Yamaha Gpd-A 125 150 Nmax (2017)

2017
SERVICE MANUAL
NMAX
NMAX 150
Ocito
GPD125-A
GPD150-A
BV3-F8197-E0
EAS20003
IMPORTANT
This manual was produced by the PT Yamaha Indonesia Motor Manufacturing. primarily for use by
Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a me-
chanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on
Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these
types of vehicles. Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic
instructions that must be observed during servicing. Repair and maintenance work attempted by any-
one without this knowledge is likely to render the vehicle unsafe and unfit for use.
PT Yamaha Indonesia Motor Manufacturing. is continually striving to improve all of its models. Modifi-
cations and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
TIP
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION

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

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

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
EAS20002
GPD125-A/GPD150-A
SERVICE MANUAL
©2017 by PT Yamaha Indonesia Motor
Manufacturing
First edition, January 2017
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
PT Yamaha Indonesia Motor Manufacturing
is expressly prohibited.
EAS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
4
2
5
7
6
EAS20005
SYMBOLS 符號
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 二硫化鉬油
Lubricant Brake fluid

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

T.
鋰皂基潤滑脂
R.
Wear limit, clearance M Molybdenum disulfide grease

二硫化鉬潤滑脂
Engine speed S Silicone grease

矽脂 / 硅脂
Electrical data Apply locking agent (LOCTITE®).

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

E
Silicone fluid
S
矽油 / 硅油
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
ENGINE SERIAL NUMBER ...................................................................... 1-1
MODEL LABEL.......................................................................................... 1-1
1
FEATURES...................................................................................................... 1-2
INSTRUMENT FUNCTIONS ..................................................................... 1-2
IMPORTANT INFORMATION ......................................................................... 1-6

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-6
REPLACEMENT PARTS...........................................................................1-6
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-6
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-6
BEARINGS AND OIL SEALS .................................................................... 1-7
CIRCLIPS ..................................................................................................1-7
RUBBER PARTS.......................................................................................1-7
BASIC SERVICE INFORMATION...................................................................1-8

QUICK FASTENERS................................................................................. 1-8
ELECTRICAL SYSTEM.............................................................................1-9
SPECIAL TOOLS .......................................................................................... 1-13

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
EAS30004
ENGINE SERIAL NUMBER

The engine serial number “1” is stamped into the
crankcase.
EAS30003
MODEL LABEL
The model label “1” is affixed to the inside of the
rear storage compartment. This information will
be needed to order spare parts.
1-1
FEATURES
EAS20008
Clock
FEATURES
1
EAS30682
INSTRUMENT FUNCTIONS
Multi-function meter unit

1 2 3 4
1. Clock
The clock uses a 12-hour time system.
7 6 5 [To set the clock]

1. Turn the key to “ON”.
1. Fuel meter 2. Push the “SELECT” button and “RESET” but-
2. Clock ton together for at least two seconds.
3. Speedometer 3. When the hour digits start flashing, push the
4. Instantaneous fuel consumption meter “RESET” button to set the hours.
5. “RESET” button 4. Push the “SELECT” button, and the minute
6. Multi-function display digits will start flashing.
7. “SELECT” button 5. Push the “RESET” button to set the minutes.
EWA17650 6. Push the “SELECT” button and then release
WARNING it to start the clock.
Be sure to stop the vehicle before making
any setting changes to the multi-function Fuel meter
meter unit. Changing settings while riding
1 2
can distract the operator and increase the
risk of an accident.
The multi-function meter unit is equipped with
the following:
• a speedometer
• a clock
• a fuel meter
• an instantaneous fuel consumption meter
• a multi-function display
1. Fuel meter
TIP
2. Fuel level warning indicator “ ”
• Be sure to turn the key to “ON” before using the
“SELECT” and “RESET” buttons. The fuel meter indicates the amount of fuel in the
• For the UK: To switch the speedometer be- fuel tank. The display segments of the fuel meter
tween km/h and MPH, press the “SELECT” disappear towards “E” (Empty) as the fuel level
button for one second when the multi-function decreases. When the last segment and fuel level
meter is in odometer mode, tripmeter 1, or trip- warning indicator “ ” start flashing, refuel as
meter 2 mode. soon as possible.
TIP
Speedometer If a problem is detected in the electrical circuit,
The speedometer shows the vehicle’s traveling the following cycle is repeated until the malfunc-
speed. tion is corrected: fuel level segments and fuel
level warning indicator “ ” flash eight times,
1-2
FEATURES
then go off for approximately 3 seconds. If this • a V-belt replacement tripmeter

occurs, have a Yamaha dealer check the electri- • an oil change indicator
cal circuit. • a V-belt replacement indicator
• a fault code display
Instantaneous fuel consumption meter
Except for the UK:
1 Push the “SELECT” button to switch the display
between the odometer mode “ODO”, tripmeter
modes “TRIP 1” and “TRIP 2”, oil change tripme-
ter mode “OIL TRIP”, V-belt replacement tripme-
ter mode “V-BELT TRIP”, instantaneous fuel
consumption mode “F/ECO” (km/L or L/100 km),
and average fuel consumption mode “AVE F/
ECO” (km/L or L/100 km) in the following order:
ODO → TRIP 1 → TRIP 2 → OIL TRIP → V-

1. Instantaneous fuel consumption meter
BELT TRIP → F/ECO → AVE F/ECO → ODO
This meter shows the instantaneous fuel con-
sumption. For the UK:
Depending on the display setting selected for Push the “SELECT” button to switch the display
the instantaneous fuel consumption mode “F/ between the odometer mode “ODO”, tripmeter
ECO”, the displayed segments increase or de- modes “TRIP 1” and “TRIP 2”, oil change tripme-
crease. ter mode “OIL TRIP”, V-belt replacement tripme-
• km/L and MPG (for the UK): The number of ter mode “V-BELT TRIP”, instantaneous fuel
segments displayed increases the more effi- consumption mode “F/ECO” (MPG or L/100
ciently the vehicle is being operated. km), and average fuel consumption mode “AVE
• L/100 km: The number of segments displayed F/ECO” (MPG or L/100 km) in the following or-
decreases the more efficiently the vehicle is der:
being operated.
ODO → TRIP 1 → TRIP 2 → OIL TRIP → V-
Multi-function display BELT TRIP → F/ECO → AVE F/ECO → ODO
If the fuel level warning indicator “ ” and last

segment of the fuel meter start flashing, the dis-
play automatically changes to the fuel reserve
tripmeter mode “TRIP F” and starts counting the
distance traveled from that point. In that case,
push the “SELECT” button to switch the display
between the various tripmeter, odometer, oil
change tripmeter, V-belt replacement tripmeter,
1 instantaneous fuel consumption and average
1. Multi-function display fuel consumption modes in the following order:
The multi-function display is equipped with the
TRIP F → TRIP 1 → TRIP 2 → OIL TRIP → V-
following:
BELT TRIP → F/ECO → AVE F/ECO → ODO
• an odometer
→ TRIP F
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
To reset a tripmeter, select it by pushing the “SE-
• a fuel reserve tripmeter (which shows the dis-
LECT” button, and then push the “RESET” but-
tance traveled since the last segment of the
ton for at least one second.
fuel meter started flashing)
• an instantaneous fuel consumption display
• an average fuel consumption display
• an oil change tripmeter
1-3
FEATURES
TIP Average fuel consumption mode

• If you do not reset the fuel reserve tripmeter
manually, it resets itself automatically and the
display returns to the prior mode after refueling
and traveling 5 km (3 mi).
• If you do not reset tripmeters 1 and 2, they will
reset to 0 and continue counting after 9999.9
has been reached.
• The odometer will lock at 999999 and cannot
be reset.
1
1. Average fuel consumption display
Instantaneous fuel consumption mode
This display shows the average fuel consump-
tion since it was last reset.
The average fuel consumption display can be
set to either “km/L” or “L/100 km”, and either
“MPG” or “L/100 km” (for the UK).
• “km/L”: The average distance that can be trav-
eled on 1.0 L of fuel is shown.
• “L/100 km”: The average amount of fuel neces-
sary to travel 100 km is shown.
1 • “MPG”: The average distance that can be trav-
1. Instantaneous fuel consumption display eled on 1.0 lmp. gal of fuel under the current
riding conditions is shown.
The instantaneous fuel consumption display can To switch between the average fuel consump-
be set to either “km/L” or “L/100 km”, and either tion display settings, push the “SELECT” button
“MPG” or “L/100 km” (for the UK). for one second.
• “km/L”: The distance that can be traveled on To reset the average fuel consumption, push the
1.0 L of fuel under the current riding conditions “RESET” button for at least one second.
is shown.
TIP
• “L/100 km”: The amount of fuel necessary to
travel 100 km under the current riding condi- • After resetting the average fuel consumption,
tions is shown. “_ _._” will be shown until the vehicle has trav-
• “MPG”: The distance that can be traveled on eled 0.1 km (0.06 mi).
1.0 lmp. gal of the fuel under the current riding • When MPG is selected, no units indicator will
conditions is shown. be displayed.
To switch between the instantaneous fuel con-
sumption display settings, push the “SELECT” Oil change tripmeter mode
button for one second.
TIP
• If traveling at speeds under 10 km/h (6 mi/h), “_
_._” is displayed.
• When MPG is selected, no units indicator will
be displayed.
1 2
1. Oil change indicator “OIL”
2. Oil change tripmeter
1-4
FEATURES
The oil change tripmeter shows the distance reached), the V-belt replacement tripmeter must
traveled since it was last reset (i.e., since the last be reset for the next periodic V-belt replacement
oil change). to be indicated at the correct time.
The oil change indicator “OIL” will flash at the ini-
tial 1000 km (600 mi), then at 6000 km (3500 mi)
and every 6000 km (3500 mi) thereafter to indi-
cate that the engine oil should be changed.
After changing the engine oil, reset the oil
change tripmeter and the oil change indicator.
To reset them both, select the oil change tripme-
ter, and then push the “RESET” button for one
second. Then, while “OIL” and the oil change
tripmeter are flashing, push the “RESET” button
for three seconds. The oil change indicator will
be reset.
If the engine oil is changed before the oil change
indicator comes on (i.e., before the periodic oil
change interval has been reached), the oil
change tripmeter must be reset for the next peri-
odic oil change to be indicated at the correct
time.
V-belt replacement tripmeter mode
1 2
1. V-belt replacement indicator “V-BELT”
2. V-belt replacement tripmeter
The V-belt replacement tripmeter shows the dis-
tance traveled since it was last reset (i.e., since
the last V-belt replacement).
The V-belt replacement indicator “V-BELT” will
flash at every 18000 km (10500 mi) thereafter to
indicate that the V-belt should be replaced.
After replacing the V-belt, reset the V-belt re-
placement tripmeter and the V-belt replacement
indicator. To reset them both, select the V-belt
replacement tripmeter, and then push the “RE-
SET” button for one second. Then, while “V-
BELT” and the V-belt replacement tripmeter are
flashing, push the “RESET” button for three sec-
onds. The V-belt replacement indicator will be
reset.
If the V-belt is replaced before the V-belt re-
placement indicator comes on (i.e., before the
periodic V-belt replacement interval has been
1-5
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 1-13.
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.
1-6
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’s 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.
1-7
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.
1-8
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.
ECA16610
NOTICE
TIP Turn the main switch to “OFF” before dis-

connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to
ponent.
rust on the battery terminal, remove the rust us-
ing hot water.
1-9
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 turning the main
switch to “OFF”, be sure to wait approximately 5 For waterproof couplers, never insert the
seconds before turning the main switch back to tester probes directly into the coupler. When
“ON”. performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-10
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.
1-11
Digital circuit tester (CD732)

90890-03243
Model 88 Multimeter with ta-
chometer
YU-A1927
TIP
The resistance values shown were obtained at
the standard measuring temperature of 20 °C
(68 °F). If the measuring temperature is not 20
4. Check: °C (68 °F), the specified measuring conditions
• Continuity will be shown.
(with the digital circuit tester)
Digital circuit tester (CD732) Coolant temperature sensor re-

90890-03243 sistance
Model 88 Multimeter with ta- 2512–2777 Ω at 20 °C (2512–
chometer 2777 Ω at 68 °F)
YU-A1927 Coolant temperature sensor re-
sistance
TIP 210–220 Ω at 100 °C (210–220 Ω
at 212 °F)
• 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
1-12
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
Digital circuit tester (CD732) 1-12, 1-12, 5-52,
90890-03243 8-103, 8-104,
Model 88 Multimeter with tachometer 8-104, 8-105,
YU-A1927 8-109, 8-109,
8-109, 8-110,
8-110, 8-110,
8-111, 8-111,
8-112, 8-113,
8-113, 8-114,
8-114, 8-114
Yamaha diagnostic tool USB 3-4, 3-7, 3-8,
90890-03256 4-64, 4-66, 7-14,
7-14, 7-14, 8-28,
8-77, 8-98,
8-105, 8-105
Yamaha diagnostic tool (A/I) 3-4, 3-7, 3-8,

90890-03254 4-64, 4-66, 7-14,
7-14, 7-14, 8-28,
8-77, 8-98,
8-105, 8-105
Tappet adjusting tool 3-7

90890-01311
Six piece tappet set
YM-A5970
YM-A5970
ø8 ø9 ø10
ø3 ø4
Steering nut wrench 3-15, 3-16, 4-84
90890-01403
Exhaust flange nut wrench
YU-A9472
1-13
SPECIAL TOOLS
Reference
pages
Thickness gauge 4-30
90890-03180
Feeler gauge set
YU-26900-9
T-handle 4-78, 4-79

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver weight 4-79, 4-80

90890-01367
Replacement hammer
YM-A9409-7
YM-A9409-7/YM-A5142-4
Fork seal driver attachment (ø30) 4-79, 4-80

90890-01400
Compression gauge 90890-03081 5-1

90890-03081
Engine compression tester
YU-33223
YU-33223
Extension 5-1
90890-04136
Camshaft wrench 5-13, 5-17

90890-04162
Camshaft wrench
YM-04162
1-14
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-16, 5-63
90890-85505
(Three bond No.1215®)
Slide hammer bolt (M8) 5-19

90890-01085
Slide hammer bolt 8 mm
YU-01083-2
Weight 5-19
90890-01084
Weight
YU-01083-3
YU-01083-3
Valve spring compressor 5-23, 5-27

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-23, 5-27

90890-04108
Valve spring compressor adapter 22 mm
YM-04108
Valve guide remover (ø5) 5-24

90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø5) 5-24

90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5) 5-24

90890-04099
Valve guide reamer (5.0 mm)
YM-04099
1-15
SPECIAL TOOLS
Reference
pages
Piston pin puller set 5-30
90890-01304
Piston pin puller
YU-01304
YU-01304
Rotor holding tool 5-38, 5-43, 5-49,

90890-01235 5-49
Universal magneto and rotor holder
YU-01235
Rotor holding tool 5-38, 5-38, 5-42,

90890-04166 5-42
Rotor holding tool
YM-04166
Socket wrench (39 mm) 5-38, 5-42

90890-01493
Sheave spring compressor 5-38, 5-41

90890-04134
Sheave spring compressor
YM-04134
1-16
SPECIAL TOOLS
Reference
pages
Sheave fixed block 5-38, 5-41
90890-04135
Sheave fixed bracket
YM-04135
Oil seal guide (37 mm) 5-41

90890-04177
ø37
Flywheel puller 5-49
90890-01189
Flywheel puller
YM-01189
Crankcase separating tool 5-62

90890-01135
Crankcase separator
YU-01135-B
Crankshaft installer pot 5-63

90890-01274
Installing pot
YU-90058
YU-90058/YU-90059
1-17
SPECIAL TOOLS
Reference
pages
Crankshaft installer bolt 5-63
90890-01275
Bolt
YU-90060
Adapter (M12) 5-63

90890-01278
Adapter #3
YU-90063
Spacer (crankshaft installer) 5-63

90890-04081
Pot spacer
YM-91044
YM-91044
Radiator cap tester 6-3, 6-3

90890-01325
Mityvac cooling system tester kit
YU-24460-A
YU-24460-A
Radiator cap tester adapter 31mm 6-3, 6-3

90890-05375
Radiator cap tester adapter 31mm
YM-05375
Mechanical seal installer 6-9

90890-04145 ø30
ø10
Middle driven shaft bearing driver 6-9

90890-04058
Middle drive bearing installer 40 & 50 mm
YM-04058
1-18
SPECIAL TOOLS
Reference
pages
Pressure gauge 7-3
90890-03153
Pressure gauge
YU-03153
Fuel pressure adapter 6.3mm 7-3

90890-03227
OBD/ GST Leadwire kit 8-28

90890-03249
Ignition checker 8-111

90890-06754
Oppama pet–4000 spark checker
YM-34487
1-19
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-7
ELECTRICAL SPECIFICATIONS ...................................................................2-9
TIGHTENING TORQUES .............................................................................. 2-11

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-11
ENGINE TIGHTENING TORQUES......................................................... 2-12
CHASSIS TIGHTENING TORQUES.......................................................2-14
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-18

ENGINE................................................................................................... 2-18
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-19

ENGINE OIL LUBRICATION CHART .....................................................2-19
LUBRICATION DIAGRAMS .................................................................... 2-21
COOLING SYSTEM DIAGRAMS .................................................................. 2-25
CABLE ROUTING ......................................................................................... 2-27

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model BV31 (GPD125-A EUR)
BV32 (GPD125-A MBK brand)
BV33 (GPD125-A GBR)
BV36 (GPD125-A KOR)
BV41 (GPD150-A EUR)
BV42 (GPD150-A AUS/NZL)
Dimensions
Overall length 1955 mm (77.0 in)
Overall width 740 mm (29.1 in)
Overall height 1115 mm (43.9 in)
Seat height 765 mm (30.1 in)
Wheelbase 1350 mm (53.1 in)
Ground clearance 135 mm (5.31 in)
Minimum turning radius 2.0 m (6.56 ft)
Weight
Curb weight 127 kg (280 lb)
Loading
Maximum load 168 kg (370 lb)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train SOHC
Displacement 125 cm³ (GPD125-A)
155 cm³ (GPD150-A)
Number of cylinders Single cylinder
Bore × stroke 52.0 × 58.7 mm (2.05 × 2.31 in) (GPD125-A)
58.0 × 58.7 mm (2.28 × 2.31 in) (GPD150-A)
Number of cylinders Single cylinder
Compression ratio 11.2 : 1 (GPD125-A)
10.5 : 1 (GPD150-A)
Compression pressure 1609–2072 kPa/840 r/min (16.1–20.7 kgf/cm²/
840 r/min, 228.9–294.7 psi/840 r/min) (GPD125-
A)
1566–2016 kPa/860 r/min (15.7–20.2 kgf/cm²/
860 r/min, 222.7–286.7 psi/860 r/min) (GPD150-
A)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol [E10]
acceptable) (EUR,GBR,AUS,NZL)
Regular unleaded gasoline only (KOR)
Fuel tank capacity 6.6 L (1.7 US gal, 1.5 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
SAE viscosity grades 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA or MB
Engine oil quantity
Quantity (disassembled) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil change 0.90 L (0.95 US qt, 0.79 Imp.qt)
Final transmission oil

