radiator • Cooling system
cap and slowly turn the radiator cap counter- (with the specified amount of the recom-
clockwise toward the detent to allow any re- mended coolant)
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi- Recommended antifreeze
ator cap and turn it counterclockwise to re- High-quality ethylene glycol anti-
move. freeze containing corrosion in-
hibitors for aluminum engines
TIP Mixing ratio
When removing the radiator cap, hold the radia- 1:1 (antifreeze:water)
Radiator (including all routes)
tor filler pipe “2”.
1.50 L (1.59 US qt, 1.32 Imp.qt)
Coolant reservoir (up to the
maximum level mark)
0.27 L (0.29 US qt, 0.24 Imp.qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
5. Remove:
tor.
• Coolant drain bolt “1”
• If coolant splashes on your clothes, quickly
(along with the O-ring)
wash it away with water and then with soap
and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
3-30
ECA13481 EAS31188
NOTICE REPLACING THE V-BELT

• Adding water instead of coolant lowers the 1. Remove:
antifreeze content of the coolant. If water is • Center cover
used instead of coolant, check, and if nec- Refer to “GENERAL CHASSIS (2)” on page
essary, correct the antifreeze concentra- 4-8.
tion of the coolant. • Side cover (right)
• Use only distilled water. However, if dis- Refer to “GENERAL CHASSIS (2)” on page
tilled water is not available, soft water may 4-8.
be used. • Footboard (right)
• If coolant comes into contact with painted Refer to “GENERAL CHASSIS (2)” on page
surfaces, immediately wash them with wa- 4-8.
ter. • Outer V-belt case
• Do not mix different types of antifreeze. Refer to “V-BELT AUTOMATIC TRANSMIS-
SION” on page 5-40.
10.Install: 2. Check:
• Radiator cap • V-belt
11.Fill: Cranks/damage/wear → Replace.
• Coolant reservoir Grease/oil → Clean the primary and second-
(with the recommended coolant to the maxi- ary pulleys.
mum level mark “a”) Refer to “V-BELT AUTOMATIC TRANSMIS-
TIP
Replace the V-belt every 20000 km (12500 mi)
of operation.
3. Install:
• Outer V-belt case
Refer to “V-BELT AUTOMATIC TRANSMIS-
• Footboard (right)
12.Install: Refer to “GENERAL CHASSIS (2)” on page
• Coolant reservoir cap 4-8.
13.Start the engine, warm it up for several min- • Side cover (right)
utes, and then stop it. Refer to “GENERAL CHASSIS (2)” on page
14.Check: 4-8.
• Coolant level • Center cover
Refer to “CHECKING THE COOLANT LEV- Refer to “GENERAL CHASSIS (2)” on page
EL” on page 3-28. 4-8.
TIP EAS30658
Before checking the coolant level, wait a few CHECKING THE BRAKE LIGHT SWITCHES
minutes until the coolant has settled. 1. Check:
• Front brake light switch operation
15.Install:
• Rear brake light switch operation
• Footboard (left)
When operating the brake lever, confirm that
the brake light comes on.
4-8.
Faulty → Refer to “CHECKING THE
• Side cover (left)
SWITCHES” on page 8-87.
4-8. EAS31147
• Center cover CHECKING AND LUBRICATING THE

Refer to “GENERAL CHASSIS (2)” on page CABLES
4-8. The following procedure applies to all of the in-
ner and outer cables.
3-31
EWA13270
3. Check:
WARNING • Throttle grip free play “a”
Damaged outer cable may cause the cable to Out of specification → Adjust.
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables Throttle grip free play
as soon as possible. 3.0–5.0 mm (0.12–0.20 in)
1. Check:
• Outer cable
Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate.
Engine oil or a suitable cable lu-
bricant
TIP 4. Adjust:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit- TIP
able lubricating device. Prior to adjusting the throttle grip free play, throt-
tle body synchronization should be adjusted
EAS30807 properly.
LUBRICATING THE REAR SUSPENSION
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Lubricate the pivoting point and metal-to-metal a. Slide back the rubber cover “1”.
moving parts of the rear suspension. b. Loosen the locknut “2”.
c. Turn the adjusting nut “3” in direction “a” or “b”
Lithium-soap-based grease until the specified throttle grip free play is ob-
tained.
EAS30815
CHECKING THE THROTTLE GRIP Direction “a”

1. Check: Throttle grip free play is increased.
Direction “b”
• Throttle cables
Throttle grip free play is decreased.
Damage/deterioration → Replace.
• Throttle cable installation
Incorrect → Reinstall the throttle cables.
Refer to “HANDLEBAR” on page 4-72.
2. Check:
• Throttle grip movement
Rough movement → Lubricate or replace the
defective part(s).
Suitable cable lubricant
TIP d. Tighten the locknut.

With the engine stopped, turn the throttle grip Throttle cable adjusting locknut
slowly and release it. Make sure that the throttle 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
T.
grip turns smoothly and returns properly when

R.
released. e. Slide the rubber cover to its original position.

Repeat this check with the handlebar turned all
the way to the left and right.
3-32
TIP
Direction “a”
Make sure that the adjusting nut is covered com-
Headlight beam moves to the right.
pletely by the rubber cover. Direction “b”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Headlight beam moves to the left.
EAS30816
CHECKING AND CHARGING THE BATTERY Right headlight

Refer to “CHECKING AND CHARGING THE
BATTERY” on page 8-91. Direction “a”
Headlight beam moves to the left.
EAS30662 Direction “b”
CHECKING THE FUSES Headlight beam moves to the right.
Refer to “CHECKING THE FUSES” on page
8-91.
EAS30664
ADJUSTING THE HEADLIGHT BEAMS

1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
TIP
Other than the socket wrench, the adjusting
screws can be turned with a screwdriver (Phillips ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
No. 2) “2” as shown in the illustration.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• Headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw “1” in direction “a” or
“b”.
TIP
Other than the socket wrench, the adjusting
screws can be turned with a screwdriver (Phillips
No. 2) “2” as shown in the illustration.
Left headlight
3-33
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE WINDSHIELD ............................................................... 4-4
INSTALLING THE WINDSHIELD.............................................................. 4-4
ADJUSTING THE WINDSHIELD HEIGHT................................................ 4-5
REMOVING THE FRONT UNDER COVER..............................................4-5
INSTALLING THE FRONT UNDER COVER ............................................4-5
REMOVING THE FRONT COVER............................................................ 4-6
INSTALLING THE FRONT COVER .......................................................... 4-6
REMOVING THE WINDSHIELD INNER PANEL ...................................... 4-7
INSTALLING THE WINDSHIELD INNER PANEL..................................... 4-7
GENERAL CHASSIS (2) ................................................................................. 4-8

REMOVING THE SIDE PANEL.................................................................4-9
INSTALLING THE SIDE PANEL ............................................................... 4-9
REMOVING THE CENTER COVER .........................................................4-9
INSTALLING THE CENTER COVER........................................................4-9
REMOVING THE SIDE COVER..............................................................4-10
INSTALLING THE SIDE COVER ............................................................ 4-10
REMOVING THE SIDE COVER MOULDING .........................................4-10
INSTALLING THE SIDE COVER MOULDING........................................ 4-11
REMOVING THE FOOTBOARD ............................................................. 4-11
4
INSTALLING THE FOOTBOARD............................................................ 4-12
GENERAL CHASSIS (3) ............................................................................... 4-13

REMOVING THE INNER PANEL CENTER COVER ..............................4-15
INSTALLING THE INNER PANEL CENTER COVER............................. 4-15
GENERAL CHASSIS (4) ............................................................................... 4-16

REMOVING THE REAR COVER ............................................................ 4-19
INSTALLING THE REAR COVER........................................................... 4-19
GENERAL CHASSIS (5) ............................................................................... 4-20

REMOVING THE FUEL HOSE ...............................................................4-21
INSTALLING THE FUEL HOSE ..............................................................4-21
FRONT WHEEL............................................................................................. 4-22

REMOVING THE FRONT WHEEL.......................................................... 4-25
DISASSEMBLING THE FRONT WHEEL................................................ 4-25
CHECKING THE FRONT WHEEL .......................................................... 4-25
ASSEMBLING THE FRONT WHEEL......................................................4-26
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-27
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC).................. 4-28
REAR WHEEL ...............................................................................................4-31
REMOVING THE REAR WHEEL (DISC BRAKE)................................... 4-35
DISASSEMBLING THE REAR WHEEL .................................................. 4-35
CHECKING THE REAR WHEEL............................................................. 4-35
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-35
CHECKING AND REPLACING THE REAR WHEEL PULLEY ............... 4-36
ASSEMBLING THE REAR WHEEL ........................................................ 4-36
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-37
INSTALLING THE REAR WHEEL (DISC BRAKE) .................................4-37
FRONT BRAKE ............................................................................................. 4-39

INTRODUCTION .....................................................................................4-45
CHECKING THE FRONT BRAKE DISCS............................................... 4-45
REPLACING THE FRONT BRAKE PADS .............................................. 4-46
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-47
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-47
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-48
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-48
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-49
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-50
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-50
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-50
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-50
REAR BRAKE ...............................................................................................4-53

INTRODUCTION .....................................................................................4-62
CHECKING THE REAR BRAKE DISC....................................................4-62
REPLACING THE REAR BRAKE PADS................................................. 4-62
REMOVING THE REAR BRAKE CALIPER ............................................4-63
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-64
CHECKING THE REAR BRAKE CALIPER............................................. 4-64
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-64
INSTALLING THE REAR BRAKE CALIPER...........................................4-65
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-66
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-66
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-66
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-66
REPLACING THE REAR BRAKE LOCK PADS...................................... 4-67
REPLACING THE REAR BRAKE LOCK CABLE.................................... 4-69
REMOVING THE REAR BRAKE LOCK CALIPER .................................4-69
CHECKING THE REAR BRAKE LOCK CALIPER ..................................4-69
ASSEMBLING THE REAR BRAKE LOCK CALIPER..............................4-70
INSTALLING THE REAR BRAKE LOCK CALIPER ................................4-71
HANDLEBAR ................................................................................................4-72
REMOVING THE HANDLEBAR..............................................................4-75
CHECKING THE HANDLEBAR ..............................................................4-75
INSTALLING THE HANDLEBAR ............................................................ 4-75
FRONT FORK................................................................................................4-78
REMOVING THE FRONT FORK LEGS.................................................. 4-82
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-82
CHECKING THE FRONT FORK LEGS .................................................. 4-83
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-84
INSTALLING THE FRONT FORK LEGS ................................................ 4-88
STEERING HEAD.......................................................................................... 4-89

REMOVING THE LOWER BRACKET.....................................................4-91
CHECKING THE STEERING HEAD .......................................................4-91
INSTALLING THE STEERING HEAD .....................................................4-92
BELT DRIVE.................................................................................................. 4-93

CHECKING THE DRIVE BELT ...............................................................4-95
INSTALLING THE DRIVE BELT ............................................................. 4-95
REAR SHOCK ABSORBER ASSEMBLY ....................................................4-96

HANDLING THE REAR SHOCK ABSORBER ........................................ 4-97
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-97
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-97
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-97
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-97
SWINGARM................................................................................................... 4-99
REMOVING THE SWINGARM..............................................................4-101
CHECKING THE SWINGARM ..............................................................4-101
INSTALLING THE SWINGARM ............................................................4-101
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the windshield and front cowling assembly
1.6 Nm (0.16 m • kgf, 1.2 ft • Ibf) 10 Nm (1.0 m • kgf, 7.2 ft • Ibf)
T.R
.
T.R
.
1 10 Nm (1.0 m • kgf, 7.2 ft • Ibf)
T.R
.
(2)
(2) (2)
6 (2)
(2) 6
3
(4)
2
1 1.5 Nm (0.15 m • kgf, 1.1 ft • Ibf)
2 (2)
T.R
.
(2)
(2)
5
(2)
(2)
(2)
(2)
(2)
4
7 Nm (0.7 m • kgf, 5.1 ft • Ibf) 7 Nm (0.7 m • kgf, 5.1 ft • Ibf)
T.R
T.R
.
Order Job/Parts to remove Q’ty Remarks

Inner panel cover (left side) 4-13.
Radiator cover 4-8.
Side panel 4-8.
1 Windshield cover 2
2 Windshield bracket 2
3 Windshield 1
4 Front under cover 1
5 Front cover 1
6 Rearview mirror 2
4-1
GENERAL CHASSIS (1)
Removing the windshield and front cowling assembly

1.6 Nm (0.16 m • kgf, 1.2 ft • Ibf) 10 Nm (1.0 m • kgf, 7.2 ft • Ibf)
T.R
.
T.R
.
10 Nm (1.0 m • kgf, 7.2 ft • Ibf)
T.R
.
(2)
(2) (2)
(2) (2)
(4)
(2) 1.5 Nm (0.15 m • kgf, 1.1 ft • Ibf)
T.R
.
(2)
(2)
7
(2)
(2)
(2)
(2) 8
(2)
7 Nm (0.7 m • kgf, 5.1 ft • Ibf) 9 7 Nm (0.7 m • kgf, 5.1 ft • Ibf)

T.R
T.R
.

7 Windshield inner panel 1
8 Headlight sub-wire harness coupler 2 Disconnect.
9 Front cowling assembly 1
4-2
GENERAL CHASSIS (1)
Disassembling the front cowling assembly
8
3
2
1
2
1
8
5
4
(3)
6
9

1 Front turn signal/position light coupler 2 Disconnect.
2 Headlight coupler 2 Disconnect.
3 Headlight sub-wire harness 1
4 Auxiliary light coupler (left) 1 Disconnect.
5 Auxiliary light coupler (right) 1 Disconnect.
6 Front turn signal/position light (left) 1
7 Front turn signal/position light (right) 1
8 Side cowling 2
9 Headlight under panel 1
4-3
GENERAL CHASSIS (1)
EAS30140
REMOVING THE WINDSHIELD

1. Remove:
• Windshield cover
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Assembling the windshield “1” and wind-
shield brackets “2” with the windshield
screws “3”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ b. Installing the windshield assembly with the
a. Remove the quick fastener “1”.
windshield bracket bolts “4”.
Windshield screw
1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
T.
R.
Windshield bracket bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
b. Slide it upwards and pull it toward you.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• Windshield
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the windshield bracket bolts “1”.
b. Removing the windshield assembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Removing the windshield screws “2”. 2. Install:
d. Removing the windshield brackets “3”. • Windshield cover
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS30141
a. Insert the projection into the hole and slide it
INSTALLING THE WINDSHIELD downwards.
1. Install: b. Installing the quick fastener “1”.
• Windshield
4-4
GENERAL CHASSIS (1)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ e. Tighten the bolts to the specified torque.

EAS31397
ADJUSTING THE WINDSHIELD HEIGHT Windshield bracket bolt

1. Adjust: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
• Windshield height
f. Installing the windshield cover.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the windshield cover and windshield Refer to “INSTALLING THE WINDSHIELD”
assembly. on page 4-4.
Refer to “REMOVING THE WINDSHIELD” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
on page 4-4. EAS31517
b. Remove the rubber caps “1”. REMOVING THE FRONT UNDER COVER
1. Remove:
• Front under cover
c. Install the rubber caps “1” in the desired posi-

tion.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the quick fasteners “1”.
b. Pull the claws “2” of the front under cover to
the front side and remove them.
2
2
d. Install the windshield assembly to the desired
position by installing the bolts “1”.
1 2 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31518
INSTALLING THE FRONT UNDER COVER

1. Install:
• Front under cover
4-5
GENERAL CHASSIS (1)
c. Pull the projections “4” of the front cover to

the front side and remove them.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the claws “1” of the front under cover. 4
b. Installing the quick fasteners “2”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31399
INSTALLING THE FRONT COVER

1
1. Install:
• Front cover
1
1
2 1 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31398
REMOVING THE FRONT COVER

1. Remove:
• Front cover ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the projections “1” of the front cover.
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the quick fastener “1”. b. Fit the metal clips “2” and claws “3” of the
b. Remove the metal clips “2” from the wind- front cover.
shield inner panel and claws “3” from the front c. Installing the quick fastener “4”.
cowling assembly.
2 2
2 2 3
3
3
3
1 4 3
3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-6
GENERAL CHASSIS (1)
EAS31400
REMOVING THE WINDSHIELD INNER

PANEL
1. Remove:
• Windshield inner panel
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the quick fasteners “1”.
b. Removing the bolts “2”.
c. Pull the projections “3” of the windshield inner
panel to the front side and remove them.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31401
INSTALLING THE WINDSHIELD INNER

PANEL
1. Install:
• Windshield inner panel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the projections “1” of the windshield in-
ner panel.
b. Installing the bolts “2”.
c. Installing the quick fasteners “3”.
4-7
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the bottom cowling
1
4
9
5
8
5
9
(3)
(6)
2 6
1
8
(4)
7
3

1 Footboard mat 4
2 Radiator cover 1
3 Side panel 2
4 Center cover 1
5 Side cover 2
6 Bottom side cowling 2
7 Bottom center cowling 1
8 Side cover moulding 2
9 Footboard 2
4-8
GENERAL CHASSIS (2)
EAS31290
REMOVING THE SIDE PANEL

1. Remove:
• Side panel
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31094
REMOVING THE CENTER COVER

1. Remove:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the quick fasteners “1”. • Center cover
b. Removing the screws “2”.
c. Remove the metal clip “3”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the screws “1”.
b. Use an appropriate hook from the service
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
hole “2” to raise the center cover.
EAS31291
c. When the center cover is raised, pull the cen-
INSTALLING THE SIDE PANEL
ter cover upwards and remove the claws “3”.
1. Install:
• Side panel
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS31095
a. Insert the metal clip “1”. INSTALLING THE CENTER COVER

b. Installing the screws “2”. 1. Install:
c. Installing the quick fasteners “3”. • Center cover
4-9
GENERAL CHASSIS (2)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Insert the claws “1”.
EAS31520
b. Installing the screws “2”. INSTALLING THE SIDE COVER
1. Install:
• Side cover
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31519
REMOVING THE SIDE COVER ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

1. Remove: a. Insert the projections “1”.
• Side cover b. Insert the claws “2”.
c. Installing the bolts “3”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the bolts “1”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Pull the claws “2” outside of the vehicle and
EAS31521
raise them. REMOVING THE SIDE COVER MOULDING
c. When the side cover is raised, pull the side 1. Remove:
cover outsides of the vehicle and remove the • Side cover moulding
projections “3”.
4-10
GENERAL CHASSIS (2)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Removing the quick fastener “1”.
EAS31523
b. Removing the screws “2”. REMOVING THE FOOTBOARD
c. Pull the side moulding outside of the vehicle 1. Remove:
and remove the claws “3”. • Footboard
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS31522 a. Removing the screws “1”.
INSTALLING THE SIDE COVER MOULDING b. Removing the bolts “2”.
1. Install:
• Side cover moulding
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the claws “1”.
b. Installing the screws “2”.
c. Installing the quick fastener “3”.
A. Left side
B. Right side
c. Remove the claws “3”.
4-11
GENERAL CHASSIS (2)
d. Slide the footboard upwards, pull it toward

you, and then remove it.
A. Left side
B. Right side
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31524
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
INSTALLING THE FOOTBOARD
1. Install:
• Footboard
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the hooks of the footboard.
b. Fit the claws “1”.
c. Installing the bolts “2”.

d. Installing the screws “3”.
4-12
GENERAL CHASSIS (3)
EAS20156
GENERAL CHASSIS (3)

Removing the leg shield
1 (4)
8
(2)
7
(2)
5
6
(2)
4
2

Front cowling assembly 4-1.
Footboard 4-8.
1 Inner panel center cover 1
2 Auxiliary DC jack assembly cover 1
3 Inner panel cover (left side) 1
4 Auxiliary DC jack assembly 1
5 Battery 1
6 Meter assembly coupler 1 Disconnect.
7 Meter panel assembly 1
8 Meter assembly 1
4-13
GENERAL CHASSIS (3)
Removing the leg shield
9
(4)
(2)
16 (2)
17
15
(2) 12
10
11 13
14
11
14

9 Meter cover 1
10 Remote control unit coupler 1 Disconnect.
11 Storage box (front right side) 1
12 Remote control unit 1
Applicable unit range: SJ13Y-0000635 and
13 Seat lock cable cover 1 after.
14 Seat lock cable 1 Disconnect.
15 Leg shield 1
16 Control switch assembly 1
17 Control switch assembly bracket 1
4-14
GENERAL CHASSIS (3)
EAS31525
REMOVING THE INNER PANEL CENTER

COVER
1. Remove:
• Inner panel center cover
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the screws “1”.
b. There are claws “2”. Remove them, starting
from the top.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31526
INSTALLING THE INNER PANEL CENTER

COVER
1. Install:
• Inner panel center cover
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the claws “1”, starting from the bottom.
b. Installing the screws “2”.
4-15
GENERAL CHASSIS (4)
EAS20157
GENERAL CHASSIS (4)

Removing the rear cowling assembly
(3) (2) (3)

Footboard 4-8.
O2 sensor lead Refer to “ENGINE REMOVAL” on page 5-2.
1 Seat 1
2 Fuel tank cover 1
3 Grab bar 2
4 Rear cover 1
5 Tail/brake light lead cover 1
6 Tail/brake light lead guide 1
7 Storage box light switch coupler 1 Disconnect.
8 Storage box light switch 1
9 Seat hinge assembly 1
4-16
GENERAL CHASSIS (4)
Removing the rear cowling assembly
12 10
13
11

10 Tail/brake light assembly coupler 1 Disconnect.
11 License plate light lead coupler 1 Disconnect.
12 Rear turn signal light lead coupler 2 Disconnect.
13 Mudguard 1
14 Rear fender 1
15 Rear cowling assembly 1
4-17
GENERAL CHASSIS (4)
Disassembling the rear cowling assembly
(2)
(2)

1 Tail/brake light bracket 1
2 Rear cowling (left) 1
3 Rear cowling (right) 1
4 Turn signal light (left) 1
5 Turn signal light (right) 1
6 Tail/brake light 1
7 Tail/brake light cover 1
4-18
GENERAL CHASSIS (4)
EAS31412
REMOVING THE REAR COVER

1. Remove:
• Rear cowling
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Removing the quick fasteners “1”.
b. Holding the rear side of the rear cover and
slightly applying a force upward, slide the
cover rearward to remove it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31413
INSTALLING THE REAR COVER

1. Install:
• Rear cowling
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert the claws “1” of the rear cover though
the holes of the rear cowling assembly. Slide
the cover forward to install it.
b. Installing the quick fasteners “2”.
4-19
GENERAL CHASSIS (5)
EAS20158
GENERAL CHASSIS (5)

Removing the storage box

Rear cowling assembly 4-16.
1 Fuel pump coupler access cover 1
2 Fuel pump coupler 1 Disconnect.
3 Fuel hose connector cover 1
4 Fuel hose 1 Disconnect.
5 Fuel tank overflow hose 1
6 Storage box inner mat 1
7 Seat lock assembly 1
8 Storage box light connector 2 Disconnect.
9 Rollover valve stay 1
10 Storage box 1
11 Storage box light 1
4-20
GENERAL CHASSIS (5)
EAS31414
2. Install:
REMOVING THE FUEL HOSE
• Fuel hose connector cover
1. Remove: ECA22030
• Fuel hose connector cover “1” NOTICE

2. Disconnect: When installing the fuel hose, make sure that
• Fuel hose “2” it is securely connected, and that the fuel
EWA15910
WARNING hose connector cover is in the correct posi-

tion, otherwise the fuel hose will not be prop-
Cover fuel hose connections with a cloth
erly installed.
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to TIP
spurt out when removing the hose. • Wipe up any fuel remaining in the recess “a” in
ECA21750 the fuel pump with a dry rag “1”.
NOTICE • After installing the fuel hose connector cover,
• Be sure to disconnect the fuel hose by make sure that it is installed securely.
hand. Do not forcefully disconnect the
hose with tools.
• Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remain-
ing in it.
• Do not disconnect the fuel hose from the
fuel hose connector. Disconnect the con-
nector from the fuel pump.
TIP
Before removing the hose, place a few rags in
the area under where it will be removed.
1
2
EAS31415
INSTALLING THE FUEL HOSE

1. Connect:
• Fuel hose
4-21
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake discs
91 Nm (9.1 m•kgf, 66 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.
35 Nm (3.5 m•kgf, 25 ft•Ibf)
1
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)

T.R
.
2 4
6
(2)
9
23 Nm (2.3 m•kgf, 17 ft•Ibf)
(4)
T.R
7
.
5 6 3
21 Nm (2.1 m•kgf, 15 ft•Ibf) 2
T.R
.
(5)
10 8
LS
(2)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
35 Nm (3.5 m•kgf, 25 ft•Ibf)
New
T.R
.
LT LT
T.R
. 7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
(5)
23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.
11
New

1 Speed sensor coupler 1 Disconnect.
2 Front reflector 2
3 Front brake hose/lead holder (left) 1
4 Front brake hose/lead holder (right) 1
5 Speed sensor 1
6 Front brake caliper 2
7 Front wheel axle pinch bolt 4 Loosen.
8 Front wheel axle bolt 1
9 Front wheel axle 1
10 Front wheel 1
11 Collar 1 Length: 12 mm (0.47 in)
4-22
FRONT WHEEL
Removing the front wheel and brake discs

91 Nm (9.1 m•kgf, 66 ft•Ibf)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.
35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
(2)
14
23 Nm (2.3 m•kgf, 17 ft•Ibf)

(4)
T.R
.
21 Nm (2.1 m•kgf, 15 ft•Ibf)

T.R
.
(5)
LS
(2)
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
12 35 Nm (3.5 m•kgf, 25 ft•Ibf)
New
T.R
.
LT LT
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
T.R
.
(5)
13 23 Nm (2.3 m•kgf, 17 ft•Ibf)
T.R
.
New
13
12 Collar 1 Length: 18 mm (0.71 in)
13 Front brake disc 2
14 Front fender 1
4-23
FRONT WHEEL
Disassembling the front wheel
New
New
2
3
4
6
1
5 New
2 New
(3)
New
LT
8 Nm (0.8 m • kgf, 5.8 ft • Ibf)

T.R
.

1 Speed sensor rotor 1
2 Oil seal 2
3 Wheel bearing (right) 1
4 Collar 1
5 Wheel bearing (left) 1
6 Air valve 1
4-24
FRONT WHEEL
EAS30145
REMOVING THE FRONT WHEEL TIP

ECA22340 To prevent damaging the wheel, place a rag “2”
NOTICE between the screwdriver and the wheel surface.
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the speed sensor or speed
sensor rotor; otherwise, the sensor or rotor
may be damaged, resulting in improper op-
eration.
• Do not drop the speed sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the speed sensor ro-
tor, wipe it off immediately.
1. Stand the vehicle on a level surface. c. Remove the wheel bearings “3” with a gener-
EWA13120
al bearing puller.
WARNING
2. Remove:
• Front brake hose/lead holders
• Speed sensor
• Front brake calipers
TIP
Do not apply the brake lever when removing the
brake calipers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Elevate: 2. Remove:
• Front wheel • Air valve
TIP
EAS30147
Place the vehicle on a suitable stand so that the CHECKING THE FRONT WHEEL
front wheel is elevated. 1. Check:
• Wheel axle
EAS30146
Roll the wheel axle on a flat surface.
DISASSEMBLING THE FRONT WHEEL Bends → Replace.
ECA22350
EWA13460
NOTICE WARNING
• Keep magnets (including magnetic pick-up Do not attempt to straighten a bent wheel ax-
tools, magnetic screwdrivers, etc.) away le.
from the speed sensor rotor.
ject it to shocks.
1. Remove:
• Speed sensor rotor
• Oil seals
• Wheel bearings
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the surface of the front wheel hub.
2. Check:
b. Remove the oil seals “1” with a flat-head
screwdriver. • Tire
4-25
FRONT WHEEL
• Front wheel 1. Install:

Damage/wear → Replace. • Wheel bearings New
Refer to “CHECKING THE TIRES” on page
3-18 and “CHECKING THE WHEELS” on • Oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
page 3-18. a. Install the new wheel bearing (left side).
3. Measure: ECA20540
• Radial wheel runout “1” NOTICE

• Lateral wheel runout “2” Do not apply pressure to the wheel bearing
Over the specified limits → Replace. inner race “1” or balls “2”. Pressure should
only be applied to the outer race “3”.
Radial wheel runout limit
1.0 mm (0.04 in) TIP
Lateral wheel runout limit Use a socket “4” that matches the diameter of
0.5 mm (0.02 in)
the wheel bearing outer race.
4. Check: b. Install the collar.

• Wheel bearings c. Install the new wheel bearing (right side).
Front wheel turns roughly or is loose → Re- TIP
place the wheel bearings. Place a suitable washer “1” between the socket
• Oil seals “2” and the bearing so that both the inner race
Damage/wear → Replace. “3” and outer race “4” are pressed at the same
time, and then press the bearing until the inner
race makes contact with the collar “5”.
EAS30151
ASSEMBLING THE FRONT WHEEL

ECA22350
NOTICE d. Install the new oil seals

• Keep magnets (including magnetic pick-up ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
tools, magnetic screwdrivers, etc.) away 2. Install:
from the speed sensor rotor. • Speed sensor rotor
ject it to shocks. Speed sensor rotor bolt
• If any solvent gets on the speed sensor ro- 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
T.
R.
tor, wipe it off immediately. LOCTITE®
4-26
FRONT WHEEL
ECA22380
NOTICE
ject it to shocks.
• Replace the brake disc bolts and speed
sensor rotor bolts with new ones.
TIP
Install the sensor rotor with the stamped mark
“a” facing outward. a. 45°–55°
A. Wheel rotation direction
B. Left side
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30152
ADJUSTING THE FRONT WHEEL STATIC

BALANCE
A
TIP
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
3. Install: brake disc installed.
• Air valve
1. Remove:
TIP
• Balancing weight(s)
• Fasten air valve nut “1” and tighten air valve 2. Find:
locknut “2” to 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf). • Front wheel’s heavy spot
• When installing the air valve, orient the air
TIP
valve referring to the illustration.
Place the front wheel on a suitable balancing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ stand.
a. Tighten the air valve nut “1”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Front wheel air valve nut a. Spin the front wheel.
2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) b. When the front wheel stops, put an “X1” mark
T.
R.
at the bottom of the wheel.

b. Tighten the air valve locknut “2” while holding
the air valve nut so as not to turn the nut.
Front wheel air valve locknut

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
T.
R.
c. Turn the front wheel 90° so that the “X1” mark

is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
4-27
FRONT WHEEL
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
each position shown.
f. Repeat steps (c) through (e) several times

until all the marks come to rest at the same
spot.
g. The spot where all the marks come to rest is b. If the front wheel does not remain stationary
the front wheel’s heavy spot “X”. at all of the positions, rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust: EAS30932
• Front wheel static balance INSTALLING THE FRONT WHEEL (FRONT

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
BRAKE DISC)
a. Install a balancing weight “1” onto the rim ex- 1. Install:
actly opposite the heavy spot “X”. • Front brake discs
TIP
Front brake disc bolt
Start with the lightest weight. 23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
LOCTITE®
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
b. Turn the front wheel 90° so that the heavy

spot is positioned as shown.
2. Check:
• Front brake discs
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-45.
3. Lubricate:
• Oil seal lips
c. If the heavy spot does not stay in that posi- Recommended lubricant
tion, install a heavier weight. Lithium-soap-based grease
d. Repeat steps (b) and (c) until the front wheel
is balanced. 4. Install:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Collars
4. Check: • Front wheel
• Front wheel static balance • Front wheel axle
4-28
FRONT WHEEL
• Front wheel axle bolt

TIP
Install the front wheel with the mark “a” on the
front tire pointing in the direction of wheel rota- 1
tion.
a
5 4 3 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Speed sensor
Speed sensor bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
5. Tighten:
ECA22011
• Front wheel axle
• Front wheel axle pinch bolt NOTICE
Make sure there are no foreign materials in
Front wheel axle the speed sensor rotor and speed sensor.
91 Nm (9.1 m·kgf, 66 ft·lbf) Foreign materials cause damage to the
T.
R.
Front wheel axle pinch bolt speed sensor rotor and speed sensor.
21 Nm (2.1 m·kgf, 15 ft·lbf)
TIP
ECA19760
• When installing the speed sensor, check the
NOTICE
speed sensor lead for twists.
Before tightening the wheel axle, push down • To route the speed sensor lead, refer to “CA-
hard on the handlebars several times and BLE ROUTING” on page 2-37.
check if the front fork rebounds smoothly.
7. Measure:
TIP • Distance “a”
First, tighten the wheel axle, then the wheel axle (between the speed sensor rotor “1” and
pinch bolt. speed sensor “2”)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Check the wheel bear-
a. Insert the front wheel axle from the right side, ing for looseness, and the speed sensor and
temporarily install the front wheel axle bolt “1” sensor rotor installation conditions (warpage
from the left side, and then tighten the front caused by overtorque, wrong installation di-
wheel axle to 91 Nm (9.1 m·kgf, 66 ft·lbf). rection, rotor decentering, LOCTITE® on the
b. Temporarily install the pinch bolts “2” and “3”, mounting surface of the rotor, deformation
and then tighten the pinch bolts to 21 Nm (2.1 caused by an impact during service and
m·kgf, 15 ft·lbf) in the order of pinch bolt “3” → caught foreign materials). If there is any de-
pinch bolt “2” → pinch bolt “3”. fective part, repair or replace the defective
c. Temporarily install the pinch bolts “4” and “5”, part.
and then tighten the pinch bolts to 21 Nm (2.1
m·kgf, 15 ft·lbf) in the order of pinch bolt “5” → Distance “a” (between the speed
sensor rotor and speed sensor)
pinch bolt “4” → pinch bolt “5”.
0.5–1.3 mm (0.02–0.05 in)
TIP
Measure the distance between the speed sen-
sor rotor and speed sensor in several places in
one rotation of the front wheel. Do not turn the
4-29
FRONT WHEEL
front wheel while the thickness gauge is in-

stalled. This may damage the speed sensor ro-
tor and the speed sensor.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
1
a
2
2 1
8. Install:
• Front brake calipers
• Front brake hose/lead holders
Front brake caliper bolt

35 Nm (3.5 m·kgf, 25 ft·lbf)
T.
R.
Front brake hose/lead holder bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-30
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel
* When replacing the rear brake caliper or rear brake caliper bracket, replace them as a set.

1 Rear brake caliper 1
2 Rear brake pad 2
3 Rear brake lock cable adjusting nut 1
4 Pin 1
5 Rear brake lock spring 1
6 Rear brake lock caliper 1
7 Drive belt upper guard 1 Non-disassemble
8 Drive belt lower guard 1 Non-disassemble
9 Drive belt adjusting locknut 2 Loosen.
10 Drive belt adjusting bolt 2 Loosen.
11 Rear wheel axle nut 1
4-31
REAR WHEEL
Removing the rear wheel
* When replacing the rear brake caliper or rear brake caliper bracket, replace them as a set.

12 Washer 1
13 Adjusting block (right) 1
14 Rear wheel axle 1
15 Adjusting block (left) 1
16 Rear wheel 1
17 Rear brake caliper bracket 1
18 Caliper bolt boot 2
19 Collar (right) 1
20 Collar (left) 1
21 Dust cover 1
4-32
REAR WHEEL
Removing the rear brake disc and rear wheel pulley

1 Rear brake disc 1
2 Drive belt guide 1
3 Rear wheel pulley 1
4 Rear wheel 1
4-33
REAR WHEEL
Disassembling the rear wheel assembly

1 Oil seal 2
2 Wheel bearing (left) 1
3 Collar 1
4 Wheel bearing (right) 1
4-34
REAR WHEEL
EAS30156
REMOVING THE REAR WHEEL (DISC

BRAKE)
EWA13120
WARNING
TIP
Place the vehicle on the centerstand so that the
rear wheel is elevated. EAS30158
DISASSEMBLING THE REAR WHEEL

2. Remove: 1. Remove:
• Rear brake caliper “1” • Oil seals
• Rear brake lock caliper “2” • Wheel bearings
TIP Refer to “DISASSEMBLING THE FRONT
Do not apply the brake lever when removing the WHEEL” on page 4-25.
brake caliper.
EAS30159
CHECKING THE REAR WHEEL

1. Check:
• Wheel axle
• Wheel bearings
• Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-25.
2. Check:
• Tire
• Rear wheel
3. Loosen: Damage/wear → Replace.
• Locknuts “1” Refer to “CHECKING THE TIRES” on page
• Adjusting bolts “2” 3-18 and “CHECKING THE WHEELS” on
(left side and right side) page 3-18.
3. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-25.
EAS30160
CHECKING THE REAR WHEEL DRIVE HUB

1. Check:
• Rear wheel drive hub “1”
Cracks/damage → Replace the rear wheel.
4. Remove:
• Wheel axle nut “1”
• Washer
• Wheel axle “2”
• Rear brake caliper bracket
• Rear wheel
• Collars
TIP
Push the rear wheel forward and remove the
drive belt from the rear wheel pulley.
4-35
REAR WHEEL
EAS30162
CHECKING AND REPLACING THE REAR

WHEEL PULLEY
1. Check:
• Rear wheel pulley
Surface plating has come off → Replace the
rear wheel pulley.
Bent teeth → Replace the rear wheel pulley.
• Drive belt guide
Cracks/damage/wear → Replace the drive
belt guide.
2. Replace: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Rear wheel pulley EAS30163
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ASSEMBLING THE REAR WHEEL

a. Remove the drive belt guide bolts and the 1. Install:
drive belt guide. • Wheel bearings New
b. Remove the rear wheel pulley bolts and the
rear wheel pulley. • Oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Clean the rear wheel drive hub with a clean a. Install the new wheel bearing (right side).
cloth, especially the surfaces that contact the ECA18110
pulley. NOTICE
d. Install the new rear wheel pulley and drive Do not contact the wheel bearing inner race
belt guide. “1” or balls “2”. Contact should be made
only with the outer race “3”.
Rear wheel pulley bolt
64 Nm (6.4 m·kgf, 46 ft·lbf) TIP
T.
R.
LOCTITE® Use a socket “4” that matches the diameter of

Drive belt guide bolt
the wheel bearing outer race.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
LOCTITE®
TIP
• Tighten the rear wheel pulley bolts in stages
and in a crisscross pattern.
• When tightening the drive belt guide bolts,
tighten the bolt at the punch mark “a” first and
then other bolts in stages and in a crisscross
pattern.
b. Install the collar.

c. Install the new wheel bearing (left side).
TIP
Place a suitable washer “1” between the socket
“2” and the bearing so that both the inner race
“3” and outer race “4” are pressed at the same
time, and then press the bearing until the inner
race makes contact with the collar “5”.
4-36
REAR WHEEL
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check:
2. Lubricate: • Rear brake disc
• Oil seal lips Refer to “CHECKING THE REAR BRAKE
DISC” on page 4-62.
Recommended lubricant 3. Install:
Lithium-soap-based grease • Drive belt guide
• Rear wheel pulley
EAS30164
ADJUSTING THE REAR WHEEL STATIC Rear wheel pulley bolt

BALANCE 64 Nm (6.4 m·kgf, 46 ft·lbf)
T.
R.
TIP LOCTITE®
• After replacing the tire, wheel or both, the rear Drive belt guide bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
wheel static balance should be adjusted.
LOCTITE®
• Adjust the rear wheel static balance with the
brake disc and rear wheel pulley installed.
TIP
1. Adjust: • Tighten the rear wheel pulley bolts in stages
• Rear wheel static balance and in a crisscross pattern.
Refer to “ADJUSTING THE FRONT WHEEL • When tightening the drive belt guide bolts,
STATIC BALANCE” on page 4-27. tighten the bolt at the punch mark “a” first and
EAS30165
then other bolts in stages and in a crisscross
INSTALLING THE REAR WHEEL (DISC pattern.
BRAKE)
1. Install:
• Rear brake disc
Rear brake disc bolt

30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
LOCTITE®
ECA19150
NOTICE
Replace the brake disc bolts with new ones.
TIP
Tighten the brake disc bolts in stages and in a
crisscross pattern.
4-37
REAR WHEEL
4. Install: 7. Tighten:
• Dust cover • Wheel axle nut
• Collars • Rear brake caliper bolts
• Brake caliper bracket • Rear brake lock caliper bolts
• Rear wheel
• Adjusting blocks Rear wheel axle nut
• Wheel axle 160 Nm (16 m·kgf, 116 ft·lbf)
T.
R.
• Washers Rear brake caliper bolt
27 Nm (2.7 m·kgf, 20 ft·lbf)
• Wheel axle nut
Rear brake lock caliper bolt
TIP 23 Nm (2.3 m·kgf, 17 ft·lbf)
• Do not install the brake caliper and brake lock
EWA13500
caliper.
WARNING
• Fit the brake torque stop pin “1” on the swing-
arm into the slot “a” on the brake caliper brack- Make sure the brake hose is routed properly.
et. TIP
• Install the left adjusting block so that projection
When tightening the wheel axle nut, there
“b” faces to the front of the vehicle.
should be no clearance “a” between the adjust-
• Install the right adjusting block so that upper
ing block “1” and adjusting bolt “2”.
chamfer “c” faces to the top of the vehicle and
lower chamfer “c” faces to the bottom of the ve-
hicle.
8. Adjust:
Refer to “ADJUSTING THE REAR BRAKE
LOCK CABLE” on page 3-17.
A. Left side
B. Right side
5. Install:
• Rear brake caliper
• Rear brake lock caliper
(temporarily)
6. Adjust:
4-38
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
7 Nm (0.7 m • kgf, 5.1 ft • Ibf)
T.R
.
5 Nm (0.5 m • kgf, 3.6 ft • Ibf)
T.R
.
35 Nm (3.5 m • kgf, 25 ft • Ibf)
T.R
.
10
2
1
7
5 9
6 4 8
35 Nm (3.5 m • kgf, 25 ft • Ibf)
T.R
.

The following procedure applies to both of
the front brake calipers.
1 Front brake hose/lead holder bolt 1
2 Front reflector 1
4 Front brake caliper bolt 2
6 Brake pad clip 2
7 Brake pad pin 1
8 Brake pad spring 1
9 Front brake pad 2
10 Bleed screw 1
4-39
FRONT BRAKE
Removing the front brake master cylinder

Upper handlebar cover Refer to “HANDLEBAR” on page 4-72.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-15.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Front brake lever 1
5 Front brake light switch connector 2 Disconnect.
6 Brake hose union bolt 1
4-40
FRONT BRAKE
Removing the front brake master cylinder

7 Front brake hose 1
8 Brake hose gasket 2
9 Front brake master cylinder holder 1
10 Front brake master cylinder 1
11 Front brake light switch 1
4-41
FRONT BRAKE
Disassembling the front brake master cylinder

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
4-42
FRONT BRAKE
Removing the front brake calipers
7 Nm (0.7 m • kgf, 5.1 ft • Ibf)
T.R
.
3
1
6
4
5 New
30 Nm (3.0 m • kgf, 22 ft • Ibf) 8

T.R
.
7
35 Nm (3.5 m • kgf, 25 ft • Ibf)
T.R
.

Drain.
1 Front brake hose/lead holder bolt 1
2 Front reflector 1
6 Front brake hose 1
7 Front brake caliper bolt 2
4-43
FRONT BRAKE
Disassembling the front brake calipers

T.R
5 Nm (0.5 m • kgf, 3.6 ft • Ibf)
.
3
2
6 New
7 New
5
6 New
1
6 New
New 7
5
6 New

1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Front 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
4-44
FRONT BRAKE
EAS30168
d. Hold the dial gauge at a right angle against
INTRODUCTION
EWA14101
the brake disc surface.
WARNING e. Measure the deflection 1.5 mm (0.06 in) be-
Disc brake components rarely require disas- low the edge of the brake disc.
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.
• Never use solvents on internal brake com-
ponents. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Use only clean or new brake fluid for clean- 4. Measure:

ing brake components. • Brake disc thickness
• Brake fluid may damage painted surfaces Measure the brake disc thickness at a few dif-
and plastic parts. Therefore, always clean ferent locations.
up any spilt brake fluid immediately. Out of specification → Replace.
• Avoid brake fluid coming into contact with
Brake disc thickness limit
the eyes as it can cause serious injury.
3.5 mm (0.14 in)
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS30169
CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake
discs.
1. Remove:
• Front wheel
Refer to “FRONT WHEEL” on page 4-22.
2. Check: 5. Adjust:
• Brake disc • Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Damage/galling → Replace. a. Remove the brake disc.
3. Measure: b. Rotate the brake disc by two bolt hole.
• Brake disc deflection c. Install the brake disc and new brake disc
Out of specification → Correct the brake disc bolts.
deflection or replace the brake disc.
Front brake disc bolt
Brake disc runout limit (as mea- 23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
sured on wheel)
R.
LOCTITE®
0.15 mm (0.0059 in)
ECA19150
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTICE
a. Place the vehicle on a suitable stand so that
Replace the brake disc bolts with new ones.
the front wheel is elevated.
b. Before measuring the front brake disc deflec- TIP
tion, turn the handlebar to the left or right to Tighten the brake disc bolts in stages and in a
ensure that the front wheel is stationary. crisscross pattern.
c. Remove the brake caliper.
4-45
FRONT BRAKE
d. Measure the brake disc deflection. 3. Measure:

e. If out of specification, repeat the adjustment • Brake pad wear limit “a”
steps until the brake disc deflection is within Out of specification → Replace the brake
specification. pads as a set.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc. Brake pad lining thickness (in-
ner)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4.0 mm (0.16 in)
6. Install: Limit
• Front wheel 0.5 mm (0.02 in)
Refer to “FRONT WHEEL” on page 4-22. Brake pad lining thickness (out-
EAS30170
er)
REPLACING THE FRONT BRAKE PADS 4.0 mm (0.16 in)
The following procedure applies to both brake Limit
0.5 mm (0.02 in)
calipers.
TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1. Remove:
• Brake pad clips “1”
• Brake pad pin “2”
• Brake pad spring
4. Remove:
• Front brake caliper
5. Install:
• Brake pads
2 TIP
1
Always install new brake pads, and new brake
pad spring as a set.
2. Remove: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Brake pads “1” a. Connect a clear plastic hose “1” tightly to the
bleed screw “2”. Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with your
finger.
4-46
FRONT BRAKE
c. Tighten the bleed screw. 8. Check:

• Brake lever operation
Front brake caliper bleed screw Soft or spongy feeling → Bleed the brake sys-
5 Nm (0.5 m·kgf, 3.6 ft·lbf) tem.
T.
R.
Refer to “BLEEDING THE HYDRAULIC

d. Install a brake pads and brake pad spring.
TIP
EAS30171
The arrow mark “a” on the brake pad spring
REMOVING THE FRONT BRAKE CALIPERS
must point in the direction of disc rotation.
brake calipers.
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Front brake hose/lead holder bolt “1”
• Brake hose union bolt “2”
• Brake hose gaskets “3”
• Front brake hose “4”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ TIP
6. Install: Put the end of the brake hose into a container
• Front brake caliper and pump out the brake fluid carefully.
• Brake pad pin
• Brake pad clips
1
35 Nm (3.5 m·kgf, 25 ft·lbf) 4
T.
R.
7. Check:
• Brake fluid level 2
Below the minimum level mark “a”→ Add the
specified brake fluid to the proper level. 3
LEVEL” on page 3-13. EAS30172
DISASSEMBLING THE FRONT BRAKE

CALIPERS
brake calipers.
1. Remove:
• Brake caliper pistons “1”
• Brake caliper piston dust seals “2”
• Brake caliper piston seals “3”
4-47
FRONT BRAKE
2 1 Recommended brake component replacement

3 schedule
2
Piston seals Every two years
Piston dust seals Every two years
Brake hoses Every four years
Every two years and
Brake fluid whenever the brake is
3 2 disassembled
1 2
1. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose joint • Brake caliper pistons “1”
opening “a” to force out the pistons from the Rust/scratches/wear → Replace the brake
brake caliper. caliper pistons.
EWA17290 • Brake caliper cylinders “2”
WARNING Scratches/wear → Replace the brake caliper
• Cover the brake caliper pistons with a rag. assembly.
Be careful not to get injured when the pis- • Brake caliper body “3”
tons are expelled from the brake caliper. Cracks/damage → Replace the brake caliper
• Never try to pry out the brake caliper pis- assembly.
tons. • Brake fluid delivery passages
• Do not loosen the bolts “4”. (brake caliper body)
Obstruction → Blow out with compressed air.
EWA13611
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seals
and brake caliper piston seals.
a 3
1
4 1
EAS30174
ASSEMBLING THE FRONT BRAKE

CALIPERS
EWA13621
WARNING
b. Remove the brake caliper piston dust seals • Before installation, all internal brake com-
and brake caliper piston seals. ponents should be cleaned and lubricated
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ with clean or new brake fluid.
EAS30173 • Never use solvents on internal brake com-
CHECKING THE FRONT BRAKE CALIPERS ponents as they will cause the brake caliper
The following procedure applies to both of the piston dust seals and brake caliper piston
brake calipers. seals to swell and distort.
Recommended brake component replacement • Whenever a brake caliper is disassembled,
schedule replace the brake caliper piston dust seals
Brake pads If necessary and brake caliper piston seals.
4-48
FRONT BRAKE
Refer to “REPLACING THE FRONT BRAKE

Specified brake fluid PADS” on page 4-46.
DOT 4 4. Fill:
• Brake master cylinder reservoir
EAS30934
INSTALLING THE FRONT BRAKE CALIPERS (with the specified amount of the specified
The following procedure applies to both of the brake fluid)
brake calipers. Specified brake fluid
1. Install: DOT 4
• Front brake caliper “1”
(temporarily) EWA13540
WARNING
• Brake hose gaskets New
• Front brake hose “2” • Use only the designated brake fluid. Other
• Brake hose union bolt “3” brake fluids may cause the rubber seals to
Front brake hose union bolt brake performance.
30 Nm (3.0 m·kgf, 22 ft·lbf) • Refill with the same type of brake fluid that
T.
R.

EWA13531
WARNING
Proper brake hose routing is essential to in- • When refilling, be careful that water does
sure safe vehicle operation. not enter the brake master cylinder reser-
ECA14170
voir. Water will significantly lower the boil-
NOTICE ing point of the brake fluid and could cause
When installing the brake hose onto the vapor lock.
brake caliper “1”, make sure the brake pipe ECA13540
“a” touches the projection “b” on the brake NOTICE

caliper. Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
a 5. Bleed:
2
• Brake system
3 BRAKE SYSTEM” on page 3-15.
6. Check:
• Brake fluid level
1 b Below the minimum level mark “a”→ Add the
specified brake fluid to the proper level.
2. Remove: Refer to “CHECKING THE BRAKE FLUID
• Front brake caliper LEVEL” on page 3-13.
3. Install:
• Brake pads
• Brake pad pin
• Brake pad clips
• Front brake caliper
• Front brake hose/lead holder

35 Nm (3.5 m·kgf, 25 ft·lbf)
T.
R.
Front brake hose/lead holder bolt

7 Nm (0.7 m·kgf, 5.1 ft·lbf)
4-49
FRONT BRAKE
7. Check: • Brake master cylinder reservoir diaphragm

• Brake lever operation holder “3”
Soft or spongy feeling → Bleed the brake sys- Cracks/damage → Replace.
tem. • Brake master cylinder reservoir diaphragm
Refer to “BLEEDING THE HYDRAULIC “4”
BRAKE SYSTEM” on page 3-15. Damage/wear → Replace.
EAS30179
REMOVING THE FRONT BRAKE MASTER

CYLINDER
TIP
Before removing the front brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.
1. Disconnect:
• Brake light switch connectors
(from the front brake light switch)
2. Remove:
• Front brake hose “3”
TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
4. Check:
• Brake hose
EAS30181
ASSEMBLING THE FRONT BRAKE MASTER

CYLINDER
EWA13520
WARNING
• Before installation, all internal brake com-
EAS30725 ponents should be cleaned and lubricated
CHECKING THE FRONT BRAKE MASTER with clean or new brake fluid.
CYLINDER • Never use solvents on internal brake com-
1. Check: ponents.
• Brake master cylinder
Damage/scratches/wear → Replace.
Specified brake fluid
• Brake fluid delivery passages DOT 4
(brake master cylinder body)
Obstruction → Blow out with compressed air. EAS30182
2. Check: INSTALLING THE FRONT BRAKE MASTER

• Brake master cylinder kit CYLINDER
Damage/scratches/wear → Replace. 1. Install:
3. Check: • Brake master cylinder “1”
• Brake master cylinder reservoir cap “1” • Front brake master cylinder holder “2”
• Brake master cylinder reservoir “2”
Brake master cylinder holder bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
4-50
FRONT BRAKE
TIP 3. Fill:
• Install the brake master cylinder holder with the • Brake master cylinder reservoir
“ ” mark “a” facing up. (with the specified amount of the specified
• Align the end of the brake master cylinder hold- brake fluid)
er with the welding line “b” on the handlebar.
• First, tighten the upper bolt, then the lower bolt. DOT 4
EWA13540
WARNING
brake performance.
2. Install: leading to poor brake performance.
• When refilling, be careful that water does
• Brake hose gaskets “1” New not enter the brake master cylinder reser-
• Front brake hose “2” voir. Water will significantly lower the boil-
• Brake hose union bolt “3” ing point of the brake fluid and could cause
vapor lock.
Front brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf) ECA13540
T.
R.
NOTICE
EWA13531
Brake fluid may damage painted surfaces
WARNING and plastic parts. Therefore, always clean up
Proper brake hose routing is essential to in- any spilt brake fluid immediately.
sure safe vehicle operation.
4. Bleed:
ECA14160
• Brake system
NOTICE
When installing the brake hose onto the BRAKE SYSTEM” on page 3-15.
brake master cylinder, make sure the brake 5. Check:
pipe touches the projection “a” as shown. • Brake fluid level
TIP Below the minimum level mark “a”→ Add the
Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
6. Check:
Soft or spongy feeling → Bleed the brake sys-
tem.
4-51
FRONT BRAKE

4-52
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads

1 Rear brake caliper bolt 2
3 Rear brake pad 2
4 Brake pad support 2
5 Bleed screw 1
4-53
REAR BRAKE
Removing the rear brake master cylinder

Upper handlebar cover Refer to “HANDLEBAR” on page 4-72.
Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Rear brake lever 1
5 Rear brake light switch connector 2 Disconnect.
4-54
REAR BRAKE
Removing the rear brake master cylinder

7 Rear brake hose 1
9 Rear brake master cylinder holder 1
10 Rear brake master cylinder 1
11 Rear brake light switch 1
4-55
REAR BRAKE
Disassembling the rear brake master cylinder

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
4-56
REAR BRAKE
Removing the rear brake caliper

Drain.
3 Rear brake hose 1
4 Rear brake caliper bolt 2
6 Rear brake pad 2
7 Brake pad support 2
8 Caliper bolt boot 2
4-57
REAR BRAKE
Disassembling the rear brake caliper

1 Brake caliper piston 1
2 Brake caliper piston dust seal 1
3 Brake caliper piston seal 1
4 Bleed screw 1
5 Brake caliper body 1
4-58
REAR BRAKE
Removing the rear brake lock pads

2 Pin 1
5 Rear brake lock pad 2
4-59
REAR BRAKE
Removing the rear brake lock caliper

2 Pin 1
4-60
REAR BRAKE
Disassembling the rear brake lock caliper

1 Cap 1
2 Rear brake lock adjusting nut 1
3 Rear brake lock caliper arm 1
4 Boot 1
5 Rear brake lock pad 2
6 Caliper piston assembly 1
7 Boot 1
8 Sleeve 1
9 Boot 2
10 Rear brake lock caliper bracket bolt 1
11 Rear brake lock caliper bracket 1
12 Slide pin bolt 1
4-61
REAR BRAKE
EAS30183
INTRODUCTION Brake disc thickness limit

EWA14101
4.5 mm (0.18 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc deflection
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISCS” on page 4-45.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
sembly. 6. Install:
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-31.
• Use only clean or new brake fluid for clean- EAS30185
ing brake components. REPLACING THE REAR BRAKE PADS

• Brake fluid may damage painted surfaces TIP
and plastic parts. Therefore, always clean When replacing the brake pads, it is not neces-
up any spilt brake fluid immediately. sary to disconnect the brake hose or disassem-
• Avoid brake fluid coming into contact with ble the brake caliper.
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING 1. Remove:
THE EYES: • Rear brake caliper bolts “1”
• Flush with water for 15 minutes and get im- • Rear brake caliper “2”
mediate medical attention.
EAS30184
CHECKING THE REAR BRAKE DISC

1. Remove:
• Rear wheel
2. Check:
• Brake disc
Damage/galling → Replace.
3. Measure: 2. Remove:
• Brake disc deflection • Rear brake pads “1”
Out of specification → Correct the brake disc • Brake pad supports “2”
deflection or replace the brake disc.
Brake disc runout limit (as mea-

sured on wheel)
0.15 mm (0.0059 in)
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
3. Measure:
ferent locations.
• Brake pad wear limit “a”
Out of specification → Replace.
Out of specification → Replace the brake
pads as a set.
4-62
REAR BRAKE
• Rear brake caliper bolts

Brake pad lining thickness (in-
ner) Rear brake caliper bolt
8.0 mm (0.31 in) 27 Nm (2.7 m·kgf, 20 ft·lbf)
T.
R.
Limit
0.8 mm (0.03 in) 6. Check:
Brake pad lining thickness (out- • Brake fluid level
er) Below the minimum level mark “a”→ Add the
8.0 mm (0.31 in) specified brake fluid to the proper level.
Limit Refer to “CHECKING THE BRAKE FLUID
0.8 mm (0.03 in)
4. Install: 7. Check:
• Brake pad supports • Brake lever operation
• Rear brake pads Soft or spongy feeling → Bleed the brake sys-
tem.
TIP
Always install new brake pads, brake pad sup- BRAKE SYSTEM” on page 3-15.
ports as a set.
EAS30186
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ REMOVING THE REAR BRAKE CALIPER
a. Connect a clear plastic hose “1” tightly to the
TIP
bleed screw “2”. Put the other end of the hose
into an open container. Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose gaskets
• Rear brake hose “2”
TIP
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
b. Loosen the bleed screw and push the brake

caliper piston into the brake caliper with your
finger.
c. Tighten the bleed screw.
Rear brake caliper bleed screw

6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
R.
d. Install brake pad supports and brake pads.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
4-63
REAR BRAKE
EAS30187
1. Check:
DISASSEMBLING THE REAR BRAKE
• Brake caliper piston “1”
CALIPER
Rust/scratches/wear → Replace the brake
1. Remove:
caliper piston.
• Brake caliper piston “1”
• Brake caliper cylinder “2”
• Brake caliper piston dust seal “2”
Scratches/wear → Replace the brake caliper
• Brake caliper piston seal “3”
assembly.
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
• Brake fluid delivery passages
(brake caliper body)
EWA13601
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
and brake caliper piston seal.
a. Blow compressed air into the brake hose joint
opening “a” to force out the piston from the
brake caliper.
EWA13550
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
2. Check:
• Brake caliper bracket “1”
b. Remove the brake caliper piston dust seal

and brake caliper piston seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30188
CHECKING THE REAR BRAKE CALIPER EAS30189
ASSEMBLING THE REAR BRAKE CALIPER

Recommended brake component replacement EWA17080
schedule WARNING
Brake pads If necessary • Before installation, all internal brake com-
Piston seal Every two years ponents should be cleaned and lubricated
with clean or new brake fluid.
Piston dust seal Every two years
Brake hoses Every four years ponents as they will cause the brake caliper
Every two years and piston dust seal and brake caliper piston
Brake fluid whenever the brake is seal to swell and distort.
disassembled
4-64
REAR BRAKE
• Whenever a brake caliper is disassembled, 4. Fill:

replace the brake caliper piston dust seal • Brake master cylinder reservoir
and brake caliper piston seal. (with the specified amount of the specified
brake fluid)
DOT 4 Specified brake fluid
DOT 4
EAS30190
EWA13540
INSTALLING THE REAR BRAKE CALIPER WARNING
1. Install:
• Rear brake caliper “1” • Use only the designated brake fluid. Other
(temporarily) brake fluids may cause the rubber seals to
• Brake hose gaskets New brake performance.
• Rear brake hose “2” • Refill with the same type of brake fluid that
• Brake hose union bolt “3” is already in the system. Mixing brake fluids
Rear brake hose union bolt
30 Nm (3.0 m·kgf, 22 ft·lbf) leading to poor brake performance.
T.

R.
EWA13531 not enter the brake master cylinder reser-

WARNING voir. Water will significantly lower the boil-
Proper brake hose routing is essential to in- ing point of the brake fluid and could cause
sure safe vehicle operation. vapor lock.
ECA14170 ECA13540
NOTICE NOTICE
When installing the brake hose onto the Brake fluid may damage painted surfaces
brake caliper “1”, make sure the brake pipe and plastic parts. Therefore, always clean up
“a” touches the projection “b” on the brake any spilt brake fluid immediately.
caliper. 5. Bleed:
• Brake system
a Refer to “BLEEDING THE HYDRAULIC
2
1
6. Check:
• Brake fluid level
Below the minimum level mark “a”→ Add the
b
3 LEVEL” on page 3-13.
2. Remove:
3. Install:
• Brake pad supports
• Rear brake pads
• Rear brake caliper bolt
Refer to “REPLACING THE REAR BRAKE
PADS” on page 4-62.
Rear brake caliper bolt

27 Nm (2.7 m·kgf, 20 ft·lbf)
T.
R.
4-65
REAR BRAKE
7. Check: 4. Check:
• Brake lever operation • Brake hose
Soft or spongy feeling → Bleed the brake sys- Cracks/damage/wear → Replace.
tem.
EAS30195
Refer to “BLEEDING THE HYDRAULIC ASSEMBLING THE REAR BRAKE MASTER
BRAKE SYSTEM” on page 3-15. CYLINDER
EWA13520
EAS30193
REMOVING THE REAR BRAKE MASTER WARNING

CYLINDER • Before installation, all internal brake com-
TIP ponents should be cleaned and lubricated
with clean or new brake fluid.
Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys-
ponents.
tem.
1. Remove: Specified brake fluid
• Brake hose union bolt “1” DOT 4
• Rear brake hose “3” EAS30196
TIP INSTALLING THE REAR BRAKE MASTER

CYLINDER
To collect any remaining brake fluid, place a
1. Install:
container under the master cylinder and the end
• Brake master cylinder “1”
of the brake hose.
• Front brake master cylinder holder “2”

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
• Install the brake master cylinder holder with the
“ ” mark “a” facing up.
• Align the end of the brake master cylinder hold-
• First, tighten the upper bolt, then the lower bolt.
EAS30194
CHECKING THE REAR BRAKE MASTER

CYLINDER
1. Check:
• Brake master cylinder
• Brake fluid delivery passages
(brake master cylinder body)
2. Check:
• Brake master cylinder kit
2. Install:
3. Check: • Brake hose gaskets “1” New
• Brake master cylinder reservoir cap • Rear brake hose “2”
• Brake master cylinder reservoir • Brake hose union bolt “3”
• Brake master cylinder reservoir diaphragm
Rear brake hose union bolt
holder
30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
4-66
REAR BRAKE
EWA13531
4. Bleed:
WARNING • Brake system
Proper brake hose routing is essential to in- Refer to “BLEEDING THE HYDRAULIC
sure safe vehicle operation. BRAKE SYSTEM” on page 3-15.
ECA14160 5. Check:
NOTICE • Brake fluid level
When installing the brake hose onto the Below the minimum level mark “a”→ Add the
brake master cylinder, make sure the brake specified brake fluid to the proper level.
pipe touches the projection “a” as shown. Refer to “CHECKING THE BRAKE FLUID
TIP
Turn the handlebar to the left and right to make
sure that the brake hose does not touch other
parts (e.g., wire harness, cables, leads). Correct
if necessary.
6. Check:
Soft or spongy feeling → Bleed the brake sys-
tem.
3. Fill: BRAKE SYSTEM” on page 3-15.
• Brake master cylinder reservoir EAS31417
(with the specified amount of the specified REPLACING THE REAR BRAKE LOCK PADS
brake fluid) 1. Remove:
• Rear brake lock cable adjusting nut “1”
Specified brake fluid • Pin “2”
DOT 4 • Rear brake lock spring “3”
EWA13540
WARNING
brake performance.
2. Remove:
• Rear brake lock caliper bolts “1”
not enter the brake master cylinder reser-
• Rear brake lock caliper “2”
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4-67
REAR BRAKE
ECA22110
NOTICE
Avoid scratching the dust seal on the side of
the piston adjusting bolt carefully.
3. Remove:
• Rear brake lock pad (left side) “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• Rear brake lock pads wear limit “a”
Out of specification → Replace the rear brake
lock pads.
Rear brake lock pad lining thick-

ness
TIP 3.0 mm (0.12 in)
Push on the back of the pad using a rod with a Limit
round end. 0.8 mm (0.03 in)
4. Remove:
• Rear brake lock pad (right side) “2”
6. Remove:
• Cap
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Rear brake lock adjusting nut
a. Slide the rear brake lock caliper bracket. • Rear brake lock caliper arm
7. Adjust:
• Piston adjusting bolt
Refer to “ASSEMBLING THE REAR BRAKE
LOCK CALIPER” on page 4-70.
8. Install:
• Rear brake lock caliper arm
• Rear brake lock adjusting nut
• Cap
• Rear brake lock pads
Refer to “ASSEMBLING THE REAR BRAKE
b. Insert a flathead screwdriver in between the LOCK CALIPER” on page 4-70.
piston adjusting bolt and rear brake lock pad 9. Install:
and then remove the rear brake lock pad. • Rear brake lock caliper
4-68
REAR BRAKE
• Rear brake lock caliper bolts EAS31419
REMOVING THE REAR BRAKE LOCK

• Rear brake lock spring
CALIPER
• Pin
1. Remove:
• Rear brake lock cable adjusting nut
Rear brake lock caliper bolt • Pin “2”
23 Nm (2.3 m·kgf, 17 ft·lbf) • Rear brake lock spring “3”
T.
R.

10.Adjust: • Rear brake lock caliper “5”
EAS31418
REPLACING THE REAR BRAKE LOCK

CABLE
1. Remove:
• Rear brake lock cable
2. Check:
• Rear brake lock cable
Cracks/damage/wear → Replace the rear EAS31420
brake lock cable. CHECKING THE REAR BRAKE LOCK

3. Install: CALIPER
• Rear brake lock cable 1. Check:
EWA13490 • Rear brake lock caliper arm “1”
WARNING • Rear brake lock caliper bracket “2”
Make sure the brake cable is routed properly. • Sleeve “3”
4. Adjust: • Locknut “5”
• Rear brake lock cable length • Shaft L “6”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Adjust the clearance for the rear brake lock • Piston adjusting bolt “7”
pad. • Boots “8”
Refer to “ADJUSTING THE REAR BRAKE Cracks/damage → Replace.
b. Activate the rear brake lock cable 10 times.
c. Carry out adjustment using rear brake lock
cable adjusting nut “1” so that dimension “a”
is 43–45 mm (1.69–1.77 in).
d. Repeat steps (a) to (c) until dimension “a” is
43–45 mm (1.69–1.77 in).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-69
REAR BRAKE
EAS31421
ASSEMBLING THE REAR BRAKE LOCK

CALIPER
1. Install:
• Slide pin bolt “1”
(to the rear brake lock caliper bracket)
Rear brake lock caliper slide pin

bolt
T.
R.
17 Nm (1.7 m·kgf, 12 ft·lbf)
5. Install:
Recommended lubricant • Shaft L “1”
Silicone grease • Piston adjusting bolt “2”
• Locknut “3”
Silicone grease
Rear brake lock caliper piston

locknut
T.
R.
22 Nm (2.2 m·kgf, 16 ft·lbf)
Left-hand thread
2. Install:
• Rear brake lock caliper bracket
Rear brake lock caliper bracket

bolt
T.
R.
22 Nm (2.2 m·kgf, 16 ft·lbf)

LOCTITE®
3. Install:
• Boots “1”
• Sleeve “2” 6. Adjust:
• Piston adjusting bolt
Recommended lubricant ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Silicone grease a. Tighten shaft L manually until it touches the
locknut.
b. With shaft L fastened, turn and adjust the pis-
ton adjusting bolt so that the length “a” be-
tween the end of shaft L and the end of the
piston adjusting bolt is changed to 19 mm
(0.75 in).
4. Install:
• Boot “1”
4-70
REAR BRAKE
Rear brake lock caliper bolt

23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• Boot
• Rear brake lock caliper arm 2. Adjust:
TIP • Rear brake lock cable length
• Check that the boot is installed correctly. Refer to “ADJUSTING THE REAR BRAKE
• Install rear brake lock caliper arm “1” in the po- LOCK CABLE” on page 3-17.
sition closest to cable holder “2”.
8. Install:
• Rear brake lock adjusting nut
• Cap
Rear brake lock adjusting nut

15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
R.
9. Install:
• Rear brake lock pads
ECA22120
NOTICE
After installing the rear brake lock pad to the
caliper, check that the pad rotates smoothly.
EAS31422
INSTALLING THE REAR BRAKE LOCK

CALIPER
1. Install:
• Rear brake lock spring “3”
• Pin “4”
4-71
HANDLEBAR
EAS20033
HANDLEBAR
Removing the handlebar
* YAMAHA GREASE “F”

Loosen.
Rear brake lock cable adjusting nut Refer to “REAR BRAKE” on page 4-53.
Meter assembly 4-13.
1 Upper handlebar cover 1
2 Holder 4
3 Grip end 2
4 Front brake light switch connector 2 Disconnect.
5 Handlebar switch (right) 1
4-72
HANDLEBAR
16
14
15
17
14
13

6 Throttle cable 2 Disconnect.
7 Throttle grip 1
8 Front brake master cylinder holder 1
9 Front brake master cylinder assembly 1
10 Rear brake light switch connector 2 Disconnect.
11 Rear brake lock holder 1
12 Rear brake lock lever 1
13 Rear brake lock cable 1 Disconnect.
14 Handlebar switch (left) 1
15 Rear brake master cylinder holder 1
16 Rear brake master cylinder assembly 1
17 Handlebar grip 1
4-73
HANDLEBAR
19 19 20
21
22
18

18 Lower handlebar cover 1
19 Upper handlebar holder 2
20 Handlebar 1
21 Lower handlebar holder 1
22 Holder bracket 1
4-74
HANDLEBAR
EAS30203
REMOVING THE HANDLEBAR

EWA13120
WARNING
2. Remove:
• Handlebar grip “1”
TIP
Blow compressed air between the left handlebar EAS30205
and the handlebar grip, and gradually push the INSTALLING THE HANDLEBAR
grip off the handlebar. 1. Stand the vehicle on a level surface.
EWA13120
WARNING
2. Install:
• Holder bracket
• Lower handlebar holder
Lower handlebar holder nut

34 Nm (3.4 m·kgf, 25 ft·lbf)
T.
R.
3. Remove: TIP
• Handlebar switch (right) “1”
Pass the projection of the lower handlebar hold-
• Throttle grip “2”
er through the hole of the holder bracket.
3. Install:
• Handlebar
• Upper handlebar holder
TIP
• Align the punch mark on the handlebar to the
end of the lower handlebar holder.
• First, tighten the bolts on the front side of the
upper handlebar holder, and then on the rear
side.
EAS30204
CHECKING THE HANDLEBAR

Upper handlebar holder bolt
1. Check:
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
• Handlebar
R.
Bends/cracks/damage → Replace. 4. Install:

EWA13690
WARNING • Lower handlebar cover

5. Install:
Do not attempt to straighten a bent handle-
• Handlebar grip
bar as this may dangerously weaken it.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of a rubber adhesive to the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
4-75
HANDLEBAR
EWA13700
WARNING 1
Do not touch the handlebar grip until the rub- a
ber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install: b
• Rear brake master cylinder assembly “1”
• Rear brake master cylinder holder “2”

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
• Install the rear brake master cylinder holder
with the “ ” mark “a” facing up.
• Align the end of the brake master cylinder hold-
• First, tighten the upper bolt, then the lower bolt.
9. Connect:
• Rear brake light switch connector
10.Install:
• Front brake master cylinder assembly “1”
• Front brake master cylinder holder “2”

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
7. Connect: TIP
• Rear brake lock cable • Install the front brake master cylinder holder
(to rear brake lock lever) with the “ ” mark “a” facing up.
TIP • Align the end of the brake master cylinder hold-
Lubricate the rear brake lock cable end with er with the welding line “b” on the handlebar.
YAMAHA GREASE “F”. • First, tighten the upper bolt, then the lower bolt.
8. Install:
• Handlebar switch (left) “1”
• Rear brake lock lever
• Rear brake lock lever holder
TIP
• Align the projection “a” on the left handlebar
switch with the hole “b” in the handlebar.
• Install the rear brake lock cable after rotating
the lever to the position shown in the illustra-
tion.
11.Install:
• Throttle grip “1”
• Throttle cables “2”
TIP
Lubricate the inside of the throttle grip with a thin
coat of lithium-soap-based grease and install it
onto the handlebar.
4-76
HANDLEBAR
LS
12.Install:
• Handlebar switch (right) “1”
EWA13720
WARNING
Make sure the throttle grip operates smooth-
ly.
TIP
Align the projection “a” on the right handlebar
switch with the hole “b” in the handlebar.
b a
13.Connect:
• Front brake light switch connector
14.Adjust:
Refer to “CHECKING THE THROTTLE
GRIP” on page 3-32.
Throttle grip free play

3.0–5.0 mm (0.12–0.20 in)
15.Adjust:
16.Install:
• Grip end
• Holder
• Upper handlebar cover
4-77
FRONT FORK
EAS20034
FRONT FORK
Removing the front fork legs

the front fork legs.
Meter assembly/Leg shield 4-13.
Front wheel/Front fender Refer to “FRONT WHEEL” on page 4-22.
1 Upper bracket pinch bolt 1 Loosen.
2 Cap bolt 1 Loosen.
3 Horn coupler 1 Disconnect.
4 Brake pipe joint 1
5 Horn 1
6 Lower bracket pinch bolt 2 Loosen.
4-78
FRONT FORK
Removing the front fork legs
7
8

7 Front fork leg 1
8 Lower bracket cover 1
9 Horn bracket 1
4-79
FRONT FORK
Disassembling the front fork legs
15 Nm (1.5 m • kgf, 11 ft • Ibf)

New
T.R
.
1
New 2
LS
3
8
4 11
5
New
New
10 New
7 New
9 New
LS
LT
6
23 Nm (2.3 m • kgf, 17 ft • Ibf)

T.R
.

the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Damper rod locknut 1
4 Spacer 1
5 Fork spring 1
6 Damper rod assembly bolt 1
7 Copper washer 1
8 Damper rod assembly 1
9 Dust seal 1
10 Oil seal clip 1
11 Outer tube 1
4-80
FRONT FORK
Disassembling the front fork legs
15 Nm (1.5 m • kgf, 11 ft • Ibf)

15 New
T.R
.
New
LS
16
14 New
13
12 New
New
New
New
LS
LT
23 Nm (2.3 m • kgf, 17 ft • Ibf)

T.R
.

12 Oil seal 1
13 Washer 1
14 Outer tube bushing 1
15 Inner tube bushing 1
16 Inner tube 1
4-81
FRONT FORK
EAS30206
1. Remove:
REMOVING THE FRONT FORK LEGS
• Cap bolt “1”
• Spacer “2”
front fork legs.
• Damper rod locknut “3”
EWA13120
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Press down on the spacer with the fork spring
WARNING
compressor “4”.
Securely support the vehicle so that there is b. Install the rod holder “5” between the damper
no danger of it falling over. rod locknut “3” and the spacer “2”.
TIP
Place the vehicle on a suitable stand so that the 90890-01441
front wheel is elevated. Fork spring compressor
2. Loosen: YM-01441
• Upper bracket pinch bolt “1” Rod holder
90890-01434
Damper rod holder double ended
• Lower bracket pinch bolts “3” YM-01434
EWA13640
WARNING
TIP
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg. Use the side of the rod holder that is marked “B”.
c. Hold the cap bolt “1” and loosen the damper
rod locknut “3”.
1
3 2
5
4
d. Remove the cap bolt.

e. Remove the rod holder and fork spring com-
pressor.
3 f. Remove the spacer and damper rod locknut.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Drain:
• Fork oil
TIP
3. Remove: Stroke the damper rod assembly “1” several
• Front fork leg times while draining the fork oil.
EAS30207
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
ECA22020
NOTICE
Because the left and right damper rod as-
semblies are different, be sure to install them
in the correct positions.
4-82
FRONT FORK
3. Remove:
• Damper rod assembly bolt
• Damper rod assembly
ECA17400
NOTICE 1
For the damper rod assembly, the right side
is used for the rebound operation and left
side for the compression. Pay attention not
to mistake the right and left.
TIP
5. Remove:
• While holding the damper rod assembly with • Outer tube
the damper rod holder “1”, loosen the damper ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
rod assembly bolt. a. Hold the front fork leg horizontally.
• The left side (for the compression) damper rod b. Securely clamp the brake caliper bracket in a
assembly has the holes “a” of oil path, unlike vise with soft jaws.
the right side. c. Separate the outer tube from the inner tube
by pulling the outer tube forcefully but careful-
ly.
ECA19880
A a
NOTICE
Excessive force will damage the bushings.
Damaged bushings must be replaced.
B
A. Compression side
B. Rebound side
Damper rod holder

90890-01423
Damping rod holder
YM-01423 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30208
CHECKING THE FRONT FORK LEGS

front fork legs.
1
1. Check:
• Inner tube “1”
• Outer tube “2”
Bends/damage/scratches → Replace.
EWA13650
WARNING
Do not attempt to straighten a bent inner
4. Remove: tube as this may dangerously weaken it.
• Dust seal
• Oil seal clip “1”
(with a flat-head screwdriver)
ECA14180
NOTICE
Do not scratch the inner tube.
4-83
FRONT FORK
EAS30209
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
1 EWA13660
2
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
2. Measure: TIP
• Spring free length “a” • When assembling the front fork leg, be sure to
Out of specification → Replace. replace the following parts:
–Inner tube bushing
Fork spring free length –Outer tube bushing
295.1 mm (11.62 in)
–Oil seal
Limit
289.2 mm (11.39 in) –Dust seal
–Oil seal clip
–O-ring
–Copper washer
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Lubricate:
• Inner tube outer surface
Recommended oil
Suspension oil 01 or equivalent
3. Check: 2. Install:
• Damper rod assembly “1” • Dust seal “1” New
Damage/wear → Replace. • Oil seal clip “2” New
Obstruction → Blow out all of the oil passag-
es with compressed air. • Oil seal “3” New
ECA19110 • Washer “4”
NOTICE • Outer tube bushing “5” New
• The front fork leg has a very sophisticated
• Inner tube bushing “6” New
internal construction, which are particular- ECA14220
ly sensitive to foreign material. NOTICE

• When disassembling and assembling the Make sure the numbered side of the oil seal
front fork leg, do not allow any foreign ma- faces up.
terial to enter the front fork.
TIP
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
1
the front fork leg with a plastic bag to protect
the oil seal during installation.
4-84
FRONT FORK
3 New
2 New
5 New 1 New
4
6 New 2
6. Install:
• Oil seal clip “1”
TIP
Adjust the oil seal clip so that it fits into the outer
tube groove.
1
3. Install:
• Outer tube
(to the inner tube)
4. Install:
• Outer tube bushing “1”
• Washer “2”
7. Install:
(with the fork seal driver “3”)
• Dust seal “1”
Fork seal driver (with the fork seal driver “2”)
90890-01442
Adjustable fork seal driver (36–46 Fork seal driver
mm) 90890-01442
YM-01442 Adjustable fork seal driver (36–46
mm)
YM-01442
3
2
1
5. Install:
• Oil seal “1”
8. Install:
(with the fork seal driver “2”)
• Damper rod assembly “1”
Fork seal driver (to inner tube “2”)
90890-01442 • Copper washer New
Adjustable fork seal driver (36–46 • Damper rod assembly bolt
mm)
YM-01442
4-85
FRONT FORK
ECA17400
NOTICE Damper rod holder

For the damper rod assembly, the right side 90890-01423
is used for the rebound operation and left Damping rod holder
side for the compression. Pay attention not YM-01423
to mistake the right and left.
TIP
The left side (for the compression) damper rod 2 1
assembly has the holes “a” of oil path, unlike the
right side.
A a
10.Install:
B • Rod puller “1”
• Rod puller attachment (M10) “2”
(onto the damper rod “3”)
Rod puller
A. Compression side 90890-01437
B. Rebound side Universal damping rod bleeding
tool set
ECA14210
YM-A8703
NOTICE
Rod puller attachment (M10)
Allow the damper rod assembly to slide 90890-01436
slowly down the inner tube until it protrudes Universal damping rod bleeding
from the bottom of the inner tube. Be careful tool set
not to damage the inner tube. YM-A8703
9. Tighten: 11.Fill:
• Damper rod assembly bolt “1” • Front fork leg
Damper rod assembly bolt (with the specified amount of the recom-
23 Nm (2.3 m·kgf, 17 ft·lbf) mended fork oil)
T.
R.
LOCTITE®
Recommended oil
Suspension oil 01 or equivalent
TIP Quantity (left)
While holding the damper rod assembly with the 434.0 cm³ (14.67 US oz, 15.31
damper rod holder “2”, tighten the damper rod Imp.oz)
assembly bolt. Quantity (right)
426.0 cm³ (14.40 US oz, 15.03
Imp.oz)
4-86
FRONT FORK
ECA14230
15.Install:
NOTICE • Damper rod locknut “1”
• Be sure to use the recommended fork oil. • Fork spring “2”
Other oils may have an adverse effect on • Spacer “3”
front fork performance. • Cap bolt “4”
• When disassembling and assembling the
(along with the O-ring New )
front fork leg, do not allow any foreign ma- EWA12850
terial to enter the front fork. WARNING

12.After filling the front fork leg, slowly stroke the Always use a new O-ring.
damper rod assembly “1” up and down (at
least ten times) to distribute the fork oil.
TIP
Be sure to stroke the damper rod assembly 4
slowly because the fork oil may spurt out.
2
1
3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the rod puller and rod puller attach-
ment.
b. Install the damper rod locknut.
c. Install the fork spring and spacer.
TIP
13.Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air Install the spring with the smaller diameter “a”
bubbles have dispersed. facing up “A”.
TIP
Be sure to bleed the front fork leg of any residual
air.
14.Measure:
• Front fork leg oil level “a”
(from the top of the outer tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification → Correct.
d. Press down in the spacer with the fork spring
Level (left)
122 mm (4.8 in) compressor “5”.
Level (right) e. Pull up the rod puller and install the rod holder
124 mm (4.9 in) “6” between the damper rod locknut “1” and
the spacer “3”.
TIP
Use the side of the rod holder that is marked “B”.
4-87
FRONT FORK
j. Remove the rod holder and fork spring com-

Fork spring compressor pressor.
90890-01441
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YM-01441 EAS30210
Rod holder INSTALLING THE FRONT FORK LEGS

90890-01434 The following procedure applies to both of the
Damper rod holder double ended front fork legs.
YM-01434 1. Install:
• Front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
TIP
1 6 Make sure the outer tube is flush with the top of
3 the upper bracket.
5
2. Tighten:
• Lower bracket pinch bolts “1”
• Upper bracket pinch bolt “3”
f. Remove the rod puller and the rod puller at-
Lower bracket pinch bolt
tachment.
23 Nm (2.3 m·kgf, 17 ft·lbf)
T.
g. Install the damper rod locknut “1” onto the
R. Front fork cap bolt
damper rod and turn it until it stops. 23 Nm (2.3 m·kgf, 17 ft·lbf)
Upper bracket pinch bolt
30 Nm (3.0 m·kgf, 22 ft·lbf)
1
h. Install the cap bolt “4”, and then tighten the

damper rod locknut “1” until it contacts the
bolt.
4
1
i. Hold the cap bolt and tighten the damper rod

locknut to specification.
Damper rod locknut

15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
R.
4-88
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
(2)

Meter assembly 4-13.
Front wheel Refer to “FRONT WHEEL” on page 4-22.
Handlebar Refer to “HANDLEBAR” on page 4-72.
Front fork legs Refer to “FRONT FORK” on page 4-78.
1 Steering stem nut 1
2 Upper bracket 1
3 Lock washer 1
4 Upper ring nut 1
5 Rubber washer 1
4-89
STEERING HEAD
Removing the lower bracket
(2)
12

6 Lower ring nut 1
7 Lower bracket 1
8 Upper bearing cover 1
9 Upper bearing 1
10 Lower bearing 1
11 Dust seal 1
12 Steering lock unit 1
4-90
STEERING HEAD
EAS30213
REMOVING THE LOWER BRACKET

EWA13120
WARNING
2. Remove:
• Upper ring nut
• Rubber washer
• Lower ring nut “1” 3. Replace:
• Lower bracket • Bearings
TIP • Bearing races
Remove the upper ring nut and lower ring nut ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
with the steering nut wrench “2”. a. Remove the bearing races from the steering
head pipe “1” with a long rod “2” and hammer.
EWA13730
b. Remove the bearing race from the lower
WARNING
bracket “3” with a floor chisel “4” and ham-
Securely support the lower bracket so that mer.
there is no danger of it falling. c. Install a new rubber seal and new bearing
races.
Steering nut wrench ECA14270
90890-01403 NOTICE
Exhaust flange nut wrench If the bearing race is not installed properly,
YU-A9472 the steering head pipe could be damaged.
TIP
• Always replace the bearings and bearing races
as a set.
• Whenever the steering head is disassembled,
replace the dust seal.
EAS30214
CHECKING THE STEERING HEAD

1. Wash:
• Bearings
• Bearing races
Recommended cleaning solvent

Kerosene
2. Check:
• Bearings “1”
• Bearing races “2”
Damage/pitting → Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-91
STEERING HEAD
4. Check:
• Upper bracket
• Lower bracket
(along with the steering stem)
Bends/cracks/damage → Replace.
EAS30216
INSTALLING THE STEERING HEAD

1. Lubricate:
• Upper bearing
• Lower bearing
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 3-23.
3
2 1
3. Install:
• Upper bracket
• Washer
• Steering stem nut
TIP
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
Refer to “FRONT FORK” on page 4-78.
TIP
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
• Steering stem nut
Steering stem nut

115 Nm (11.5 m·kgf, 83 ft·lbf)
T.
R.
4-92
BELT DRIVE
EAS20039
BELT DRIVE
Removing the drive belt
3 4
10
* Filling the YAMAHA GREASE “J” (Shell Alvania EP Grease R0®).