Type Motor oil SAE 10W-30 type SE or higher or Gear
oil SAE 85W GL-3
Quantity (disassembled) 0.16 L (0.17 US qt, 0.14 Imp.qt)
Quantity 0.15 L (0.16 US qt, 0.13 Imp.qt)
Oil filter
Oil filter type Centrifugal
Oil pump
Inner-rotor-to-outer-rotor-tip clearance Less than 0.15 mm (0.006 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.25 mm (0.0098 in)
2-2
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.11 mm (0.0024–0.0043 in)
Limit 0.18 mm (0.0071 in)
Cooling system
Coolant quantity
Radiator (including all routes) 0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator cap valve opening pressure 78.6–137.4 kPa (0.79–1.37 kgf/cm², 11.4–19.9
psi)
Thermostat
Valve opening temperature 74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature 90.0 °C (194.00 °F)
Valve lift (full open) 7.0 mm (0.28 in)
Water pump
Water pump type Single suction centrifugal pump
Impeller shaft tilt limit 0.15 mm (0.006 in)
Spark plug(s)
Manufacturer/model NGK/CPR8EA-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Camshaft lobe dimensions
Lobe height (Intake) 32.211–32.311 mm (1.2681–1.2721 in)
Limit 32.111 mm (1.2642 in)
Lobe height (Intake high speed) 32.587–32.687 mm (1.2830–1.2869 in)
Limit (Intake high speed) 32.487 mm (1.2790 in)
Lobe height (Exhaust) 29.224–29.324 mm (1.1505–1.1545 in)
(GPD125-A)
29.420–29.520 mm (1.1583–1.1622 in)
(GPD150-A)
Limit 29.124 mm (1.1466 in) (GPD125-A)
29.320 mm (1.1543 in) (GPD150-A)
Camshaft runout limit 0.030 mm (0.0012 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in)
Limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in)
Limit 9.935 mm (0.3911 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm (0.0004–0.0013 in)
Limit 0.080 mm (0.0032 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
2-3
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)

Valve dimensions
Valve seat contact width (intake) 0.90–1.20 mm (0.0354–0.0472 in)
Limit 1.7 mm (0.07 in)
Valve seat contact width (exhaust) 0.90–1.20 mm (0.0354–0.0472 in)
Valve stem diameter (intake) 4.975–4.990 mm (0.1959–0.1965 in)
Limit 4.945 mm (0.1947 in)
Valve stem diameter (exhaust) 4.960–4.975 mm (0.1953–0.1959 in)
Limit 4.930 mm (0.1941 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 33.79 mm (1.33 in)
Limit 32.10 mm (1.26 in)
Free length (exhaust) 33.80 mm (1.33 in) (GPD125-A)
33.79 mm (1.33 in) (GPD150-A)
Limit 32.06 mm (1.26 in) (GPD125-A)

32.10 mm (1.26 in) (GPD150-A)
Spring tilt (intake) 1.5 mm (0.06 in) (GPD125-A)
1.7 mm (0.07 in) (GPD150-A)
Spring tilt (exhaust) 1.5 mm (0.06 in) (GPD125-A)
1.7 mm (0.07 in) (GPD150-A)
Cylinder
Bore 52.000–52.010 mm (2.0472–2.0476 in)
(GPD125-A)
58.000–58.010 mm (2.2835–2.2839 in)
(GPD150-A)
Wear limit 52.060 mm (2.0496 in) (GPD125-A)
58.060 mm (2.2858 in) (GPD150-A)
Piston
Piston-to-cylinder clearance 0.015–0.048 mm (0.0006–0.0019 in)
Diameter 51.962–51.985 mm (2.0457–2.0466 in)
(GPD125-A)
57.962–57.985 mm (2.2820–2.2829 in)
(GPD150-A)
Measuring point (from piston skirt bottom) 6.0 mm (0.24 in)
Piston pin bore inside diameter 14.002–14.013 mm (0.5513–0.5517 in)
Limit 14.043 mm (0.5529 in)
Piston pin outside diameter 13.995–14.000 mm (0.5510–0.5512 in)
Limit 13.975 mm (0.5502 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.018 mm (0.0001–0.0007 in)
2-4
Piston ring
Top ring
Ring type Barrel
End gap limit 0.50 mm (0.0197 in)
Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
Ring type Taper
End gap limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in)
Side clearance limit 0.115 mm (0.0045 in)
Crankshaft
Crank assembly width 51.45–51.50 mm (2.026–2.028 in)
Runout limit 0.030 mm (0.0012 in)
Clutch
Clutch type Dry, centrifugal, shoe
Automatic centrifugal clutch

Clutch shoe thickness 2.5 mm (0.10 in) (GPD125-A)
4.0 mm (0.16 in) (GPD150-A)
Limit 1.0 mm (0.04 in) (GPD125-A)
2.5 mm (0.10 in) (GPD150-A)
Clutch shoe spring free length 31.8 mm (1.25 in) (GPD125-A)
31.0 mm (1.22 in) (GPD150-A)
Clutch housing inside diameter 125.0 mm (4.92 in)
Limit 125.5 mm (4.94 in)
Compression spring free length 95.0 mm (3.74 in)
Limit 85.5 mm (3.37 in)
Weight outside diameter 20.0 mm (0.79 in)
Limit 19.5 mm (0.77 in)
Clutch-in revolution 2800–3200 r/min (GPD125-A)
2200–2600 r/min (GPD150-A)
Clutch-stall revolution 4700–5300 r/min
V-belt
V-belt width 25.5 mm (1.00 in)
Limit 23.0 mm (0.91 in)
Drivetrain
Transmission
Transmission type V-belt automatic
Primary reduction ratio 1.000
Final drive Gear
Secondary reduction ratio 10.208 (56/16 × 35/12)
Transmission ratio 2.326–0.731 : 1 (GPD125-A)
2.248–0.708 : 1 (GPD150-A)
Air filter
Air filter element Oil-coated paper element
2-5
Fuel injector
Resistance 12.0 Ω (GPD125-A)
12.2 Ω (GPD150-A)
Fuel pump
Pump type Electrical
Maximum consumption amperage 0.7 A
Throttle body
ID mark 2DS1 01
Fuel injection sensor

Crankshaft position sensor resistance 228–342 Ω
Intake air pressure sensor output voltage 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at 1.01
kgf/cm², 3.88–4.12 V at 14.7 psi)
Intake air temperature sensor resistance 5700–6300 Ω at 0 °C (5700–6300 Ω at 32 °F)
Coolant temperature sensor resistance 2512–2777 Ω at 20 °C (2512–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–220 Ω at 100 °C (210–220 Ω at 212 °F)
Idling condition
Engine idling speed 1500–1700 r/min
O2 feedback control Active
Exhaust gas sampling point Muffler tail pipe
Coolant temperature 75–85 °C (167–185 °F) (GPD125-A)
80–90 °C (176–194 °F) (GPD150-A)
CO% Less than 2.0 % (GPD125-A)
Less than 1.3 % (GPD150-A) (AUS,NZL)
Less than 1.5 % (GPD150-A) (EUR)
Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-6
CHASSIS SPECIFICATIONS
EAS20015
Chassis
Frame type Backbone
Caster angle 26.0 °
Trail 92 mm (3.6 in)
Front wheel
Wheel type Cast wheel
Rim size 13M/C × MT3.00
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Rear wheel
Wheel type Cast wheel
Rim size 13M/C × MT3.50
Rim material Aluminum
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Front tire
Type Tubeless
Size 110/70–13M/C 48P
Manufacturer/model DUNLOP/SCOOTSMART
Wear limit (front) 1.6 mm (0.06 in) (EUR, MBK brand)
1.5 mm (0.06 in) (AUS/NZL)
1.0 mm (0.04 in) (KOR)
Rear tire
Type Tubeless
Size 130/70–13M/C 57P
Manufacturer/model DUNLOP/SCOOTSMART
Wear limit (rear) 1.6 mm (0.06 in) (EUR, MBK brand)
1.5 mm (0.06 in) (AUS/NZL)
1.0 mm (0.04 in) (KOR)
Tire air pressure (measured on cold tires)

1 person
Front 150 kPa (1.50 kgf/cm², 22 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
2 persons
Front 150 kPa (1.50 kgf/cm², 22 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
Front brake
Type Hydraulic single disc brake
Disc outside diameter × thickness 230.0 × 4.0 mm (9.06 × 0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 4.4 mm (0.17 in)
2-7
Master cylinder inside diameter 11.00 mm (0.43 in)

Caliper cylinder inside diameter 33.30 mm (1.31 in)
Specified brake fluid DOT 4
Rear brake
Type Hydraulic single disc brake
Disc outside diameter × thickness 230.0 × 4.5 mm (9.06 × 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 5.3 mm (0.21 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 33.30 mm (1.31 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Fork spring free length 245.3 mm (9.66 in)
Limit 240.3 mm (9.46 in)
Recommended oil Yamaha Suspension Oil G10
Quantity 86.0 cm³ (2.91 US oz, 3.03 Imp.oz)
Level 78.0 mm (3.07 in)
Rear suspension
Type Unit swing
Spring Coil spring
Shock absorber Hydraulic damper
2-8
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Engine control unit

Model/manufacturer BV30/YEID (GPD125-A)
BV41/YEID (GPD150-A)
Ignition system
Ignition system TCI
Advancer type Digital
Ignition timing (B.T.D.C.) 5.0 °/1600 r/min
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ
Spark plug cap

Resistance 3.75–6.25 kΩ
Charging system
Charging system AC magneto
Standard output 14.0 V, 10.7 A at 5000 r/min
Standard output 14.0 V, 150 W at 5000 r/min
Stator coil resistance 0.496–0.744 Ω
Rectifier/regulator
Regulator type Single-phase
Regulated voltage (DC) 13.7–14.7 V
Rectifier capacity (DC) 15.0 A
Battery
Model YTZ7V
Voltage, capacity 12 V, 6.0 Ah (10 HR)
Bulb wattage
Headlight LED
Auxiliary light 5.0 W
Brake/tail light LED/10.0 W
Front turn signal light 10.0 W
Rear turn signal light 10.0 W
Meter lighting LED
Indicator light
Turn signal indicator light LED
High beam indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED
ABS warning light LED
2-9
Starter motor
Power output 0.36 kW
Armature coil resistance 0.0279–0.0341 Ω
Brush overall length 7.0 mm (0.28 in)
Limit 3.50 mm (0.14 in)
Brush spring force 3.92–5.88 N (400–600 gf, 14.11–21.17 oz)
Commutator diameter 17.6 mm (0.69 in)
Limit 16.6 mm (0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in)
Fuel sender unit

Sender unit resistance (full) 10.0–14.0 Ω
Sender unit resistance (empty) 267.0–273.0 Ω
Fuse(s)
Main fuse 15.0 A
Main fuse 2 7.5 A
Taillight fuse 7.5 A
Signaling system fuse 7.5 A
ABS motor fuse 30.0 A
ABS control unit fuse 7.5 A
ABS solenoid fuse 15.0 A
2-10
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)
N·m kgf·m lb·ft
10 mm 6 mm 6 0.6 4.4
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 41
19 mm 14 mm 85 8.5 63
22 mm 16 mm 130 13 96
2-11
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Muffler nut M8 2 15 N·m (1.5 kgf·m, 11 lb·ft)
Muffler bolt M10 3 53 N·m (5.3 kgf·m, 39 lb·ft)
Muffler protector bolt M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
O2 sensor M12 1 25 N·m (2.5 kgf·m, 18 lb·ft)
Camshaft stopper plate bolt (M5×16) M5 2 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Camshaft stopper plate bolt (M6×14) M6 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Cylinder head bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Cylinder head nut M8 4 24 N·m (2.4 kgf·m, 18 lb·ft) M
VVA (variable valve actuator) sole-

M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
noid bolt
Fuel hose holder M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Cylinder head cover bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Engine oil check bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Cylinder head stud bolt (exhaust
M8 2 15 N·m (1.5 kgf·m, 11 lb·ft)
pipe)
Camshaft sprocket bolt M8 1 30 N·m (3.0 kgf·m, 22 lb·ft)
Spark plug M10 1 13 N·m (1.3 kgf·m, 9.6 lb·ft)
Cylinder head blind plug M12 1 28 N·m (2.8 kgf·m, 21 lb·ft) LT
Cylinder head cover breather plate

M5 4 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) LT
bolt
Valve clearance adjusting screw
M5 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
locknut
Yamaha
Timing chain tensioner bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) bond No.
1215
Timing chain guide bolt (intake side) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Timing chain guide stopper bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Coolant temperature sensor M10 1 15 N·m (1.5 kgf·m, 11 lb·ft)

Coolant drain bolt (cylinder side) M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Water pump assembly bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Water pump housing bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator fan case bolt M6 5 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Thermostat assembly bolt M6 2 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Radiator fan bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Radiator bolt M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Coolant drain bolt (radiator side) M12 1 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
Radiator cover bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Oil pump assembly screw M5 2 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Oil pump housing cover screw M3 1 1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
Oil strainer cover M35 1 32 N·m (3.2 kgf·m, 24 lb·ft)
Fuel injector bolt M6 1 10 N·m (1.0 kgf·m, 7.4 lb·ft)
2-12
TIGHTENING TORQUES
Thread
size
Intake manifold bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Intake manifold clamp screw M5 1 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
ISC (Idle Speed Control) unit holder
M6 1 5 N·m (0.5 kgf·m, 3.7 lb·ft)
screw
Air filter case joint clamp screw M5 1 3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
Air filter case bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Air filter case cover screw M5 6 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
Air filter case duct cover screw M5 2 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
AC magneto rotor nut M12 1 80 N·m (8.0 kgf·m, 59 lb·ft)
Yamaha
Crankcase cover bolt 1 M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) bond No.
1215
Crankcase cover bolt 2 M6 4 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Stator coil assembly bolt M6 3 10 N·m (1.0 kgf·m, 7.4 lb·ft) LT
Starter motor bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Starter motor sub-wire harness bolt M5 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Starter motor cover bolt M4 2 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
Brush holder screw M4 2 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
Crankcase bolt M6 11 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Crankshaft position sensor holder
M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)
bolt
Transmission case cover bolt M8 6 19 N·m (1.9 kgf·m, 14 lb·ft)
Final transmission oil drain bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Yamaha
Starter clutch cover bolt 1 M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft) bond No.
1215
Starter clutch cover bolt 2 M6 5 10 N·m (1.0 kgf·m, 7.4 lb·ft)
V-belt case bolt M6 11 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Engine oil drain bolt M12 1 20 N·m (2.0 kgf·m, 15 lb·ft)
Crankcase stud bolt M8 4 13 N·m (1.3 kgf·m, 9.6 lb·ft)
V-belt case air filter element cover
M6 6 7 N·m (0.7 kgf·m, 5.2 lb·ft)
bolt
Primary fixed sheave nut M12 1 49 N·m (4.9 kgf·m, 36 lb·ft)
Clutch housing nut M12 1 45 N·m (4.5 kgf·m, 33 lb·ft)
Secondary sheave nut M28 1 55 N·m (5.5 kgf·m, 41 lb·ft)
Cylinder head tightening sequence:
3 4
1 2
6 5
2-13
TIGHTENING TORQUES
EAS30017
CHASSIS TIGHTENING TORQUES

Thread
size
Engine bracket nut M10 1 52 N·m (5.2 kgf·m, 38 lb·ft)
Engine mounting nut (front right
M10 1 68 N·m (6.8 kgf·m, 50 lb·ft)
side)
Engine mounting bolt (front left side) M10 1 68 N·m (6.8 kgf·m, 50 lb·ft)
Engine mounting nut (rear side) M10 1 68 N·m (6.8 kgf·m, 50 lb·ft)
Engine ground lead bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Headlight unit screw M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Lower handlebar cover screw M5 1 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Front lower cowling screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Meter assembly screw M5 4 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Front upper cowling assembly screw M5 3 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Meter assembly panel screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Leg shield bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Key shutter screw M5 1 3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
Front upper panel screw M5 6 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Front side cowling screw M5 8 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Front side cover screw M5 6 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Front cowling assembly screw (M5 ×
M5 4 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
15)
Front cowling assembly screw (M5 ×
M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
11)
Meter assembly panel bolt M6 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Footrest board and rear side cover
M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
bolt
Footrest board assembly bolt M6 4 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Footrest board screw M5 6 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Grab bar bolt M8 4 17 N·m (1.7 kgf·m, 13 lb·ft)
Upper handlebar cover assembly
M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
screw
Turn signal light screw M5 6 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Handlebar switch screw (right) M5 2 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
Fuel tank cover screw M5 4 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Center side cover screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Tail/brake light outer cover screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Rear side cover assembly screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Seat lock bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat nut M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat hinge nut M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat lock cable guide bolt M5 1 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
Center cover bolt M5 1 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
Battery cover screw M5 2 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
2-14
TIGHTENING TORQUES
Thread
size
Storage box bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Seat hinge bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rear fender bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake master cylinder holder
M6 2 11 N·m (1.1 kgf·m, 8.1 lb·ft)
bolt
Brake master cylinder reservoir cap
M4 4 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
screw
Front brake hose union bolt (master
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
cylinder side)
Rear brake hose union bolt (master
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
cylinder side)
Throttle cable holder bolt (handlebar
M5 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
switch side)
Throttle cable adjusting locknut M7 1 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Rearview mirror locknut M10 2 22 N·m (2.2 kgf·m, 16 lb·ft)
Rearview mirror adaptor M10 2 22 N·m (2.2 kgf·m, 16 lb·ft)
Handlebar switch screw (left) M5 2 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
Rear brake master cylinder holder
M6 2 11 N·m (1.1 kgf·m, 8.1 lb·ft)
bolt
Rear brake lever pivot bolt M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft) S
Rear brake lever pivot nut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front brake lever pivot bolt M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft) S
Front brake lever pivot nut M6 1 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Grip end bolt (left) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Grip end bolt (right) M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Brake light switch screw M4 2 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
Handlebar bracket nut M10 1 63 N·m (6.3 kgf·m, 47 lb·ft)
Upper handlebar holder bolt M8 4 21 N·m (2.1 kgf·m, 15 lb·ft)
Main switch bolt M8 2 19 N·m (1.9 kgf·m, 14 lb·ft)
Lower ring nut M25 1 See TIP.
Upper ring nut M25 1 See TIP.
Horn bracket bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Horn bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Lower bracket pinch bolt M10 4 53 N·m (5.3 kgf·m, 39 lb·ft)
Front fork damper rod bolt M10 2 23 N·m (2.3 kgf·m, 17 lb·ft) LT
Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Ignition coil bracket bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Throttle cable guide bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front fender bolt M6 4 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Front wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)
Front brake hose union bolt (brake
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
caliper side)
2-15
TIGHTENING TORQUES
Thread
size
Brake caliper bleed screw M8 2 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front brake hose guide bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front wheel axle nut M10 1 40 N·m (4.0 kgf·m, 30 lb·ft)
Front brake hose holder bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft) LT
Front wheel sensor rotor bolt M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Rear wheel sensor rotor bolt M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Rear brake hose bracket bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rear brake hose holder bolt (front
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
side)
Rear brake hose holder bolt (rear
M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
side)
Rear brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft) LT
Rear brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)