Rear wheel Refer to “REAR WHEEL” on page 4-31.
1 Rear brake lock cable holder (swingarm) 1
2 Rear brake hose bracket 1
3 Rear brake hose holder (right) 1
4 Rear brake hose holder (left) 1
5 Drive pulley cover 1
6 Dust cover 1
7 Holder 1
8 Circlip 1
9 Bearing 1
10 Oil seal 1
4-93
BELT DRIVE
Removing the drive belt
12
11
12
13
* Filling the YAMAHA GREASE “J” (Shell Alvania EP Grease R0®).

11 Drive pulley 1
12 Collar 2
13 Drive belt 1
4-94
BELT DRIVE
EAS30236
CHECKING THE DRIVE BELT

1. Clean:
• Drive belt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive belt with a clean cloth.
b. Put the drive belt in a mixture of mild deter-
gent and water. Then, remove any dirt from
the drive belt.
c. Remove the drive belt from the mixture and
rinse it off with clean water. Then, let the drive
belt thoroughly dry. EAS31423
INSTALLING THE DRIVE BELT

1. Install:
• Drive belt
2. Adjust:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Drive belt
Refer to “CHECKING THE DRIVE BELT” on
page 3-20.
3. Check:
• Drive pulley “1”
• Rear wheel pulley “2”
Bent teeth → Replace the drive belt and pul-
leys as a set.
4. Check:
• Holder “1”
4-95
REAR SHOCK ABSORBER ASSEMBLY
EAS20036

Removing the rear shock absorber assembly

Exhaust assembly Refer to “ENGINE REMOVAL” on page 5-2.
1 Rear shock absorber assembly bolt (front side) 1
2 Lock washer 1
3 Collar 1
Rear shock absorber assembly bolt/nut (rear
4 1/1
side)
5 Rear shock absorber assembly 1
6 Collar 1
7 Washer 1
8 Spacer 1
9 Bearing 2
4-96
EAS30826
HANDLING THE REAR SHOCK ABSORBER TIP

EWA13740 Place the vehicle on the centerstand so that the
WARNING rear wheel is elevated.
This rear shock absorber contains highly 2. Remove:
compressed nitrogen gas. Before handling • Rear shock absorber assembly bolts “1”
the rear shock absorber, read and make sure
TIP
you understand the following information.
The manufacturer cannot be held responsi- • Straighten the lock washer tab.
ble for property damage or personal injury • When removing the rear shock absorber as-
that may result from improper handling of sembly bolts “1”, hold the swingarm so that it
the rear shock absorber. does not drop down.
• Do not tamper or attempt to open the rear
shock absorber.
• Do not subject the rear shock absorber to
an open flame or any other source of high
heat. High heat can cause an explosion due
to excessive gas pressure.
• Do not deform or damage the rear shock
absorber in any way. Rear shock absorber
damage will result in poor damping perfor-
mance.
3. Remove:
EAS30729
DISPOSING OF A REAR SHOCK ABSORBER
1. Gas pressure must be released before dis- EAS30220
posing of a rear shock absorber. To release CHECKING THE REAR SHOCK ABSORBER
the gas pressure, drill a 2–3 mm (0.08–0.12 ASSEMBLY
in) hole through the rear shock absorber at a 1. Check:
point from its end as shown. • Rear shock absorber assembly
EWA13760 Gas leaks/oil leaks → Replace the rear shock
WARNING absorber assembly.
Wear eye protection to prevent eye damage • Spring
from released gas or metal chips. Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bearing
Damage/wear → Replace.
• Spacer
Damage/wear → Replace.
• Bolts
Bends/damage/wear → Replace.
EAS30225
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
EAS30219
1. Lubricate:
REMOVING THE REAR SHOCK ABSORBER • Spacer
ASSEMBLY • Bearings
1. Stand the vehicle on a level surface. • Rear shock absorber assembly bolt (front
EWA13120
side)
WARNING
TIP
Securely support the vehicle so that there is Lubricate the rear shock absorber assembly bolt
no danger of it falling over. (front side) seats with lithium-soap-based
grease.
4-97
2. Install:
TIP
• Make sure that the warning label “1” on the rear
shock absorber assembly faces up.
• When installing the rear shock absorber as-
sembly, lift up the swingarm.
3. Tighten:
• Rear shock absorber assembly nut (rear
side)
• Rear shock absorber assembly bolt (front
side)
Rear shock absorber assembly

nut (rear side)
T.
R.
53 Nm (5.3 m·kgf, 38 ft·lbf)

Rear shock absorber assembly
bolt (front side)
68 Nm (6.8 m·kgf, 49 ft·lbf)
TIP
• With the swingarm and rear wheel lowered by
own weight, tighten the rear shock absorber
assembly bolt (front side) and rear shock ab-
sorber assembly nut (rear side).
• After tightening the rear shock absorber as-
sembly bolt (front side), align the wide claw
with the bolt head and bent it.
4-98
SWINGARM
EAS20037
SWINGARM
Removing the swingarm

Rear shock absorber assembly SEMBLY” on page 4-96.
Drive belt Refer to “BELT DRIVE” on page 4-93.
1 Drive belt inner guard 1 Non-disassemble
2 Swingarm (left) 1
3 Swingarm (right) 1
4 Dowel pin 2
5 Swingarm stopper 1
6 Pivot shaft 1
7 Oil seal 1
8 Oil seal 1
4-99
SWINGARM
Removing the swingarm
14
13
15

9 Outer race 1
10 Bearing 1
11 Bearing housing 1
12 O-ring 1
13 Collar 1
14 Oil seal 1
15 Bearing 1
4-100
SWINGARM
EAS30226
3. Remove:
REMOVING THE SWINGARM
• Drive belt
EWA13120
WARNING 4. Remove:
Securely support the vehicle so that there is • Drive pulley assembly bolt
no danger of it falling over. • Swingarm bolt
• Pivot shaft nut
TIP
EAS30227
Place the vehicle on a suitable stand so that the CHECKING THE SWINGARM
rear wheel is elevated. 1. Check:
2. Measure: • Swingarm (left) “1”
• Swingarm side play • Swingarm (right) “2”
• Swingarm vertical movement Bends/cracks/damage → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the drive
pulley assembly bolts, swingarm bolts and
pivot shaft nut.
Drive pulley assembly bolt

48 Nm (4.8 m·kgf, 35 ft·lbf)
T.
R.
Swingarm bolt
40 Nm (4.0 m·kgf, 29 ft·lbf)
Pivot shaft
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft nut 2. Check:
100 Nm (10 m·kgf, 72 ft·lbf) • Drive pulley assembly bolts
• Swingarm bolts
b. Measure the swingarm side play “A” by mov- Damage/wear → Replace.
ing the swingarm from side to side. EAS30228
c. If the swingarm side play is out of specifica- INSTALLING THE SWINGARM
tion, check the bearings. 1. Lubricate:
• Taper roller bearing
Swingarm end free play limit (ra-
dial) TIP
1.0 mm (0.04 in) Lubricate the space in the swingarm with lithium-
Swingarm end free play limit (axi- soap-based grease before installing the taper
al) roller bearing.
1.0 mm (0.04 in)
d. Check the swingarm vertical movement “B”

by moving the swingarm up and down.
If swingarm vertical movement is not smooth
or if there is binding, check the bearings.
2. Install:
• Pivot shaft “1”
• Washer “2”
• Pivot shaft nut “3”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-101
SWINGARM
TIP
Install the parts to the swingarm “4” temporarily,
making sure that the portion “a” of the pivot shaft
does not protrude past the swingarm surface “b”.
3. Install:
• Dowel pins
• Swingarm
• Swingarm bolts
• Drive pulley assembly
• Drive pulley assembly bolt
Swingarm bolt
40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.
Drive pulley assembly bolt

48 Nm (4.8 m·kgf, 35 ft·lbf)
4. Tighten:
• Pivot shaft
• Pivot shaft nut
Pivot shaft
7 Nm (0.7 m·kgf, 5.1 ft·lbf)
T.
R.
Pivot shaft nut

100 Nm (10 m·kgf, 72 ft·lbf)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. With your fingers, screw in the pivot shaft until
it touches the collar, and then tighten the piv-
ot shaft to the specified torque.
b. Tighten the pivot shaft nut to the specified
torque.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-102
SWINGARM
4-103
ENGINE
ENGINE INSPECTION .................................................................................... 5-1

MEASURE THE COMPRESSION PRESSURE........................................ 5-1
ENGINE REMOVAL ........................................................................................5-2

INSTALLING THE ENGINE....................................................................... 5-9
CAMSHAFTS.................................................................................................5-10
REMOVING THE CAMSHAFTS..............................................................5-13
CHECKING THE CAMSHAFTS ..............................................................5-14
CHECKING THE CAMSHAFT SPROCKETS .........................................5-15
CHECKING THE TIMING CHAIN GUIDES............................................. 5-15
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-16
INSTALLING THE CAMSHAFTS ............................................................ 5-16
CYLINDER HEAD.......................................................................................... 5-20

REMOVING THE CYLINDER HEAD.......................................................5-21
CHECKING THE CYLINDER HEAD .......................................................5-21
INSTALLING THE CYLINDER HEAD .....................................................5-21
VALVES AND VALVE SPRINGS.................................................................. 5-23

REMOVING THE VALVES...................................................................... 5-24
CHECKING THE VALVES AND VALVE GUIDES ..................................5-24
CHECKING THE VALVE SEATS ............................................................ 5-26
CHECKING THE VALVE SPRINGS........................................................ 5-28
5
CHECKING THE VALVE LIFTERS ......................................................... 5-28
INSTALLING THE VALVES .................................................................... 5-29
CYLINDER AND PISTONS ...........................................................................5-31

REMOVING THE PISTON ...................................................................... 5-32
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-32
CHECKING THE PISTON RINGS........................................................... 5-33
CHECKING THE PISTON PINS..............................................................5-34
INSTALLING THE PISTON AND CYLINDER .........................................5-34
ELECTRIC STARTER ...................................................................................5-36

CHECKING THE STARTER MOTOR .....................................................5-38
ASSEMBLING THE STARTER MOTOR................................................. 5-39
INSTALLING THE STARTER MOTOR ...................................................5-39
V-BELT AUTOMATIC TRANSMISSION .......................................................5-40
REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE.... 5-46
DISASSEMBLY THE SECONDARY SHEAVE........................................ 5-46
CHECKING THE V-BELT........................................................................5-47
CHECKING THE PRIMARY SHEAVE ....................................................5-47
CHECKING THE V-BELT CASE AIR DUCT ...........................................5-47
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-47
CHECKING THE SLIDERS ..................................................................... 5-47
CHECKING THE SECONDARY SHEAVE .............................................. 5-47
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-48
ASSEMBLING THE SECONDARY SHEAVE..........................................5-48
INSTALLING THE PRIMARY SHEAVE ASSEMBLY,
SECONDARY SHEAVE ASSEMBLY AND V-BELT...............................5-49
INSTALLING THE V-BELT CASE ........................................................... 5-51
GENERATOR AND STARTER CLUTCH......................................................5-52

REMOVING THE GENERATOR ............................................................. 5-56
REMOVING THE STARTER CLUTCH ...................................................5-56
CHECKING THE STARTER CLUTCH ....................................................5-56
CHECKING THE OIL STRAINER ........................................................... 5-57
ASSEMBLING THE OIL TANK................................................................5-57
INSTALLING THE STARTER CLUTCH .................................................. 5-57
INSTALLING THE GENERATOR............................................................ 5-58
CLUTCH ........................................................................................................5-60
REMOVING THE CLUTCH ..................................................................... 5-63
DISASSEMBLING THE CLUTCH ........................................................... 5-63
CHECKING THE FRICTION PLATES.....................................................5-64
CHECKING THE CLUTCH PLATES .......................................................5-64
CHECKING THE CLUTCH DAMPER SPRINGS .................................... 5-64
CHECKING THE CLUTCH SPRING PLATE...........................................5-64
CHECKING THE CLUTCH SPRINGS.....................................................5-65
CHECKING THE CLUTCH HOUSING ....................................................5-65
CHECKING THE CLUTCH BOSS........................................................... 5-65
CHECKING THE PRESSURE PLATE AND THRUST PLATE................ 5-65
ASSEMBLING THE CLUTCH .................................................................5-66
INSTALLING THE CLUTCH.................................................................... 5-67
OIL PUMP...................................................................................................... 5-68

CHECKING THE OIL PUMP ................................................................... 5-70
CHECKING THE RELIEF VALVE ........................................................... 5-70
CHECKING THE OIL PIPES ................................................................... 5-70
CHECKING THE OIL PUMP DRIVE CHAIN ...........................................5-70
ASSEMBLING THE OIL PUMP...............................................................5-70
INSTALLING THE OIL PUMP .................................................................5-70
CRANKCASE ................................................................................................5-71
DISASSEMBLING THE CRANKCASE....................................................5-74
CHECKING THE CRANKCASE ..............................................................5-74
CHECKING THE TIMING CHAIN............................................................ 5-74
ASSEMBLING THE CRANKCASE.......................................................... 5-74
CRANKSHAFT ..............................................................................................5-76
REMOVING THE CONNECTING RODS ................................................ 5-78
REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......................5-78
CHECKING THE CRANKSHAFT AND CONNECTING RODS............... 5-78
INSTALLING THE CRANKSHAFT JOURNAL BEARINGS.....................5-82
INSTALLING THE CONNECTING RODS............................................... 5-82
INSTALLING THE CRANKSHAFT ASSEMBLY...................................... 5-84
TRANSMISSION............................................................................................ 5-85
CHECKING THE TRANSMISSION ......................................................... 5-86
ENGINE INSPECTION
EAS20041
ENGINE INSPECTION Standard compression pressure

(at sea level)
EAS30249
1950 kPa/470 r/min (19.5
MEASURE THE COMPRESSION PRESSURE kgf/cm²/470 r/min, 277.3 psi/470
The following procedure applies to all of the cyl- r/min)
inders. Minimum–maximum
TIP 1697–2184 kPa/470 r/min (17.0–
Insufficient compression pressure will result in a 21.8 kgf/cm²/470 r/min, 241.4–
loss of performance. 310.6 psi/470 r/min)
1. Measure: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve clearance a. Push the ON/start switch “ ”.
Out of specification → Adjust. b. With the throttle wide open, crank the engine
Refer to “ADJUSTING THE VALVE CLEAR- until the reading on the compression gauge
ANCE” on page 3-5. stabilizes.
2. Start the engine, warm it up for several min- TIP
utes, and then turn it off. The difference in compression pressure be-
3. Remove: tween cylinders should not exceed 100 kPa (1
• Radiator cover kgf/cm², 14 psi).
4-8. c. If the compression pressure is above the
4. Disconnect: maximum specification, check the cylinder
• Spark plug caps head, valve surfaces and piston crown for
5. Remove: carbon deposits.
• Spark plugs Carbon deposits → Eliminate.
ECA13340 d. If the compression pressure is below the min-
NOTICE imum specification, pour a teaspoonful of en-
Before removing the spark plugs, use com- gine oil into the spark plug bore and measure
pressed air to blow away any dirt accumulat- again.
ed in the spark plug wells to prevent it from Refer to the following table.
falling into the cylinders. Compression pressure (with oil applied into the
cylinder)
6. Install:
Reading Diagnosis
• Compression gauge “1”
Higher than without oil Piston ring(s) wear or
Compression gauge damage → Replace.
90890-03081 Same as without oil Piston, valves or cylin-
Engine compression tester der head gasket possi-
YU-33223 bly defective →
Replace.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• Spark plugs
Spark plug
13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
9. Connect:
• Spark plug caps
10.Install:
7. Measure:
• Radiator cover
• Compression pressure
Out of specification → Refer to steps (c) and
4-8.
(d).
5-1
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the exhaust assembly

Side cover (right) 4-8.
1 O2 sensor coupler 1 Disconnect.
Remove the O2 sensor only when neccessa-

2 O2 sensor 1
ry.
3 Exhaust assembly 1
4 Gasket 2
5 Front muffler protector 1
6 Center muffler protector 1
7 Upper muffler protector 1
5-2
ENGINE REMOVAL
Removing the exhaust assembly
TIP
8 Muffler end 1 When installing the muffler end, face the
dummy bolt to the upper side of the muffler.
It is not required to remove the dummy bolt.
9 Muffler end bracket 1
5-3
ENGINE REMOVAL
Disconnecting the leads

Battery 4-13.
Storage box 4-20.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-26.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-29.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Front wheel/Front fender Refer to “FRONT WHEEL” on page 4-22
Intake manifold Refer to “THROTTLE BODY” on page 7-6.
5-4
ENGINE REMOVAL

Radiator bracket Refer to “RADIATOR” on page 6-1.
Water pump inlet pipe Refer to “WATER PUMP” on page 6-11.
Oil cooler outlet hose Refer to “OIL COOLER” on page 6-5.
Rear wheel Refer to “REAR WHEEL” on page 4-31.
Rear shock absorber assembly SEMBLY” on page 4-96.
Swingarm Refer to “SWINGARM” on page 4-99.
1 Spark plug cap 2 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Stator coil coupler 1 Disconnect.
4 Sidestand switch coupler 1 Disconnect.
5 Coolant temperature sensor coupler 1 Disconnect.
5-5
ENGINE REMOVAL

6 Ground lead 1 Disconnect.
7 Starter motor lead 1 Disconnect.
8 Rear brake lock cable holder (crankcase) 1
9 Wire harness 1 Disconnect.
5-6
ENGINE REMOVAL
Removing the engine

Passenger footrest (right) SION” on page 5-40.
1 Damper 2
2 Rear frame bolt 2
3 Engine mounting nut (rear side) 1
4 Engine mounting bolt (rear side) 1
5 Spacer 1
6 Rear frame 1
7 Engine mounting bolt (front left lower side) 2
8 Footboard bracket (left) 1
9 Sidestand 1
10 Engine mounting bolt (front right lower side) 2
11 Engine mounting nut (front upper side) 1
5-7
ENGINE REMOVAL
Removing the engine

12 Engine mounting bolt (front upper side) 1
13 Engine 1
5-8
ENGINE REMOVAL
EAS30251
INSTALLING THE ENGINE

1. Install:
TIP
• Apply locking agent (LOCTITE®) to engine
mounting bolts (front right lower side) “2”, en-
gine mounting bolts (front left lower side) “3”,
and rear frame bolts “5”.
• For installation, reverse the removal proce-
dure.
• Do not fully tighten the bolts and nuts.
2. Tighten:
• Engine mounting nut (front upper side) “1”
• Engine mounting bolts (front right lower side)
“2”
• Engine mounting bolts (front left lower side)
“3”
• Engine mounting nut (rear side) “4”
• Rear frame bolts “5”
TIP
When tightening the engine mounting nuts and
engine mounting bolts, do not apply an upward
load to the frame, such as supporting the area
around steering head of the frame upwards. Al-
so, do not apply an upward or downward load on
the rear frame, such as supporting the rear end
of the rear frame upwards or pushing it down-
wards.
Engine mounting nut (front upper

side)
T.
R.
88 Nm (8.8 m·kgf, 64 ft·lbf)

Engine mounting bolt (front right
lower side)
45 Nm (4.5 m·kgf, 33 ft·lbf)
LOCTITE®
Engine mounting bolt (front left
lower side)
45 Nm (4.5 m·kgf, 33 ft·lbf)
LOCTITE®
Engine mounting nut (rear side)
105 Nm (10.5 m·kgf, 76 ft·lbf)
Rear frame bolt
83 Nm (8.3 m·kgf, 60 ft·lbf)
LOCTITE®
5-9
CAMSHAFTS
EAS20043
CAMSHAFTS
Removing the cylinder head cover

Drain.
page 3-26.
Air filter case Refer to “THROTTLE BODY” on page 7-6.
1 Spark plug cap 2 Disconnect.
2 Spark plug 2
3 Cylinder head breather hose 1 Disconnect.
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Dowel pin 2
7 Gasket 2
8 Timing chain guide (upper side) 1
5-10
CAMSHAFTS
Removing the camshafts

Drain.
page 3-29.
Crankshaft end access cover SION” on page 5-40.
Storage box 4-20.
Intake manifold Refer to “THROTTLE BODY” on page 7-6.
Cylinder head cover Refer to “CAMSHAFTS” on page 5-10.
1 Timing mark accessing plug 1
2 Timing chain tensioner rod accessing plug 1
3 Timing chain tensioner 1
5-11
CAMSHAFTS
Removing the camshafts

4 Timing chain tensioner gasket 1
5 Intake camshaft cap 1
6 Exhaust camshaft cap 1
TIP
7 Dowel pin 4 During removal, the dowel pins may still be
connected to the camshaft caps.
8 Intake camshaft 1
9 Exhaust camshaft 1
5-12
CAMSHAFTS
EAS30256
2. Remove:
REMOVING THE CAMSHAFTS
• Timing chain tensioner “1”
1. Align:
• Timing chain tensioner gasket
• “I” mark “a” on the generator rotor
(with the stationary pointer “b” on the genera-
tor cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
3. Remove:
• Intake camshaft cap “1”
• Exhaust camshaft cap “2”
• Dowel pins
ECA13720
b. When piston #1 is at TDC on the compres- NOTICE
sion stroke, align the “I” mark “a” on the gen-
To prevent damage to the cylinder head,
erator rotor with the stationary pointer “b” on
camshafts or camshaft caps, loosen the
the generator cover.
camshaft cap bolts in stages and in a criss-
TIP
cross pattern, working from the outside in.
• TDC on the compression stroke can be found
when the cylinder #1 camshaft lobes are
turned away from each other.
• In order to be sure that the piston is at TDC, the
alignment marks “c” on the intake camshaft
sprocket and the alignment marks “d” on the
exhaust camshaft sprocket must align with the
cylinder head mating surface as shown in the
illustration.
4. Remove:
• Intake camshaft “1”
• Exhaust camshaft “2”
TIP
To prevent the timing chain from falling into the
crankcase, fasten with a wire “3”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-13
CAMSHAFTS
EAS30257 3. Measure:
CHECKING THE CAMSHAFTS • Camshaft runout
1. Check: Out of specification → Replace.
• Camshaft lobes
Blue discoloration/pitting/scratches → Re- Camshaft runout limit
place the camshaft. 0.030 mm (0.0012 in)
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions

Lobe height (Intake)
32.490–32.590 mm (1.2791–
1.2831 in)
Limit
32.390 mm (1.2752 in)
Base circle diameter (Intake)
24.950–25.050 mm (0.9823– 4. Measure:
0.9862 in)
• Camshaft-journal-to-camshaft-cap clearance
Limit
24.850 mm (0.9783 in) Out of specification → Measure the camshaft
Lobe height (Exhaust) journal diameter.
32.690–32.790 mm (1.2870–
1.2909 in) Camshaft-journal-to-camshaft-
Limit cap clearance
32.590 mm (1.2831 in) 0.028–0.062 mm (0.0011–0.0024
Base circle diameter (Exhaust) in)
24.950–25.050 mm (0.9823– Limit
0.9862 in) 0.080 mm (0.0032 in)
Limit
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
24.850 mm (0.9783 in) a. Install the camshaft into the cylinder head
(without the dowel pins and camshaft caps).
b. Position a strip of Plastigauge® “1” onto the
camshaft journal as shown.
5-14
CAMSHAFTS
c. Install the dowel pins and camshaft caps.

TIP
• When tightening the camshaft cap, tighten the
four bolts on the both ends of the cap tempo-
rarily to lower the entire cap, while paying at-
tention not to twist the dowel pins and camshaft
journal. After the camshaft cap touches the cyl-
inder head, tighten the two bolts in the middle
to the specified torque and then the remaining
four bolts to the specified torque.
• To prevent the camshaft cap from cracking, EAS30936
tighten the camshaft cap carefully by tapping CHECKING THE CAMSHAFT SPROCKETS
the camshaft using a soft-face hammer (both The following procedure applies to both of the
for temporary and final tightening). camshaft sprockets.
• Do not turn the camshaft when measuring the 1. Check:
camshaft journal-to-camshaft cap clearance • Camshaft sprocket
with the Plastigauge®. More than 1/4 tooth wear “a”→ Replace the
camshafts and the timing chain as a set.
Camshaft cap bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge® “1”.
1
a. 1/4 tooth
b. Correct
1. Timing chain
2. Camshaft sprocket
EAS30265
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE TIMING CHAIN GUIDES

5. Measure: 1. Check:
• Camshaft journal diameter “a” • Timing chain guide (intake side) “1”
Out of specification → Replace the camshaft. • Timing chain guide (exhaust side) “2”
Within specification → Replace the cylinder • Timing chain guide (upper side) “3”
head and the camshaft caps as a set. Damage/wear → Replace the defective
part(s).
Camshaft journal diameter
22.959–22.972 mm (0.9039–
0.9044 in)
5-15
CAMSHAFTS
EAS30266 EAS30269
CHECKING THE TIMING CHAIN TENSIONER INSTALLING THE CAMSHAFTS

• Timing chain tensioner • Exhaust camshaft “1”
Cracks/damage → Replace. • Intake camshaft “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Push the timing chain tensioner rod “1” into
the timing chain tensioner housing by hand.
TIP
While pushing the timing chain tensioner rod “a”,
turn it clockwise “b” with the timing chain ten-
sioner body “2” until if stops.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b
2
a
1
b. Lock the timing chain tensioner rod by setting
the circlip “3” to groove “4” while pushing the
timing chain tensioner rod.
b. When piston #1 is at TDC on the compres-

3
sion stroke, align the “I” mark “a” on the gen-
erator rotor with the stationary pointer “b” on
the generator cover.
4
c. Push the timing chain tensioner rod “c”.

d. Make sure that the timing chain tensioner rod
comes out “d” of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
c. Install the timing chain onto both camshaft
sprockets, and then install the camshafts
c
onto the cylinder head.
TIP
• Lubricate the camshaft journal with the molyb-
denum disulfide oil.
• When installing the timing chain, start with the
d exhaust camshaft and be sure to keep the tim-
ing chain as tight as possible on the exhaust
side.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-16
CAMSHAFTS
• The camshafts should be installed onto the cyl- ECA13730
inder head so that the alignment marks “c” on NOTICE

the intake camshaft sprocket and the align- The camshaft cap bolts must be tightened
ment marks “d” on the exhaust camshaft evenly or damage to the cylinder head, cam-
sprocket align with the cylinder head mating shaft caps, and camshafts will result.
surface, as shown in the illustration.
TIP
ECA13740
• Lubricate the camshaft cap bolt seats with the
NOTICE
engine oil.
Do not turn the crankshaft when installing • When tightening the camshaft cap, tighten the
the camshaft(s) to avoid damage or improper four bolts on the both ends of the cap tempo-
valve timing. rarily to lower the entire cap, while paying at-
tention not to twist the dowel pins and camshaft
journal. After the camshaft cap touches the cyl-
inder head, tighten the two bolts in the middle
to the specified torque and then the remaining
four bolts to the specified torque.
• To prevent the camshaft cap from cracking,
tighten the camshaft cap carefully by tapping
the camshaft using a soft-face hammer (both
for temporary and final tightening).
4. Install:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Timing chain tensioner gasket New
2. Install: • Timing chain tensioner
• Dowel pins ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Exhaust camshaft cap “1” a. Push the timing chain tensioner rod “1” into
• Intake camshaft cap “2” the timing chain tensioner housing by hand.
TIP TIP
Make sure each camshaft cap is installed in its While pushing the timing chain tensioner rod “a”,
original place. Refer to the identification marks turn it clockwise “b” with the timing chain ten-
as follows: sioner body “2” until if stops.
“IN”: Intake
“EX”: Exhaust
b
2
a
1
b. Lock the timing chain tensioner rod by setting
the circlip “3” into groove “4” while pushing
3. Install: the timing chain tensioner rod.
• Camshaft cap bolts
Camshaft cap bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
5-17
CAMSHAFTS
c. Install the timing chain tensioner to the cylin-

der block.
TIP
Always use a new gasket.
Timing chain tensioner bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
d. Release the timing chain tensioner rod by

pushing up the timing chain guide “5” from the
hole “6”. 7. Measure:
TIP • Valve clearance
Do not push up the timing chain. Out of specification → Adjust.
Push up the timing chain guide “5” in the direc- Refer to “ADJUSTING THE VALVE CLEAR-
tion “c” shown. ANCE” on page 3-5.
8. Install:
• Timing chain guide (upper side)
• Gaskets New
(to the cylinder head cover)
TIP
Apply Yamaha bond No.1215 “1” onto the mat-
ing surfaces of the cylinder head cover and gas-
kets.
Yamaha bond No. 1215

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 90890-85505
5. Turn: (Three bond No.1215®)
• Crankshaft
(several turns clockwise)
6. Check:
• “I” mark “a”
Make sure that the “I” mark is aligned with the
stationary pointer “b” on the generator cover.
• Camshaft sprocket alignment marks “c” and
“d”.
Make sure that the camshaft sprocket align-
ment marks are aligned with the cylinder
head mating surface.
9. Install:
Out of alignment → Correct.
Refer to the installation steps above. • Cylinder head cover gasket New
• Cylinder head cover
5-18
CAMSHAFTS
Cylinder head cover bolt

T.
R.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten the cylinder head cover bolts in stages
and in a crisscross pattern.
5-19
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head

Camshafts Refer to “CAMSHAFTS” on page 5-10.
Thermostat/Coolant temperature sensor Refer to “THERMOSTAT” on page 6-8.
Radiator bracket Refer to “RADIATOR” on page 6-1.
1 Cylinder head 1
2 Cylinder head gasket 1
3 Dowel pin 2
5-20
CYLINDER HEAD
EAS30276
REMOVING THE CYLINDER HEAD

1. Remove:
• Cylinder head bolts
• Cylinder head nuts
TIP
• Loosen the bolts and nuts in the proper se-
quence as shown.
• Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
EAS30277
CHECKING THE CYLINDER HEAD

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

• Cylinder head • Dowel pins
Damage/scratches → Replace. • Cylinder head gasket New
• Cylinder head water jacket 2. Install:
Mineral deposits/rust → Eliminate. • Cylinder head
3. Measure:
• Cylinder head warpage • Washers New
Out of specification → Resurface the cylinder • Cylinder head nuts New
head. • Cylinder head bolts
TIP
Warpage limit
• Pass the timing chain through the timing chain
0.03 mm (0.0012 in)
cavity.
5-21
CYLINDER HEAD
• Lubricate the cylinder head nuts and washers

with engine oil.
3. Tighten:
• Cylinder head nuts “1”–“6”
• Cylinder head bolts “7”, “8”
• Cylinder bolt “9”
Cylinder head nut

1st: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
2nd: 20 Nm (2.0 m·kgf, 14 ft·lbf)

3rd: 120°
Cylinder head bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
• Using the indicated tightening sequence, tight-
en the cylinder head nuts, cylinder head bolts,
and cylinder bolt when the cylinder head and
cylinder are cold.
• Use three steps to tighten the cylinder head
nuts.
4. Install:
• Exhaust camshaft
• Intake camshaft
Refer to “INSTALLING THE CAMSHAFTS”
on page 5-16.
5-22
VALVES AND VALVE SPRINGS
EAS20045

Removing the valves and valve springs
* Silicone fluid

Cylinder head Refer to “CYLINDER HEAD” on page 5-20.
1 Valve lifter 8
2 Valve pad 8
3 Valve cotter 16
4 Valve spring retainer 8
5 Valve spring 8
6 Intake valve 4
7 Exhaust valve 4
8 Valve stem seal 8
9 Valve spring seat 8
10 Valve guide 8
5-23
EAS30283
REMOVING THE VALVES TIP

The following procedure applies to all of the Remove the valve cotters by compressing the
valves and related components. valve spring with the valve spring compressor
TIP
“1” and the valve spring compressor attachment
“2”.
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal. Valve spring compressor
90890-04019
1. Remove: Valve spring compressor
• Valve lifter “1” YM-04019
• Valve pad “2” Valve spring compressor attach-
TIP ment
90890-04114
Make a note of the position of each valve lifter Valve spring compressor adapt-
and valve pad so that they can be reinstalled in er 19.5 mm
their original place. YM-04114
2. Check:
• Valve sealing 4. Remove:
Leakage at the valve seat → Check the valve • Valve spring retainer “1”
face, valve seat, and valve seat width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-26. • Valve stem seal “4”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve spring seat “5”
a. Pour a clean solvent “a” into the intake and TIP
exhaust ports. Identify the position of each part very carefully so
b. Check that the valves properly seal. that it can be reinstalled in its original place.
TIP
There should be no leakage at the valve seat “1”.
EAS30284
CHECKING THE VALVES AND VALVE

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
GUIDES
3. Remove:
valves and valve guides.
• Valve cotters
5-24
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”
Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004–0.0015 b. Install the new valve guide with the valve
in) guide installer “2” and valve guide remover
Limit “1”.
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
c. After installing the valve guide, bore the valve

guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
TIP
After replacing the valve guide, reface the valve
seat.
2. Replace:
• Valve guide
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
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a. Remove the valve guide with the valve guide
remover “1”.
5-25
Valve guide remover (ø4)

90890-04111
Valve guide remover (4.0 mm)
YM-04111
Valve guide installer (ø4)
90890-04112
Valve guide installer (4.0 mm)
YM-04112
Valve guide reamer (ø4)
90890-04113
Valve guide reamer (4.0 mm) EAS30285
YM-04113 CHECKING THE VALVE SEATS

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ valves and valve seats.
3. Eliminate: 1. Eliminate:
• Carbon deposits • Carbon deposits
(from the valve face and valve seat) (from the valve face and valve seat)
4. Check: 2. Check:
• Valve face • Valve seat
Pitting/wear → Grind the valve face. Pitting/wear → Replace the cylinder head.
• Valve stem end 3. Measure:
Mushroom shape or diameter larger than the • Valve seat width “a”
body of the valve stem → Replace the valve. Out of specification → Replace the cylinder
5. Measure: head.
• Valve margin thickness “a”
Out of specification → Replace the valve. Valve seat contact width (intake)
0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness (intake) Limit
0.50–0.90 mm (0.0197–0.0354 in) 1.6 mm (0.06 in)
Valve margin thickness (exhaust) Valve seat contact width (ex-
0.50–0.90 mm (0.0197–0.0354 in) haust)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.6 mm (0.06 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
TIP a. Apply blue layout fluid “b” onto the valve face.
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.040 mm (0.0016 in)
5-26
b. Install the valve into the cylinder head. c. Install the valve into the cylinder head.
c. Press the valve through the valve guide and d. Turn the valve until the valve face and valve
onto the valve seat to make a clear impres- seat are evenly polished, then clean off all of
sion. the lapping compound.
d. Measure the valve seat width. TIP
TIP For the best lapping results, lightly tap the valve
Where the valve seat and valve face contacted seat while rotating the valve back and forth be-
one another, the blueing will have been re- tween your hands.
moved.
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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.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ e. Apply a fine lapping compound to the valve
a. Apply a coarse lapping compound “a” to the face and repeat the above steps.
valve face. f. After every lapping procedure, be sure to
ECA13790
clean off all of the lapping compound from the
NOTICE
valve face and valve seat.
Do not let the lapping compound enter the g. Apply blue layout fluid “b” onto the valve face.
gap between the valve stem and the valve
guide.
h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and
b. Apply molybdenum disulfide oil onto the onto the valve seat to make a clear impres-
valve stem. sion.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
5-27
Installed compression spring

force (intake)
96.60–111.20 N (9.85–11.34 kgf,
21.72–25.00 lbf)
Installed compression spring
force (exhaust)
96.60–111.20 N (9.85–11.34 kgf,
21.72–25.00 lbf)
Installed length (intake)
30.60 mm (1.20 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Installed length (exhaust)
EAS30286
30.60 mm (1.20 in)
CHECKING THE VALVE SPRINGS
valve springs.
1. Measure:
• Valve spring free length “a”
spring.
Free length (intake)

36.73 mm (1.45 in)
Limit
34.89 mm (1.37 in) b. Installed length
Free length (exhaust)
36.73 mm (1.45 in) 3. Measure:
Limit • Valve spring tilt “a”
34.89 mm (1.37 in) Out of specification → Replace the valve
spring.
Spring tilt (intake)

1.6 mm (0.06 in)
Spring tilt (exhaust)
1.6 mm (0.06 in)
2. Measure:
• Compressed valve spring force “a”
spring.
EAS30287
CHECKING THE VALVE LIFTERS

valve lifters.
1. Check:
• Valve lifter
Damage/scratches → Replace the valve lift-
ers and cylinder head.
5-28
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
EAS30288
INSTALLING THE VALVES

valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)
b. Smaller pitch
2. Lubricate:
• Valve stem “1” 4. Install:
• Valve stem seal “2” • Valve cotters “1”
(with the recommended lubricant) TIP
Install the valve cotters by compressing the
Recommended lubricant valve spring with the valve spring compressor
Molybdenum disulfide oil “2” and the valve spring compressor attachment
“3”.

90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-04114
Valve spring compressor adapt-
er 19.5 mm
3. Install: YM-04114
• Valve spring seat “1”
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
5-29
• Each valve lifter and valve pad must be rein-

stalled in its original position.
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.
6. Lubricate:
• Valve pad
(with the recommended lubricant)
Molybdenum disulfide oil
7. Lubricate:
• Valve lifter
Engine oil
8. Install:
• Valve pad
• Valve lifter
ECA22150
NOTICE
After making sure that the valve pads are ful-
ly inserted, install the valve lifter taking care
so that the pads do not fall.
TIP
• The valve lifter must move smoothly when ro-
tated with a finger.
5-30
CYLINDER AND PISTONS
EAS20046

Removing the cylinder and pistons

Coolant hose Refer to “WATER PUMP” on page 6-11.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 4
6 Piston pin 2
7 Piston 2
8 Top ring 2
9 2nd ring 2
10 Oil ring 2
5-31
EAS30289
• Oil ring
REMOVING THE PISTON
The following procedure applies to all of the pis- TIP
ton. When removing a piston ring, open the end gap
1. Remove: with your fingers and lift the other side of the ring
• Piston pin clips “1” over the piston crown.
• Piston pin “2”
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case. EAS30291
• For reference during installation, put an identi- CHECKING THE CYLINDERS AND PISTONS
fication mark on each piston crown. The following procedure applies to all of the cyl-
• Before removing the piston pin, deburr the pis- inders and pistons.
ton pin clip’s groove and the piston’s pin bore 1. Check:
area. If both areas are deburred and the piston • Piston wall
pin is still difficult to remove, remove it with the • Cylinder wall
piston pin puller set “4”. Vertical scratches → Replace the cylinder,
piston and piston rings as a set.
2. Measure:
Piston pin puller set • Piston-to-cylinder clearance
90890-01304 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Piston pin puller a. Measure cylinder bore with the cylinder bore
YU-01304 gauge.
TIP
Measure cylinder bore by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Bore
68.000–68.010 mm (2.6772–
2.6776 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
Bore = maximum of D1–D2

Taper limit = maximum of D1 or D2 - maximum of
D5 or D6
Out of round limit = maximum of D1, D3 or D5 -
minimum of D2, D4 or D6
2. Remove:
• Top ring
• 2nd ring
5-32
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
Piston ring
Top ring
Ring side clearance
0.030–0.065 mm (0.0012–
0.0026 in)
b. If out of specification, replace the cylinder, Limit
piston and piston rings as a set. 0.100 mm (0.0039 in)
c. Measure piston skirt diameter “a” with the mi- 2nd ring
crometer. Ring side clearance
0.020–0.055 mm (0.0008–
0.0022 in)
Limit
0.100 mm (0.0039 in)
b. 9.0 mm (0.35 in) from the bottom edge of the

piston
Piston
Diameter 2. Install:
67.975–67.990 mm (2.6762– • Piston ring
2.6768 in)
(into the cylinder)
d. If out of specification, replace the piston and TIP
piston rings as a set. Use the piston crown to level the piston ring near
e. Calculate the piston-to-cylinder clearance the bottom of the cylinder where the cylinder
with the following formula. wear is lowest.
Piston-to-cylinder clearance = 3. Measure:
Cylinder bore -
• Piston ring end gap
Piston skirt diameter
Out of specification → Replace the piston ring
set.
Piston-to-cylinder clearance TIP
0.010–0.035 mm (0.0004–0.0014
in) The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
f. If out of specification, replace the cylinder, sive, replace all three piston rings.
piston and piston rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30292
CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
5-33
Piston ring
Top ring
End gap (installed)
0.25–0.35 mm (0.0098–0.0138
in)
Limit
0.60 mm (0.0236 in)
2nd ring
End gap (installed)
0.35–0.50 mm (0.0138–0.0197
in) 3. Measure:
Limit • Piston pin bore inside diameter “b”
0.75 mm (0.0295 in) Out of specification → Replace the piston.
Oil ring
End gap (installed) Piston pin bore inside diameter
0.10–0.35 mm (0.0039–0.0138 16.002–16.013 mm (0.6300–
in) 0.6304 in)
Limit
16.043 mm (0.6316 in)
a
b
a. Bottom of cylinder
b. Upper of cylinder
4. Calculate:
EAS30293
• Piston-pin-to-piston-pin-bore clearance
CHECKING THE PISTON PINS
Out of specification → Replace the piston pin
and piston as a set.
piston pins.
1. Check: Piston-pin-to-piston-pin-bore clearance =
Piston pin bore inside diameter -
• Piston pin Piston pin outside diameter
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication sys-
tem. Piston-pin-to-piston-pin-bore
2. Measure: clearance
• Piston pin outside diameter “a” 0.002–0.022 mm (0.0001–0.0009
in)
Out of specification → Replace the piston pin.
EAS30294
Piston pin outside diameter
INSTALLING THE PISTON AND CYLINDER
15.991–16.000 mm (0.6296–
0.6299 in) The following procedure applies to all of the pis-
Limit tons and cylinders.
15.971 mm (0.6288 in) 1. Install:
• Oil ring expander “1”
• Lower oil ring rail “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
(into the piston)
5-34
TIP • Cylinder gasket New

Be sure to install the top and 2nd rings so that 4. Lubricate:
the manufacturer marks or numbers “a” face up. • Piston
• Piston rings
• Cylinder
Engine oil
5. Offset:
• Piston ring end gaps
2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
TIP
• Apply engine oil onto the piston pin.
• Make sure the mark “a” on the piston points to-
wards the exhaust side of the cylinder.
a. Top ring
• Before installing the piston pin clip, cover the
b. 2nd ring
crankcase opening with a clean rag to prevent
c. Upper oil ring rail
the piston pin clip from falling into the crank-
d. Oil ring expander
case.
e. Lower oil ring rail
• Install the piston pin clips so that the clip ends
A. Exhaust side
are 3 mm (0.12 in) “b” or more from the cutout
in the piston. 6. Install:
• Reinstall each piston into its original cylinder. • Cylinder
• Cylinder bolt
TIP
• While compressing the piston rings, install the
cylinder.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
7. Tighten:
• Cylinder bolt
Cylinder bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
3. Install:
• Dowel pins
5-35
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor

Storage box 4-20.
1 Ground lead 1 Disconnect.
2 Starter motor lead 1 Disconnect.
3 Starter motor assembly 1
5-36
ELECTRIC STARTER
Disassembling the starter motor
* When replacing any of the starter motor front cover, armature assembly, starter motor yoke, insulator, and
starter motor rear cover, replace the starter motor assembly.

1 Starter motor front cover 1
2 Armature assembly 1
3 Starter motor yoke 1
4 O-ring 2
5 Brush holder set 1
6 Insulator 1
7 Starter motor rear cover 1
5-37
ELECTRIC STARTER
EAS30325
CHECKING THE STARTER MOTOR

1. Check:
• 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) 1. Commutator resistance

0.70 mm (0.03 in) 2. Insulation resistance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
4. Measure:
The mica of the commutator must be undercut to
• Brush length “a”
ensure proper operation of the commutator.
Out of specification → Replace the brush
holder set.
Brush overall length

12.0 mm (0.47 in)
Limit
6.50 mm (0.26 in)
3. Measure:
• Armature assembly resistances (commutator
and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resistances
with the digital circuit tester. 5. Measure:
• Brush spring force
Digital circuit tester (CD–731a) Out of specification → Replace the brush
90890-03189 holder set.
Model 88 Multimeter with ta-
chometer Brush spring force
YU-A1927 6.02–6.51 N (614–664 gf, 21.69–
23.45 oz)
Armature coil resistance

0.0100–0.0200 Ω
Insulation resistance
No continuity (Above 1 MΩ)
b. If any resistance is out of specification, re-

place the starter motor assembly.
5-38
ELECTRIC STARTER
6. Check:
• Gear teeth
Damage/wear → Replace the starter motor
assembly.
7. Check:
• Bearing
Damage/pitting → Replace the starter motor
assembly.
EAS30326
ASSEMBLING THE STARTER MOTOR

• Insulator “1” INSTALLING THE STARTER MOTOR

TIP 1. Connect:
• Battery negative lead “1”
Install the insulator so that the slot “a” is posi-
tioned as shown in the illustration. TIP
Make sure that the battery negative lead “1”
does not touch the starter motor bolt “2”.
1
2
a
1
2. Install:
• Starter motor yoke “1”
• Starter motor rear cover “2”
• Starter motor front cover “3”
TIP
• Align tab “a” of the starter motor rear cover with
notch “b” of the starter motor yoke.
• Align the match mark “c” on the starter motor
yoke with the match mark “d” on the starter mo-
tor front cover.
5-39
V-BELT AUTOMATIC TRANSMISSION
EAS20050

Removing the V-belt case cover
* Water

Footboard (right) 4-8.
Storage box 4-20.
V-belt case air filter element (left) Refer to “WATER PUMP” on page 6-11.
1 Passenger footrest (right) 1
2 Crankshaft end access cover 1
3 V-belt case air filter case cover 1
4 V-belt case air filter case 1
5-40
Removing the V-belt case cover
* Water

5 V-belt case air filter element (right) 1
6 Rear brake lock cable holder (crankcase) 1
7 Rear brake lock cable holder bracket 1
8 Outer V-belt case 1
9 Outer V-belt case gasket 1
10 Bearing retainer 1
11 Bearing 1
12 Circlip 1
13 Oil seal 1
14 Bearing 1
5-41
Removing the V-belt and primary/secondary sheave
*1 Apply YAMAHA GREASE “G” (Shell Sunlight Grease 3®).
*2 Apply YAMAHA GREASE “H” (Polyurea Grease®).

1 Primary sheave nut 1
2 Spacer 1
3 O-ring 2
4 Primary sheave assembly 1
5 Secondary sheave nut 1
6 Secondary sheave assembly 1
7 V-belt 1
8 Primary fixed sheave 1
9 V-belt case air duct joint clamp 1 Loosen.
10 V-belt case air duct 1
11 Inner V-belt case plate 1
5-42
Removing the V-belt and primary/secondary sheave
*1 Apply YAMAHA GREASE “G” (Shell Sunlight Grease 3®).

12 Inner V-belt case 1
13 Dowel pin 2
14 Plate 1
15 Inner V-belt case seal 1
5-43
Disassembling the primary sheave
*2 When replacing the primary sliding sheave or collar, replace them as a set.

1 Cam 1
2 Slider 8
3 Primary sheave weight 8
4 Primary sliding sheave 1
5 Collar 1
6 Oil seal 2
5-44
Disassembling the secondary sheave
* Apply YAMAHA GREASE “H” (Polyurea Grease®).

1 Secondary sheave spring seat nut 1
2 Upper spring seat 1
3 Secondary sheave compression spring 1
4 Spring seat 1
5 Guide pin 6
6 Secondary sliding sheave 1
7 O-ring 2
8 Oil seal 2
9 Secondary fixed sheave 1
5-45
EAS31435 EAS30312
REMOVING THE PRIMARY SHEAVE AND DISASSEMBLY THE SECONDARY SHEAVE

SECONDARY SHEAVE 1. Loosen:
1. Remove: • Secondary sheave spring seat nut “1”
• Primary sheave nut “1” TIP
• Secondary sheave nut “2” • While holding the secondary fixed sheave “2”
TIP with the sheave holder “3”, loosen the second-
While holding the primary and secondary ary sheave spring seat nut with the locknut
sheave with the sheave holder “3”, loosen the wrench “4”.
nut. • Do not loosen the secondary sheave spring
seat nut “1” more than 1/4 turn.
Sheave holder
90890-01481 Sheave holder
90890-01481
Locknut wrench
90890-01348
Locknut wrench
YM-01348
3
4
4
3
1
2
2. Remove:
• Secondary sheave spring seat nut “1”
TIP
Install the sheave spring compressor “2” and
sheave fixed block “3” onto the secondary
2. Remove: sheave assembly as shown. Then, compress
• Primary sheave assembly “1” the spring, and remove the secondary sheave
• Secondary sheave assembly “2” spring seat nut with locknut wrench “4”.
• V-belt “3”
TIP Sheave spring compressor
• Before removal, put alignment marks “a” and 90890-04134
“b” as shown.
YM-04134
• Align these marks during reassembly. Locknut wrench
90890-01348
Locknut wrench
YM-01348
Sheave fixed block
90890-04135
YM-04135
5-46
EAS31436
CHECKING THE V-BELT CASE AIR DUCT

1. Check
• V-belt case air duct
EAS30317
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
EAS30315
1. Check:
CHECKING THE V-BELT • Primary sheave weight
1. Check: Cracks/damage/wear → Replace.
• V-belt “1” 2. Measure:
Cracks/damage/wear → Replace. • Primary sheave weight outside diameter
Grease/oil → Clean the primary and second- Out of specification → Replace.
ary sheave.
2. Measure: Weight outside diameter
• V-belt width “a” 25.0 mm (0.98 in)
Limit
24.5 mm (0.96 in)
TIP
Measure the V-belt width as illustration.
V-belt
V-belt width
32.9 mm (1.30 in)
Limit
31.4 mm (1.24 in)
a 2 1
EAS30318
CHECKING THE SLIDERS

The following procedure applies to all of the slid-
ers.
3 1. Check:
• Slider
EAS30319
2. Plastic board CHECKING THE SECONDARY SHEAVE
3. Ruler 1. Check:
EAS30316 • Secondary fixed sheave
CHECKING THE PRIMARY SHEAVE • Secondary sliding sheave
1. Check: Cracks/damage/wear → Replace the sec-
• Primary sliding sheave ondary fixed and sliding sheaves as a set.
• Primary fixed sheave 2. Check:
Cracks/damage/wear → Replace the primary • Torque cam groove “1”
sliding sheave and primary fixed sheave as a Damage/wear → Replace the secondary
set. fixed and sliding sheaves as a set.
3. Check:
• Guide pin “2”
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
5-47
EAS30320 2. Install:
ASSEMBLING THE PRIMARY SHEAVE • Guide pins
1. Clean: TIP
• Primary fixed sheave Before installing the guide pin, align the position
• Primary sliding sheave (where fixed sheave rivet head “a” and guide pin
• Collar hole “b” are in alignment with each other) with
• Cam alignment mark “c” of the sliding sheave. Install
• Primary sheave weights the guide pin. Then, make sure that the sliding
2. Install: sheave slides to the LOW side without an inter-
• Primary sheave weights “1” ference of rivet head “d”.
• Sliders “2”
• Cam “3”
TIP
Do not apply the grease inside of the primary
sheave.
EAS30321
ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:
• Secondary fixed sheave inner surface “1”
• Secondary sliding sheave inner surface “2”
• Oil seals New 3. Lubricate:
(with the recommended lubricant) • Guide pin groove “1”
Recommended lubricant • O-rings “2” New

YAMAHA GREASE “H” (Poly- (with the recommended lubricant)
urea Grease®)
YAMAHA GREASE “H” (Poly-
urea Grease®)
5-48
TIP
While holding the secondary fixed sheave “2”
with the sheave holder “3”, tighten the second-
ary sheave spring seat nut “1” with the locknut
wrench “4”.
Sheave holder
90890-01481
Locknut wrench
90890-01348
4. Install: Locknut wrench
• Secondary sheave spring seat nut “1” YM-01348
TIP
• Install the secondary sheave spring seat nut
Secondary sheave spring seat
with its beveled side “a” facing the spring seat. nut
T.
• Attach the sheave spring compressor “2” and
R.
90 Nm (9.0 m·kgf, 65 ft·lbf)
sheave fixed block “3” onto the secondary
sheave as shown.
Then compress the spring, and temporarily 3
tighten the secondary sheave spring seat nut. 4
4
90890-04134 3
YM-04134 1
Sheave fixed block 2
90890-04135
EAS31437
YM-04135 INSTALLING THE PRIMARY SHEAVE
ASSEMBLY, SECONDARY SHEAVE
ASSEMBLY AND V-BELT
a 1. Apply:
• Sealant
(onto the inner V-belt case seal)

90890-85505
1
2
2. Install:
5. Tighten: • V-belt case air duct joint clamp “1”
• Secondary sheave spring seat nut “1” • V-belt case air duct “2”
5-49
TIP TIP
• Align the projection “a” in the V-belt case air While holding the secondary sheave with the
duct “2” with the slot “b” on the V-belt case air sheave holder “2”, tighten the secondary sheave
duct joint clamp “1”. nut.
• Align the projection “c” in the V-belt case air
duct “2” with the slot “d” in the inner V-belt case Secondary sheave nut
“3”. 90 Nm (9.0 m·kgf, 65 ft·lbf)
T.
R.
1 b
2 Sheave holder
3 c 90890-01481
a
d
3. Install:
• Primary fixed sheave “1”
• V-belt “2”
• Secondary sheave assembly “3”
ECA22160
5. Tighten:
NOTICE
• Primary sheave nut “1”
Do not allow grease to contact the V-belt, pri- ECA22200
mary and secondary sheave. NOTICE

• Before tightening the nut to remount the
TIP
primary sheave, make sure that the serra-
• When installing the belt, screw M6 (more than tions of the cam are fitted firmly into the
45 mm (1.77 in)) bolts “4” to spread apart the serrations of the crankshaft.
secondary sheave and then install the V-belt. • Also, make sure that cam is properly seat-
Make sure to install the V-belt with the arrow ed.
facing in the direction shown. • Apply grease to the thread and seat of the
• Install the V-belt and secondary sheave as- primary sheave nut.
sembly then pass the V-belt the primary
sheave side.
• Align the “a” and “b” during reassembly.
YAMAHA GREASE “G” (Shell
Sunlight Grease 3®)
3 1
a TIP
While holding the primary sheave with the
sheave holder “2”, tighten the primary sheave
2 nut.
4
Primary sheave nut
b 160 Nm (16 m·kgf, 116 ft·lbf)
4
T.
R.
4. Tighten:
• Secondary sheave nut “1” Sheave holder
90890-01481
5-50
1
a
EAS31235
INSTALLING THE V-BELT CASE

1. Install:
• Oil seal “1”
(into outer V-belt case)
Installed depth of oil seal “a”

4.0–4.3 mm (0.16–0.17 in)
2. Fill the space “b” shown in the illustration with

10 g (0.35 oz) or more of lithium-soap-based
grease.
3. Install:
• Bearing retainer “1”
TIP
• Install the bearing retainer “1” with its mark “a”
facing outward.
• Apply locking agent (LOCTITE®) to the
threads of the bearing retainer screw.
V-belt case bearing retainer

screw
T.
R.
11 Nm (1.1 m·kgf, 8.0 ft·lbf)

LOCTITE®
5-51
GENERATOR AND STARTER CLUTCH
EAS20140

Removing the generator rotor and starter clutch
8
7
14
15
6
16 13
12 5
7
11
10

Drain.
page 3-26.
Drain.
page 3-29.
Storage box 4-20.
Water pump assembly Refer to “WATER PUMP” on page 6-11.
V-belt case air duct SION” on page 5-40.
5-52
8
7
6
13
12 5
7
11
10

1 Rear brake hose holder 1
2 Passenger footrest (left) 1
3 Crankshaft position sensor coupler 1 Disconnect.
4 Stator coil coupler 1 Disconnect.
5 Generator cover 1
6 Generator cover gasket 1
7 Dowel pin 2
8 Starter clutch idle gear shaft 1
9 Starter clutch idle gear 1
10 Generator rotor nut 1
11 Spacer 1
12 Generator rotor 1
13 Starter clutch 1
5-53
14
15
16

14 Woodruff key 1
15 Starter clutch gear 1
16 Washer 1
5-54
Removing the stator coil and oil tank
* When replacing the crankshaft position sensor or stator coil, replace them as a set.

1 Oil tank 1
2 Oil tank gasket 1
3 Dowel pin 2
4 Oil strainer 1
5 Crankshaft position sensor 1
6 Stator coil 1
7 Bearing cover 1
8 Oil seal 1
9 Bearing 1
10 Bearing 1
5-55
EAS30867
REMOVING THE GENERATOR Flywheel puller

1. Remove: 90890-01362
• Generator cover Heavy duty puller
TIP YU-33270-B
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.
EAS30868
REMOVING THE STARTER CLUTCH

1. Remove:
• Starter clutch bolts “1”
2. Remove: • Starter clutch
• Generator rotor nut “1” TIP
• Spacer “2” • While holding the generator rotor “2” with the
TIP sheave holder “3”, remove the starter clutch
• While holding the generator rotor “3” with the bolts.
sheave holder “4”, loosen the generator rotor • Do not allow the sheave holder to touch the
nut. projection on the generator rotor.
• Do not allow the sheave holder to touch the
projection on the generator rotor. Sheave holder
90890-01701
Sheave holder Primary clutch holder
90890-01701 YS-01880-A
YS-01880-A
EAS30869
CHECKING THE STARTER CLUTCH

3. Remove: 1. Check:
• Generator rotor “1” • Starter clutch rollers “1”
(with the flywheel puller “2”) Damage/wear → Replace.
• Woodruff key
TIP
Make sure the flywheel puller is centered over
the generator rotor.
5-56
EAS31439
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS31440
ASSEMBLING THE OIL TANK

1 1. Install:
• Bearing
2. Check: TIP
• Starter clutch idle gear “1” Seal “a” is adhered only on one side of the bear-
• Starter clutch gear “2” ing. Note the press-in orientation.
Burrs/chips/roughness/wear → Replace the
defective part(s).
EAS30871
INSTALLING THE STARTER CLUTCH

3. Check:
1. Install:
• Starter clutch gear contacting surfaces
• Starter clutch
Damage/pitting/wear → Replace the starter
• Starter clutch bolts “1”
clutch gear.
4. Check: Starter clutch bolt
• Starter clutch operation 30 Nm (3.0 m·kgf, 22 ft·lbf)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ LOCTITE®
a. Install the starter clutch gear “1” onto the
starter clutch “2” and hold the starter clutch. TIP
b. When turning the starter clutch gear counter-
• While holding the generator rotor “2” with the
clockwise “A”, the starter clutch and the start-
sheave holder “3”, tighten the starter clutch
er clutch gear should engage, otherwise the
bolts.
starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear clock-
projection on the generator rotor.
wise “B”, it should turn freely, otherwise the
starter clutch is faulty and must be replaced.
Sheave holder
90890-01701
YS-01880-A
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-57
EAS30872
INSTALLING THE GENERATOR Generator rotor nut (2nd)

1. Install: Specified angle 120°
T.
R.
• Woodruff key
• Generator rotor “1” TIP
• Spacer “2” • When tightening the generator rotor nut, be
• Generator rotor nut “3” New sure to use a beam type torque wrench.
• Tighten the nut until it is at the specified angle.
TIP
• Clean the tapered portion of the crankshaft and
the generator rotor hub.
• When installing the generator rotor, make sure
the woodruff key is properly sealed in the key-
way of the crankshaft.
• Lubricate the generator rotor nut seats and
threads with engine oil.
3. Apply:
• Sealant
(onto the crankshaft position sensor/stator
lead grommet)

90890-85505
2. Tighten:
• Generator rotor nut “1”
Generator rotor nut (1st)

65 Nm (6.5 m·kgf, 47 ft·lbf)
T.
R.
TIP
• While holding the generator rotor “2” with the
sheave holder “3”, tighten the generator rotor
nut.
projection on the generator rotor. 4. Install:
• Generator cover
Sheave holder Generator cover bolt
90890-01701 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.

R.
YS-01880-A
5-58
TIP
Tighten the generator cover bolts in stages and
in a crisscross pattern.
5-59
CLUTCH
EAS20055
CLUTCH
Removing the clutch

Refer to “GENERATOR AND STARTER
Generator cover CLUTCH” on page 5-52.
1 Clutch assembly nut 1
2 Clutch assembly 1
3 Washer 1
5-60
CLUTCH
Disassembling the clutch

1 Clip 1
2 Spring stopper plate 1
3 Clutch spring plate 1
4 Pressure plate 1
5 Clutch plate 2 2
6 Clutch damper spring 7
7 Friction plate 6
8 Clutch plate 1 5
9 Clutch spring 6
10 Thrust plate 1
11 Clutch boss nut 1
12 Primary drive gear 1
13 Bearing 2
14 Clutch boss 1
15 Collar 1
5-61
CLUTCH
Disassembling the clutch

16 Thrust plate 1
17 Clutch weight 12
18 Clutch housing 1
5-62
CLUTCH
EAS30346
REMOVING THE CLUTCH

1. Remove:
• Clutch assembly nut “1”
• Clutch assembly “2”
TIP
• Before removal, put alignment marks “a” and
“b” as shown.
• While holding the clutch assembly with the ro-
tor holding tool “3”, loosen the clutch assembly
nut. 2. Remove:
• Align these marks during reassembly. • Spring stopper plate “1”
TIP
Rotor holding tool To ensure proper balance of the clutch assem-
90890-01235 bly, one to three holes “a”, or no hole at all, may
Universal magneto and rotor have been drilled in the spring stopper plate. Be-
holder
fore removing the spring stopper plate, make
YU-01235
alignment marks on both the plate and the clutch
housing so that the plate can be reinstalled in its
original position.
3. Loosen:
• Clutch boss nut “1”
TIP
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, loosen the clutch boss nut.

90890-04086
EAS31441
DISASSEMBLING THE CLUTCH YM-91042
1. Remove:
• Clip “1”
TIP
While compressing the clutch springs with the 1
clutch spring compressor “2”, remove the clip.
Clutch spring compressor

90890-01482 2
5-63
CLUTCH
EAS30348
CHECKING THE FRICTION PLATES Clutch plate 1 thickness

The following procedure applies to all of the fric- 1.30–1.50 mm (0.051–0.059 in)
tion plates. Warpage limit
1. Check: 0.10 mm (0.004 in)
• Friction plate Clutch plate 2 thickness
Damage/wear → Replace the friction plates 1.80–2.00 mm (0.071–0.079 in)
as a set. Warpage limit
2. Measure: 0.20 mm (0.008 in)
• Friction plate thickness
Out of specification → Replace the friction
plates as a set.
TIP
Measure the friction plate at four places.
Friction plate thickness

2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in)
EAS31442
CHECKING THE CLUTCH DAMPER

SPRINGS
clutch damper springs.
1. Check:
• Clutch damper spring
Damage → Replace.
2. Measure:
• Clutch damper spring free height “a”
Out of specification → Replace the clutch
EAS30349
damper springs as a set.
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the Clutch damper spring height
clutch plates. 3.50 mm (0.14 in)
1. Check: Minimum height
• Clutch plate 3.10 mm (0.12 in)
Damage → Replace the clutch plates as a
set.
2. Measure:
• Clutch plate warpage
(with a surface plate and thickness gauge “1”)
plates as a set.
Thickness gauge
90890-03180 a
Feeler gauge set
YU-26900-9 EAS30350
CHECKING THE CLUTCH SPRING PLATE

1. Check:
• Clutch spring plate
Damage → Replace.
5-64
CLUTCH
2. Measure: TIP
• Clutch spring plate free height “a” Pitting on the clutch housing dogs will cause er-
Out of specification → Replace the clutch ratic clutch operation.
spring plate.
Clutch spring plate height

4.70 mm (0.19 in)
Minimum height
4.40 mm (0.17 in)
EAS30353
CHECKING THE CLUTCH BOSS

1. Check:
• Clutch boss splines
a Damage/pitting/wear → Replace the clutch
boss.
EAS30351
TIP
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the Pitting on the clutch boss splines will cause er-
clutch springs. ratic clutch operation.
1. Check:
• Clutch spring
Damage → Replace the clutch springs as a
set.
2. Measure:
• Clutch spring free length
springs as a set.
Clutch spring free length

31.90 mm (1.26 in)
EAS31443
Limit
24.80 mm (0.98 in) CHECKING THE PRESSURE PLATE AND
THRUST PLATE
1. Check:
• Pressure plate “1”
• Thrust plate “2”
EAS30352
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
5-65
CLUTCH
EAS31444
ASSEMBLING THE CLUTCH

1. Install:
• Clutch boss
• Primary drive gear
• Clutch boss nut
2. Tighten:
• Clutch boss nut “1”
Clutch boss nut

130 Nm (13 m·kgf, 94 ft·lbf)
T.
R.
TIP
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, tighten the clutch boss nut.

90890-04086
YM-91042
3. Install:
• Clutch weights 4. Install:
• Thrust plate “1” • Clip “1”
• Clutch springs TIP
• Clutch damper springs “2” While compressing the clutch springs with the
• Clutch plates 2 “3” clutch spring compressor “2”, install the clip.
• Friction plates “4”
• Clutch plates 1 “5”
Clutch spring compressor
• Pressure plate “6” 90890-01482
• Clutch spring plate “7”
TIP
• Clutch damper spring “a” installed at the end
must be installed backwards.
• The pressure plate “6” and thrust plate “1” can
be identified by punch mark “b” on the pressure
plate.
5-66
CLUTCH
EAS30363
INSTALLING THE CLUTCH

1. Install:
• Clutch assembly “1”
• Clutch assembly nut “2”
Clutch assembly nut

65 Nm (6.5 m·kgf, 47 ft·lbf)
T.
R.
TIP
• Align the “a” and “b” during reassembly.
• While holding the clutch assembly with the ro-
tor holding tool “3”, tighten the clutch assembly
nut.
Rotor holding tool

90890-01235
Universal magneto and rotor
holder
YU-01235
5-67
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump assembly

Starter clutch gear CLUTCH” on page 5-52.
1 Oil pump assembly 1
2 Oil pump drive chain 1
3 Gasket 2
4 Oil delivery pipe 1
5 Oil pipe 1
6 Relief valve assembly 1
5-68
OIL PUMP
Disassembling the oil pump assembly
* When replacing any of the part, replace the oil pump assembly.

1 Oil pump housing 1 1
2 Dowel pin 2
3 Oil pump outer rotor 1 1
4 Oil pump inner rotor 1 1
5 Pin 1
6 Washer 1
7 Oil pump housing center 1
8 Oil pump outer rotor 2 1
9 Oil pump inner rotor 2 1
10 Pin 1
11 Oil pump driven gear 1
12 Oil pump housing 2 1
5-69
OIL PUMP
EAS30337
CHECKING THE OIL PUMP

1. Check:
• Oil pump driven gear “1”
• Oil pump housing 2 “2”
• Oil pump housing 1 “3”
Cracks/damage/wear → Replace the oil
pump assembly.
EAS30342
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
2. Check: Recommended lubricant
• Oil pump operation Engine oil
Rough movement → Repeat steps (1) and
(2) or replace the oil pump assembly. 2. Install:
• Inner rotors
TIP
When installing the inner rotor, align the pins “1”
in the oil pump shaft with the grooves “a” in the
inner rotor.
EAS30338
CHECKING THE RELIEF VALVE

1. Check: 1
• Relief valve body a
Damage/wear → Replace. a
EAS30742
3. Check:
CHECKING THE OIL PIPES
• Oil pump operation
1. Check:
Refer to “CHECKING THE OIL PUMP” on
• Oil pipe
page 5-70.
• Oil delivery pipe
Damage → Replace. EAS30343
Obstruction → Wash and blow out with com- INSTALLING THE OIL PUMP
pressed air. 1. Install:
• Oil pump assembly
EAS30785
CHECKING THE OIL PUMP DRIVE CHAIN Oil pump bolt

1. Check: 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
• Oil pump drive chain

Cracks/stiffness → Replace the oil pump ECA13890
chain and oil pump assembly as a set. NOTICE

After tightening the bolts, make sure the oil
pump turns smoothly.
5-70
CRANKCASE
EAS20059
CRANKCASE
Separating the crankcase

Engine Refer to “ENGINE REMOVAL” on page 5-2.
Refer to “CYLINDER AND PISTONS” on
Cylinder/Pistons page 5-31.
Oil cooler Refer to “OIL COOLER” on page 6-5.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-36.
Starter clutch gear CLUTCH” on page 5-52.
Clutch assembly Refer to “CLUTCH” on page 5-60.
Oil pump assembly Refer to “OIL PUMP” on page 5-68.
Inner V-belt case SION” on page 5-40.
5-71
CRANKCASE
Separating the crankcase

Bearing housing Refer to “SWINGARM” on page 4-99.
1 Centerstand assembly 1
2 Timing chain 1
3 Timing chain guide (intake side) 1
4 Crankcase (left) 1
5 Dowel pin 2
6 Oil strainer 1
7 Crankcase (right) 1
5-72
CRANKCASE
Removing the oil seals and bearings

Crankshaft assembly Refer to “CRANKSHAFT” on page 5-76.
Transmission Refer to “TRANSMISSION” on page 5-85.
1 Bearing retainer 2
2 Oil seal 2
3 Bearing 5
5-73
CRANKCASE
EAS30389 EAS30397
DISASSEMBLING THE CRANKCASE ASSEMBLING THE CRANKCASE

1. Remove: 1. Install:
• Crankcase bolts • Cylinder stud bolts “1”
TIP TIP
Loosen each bolt 1/4 of a turn at a time, in stag- For the cylinder stud bolt, embedded height “a”
es and in a crisscross pattern. After all of the is the standard value and the tightening torque is
bolts are fully loosened, remove them. the reference value.
• M6 × 35 mm (1.38 in) bolts “1”
• M6 × 50 mm (1.97 in) bolts “2” Cylinder stud bolt
• M8 × 110 mm (4.33 in) bolts “3” 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
T.
R.
2. Remove:
• Crankcase (left) a. 150.2–152.2 mm (5.91–5.99 in)
ECA13900
NOTICE 2. Thoroughly clean all the gasket mating sur-

Tap on one side of the crankcase with a soft- faces and crankcase mating surfaces.
face hammer. Tap only on reinforced por- 3. Apply:
tions of the crankcase, not on the crankcase • Sealant
mating surfaces. Work slowly and carefully (onto the crankcase mating surfaces)
and make sure the crankcase halves sepa- Yamaha bond No. 1215
rate evenly. 90890-85505
EAS30390
CHECKING THE CRANKCASE

TIP
1. Thoroughly wash the crankcase halves in a
mild solvent. Do not allow any sealant to come into contact
2. Thoroughly clean all the gasket surfaces and with the oil gallery.
crankcase mating surfaces.
3. Check:
• Crankcase
• Oil delivery passages
EAS31445
CHECKING THE TIMING CHAIN

1. Check:
• Timing chain
Damage/stiffness → Replace the timing 4. Install:
chain, camshafts and crankshaft assembly • Dowel pins
as a set. • Crankcase (left)
5-74
CRANKCASE
5. Install:
• Crankcase bolts (M8)
• Crankcase bolts (M6)
Crankcase bolt (M8)

24 Nm (2.4 m·kgf, 17 ft·lbf)
T.
R.
Crankcase bolt (M6)

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
• M8 × 110 mm (4.33 in) bolts “1”
• M6 × 50 mm (1.97 in) bolts “2”
• M6 × 35 mm (1.38 in) bolts “3”
6. Check:
• Crankshaft and transmission operation
Rough movement → Repair.
5-75
CRANKSHAFT
EAS20061
CRANKSHAFT
Removing the crankshaft assembly

Separate.
Crankcase Refer to “CRANKCASE” on page 5-71.
1 Dowel pin 2
2 Balancer cylinder 1
3 Crankshaft assembly 1
4 Oil seal 1
5 Crankshaft journal bearing 2
5-76
CRANKSHAFT
Removing the connecting rods
60 Nm (6.0 m kgf, 43 ft Ibf)

T.
R

1 Connecting rod cap 2
2 Big end lower bearing 2
3 Connecting rod 2
4 Big end upper bearing 2
5 Circlip 2
6 Balancer piston pin 1
7 Balancer piston 1
8 Balancer connecting rod cap 1
9 Balancer big end lower bearing 1
10 Balancer connecting rod 1
11 Balancer big end upper bearing 1
5-77
CRANKSHAFT
EAS30415
REMOVING THE CONNECTING RODS

The following procedure applies to all of the con-
necting rods.
1. Remove:
• Connecting rod cap “1”
• Connecting rod “2”
• Big end bearings
TIP
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
EAS30419
TIP
REMOVING THE CRANKSHAFT JOURNAL Identify the position of each crankshaft journal
BEARINGS bearing so that it can be reinstalled in its original
The following procedure applies to both of the place.
crankshaft journal bearings.
1. Remove: EAS30423
• Crankshaft assembly CHECKING THE CRANKSHAFT AND

• Crankshaft journal bearing “1” CONNECTING RODS
TIP
1. Measure:
• Crankshaft runout
Remove the crankshaft journal bearing using the
Out of specification → Replace the crank-
plane bearing installer “2”.
shaft.
Plane bearing installer Runout limit

90890-04139 0.030 mm (0.0012 in)
2. Check:
• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear → Replace the crankshaft.
5-78
CRANKSHAFT
3. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.
Connecting rod
Oil clearance
0.036–0.060 mm (0.0014–0.0024
in)
Balancer connecting rod
Oil clearance
0.036–0.060 mm (0.0014–0.0024 d. Assemble the connecting rod halves.
in) TIP
• Do not move the connecting rod or crankshaft
The following procedure applies to all of the until the clearance measurement has been
connecting rods and balancer connecting completed.
rod. • Lubricate the bolts threads and nut seats with
ECA13930
NOTICE
molybdenum disulfide grease.
• Make sure the “Y” mark “c” on the connecting
Do not interchange the big end bearings and rod faces towards the left side of the crank-
connecting rods. To obtain the correct shaft.
crankshaft-pin-to-big-end-bearing clear- • Make sure the characters “d” on both the con-
ance and prevent engine damage, the big necting rod and connecting rod cap are
end bearings must be installed in their origi- aligned.
nal positions.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing into
the connecting rod cap.
TIP
Align the projections “a” on the big end bearings
with the notches “b” in the connecting rod and
connecting rod cap. e. Tighten the connecting rod nuts.
Refer to “INSTALLING THE CONNECTING
RODS” on page 5-82.
f. Remove the connecting rod and big end
bearings.
Refer to “REMOVING THE CONNECTING
RODS” on page 5-78.
g. Measure the compressed Plastigauge®
width “e” on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select re-
c. Put a piece of Plastigauge® “1” on the crank- placement big end bearings.
shaft pin.
5-79
CRANKSHAFT
For example, if the connecting rod P1 and the

crankshaft web P1 numbers are 5 and 1 re-
spectively, then the bearing size for P1 is:
P1 (connecting rod) - P1 (crankshaft)
=5-1
= 4 (green)
Bearing color code

0. White 1.Blue 2.Black 3.Brown
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4.Green 5.Yellow
4. Select: 5. Measure:
• Big end bearings (P1–P3) • Crankshaft-journal-to-crankshaft-journal
TIP bearing clearance.
• The numbers “A” stamped into the crankshaft Out of specification → Replace the crank-
web and the numbers “B” on the connecting shaft journal bearings.
rods are used to determine the replacement
big end bearing sizes. Journal oil clearance
• P1–P3 refer to the bearings shown in the crank- 0.040–0.087 mm (0.0016–0.0034
in)
shaft illustration.
TIP
On the journal, the larger value is used as a ba-
sis for calculation of the oil clearance, and on the
journal bearing, the smaller value is used.
ECA13920
NOTICE
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing clear-
ance and prevent engine damage, the crank-
shaft journal bearings must be installed in
their original positions.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the crankshaft journal bearings, crank-
shaft journals, and bearing portions of the
crankcase.
b. Check the bearing surface. If the bearing sur-
face is worn or scratched, both bearings
should be replaced.
TIP
If either of the right or left journal bearing is worn
or scratched, both bearings should be replaced
as a set.
c. Measure the crankshaft journal diameter “a”
of each crankshaft journal at two places. If it
is out of specification, replace the crankshaft.
5-80
CRANKSHAFT
Crankshaft journal diameter

54.984-55.000 mm (2.1647-
2.1654 in)
d. Measure the crankshaft journal bearing in-

side diameter “b” of each crankshaft journal
bearing at two places.
e. If crankshaft journal bearing inside diameter

is “55.03” and crankshaft journal diameter is
“54.98”, then the journal oil clearance is:
Journal oil clearance: For example, if the crankcase J1 and the
Crankshaft journal bearing inside diameter - crankshaft web J1 numbers are 4 and 2 re-
Crankshaft journal diameter
= 55.03 - 54.98
spectively, then the bearing size for J1 is:
= 0.05 mm J1 (crankcase) - J1 (crankshaft web)
=4-2
If the oil clearance is out of specification, se- = 2 (black)
lect replacement bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Select:
• Crankshaft journal bearings (J1–J2)
TIP
• The numbers “A” stamped into the crankshaft
web and the numbers “B” on the crankcase are
used to determine the replacement crankshaft
journal bearing size.
• J1–J2 refer to the bearings shown in the crank-
shaft illustration.
5-81
CRANKSHAFT
Bearing color code

0. White 1.Blue 2.Black 3.Brown
4.Green 5.Yellow
Bearing thickness
White: 2.499–2.512 mm (0.0984–
0.0989 in)
Blue: 2.495–2.508 mm (0.0982–
0.0987 in)
Black: 2.491–2.504 mm (0.0981–
0.0986 in)
Brown: 2.487–2.500 mm
(0.0979–0.0984 in)
Green: 2.483–2.496 mm (0.0978–
0.0983 in)
Yellow: 2.479–2.492 mm
(0.0976–0.0981 in)
EAS31446
INSTALLING THE CRANKSHAFT JOURNAL

BEARINGS
1. Attach: EAS30426
INSTALLING THE CONNECTING RODS

• Crankshaft journal bearing “1”
1. Lubricate:
TIP
• Bolt threads New
Attach the crankshaft journal bearing to the
plane bearing installer “2”. • Nut seats New
Plane bearing installer Recommended lubricant
90890-04139 Molybdenum disulfide oil
2. Install: 2. Lubricate:
• Crankshaft journal bearing • Crankshaft pins
TIP • Big end bearings inner surface
• Align the projection “a” on the bearing with the • Balancer big end bearings inner surface
projection “b” on the crankcase. (with the recommended lubricant)
• Place an iron plate “3” beneath the crankcase
and press fit until the end of the plain bearing Recommended lubricant
installer touches the iron plate. Engine oil
3. Install:
• Big end bearings
• Connecting rods
• Connecting rod caps
(onto the crankshaft pins)
TIP
• Align the projections “a” on the big end bear-
ings with the notches “b” in the connecting rods
and connecting rod caps.
• Be sure to reinstall each big end bearing in its
original place.
5-82
CRANKSHAFT
• Make sure the “Y” marks “c” on the connecting

rods face towards the left side of the crank-
shaft.
• Make sure the characters “d” on both the con-
necting rod and connecting rod cap are
aligned.
c. Tighten the connecting rod nuts further to

reach the specified angle 90°.
Connecting rod nut (2nd)

Specified angle 90°
T.
R.
EWA13400
WARNING
4. Tighten:
• Connecting rod nuts If the connecting rod nut is tightened more
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ than the specified angle, do not loosen the
EWA13390
nut and then retighten it. Instead, replace the
WARNING connecting rod bolt and nut with a new one
• Replace the connecting rod bolts and nuts and perform the procedure again.
with new ones. ECA19930
• Clean the connecting rod bolts and nuts. NOTICE