Rear wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Rear wheel axle nut M16 1 125 N·m (12.5 kgf·m, 92 lb·ft)
Rear brake hose union bolt (brake
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
caliper side)
Front brake hose guide bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Hydraulic unit assembly bolt M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake hose union bolt (hydrau-
M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
lic unit assembly side)
Rear brake hose union bolt (hydrau-
M10 2 29 N·m (2.9 kgf·m, 21 lb·ft)
lic unit assembly side)
Rectifier/regulator nut M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front cowling assembly bracket M8 2 23 N·m (2.3 kgf·m, 17 lb·ft)
Rear shock absorber assembly nut M10 2 21 N·m (2.1 kgf·m, 15 lb·ft)
Rear shock absorber assembly bolt M8 2 21 N·m (2.1 kgf·m, 15 lb·ft)
Swingarm mounting bolt M10 2 57 N·m (5.7 kgf·m, 42 lb·ft)
Bearing retaining plate bolt M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fuel tank bolt M6 4 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Fuel pump bracket bolt M5 4 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
Throttle cable holder bolt (throttle
M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
body side)
Coolant reservoir bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Sidestand switch bolt M5 2 4.0 N·m (0.40 kgf·m, 3.0 lb·ft) LT
Centerstand spring hook bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Sidestand nut M8 1 24 N·m (2.4 kgf·m, 18 lb·ft)
Passenger footrest assembly bolt M8 4 28 N·m (2.8 kgf·m, 21 lb·ft)
2-16
TIGHTENING TORQUES
TIP
Steering column ring nut
1. Tighten the lower ring nut 38 N·m (3.8 kgf·m, 28 lb·ft) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 16 N·m (1.6 kgf·m, 12 lb·ft) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 N·m (7.5 kgf·m, 55 lb·ft)
with a torque wrench and the steering nut wrench.
2-17
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20018
LUBRICATION POINTS AND LUBRICANT TYPES

EAS30018
ENGINE
Lubrication point Lubricant
Bearings E
O-rings LS
O-rings (cam shaft) M
Oil seals LS
Rocker arm stopper pin M
Cylinder head nut contact face and stud bolt thread M
Camshaft lobes M
Decompression cam M
Rocker arm shafts M
Valve stems and valve guide (intake and exhaust) M
Valve stem seals E
Valve stem ends (intake and exhaust) M
Rocker arm valve inner surface M
Camshaft sprocket M
Connecting rod big end face E
Piston pin outer surface E
Piston, piston ring, and cylinder inner surface E
Crank pin E
Cam chain sprocket inner surface M
Oil pump drive gear inner surface M
Oil pump shaft E
O-ring (fuel injector) E
Starter wheel and bearing E
Starter clutch idle gear inner surface M
Drive axle and bearings LS
Crankshaft threads and conical spring washer outer mating surface LS
Yamaha bond
Timing chain tensioner bolts
No.1215®
Yamaha bond
Crankcase mating surfaces
No.1215®
Yamaha bond
Crankcase bolt
No.1215®
2-18
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20019

EAS30020
ENGINE OIL LUBRICATION CHART
2-19
1. Oil strainer
2. Oil pump assembly
3. Crankshaft
4. Oil nozzle
5. Camshaft
2-20
EAS30021
LUBRICATION DIAGRAMS
2 1
2-21
1. Oil strainer
3. Camshaft
2-22
2-23
1. Oil strainer
3. Crankshaft
4. Rocker arm/Valve stem end
2-24
COOLING SYSTEM DIAGRAMS
EAS20020

1
2 3
4
6
8
5
5
1 2 3 4
2-25
1. Radiator cap
2. Coolant reservoir hose
3. Radiator
4. Radiator inlet hose
5. Radiator outlet hose
6. Thermostat assembly
7. Water pump inlet hose
8. Water pump assembly
2-26
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
1 A B
2
1 2
6 5 3
4
2-27
CABLE ROUTING
1. Front brake hose (front brake master cylinder to

hydraulic unit)
2. Rear brake hose (rear brake master cylinder to
hydraulic unit)
3. Rear brake light switch lead
4. Throttle cable (decelerator cable)
5. Throttle cable (accelerator cable)
6. Front brake light switch lead
7. Lower handlebar cover
A. 40–44 mm (1.57–1.73 in)
B. 5–9 mm (0.20–0.35 in)
C. Route the throttle cables through the hole in the
lower handlebar cover.
2-28
CABLE ROUTING
Handlebar (left side view)
4
3
7 8
7 7
1
1
1
3 5
3
6
4 6 4
2
1
A
5 4
3
10
5 9
8
6
6
B
11
6
2-29
CABLE ROUTING

hydraulic unit)
2. Rear brake light switch lead
5. Handlebar switch coupler (left handlebar switch)
6. Wire harness
hydraulic unit)
8. Handlebar switch coupler (right handlebar switch)
9. Front brake light switch lead
10. Handlebar switch connector (left handlebar switch)
11. Bracket
A. Route the throttle cable (accelerator cable) to the
front of the throttle cable (decelerator cable).
B. Insert the projection on the wire harness holder
into the hole in the bracket.
2-30
CABLE ROUTING
Front frame (front and left side view)
19
10
9
18
2
3 3 A 16
18
1
4 4 19
20
17
5
6 21 B
15
7 5
8
14 23
10
9 22
10
13
11
11
12
19 18
14 15
10
C
11 24
19 18 12
2-31
CABLE ROUTING
1. Main switch lead

2. Rectifier/regulator
3. Meter assembly lead
4. Turn signal relay
5. Turn signal relay lead
6. Headlight lead
7. Auxiliary light lead
8. Front turn signal light lead (front left turn signal
light)
9. Front wheel sensor lead
10. Front brake hose (hydraulic unit to front brake
caliper)
11. Wire harness
12. Rear brake hose (hydraulic unit to rear brake
caliper)
13. Hydraulic unit assembly lead
14. Hydraulic unit assembly
15. Front turn signal light lead (front right turn signal
light)
16. Meter assembly
17. Front wheel sensor coupler
hydraulic unit)
hydraulic unit)
22. Seat lock cable
23. Rectifier/regulator lead
24. Front turn signal light
A. After connecting the meter assembly coupler,
install the coupler cover completely until it contacts
the meter assembly.
B. Route the throttle cable (accelerator cable) to the
outside of the throttle cable (decelerator cable).
C. Route the front turn signal light lead as shown in
the illustration.
2-32
CABLE ROUTING
Front fork (rear and right side view)

1 2
C
1
3
3
6
F 6
7
G
7
B B
3
C
A
7
6
6
4
D
2
C 1 E
7 6
I H
6
6 7
7
B
F G
2-33
CABLE ROUTING
1. Horn lead
2. Front brake hose holder
3. Horn
4. Front wheel sensor
5. Front brake caliper
caliper)
7. Front wheel sensor lead
A. Route the front brake hose (hydraulic unit to front
brake caliper) through the guide.
B. Position the holder within the range shown in the
illustration.
C. Route the horn lead through the holder.
D. Connect the horn lead (pink) to the horn terminal.
E. Connect the horn lead (brown) to the horn
terminal.
F. Inward
G. Outward
H. Forward
I. Rearward
2-34
CABLE ROUTING
Frame (left side view)
10
11 10
16 C
9
C 17 18
16
11 21 10
12 20
14
19
16 14 E
13
11
15
D
E
9 15
1 2 A
2
1
3 4
B
9
8
7 3
4
6
8 6 H
6 F
2-35
CABLE ROUTING

3. Seat lock cable
4. Tail/brake light assembly lead
5. Sidestand switch
6. Frame ground lead
7. Fuel pump lead
8. Sidestand switch lead
9. Wire harness
10. AC magneto lead
11. Starter motor lead
12. Starter motor sub-wire harness
13. Engine ground lead
14. Ignition coil lead
15. Positive battery lead
16. Negative battery lead
17. Yamaha diagnostic tool lead
18. ABS test coupler lead
19. ECU lead
20. Fuse box 1
21. Fuse box 2
A. White tape
B. Route the throttle cable (accelerator cable) and
throttle cable (decelerator cable) through the guide.
Be sure to route the throttle cable (accelerator
cable) above the throttle cable (decelerator cable).
C. Fasten the wire harness and negative battery lead
with the plastic band.
D. Make sure that the engine ground lead terminal
contacts the stopper on the crankcase.
E. To starter relay
F. Install the frame ground terminal as shown in the
illustration.
G. 90°
H. Install the frame ground lead terminal so that the
crimped section of the terminal that secures the
lead is facing upward.
2-36
CABLE ROUTING
Frame (right side view)
21
22
23
1
2 6
8
15
14
11 12 13
4 5 6 9 10
3 7 8
2
1
20
19
18 17 A 16 15
13 B
C
1
12
20 24
9
2-37
CABLE ROUTING
1. Coolant temperature sensor lead