TIP • Do not use a torque wrench to tighten the
Tighten the connecting rod nuts using the follow- connecting rod nut to the specified angle.
ing procedure. • Tighten the nut until it is at the specified an-
gle.
a. Tighten the connecting rod nuts with a torque
wrench. TIP
On a hexagonal nut, note that the angle from
Connecting rod nut (1st) one corner to another is 60°.
16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Put a mark “1” on the corner of the connecting 5. Install:
rod nut “2” and the connecting rod cap “3”. • Balancer big end bearings
• Balancer connecting rod
• Balancer connecting rod cap
(onto the crankshaft pin)
5-83
CRANKSHAFT
TIP between 30 Nm (3.0 m·kgf, 22 ft·lbf) and 60 Nm

• Align the projections “a” on the balancer big (6.0 m·kgf, 43 ft·lbf), loosen the nut to less than
end bearings with the notches “b” in the bal- 30 Nm (3.0 m·kgf, 22 ft·lbf) and start again.
ancer connecting rod and balancer connecting
EAS30428
rod cap.
INSTALLING THE CRANKSHAFT
• Be sure to reinstall each balancer big end bear-
ASSEMBLY
ing in its original place.
1. Install:
• Make sure the “Y” marks “c” on the balancer
• Crankshaft assembly “1”
connecting rod face towards the left side of the
• Balancer cylinder “2”
crankshaft.
• Make sure the characters “d” on both the bal- Balancer cylinder bolt
ancer connecting rod and balancer connecting 58 Nm (5.8 m·kgf, 42 ft·lbf)
T.
R.
rod cap are aligned. LOCTITE®
ECA13970
NOTICE
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
6. Tighten:
• Balancer connecting rod nuts
Balancer connecting rod nut

60 Nm (6.0 m·kgf, 43 ft·lbf)
T.
R.
ECA22190
NOTICE
When tightening the nuts, be sure to use an
F-type torque wrench.
TIP
Tighten the nuts to the specified torque. Apply
continuous torque between 30 Nm (3.0 m·kgf,
22 ft·lbf) and 60 Nm (6.0 m·kgf, 43 ft·lbf) without
pausing. After reaching 30 Nm (3.0 m·kgf, 22
ft·lbf), do not stop tightening until the specified
torque is achieved. If the tightening is interrupted
5-84
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission

Separate.
Crankcase Refer to “CRANKCASE” on page 5-71.
1 Secondary shaft 1
2 Collar 1
3 Primary driven gear 1
TIP
4 Main axle 1 When installing main axle, install the main
axle with groove “a” facing to the primary
driven gear.
5 1st pinion gear 1

6 Drive axle 1
7 1st wheel gear 1
8 Circlip 1
5-85
TRANSMISSION
EAS30433
CHECKING THE TRANSMISSION

1. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace.
2. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s).
3. Check:
• Main axle
Cracks/damage/wear → Replace the main
axle.
4. Measure:
• Drive axle runout
(with a centering device and dial gauge)
Out of specification → Replace the drive axle.
Drive axle runout limit

0.10 mm (0.0039 in)
5. Measure:
• Secondary shaft runout
(with a centering device and dial gauge)
Out of specification → Replace the second-
ary shaft.
Secondary shaft runout limit

0.120 mm (0.0047 in)
5-86
TRANSMISSION
5-87
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1

CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR..................................................................6-3
OIL COOLER...................................................................................................6-5
CHECKING THE OIL COOLER ................................................................6-7
INSTALLING THE OIL COOLER .............................................................. 6-7
THERMOSTAT ................................................................................................6-8
CHECKING THE THERMOSTAT............................................................ 6-10
INSTALLING THE THERMOSTAT ASSEMBLY ..................................... 6-10
WATER PUMP...............................................................................................6-11
DISASSEMBLING THE WATER PUMP.................................................. 6-14
CHECKING THE WATER PUMP ............................................................ 6-14
ASSEMBLING THE WATER PUMP........................................................ 6-14
INSTALLING THE WATER PUMP .......................................................... 6-15
6
RADIATOR
EAS20063
RADIATOR
Removing the radiator

Footboards 4-8.
Drain.
page 3-29.
1 Coolant reservoir hose 1
2 Coolant reservoir 1
3 Coolant reservoir cap 1
4 Coolant reservoir breather hose 1
TIP
5 Radiator cap 1 Remove/Install it with the radiator filler pipe
held.
6-1
RADIATOR
Removing the radiator
15
12
14
13

6 Cooling system air bleed hose 1 Disconnect.
7 Radiator filler pipe 1
8 Radiator filler hose 1
9 Fast idle plunger outlet coolant hose 1 Disconnect.
10 Radiator outlet hose 1 Disconnect.
11 Radiator fan motor coupler 1 Disconnect.
12 Radiator 1
13 Radiator fan 1
14 Radiator inlet hose 1
15 Radiator bracket 1
6-2
RADIATOR
EAS30439
CHECKING THE RADIATOR

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

1. Fill:
2. Check: • Cooling system
• Radiator hoses (with the specified amount of the recom-
• Radiator pipes mended coolant)
Cracks/damage → Replace. Refer to “CHANGING THE COOLANT” on
3. Measure: page 3-29.
• Radiator cap opening pressure 2. Check:
Below the specified pressure → Replace the • Cooling system
radiator cap. Leaks → Repair or replace any faulty part.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Radiator cap opening pressure a. Attach the radiator cap tester “1” and radiator
107.9–137.3 kPa (1.08–1.37 cap tester adapter “2” to the radiator.
kgf/cm², 15.6–19.9 psi)
Radiator cap tester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 90890-01325
a. Install the radiator cap tester “1” and radiator Mityvac cooling system tester kit
cap tester adapter “2” to the radiator cap “3”. YU-24460-A
Radiator cap tester adapter
Radiator cap tester 90890-01352
90890-01325 Pressure tester adapter
Mityvac cooling system tester kit YU-33984
YU-24460-A
Radiator cap tester adapter
90890-01352
Pressure tester adapter
YU-33984
6-3
RADIATOR
b. Apply 137.3 kPa (1.37 kgf/cm2, 19.9 psi) of

pressure.
c. Measure the indicated pressure with the
gauge.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-4
OIL COOLER
EAS20064
OIL COOLER
Removing the oil cooler

Storage box 4-20.
Drain.
page 3-26.
Drain.
page 3-29.
1 Oil filter cartridge 1
2 Oil cooler inlet hose 1
3 Oil cooler outlet hose 1
6-5
OIL COOLER
Removing the oil cooler

4 Radiator inlet hose 1 Disconnect.
5 Coolant pipe 1
6 Thermostat outlet hose 1
7 Oil filter cartridge union bolt 1
8 Oil cooler 1
6-6
OIL COOLER
EAS30441
4. Fill:
CHECKING THE OIL COOLER
• Cooling system
1. Check:
(with the specified amount of the recom-
• Oil cooler
mended coolant)
Refer to “CHANGING THE COOLANT” on
2. Check:
page 3-29.
• Oil cooler inlet hose
• Crankcase
• Oil cooler outlet hose
mended engine oil)
EAS30442 Refer to “CHANGING THE ENGINE OIL” on
INSTALLING THE OIL COOLER page 3-26.
1. Clean: 5. Check:
• Mating surfaces of the oil cooler and the • Cooling system
crankcase Leaks → Repair or replace any faulty part.
(with a cloth dampened with lacquer thinner) Refer to “INSTALLING THE RADIATOR” on
2. Install: page 6-3.
• O-ring New 6. Measure:
• Oil cooler “1” • Radiator cap opening pressure
• Oil filter cartridge union bolt “2” Below the specified pressure → Replace the
radiator cap.
Oil filter cartridge union bolt Refer to “CHECKING THE RADIATOR” on
63 Nm (6.3 m·kgf, 46 ft·lbf) page 6-3.
T.
R.
TIP
• Make sure that the O-ring is positioned proper-
ly.
• Align the projection “a” on the oil cooler with the
slot “b” in the crankcase.
3. Install:
• Oil filter cartridge
Oil filter wrench

90890-01469
Oil filter wrench
YM-01469
Oil filter cartridge

17 Nm (1.7 m·kgf, 12 ft·lbf)
T.
R.
Refer to “CHANGING THE ENGINE OIL” on

page 3-26.
6-7
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat

Storage box 4-20.
Drain.
page 3-29.
1 Coolant temperature sensor coupler 1 Disconnect.
2 Coolant temperature sensor 1
3 Copper washer 1
4 Cooling system air bleed hose 1 Disconnect.
5 Thermostat outlet hose 1 Disconnect.
6 Thermostat cover 1
6-8
THERMOSTAT
Removing the thermostat

7 Thermostat 1
8 Fast idle plunger inlet coolant hose 1 Disconnect.
9 Coolant hose 1 Disconnect.
6-9
THERMOSTAT
EAS30443
2. Check:
CHECKING THE THERMOSTAT
• Thermostat cover
1. Check:
• Thermostat
Does not open at 71–85 °C (159.8–185.0 °F) EAS30445
→ Replace. INSTALLING THE THERMOSTAT

ASSEMBLY
1. Install:
• Thermostat
TIP
Install the thermostat with its breather hole “a”
facing forward.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat “1” in a container “2”
filled with water.
b. Slowly heat the water “3”.
c. Place a thermometer “4” in the water. a
d. While stirring the water, observe the thermo-
stat and thermometer’s indicated tempera-
ture. 2. Fill:
• Cooling system
mended coolant)
page 3-29.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-10
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
* Water or silicone fluid

Footboard (left) 4-8.
Drain.
page 3-29.
1 V-belt case air filter element joint clamp 1 Loosen.
2 V-belt case air filter element (left) 1
3 Generator cover protector cover 1
4 Generator cover protector 1
5 Oil cooler inlet hose 1 Disconnect.
6 Coolant hose 1 Disconnect.
6-11
WATER PUMP
Removing the water pump
* Water or silicone fluid

7 Radiator outlet hose 1 Disconnect.
8 Water pump inlet pipe 1
9 Water pump outlet pipe 1
10 Water pump assembly 1
6-12
WATER PUMP
Disassembling the water pump

1 Water pump housing cover 1
2 Circlip 1
3 Impeller shaft 1
4 Mechanical seal 1
5 Bearing 1
6 Oil seal 1
7 Water pump housing 1
6-13
WATER PUMP
EAS30446 EAS30447
DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP

1. Remove: 1. Check:
• Mechanical seal (impeller side) “1” • Water pump housing cover “1”
(from the impeller, with a thin, flathead screw- • Water pump housing “2”
driver) • Impeller shaft “3”
TIP Cracks/damage/wear → Replace.
Do not scratch the impeller shaft.
2. Check:
• Water pump inlet pipe
2. Remove: • Water pump outlet pipe
• Mechanical seal (housing side) “1” Cracks/damage/wear → Replace.
TIP
EAS30448
Remove the mechanical seal (housing side) ASSEMBLING THE WATER PUMP
from the inside of the water pump housing. 1. Install:
• Oil seal “1” New
• Bearing “2” New
(into the water pump housing)
TIP
• Before installing the oil seal, apply tap water or
coolant onto its outer surface.
• Install the oil seal with a socket that matches its
outside diameter.
• Install the oil seal from the inside of the water
3. Remove: pump housing.
• Bearing “1”
• Oil seal “2” Installed depth of oil seal “a”
TIP 11.5 mm (0.45 in)
Remove the bearing and oil seal from the out-
side of the water pump housing.
New
New
2. Install:
• Mechanical seal (housing side) “1” New
(into the water pump housing “2”)
6-14
WATER PUMP
ECA20330
4. Measure:
NOTICE • Impeller shaft tilt
Never lubricate the mechanical seal (hous- Out of specification → Repeat step (3) and
ing side) surface with oil or grease. (4).
ECA20340
TIP NOTICE
Use the special tool and a press to press the me- Make sure the mechanical seal (impeller
chanical seal (housing side) straight in until it side) is flush with the impeller.
touches the water pump housing.
TIP
Mechanical seal installer If the surface “a” of the mechanical seal (impeller
90890-04132 side) that contacts the mechanical seal (housing
Water pump seal installer side) is dirty, clean it.
YM-33221-A
Middle driven shaft bearing driv- Impeller shaft tilt limit
er 0.15 mm (0.006 in)
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058
4
3
a
1 New
1. Straightedge
2 2. Impeller shaft
EAS30449
A. Push down INSTALLING THE WATER PUMP

3. Mechanical seal installer 1. Install:
4. Middle driven shaft bearing driver • O-ring New
3. Install: • Water pump assembly
• Mechanical seal (impeller side) “1” New TIP
TIP
• Align the slit “a” on the impeller shaft with the
projection “b” on the oil pump shaft.
Before installing the mechanical seal (impeller
• Lubricate the O-ring with a thin coat of lithium-
side), apply tap water or coolant onto its outer
soap-based grease.
surface.
Water pump assembly bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
New
6-15
WATER PUMP
2. Fill:
• Cooling system
mended coolant)
page 3-29.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
4. Measure:
• Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-16
WATER PUMP
6-17
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL HOSE .................................................................7-3
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
CHECKING THE ROLLOVER VALVE ......................................................7-3
INSTALLING THE FUEL PUMP................................................................7-4
INSTALLING THE FUEL TANK.................................................................7-4
INSTALLING THE FUEL HOSE ................................................................7-4
CHECKING THE FUEL PRESSURE ........................................................7-4
THROTTLE BODY........................................................................................... 7-6

REMOVING THE FUEL HOSE (INJECTOR SIDE)...................................7-9
CHECKING THE INJECTORS ..................................................................7-9
CHECKING THE THROTTLE BODY ........................................................7-9
INSTALLING THE INJECTORS ................................................................7-9
INSTALLING THE FUEL HOSE (INJECTOR SIDE) ...............................7-10
ADJUSTING THE THROTTLE POSITION SENSOR..............................7-10
7
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank

Storage box 4-20.
1 Fuel pump coupler 1 Disconnect.
2 Fuel hose connector cover 1
3 Fuel hose 1 Disconnect.
4 Fuel tank overflow hose 1
5 Fuel tank breather hose 2
6 Rollover valve 1
7 Fuel tank 1
8 Fuel tank cap 1
9 Filler cover 1
10 Fuel pump bracket 1
11 Fuel pump 1
12 Fuel pump gasket 1
7-1
FUEL TANK
Removing the canister

Storage box 4-20.
1 Fuel tank breather hose 1
2 Canister purge hose (3-way joint to canister) 1
Canister purge hose (throttle body to 3-way
3 2
joint)
4 Canister 1
5 Canister bracket 1
7-2
FUEL TANK
EAS31447 EAS30450
REMOVING THE FUEL HOSE REMOVING THE FUEL TANK

1. Remove: 1. Extract the fuel in the fuel tank through the
• Fuel hose connector cover “1” fuel tank cap with a pump.
2. Disconnect: 2. Remove:
• Fuel hose “2” • Fuel tank overflow hose
EWA15910
• Fuel tank breather hoses
WARNING • Rollover valve
Cover fuel hose connections with a cloth 3. Disconnect:
when disconnecting them. Residual pres- • Fuel pump coupler
sure in the fuel lines could cause fuel to 4. Remove:
spurt out when removing the hose. • Fuel tank
ECA21750
EAS30451
NOTICE
REMOVING THE FUEL PUMP
• Be sure to disconnect the fuel hose by 1. Remove:
hand. Do not forcefully disconnect the • Fuel pump bracket
hose with tools. • Fuel pump
• Although the fuel has been removed from • Fuel pump gasket
the fuel tank, be careful when removing the ECA14721
fuel hose, since there may be fuel remain- NOTICE

ing in it. • Do not drop the fuel pump or give it a
• Do not disconnect the fuel hose from the strong shock.
fuel hose connector. Disconnect the con- • Do not touch the base section of the fuel
nector from the fuel pump. sender.
TIP EAS30454
Before removing the hose, place a few rags in CHECKING THE FUEL PUMP BODY
the area under where it will be removed. 1. Check:
• Fuel pump body
Obstruction → Clean.
2
Cracks/damage → Replace the fuel pump
assembly.
EAS30455
CHECKING THE FUEL PUMP OPERATION

1 1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PRES-
SURE” on page 7-4.
EAS30699
CHECKING THE ROLLOVER VALVE

1. Check:
1
2 • Rollover valve “1”
Damage/faulty → Replace.
TIP
• Check that air flows smoothly only in the direc-
tion of the arrow shown in the illustration.
• The rollover valve must be in an upright posi-
tion when checking the airflow.
7-3
FUEL TANK
3. Install:
• Fuel tank overflow hose
• Fuel tank breather hoses
1 • Rollover valve
EAS31448
INSTALLING THE FUEL HOSE

1. Connect:
• Fuel hose
2. Install:
• Fuel hose connector cover
EAS30456 ECA22030
INSTALLING THE FUEL PUMP NOTICE

1. Install: When installing the fuel hose, make sure that
• Fuel pump gasket New it is securely connected, and that the fuel
• Fuel pump hose connector cover is in the correct posi-
• Fuel pump bracket tion, otherwise the fuel hose will not be prop-
erly installed.
Fuel pump bolt
3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) TIP
T.
R.
• Wipe up any fuel remaining in the recess “a” in

TIP the fuel pump with a dry rag “1”.
• Do not damage the installation surfaces of the • After installing the fuel hose connector cover,
fuel tank when installing the fuel pump. make sure that it is installed securely.
• Always use a new fuel pump gasket.
• Install the fuel pump as shown in the illustra-
tion.
• Align projection “a” on the fuel pump with point
“b” of the fuel tank.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
EAS30703
CHECKING THE FUEL PRESSURE

1. Check:
• Fuel pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuel hose connector cover “1”
and disconnect the fuel hose “2” from the fuel
pump.
A. Forward EWA15910
WARNING
EAS30457
INSTALLING THE FUEL TANK Cover fuel hose connections with a cloth
1. Install: when disconnecting them. Residual pres-
• Fuel tank sure in the fuel lines could cause fuel to
spurt out when removing the hose.
Fuel tank nut ECA21750
9 Nm (0.9 m·kgf, 6.5 ft·lbf) NOTICE
T.
R.
Fuel tank bolt

9 Nm (0.9 m·kgf, 6.5 ft·lbf) • Be sure to disconnect the fuel hose by
hand. Do not forcefully disconnect the
2. Connect: hose with tools.
• Fuel pump coupler
7-4
FUEL TANK
• Although the fuel has been removed from f. Remove the pressure gauge and fuel pres-
the fuel tank, be careful when removing the sure adapter.
fuel hose, since there may be fuel remain- TIP
ing in it. Before removing the special tools, place a few
• Do not disconnect the fuel hose from the rags in the area under where they will be re-
fuel hose connector. Disconnect the con- moved.
nector from the fuel pump.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP
Before removing the hose, place a few rags in
the area under where it will be removed.
b. Connect the pressure gauge “1” and fuel

pressure adapter “2” to the fuel pump and the
fuel hose “3”.
Pressure gauge
90890-03153
Pressure gauge
YU-03153
90890-03181
YM-03181
c. Start the engine.

d. Measure the fuel pressure.
Faulty → Replace the fuel pump.
Fuel line pressure at idling

220–300 kPa (2.2–3.0 kgf/cm²,
31.9–43.5 psi)
e. Push the OFF/steering lock switch.
7-5
THROTTLE BODY
EAS20070
THROTTLE BODY
Removing the throttle body
2
4
5
1
8
3
7
7

Storage box 4-20.
Drain.
page 3-29.
1 Cylinder head breather hose 1
2 Fast idle plunger intake hose 1
3 Air filter case joint clamp 2 Loosen.
4 Air filter case cover 1
5 Air filter element 1
6 Air filter case 1
7 Throttle cable 2 Disconnect.
8 Fast idle plunger outlet coolant hose 1 Disconnect.
7-6
THROTTLE BODY
Removing the throttle body
10
13 19
15
12 17
11
14
11 16
20 16
11
11 18
9 14 18

9 Fast idle plunger inlet coolant hose 1 Disconnect.
Throttle position sensor sub-wire harness cou-
10 1 Disconnect.
pler
11 Throttle body joint clamp 4 Loosen.
12 Throttle body assembly 1
13 Throttle position sensor sub-wire harness 1
14 Throttle body joint 2
15 Fuel hose 1
16 Fuel injector coupler 2 Disconnect.
17 Fuel rail 1
18 Fuel injector 2
19 Intake air pressure sensor hose 1 Disconnect.
20 Intake manifold 1
7-7
THROTTLE BODY
Disassembling the throttle body assembly
TIP
Before disassembling the throttle body as-
sembly, make sure to note the number of
times the air screw is turned out from the
seated position to its set position.
1 Throttle position sensor 1

2 Idling speed adjusting screw set 1
3 Plunger 1
4 Plunger spring 1
5 Air screw set 2
7-8
THROTTLE BODY
EAS30840
2. Check:
REMOVING THE FUEL HOSE (INJECTOR
• Fuel passages
SIDE)
Obstructions → Clean.
1. Disconnect: ECA21770
• Fuel hose (injector side) NOTICE

EWA15910
WARNING Do not adjust the stop screw “1”.

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.
ECA17490
NOTICE
Be sure to disconnect the fuel hose by hand.
Do not forcefully disconnect the hose with
tools.
TIP ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• To remove the fuel hose from the fuel rail, slide a. Wash the throttle body in a petroleum- based
the fuel hose connector cover “1” on the end of solvent.
the hose in the direction of the arrow shown, Do not use any caustic carburetor cleaning
press the two buttons “2” on the sides of the solution.
connector, and then remove the hose. b. Blow out all of the passages with compressed
• Before removing the hose, place a few rags in air.
the area under where it will be removed. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30480
INSTALLING THE INJECTORS

ECA22210
NOTICE
• Always use new gaskets, seals, and O-
rings.
• When installing the injectors, do not allow
any foreign material to enter or adhere to
the injectors, fuel rail, seals or O-rings.
• Be careful not to twist or pinch the O-rings
when installing the injectors.
EAS30477 • When installing the injector, install it at the
CHECKING THE INJECTORS same position as the removed cylinder.
1. Check: • If an injector is subject to strong shocks or
• Injectors excessive force, replace it.
Obstruction → Replace and check the fuel • If installing the original fuel rail and bolts,
pump/fuel supply system. remove the white paint marks using a
Deposit → Replace. cleaning solvent. Otherwise, paint chips on
Damage → Replace. the bolt seats could prevent the bolts from
2. Check: being tightened to the specified torque.
• Injector resistance
Refer to “CHECKING THE FUEL INJEC-
TOR” on page 8-106.
EAS30479
CHECKING THE THROTTLE BODY

1. Check:
• Throttle body
7-9
THROTTLE BODY
1. Install a new O-ring onto the end of each in-

jector.
2. Install the injectors “1” to the fuel rail “2”, mak-
ing sure to install them in the correct direc-
tion.
3. Install a new seal onto the end of each injec-
tor.
EAS30485
ADJUSTING THE THROTTLE POSITION

SENSOR
EWA15950
WARNING
• Handle the throttle position sensor with
special care.
4. Install the injector assembly to the intake • Never subject the throttle position sensor
manifold with the screws and new gaskets. to strong shocks. If the throttle position
sensor is dropped, replace it.
Fuel rail screw
3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) TIP
T.
R.
Before adjusting the throttle position sensor, the

5. Check the fuel pressure. engine idling speed should be properly adjusted.
Refer to “CHECKING THE FUEL PRES-
1. Check:
SURE” on page 7-4.
• Throttle position sensor
EAS30841 Refer to “CHECKING THE THROTTLE PO-
INSTALLING THE FUEL HOSE (INJECTOR SITION SENSOR” on page 8-104.
SIDE) 2. Adjust:
1. Connect: • Throttle position sensor angle
• Fuel hose (injector side) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ECA17500
a. Temporary tighten the throttle position sen-
NOTICE sor.
When installing the fuel hose, make sure that b. Check that the throttle grip is fully closed.
it is securely connected, and that the fuel c. Connect the throttle position sensor to the
hose connector cover on the fuel hose is in wire harness.
the correct position, otherwise the fuel hose d. Push the OFF/steering lock switch.
will not be properly installed. e. Simultaneously press and hold the “SE-
LECT” and “RESET” buttons “1”, push the
TIP
ON/start switch “ ”, and continue to
• Install the fuel hose securely onto the fuel rail press the buttons for 8 seconds more.
until a distinct “click” is heard.
TIP
• To install the fuel hose onto the fuel rail, slide
the fuel hose connector cover “1” on the end of “dIAG” appears on the odometer LCD.
the hose in the direction of the arrow shown.
• It is prohibited to wear the cotton work gloves
or equivalent coverings.
7-10
THROTTLE BODY
f. Diagnostic code number “d:01” is selected.

g. Adjust the position of the throttle position sen-
sor angle so that 14–20 can appear in the
meter.
h. After adjusting the throttle position sensor an-
gle, tighten the throttle position sensor
screws “2”.
Throttle position sensor screw

3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-11
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

CIRCUIT DIAGRAM .................................................................................. 8-1
TROUBLESHOOTING ..............................................................................8-3
ELECTRIC STARTING SYSTEM .................................................................... 8-5

CIRCUIT DIAGRAM .................................................................................. 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-7
TROUBLESHOOTING ..............................................................................8-9
CHARGING SYSTEM....................................................................................8-11
CIRCUIT DIAGRAM ................................................................................ 8-11
TROUBLESHOOTING ............................................................................8-13
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 INJECTION SYSTEM..........................................................................8-31

CIRCUIT DIAGRAM ................................................................................ 8-31
ECU SELF-DIAGNOSTIC FUNCTION....................................................8-33
TROUBLESHOOTING METHOD............................................................ 8-33
YAMAHA DIAGNOSTIC TOOL ...............................................................8-34
TROUBLESHOOTING DETAILS ............................................................ 8-37
FUEL PUMP SYSTEM...................................................................................8-63

CIRCUIT DIAGRAM ................................................................................ 8-63
8
SMART KEY SYSTEM .................................................................................. 8-67
CIRCUIT DIAGRAM ................................................................................ 8-67
SMART KEY SYSTEM SELF-DIAGNOSIS............................................. 8-72
SMART KEY SYSTEM EMERGENCY MODE ........................................ 8-75
REGISTERING A SMART KEY...............................................................8-77
DISABLING A SMART KEY .................................................................... 8-79
REPLACING THE SMART KEY UNIT, STEERING LOCK, AND ECU ... 8-79
REPLACING THE SMART KEY UNIT ....................................................8-80
REPLACING THE STEERING LOCK UNIT ............................................8-80
REPLACING THE ECU ...........................................................................8-80
REPLACEMENT PARTS LIST ................................................................8-80
ELECTRICAL COMPONENTS...................................................................... 8-83

CHECKING THE SWITCHES .................................................................8-87
CHECKING THE BULBS AND BULB SOCKETS ................................... 8-90
CHECKING THE FUSES ........................................................................8-91
CHECKING AND CHARGING THE BATTERY....................................... 8-91
CHECKING THE RELAYS ...................................................................... 8-94
CHECKING THE TURN SIGNAL/HAZARD RELAY 2............................. 8-97
CHECKING THE DIODES....................................................................... 8-98
CHECKING THE SPARK PLUG CAPS...................................................8-98
CHECKING THE IGNITION COIL ........................................................... 8-99
CHECKING THE IGNITION SPARK GAP............................................... 8-99
CHECKING THE CRANKSHAFT POSITION SENSOR........................8-100
CHECKING THE LEAN ANGLE SENSOR............................................8-100
CHECKING THE STARTER MOTOR OPERATION .............................8-101
CHECKING THE STATOR COIL ..........................................................8-101
CHECKING THE RECTIFIER/REGULATOR ........................................8-101
CHECKING THE FUEL SENDER .........................................................8-102
CHECKING THE FUEL METER/FUEL LEVEL WARNING
INDICATOR ..........................................................................................8-102
CHECKING THE SPEED SENSOR ......................................................8-103
CHECKING THE RADIATOR FAN MOTOR .........................................8-103
CHECKING THE COOLANT TEMPERATURE SENSOR.....................8-103
CHECKING THE THROTTLE POSITION SENSOR .............................8-104
CHECKING THE INTAKE AIR PRESSURE SENSOR .........................8-105
CHECKING THE INTAKE AIR TEMPERATURE SENSOR ..................8-105
CHECKING THE FUEL INJECTOR ......................................................8-106
CHECKING THE SMART KEY BATTERY ............................................8-106
CHECKING THE SEAT LOCK SOLENOID...........................................8-107
CHECKING THE BUZZER ....................................................................8-107
EAS30490
EAS20072
B/W B/W B/W B/L B/L B/L B/L B/L

Lg L/G Br/W R/B G/L L/R Br/L W/Y G/B 19
B/W B/W B/W B/L B/L B/L 19 19 B/L B/L B/L
G G/Y L/W Y/L B L R/G L/Y Br B/W B/W B/W
BBBBBBBBBB B/L B/L B/L B/L B/L B/L
B/W B/W B/W
(B) B/L B/L B/L B/L B/L
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
G G L L 9 G/W G/W L/Y R/B R/B R/B
G/Y R L/Y R/B R/B 37 G/R B/L
Y W R R
R/G R/G 5 28 R/B
6 W R R 26 R/G R R/B
G/Y L
10 W
11 B G/W
(Dg)
L/W R L/W 27 O
3 R/G W W W L/W L/Y B/L G/R
R/G G Y Y R R G/W G/B G/Y 38
Y R/B 29 R
Br/W R B 19 L/W L/W L/W L/Y Lg
G/Y B B
B R
B
20 22 R/L
39
R/G W W W L/W L/W B/L
CIRCUIT DIAGRAM
L B W W W
R/G RB B G/B G/Y Lg R/B L/Y G/R
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
R R 23 B/Y 40 Br/W B/L
L/W B A B B L/W L/W
Br/W L/W 4 B R R B B
1 RR B B/L Br/W (B)
B L/W L/W L/W Br/W L/W Lg
R B Lg Br/W
B/L
IGNITION SYSTEM
24 R R Lg Lg
Br/L L/W P/W P/W
B R/G 12 B L/W Lg B/L P/W L
R/G R L/Y 21 25 B B/W L
42
R/G
L/R L/R L B R/G R/G Br/L L/Y (B) (B) B Y/L Y/L Y/L (L)
30 B B Lg B
41 B/L
L L G B R/G B B/L
(L)
G L L/R L Y B Y L Y B/L
7 B B B B/W R/G L B L
43
B/W B
Br/L B B Y/L Y/L (B)
Br B
Lg R/B G/B B G/B 36 Y B/L
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
W/Y Br/L Br/L Br Dg R/W R/W Dg 45
Br R/B Br Br/W Ch G/Y (Gy)
46 L R B B/L
G/Y Ch Br/W Br R/B
13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
R/W B Ch Br/W Dg Br G/Y Gy/G Gy/G L W B/L
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
R/W R/L G/B B B R/L B
R/G Br R Br/R 48 W L Gy/G B/L
L/RBr (Gy) (B) (B)
16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
R/G R/W Y Y/W L L L L
18 R/G L
80 L/W Y/W Y/L Y/G Gy/G W B/Y B/W L R/W R/B O
Br Y/B L/B L L L
R/L Lg G/R Br/W P/W Y B/L L/Y Y/R G/B B
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
L/B
8-1
B/W R/L R/L R/L R/L
Ch Br/R R/L
75 Br/W Br/W
R/L R/L R/L R/L
L
83 Br/L Br/B 51 R/W Y/R
B/W Dg Br/W L/B L/B Br Br/W Br G/Y
76 56 19
Br/B L Y/R
84 R B/Y L/Y B B B B
Y Br/W 57 58 59 60 B
B/W Br/B 77 64 B B B B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
Dg Ch L/B Br/W B G/Y
G/Y G/Y G/Y G/Y
62 B G/Y L/B Br Br G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/Y Y/BY D B Ch Dg B
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
B/W G/L R/W Y/L R/G G R/Y L L
R/Y L Ch L Dg L Ch Dg B
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
(Gy) R/Y Y/B Y B B R/Y Y/BY L L
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
L/G Br/G Br/G L Y 53
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
L/G L B L B Ch Dg B B L
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
R/G R/Y B Y/B Y B R/Y R/Y B Y/B Y B R/Y
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G R/Y Y/B Y
R/G W/Y Dg Ch B Y Y/B R/Y
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
IGNITION SYSTEM
IGNITION SYSTEM
1. Smart key unit

12.Smart key system relay
14.Ignition fuse
18.Backup fuse
19.Joint coupler
20.Battery
21.Engine ground
22.Main fuse
30.Sidestand switch
31.Handlebar switch (right)
32.Engine stop switch
36.ECU (engine control unit)
37.Ignition coil
38.Spark plug
44.Lean angle sensor
A. Wire harness
B. Negative battery sub-wire harness
8-2
IGNITION SYSTEM
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Footboards
2. Front cowling assembly
1. Check the fuses. NG →

(Main, ignition and backup)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 8-91.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-91.
OK ↓
3. Check the spark plugs. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plugs.
PLUGS” on page 3-4.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 8-99.
NG ↓
5. Check the spark plug caps. NG →
Refer to “CHECKING THE SPARK Replace the spark plug caps.
PLUG CAPS” on page 8-98.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-99.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the stator coil.
SHAFT POSITION SENSOR” on
page 8-100.
OK ↓
8. Check the smart key system relay. NG →
Refer to “CHECKING THE RE- Replace the smart key system relay.
LAYS” on page 8-94.
OK ↓
8-3
IGNITION SYSTEM
9. Check the sidestand switch. NG →

Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
10.Check the engine stop switch. NG →
The engine stop switch is faulty. Replace
Refer to “CHECKING THE
the right handlebar switch.
OK ↓
11.Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 8-100.
OK ↓
12.Check the entire ignition system’s NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-1.
OK ↓
Replace the ECU or smart key unit.
8-4
EAS30493
EAS20073

B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
R/G Y W R R
R/G 5 28 R/B
G/Y L 10 W
11 B G/W
(Dg)
L/W R L/W 27 O
3 R/G R/G G W W W L/W L/Y B/L G/R
Y Y R R G/W G/B G/Y 38
Y R/B 29 R
G/Y B B
B R
B
20 22 R/L
39
CIRCUIT DIAGRAM
L B W W W
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
L/W B A B B L/W L/W
1 RR B B/L Br/W (B)
R B Lg Br/W
24 R R Lg Lg B/L
Br/L L/W P/W P/W
R/G R L/Y 21 25 B B/W L
42
R/G
30 B B Lg B
41 B/L
L L G B R/G B B/L
(L)
43
B/W B
Br B
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
46 L R B B/L
G/Y Ch Br/W Br R/B
13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
ELECTRIC STARTING SYSTEM
L/RBr (Gy) (B) (B)

16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
18 R/G L
Br Y/B L/B L L L
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
L/B
8-5
B/W R/L R/L R/L R/L
Ch Br/R R/L
75 Br/W Br/W
R/L R/L R/L R/L
L
76 56 19
Br/B L Y/R
Y Br/W 57 58 59 60 B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
G/Y G/Y G/Y G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
1. Smart key unit

13.Signaling system fuse
14.Ignition fuse
19.Joint coupler
20.Battery
21.Engine ground
22.Main fuse
23.Starter relay
24.Starter motor
25.Diode 1
26.Starting circuit cut-off relay
27.Sidestand relay
28.Diode 2
30.Sidestand switch
33.ON/start switch
35.Front brake light switch
56.Handlebar switch (left)
61.Rear brake light switch
A. Wire harness
8-6
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to “ ” and pressing the ON/start switch “ ” for one second, the start-
er motor can only operate if at least one of the following conditions is met:
• The front brake lever is pulled to the handlebar (the front brake light switch is closed) and the side-
stand is up (the sidestand switch is closed).
• The rear brake lever is pulled to the handlebar (the rear brake light switch is closed) and the sidestand
is up (the sidestand switch is closed).
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 ON/start switch “ ”.
14
13
1
15
3
4
17
16
5 6
7 8 9
10
11
12
8-7
1. Battery
2. Main fuse
3. Smart key system relay
4. Smart key unit
5. Signaling system fuse
6. Ignition fuse
7. Front brake light switch
8. Rear brake light switch
9. Engine stop switch
10. Diode 2
11. Sidestand relay
12. Sidestand switch
13. Starter relay
14. Starter motor
15. Starting circuit cut-off relay
16. ON/start switch
17. Diode 1
8-8
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
2. Storage box
3. Fuel tank

(Main, ignition and signaling sys-
tem) Replace the fuse(s).
ES” on page 8-91.
OK ↓
page 8-91.
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.
8-101.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-38.
OK ↓
OK ↓
6. Check the starting circuit cut-off re- NG →
lay.
Replace the starting circuit cut-off relay.
Refer to “CHECKING THE RE-
OK ↓
7. Check the sidestand relay. NG →
Refer to “CHECKING THE RE- Replace the sidestand relay.
OK ↓
8-9
8. Check the starter relay. NG →

Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
9. Check the engine stop switch. NG →
OK ↓
10.Check the sidestand switch. NG →
OK ↓
11.Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
12.Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
13.Check the ON/start switch “ ”. NG →
The ON/start switch “ ” is faulty. Re-
place the right handlebar switch.
OK ↓
14.Check the start diodes (diode 1 and NG →
2).
Replace the diode(s).
Refer to “CHECKING THE DI-
ODES” on page 8-98.
OK ↓
15.Check the entire starting system’s NG →
page 8-5.
OK ↓
Replace the smart key unit. Refer to
“SMART KEY SYSTEM” on page
8-67.
8-10
EAS30496
EAS20074

B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
R/G Y W R R
R/G 5 28 R/B
G/Y L 10 11 (Dg)
W B R L/W 27 G/W
L/W R/G R/G G L/Y O
3 W W W L/W G/Y B/L G/R
Y Y R R G/W G/B 38
Y R/B 29 R
G/Y B B
B R
B
20 22 R/L
39
CIRCUIT DIAGRAM
L B W W W
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
L/W B A B B L/W L/W
1 RR B B/L Br/W (B)
R B Lg Br/W
24 R R Lg Lg B/L
Br/L L/W P/W P/W
R/G R L/Y 21 25 B B/W L
42
R/G
41
CHARGING SYSTEM
30 B B Lg B B/L
L L G B R/G B B/L
(L)
43
B/W B
Br B
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
46 L R B B/L
G/Y Ch Br/W Br R/B
13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
L/RBr (Gy) (B) (B)
16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
18 R/G L
Br Y/B L/B L L L
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
B/W L/B R/L R/L R/L R/L
Ch Br/R R/L
8-11
75 Br/W Br/W
R/L R/L R/L R/L
L
76 56 19
Br/B L Y/R
Y Br/W 57 58 59 60 B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
G/Y G/Y G/Y G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
CHARGING SYSTEM
CHARGING SYSTEM
10.AC magneto
11.Rectifier/regulator
20.Battery
21.Engine ground
22.Main fuse
A. Wire harness
8-12
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
2. Storage box
3. Fuel tank
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 8-91.
OK ↓
page 8-91.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator coil.
COIL” on page 8-101.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
8-101.
OK ↓
5. Check the entire charging system’s NG →
page 8-11.
OK ↓
The charging system circuit is OK.
8-13
CHARGING SYSTEM
8-14
EAS30498
EAS20075

B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
R/G Y W R R
R/G 5 28 R/B
G/Y L 10 W
11 B G/W
(Dg)
L/W R L/W 27 O
Y R/B 29 R
G/Y B B
B R
B
20 22 R/L
39
CIRCUIT DIAGRAM
L B W W W
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
L/W B A B B L/W L/W
1 RR B B/L Br/W (B)
R B Lg Br/W
24 R R Lg Lg B/L
Br/L L/W P/W P/W
B R/G 12 Lg
LIGHTING SYSTEM
R L/Y 21 B L/W 42 B/L P/W L

R/G 25 B B/W L
R/G
30 B B Lg B
41 B/L
L L G B R/G B B/L
(L)
43
B/W B
Br B
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
46 L R B B/L
G/Y Ch Br/W Br R/B
13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
L/RBr (Gy) (B) (B)
16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
18 R/G L
Br Y/B L/B L L L
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
Ch Br/R R/L
8-15
75 Br/W Br/W
R/L R/L R/L R/L
L
76 56 19
Br/B L Y/R
Y Br/W 57 58 59 60 B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
G/Y G/Y G/Y G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
LIGHTING SYSTEM
LIGHTING SYSTEM
1. Smart key unit

14.Ignition fuse
15.Parking lighting fuse
18.Backup fuse
19.Joint coupler
20.Battery
21.Engine ground
22.Main fuse
41.Yamaha diagnostic tool coupler
53.License plate light
54.Tail/brake light assembly
57.Pass switch
58.Dimmer switch
63.Headlight relay
66.Auxiliary light
71.Headlight control unit
72.Headlight (low)
73.Headlight (hight)
75.Headlight fuse
78.Storage box light
79.Storage box light switch
80.Meter assembly
84.High beam indicator light
88.Multi-function meter
89.Meter light
A. Wire harness
D. Head light harness
8-16
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, auxiliary light, front position light, high beam indicator light,
tail/brake light, license plate light, meter light or storage box light.
TIP
2. Mudguard
1. Check the each bulbs and bulb NG →

sockets condition.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket.
AND BULB SOCKETS” on page
8-90.
OK ↓
(Main, headlight, ignition, parking
lighting, signaling system and back-
up)
ES” on page 8-91.
OK ↓
page 8-91.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
left handlebar switch.
OK ↓
6. Check the pass switch. NG →
The pass switch is faulty. Replace the left
handlebar switch.
OK ↓
7. Check the headlight relay. NG →
Refer to “CHECKING THE RE- Replace the headlight relay.
OK ↓
8-17
LIGHTING SYSTEM
8. Check the storage box light switch. NG →

Refer to “CHECKING THE Replace the storage box light switch.
OK ↓
9. Check the entire lighting system’s NG →
page 8-15.
OK ↓
Replace the ECU, headlight assembly,
smart key unit or meter assembly.
8-18
EAS30500
EAS20076

B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
R/G Y W R R
R/G 5 28 R/B
G/Y L 10 W
11 B G/W
(Dg)
L/W R L/W 27 O
Y R/B 29 R
G/Y B B
B R
B
20 22 R/L
39
CIRCUIT DIAGRAM
L B W W W
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
L/W B A B B L/W L/W
1 RR B B/L Br/W (B)
R B Lg Br/W
24 R R Lg Lg B/L
Br/L L/W P/W P/W
R/G R L/Y 21 25 B B/W L
42
R/G
B B Lg B
41 B/L
SIGNALING SYSTEM
L L G B
30 R/G B B/L
(L)
43
B/W B
Br B
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
46 L R B B/L
G/Y Ch Br/W Br R/B
13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
L/RBr (Gy) (B) (B)
16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
18 R/G L
Br Y/B L/B L L L
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
Ch Br/R R/L
8-19
75 Br/W Br/W
R/L R/L R/L R/L
L
76 56 19
Br/B L Y/R
Y Br/W 57 58 59 60 B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
G/Y G/Y G/Y G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
SIGNALING SYSTEM
SIGNALING SYSTEM
1. Smart key unit

2. Buzzer
14.Ignition fuse
15.Parking lighting fuse
18.Backup fuse
19.Joint coupler
20.Battery
21.Engine ground
22.Main fuse
30.Sidestand switch
34.Hazard switch
39.Coolant temperature sensor
40.Intake air temperature sensor
45.Speed sensor
50.Fuel sender
54.Tail/brake light assembly
55.Tail/brake light
59.Horn switch
60.Turn signal switch
61.Rear brake light switch
62.Horn
64.Turn signal/hazard relay 2
67.Front turn signal/position light (left)
68.Front turn signal/position light (right)
69.Rear turn signal light (left)
70.Rear turn signal light (right)
80.Meter assembly
82.Turn signal indicator light (left)
83.Turn signal indicator light (right)
85.Speedometer
86.Tachometer
A. Wire harness
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 fuel meter fails to operate.
• The speedometer fails to operate.
• The buzzer fails to sound.
• The V-belt replacement meter fails to operate.
• The ambient temperature meter fails to operate.
• The coolant temperature meter fails to operate.
• The oil change meter fails to operate.
TIP
2. Storage box
3. Fuel tank

(Main, ignition, signaling system,
parking lightning and backup) Replace the fuse(s).
ES” on page 8-91.
OK ↓
page 8-91.
OK ↓
OK ↓
4. Check the entire signaling system’s NG →
page 8-19.
OK ↓
This circuit is OK.
Checking the signaling system

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

page 8-19.
OK ↓
Replace the horn or smart key unit.
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 assembly
or smart key unit.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
2. Check the hazard switch. NG →
The hazard switch is faulty. Replace the
right handlebar switch.
OK ↓
3. Check the turn signal/hazard relay NG →
1.
Replace the turn signal/hazard relay 1.
OK ↓
2.
OK ↓
8-22
SIGNALING SYSTEM

page 8-19.
OK ↓
Replace the meter assembly or smart
key unit.
The fuel meter fails to operate.