2. Throttle body sensor assembly lead
3. Starter motor lead
4. ISC (Idle Speed Control) unit lead
5. AC magneto lead
6. Fuel injector lead
7. O2 sensor lead
8. VVA (variable valve actuator) solenoid lead
9. Ignition coil
caliper)
11. Rear wheel sensor lead
12. Fuel tank overflow tray
13. Rear wheel sensor coupler
14. Wire harness
15. Fuel hose
16. VVA (variable valve actuator) solenoid
17. Spark plug lead
21. Sidestand switch lead
22. Fuel pump lead
23. Fuel pump
24. Ignition coil lead
A. Route the spark plug lead between the VVA
(variable valve actuator) solenoid and the water
pump inlet hose. Make sure that the spark plug
lead does not contact the VVA (variable valve
actuator) solenoid or water pump inlet hose.
B. Insert the projection on the rear wheel sensor
coupler into the hole in the fuel tank overflow tray.
C. Fasten the coolant temperature sensor lead to the
radiator inlet hose with the plastic band. Point the
end of the plastic band outward.
2-38
CABLE ROUTING
Frame (top view)
3
E 4 6
9 5 9
3
2
7
8 B
4
1
5
6
9 12
C
13
9
D
11
10
2-39
CABLE ROUTING
1. ECU lead
2. Positive battery lead
3. Fuse box 1
4. Fuse box 2
5. Fuel tank overflow tray
6. Negative battery lead
7. ABS test coupler lead
8. Yamaha diagnostic tool lead
9. Storage box
10. Tail/brake light assembly lead
11. Seat lock cable
12. ABS test coupler
13. Yamaha diagnostic tool coupler
A. Route the seat lock cable through the hole in the
frame.
B. Install fuse box 2 completely onto the tab on the
storage box.
C. Install the protective cap onto the ABS test
coupler.
D. Route the negative battery lead through the hole in
the storage box.
E. Install fuse box 1 completely onto the tab on the
storage box.
2-40
CABLE ROUTING
Hydraulic unit (top and right side view)
6 2
5
4
6
1
5
2
7
C
2-41
CABLE ROUTING
1. Hydraulic unit assembly

2. Main switch lead
caliper)
hydraulic unit)
hydraulic unit)
caliper)
7. Hydraulic unit assembly lead
A. Route the main switch lead through the guide.
B. 30°
C. The holder may be facing in any direction.
2-42
CABLE ROUTING
Rear brake (right side view)
8
3
6 C 6 3
5 6 C
10
9 3
6
7
5
7
2
A
5
4
3
1
3 B
D
6 E
7 6
2-43
CABLE ROUTING
1. Rear brake caliper

2. Rear wheel sensor
4. Radiator
caliper)
7. Swingarm
8. Rear brake hose bracket
9. Rear brake hose holder
10. AC magneto lead
A. Connect the coolant reservoir hose to the radiator,
and then fasten the hose by inserting the projection
on the holder into the hole in the rear brake hose
bracket and rear brake hose holder.
B. Position the holder within the range shown in the
illustration.
C. Route the rear brake hose (hydraulic unit to rear
brake caliper) through the guide.
D. Upward
E. Downward
2-44
CABLE ROUTING
Fuel tank (right side view)
C
9
1
9
3
1 2
3
7
4
A
6 A
2-45
CABLE ROUTING

caliper)
3. Fuel hose
4. Fuel tank overflow hose
5. Center lower cover
7. Coolant reservoir breather hose
8. Fuel hose holder
9. O2 sensor lead
A. Install the hose completely onto the hose fitting.
B. Position the hose clamp 3–7 mm (0.12–0.28 in)
from the end of the hose. Point the ends of the
hose clamp upward.
C. Fasten the grommet on the fuel hose with the
holder.
D. Insert the end of the fuel tank overflow hose into
the center lower cover. Make sure that the end of
the hose protector on the fuel tank overflow hose
contacts the edge of the hole in the center lower
cover.
2-46
CABLE ROUTING
Fuel tank (top and bottom view)
3 B
2 B 1 A
C 4
2-47
CABLE ROUTING
1. Coolant reservoir cap

2. Coolant reservoir breather hose
4. Fuel hose
A. Install the coolant reservoir cap as shown in the
illustration.
B. Align the white paint mark on the hose with the
projection on the coolant reservoir.
C. Fasten the grommet on the fuel hose with the
holder.
2-48
CABLE ROUTING
Radiator (top and right side view)
1 D
C
1
E
2 B
2
G F
A 3
4
D
G F
D 6 5 A E
O
6 A H D
E
I N M D
5
7 B
E N M
3 E
J A
K
4
L
A
2-49
CABLE ROUTING
1. Water pump
4. Radiator outlet hose
5. Radiator
A. Install the hose completely onto the hose fitting.
B. Face the white paint mark on the hose to the left.
C. 3–5 mm (0.12–0.20 in)
D. Upward
E. Downward
F. Forward
G. Rearward
H. Point the ends of the hose clamp to the left. Make
sure not to install the hose clamp on the raised
portion of the hose fitting.
I. To coolant reservoir
J. Face the yellow paint mark on the hose to the right.
K. Align the yellow paint mark on the hose with the
center of the thermostat assembly.
L. Face the white paint mark on the hose upward.
M. Outward
N. Inward
O. Make sure that the hose clamp does not contact
the radiator fan cover.
2-50
CABLE ROUTING
Air filter case (top and left side view)
1
C C B
A B
2
D 3 E
1 3
2-51
CABLE ROUTING
1. Cylinder head breather hose

2. V-belt case breather hose
3. Air filter case
A. Face the white paint mark on the hose upward.
B. Point the ends of the hose clamp upward.
C. Install the hose completely onto the hose fitting.
D. 1–5 mm (0.04–0.20 in)
E. 5–6 mm (0.20–0.24 in)
F. Face the yellow paint mark on the hose outward.
G. Point the ends of the hose clamp outward.
2-52
CABLE ROUTING
2-53
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE VEHICLE USING THE YAMAHA DIAGNOSTIC
TOOL ........................................................................................................ 3-4
CHECKING THE FUEL LINE .................................................................... 3-4
CHECKING THE SPARK PLUG ............................................................... 3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-5
CHECKING THE ENGINE IDLING SPEED ..............................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-7
ADJUSTING THE EXHAUST GAS VOLUME ...........................................3-8
REPLACING THE AIR FILTER ELEMENT AND CLEANING THE
CHECK HOSE .......................................................................................... 3-8
CHECKING THE BREATHER HOSES .....................................................3-8
3
CLEANING THE V-BELT CASE AIR FILTER ELEMENT AND
CLEANING THE CHECK HOSE .............................................................. 3-9
CHECKING THE BRAKE OPERATION .................................................. 3-10
CHECKING THE FRONT BRAKE PADS ................................................ 3-10
CHECKING THE REAR BRAKE PADS .................................................. 3-10
CHECKING THE BRAKE FLUID LEVEL................................................. 3-10
CHECKING THE FRONT BRAKE HOSES ............................................. 3-11
CHECKING THE REAR BRAKE HOSES................................................ 3-11
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-12
CHECKING THE WHEELS ..................................................................... 3-13
CHECKING THE TIRES..........................................................................3-13
CHECKING THE WHEEL BEARINGS ....................................................3-14
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-14
LUBRICATING THE STEERING HEAD.................................................. 3-16
CHECKING THE CHASSIS FASTENERS .............................................. 3-16
LUBRICATING THE LEVERS .................................................................3-16
CHECKING THE SIDESTAND................................................................3-16
LUBRICATING THE SIDESTAND........................................................... 3-16
CHECKING THE CENTERSTAND ......................................................... 3-16
LUBRICATING THE CENTERSTAND ....................................................3-16
CHECKING THE SIDESTAND SWITCH................................................. 3-16
CHECKING THE FRONT FORK ............................................................. 3-16
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-17
CHECKING THE ENGINE OIL LEVEL....................................................3-17
CHANGING THE ENGINE OIL ...............................................................3-17
CHECKING THE COOLANT LEVEL.......................................................3-19
CHECKING THE COOLING SYSTEM ....................................................3-19
CHANGING THE COOLANT................................................................... 3-19
CHANGING THE FINAL TRANSMISSION OIL....................................... 3-22
REPLACING THE V-BELT ...................................................................... 3-23
CHECKING THE BRAKE LIGHT SWITCHES.........................................3-23
CHECKING AND LUBRICATING THE CABLES .................................... 3-23
CHECKING THE THROTTLE GRIP OPERATION .................................3-23
CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......................... 3-24
ADJUSTING THE HEADLIGHT BEAM ...................................................3-24
PERIODIC MAINTENANCE
EAS20022
EAS30022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance,
or for the UK, a mileage-based maintenance, is performed instead.
• From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READINGS
CHECK OR MAINTENANCE ANNUAL
No. ITEM JOB CHECK
1000 km 6000 km 12000 km 18000 km 24000 km
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √
• Check condition. √ √
2 Spark plug • Clean and regap.
• Replace. √ √
3 * Valves • Check valve clearance. √ √ √ √

• Adjust.
4 * Fuel injection • Check engine idle speed. √ √ √ √ √
• Check for leakage.
5 * Exhaust system • Tighten if necessary. √ √ √ √ √
• Replace gasket if necessary.
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• The annual checks must be performed every year, except if a kilometer-based maintenance,
or for the UK, a mileage-based maintenance, is performed instead.
• From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
ODOMETER READINGS
No. ITEM
JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Perform dynamic inspection
Diagnostic sys-
1 * tem check using Yamaha diagnostic tool. √ √ √ √ √ √
• Check the error codes.
2 * Air filter element • Replace. Every 18000 km (10500 mi)
3 Air filter case • Clean. √ √ √ √ √

check hose
V-belt case air fil- • Clean.
4 * √ √ √ √ √
ter element • Replace if necessary.
3-1
ODOMETER READINGS
No. ITEM
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check operation, fluid level,

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

looseness.
12 * Steering bearings
• Moderately repack with lithi-
√
um-soap-based grease.
• Make sure that all nuts, bolts
13 * Chassis fasteners and screws are properly tight- √ √ √ √ √
ened.
Front and rear
14 brake lever pivot • Lubricate with silicone √ √ √ √ √
grease.
shaft
• Check operation.
15 Sidestand, center- • Lubricate with lithium-soap- √ √ √ √ √
stand
based grease.
• Check operation and replace
16 * Sidestand switch if necessary. √ √ √ √ √ √
• Check operation and for oil

17 * Front fork leakage. √ √ √ √
• Replace if necessary.
Shock absorber • Check operation and for oil

18 * leakage. √ √ √ √
assemblies • Replace if necessary.
• Change (warm engine before
draining). At the initial interval and when the oil change indicator flash-
19 Engine oil • Check oil level and vehicle for es or comes on [every 6000 km (3500 mi)]. √
oil leakage.
20 * Engine oil strainer • Clean. √
Final transmis- • Check vehicle for oil leakage. √ √ √ √ √

21 *
sion oil • Change. √ √ √
• Check coolant level and vehi-
cle for coolant leakage. √ √ √ √ √
22 * Cooling system
• Change. Every 3 years
23 * V-belt • Replace. When the V-belt replacement indicator flashes or comes on.
Front and rear
24 * • Check operation. √ √ √ √ √ √
brake switches
Moving parts and
25 * • Lubricate. √ √ √ √ √
cables
3-2
ODOMETER READINGS
No. ITEM
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check operation and free

Throttle grip play.
• Adjust the throttle cable free
26 * housing and ca- play if necessary. √ √ √ √ √
ble
• Lubricate the throttle grip
housing and cable.
27 * Lights, signals • Check operation. √ √ √ √ √ √

and switches • Adjust headlight beam.
TIP
• Engine air filter and V-belt air filter
• This model’s engine air filter is equipped with a disposable oil-coated paper element, which must not
be cleaned with compressed air to avoid damaging it.
• The engine air filter element needs to be replaced and the V-belt air filter element needs to be ser-
viced more frequently when riding in unusually wet or dusty areas.
• Hydraulic brake service
• After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-3
EAS32024 EAS30619
CHECKING THE VEHICLE USING THE CHECKING THE FUEL LINE

YAMAHA DIAGNOSTIC TOOL 1. Remove:
Use the Yamaha diagnostic tool and check the • Front side cover (right)
vehicle according to the following procedure. Refer to “GENERAL CHASSIS (2)” on page
1. Remove: 4-3.
• Battery cover • Footrest board assembly (right)
Refer to “GENERAL CHASSIS (1)” on page Refer to “GENERAL CHASSIS (5)” on page
4-1. 4-11.
2. Remove the protective cap, and then connect 2. Check:
the Yamaha diagnostic tool to the coupler “1”. • Fuel hose “1”
Cracks/damage → Replace.
Yamaha diagnostic tool USB Loose connections → Connect properly.
90890-03256
Yamaha diagnostic tool (A/I)
90890-03254
3. Install:
• Footrest board assembly (right)
Refer to “GENERAL CHASSIS (5)” on page
3. Check: 4-11.
• Fault codes • Front side cover (right)
TIP
4-3.
Use the “Diagnosis of malfunction” function of
the Yamaha diagnostic tool to check the fault EAS30620
codes. For information about using the Yamaha CHECKING THE SPARK PLUG
diagnostic tool, refer to the operation manual 1. Remove:
that is included with the tool. • Front side cover (right)
Fault code number is displayed → Check and 4-3.
repair the probable cause of the malfunction. • Footrest board assembly (right)
Refer to “TROUBLESHOOTING DETAILS Refer to “GENERAL CHASSIS (5)” on page
(FAULT CODE)” on page 8-28. 4-11.
4. Perform: 2. Remove:
• Dynamic inspection • Spark plug cap
TIP • Spark plug
ECA13330
Use the “Dynamic inspection” function of the
NOTICE
Yamaha diagnostic tool version 3.0 and after to
perform the dynamic inspection. For information Before removing the spark plug, blow away
about using the Yamaha diagnostic tool, refer to any dirt accumulated in the spark plug well
the operation manual that is included with the with compressed air to prevent it from falling
tool. into the cylinder.
5. Install: 3. Check:
• Battery cover • Spark plug type
Refer to “GENERAL CHASSIS (1)” on page Incorrect → Change.
4-1.
3-4
• When tightening the spark plug, make sure

Manufacturer/model that the inside “a” of the spark plug wrench “2”
NGK/CPR8EA-9 does not the contact the portion “b” of the spark
plug.
4. Check:
• To route the spark plug lead, refer to “CON-
• Electrode “1”
NECTING THE LEADS” on page 5-8.
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug. b
a 2
Normal color is medium-to-light tan.
8. Install:
5. Clean: 4-11.
• Spark plug • Front side cover (right)
(with a spark plug cleaner or wire brush) Refer to “GENERAL CHASSIS (2)” on page
6. Measure: 4-3.
• Spark plug gap “a” EAS30622
(with a wire thickness gauge) ADJUSTING THE VALVE CLEARANCE
Out of specification → Regap. The following procedure applies to all of the
valves.
Spark plug gap
0.8–0.9 mm (0.031–0.035 in) TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Remove:
• Battery
4-1.
• Front side covers
7. Install:
4-3.
• Spark plug “1”
• Fuel tank cover
• Spark plug cap
Spark plug 4-6.
13 N·m (1.3 kgf·m, 9.6 lb·ft) • Center lower cover
T.
R.

TIP 4-11.
• Before installing the spark plug, clean the • Fuel tank
spark plug and gasket surface. Refer to “FUEL TANK” on page 7-1.
• Cylinder head cover
Refer to “CYLINDER HEAD” on page 5-9.
• Radiator cover
Refer to “RADIATOR” on page 6-1.
3-5
2. Move: b. When the piston is at the Top Dead Center

• Radiator “1” (TDC) on the compression stroke, align
TIP the mark “a” on the camshaft sprocket with
Move the rear of the radiator outward. the match mark “b” on the camshaft stop-
per plate.
a b
3. Move: c. Measure the valve clearance with a thick-

• Water pump assembly “1” ness gauge “1”.
TIP Out of specification → Adjust.
Move the water pump assembly in the direction
shown in the illustration.
5. Adjust:
• Valve clearance
a. Loosen the locknut “1”.
4. Measure:
b. Insert a thickness gauge “2” between the
• Valve clearance
end of the adjusting screw and the valve
Out of specification → Adjust.
tip.
Valve clearance (cold)
Intake
0.10–0.14 mm (0.0039–0.0055 in)
Exhaust
0.21–0.25 mm (0.0083–0.0098 in) 1
a. Turn the crankshaft clockwise.
c. Turn the adjusting screw “3” in direction

“a” or “b” with the tappet adjusting tool “4”
until the specified valve clearance is ob-
tained.
Direction “a”
Valve clearance is increased.
Direction “b”
Valve clearance is decreased.
3-6
Refer to “CLEANING THE ISC (IDLE SPEED

Tappet adjusting tool CONTROL) UNIT AND THROTTLE BODY”
90890-01311 on page 7-12.
Six piece tappet set a. Connect the Yamaha diagnostic tool.
YM-A5970
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNC-
TION AND DIAGNOSTIC CODE TABLE”
on page 9-5.
Yamaha diagnostic tool USB

3 90890-03256
90890-03254
a
b 4 EAS30625
CHECKING THE EXHAUST SYSTEM

d. Hold the adjusting screw to prevent it from 1. Check:
moving and tighten the locknut to specifi- • Muffler “1”
cation. Cracks/damage → Replace.
• Gasket “2”
Valve clearance adjusting screw Exhaust gas leaks → Replace.
locknut 2. Check:
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft) Tightening torque

• Muffler nuts “3”
e. Measure the valve clearance again. • Muffler bolts “4”
f. If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance Muffler nut
adjustment steps until the specified clear- 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
ance is obtained. Muffler bolt

6. Install: 53 N·m (5.3 kgf·m, 39 lb·ft)
• All removed parts
TIP
For installation, reverse the removal procedure.
EAS31017
CHECKING THE ENGINE IDLING SPEED

TIP
Prior to checking the engine idling speed, the air
filter element should be clean, and the engine 4
should have adequate compression.
1. Start the engine and let it warm up for several 1
minutes. 2
2. Check: 4
• Engine idling speed
Out of specification → Go to next step.
3
Engine idling speed
1500–1700 r/min
3. Check: 4
• ISC (idle speed control) learning value
“00” or “01” → Check the intake system.
“02” → Clean the ISC (idle speed control) unit
and throttle body.
3-7
EAS30799
ADJUSTING THE EXHAUST GAS VOLUME 2

TIP
• Be sure to set the CO density level to standard,
and then adjust the exhaust gas volume.
• To adjust the exhaust gas volume, use the CO
adjustment mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
1. Connect the Yamaha diagnostic tool to the
connector. For information about connecting 2. Check:
the Yamaha diagnostic tool, refer to • Air filter element
“YAMAHA DIAGNOSTIC TOOL” on page Damage → Replace.
8-28. TIP
• Replace the air filter element every 18000 km
(10500 mi) of operation.
90890-03256
Yamaha diagnostic tool (A/I) • The air filter needs more frequent service if you
90890-03254 are riding in unusually wet or dusty areas.
3. Install:
EAS31130
• Air filter element
REPLACING THE AIR FILTER ELEMENT
• Air filter case cover
AND CLEANING THE CHECK HOSE
TIP Air filter case cover screw
Check the air filter check hose “1” that is located 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
T.
R.
on the rear side of the air filter case. If dust or ECA20480

water or both collects in the hose, clean the hose NOTICE
and replace the air filter element.
Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
1 the engine. Operating the engine without the
air filter element will also affect throttle body
tuning, leading to poor engine performance
and possible overheating.
TIP
When installing the air filter element into the air
filter case, make sure that the sealing surfaces
1. Remove: are aligned to prevent any air leaks.
• Air filter case cover “1”
• Air filter element “2” EAS31179
CHECKING THE BREATHER HOSES