1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
SENDER” on page 8-102.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The coolant temperature meter fails to operate.

1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-103.
OK ↓
2. Check the entire signaling system NG →
page 8-19.
OK ↓
Replace the ECU or meter assembly.
The speedometer fails to operate.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
SENSOR” on page 8-103.
OK ↓
8-23
SIGNALING SYSTEM

page 8-19.
OK ↓
The tachometer fails to operate.

1. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the stator coil.
SHAFT POSITION SENSOR” on
page 8-100.
OK ↓
page 8-19.
OK ↓
The ambient temperature meter fails to operate.

1. Check the air temperature sensor. NG →
Refer to “CHECKING THE INTAKE
Replace the intake air temperature sensor.
AIR TEMPERATURE SENSOR” on
page 8-105.
OK ↓
page 8-19.
OK ↓
The V-belt replacement indicator fails to come on.

page 8-19.
OK ↓
8-24
SIGNALING SYSTEM
The oil change indicator fails to come on.

page 8-19.
OK ↓
The buzzer does not sound.

1. Check that the buzzer sounds when NG →
Perform the signaling system troubleshoot-
the ON/start switch “ ” or
ing, starting with step 3.
OFF/steering lock switch is pushed.
OK ↓
2. Check the sidestand switch. NG →
OK ↓
3. Check the buzzer. NG →
Refer to “CHECKING THE BUZZ- Replace the buzzer.
ER” on page 8-107.
OK ↓
page 8-19.
OK ↓
Replace the smart key unit or ECU.
8-25
SIGNALING SYSTEM
8-26
EAS30502
EAS20077

B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
R/G Y W R R
R/G 5 28 R/B
G/Y L 10 W
11 B G/W
(Dg)
L/W R L/W 27 O
Y R/B 29 R
G/Y B B
B R
B
20 22 R/L
39
CIRCUIT DIAGRAM
L B W W W
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
L/W B A B B L/W L/W
1 RR B B/L Br/W (B)
R B Lg Br/W
24 R R Lg Lg B/L
Br/L L/W P/W P/W
COOLING SYSTEM

R/G R L/Y 21 25 B B/W L
42
R/G
30 B B Lg B
41 B/L
L L G B R/G B B/L
(L)
43
B/W B
Br B
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
46 L R B B/L
G/Y Ch Br/W Br R/B
13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
L/RBr (Gy) (B) (B)
16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
18 R/G L
Br Y/B L/B L L L
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
Ch Br/R R/L
8-27
75 Br/W Br/W
R/L R/L R/L R/L
L
76 56 19
Br/B L Y/R
Y Br/W 57 58 59 60 B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
G/Y G/Y G/Y G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
COOLING SYSTEM
COOLING SYSTEM
1. Smart key unit

14.Ignition fuse
16.Radiator fan motor fuse
18.Backup fuse
19.Joint coupler
20.Battery
21.Engine ground
22.Main fuse
51.Radiator fan motor relay
52.Radiator fan motor
80.Meter assembly
A. Wire harness
8-28
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
The radiator fan motor fails to turn.
TIP
2. Storage box
3. Fuel tank

(Main, ignition, radiator fan motor
and backup) Replace the fuse(s).
ES” on page 8-91.
OK ↓
page 8-91.
OK ↓
OK ↓
4. Check the radiator fan motor. NG →
Refer to “CHECKING THE RADIA- Replace the radiator fan motor.
TOR FAN MOTOR” on page 8-103.
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 8-103.
OK ↓
7. Check the entire cooling system’s NG →
page 8-27.
OK ↓
8-29
COOLING SYSTEM
8-30
EAS30504
EAS20078

B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
R/G Y W R R
R/G 5 28 R/B
G/Y L 10 W
11 B G/W
(Dg)
L/W R L/W 27 O
Y R/B 29 R
G/Y B B
B R
B
20 22 R/L
39
CIRCUIT DIAGRAM
L B W W W
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
L/W B A B B L/W L/W
1 RR B B/L Br/W (B)
R B Lg Br/W
24 R R Lg Lg B/L
Br/L L/W P/W P/W
R/G R L/Y 21 25 B B/W L
42
R/G
30 B B Lg B
41 B/L
L L G B R/G B B/L
(L)
43
B/W B
Br B
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
Br 46 B B/L
FUEL INJECTION SYSTEM
G/Y Ch Br/W Br R/B R/B Br Br/W Ch G/Y (Gy) L R

13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
L/RBr (Gy) (B) (B)
16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
18 R/G L
Br Y/B L/B L L L
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
Ch Br/R R/L
8-31
75 Br/W Br/W
R/L R/L R/L R/L
L
76 56 19
Br/B L Y/R
Y Br/W 57 58 59 60 B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
G/Y G/Y G/Y G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
1. Smart key unit

14.Ignition fuse
17.Fuel injection system fuse
18.Backup fuse
19.Joint coupler
20.Battery
21.Engine ground
22.Main fuse
27.Sidestand relay
28.Diode 2
29.Fuel injection system relay
30.Sidestand switch
37.Ignition coil
38.Spark plug
40.Intake air temperature sensor
42.Intake air pressure sensor
43.Throttle position sensor
45.Speed sensor
46.Fuel injector #1
47.Fuel injector #2
48.O2 sensor
63.Headlight relay
72.Headlight (low)
73.Headlight (high)
80.Meter assembly
84.High beam indicator light
87.Engine trouble warning light
A. Wire harness
C. Throttle position sensor sub-lead
8-32
EAS30505
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code
number is stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes while the ON/start switch “ ” is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the odometer LCD. This
number remains stored in the memory of the ECU until it is deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation
Warning provided when
Flashing* Operation stopped Cannot be operated
unable to start engine
Operated with substitute
Can or cannot be operat-
characteristics in accor-
Remains on Malfunction detected ed depending on the fault
dance with the descrip-
code
tion of the malfunction
* The warning light flashes when any one of the following conditions is present and the ON/start switch
“ ” is pushed:
12: Crankshaft position sensor 33: Ignition coil
Sidestand switch Lean angle sensor
19: 41:
(open circuit in the wire to the ECU) (open or short circuit)
Lean angle sensor ECU internal malfunction
30: 50:
(latch up detected) (faulty ECU memory)
Checking the engine trouble warning light

The engine trouble warning light comes on for around 2 seconds after the ON/start switch “ ” is
pushed. If the warning light does not come on under these conditions, the warning light (LED) may be
defective.
ECU detects an abnormal signal from a sensor

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS30506
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the fault code number displayed on the meter.
b. Identify the faulty system with the fault code number.
8-33
c. Identify the probable cause of the malfunction.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of the malfunction.
Fault code No. No fault code No.
Check and repair. Refer to “TROUBLESHOOTING Check and repair.
DETAILS” on page 8-37.
Monitor the operation of the sensors and actuators in
the diagnostic mode. Refer to “TROUBLESHOOT-
ING DETAILS” on page 8-37.
3. Perform the reinstatement action for the fuel injection system.

Refer to “Confirmation of service completion” in the appropriate table in “TROUBLESHOOTING DE-
TAILS” on page 8-37.
4. Push the OFF/steering lock switch, push the ON/start switch “ ”, and then check that no fault
code number is displayed.
TIP
If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode. Refer to “Sensor operation table (Diagnostic
code No.62)”.
TIP
Pushing the OFF/steering lock switch will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to “TROU-
BLESHOOTING DETAILS” on page 8-37.
01: Throttle position sensor (throttle angle)
03: Intake air pressure sensor
05: Intake air temperature sensor
06: Coolant temperature sensor
07: Speed sensor
08: Lean angle sensor
30: Ignition coil
36: Injector #1
37: Injector #2
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
EAS30951
YAMAHA DIAGNOSTIC TOOL

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

90890-03234
Features of the Yamaha diagnostic tool

You can use the Yamaha diagnostic tool to identify malfunctions quicker than with conventional meth-
ods.
8-34
By connecting the adapter interface, which is connected to the USB port of a computer, to a vehicle’s
ECU using the communication cable, you can display information that is necessary for identifying mal-
functions and for maintenance to display on the computer. The displayed information includes the sen-
sor output data and information recorded in the ECU.
Functions of the Yamaha diagnostic tool
Fault diagnosis mode: Fault codes recorded on the ECU are read, and the contents are dis-
played.
Function diagnostic mode: Check the operation of the output value of each sensor and actuator.
Inspection mode: Determine whether each sensor or actuator is functioning properly.
CO adjustment mode: Adjust the concentration of CO admissions during idling.
Monitoring mode: Displays a graph of sensor output values for actual operating condi-
tions.
Logging mode: Records and saves the sensor output value in actual driving conditions.
View log: Displays the logging data.
ECU rewrite: If necessary, the ECU is rewritten using ECU rewrite data provided by
Yamaha.
Ignition timing adjustment, etc. cannot be changed from the vehicle’s
original state.
However, the Diagnostic Tool cannot be used to freely change the basic vehicle functions, such as ad-
justing the ignition timing.
Connecting the Yamaha diagnostic tool
Disconnect the Yamaha diagnostic tool coupler “1”, and then connect the Yamaha diagnostic tool “2”
to the coupler.
1
2
TIP
When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter
and indicators will be different from the normal operation.
Operation of the Yamaha diagnostic tool (Malfunction mode)
Malfunction results are displayed in the top part of the window area.
8-35
3 4 5 6 7 8 9 10 11 12
1. Recovered
The item list of the malfunction detected in the past (already recovered) are displayed.
2. Detected
The item list of the malfunction currently occurred are displayed.
3. Code
The following icons and the fault code numbers for the detected malfunctions are displayed.
A B
A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed.
5. Item
The item names of the detected malfunction are displayed.
8-36
6. Condition
The current conditions are displayed. (Detected/Recovered)
7. Symptom
The symptoms of the detected malfunction are displayed.
8. Diagnosis code
The diagnosis codes related to the detected malfunction are displayed.
9. FFD (only for models that can display freeze frame data)
The mark “ ” is displayed when the freeze frame data is available.
10.ECU conduction time (hour: minute: second)
The total ECU conduction time (total hours the vehicle’s main switch was ON) when the malfunction
was detected is displayed.
11.Number of main switch operation after detection
The number of times the main switch was turned on between the malfunction detection and code
reading is displayed.
12.Number of occurrences
The number of malfunction occurrences between the malfunction detection and code reading is dis-
played.
EAS30508
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Check and service
the items or components that are the probable cause of the malfunction following the order given.
After the check and service of the malfunctioning part have been completed, reset the meter display
according to the reinstatement method.
Fault code No.:
Fault code number displayed on the meter when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5.
Fault code No. 12

Fault code No. 12
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. —
Indicated —
Procedure —
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of crankshaft posi- Poor connection → Connect it Crank the engine, and check the
tion sensor coupler. securely, or replace the wire fault code indication.
Check the locking condition of harness. No fault code indicated. → Ser-
the coupler. vice is finished.
Disconnect the coupler, and Fault code indicated. → Go to
check each pin (for bending, item 2.
wear, or locking).
8-37
Fault code No. 12
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
2 Connection of ECU coupler. Poor connection → Connect it Crank the engine, and check the
Check the locking condition of securely, or replace the wire fault code indication.
the coupler. harness. No fault code indicated. → Ser-
Disconnect the coupler, and vice is finished.
check each pin (for bending, Fault code indicated. → Go to
wear, or locking). item 3.
3 Continuity of wire harness. Open or short circuit → Replace Crank the engine, and check the
the wire harness. fault code indication.
Between crankshaft position No fault code indicated. → Ser-
sensor coupler and ECU cou- vice is finished.
pler. Fault code indicated. → Go to
Black/Yellow–Black/Yellow item 4.
Between crankshaft position
sensor coupler and joint cou-
pler.
Black/Blue–Black/Blue
Between joint coupler and ECU
coupler.
4 Installed condition of crankshaft Incorrect installation → Reinstall Crank the engine, and check the
position sensor. the sensor. fault code indication.
Check for looseness or pinch- Refer to “GENERATOR AND No fault code indicated. → Ser-
ing. STARTER CLUTCH” on page vice is finished.
Check the gap between the 5-52. Fault code indicated. → Go to
crankshaft position sensor and item 5.
the pickup rotor.
5 Crankshaft position sensor mal- Sensor inspection procedure Crank the engine, and check the
function. Refer to “CHECKING THE fault code indication.
CRANKSHAFT POSITION No fault code indicated. → Ser-
SENSOR” on page 8-100. vice is finished.
Replace if defective. Fault code indicated. → Go to
item 6.
6 ECU malfunction. Replace the ECU.
Fault code No. 13

TIP
If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first.
Fault code No. 13
Item Intake air pressure sensor: open or short circuit detected.

Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Indicated Displays the intake air pressure.
Set the engine stop switch to “ ”, and then operate the throttle while
Procedure pushing the ON/start switch “ ”. (If the display value changes, the
performance is OK.)
8-38
Fault code No. 13

1 Connection of intake air pres- Poor connection → Connect it Push the ON/start switch
sure sensor coupler. securely, or replace the wire “ ”, and check the fault
Check the locking condition of harness. code indication.
the coupler. No fault code indicated. → Ser-
2 Connection of wire harness Poor connection → Connect it Push the ON/start switch
ECU coupler. securely, or replace the wire “ ”, and check the fault
Disconnect the coupler and vice is finished.
3 Continuity of wire harness. Open or short circuit → Replace Push the ON/start switch
the wire harness. “ ”, and check the fault
Between intake air pressure code indication.
sensor coupler and ECU cou- No fault code indicated. → Ser-
pler. vice is finished.
Pink/White–Pink/White Fault code indicated. → Go to
Between intake air pressure item 4.
pler.
Blue–Blue
coupler.
Blue–Blue
4 Sensor installation status. Incorrect installation → Reinstall Push the ON/start switch
Check the mounting section for the sensor. “ ”, and check the fault
loose or pinched mounting. code indication.
No fault code indicated. → Ser-
vice is finished.
Fault code indicated. → Go to
item 5.
8-39
Fault code No. 13

5 Intake air pressure sensor mal- Check in the diagnostic mode Push the ON/start switch
function. (Code No. 03). “ ”, and check the fault
When engine is stopped: Atmo- code indication.
spheric pressure at the current No fault code indicated. → Ser-
altitude and weather conditions vice is finished.
is indicated. Fault code indicated. → Go to
0 m (0 ft) above sea level: Ap- item 6.
prox. 101 kPa (757.6 mmHg,
29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
Incorrect indication → Sensor
malfunction → Replace the in-
take air pressure sensor.
Confirmation of service comple-
tion
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR” on page 8-105.
Fault code No. 14

TIP
Fault code No. 14
Intake air pressure sensor: hose system malfunction (clogged or de-

Item
tached hose).
Fail-safe system
Indicated Displays the intake air pressure.
Set the engine stop switch to “ ”, and then operate the throttle while
Procedure pushing the ON/start switch “ ”. (If the display value changes, the
performance is OK.)
8-40
Fault code No. 14
Intake air pressure sensor: hose system malfunction (clogged or de-

Item
tached hose).
1 The intake air pressure sensor Repair or replace the sensor Start and idle the engine for ap-
hose is damaged, disconnect- hose. proximately 5 seconds.
ed, clogged, twisted or bent. No fault code indicated. → Ser-
vice is finished.
item 2.
2 Intake air pressure sensor mal- Check in the diagnostic mode
function. (Code No. 03).
When engine is stopped: Atmo-
spheric pressure at the current
altitude and weather conditions
is indicated.
0 m (0 ft) above sea level: Ap-
prox. 101 kPa (757.6 mmHg,
29.8 inHg)
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. → Re-
place the intake air pressure
sensor.
tion
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SEN-
Fault code No. 15

TIP
Fault code No. 15
Item Throttle position sensor: open or short circuit detected.

Under certain conditions
Fail-safe system
Indicated • 14–20 (fully closed position)
• 97–107 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
8-41
Fault code No. 15

1 Connection of throttle position Poor connection → Connect it Push the ON/start switch
sensor coupler. securely, or replace the wire “ ”, and check the fault
3 Connection of throttle position Poor connection → Connect it Push the ON/start switch
sensor sub-lead coupler. securely, or replace the wire “ ”, and check the fault
Disconnect the coupler and vice is finished.
Between throttle position sensor code indication.
coupler and sub-wire harness No fault code indicated. → Ser-
coupler. vice is finished.
Black/Blue–Black/Blue Fault code indicated. → Go to
Yellow–Yellow item 5.
Blue–Blue
Between sub-wire harness cou-
pler and ECU coupler.
Yellow–Yellow
Between sub-wire harness cou-
pler and joint coupler.
Blue–Blue
coupler.
Blue–Blue
5 Sensor installation status. Check for loose mounting, Push the ON/start switch
pinched mounting, or hard “ ”, and check the fault
mounting. code indication.
Make sure that the mounting No fault code indicated. → Ser-
position is correct. vice is finished.
Refer to “ADJUSTING THE Fault code indicated. → Go to
THROTTLE POSITION SEN- item 6.
8-42
Fault code No. 15

6 Supply voltage of throttle posi- Check the supply voltage. Push the ON/start switch
tion sensor lead. Blue–Black/Blue “ ”, and check the fault
Black/Blue–Yellow code indication.
Refer to “CHECKING THE No fault code indicated. → Ser-
THROTTLE POSITION SEN- vice is finished.
SOR” on page 8-104. Fault code indicated. → Go to
Line disconnec- Output volt- item 7.
tion points age
Disconnection of 5V
ground lead
Disconnection of 0V
output line
Disconnection of 0 V
power supply line
7 Throttle position sensor mal- Check in the diagnostic mode Push the ON/start switch
function. (Code No. 01). “ ”, and check the fault
When throttle is fully closed: A code indication.
value of 14–20 is indicated. No fault code indicated. → Ser-
When throttle is fully open: A vice is finished.
value of 97–107 is indicated. Fault code indicated. → Go to
If the indication is outside of item 8.
range → Replace the throttle
position sensor.
Fault code No. 16

TIP
• If fault codes 15 and 16 are indicated simultaneously, take the actions specified for fault code 15 first.
Fault code No. 16
Throttle position sensor: stuck throttle position sensor is detected.

Item
(Signal from throttle position sensor will not change.)
Fail-safe system
Indicated • 14–20 (fully closed position)
• 97–107 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
8-43
Fault code No. 16
Throttle position sensor: stuck throttle position sensor is detected.

Item
(Signal from throttle position sensor will not change.)
1 Sensor installation status. Check for loose mounting, Push the ON/start switch
pinched mounting, or hard “ ”, and then open and
mounting. close the throttle.
Make sure that the mounting No fault code indicated. → Ser-
position is correct. vice is finished.
Refer to “ADJUSTING THE Fault code indicated. → Go to
THROTTLE POSITION SEN- item 2.
2 Throttle position sensor mal- Check in the diagnostic mode Push the ON/start switch
function. (Code No. 01). “ ”, and then open and
When throttle is fully closed: A close the throttle.
value of 14–20 is indicated. No fault code indicated. → Ser-
When throttle is fully open: A vice is finished.
value of 97–107 is indicated. Fault code indicated. → Go to
If the indication is outside of item 3.
range → Replace the throttle
position sensor.
Fault code No. 19

Fault code No. 19
Sidestand switch: a break or disconnection of the light green lead of

Item
the ECU is detected.
Fail-safe system
Sidestand switch
Indicated • ON (sidestand retracted)
• OFF (sidestand extended)
Procedure Extend and retract the sidestand.
1 Connection of sidestand switch Poor connection → Connect it Push the ON/start switch
coupler. securely, or replace the wire “ ”, and check the fault
Check the locking condition of harness. code indication when the side-
the coupler. stand is retracted and extended.
Disconnect the coupler, and No fault code indicated. → Ser-
check each pin (for bending, vice is finished.
wear, or locking). Fault code indicated. → Go to
item 2.
item 3.
8-44
Fault code No. 19
Sidestand switch: a break or disconnection of the light green lead of

Item
the ECU is detected.
3 Connection of smart key unit Poor connection → Connect it Push the ON/start switch
coupler. securely, or replace the wire “ ”, and check the fault
item 4.
Between sidestand switch cou- code indication when the side-
pler and ECU coupler. stand is retracted and extended.
Light green–Light green No fault code indicated. → Ser-
Between sidestand switch cou- vice is finished.
pler and smart key unit. Fault code indicated. → Go to
Light green–Light green item 5.
Between sidestand switch cou-
pler and joint coupler.
Black–Black
5 Sidestand switch malfunction. Check in the diagnostic mode Push the ON/start switch
(Code No. 20). “ ”, and check the fault
Sidestand retracted: ON indica- code indication when the side-
tion stand is retracted and extended.
Sidestand extended: OFF indi- No fault code indicated. → Ser-
cation vice is finished.
Indication is incorrect. → Re- Fault code indicated. → Go to
place the sidestand switch. item 6.
Fault code No. 21

TIP
Work in a complete cold-engine condition.
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

Fail-safe system
• Displays the coolant temperature.
Indicated • Displays temperature closer to air temperature (when engine is cold).
• Displays current coolant temperature (when engine is hot).
Compare the actually measured coolant temperature with the meter dis-
Procedure
play value.
8-45
Fault code No. 21
Item Coolant temperature sensor: open or short circuit detected.

1 Connection of coolant tempera- Poor connection → Connect it Push the ON/start switch
ture sensor coupler. securely, or replace the wire “ ”, and check the fault
the wire harness “ ”, and check the fault
Between coolant temperature code indication.
coupler and ECU coupler. No fault code indicated. → Ser-
Green/Red–Green/Red vice is finished.
Between coolant temperature Fault code indicated. → Go to
coupler and joint coupler. item 4.
coupler.
4 Installation status of coolant Check the mounting section for Push the ON/start switch
temperature sensor. a loose or pinched mounting. “ ”, and check the fault
Make sure that the mounting code indication.
position is correct. No fault code indicated. → Ser-
vice is finished.
item 5.
5 Coolant temperature sensor Check in the diagnostic mode Push the ON/start switch
malfunction. (Code No. 06). “ ”, and check the fault
During cold starting: A tempera- code indication.
ture close to the ambient tem- No fault code indicated. → Ser-
perature is indicated. vice is finished.
Indication is incorrect. → Re- Fault code indicated. → Go to
place the coolant temperature item 6.
sensor.
tion.
COOLANT TEMPERATURE
SENSOR” on page 8-103.
Fault code No. 22

TIP
Work in a complete cold-engine condition.
8-46
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.

Fail-safe system
• Displays the intake air temperature.
Indicated • Displays temperature closer to air temperature (when engine is cold).
• Air temperature + approx. 20 °C (68 °F) (when engine is hot).
Compare the actually measured intake air temperature with the meter
Procedure
display value.
1 Connection of intake air temper- Poor connection → Connect it Push the ON/start switch
ature sensor coupler. securely, or replace the wire “ ”, and check the fault
Between intake air temperature code indication.
sensor coupler and ECU cou- No fault code indicated. → Ser-
pler. vice is finished.
Brown/White–Brown/White Fault code indicated. → Go to
Between coolant temperature item 4.
pler.
coupler.
4 Installation status of intake air Check the mounting section for Push the ON/start switch
temperature sensor. a loose or pinched mounting. “ ”, and check the fault
Make sure that the mounting code indication.
position is correct. No fault code indicated. → Ser-
vice is finished.
item 5.
8-47
Fault code No. 22
Item Intake air temperature sensor: open or short circuit detected.

5 Intake air temperature sensor Check in the diagnostic mode Push the ON/start switch
malfunction. (Code No. 05). “ ”, and check the fault
Confirmation of service comple- code indication.
tion No fault code indicated. → Ser-
Refer to “CHECKING THE IN- vice is finished.
TAKE AIR TEMPERATURE Fault code indicated. → Go to
SENSOR” on page 8-105. item 6.
During cold starting: A tempera-
ture close to the ambient tem-
perature is indicated.
Indication is incorrect. → Re-
place the intake air temperature
sensor.
6 ECU malfunction. Replace the ECU
Fault code No. 24

Fault code No. 24
Item O2 sensor: no normal signals are received from the O2 sensor.

Fail-safe system
Indicated —
Procedure —
1 O2 sensor installation status. Check the sensor for a loose Either start and warm up the en-
mounting or a pinch. gine, and then racing it, or reset
it with diagnostic code No. 63.
vice is finished.
item 2.
2 Connection of O2 sensor cou- Poor connection → Connect it Either start and warm up the en-
pler. securely, or replace the wire gine, and then racing it, or reset
Check the locking condition of harness. it with diagnostic code No. 63.
3 Connection of wire harness Poor connection → Connect it Either start and warm up the en-
ECU coupler. securely, or replace the wire gine, and then racing it, or reset
Check the locking condition of harness. it with diagnostic code No. 63.
8-48
Fault code No. 24
Item O2 sensor: no normal signals are received from the O2 sensor.

4 Continuity of wire harness. Open or short circuit → Connect Either start and warm up the en-
it securely, or replace the wire gine, and then racing it, or reset
harness. it with diagnostic code No. 63.
Between O2 sensor coupler and No fault code indicated. → Ser-
ECU coupler. vice is finished.
Gray/Green–Gray/Green Fault code indicated. → Go to
Between O2 sensor coupler and item 5.
joint coupler.
Red/Blue–Red/Blue
Black–Black
coupler.
Red/Blue–Red/Blue
5 Check the fuel pressure. Refer to “CHECKING THE Either start and warm up the en-
FUEL PRESSURE” on page gine, and then racing it, or reset
7-4. it with diagnostic code No. 63.
vice is finished.
item 6.
6 O2 sensor malfunction. Check the O2 sensor for an ab- Either start and warm up the en-
normality. gine, and then racing it, or reset
Refer to “ENGINE REMOVAL” it with diagnostic code No. 63.
on page 5-2. No fault code indicated. → Ser-
O2 sensor malfunction → Re- vice is finished.
place the O2 sensor. Fault code indicated. → Go to
item 7.
Fault code No. 30

Fault code No. 30
Item Latch up detected.

Fail-safe system
Indicated • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
8-49
Fault code No. 30
Item Latch up detected.

1 Turnover of vehicle. Raise the vehicle to the upright Push the ON/start switch
position. “ ”, then push the
OFF/steering lock switch, and
then push the ON/start switch
“ ” again. Then, check the
fault code indication.
vice is finished.
item 2.
2 Sensor installation status. Check for a loose mounting, Push the ON/start switch
pinched mounting, or sensor “ ”, then push the
mounting direction (up or down). OFF/steering lock switch, and
Make sure that the mounting then push the ON/start switch
position is correct. “ ” again. Then, check the
fault code indication.
vice is finished.
item 3.
3 Lean angle sensor malfunction. Check in the diagnostic mode Push the ON/start switch
(Code No. 08). “ ”, then push the
Confirmation of service comple- OFF/steering lock switch, and
tion then push the ON/start switch
Refer to “CHECKING THE “ ” again. Then, check the
LEAN ANGLE SENSOR” on fault code indication.
page 8-100. No fault code indicated. → Ser-
In vertical position: vice is finished.
0.4–1.4 V Fault code indicated. → Go to
When turned over: item 4.
3.7–4.4 V
Indication is incorrect. → Re-
place the lean angle sensor.
Fault code No. 33

Fault code No. 33
Item Ignition coil: open or short circuit detected.

Fail-safe system
Actuates the ignition coil five times at one-second intervals.
Actuation The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen
come on each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
8-50
Fault code No. 33
Item Ignition coil: open or short circuit detected.

1 Connection of ignition coil con- Poor connection → Connect it Start and idle the engine for ap-
nectors. securely or replace the wire har- proximately 5 seconds.
Check the locking condition of ness. Then, check the fault code indi-
the connectors. cation.
Disconnect the connectors, and No fault code indicated. → Ser-
item 2.
2 Connection of wire harness Poor connection → Connect it Start and idle the engine for ap-
ECU coupler. securely or replace the wire har- proximately 5 seconds.
Check the locking condition of ness. Then, check the fault code indi-
the coupler. cation.
item 3.
3 Continuity of wire harness. Open or short circuit → Replace Start and idle the engine for ap-
the wire harness. proximately 5 seconds.
Between ignition coil coupler Then, check the fault code indi-
and ECU coupler. cation.
Orange–Orange No fault code indicated. → Ser-
vice is finished.
item 4.
4 Ignition coil installation status. Check the mounting section for Start and idle the engine for ap-
a loose or pinched mounting. proximately 5 seconds.
Make sure that the mounting Then, check the fault code indi-
position is correct. cation.
vice is finished.
item 5.
5 Ignition coil malfunction. (Check Ignition coil inspection method. Start and idle the engine for ap-
the continuity of primary coil.) Refer to “CHECKING THE IG- proximately 5 seconds.
NITION COIL” on page 8-99. Then, check the fault code indi-
cation.
vice is finished.
item 6.
6 ECU malfunction. Check in the diagnostic mode
(Code No. 30).
If not ignited, replace the defec-
tive ECU.
Fault code No. 37

TIP
• Do not remove the fast idle plunger.
8-51
Fault code No. 37
Item Fast idle plunger: engine speed is high when the engine is idling.
Fail-safe system
Actuation —
Procedure —
1 Incorrect speed sensor signal. Check the speed sensor. Start and idle the engine for ap-
Check in the diagnostic mode proximately 10 seconds.
(Code No. 07). Then, check the fault code indi-
Front wheel stop: The pulse in- cation.
tegrated value should be con- No fault code indicated. → Ser-
stant. vice is finished.
Rotate the front wheel a few Fault code indicated. → Go to
turns manually and enter the item 2.
speed pulse: The pulse integrat-
ed value will be added.
Indication is incorrect. → Refer
to Fault code No. 42
2 Throttle valve does not fully • Check the throttle body. Start and idle the engine for ap-
close. Refer to “THROTTLE BODY” proximately 10 seconds. Then,
on page 7-6. check the fault code indication.
• Check the throttle cables. No fault code indicated. → Ser-
Refer to “CHECKING THE vice is finished.
THROTTLE GRIP” on page Fault code indicated. → Go to
3-32. item 3.
3 Stuck fast idle plunger detected. • Check the throttle body. Start and idle the engine for
Refer to “THROTTLE BODY” several minutes. Then, check
on page 7-6. the fault code indication.
vice is finished.
item 4.
Fault code No. 41

Fault code No. 41
Item Lean angle sensor: open or short circuit detected.

Fail-safe system
Indicated • 0.4–1.4 (upright)
• 3.7–4.4 (overturned)
Procedure Remove the lean angle sensor and incline it more than 65 degrees.
8-52
Fault code No. 41
Item Lean angle sensor: open or short circuit detected.

1 Connection of lean angle sensor Poor connection → Connect it Push the ON/start switch
coupler. securely, or replace the wire “ ”, then push the
Check the locking condition of harness. OFF/steering lock switch, and
the coupler. then push the ON/start switch
Disconnect the coupler, and “ ” again.
check each pin (for bending, Then, check the fault code indi-
wear, or locking). cation.
vice is finished.
item 2.
ECU coupler. securely, or replace the har- “ ”, then push the
Check the locking condition of ness. OFF/steering lock switch, and
the coupler. then push the ON/start switch
Disconnect the coupler, and “ ” again.
check each pin (for bending, Then, check the fault code indi-
wear, or locking). cation.
vice is finished.
item 3.
the wire harness. “ ”, then push the
Between lean angle sensor cou- OFF/steering lock switch, and
pler and ECU coupler. then push the ON/start switch
Yellow/Green–Yellow/Green “ ” again.
Between lean angle sensor cou- Then, check the fault code indi-
pler and joint coupler. cation.
Black/Blue–Black/Blue No fault code indicated. → Ser-
Blue–Blue vice is finished.
Between joint coupler and ECU Fault code indicated. → Go to
coupler. item 4.
Blue–Blue
4 Lean angle sensor malfunction. Check in the diagnostic mode Push the ON/start switch
(Code No. 08). “ ”, then push the
Sensor inspection procedure OFF/steering lock switch, and
Refer to “CHECKING THE then push the ON/start switch
LEAN ANGLE SENSOR” on “ ” again.
page 8-100. Then, check the fault code indi-
In vertical position: cation.
0.4–1.4 V No fault code indicated. → Ser-
When turned over: vice is finished.
3.7–4.4 V Fault code indicated. → Go to
Indication is incorrect. → Re- item 5.
place the lean angle sensor.
Fault code No. 42

TIP
8-53
Fault code No. 42
Speed sensor: no normal signals are received from the speed sen-
Item
sor.
Fail-safe system
Vehicle speed pulse
Indicated
0–999
Check that the number increases when the front wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
1 Connection of speed sensor Improperly connected → Con- Execute the diagnostic mode.
coupler. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate the front wheel by hand
the coupler. and check that the indicated val-
Disconnect the coupler and ue increases.
check the pins (bent or broken Value increases → Service is
terminals and locking condition finished.
of the pins). Value does not increase → Go
to item 2.
2 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 07)
the coupler. place the wire harness. Rotate the front wheel by hand
Disconnect the coupler and and check that the indicated val-
check the pins (bent or broken ue increases.
terminals and locking condition Value increases → Service is
of the pins). finished.
Value does not increase → Go
to item 3.
3 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 07)
Between speed sensor coupler Rotate the front wheel by hand
and ECU coupler. and check that the indicated val-
White–White ue increases.
Between speed sensor coupler Value increases → Service is
and joint coupler. finished.
Black/Blue–Black/Blue Value does not increase → Go
Blue–Blue to item 4.
coupler.
Blue–Blue
4 Malfunction in ECU. Replace the ECU.
Fault code No. 43

Fault code No. 43
Fuel system voltage: incorrect voltage supplied to the fuel injection

Item
system relay, fuel injector and fuel pump.
Fail-safe system
Diagnostic code No. 09, 50
8-54
Fault code No. 43

Item
Fuel system voltage (battery voltage)
Indicated
Approximately 12.0
09 Set the engine stop switch to “ ”, and then compare the actually mea-
Procedure sured battery voltage with the display value. (If the actually measured
battery voltage is low, recharge the battery.)
Actuates the fuel injection system relay five times at one-second inter-
vals.
Actuation
The “CHECK” indicator and “ ” on the Yamaha diagnostic tool screen
50 come on each time the fuel injector is actuated.
Check that the fuel injection system relay is actuated five times by listen-
Procedure
ing for the operating sound.
1 Connection of fuel injection sys- Poor connection → Connect it Start and idle the engine for ap-
tem relay coupler. securely, or replace the wire proximately 5 seconds.
Check the locking condition of harness. Then, check the fault code indi-
item 2.
2 Connection of wire harness Poor connection → Connect it Start and idle the engine for ap-
ECU coupler. securely, or replace the wire proximately 5 seconds.
Check the locking condition of harness. Then, check the fault code indi-
item 3.
3 Continuity of wire harness. Open or short circuit → Replace Start and idle the engine for ap-
the wire harness. proximately 5 seconds.
Between fuel injection system Then, check the fault code indi-
relay coupler and joint coupler. cation.
Red/Blue–Red/Blue No fault code indicated. → Ser-
Between joint coupler and ECU vice is finished.
coupler. Fault code indicated. → Go to
Red/Blue–Red/Blue item 4.
Between fuel injection system
relay coupler and fuel injection
system fuse.
Red–Red
4 Fuel injection system relay mal- Check in the diagnostic mode Start and idle the engine for ap-
function. (Code No. 50). proximately 5 seconds.
No operation sound of fuel in- Then, check the fault code indi-
jection system relay is heard. → cation.
Replace the fuel injection sys- No fault code indicated. → Ser-
tem relay. vice is finished.
item 5.
8-55
Fault code No. 43

Item
5 Fuel injection system relay mal- Check in the diagnostic mode Start and idle the engine for ap-
function. (Code No. 09) proximately 5 seconds.
Fuel-related voltage: 3 V or less Then, check the fault code indi-
→ Replace the main relay. cation.
vice is finished.
item 6.
Fault code No. 44

Fault code No. 44
EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
Fail-safe system
EEPROM fault code display
• 00 (no history)
Indicated • 01 or 02: Cylinder fault code number (history exists)
If both cylinders are defective, the display alternates every two sec-
onds.
Procedure —
1 Locate the malfunction. Check in the diagnostic mode —
(Code No. 60)
Replace the ECU if defective.
Fault code No. 46

TIP
Fault code No. 46
Item Charging voltage is abnormal.

Fail-safe system
Indicated —
Procedure —
8-56
Fault code No. 46
Item Charging voltage is abnormal.

1 Charging system malfunction. Check the charging system. Start and idle the engine for ap-
Refer to “CHARGING SYSTEM” proximately 5 seconds.
on page 8-11. Then, check the fault code indi-
Check the rectifier/regulator, AC cation.
magneto and wire harness. → No fault code indicated. → Ser-
Replace if defective. vice is finished.
Fault code indicated. → Re-
check.
Fault code No. 50

Fault code No. 50
Faulty ECU memory. (When this malfunction is detected in the ECU,

Item
the fault code number might not appear.)
Fail-safe system
Indicated —
Procedure —
1 ECU malfunction. Replace the ECU. Push the ON/start switch
“ ”.
Then, check that no fault code
indicated.
Fault code No. Er-1 (fault code display)

ECU (engine control unit) internal malfunction (output signal error):

Item signals cannot be transmitted between the ECU and the multi-func-
tion meter.
Able to start engine (Unable if ECU Failure)
Fail-safe system
Able to drive vehicle (Unable if ECU Failure)
Indicated —
Procedure —
1 Connection of meter coupler. Poor connection → Connect it Push the ON/start switch
Check the locking condition of securely, or replace the wire “ ”, and check the fault
the coupler. harness. code indication.
item 2.
8-57

Item signals cannot be transmitted between the ECU and the multi-func-
tion meter.
3 Continuity of wire harness. Open or short circuit → Connect Push the ON/start switch
it securely, or replace the wire “ ”, and check the fault
harness. code indication.
Between meter assembly cou- No fault code indicated. → Ser-
pler and joint coupler. vice is finished.
Yellow/Blue–Yellow/Blue Fault code indicated. → Go to
Between joint coupler and item 4.
Yamaha diagnostic tool coupler.
Yellow/Blue–Yellow/Blue
Between Yamaha diagnostic
tool coupler and ECU coupler.
4 Abnormal meter unit operation. Replace the meter assembly. Push the ON/start switch
“ ”, and check the fault
code indication.
vice is finished.
item 5.
Fault code No. Er-2

Fault code No. Er-2

Item
no signals are received from the ECU within the specified duration.
Fail-safe system
Indicated —
Procedure —
item 2.
8-58
Fault code No. Er-2

Item
no signals are received from the ECU within the specified duration.
code indication.
vice is finished.
item 5.
Fault code No. Er-3

Fault code No. Er-3

Item
data from the ECU cannot be received correctly.
Fail-safe system
Indicated —
Procedure —
item 2.
8-59
Fault code No. Er-3

Item
data from the ECU cannot be received correctly.
code indication.
vice is finished.
item 5.

ECU (engine control unit) internal malfunction (input signal error):

Item
non-registered data has been received from the meter.
Fail-safe system
Indicated —
Procedure —
item 2.
8-60
ECU (engine control unit) internal malfunction (input signal error):

Item
non-registered data has been received from the meter.
Yamaha diagnostic coupler.
coupler and ECU coupler.
code indication.
vice is finished.
item 5.
8-61
8-62
EAS30513
EAS20081

B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
R/G Y W R R
R/G 5 28 R/B
G/Y L 10 W
11 B G/W
(Dg)
L/W R L/W 27 O
Y R/B 29 R
G/Y B B
B R
B
20 22 R/L
39
CIRCUIT DIAGRAM
L B W W W
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
L/W B A B B L/W L/W
1 RR B B/L Br/W (B)
R B Lg Br/W
24 R R Lg Lg B/L
Br/L L/W P/W P/W
R/G R L/Y 21 25 B B/W L
42
R/G
30 B B Lg B
41 B/L
L L G B R/G B B/L
(L)
FUEL PUMP SYSTEM
43
B/W B
Br B
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
46 L R B B/L
G/Y Ch Br/W Br R/B
13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
L/RBr (Gy) (B) (B)
16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
18 R/G L
Br Y/B L/B L L L
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
Ch Br/R R/L
8-63
75 Br/W Br/W
R/L R/L R/L R/L
L
76 56 19
Br/B L Y/R
Y Br/W 57 58 59 60 B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
G/Y G/Y G/Y G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
1. Smart key unit

14.Ignition fuse
17.Fuel injection system fuse
18.Backup fuse
19.Joint coupler
20.Battery
21.Engine ground
22.Main fuse
49.Fuel pump
A. Wire harness
8-64
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
2. Storage box

(Main, ignition, backup and fuel in-
jection system) Replace the fuse(s).
ES” on page 8-91.
OK ↓
page 8-91.
OK ↓
3. Check the engine stop switch. NG →
OK ↓
OK ↓
5. Check the fuel injection system re- NG →
lay.
Replace the fuel injection system relay.
OK ↓
6. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
PRESSURE” on page 7-4.
OK ↓
7. Check the entire fuel pump sys- NG →
tem’s wiring. Properly connect or replace the wire har-
page 8-63.
OK ↓
Replace the ECU or smart key unit.
8-65
FUEL PUMP SYSTEM
8-66
EAS31452
EAS20201

B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
R/G
R/G Y W R R
R/G 5 28 R/B
G/Y L 10 W
11 B G/W
(Dg)
L/W R L/W 27 O
Y R/B 29 R
G/Y B B
B R
B
20 22 R/L
39
CIRCUIT DIAGRAM
L B W W W
L/W L/W L/W G/B
R B R
R R/L L/Y L/Y
L/W B A B B L/W L/W
1 RR B B/L Br/W (B)
R B Lg Br/W
24 R R Lg Lg B/L
Br/L L/W P/W P/W
R/G R L/Y 21 25 B B/W L
42
R/G
30 B B Lg B
41 B/L
L L G B R/G B B/L
(L)
G L L/R L
SMART KEY SYSTEM
Y B Y 43 L Y B/L
B/W B
Br B
L/Y Y/G Y/G 44
Br/L W L L Y/G B/L
Br/L 31 L/W
G/L 32 33 L/W B 34
Y/L Br/L Br/L
Br/L 35 B/L B
L/G R/L R/B L W
W G G R
46 L R B B/L
G/Y Ch Br/W Br R/B
13 (B) R/B R/B R/L (B)
R/W (B)
R/G (B) B/W
R/G R/W
14 Br
L G/B G/B R/L
R/G Br Br R/L B B
L
L/R 8 15 Br Br
47
L/RBr (Gy) (B) (B)
16 R/W Y/W
R/W B
R R/W R/W L
R/W R/L
17 Y/R
19
L
Y/W L
18 R/G L
Br Y/B L/B L L L
R/W (B) 63
81 74 Y/B
B/W Y Y/B (B) 19
G/L R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y R/W R/L
Ch Br/R R/L
8-67
75 Br/W Br/W
R/L R/L R/L R/L
L
76 56 19
Br/B L Y/R
Y Br/W 57 58 59 60 B
L/R OFF B
(B) N B
L/R ON 61 B
85 B/W
B Y Br/W R Ch Dg
L/R L/R P
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
B B Ch Dg G/Y
Y 65 L G/Y
G/Y G/Y G/Y G/Y
L L
87 L P B
G L L
Ch B B
Y/L 88
89 Ch Ch
Ch Dg
Ch 52
Dg Dg
B B G B
R/G Dg Dg
Y Y L G/Y L L 50 49
R/W L 54 R/L B
D D
R/G
Y/B Y
Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch Dg Y 78 L L
R/Y R/Y 55 B B
B Br G Br/G Br/G
B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
66 66 Br L G L
L/G 71 71 B B L
Y/L B B
19 Y/L B
Y/L B L B L B (B)
B L Ch B L Dg B B
B B
B B B B
W/Y G/Y L
R
72 73 72 73 B B
79 (B) A B
90 R L/G L/G
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
SMART KEY SYSTEM
SMART KEY SYSTEM
1. Smart key unit

2. Buzzer
4. Steering lock unit
5. Seat open relay
6. Seat lock solenoid
7. Smart key switch assembly
14.Ignition fuse
18.Backup fuse
19.Joint coupler
20.Battery
21.Engine ground
22.Main fuse
30.Sidestand switch
31.Handlebar switch
33.ON/start switch
34.Hazard switch
60.Turn signal switch
67.Front turn signal/position light (left)
68.Front turn signal/position light (right)
69.Rear turn signal light (left)
70.Rear turn signal light (right)
78.Storage box light
80.Meter assembly
81.Smart key indicator light
82.Turn signal indicator light (left)
83.Turn signal indicator light (right)
A. Wire harness
8-68
SMART KEY SYSTEM
EAS31453
TROUBLESHOOTING
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
Engine does not start even though vehicle power is turned on.
Seat does not open. (Vehicle power is turned on.)
TIP
Before troubleshooting, remove the following part(s):
Checking the vehicle power

1. Check the fuses. (Main, backup, NG →
and ignition)
ES” on page 8-91.
OK ↓
page 8-91.
OK ↓
3. Check the smart key switch assem- NG →
bly.
Replace the smart key switch assembly.
OK ↓
OK ↓
5. Check the smart key. NG →
→ The smart key indicator light
comes on when the ON/OFF switch
Replace the button cell battery of the
“ ” is pushed.
smart key. Standard battery: CR2025
→ Check the button cell battery.
Refer to “CHECKING THE SMART
KEY BATTERY” on page 8-106.
OK ↓
6. Check the entire smart key sys- NG →
tem’s wiring. Properly connect or replace the wire har-
page 8-67.
OK ↓
Replace the smart key unit.
8-69
SMART KEY SYSTEM
Checking the smart key system

Before checking the smart key system, make sure that the smart key is located within the operating
range of the smart key system and that the key is turned on.
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
TIP
• Before performing this procedure, make sure that there are no sources of strong electromagnetic
waves in the vicinity. (Because the amount of electromagnetic waves will change if the vehicle is
moved a short distance, move the vehicle away from sources of strong electromagnetic waves before
performing the procedure.)
• Use the smart key that is registered to the vehicle.
1. Check the vehicle power. NG →

Refer to “Checking the vehicle pow- Repair or replace any defective parts.
er”.
OK ↓
YES → • The vehicle can be operated in the emer-
gency mode. → Replace the smart key or
smart key unit.
• The vehicle cannot be turned on in the
2. Check that the smart key system in-
emergency mode, but the storage box
dicator light “ ” flashes when the
light comes on when the seat is opened.
ON/start switch “ ” is pushed.
→ Replace the smart key unit.
• The storage box light does not come on
when the seat is opened. → Replace the
seat or storage box light.
NO ↓
3. The smart key system indicator YES →
• The steering lock is stuck and cannot be
light “ ” flashes.
released.
(The indicator light flashes once ev-
• Release the steering lock. → Try moving
ery 2 seconds, and then goes off
the handlebar gently to the left or right.
after approximately 20 seconds.)
• The steering lock is not stuck. → Replace
Refer to “SMART KEY SYSTEM
the steering lock unit.
SELF-DIAGNOSIS” on page 8-72.
NO ↓
4. The smart key system indicator YES → • A steering lock communication error has
light “ ” flashes. occurred.
(The indicator light repeatedly • Check for an open or short circuit be-
flashes 2 times, and then goes off tween the steering lock unit and the
after approximately 20 seconds.) smart key unit (Blue/White–
Refer to “SMART KEY SYSTEM Brown/White). → Repair or replace any
SELF-DIAGNOSIS” on page 8-72. defective parts.
NO ↓
8-70
SMART KEY SYSTEM
5. The smart key system indicator YES →

light “ ” flashes.
(The indicator light repeatedly
Steering lock unit data error or malfunction
flashes 3 times, and then goes off
→ Replace the steering lock unit.
after approximately 20 seconds.)
NO ↓
• The smart key system indicator light
“ ” does not flash.
• There are sources of strong electro-
magnetic waves in the vicinity →
Move the vehicle.
• Smart key malfunction → Register
and use a different smart key.
• Smart key unit malfunction → Re-
place the smart key unit.
Engine does not start even though vehicle power is turned on.
1. When the vehicle power is turned NO →
on, the smart key system indicator Check and repair the electric starting sys-
light “ ” flashes. tem. Refer to “ELECTRIC STARTING
Refer to “SMART KEY SYSTEM SYSTEM” on page 8-5.
YES ↓
2. Check for continuity in the commu- NG →
nication line between the ECU and Replace the wire harness.
the smart key unit (Yellow/Blue).
OK ↓
3. A fault code number (fault code No. YES →
53, 54, or 56) for a communication
• Replace the ECU.
error is displayed on the meter.
• Replace the smart key unit.
NO ↓
Check the engine. Refer to “FUEL IN-
JECTION SYSTEM” on page 8-31.
Seat does not open. (Vehicle power is turned on.)

TIP
If the smart key system indicator light “ ” flashes quickly 10 times (error) when the seat is opened, the
seat cannot be opened if the vehicle power is not turned off and on.
1. Check the vehicle power. NG →

Refer to “Checking the vehicle pow- Repair or replace any defective parts.
er”.
OK ↓
8-71
SMART KEY SYSTEM
2. Check the smart key switch assem- NG →

bly.
Replace the smart key switch assembly.
OK ↓
3. Check that the smart key system in- YES →
dicator light “ ” flashes when the
• The seat can be opened.
seat open/parking switch on the ve-
• There is a sensor malfunction in the seat
hicle is operated.
lock solenoid. → Replace the smart key
(Flashes quickly 10 times.)
unit.
NO ↓
• The seat cannot be opened.
• Check the mechanical components
of the lock for malfunctions. Repair or
replace any defective parts.
• Adjust or replace the seat lock cable.
→ Check the seat lock solenoid. Re-
fer to “CHECKING THE SEAT LOCK
SOLENOID” on page 8-107. → Re-
place the smart key unit.
The turn signal light fails to blink (parking mode operation).

1.
OK ↓
2.
OK ↓
3. Check for open or short circuit be- NG →
tween the smart key unit and turn
signal/hazard relay 1 (Brown), and Replace the wire harness.
turn signal/hazard relay 1 and turn
signal/hazard relay 2 (Blue/Red).
OK ↓
Replace the smart key unit.
EAS31534
SMART KEY SYSTEM SELF-DIAGNOSIS

The smart key system is equipped with a self-diagnostic function. If a malfunction is detected in the sys-
tem, the malfunction will be indicated by the flash pattern of the smart key system indicator light “ ”.
8-72
SMART KEY SYSTEM
TIP
The smart key system indicator light “ ” comes on for 1 second when the ON/start switch “ ” is
pushed. If one of the following malfunctions is detected, the indicator light starts flashing.
Flashing time/number Malfunction and check

Item Flash pattern
of flashes point
0.5 (s)
a Replace the button cell
battery of the smart key.
Low voltage of smart b
0.5 (s)
20 (seconds) Refer to “SMART KEY
key button cell battery
SYSTEM” on page
a.LED on 8-67.
b.LED off
The smart key cannot
0.15 (s) be recognized.
a Check that there are no
sources of strong elec-
Vehicle power off verifi- b
0.15 (s)
10 (seconds) tromagnetic waves in
cation error
the vicinity, the smart
a.LED on key is not lost, and the
b.LED off battery is not dis-
charged.
The smart key cannot
0.15 (s) be recognized.
Check that there are no
a
Flashes continuously sources of strong elec-
Running detection er- b
0.15 (s)
until the error is re- tromagnetic waves in
ror*
solved. the vicinity, the smart
a.LED on key is not lost, and the
b.LED off battery is not dis-
charged.
0.5 (s)
a
• Steering lock is stuck
b Check whether the
• Steering lock cannot 1.5 (s)
20 (seconds)/10 times
steering lock is stuck.
be released
a.LED on
b.LED off
0.3 (s)
a
20 (seconds)/flashes 2
Steering lock communi- b 1.0 (s) times in a repeating cy- Check the wire harness.
cation error 0.3 (s)
cle
a.LED on
b.LED off
0.3 (s)
• Steering lock data er- a
20 (seconds)/flashes 3 Check the wire harness.
ror b times in a repeating cy- Check the steering lock
• Steering lock unit mal- 0.3 (s) 1.0 (s)
cle unit.
function
a.LED on
b.LED off
8-73
SMART KEY SYSTEM
Flashing time/number Malfunction and check

Item Flash pattern
of flashes point
Check the wire harness.

0.3 (s)
Check the ECU.
• ECU communication a Flashes continuously
Check the smart key
error b until the error is re-
unit.
• Data error 0.3 (s) 1.0 (s) solved./flashes 4 times
Fault code No. 53, 54,
• ECU malfunction in a repeating cycle
a.LED on or 56 is displayed on
b.LED off the meter.
0.15 (s)
a Check the seat lock.
Check and adjust the
Seat lock solenoid b 3 (seconds) seat lock cable.
0.15 (s)
Check the smart key
a.LED on unit.
b.LED off
* The running detection error
If the smart key is dropped or can no longer be recognized while the vehicle is traveling. If the vehicle
travels 1 km or more while the smart key cannot be recognized, the smart key system indicator light
“ ” flashes in 0.15-second intervals.
The vehicle can be ridden, but the vehicle power cannot be turned off.
Although a forced shutdown can be performed to turn off the vehicle power (the OFF/steering lock
switch is pushed for 1 second or more while the smart key system indicator light “ ” is flashing in
0.15-second intervals), the vehicle power cannot be turned back on.
Communication error between the ECU and the smart key unit
If a communication error between the ECU and the smart key unit is detected, the following fault code
numbers will be displayed on the meter to indicate the location of the malfunction.
TIP
These fault code numbers are not stored in the memory of the ECU. Note all of the displayed fault code
numbers, and then check the vehicle.
Device that de-

Fault code Check or maintenance
tected the mal- Symptom Cause
No. job
function
53 Smart key unit Communication error Radio wave noise inter- • Check the wire har-
between the ECU and ference or disconnect- ness.
the smart key unit. ed lead. • Replace the ECU.
• Obstruction due to ra- • Replace the smart
dio wave noise key unit.
• Disconnection in the
wire harness
• Defective ECU
• Defective smart key
unit
8-74
SMART KEY SYSTEM
Device that de-

Fault code Check or maintenance
tected the mal- Symptom Cause
No. job
function
54 Smart key unit Codes transmitted be- Radio wave noise inter- • Register the smart
tween the ECU and the ference or disconnect- key.
smart key unit do not ed lead. • Check the wire har-
match. • Obstruction due to ra- ness.
dio wave noise. • Replace the ECU.
• Disconnection in the • Replace the smart
wire harness key unit.
• Defective ECU (when
the ECU or smart key
unit is replaced with a
unit from a different
vehicle)
unit
56 ECU Unidentified code is re- Radio wave noise inter- • Check the wire har-
ceived. ference or disconnect- ness.
ed lead. • Replace the ECU.
• Obstruction due to ra- • Replace the smart
dio wave noise key unit.
• Disconnection in the
wire harness
• Defective ECU
unit
EAS31535
SMART KEY SYSTEM EMERGENCY MODE

If the smart key is lost or if it cannot be used due a discharged battery or malfunction, this mode can be
used to turn on the smart key system.
TIP
• The emergency mode operation will be canceled if the respective steps are not carried out within the
time set for each operation.
• To deactivate the emergency mode, push the OFF/steering lock switch.
1. Stop the vehicle in a safe place.
2. Release the seat lock.
TIP
Insert the mechanical key into the lock inside the storage box (front right side) and turn it clockwise as
shown.
1. Seat lock key cylinder
8-75
SMART KEY SYSTEM
3. Open the seat. Check that the storage box light comes on when the seat is opened. If the storage
box light does not come on, check the storage box light and storage box light switch.
4. Push the ON/start switch “ ”.
5. With the seat opened, raise and lower the seat (without completely shutting it) 3 times within 10 sec-
onds. Use the storage box light as a guide when raising and lowering the seat. When the emergency
mode is activated, the smart key system indicator light “ ” on the meter will come on for 3 seconds.
1. Smart key system indicator light “ ”

6. After the smart key system indicator light “ ” goes off, use the seat open/parking switch to enter the
smart key identification number “1” located inside the smart key case (open the smart key case as
shown) or the identification number “2” located on the key tag. (Refer to the following procedure on
how to input the identification number.)
7. The input identification number is indicated by the number of flashes of the smart key system indi-
cator light “ ” while the seat open/parking switch is pushed.
For example, if the smart key identification number is 123456:
Push and hold the seat open/parking switch. →
The smart key system indicator light “ ” will start to flash. →
8-76
SMART KEY SYSTEM
Release the seat open/parking switch after the smart key system indicator light “ ” flashes 1 time. →
The first digit of the identification number has been set as 1. →
Push and hold the seat open/parking switch again. →
Release the seat open/parking switch after the smart key system indicator light “ ” flashes 2 times.
→
The second digit of the identification number has been set as 2. →
Repeat the above procedure until all 6 digits of the identification number have been set.
The emergency mode will become deactivated under either of the following conditions. If the emer-
gency mode is deactivated, repeat the procedure from step 4.
• During the identification number input procedure, there are no seat open/parking switch operations
for 10 seconds or more.
• The smart key system indicator light “ ” flashes 10 times or more.
8. The smart key system indicator light “ ” will come on for 10 seconds if the correct 6-digit identifica-
tion number was entered.
9. Press the ON/start switch “ ” while the smart key system indicator light “ ” is on to turn on the
vehicle power.
TIP
• If the identification number is not correctly entered, the smart key system indicator light “ ” will flash
quickly for 3 seconds and the emergency mode will become deactivated. If the emergency mode is
deactivated, repeat the procedure from step 4.
• If the smart key is lost, this procedure can be performed using the spare mechanical key and the smart
key identification number. In addition, the spare mechanical key and the smart key identification num-
ber can be used to start the engine and register a new smart key.
EAS31536
REGISTERING A SMART KEY

The following procedure can be used to register additional smart keys or a new smart key in case the
original smart key is lost.
TIP
• A maximum of 6 smart keys can be registered to the smart key unit.
• Be sure to register the smart keys one at a time. Do not register multiple smart keys at the same time.
8-77
SMART KEY SYSTEM
1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the smart key unit.
a
1
2. Perform steps 1–8 in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-75.
3. While the smart key system indicator light “ ” is on for 10 seconds, push the seat open/parking
switch “1” and OFF/steering lock switch “2” alternately 3 times (total of 6 times).
TIP
Either switch can be pushed first.
1 2
4. The smart key indicator light (red) “1” on the new smart key comes on for 10 seconds.
TIP
While the smart key indicator light on the smart key is on, the smart key system indicator light “ ” flash-
es according to the number of currently registered smart keys. (For example, if 5 smart keys are regis-
tered, the indicator light flashes 5 times.)
5. While the smart key indicator light is on for 10 seconds, push the ON/OFF switch on the smart key
to transmit a signal from the smart key to the smart key unit.
6. If the smart key is registered successfully, the smart key system indicator light “ ” will come on for
3 seconds, and then the smart key system will turn off.
If the smart key was not registered successfully, the smart key system indicator light “ ” will flash
for 3 seconds, and then the smart key system will turn off.
TIP
If this registration procedure is performed for a smart key that is already registered, the smart key sys-
tem indicator light “ ” will flash for 7 seconds (on for 0.2 second and off for 0.8 second).
8-78
SMART KEY SYSTEM
EAS31537
DISABLING A SMART KEY

If a smart key is lost or stolen, the smart key can be disabled.
1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com-
munication.
1 a
2. Perform steps 1–8 in “SMART KEY SYSTEM EMERGENCY MODE” on page 8-75.
3. While the smart key system indicator light “ ” is on for 10 seconds, perform the following procedure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. While pushing the OFF/steering lock switch “1”, push the seat open/parking switch “2” 3 times. Then,
release both switches.
2 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check that the smart key system indicator light “ ” goes off (the smart key disable mode is activat-
ed).
5. Turn on (unlocked setting) the smart keys that you want to enable and place them within 80 cm (31.5
in) of the smart key unit.
6. Push the OFF/steering lock switch 1 time to start the communication between the smart key unit and
the smart keys that are located within 80 cm (31.5 in) of the unit.
TIP
The number of smart keys that currently can be used will be indicated.
Number of flashes = Number of verified smart keys. (1 cycle of on for 0.3 second and off for 0.3 second
= 1 smart key)
7. Push the OFF/steering lock switch and seat open/parking switch simultaneously for 2 seconds. The
use of only the verified smart keys will be enabled. The use of all other smart keys will be disabled.
TIP
If the procedure was not completed successfully, repeat the procedure from step 1.
EAS31538
REPLACING THE SMART KEY UNIT, STEERING LOCK, AND ECU

TIP
The smart key unit, steering lock, and ECU cannot be replaced at the same time.
8-79
SMART KEY SYSTEM
EAS31539
REPLACING THE SMART KEY UNIT

1. Replace the smart key unit, and then place only 1 previously used smart key within 80 cm (31.5 in)
of the smart key unit.
3. Push the OFF/steering lock switch, and then push the ON/start switch “ ” to check that the op-
eration is correct.
4. Register any additional smart keys.
TIP
• If multiple smart keys were registered to the previous smart key unit, perform the preceding procedure
for only 1 smart key. Do not perform the procedure for multiple smart keys at the same time.
• If the smart key identification number matches, it can be determined that the replacement procedure
is being performed for a legitimate user. Write the smart key unit identification number and smart key
identification number to the smart key unit and overwrite the smart identification number on the smart
key with the new number.
EAS31556
REPLACING THE STEERING LOCK UNIT

1. Replace the steering lock unit, and then place the previously used smart key within 80 cm (31.5 in)
of the smart key unit.
eration is correct.
TIP
An identification number is not written to the steering lock unit when it is shipped from the factory. When
the vehicle system is turned on for the first time, the smart key unit identification number and smart key
identification number are automatically registered from the smart key unit to the steering lock unit.
EAS31541
REPLACING THE ECU

1. Replace the ECU, and then place the previously used smart key within 80 cm (31.5 in) of the smart
key unit.
eration is correct.
TIP
An identification number is not written to the ECU when it is shipped from the factory. When the vehicle
system is turned on for the first time, the smart key unit identification number is automatically written
from the smart key unit to the ECU.
EAS31719
REPLACEMENT PARTS LIST

TIP
When replacing the parts, refer to the following sections.
• Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 8-75.
• Refer to “REGISTERING A SMART KEY” on page 8-77.
• Refer to “REPLACING THE SMART KEY UNIT, STEERING LOCK, AND ECU” on page 8-79.
• Refer to “REPLACING THE SMART KEY UNIT” on page 8-80.
• Refer to “REPLACING THE STEERING LOCK UNIT” on page 8-80.
• Refer to “REPLACING THE ECU” on page 8-80.
8-80
SMART KEY SYSTEM
Required item when re- Replacement parts (when an item is required

placing parts in order to replace parts)
 : Required.  : Replace.
Smart key identifi-
 : cation number or
smart key is re- × : Do not replace.
Faulty part quired. Remarks
× : Not required. * : This part must be replaced even if it is

not faulty.
Smart key
identifica- Smart key Steering
Smart key Smart key ECU
tion num- unit lock unit
ber
Register the smart key identifica-

Smart key  ×  × × × tion number in the emergency
mode.
When the vehicle system is
turned on, the smart key identifi-
Smart key unit ×  ×  × × cation number is automatically
registered to the smart key unit.
Steering lock unit   × ×  × cation number is automatically
registered to the steering lock
unit.
ECU   × × ×  cation number is automatically
registered to the ECU.
Steering lock
unit/ECU   × ×   cation number is automatically
unit and ECU.
Smart key unit/ECU ×  ×  ×  cation number is automatically
registered to the smart key unit
and ECU.
The original smart keys can be
Smart key used if they are registered as ad-
unit/Steering lock × × *   * ditional smart keys. Replace the
unit smart key, smart key unit, steer-
ing lock unit, and ECU as a set.
Replace the smart key, smart
Smart key/Smart
key unit × ×   * * key unit, steering lock unit, and
ECU as a set.
tion number in the emergency
mode.
Smart key/Steering When the vehicle system is
lock unit  ×  ×  × turned on, the smart key identifi-
cation number is automatically
unit.
mode.
Smart key/ECU  ×  × ×  When the vehicle system is
registered to the ECU.
Smart key Replace the smart key, smart
unit/Steering lock key unit, steering lock unit, and
unit/ECU/(Smart × ×     ECU as a set.
key)
Smart key/Smart Replace the smart key, smart
key unit/Steering × ×    * key unit, steering lock unit, and
lock unit ECU as a set.
8-81
SMART KEY SYSTEM
Required item when re- Replacement parts (when an item is required

placing parts in order to replace parts)
 : Required.  : Replace.
Smart key identifi-
 : cation number or
smart key is re- × : Do not replace.
Faulty part quired. Remarks
× : Not required. * : This part must be replaced even if it is

not faulty.
Smart key
identifica- Smart key Steering
Smart key Smart key ECU
tion num- unit lock unit
ber
Smart key/Smart Replace the smart key, smart

key unit/ECU × ×   *  key unit, steering lock unit, and
ECU as a set.
mode.
Smart key/Steering When the vehicle system is
lock unit/ECU  ×  ×   turned on, the smart key identifi-
unit and ECU.
8-82
ELECTRICAL COMPONENTS
EAS20089
4 5
3 6
2
1 7
8
28 10
11
12
27
13
14
15
26
16
25
24
23
17
22
21
20
19 18
8-83
1. Front brake light switch

2. Fuse box
3. Diode 3
8. Main fuse
9. Starter relay
10.Battery
11.Starting circuit cut-off relay
12.Sidestand relay
14.Diode 1
15.Diode 2
16.Horn
17.Rectifier/regulator
19.Seat open relay
23.Headlight relay
24.Buzzer
26.Diode 4
27.Smart key unit
8-84
3 4 6
5
2
7
16
15
14 10
11
13
12
8-85
1. Auxiliary DC jack
2. Steering lock unit
4. Fuel injector
6. Fuel pump
8. O2 sensor
10.AC magneto
11.Sidestand switch
12.Spark plug
13.Radiator fan motor
14.Speed sensor
15.Ignition coil
16.Throttle position sensor
8-86
EAS30549
CHECKING THE SWITCHES
1 2 3 4 B/Y L/Y
R Y Y L/B Br P Ch Br/W Dg 5 6
OFF L
ON N
G B
G L
B
Y Br/W R Ch Dg
Br B/Y L/B L/Y B
7 8 9 10 11 12
R/B R/W L/W B Ch Br/W Dg
R
B
B B
(L)
B R L/G
L/G
R/W Dg
R/B Br Br/W Ch G/Y L/W B
Br G/Y
(B)
8-87
1. Pass switch
2. Dimmer switch
3. Horn switch
4. Turn signal switch
7. Engine stop switch
8. ON/start switch
9. Hazard switch
11.Sidestand switch
8-88
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA18520
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the ON/start
switch “ ”.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”.
There is continuity between Blue/White and black when the switch is set to “ON”.
L/W B
L/W B
8-89
EAS30550
• Avoid touching the glass part of a headlight
CHECKING THE BULBS AND BULB
bulb to keep it free from oil, otherwise the
SOCKETS
transparency of the glass, the life of the
TIP bulb, and the luminous flux will be adverse-
Do not check any of the lights that use LEDs. ly affected. If the headlight bulb gets soiled,
Check each bulb and bulb socket for damage or thoroughly clean it with a cloth moistened
wear, proper connections, and also for continuity with alcohol or lacquer thinner.
between the terminals. 2. Check:
Damage/wear → Repair or replace the bulb, • Bulb (for continuity)
bulb socket or both. (with the pocket tester)
Improperly connected → Properly connect. No continuity → Replace.
No continuity → Repair or replace the bulb, bulb
socket or both. Pocket tester
90890-03112
Types of bulbs Analog pocket tester
The bulbs used on this vehicle are shown in the YU-03112-C
illustration.
• Bulbs “a” are used for turn signal lights and can TIP
be removed from the socket by pushing and Before checking for continuity, set the pocket
turning the bulb counterclockwise. tester to “0” and to the “Ω × 1” range.
• Bulbs “b” are used for auxiliary, license plate ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
and storage box lights and can be removed a. Connect the positive tester probe to terminal
from their respective socket by carefully pulling “1” and the negative tester probe to terminal
them out. “2”, and check the continuity.
b. If reading indicate no continuity, replace the
bulb.
a b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
1. Remove: Checking the condition of the bulb sockets
• Bulb The following procedure applies to all of the bulb
EWA17540
WARNING sockets.
1. Check:
Since headlight bulbs get extremely hot,
• Bulb socket (for continuity)
keep flammable products and your hands
(with the pocket tester)
away from them until they have cooled
No continuity → Replace.
down.
ECA14381 Pocket tester
NOTICE 90890-03112
• Be sure to hold the socket firmly when re- Analog pocket tester
moving the bulb. Never pull the lead, other- YU-03112-C
wise it may be pulled out of the terminal in
the coupler.
8-90
TIP Amperage
Fuses Q’ty
Check each bulb socket for continuity in the rating
same manner as described in the bulb section, Main 40 A 1
however, note the following.
Headlight 10 A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Signaling system 15 A 1
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the re- Ignition 7.5 A 1
spective leads of the bulb socket. Radiator fan motor 15 A 1
c. Check the bulb socket for continuity. If any of Parking lighting 10 A 1
the readings indicate no continuity, replace Fuel injection system 7.5 A 1
the bulb socket.
Backup 7.5 A 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30551
Auxiliary DC jack fuse 5A 1
CHECKING THE FUSES Spare 40 A 1
The following procedure applies to all of the fus- Spare 15 A 1
es.
ECA22360
Spare 10 A 1
NOTICE Spare 7.5 A 1
To avoid a short circuit, always press the Spare 5A 1
OFF/steering lock switch when checking or
EWA13310
replacing a fuse. WARNING
1. Remove: Never use a fuse with an amperage rating
• Front cover other than that specified. Improvising or us-
Refer to “GENERAL CHASSIS (1)” on page ing a fuse with the wrong amperage rating
4-1. may cause extensive damage to the electri-
2. Check: cal system, cause the lighting and ignition
• Fuse systems to malfunction and could possibly
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ cause a fire.
a. Connect the pocket tester to the fuse and
check the continuity. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
TIP 4. Install:
Set the pocket tester selector to “Ω × 1”. • Front cover
4-1.
Pocket tester
90890-03112 EAS30552
Analog pocket tester CHECKING AND CHARGING THE BATTERY

YU-03112-C EWA13290
WARNING
b. If the pocket tester indicates “ ”, replace the Batteries generate explosive hydrogen gas
fuse. and contain electrolyte which is made of poi-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ sonous and highly caustic sulfuric acid.
3. Replace: Therefore, always follow these preventive
• Fuse (blown fuse) measures:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Wear protective eye gear when handling or
a. Press the OFF/steering lock switch. working near batteries.
b. Install a new fuse of the correct amperage • Charge batteries in a well-ventilated area.
rating. • Keep batteries away from fire, sparks or
c. Set on the switches to verify if the electrical open flames (e.g., welding equipment,
circuit is operational. lighted cigarettes).
d. If the fuse immediately blows again, check • DO NOT SMOKE when charging or han-
the electrical circuit. dling batteries.
8-91
• KEEP BATTERIES AND ELECTROLYTE

OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it 1
can cause severe burns or permanent eye 2
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL 3. Remove:
• Drink large quantities of water or milk fol- • Battery
lowed with milk of magnesia, beaten egg or Refer to “GENERAL CHASSIS (3)” on page
vegetable oil. Get immediate medical atten- 4-13.
tion. 4. Check:
ECA13661 • Battery charge
NOTICE ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery termi-
• This is a VRLA (Valve Regulated Lead Acid)
nals.
battery. Never remove the sealing caps be-
cause the balance between cells will not be • Positive tester probe →
positive battery terminal
maintained and battery performance will • Negative tester probe →
deteriorate. negative battery terminal
• Charging time, charging amperage and
charging voltage for a VRLA (Valve Regu- TIP
lated Lead Acid) battery are different from • The charge state of a VRLA (Valve Regulated
those of conventional batteries. The VRLA Lead Acid) battery can be checked by measur-
(Valve Regulated Lead Acid) battery should ing its open-circuit voltage (i.e., the voltage
be charged according to the appropriate when the positive battery terminal is discon-
charging method. If the battery is over- nected).
charged, the electrolyte level will drop con- • No charging is necessary when the open-cir-
siderably. Therefore, take special care cuit voltage equals or exceeds 12.8 V.
when charging the battery.
b. Check the charge of the battery, as shown in
TIP the charts and the following example.
Since VRLA (Valve Regulated Lead Acid) bat- Example
teries are sealed, it is not possible to check the Open-circuit voltage = 12.0 V
charge state of the battery by measuring the Charging time = 6.5 hours
specific gravity of the electrolyte. Therefore, the Charge of the battery = 20–30%
charge of the battery has to be checked by mea-
suring the voltage at the battery terminals.
1. Remove:
• Inner panel cover (left side)
4-13.
2. Disconnect:
• Battery leads
(from the battery terminals)
ECA13640
NOTICE A. Open-circuit voltage (V)

First, disconnect the negative battery lead B. Charging time (hours)
“1”, and then positive battery lead “2”. C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
8-92
D. These values vary with the temperature, the • If the battery becomes hot to the touch at
condition of the battery plates, and the any time during the charging process, dis-
electrolyte level. connect the battery charger and let the bat-
tery cool before reconnecting it. Hot
batteries can explode!
• As shown in the following illustration, the
open-circuit voltage of a VRLA (Valve Reg-
ulated Lead Acid) battery stabilizes about
30 minutes after charging has been com-
pleted. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.
A. Open-circuit voltage (V)

B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Charge:
• Battery
(refer to the appropriate charging method)
EWA13300
WARNING
A. Open-circuit voltage (V)
Do not quick charge a battery. B. Time (minutes)
ECA13671
C. Charging
NOTICE D. Ambient temperature 20 °C (68 °F)
• Do not use a high-rate battery charger E. Check the open-circuit voltage.
since it forces a high-amperage current
into the battery quickly and can cause bat- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tery overheating and battery plate damage. Charging method using a variable-current
• If it is impossible to regulate the charging (voltage) charger
current on the battery charger, be careful a. Measure the open-circuit voltage prior to
not to overcharge the battery. charging.
• When charging a battery, be sure to remove TIP
it from the vehicle. (If charging has to be Voltage should be measured 30 minutes after
done with the battery mounted on the vehi- the engine is stopped.
cle, disconnect the negative battery lead
from the battery terminal.) b. Connect a charger and ammeter to the bat-
• To reduce the chance of sparks, do not tery and start charging.
plug in the battery charger until the battery TIP
charger leads are connected to the battery. Set the charging voltage to 16–17 V. If the set-
• Before removing the battery charger lead ting is lower, charging will be insufficient. If too
clips from the battery terminals, be sure to high, the battery will be over-charged.
turn off the battery charger.
c. Make sure that the current is higher than the
• Make sure the battery charger lead clips are
standard charging current written on the bat-
in full contact with the battery terminal and
tery.
that they are not shorted. A corroded bat-
TIP
tery charger lead clip may generate heat in
the contact area and a weak clip spring may If the current is lower than the standard charging
cause sparks. current written on the battery, set the charging
voltage adjust dial at 20–24 V and monitor the
amperage for 3–5 minutes to check the battery.
8-93
• Standard charging current is reached 12.8 V or more --- Charging is complete.

Battery is good. 12.7 V or less --- Recharging is required.
• Standard charging current is not reached Under 12.0 V --- Replace the battery.
Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
d. Adjust the voltage so that the current is at the 6. Install:
standard charging level. • Battery
e. Set the time according to the charging time Refer to “GENERAL CHASSIS (3)” on page
suitable for the open-circuit voltage. 4-13.
f. If charging requires more than 5 hours, it is 7. Connect:
advisable to check the charging current after • Battery leads
a lapse of 5 hours. If there is any change in (to the battery terminals)
the amperage, readjust the voltage to obtain ECA13630
the standard charging current. NOTICE

g. Measure the battery open-circuit voltage after First, connect the positive battery lead “1”,
leaving the battery unused for more than 30 and then the negative battery lead “2”.
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery. 2
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt-
age charger
a. Measure the open-circuit voltage prior to
charging.
8. Check:
TIP
• Battery terminals
Voltage should be measured 30 minutes after Dirt → Clean with a wire brush.
the engine is stopped. Loose connection → Connect properly.
b. Connect a charger and ammeter to the bat- 9. Lubricate:
tery and start charging. • Battery terminals
c. Make sure that the current is higher than the
standard charging current written on the bat- Recommended lubricant
Dielectric grease
tery.
TIP 10.Install:
If the current is lower than the standard charging • Inner panel cover (left side)
current written on the battery, this type of battery Refer to “GENERAL CHASSIS (3)” on page
charger cannot charge the VRLA (Valve Regu- 4-13.
lated Lead Acid) battery. A variable voltage
EAS30553
charger is recommended. CHECKING THE RELAYS
d. Charge the battery until the battery’s charg- Check each switch for continuity with the pocket
ing voltage is 15 V. tester. If the continuity reading is incorrect, re-
TIP place the relay.
Set the charging time at 20 hours (maximum). Pocket tester
e. Measure the battery open-circuit voltage after 90890-03112
leaving the battery unused for more than 30 Analog pocket tester
minutes. YU-03112-C
8-94
1. Disconnect the relay from the wire harness. Headlight relay

2. Connect the pocket tester (Ω × 1) and battery First step:
(12 V) to the relay terminal as shown.
Check the relay operation. 1
Out of specification → Replace. 3
Starting circuit cut-off relay 2
L/B Y/B Br
Y
Y/W
1. Positive tester probe

G/B G/W
2. Negative tester probe
L/W
R/G
Result
1. Positive battery terminal Continuity
2. Negative battery terminal (between “1” and “2”)
3. Positive tester probe No continuity
4. Negative tester probe (between “1” and “3”)
Result Second step:

Continuity 3
(between “3” and “4”)
5 +
4
Starter relay
2 1
L/B Y/B Br
Y
Y/W
B 1. Positive battery terminal

2. Negative battery terminal
1 2 3. Positive tester probe
1. Positive battery terminal
Result
3. Positive tester probe Continuity
4. Negative tester probe (between “3” and “5”)
No continuity
Result (between “3” and “4”)
Continuity
8-95
Radiator fan motor relay 2. Negative battery terminal

Result
Continuity
Turn signal/hazard relay 1

Br R/G
Result L/R
Continuity R/G
Fuel injection system relay 2. Negative battery terminal
Result
Continuity
Steering lock relay

B G/Y
Result R
Continuity R/G
Sidestand relay 2. Negative battery terminal
Result
Continuity
Lg L/Y
G/Y
G/W
8-96
Seat open relay ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay 2 terminal as shown.
Pocket tester
90890-03112
YU-03112-C
G R/G
L
R/G
• Positive tester probe →
Blue/Red “1”
• Negative tester probe →
1. Positive battery terminal Ground
Result
Continuity
(between “3” and “4”) L/R
Smart key system relay
b. Press the ON/start switch “ ”.

c. Measure the turn signal/hazard relay 2 input
voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
L/Y R
• Turn signal/hazard relay 2 output voltage
Br/L
R
Turn signal/hazard relay 2 output

1. Positive battery terminal voltage
2. Negative battery terminal DC 12 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4. Negative tester probe a. Connect the pocket tester (DC 20 V) to the
turn signal/hazard relay 2 terminal as shown.
Result
Continuity Pocket tester
(between “3” and “4”) 90890-03112
EAS31169 YU-03112-C
CHECKING THE TURN SIGNAL/HAZARD
RELAY 2 • Positive tester probe →
1. Check: Brown/White “1”
• Turn signal/hazard relay 2 input voltage • Negative tester probe →
Ground
Out of specification → The wiring circuit from
the starter relay coupler to the turn sig-
nal/hazard relay 2 coupler is faulty and must
be repaired.
Turn signal/hazard relay 2 input

voltage
DC 12 V
8-97
A
1
L/Y
R/B
L/R
b. Press the ON/start switch “ ”.

c. Measure the turn signal/hazard relay 2 output B
voltage. 3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30555
L/R
CHECKING THE DIODES
L
1. Check:
• Diodes
Out of specification → Replace. 4
Pocket tester
A. Diode 2
90890-03112
Analog pocket tester B. Diode 3
YU-03112-C ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the diode from the wire harness.
TIP b. Connect the pocket tester (Ω × 1) to the diode
The pocket tester or the analog pocket tester terminals as shown.
reading are shown in the following table. c. Check the diode for continuity.
d. Check the diode for no continuity.
Diode 2 TIP
Continuity When you switch the positive and negative
Positive tester probe → tester probes, the readings in the above chart
Blue/Yellow “1” will be reversed.
Negative tester probe →
Red/Black “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
No continuity EAS30557
Positive tester probe → CHECKING THE SPARK PLUG CAPS

Red/Black “2” The following procedure applies to all of the
Negative tester probe → spark plug caps.
Blue/Yellow “1” 1. Check:
Diode 3 • Spark plug cap resistance
Continuity Out of specification → Replace.
Positive tester probe →
Blue/Red “3” Resistance
Negative tester probe → 7.50–12.50 kΩ
Blue “4”
No continuity ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Positive tester probe → a. Remove the spark plug cap from the spark
Blue “4” plug lead.
Negative tester probe → b. Connect the pocket tester (Ω × 1k) to the
Blue/Red “3” spark plug cap as shown.
8-98
2. Check:
Pocket tester • Secondary coil resistance
90890-03112 Out of specification → Replace.
YU-03112-C Secondary coil resistance
12.00–18.00 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
Pocket tester
90890-03112
YU-03112-C
c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30558 Spark plug lead “1”
CHECKING THE IGNITION COIL • Negative tester probe →
1. Check: Spark plug lead “2”
• Primary coil resistance
Primary coil resistance

1.87–2.53 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the igni-
tion coil as shown.
c. Measure the secondary coil resistance.
Pocket tester
90890-03112 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Analog pocket tester EAS30556
YU-03112-C CHECKING THE IGNITION SPARK GAP

1. Check:
• Positive tester probe→ • Ignition spark gap
Orange “1” Out of specification → Perform the ignition
• Negative tester probe → system troubleshooting, starting with step 5.
Red/Black “2” Refer to “TROUBLESHOOTING” on page
8-3.
Minimum ignition spark gap

6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the spark
c. Measure the primary coil resistance. plug.
b. Connect the ignition checker “1” as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-99
E L E C T R IC A L C O M P O N E N T S
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487
c. Push the ON/start switch “ ” and the en-

gine stop switch to “ ”.
d. Measure the ignition spark gap “a”.
b. Measure the crankshaft position sensor re-

sistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30561
CHECKING THE LEAN ANGLE SENSOR

1. Remove:
• Lean angle sensor
(from the bracket.)
2. Check:
2. Spark plug cap
• Lean angle sensor output voltage
e. Crank the engine by pushing the ON/start Out of specification → Replace.
switch “ ” and gradually increase the
spark gap until a misfire occurs. Lean angle sensor output voltage
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Less than 65°
0.4–1.4 V
EAS30560
More than 65°
CHECKING THE CRANKSHAFT POSITION
3.7–4.4 V
SENSOR
1. Disconnect: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Crankshaft position sensor coupler a. Connect the test harness– lean angle sensor
(from the wire harness) (6P) “1” to the lean angle sensor and wire
2. Check: harness as shown.
• Crankshaft position sensor resistance b. Connect the pocket tester (DC 20 V) to the
Out of specification → Replace the crank- test harness– lean angle sensor (6P).
shaft position sensor/stator assembly.
Pocket tester
Crankshaft position sensor resis- 90890-03112
tance Analog pocket tester
284–372 Ω YU-03112-C
Test harness– lean angle sensor
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ (6P)
a. Connect the pocket tester (Ω × 100) to the 90890-03209
crankshaft position sensor coupler as shown. Test harness– lean angle sensor
(6P)
Pocket tester YU-03209
90890-03112
Analog pocket tester • Positive tester probe →
YU-03112-C Yellow/Green (wire harness color)
• Positive tester probe → Black/Blue (wire harness color)
Gray “1”
Black “2”
8-100
EAS30566
CHECKING THE STATOR COIL

1. Disconnect:
65 • Stator coil coupler
65 (from the wire harness)
2. Check:
• Stator coil resistance
Out of specification → Replace the stator coil.
Stator coil resistance

0.224–0.336 Ω (W-W)
c. Push the ON/start switch “ ”.
d. When turn the lean angle sensor to 65°. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
e. Measure the lean angle sensor output volt- a. Connect the digital circuit tester (CD–731a)
age. (Ω × 1) to the stator coil coupler as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Digital circuit tester (CD–731a)
EAS30562
90890-03189
CHECKING THE STARTER MOTOR Model 88 Multimeter with ta-
OPERATION chometer
1. Check: YU-A1927
• Starter motor operation
Does not operate → Perform the electric • Positive tester probe →
starting system troubleshooting, starting with White “1”
step 4. • Negative tester probe →
Refer to “TROUBLESHOOTING” on page White “2”
8-9.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1” and White “1”
starter motor lead “2” with a jumper lead “3”. White “3”
EWA13810
WARNING
• A wire that is used as a jumper lead must White “2”
have at least the same capacity of the bat- • Negative tester probe →
tery lead, otherwise the jumper lead may White “3”
burn.
• This check is likely to produce sparks,
therefore, make sure no flammable gas or
fluid is in the vicinity.
b. Measure the stator coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30680
CHECKING THE RECTIFIER/REGULATOR

b. Check the starter motor operation. 1. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Battery charging voltage
Out of specification → Check the stator coil
condition. If the stator coil does not have a
problem, replace the rectifier/regulator.
8-101
Refer to “CHECKING THE STATOR COIL”

on page 8-101. Pocket tester
90890-03112
Battery charging voltage Analog pocket tester
above 14 V at 5000 r/min YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe →

a. Connect the pocket tester (AC 20 V) to the Green “1”
battery terminal as shown. • Negative tester probe →
Black “2”
Pocket tester
90890-03112
YU-03112-C

Battery positive terminal “1”
Battery negative terminal “2”
2 b. Move the fuel sender float to empty fuel tank

position “3” and full fuel tank position “4” level
1
position.
b. Start the engine and let it run at approximate-

ly 5000 r/min.
c. Measure the rectifier/regulator input voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3
EAS30573
CHECKING THE FUEL SENDER c. Measure the fuel sender resistance.

1. Remove: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuel pump 3. Install:
(from the fuel tank) • Fuel pump
Refer to “FUEL TANK” on page 7-1. Refer to “FUEL TANK” on page 7-1.
2. Check: EAS31557
• Fuel sender resistance CHECKING THE FUEL METER/FUEL LEVEL
Out of specification → Replace the fuel WARNING INDICATOR
pump. This model is equipped with a self-diagnosis de-
vice for the fuel level detection circuit.
Sender unit resistance (full) 1. Check:
4.0–10.0 Ω
• Fuel meter/fuel level warning indicator “1”
Sender unit resistance (empty)
93.0–100.0 Ω (Push the ON/start switch “ ”.)
Fuel meter/fuel level warning indicator comes
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ on for a few seconds, then goes off → Fuel
a. Connect the pocket tester (Ω × 1) to the fuel meter/fuel level warning indicator is OK.
pump terminals as shown. Fuel meter/fuel level warning indicator does
not come on → Replace the meter assembly.
8-102
Fuel meter/fuel level warning indicator flash- c. Push the ON/start switch “ ”.
es eight times, then goes off for 3 seconds in d. Elevate the front wheel and slowly rotate it.
a repeated cycle (malfunction detected in fuel e. Measure the voltage of White and
sender) → Replace the fuel pump assembly. Black/Blue. With each full rotation of the front
wheel, the voltage reading should cycle from
0.6 V to 4.8 V to 0.6 V to 4.8 V.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS30577
CHECKING THE RADIATOR FAN MOTOR

1. Check:
• Radiator fan motor
Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Disconnect the radiator fan motor coupler
EAS30576
from the wire harness.
CHECKING THE SPEED SENSOR b. Connect the battery (DC 12 V) as shown.
1. Check: • Positive battery terminal →
• Speed sensor output voltage Blue “1”
Out of specification → Replace. • Negative battery terminal →
Black “2”
Output voltage reading cycle
0.6 V to 4.8 V to 0.6 V to 4.8 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the test harness– speed sensor (3P)
“1” to the speed sensor and wire harness as
shown.
b. Connect the pocket tester (DC 20 V) to the
speed sensor coupler (wire harness side) as
shown.
Pocket tester c. Measure the radiator fan motor movement.

90890-03112
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YU-03112-C EAS30578
Test harness– speed sensor (3P) CHECKING THE COOLANT TEMPERATURE

90890-03208 SENSOR
Test harness– speed sensor (3P) 1. Remove:
YU-03208 • Coolant temperature sensor
Refer to “THERMOSTAT” on page 6-8.
EWA14130
• Positive tester probe
White (wire harness color) WARNING
• Negative tester probe • Handle the coolant temperature sensor
Black/Blue (wire harness color) with special care.
• Never subject the coolant temperature sen-
sor to strong shocks. If the coolant temper-
ature sensor is dropped, replace it.
1 2. Check:
• Coolant temperature sensor resistance
8-103
Coolant temperature sensor re- Coolant temperature sensor

sistance 18 Nm (1.8 m·kgf, 13 ft·lbf)
T.
R.
2320–2590 Ω@20 °C (2320–2590
Ω@68 °F) EAS30581
Coolant temperature sensor re- CHECKING THE THROTTLE POSITION

sistance SENSOR
310–329 Ω@80 °C (310–329 1. Remove:
Ω@176 °F) • Throttle position sensor
(from the throttle body)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check:
a. Connect the pocket tester (Ω × 100/ × 1k) to
the coolant temperature sensor terminals as
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
shown. a. Connect the pocket tester (Ω × 1 k) to the
throttle position sensor as shown.
Pocket tester
90890-03112 Pocket tester
Analog pocket tester 90890-03112
YU-03112-C Analog pocket tester
YU-03112-C
b. Immerse the coolant temperature sensor “1”
in a container filled with coolant “2”.
TIP Blue “1”
Make sure the coolant temperature sensor ter- • Negative tester probe →
minals do not get wet. Black/Blue “2”
c. Place a thermometer “3” in the coolant. b. Measure the throttle position sensor maxi-
mum resistance.
Out of specification → Replace the throttle
position sensor.
Throttle position sensor maxi-

mum resistance
2.64–6.16 kΩ
c. Connect the pocket tester (Ω × 1 k) to the

throttle position sensor as shown.
Yellow “3”
Black/Blue “2”
d. Heat the coolant or let it cool down to the

specified temperature.
e. Measure the coolant temperature sensor re-
sistance. d. While slowly turning the throttle position sen-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sor shaft, check that the throttle position sen-
3. Install: sor resistance is within the specified range.
• Coolant temperature sensor
8-104
The resistance does not change or it changes • Positive tester probe →

abruptly → Replace the throttle position sen- Pink/White (wire harness color)
sor. • Negative tester probe →
Black/Blue (wire harness color)
Resistance
0–6.16 kΩ
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
TIP
When installing the throttle position sensor, ad-
just its angle properly. Refer to “ADJUSTING
THE THROTTLE POSITION SENSOR” on page 1
7-10. c. Push the ON/start switch “ ”.
d. Measure the intake air pressure sensor out-
EAS30593
put voltage.
CHECKING THE INTAKE AIR PRESSURE
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
SENSOR
1. Check: EAS30594
• Intake air pressure sensor output voltage CHECKING THE INTAKE AIR
Out of specification → Replace. TEMPERATURE SENSOR
1. Remove:
Intake air pressure sensor output • Intake air temperature sensor
voltage (from the air filter case.)
3.57–3.71 [email protected] kPa (3.57– EWA14110
3.71 [email protected] kgf/cm², 3.57–3.71 WARNING

[email protected] psi) • Handle the intake air temperature sensor
with special care.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Never subject the intake air temperature
a. Connect the test harness S– pressure sensor sensor to strong shocks. If the intake air
(CD–731a) “1” to the intake air pressure sen- temperature sensor is dropped, replace it.
sor and wire harness as shown.
ECA20040 2. Check:
NOTICE • Intake air temperature sensor resistance
Pay attention to the installing direction of the Out of specification → Replace.
test harness S-pressure sensor (3P) coupler
“a”. Intake air temperature sensor re-
sistance
b. Connect the digital circuit tester (CD–731a) 5400–6600 Ω@0 °C (5400–6600
to the test harness S– pressure sensor (3P). Ω@32 °F)
Intake air temperature sensor re-
Digital circuit tester (CD–731a) sistance
90890-03189 290–390 Ω@80 °C (290–390
Model 88 Multimeter with ta- Ω@176 °F)
chometer
YU-A1927 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Test harness S– pressure sensor a. Connect the pocket tester (Ω × 1k/ × 100) to
(3P) the intake air temperature sensor terminal as
90890-03207 shown.
Test harness S– pressure sensor
(3P) Pocket tester
YU-03207 90890-03112
YU-03112-C
8-105
b. Immerse the intake air temperature sensor

“1” in a container filled with water “2”.
TIP
Make sure that the intake air temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the water.
c. Measure the fuel injector resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31553
CHECKING THE SMART KEY BATTERY

1. Check:
• Smart key battery voltage
Out of specification → Replace the smart key
d. Heat the water or let it cool down to the spec- battery.
ified temperatures.
e. Measure the intake air temperature sensor Smart key battery voltage
2.7–3.2 V
resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Install: a. Remove the smart key battery from the smart
• Intake air temperature sensor key.
b. Connect the pocket tester (DC 20 V) to the
Intake air temperature sensor smart key battery as shown.
bolt
T.
R.
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) Pocket tester

90890-03112
EAS30681 Analog pocket tester
CHECKING THE FUEL INJECTOR YU-03112-C
1. Check:
• Fuel injector resistance • Positive tester probe →
Out of specification → Replace the fuel injec- positive battery terminal “1”
tor. • Negative tester probe →
negative battery terminal “2”
Resistance
12.0 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the fuel injector coupler from wire 1
harness.
b. Connect the pocket tester (Ω × 1) to the fuel
injector coupler. 2
Pocket tester
90890-03112
c. Measure the smart key battery voltage.
YU-03112-C
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Injector terminal “1”
Injector terminal “2”
8-106
EAS31554
CHECKING THE SEAT LOCK SOLENOID

1. Check: 2 1
• Seat lock solenoid resistance P Y
Out of specification → Replace the seat lock
assembly.
Seat lock solenoid resistance

2.85–3.15 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the seat lock solenoid coupler c. Check that the buzzer sounds.
from the wire harness. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. Connect the pocket tester (Ω 10) to the seat
lock solenoid terminals as shown.
Pocket tester
90890-03112
YU-03112-C

Yellow “1”
Yellow “2”
2 1
Y Y
c. Measure the seat lock solenoid resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS31555
CHECKING THE BUZZER

1. Check:
• Buzzer operation
Buzzer does not sound → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the buzzer coupler from the wire
harness.
b. Connect the battery (12 V) to the buzzer cou-
pler as shown.
• Positive battery lead →
Yellow “1”
• Negative battery lead →
Pink “2”
8-107
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................9-1
GENERAL INFORMATION ....................................................................... 9-1
STARTING FAILURE/HARD STARTING.................................................. 9-1
INCORRECT ENGINE IDLING SPEED .................................................... 9-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................... 9-2
FAULTY CLUTCH .....................................................................................9-2
OVERHEATING ........................................................................................9-2
OVERCOOLING........................................................................................9-3
POOR BRAKING PERFORMANCE.......................................................... 9-3
FAULTY FRONT FORK LEGS..................................................................9-3
UNSTABLE HANDLING ............................................................................9-3
FAULTY LIGHTING OR SIGNALING SYSTEM ........................................ 9-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE............9-5

SELF-DIAGNOSTIC FUNCTION TABLE .................................................. 9-5
COMMUNICATION ERROR WITH THE METER OR
YAMAHA DIAGNOSTIC TOOL ................................................................9-5
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ............................. 9-6
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ........................9-8
9
TROUBLESHOOTING
EAS20090
3. Throttle body
TROUBLESHOOTING • Deteriorated or contaminated fuel
EAS30599
• Sucked-in air
GENERAL INFORMATION
TIP
Electrical system
1. Battery
The following guide for troubleshooting does not
• Discharged battery
cover all the possible causes of trouble. It should
• Faulty battery
be helpful, however, as a guide to basic trouble-
2. Fuse(s)
shooting. Refer to the relative procedure in this
• Blown, damaged or incorrect fuse
manual for checks, adjustments, and replace-
• Improperly installed fuse
ment of parts.
3. Spark plug(s)
• Incorrect spark plug gap
EAS31258
STARTING FAILURE/HARD STARTING • Incorrect spark plug heat range

• Fouled spark plug
Engine • Worn or damaged electrode
1. Cylinder(s) and cylinder head • Worn or damaged insulator
• Loose spark plug • Faulty spark plug cap
• Loose cylinder head or cylinder 4. Ignition coil
• Damaged cylinder head gasket • Cracked or broken ignition coil body
• Damaged cylinder gasket • Broken or shorted primary or secondary coils
• Worn or damaged cylinder • Faulty spark plug lead
• Incorrect valve clearance 5. Ignition system
• Improperly sealed valve • Faulty ECU (engine control unit)
• Incorrect valve-to-valve-seat contact • Faulty crankshaft position sensor
• Incorrect valve timing • Broken generator rotor woodruff key
• Faulty valve spring 6. Switches and wiring
• Seized valve • Faulty control switch assembly
2. Piston(s) and piston ring(s) • Faulty engine stop switch
• Improperly installed piston ring • Broken or shorted wiring
• Damaged, worn or fatigued piston ring • Faulty front, rear or both brake light switches
• Seized piston ring • Faulty ON/start switch
• Seized or damaged piston • Faulty sidestand switch
3. Air filter • Improperly grounded circuit
• Improperly installed air filter • Loose connections
• Clogged air filter element 7. Starting system
4. Crankcase and crankshaft • Faulty starter motor
• Improperly assembled crankcase • Faulty starter relay
• Seized crankshaft • Faulty starting circuit cut-off relay
• Faulty starter clutch
Fuel system EAS30601
1. Fuel tank INCORRECT ENGINE IDLING SPEED
• Empty fuel tank
• Clogged rollover valve Engine
• Clogged fuel tank breather hose 1. Cylinder(s) and cylinder head
• Deteriorated or contaminated fuel • Incorrect valve clearance
• Clogged or damaged fuel hose • Damaged valve train components
2. Fuel pump 2. Air filter
• Faulty fuel pump • Clogged air filter element
• Faulty fuel injection system relay
• Damaged vacuum hose Fuel system
• Improperly routed hose 1. Throttle body
• Damaged or loose throttle body joint
9-1
TROUBLESHOOTING
• Improperly synchronized throttle body 4. Transmission gear(s)

• Improperly adjusted engine idling speed (idle • Damaged transmission gear
adjusting screw)
• Improper throttle grip free play Clutch slips
• Flooded throttle body 1. Clutch
• Improperly assembled clutch
Electrical system • Fatigued clutch spring
1. Battery • Worn clutch weight
• Discharged battery • Worn friction plate
• Faulty battery • Worn clutch plate
2. Spark plug(s) 2. Engine oil
• Incorrect spark plug gap • Incorrect oil level
• Incorrect spark plug heat range • Incorrect oil viscosity (low)
• Fouled spark plug • Deteriorated oil
• Worn or damaged electrode 3. Primary sliding sheave
• Worn or damaged insulator • Seized primary sliding sheave
• Faulty spark plug cap
3. Ignition coil Poor starting performance
• Broken or shorted primary or secondary coils 1. V-belt
• Faulty spark plug lead • V-belt slips
• Cracked or broken ignition coil • Oil or grease on the V-belt
4. Ignition system 2. Primary sliding sheave
• Faulty ECU (engine control unit) • Faulty operation
• Faulty crankshaft position sensor • Worn pin groove
• Broken generator rotor woodruff key • Worn pin
EAS30602
Poor speed performance
POOR MEDIUM-AND-HIGH-SPEED
1. V-belt
PERFORMANCE
• Oil or grease on the V-belt
Refer to “STARTING FAILURE/HARD START-
2. Primary pulley weight(s)
ING” on page 9-1.
• Faulty operation
Engine • Worn primary pulley weight
1. Air filter 3. Primary fixed sheave
• Clogged air filter element • Worn primary fixed sheave
4. Primary sliding sheave
Fuel system • Worn primary sliding sheave
1. Throttle body 5. Secondary fixed sheave
• Faulty throttle body • Worn secondary fixed sheave
2. Fuel pump 6. Secondary sliding sheave
• Faulty fuel pump • Worn secondary sliding sheave
EAS30607
EAS30849
FAULTY CLUTCH OVERHEATING
Engine operates but scooter will not move Engine

1. V-belt 1. Clogged coolant passages
• Bent, damaged or worn V-belt • Cylinder head and piston(s)
• Slipping V-belt • Heavy carbon buildup
2. Primary pulley cam and primary pulley slider 2. Engine oil
• Damaged or worn primary pulley cam • Incorrect oil level
• Damaged or worn primary pulley slider • Incorrect oil viscosity
3. Clutch spring(s) • Inferior oil quality
• Damaged clutch spring
9-2
TROUBLESHOOTING
Cooling system • Incorrect brake fluid level

1. Coolant
EAS30610
• Low coolant level FAULTY FRONT FORK LEGS
2. Radiator
• Damaged or leaking radiator Leaking oil
• Faulty radiator cap • Bent, damaged or rusty inner tube
• Bent or damaged radiator fin • Cracked or damaged outer tube
3. Water pump • Improperly installed oil seal
• Damaged or faulty water pump • Damaged oil seal lip
4. Thermostat • Incorrect oil level (high)
• Thermostat stays closed • Loose damper rod bolt
5. Oil cooler • Damaged damper rod bolt copper washer
• Clogged or damaged oil cooler • Cracked or damaged cap bolt O-ring
6. Hose(s) and pipe(s)
• Damaged hose Malfunction
• Improperly connected hose • Bent or damaged inner tube
• Damaged pipe • Bent or damaged outer tube
• Improperly connected pipe • Damaged fork spring
• Worn or damaged outer tube bushing
Fuel system • Bent or damaged damper rod
1. Throttle body • Incorrect oil viscosity
• Damaged or loose throttle body joint • Incorrect oil level
2. Air filter
• Clogged air filter element EAS30611
UNSTABLE HANDLING
Chassis 1. Handlebar
1. Brake(s) • Bent or improperly installed handlebar
• Dragging brake 2. Steering head components
• Improperly installed upper bracket
Electrical system • Improperly installed lower bracket
1. Spark plug(s) (improperly tightened ring nut)
• Incorrect spark plug gap • Bent steering stem
• Incorrect spark plug heat range • Damaged ball bearing or bearing race
2. Ignition system 3. Front fork leg(s)
• Faulty ECU • Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
EAS30608
fork legs)
OVERCOOLING • Broken fork spring
• Bent or damaged inner tube
Cooling system
• Bent or damaged outer tube
1. Thermostat
4. Swingarm
• Thermostat stays open
• Worn bearing or bushing
EAS30609 • Bent or damaged swingarm
POOR BRAKING PERFORMANCE 5. Rear shock absorber assembly
• Worn brake pad • Faulty rear shock absorber spring
• Worn brake disc • Leaking oil or gas
• Air in hydraulic brake system 6. Tire(s)
• Leaking brake fluid • Uneven tire pressures (front and rear)
• Faulty brake caliper kit • Incorrect tire pressure
• Faulty brake caliper seal • Uneven tire wear
• Loose union bolt 7. Wheel(s)
• Damaged brake hose • Incorrect wheel balance
• Oil or grease on the brake disc • Deformed cast wheel
• Oil or grease on the brake pad • Damaged wheel bearing
9-3
TROUBLESHOOTING
• Bent or loose wheel axle Horn does not sound

• Excessive wheel runout • Improperly adjusted horn
8. Frame • Damaged or faulty horn
• Bent frame • Faulty smart key unit
• Damaged steering head pipe • Faulty horn switch
• Improperly installed bearing race • Faulty battery
EAS30612
FAULTY LIGHTING OR SIGNALING SYSTEM • Faulty wire harness
Headlight does not come on

• Faulty headlight assembly
• Too many electrical accessories
• Hard charging
• Incorrect connection
• Improperly grounded circuit
• Poor contacts (dimmer switch)
• Faulty headlight relay
• Faulty smart key system relay
• Faulty smart key unit
Tail/brake light does not come on

• Faulty brake light switch
• Too many electrical accessories
• Faulty tail/brake light
• Faulty smart key system relay
Turn signal does not come on

• Faulty turn signal switch
• Faulty turn signal/hazard relay
• Burnt-out turn signal bulb
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
Turn signal blinks slowly

• Faulty turn signal switch
• Incorrect turn signal bulb
Turn signal remains lit

Turn signal blinks quickly

• Incorrect turn signal bulb
9-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20116

EAS31118
SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-33.
Fault code
Item
No.
Crankshaft position sensor: no normal signals are received from the crankshaft position sen-
12
sor.
13 Intake air pressure sensor: open or short circuit detected.
14 Intake air pressure sensor: hose system malfunction (clogged or detached hose).
15 Throttle position sensor: open or short circuit detected.
Throttle position sensor: stuck throttle position sensor is detected. (Signal from throttle position
16
sensor will not change.)
19 Sidestand switch: a break or disconnection of the light green lead of the ECU is detected.
21 Coolant temperature sensor: open or short circuit detected.
22 Intake air temperature sensor: open or short circuit detected.
24 O2 sensor: no normal signals are received from the O2 sensor.
30 Latch up detected.
33 Ignition coil: open or short circuit detected.
37 Fast idle plunger: engine speed is high when the engine is idling.
41 Lean angle sensor: open or short circuit detected.
42 Speed sensor: no normal signals are received from the speed sensor.
Fuel system voltage: incorrect voltage supplied to the fuel injection system relay, fuel injector
43
and fuel pump.
44 EEPROM fault code number: an error is detected while reading or writing on EEPROM.
46 Charging voltage is abnormal.
Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number
50
might not appear.)
70 Engine idling stop
EAS31373
COMMUNICATION ERROR WITH THE METER OR YAMAHA DIAGNOSTIC TOOL

TIP
For details of the fault code, refer to “TROUBLESHOOTING METHOD” on page 8-33.
Fault code No. Item

ECU (engine control unit) internal malfunction (output signal error): sig-
Er-1 (fault code display) nals cannot be transmitted between the ECU and the multi-function
meter.
ECU (engine control unit) internal malfunction (output signal error): no
Er-2
signals are received from the ECU within the specified duration.
ECU (engine control unit) internal malfunction (output signal error): data
Er-3
from the ECU cannot be received correctly.
ECU (engine control unit) internal malfunction (input signal error): non-
Er-4 (fault code display)
registered data has been received from the meter.
9-5
EAS31120
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Display Procedure
code No.
01 Throttle position sensor sig-
nal
• Fully closed position 14–20 Check with throttle valves
fully closed.
• Fully open position 97–107 Check with throttle valves
fully open.
03 Intake air pressure Displays the intake air pres- Set the engine stop switch to
sure. “ ”, and then operate the
throttle while pushing the
ON/start switch “ ”. (If
the display value changes,
the performance is OK.)
05 Air temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured air temperature with
air temperature. the meter display value.
When engine is hot: Air tem-
perature + approx. 20 °C (68
°F)
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
air temperature. with the meter display value.
When engine is hot: Displays
current coolant temperature.
07 Speed sensor pulses Speed sensor pulse Check that the number in-
0–999 creases when the front
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
08 Lean angle sensor Lean angle sensor output Remove the lean angle sen-
voltage sor and incline it more than
65 degrees.
• Upright 0.4–1.4
• Overturned 3.7–4.4
09 Fuel system voltage Approximately 12.0 Set the engine stop switch to
(battery voltage) “ ”, and then compare the
actually measured battery
voltage with the display val-
ue. (If the actually measured
battery voltage is low, re-
charge the battery.)
20 Sidestand switch Extend and retract the side-
stand.
• Stand retracted ON
• Stand extended OFF
9-6
Diagnostic
Item Display Procedure
code No.
60 EEPROM fault code display
• No history 00 —
• No malfunctions detected
• History exists 01–02 (Cylinder fault code) —
• (If more than one cylinder
is defective, the display al-
ternates every two seconds
to show all the detected
cylinder numbers.
When all cylinder numbers
are shown, the display re-
peats the same process.)
61 Malfunction history code dis-
play
• History exists Fault codes 12–70 —
• (If more than one code
number is detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code era-
sure
• History exists • Displays the total number Save the malfunction history
of malfunctions, including to the computer, and then
the current malfunction, delete the fault codes.
that have occurred since
the history was last erased.
(For example, if there have
been three malfunctions,
“03” is displayed.)
63 Malfunction code reinstate-
ment (for fault code No. 24
only)
• No malfunction code 00 —
• Malfunction code exists Fault code 24 Save the malfunction history
to the computer, and then
delete the fault codes.
70 Control number 0–254 [-] —
9-7
EAS31121
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil five Check that a spark is gener-
times at one-second inter- ated five times.
vals. • Connect an ignition check-
The “CHECK” indicator and er.
“ ” on the Yamaha diag-
nostic tool screen come on
each time the ignition coil is
actuated.
36 Fuel injector #1 Actuates fuel injector #1 five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that fuel injector #1 is
The “CHECK” indicator and actuated five times by listen-
“ ” on the Yamaha diag- ing for the operating sound.
each time the fuel injector is
actuated.
37 Fuel injector #2 Actuates fuel injector #2 five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that fuel injector #2 is
The “CHECK” indicator and actuated five times by listen-
“ ” on the Yamaha diag- ing for the operating sound.
each time the fuel injector is
actuated.
50 Fuel injection system relay Actuates the fuel injection Check that the fuel injection
system relay five times at system relay is actuated five
one-second intervals. times by listening for the op-
The “CHECK” indicator and erating sound.
each time the fuel pump is
actuated.
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
second intervals. times by listening for the op-
The “CHECK” indicator and erating sound.
each time the relay is actuat-
ed.
52 Headlight relay Actuates the headlight relay Check that the headlight re-
five times at five-second in- lay is actuated five times by
tervals. listening for the operating
The “CHECK” indicator and sound.
each time the relay is actuat-
ed.
9-8
EAS20091
58. Dimmer switch EAS30613
WIRING DIAGRAM 59. Horn switch COLOR CODE

XP500F 2015 60. Turn signal switch B Black
1. Smart key unit 61. Rear brake light switch Br Brown
2. Buzzer 62. Horn Ch Chocolate
3. Steering lock relay 63. Headlight relay Dg Dark green
4. Steering lock unit 64. Turn signal/hazard relay 2 G Green
5. Seat open relay 65. Diode 3 Gy Gray
66. Auxiliary light L Blue
67. Front turn signal/position light Lg Light green
O Orange
8. Turn signal/hazard relay 1 (left)
P Pink
9. Crankshaft position sensor 68. Front turn signal/position light
R Red
10. AC magneto (right)
W White
11. Rectifier/regulator 69. Rear turn signal light (left) Y Yellow
12. Smart key system relay 70. Rear turn signal light (right) B/G Black/Green
13. Signaling system fuse 71. Headlight control unit B/L Black/Blue
14. Ignition fuse 72. Headlight (low) B/W Black/White
15. Parking lighting fuse 73. Headlight (high) B/Y Black/Yellow
16. Radiator fan motor fuse 74. Diode 4 Br/B Brown/Black
17. Fuel injection system fuse 75. Headlight fuse Br/G Brown/Green
18. Backup fuse 76. Auxiliary DC jack fuse Br/L Brown/Blue
19. Joint coupler 77. Auxiliary DC jack Br/R Brown/Red
20. Battery 78. Storage box light Br/W Brown/White
21. Engine ground 79. Storage box light switch G/B Green/Black
22. Main fuse 80. Meter assembly G/L Green/Blue
23. Starter relay 81. Smart key indicator light G/R Green/Red
24. Starter motor 82. Turn signal indicator light (left) G/W Green/White
25. Diode 1 83. Turn signal indicator light (right) G/Y Green/Yellow
26. Starting circuit cut-off relay 84. High beam indicator light Gy/G Gray/Green
27. Sidestand relay 85. Speedometer L/B Blue/Black
86. Tachometer L/G Blue/Green
28. Diode 2
87. Engine trouble warning light L/R Blue/Red
29. Fuel injection system relay
L/W Blue/White
30. Sidestand switch 88. Multi-function meter
L/Y Blue/Yellow
31. Handlebar switch (right) 89. Meter light
P/W Pink/White
32. Engine stop switch 90. Anti-theft alarm (option)
R/B Red/Black
33. ON/start switch A. Wire harness R/G Red/Green
34. Hazard switch B. Negative battery sub-wire har- R/L Red/Blue
35. Front brake light switch ness R/W Red/White
36. ECU (engine control unit) C. Throttle position sensor sub- R/Y Red/Yellow
37. Ignition coil lead W/Y White/Yellow
38. Spark plug D. Head light harness Y/B Yellow/Black
39. Coolant temperature sensor Y/G Yellow/Green
40. Intake air temperature sensor Y/L Yellow/Blue
41. Yamaha diagnostic tool coupler Y/R Yellow/Red
42. Intake air pressure sensor Y/W Yellow/White
43. Throttle position sensor
44. Lean angle sensor
45. Speed sensor
48. O2 sensor
49. Fuel pump
50. Fuel sender
51. Radiator fan motor relay
52. Radiator fan motor
53. License plate light
54. Tail/brake light assembly
55. Tail/brake light
56. Handlebar switch (left)
57. Pass switch
XP500F 2015 WIRING DIAGRAM
Lg L/G Br/W R/B G/L L/R Br/L W/Y G/B 19 B/W B/W B/W B/L B/L B/L B/L B/L
G G/Y L/W Y/L B L R/G L/Y Br

B/W B/W B/W
B/W B/W B/W
R/G R/G
G/B R/G R/B
R/G P Y
R/G R/G B/Y B/L
(B) Gy B
(B) R/G
R/B R/B P 2 Y R/G
B B/Y
Gy B/L
G G L L 9 R/G
G/W G/W L/Y R/B R/B R/B
G/Y Y
R L/Y R/B R/B 37 G/R B/L
R/G R/G 5 6 10
W
W 11
R
R
R
R 26 R/G 28 R R/B
R/B
G/Y L W B R L/W 27 G/W
(Dg)
L/W
3 R/G
R/G G Y Y
Y
W W W R R
L/W
G/W G/B G/Y
L/Y
29
O
38 B/L G/R
Br/W R
B R
B
20 22 19 L/W L/W L/W L/Y Lg
R/B R
39
G/Y B B B R/L B/L
R/G L B W W W L/W L/W
W W W G/B R/B L/Y G/R
R/G RB B G/Y Lg
L/W L/W L/W G/B
R B R
R R
R 23 R/L L/Y L/Y
B/Y 40 Br/W B/L
1 L/W
Br/W L/W 4 B R R B RR
B A B B
B
B
L/W L/W
B/L Br/W (B)
R B Lg Br/W
12 Br/L
24 R R
L/W
Lg Lg
P/W P/W
B/L
B
R/G
R/G
R L/Y 21 B L/W
25 B
Lg
B/W L
42 B/L P/W L
R/G
L/R L/R L B R/G R/G Br/L L/Y (B) (B)
30
B
B B Lg B
Y/L Y/L 41 Y/L
B/L
(L)
L L G B R/G B B/L
(L)
7
G
B
L L/R L
B B B/W R/G
Y B Y
L B L
43 L Y B/L
B/W B
Br
Lg
B R/B G/B B G/B 36 Y B/L
L/Y Y/G Y/G 44
Br/L
G/L Br/L 31 32 33 L/W
L/W B 34 W L L Y/G B/L
Y/L
L/G
Br/L
Br/L
Br/L
35 R/L R/B
B/L B
L W
W/Y Br/L Br/L Br
Br
Dg R/W R/W Dg
46 W G 45 G
B
R
B/L
L R
13 G/Y Ch Br/W Br R/B R/B Br Br/W Ch G/Y
(B) R/B
(Gy)
R/B R/L (B)
R/W (B)
R/G (B) B/W
R/W
R/G
14 Br
L G/B G/B R/L

R/L B B
R/G
L/R 8 15
L Br
Br Br
Br
47
R/W B B R/L B
R/G Br R Br/R
R/L G/B
48 W L Gy/G B/L
(Gy) (B)
L/RBr
16 R/W
R/W
Y/W
B
(B)
R R/W R/W L
17
R/W R/L
Y/R
19
L
Y/W L
R/G
80 18 R/G
R/W Y Y/W
L/W Y/W Y/L Y/G Gy/G W B/Y B/W L R/W R/B O
L
L
L
L
L
L
L
Br Y/B L/B L
81 74
R/W (B) 63 R/L Lg G/R Br/W P/W Y B/L L/Y Y/R G/B B
G/L
B/W Y Y/B
Y/B
(B) 19
R/L
(B) L/B Br R/L
Br/R
82 Br/L R/Y
B/W L/B
R/W R/L
R/L R/L R/L R/L
Ch
75 Br/W Br/W
Br/R R/L
R/L R/L R/L R/L
83 Br/L Br/B 51 R/W
L
Y/R
B/W Dg
76 Br/W 56 L/B L/B Br Br/W Br G/Y
19
L Y/R
84 Br/B
R B/Y L/Y B
Y
64 Br/W 57 58 59 60 B
B B B
B/W Br/B 77 L/R OFF

B
B
B B B
(B) B
85 B/W L/R ON N
61 Y Br/W R Ch Dg
B
L/R B P
L/R
Y Br B/Y L/B L/Y B
Y
86 Y Y L/R
19
Y 65 L
B B Ch Dg
Dg Ch L/B Br/W B
G/Y
G/Y
G/Y
L
62 B G/Y L/B Br Br
G/Y
G/Y
G/Y G/Y G/Y
87 L P B L
L L
G
Y/L 88 Ch B B
89 Ch Ch
Ch Ch
Dg
Dg Dg
52 B B
Dg Dg G B
R/G
R/W
Y Y
L 54 L G/Y L L 50 49 R/L B
D D
R/Y Y/B Y Y/BY D B Ch Dg B
R/G Y (B)
D D D L C C C G R/L
R/Y Y/B Y/B B Ch Dg
Ch L Dg L Ch Dg
Ch Dg Y 78 R/Y
R/Y
R/Y L
L
L 55
B
Br G Br/G Br/G B B
B R/Y Y/B Y B B R/Y Y/BY L L
(Gy) B 67 68 69 70 L BB
Y/L Y/L Y/L L/G
L/G 71 71 66 66 Br L G L
B B L
Y/L B B
Br/G Br/G 53
19 Y/L
Y/L
L/G
B L B L
L
B
Y
B
(B)
B L Ch B L Dg B B
B B
B B B B
W/Y
R
72 73 72 73 G/Y L
B B
79 (B) A B
90 R/G
R L/G L/G
R/Y B Y/B Y B R/Y R/Y B Y/B Y B R/Y
(B) (B)
Y L L Y
B B
Br B B/L B/L
B B L/G
BBBBBBBBB BBBBBB
Br B B B A B A C
B
19 B B B C D
R/G R/G R/G
R/G R/G R/G B Ch Dg
Y/B Y L Y/B Y L
R/G R/G R/G 19
A D A D
XP500F 2015 WIRING DIAGRAM
19
19 19
(B)
(B)
(B)
2
9
37
5 6 10 11 26 28
27 (Dg)
3 29 38
20 22 19 39
23 40
1 4 A
(B)
12 24
21 25 42
(B) (B)
30 41 (L)
(L) B
7
B
B
43
(B)
36
44
31 32 33 34
35
46 45
13 (B)
(Gy)
(B)
(B)
(B)
14
8 15 47
48
(Gy) (B)
16 (B)
17 19
80 18
81 74 (B) 63
(B) 19
(B)
82
75
83 51
76 56 19
84
64 57 58 59 60
77 OFF
(B)
85
ON N
61
86 19
65
62
87
88
89
52
54 50 49
D D
D
(B)
D D D C C C
78 55
(Gy)
67 68 69 70
71 71 66 66
53
19
(B)
72 73 72 73
79 (B) A B
90
(B) (B)
A B A C
19 C D
19
A D A D

Tmax xp500f 2015

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2015

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

IMPORTANT INFORMATION ......................................................................... 1-9

BASIC SERVICE INFORMATION.................................................................1-11

SPECIAL TOOLS .......................................................................................... 1-16

VEHICLE IDENTIFICATION NUMBER

OUTLINE OF THE FI SYSTEM

1. Fuel pump 13. Throttle position sensor

1. Tripmeter/fuel reserve tripmeter

Odometer and tripmeter modes

1. Fuel reserve tripmeter

1. V-belt replacement tripmeter

3. If the oil change indicator does not come on,

V-belt replacement indicator “V-Belt”

Oil change indicator “Oil”

Ambient temperature display, average fuel Average fuel consumption mode

1 1. Average fuel consumption display

1. Ambient temperature display

The temperature displayed may vary from the 1

The distance that can be traveled on 1.0 Imp.gal

1. Fault code display

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS RUBBER PARTS

BASIC SERVICE INFORMATION

TIP Push the OFF/steering lock switch before

NOTICE Checking the electrical system

Intake air temperature sensor re-

Piston pin puller set 5-32

Radiator cap tester 6-3, 6-3

Locknut wrench 5-46, 5-46, 5-49

Flywheel puller 5-56

Steering nut wrench 3-24, 4-91

Damper rod holder 4-83, 4-86

Rod holder 4-82, 4-88

Rod puller attachment (M10) 4-86

Fork spring compressor 4-82, 4-88

Fork seal driver 4-85, 4-85, 4-85

Oil filter wrench 3-26, 6-7

Sheave holder 5-46, 5-46, 5-49,

Clutch spring compressor 5-63, 5-66

Sheave holder 5-56, 5-56, 5-57,

Vacuum gauge 3-9