1 1. Remove:
• Battery
4-1.
4-3.
• Fuel tank cover
4-6.
3-8
• Storage box EAS31704
CLEANING THE V-BELT CASE AIR FILTER

ELEMENT AND CLEANING THE CHECK
4-8.
HOSE
2. Check:
• Cylinder head breather hose “1” TIP
• Transmission case breather hose “2” Check the V-belt case air filter check hose “1”
Cracks/damage → Replace. that is located on the rear side of the V-belt case.
Loose connections → Connect properly. If dust or water or both collects in the hose, clean
ECA21600 the hose and replace the V-belt case air filter el-
NOTICE ement.
Make sure the cylinder head breather hose
and transmission case breather hose are
routed correctly.
1. Remove:
• V-belt case air filter element cover “1”
• V-belt case air filter element “2”
2 1
3. Install:
• Storage box
4-8.
• Fuel tank cover
4-6. 2
4-3.
• Battery 2. Clean:
Refer to “GENERAL CHASSIS (1)” on page • V-belt case air filter element
4-1. (with solvent)
EWA17971
WARNING
Never use low flash point solvents, such as
gasoline, to clean the V-belt case air filter el-
ement. Such solvents may cause a fire or an
explosion.
3-9
EAS30633
TIP CHECKING THE FRONT BRAKE PADS
• The air filter needs more frequent service if you The following procedure applies to all of the
are riding in unusually wet or dusty areas. brake pads.
• After cleaning, gently squeeze the V-belt case 1. Operate the brake.
air filter element to remove the excess solvent. 2. Check:
ECA21590 • Front brake pad
NOTICE Wear indicator grooves “a” almost disap-
Do not twist the V-belt case air filter element peared → Replace the brake pads as a set.
when squeezing it. Refer to “FRONT BRAKE” on page 4-35.
a
a
EAS30634
3. Check: CHECKING THE REAR BRAKE PADS
• V-belt case air filter element The following procedure applies to all of the
Damage → Replace. brake pads.
4. Apply the recommended oil to the entire sur- 1. Operate the brake.
face of the V-belt case air filter element and 2. Check:
squeeze out the excess oil. The V-belt case • Rear brake pad
air filter element should be wet but not drip- Wear indicators “a” almost touch the brake
ping. disc → Replace the brake pads as a set.
Recommended oil Refer to “REAR BRAKE” on page 4-48.
Engine oil
5. Install:
• V-belt case air filter element
• V-belt case air filter element cover
V-belt case air filter element cov-

er bolt
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft) a

EAS30801
EAS30632
CHECKING THE BRAKE OPERATION
CHECKING THE BRAKE FLUID LEVEL
1. Check:
1. Stand the vehicle on a level surface.
• Brake operation
Brake not working properly → Check the TIP
brake system. • Place the vehicle on the centerstand.
Refer to “FRONT BRAKE” on page 4-35 and • Make sure the vehicle is upright.
“REAR BRAKE” on page 4-48. • In order to ensure a correct reading of the
TIP
brake fluid level, make sure the top of the brake
fluid reservoir is horizontal.
Drive on the road, operate the front and rear
brakes separately and check to see if the brakes 2. Check:
are operating properly. • Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
3-10
Specified brake fluid

DOT 4 1
A
a
1
2. Check:
• Brake hose holder
• Brake hose guide
Loose → Tighten the holder and guide bolt.
B 3. Hold the vehicle upright and apply the front
brake several times.
4. Check:
• Brake hoses
a Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-35 and
“ABS (ANTI-LOCK BRAKE SYSTEM)” on
page 4-60.
EAS30636
A. Front brake
CHECKING THE REAR BRAKE HOSES
B. Rear brake
1. Check:
EWA13540
• Brake hoses “1”
WARNING Cracks/damage/wear → Replace.
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor 1
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids 1
may result in a harmful chemical reaction,
leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil- 2. Check:
ing point of the brake fluid and could cause • Brake hose holder
vapor lock. Loose → Tighten the holder bolt.
ECA13540 3. Hold the vehicle upright and apply the rear
NOTICE brake several times.
Brake fluid may damage painted surfaces 4. Check:
and plastic parts. Therefore, always clean up • Brake hoses
any spilt brake fluid immediately. Brake fluid leakage → Replace the brake
hose.
EAS30635 Refer to “REAR BRAKE” on page 4-48 and
CHECKING THE FRONT BRAKE HOSES “ABS (ANTI-LOCK BRAKE SYSTEM)” on
1. Check: page 4-60.
• Brake hoses “1”
3-11
EAS30893
BLEEDING THE HYDRAULIC BRAKE B

SYSTEM
EWA14000
WARNING
Always bleed the brake system when the 1
brake related parts are removed.
ECA22780
2
NOTICE
• Bleed the brake system in the following or-
der.
• 1st step: Front brake caliper A. Front brake caliper
• 2nd step: Rear brake caliper B. Rear brake caliper
EWA16530 d. Place the other end of the hose into a con-
WARNING tainer.
Bleed the ABS whenever: e. Slowly apply the brake several times.
• the system is disassembled. f. Fully squeeze the brake lever and hold it in
• a brake hose is loosened, disconnected or position.
replaced. g. Loosen the bleed screw.
• the brake fluid level is very low. TIP
• brake operation is faulty. Loosening the bleed screw will release the pres-
TIP sure and cause the brake lever to contact the
throttle grip or handlebar grip.
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir to overflow. h. Tighten the bleed screw and then release
• When bleeding the ABS, make sure that there the brake lever.
is always enough brake fluid before applying i. Repeat steps (e) to (h) until all of the air
the brake. Ignoring this precaution could allow bubbles have disappeared from the brake
air to enter the ABS, considerably lengthening fluid in the plastic hose.
the bleeding procedure. j. Check the operation of the hydraulic unit.
• If bleeding is difficult, it may be necessary to let Refer to “HYDRAULIC UNIT OPERA-
the brake fluid settle for a few hours. TION TESTS” on page 4-64.
ECA18060
• Repeat the bleeding procedure when the tiny
NOTICE
bubbles in the hose have disappeared.
Make sure that the main switch is turned to
1. Bleed: “OFF” before checking the operation of the
• ABS hydraulic unit.
a. Fill the brake master cylinder reservoir to
the proper level with the specified brake k. After operating the ABS, repeat steps (e)
fluid. to (i), and then fill the brake master cylin-
b. Install the brake master cylinder dia- der reservoir to the proper level with the
phragm. specified brake fluid.
c. Connect a clear plastic hose “1” tightly to l. Tighten the bleed screw to specification.
the bleed screw “2”.
Brake caliper bleed screw
A 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
2
m. Fill the brake master cylinder reservoir to
the proper level with the specified brake
1 fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-10.
3-12
EWA13110
• Operation of an overloaded vehicle could
WARNING cause tire damage, an accident or an injury.
After bleeding the hydraulic brake system, NEVER OVERLOAD THE VEHICLE.
check the brake operation.
Tire air pressure (measured on
EAS30638
cold tires)
CHECKING THE WHEELS
1 person
The following procedure applies to all of the Front
wheels. 150 kPa (1.50 kgf/cm², 22 psi)
1. Check: Rear
• Wheel 250 kPa (2.50 kgf/cm², 36 psi)
Damage/out-of-round → Replace. 2 persons
EWA13260
Front
WARNING 150 kPa (1.50 kgf/cm², 22 psi)
Never attempt to make any repairs to the Rear
wheel. 250 kPa (2.50 kgf/cm², 36 psi)
* Total weight of rider, passenger, cargo
TIP
and accessories
After a tire or wheel has been changed or re-
placed, always balance the wheel. EWA13190
WARNING
2. Measure:
It is dangerous to ride with a worn-out tire.
• Radial wheel runout
When the tire tread reaches the wear limit, re-
• Lateral wheel runout
place the tire immediately.
Refer to “CHECKING THE FRONT WHEEL”
on page 4-26 and “CHECKING THE REAR 2. Check:
WHEEL” on page 4-33. • Tire surfaces
Damage/wear → Replace the tire.
EAS30640
CHECKING THE TIRES

The following procedure applies to all of the
tires.
1. Check:
• Tire pressure
Out of specification → Regulate.
1. Tire tread depth

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

1.6 mm (0.06 in) (EUR, MBK
EWA13181 brand)
WARNING 1.5 mm (0.06 in) (AUS/NZL)
• The tire pressure should only be checked 1.0 mm (0.04 in) (KOR)
and regulated when the tire temperature Wear limit (rear)
equals the ambient air temperature. 1.6 mm (0.06 in) (EUR, MBK
brand)
• The tire pressure and the suspension must
1.5 mm (0.06 in) (AUS/NZL)
be adjusted according to the total weight 1.0 mm (0.04 in) (KOR)
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
3-13
EWA14080
WARNING Rear tire

• Do not use a tubeless tire on a wheel de- Size
signed only for tube tires to avoid tire fail- 130/70–13M/C 57P
ure and personal injury from sudden Manufacturer/model
deflation. DUNLOP/SCOOTSMART
• When using a tube tire, be sure to install the EWA13210
correct tube. WARNING

• Always replace a new tube tire and a new New tires have a relatively low grip on the
tube as a set. road surface until they have been slightly
• To avoid pinching the tube, make sure the worn. Therefore, approximately 100 km
wheel rim band and tube are centered in the should be traveled at normal speed before
wheel groove. any high-speed riding is done.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to do TIP
so, use great care and replace the tube as For tires with a direction of rotation mark “1”:
soon as possible with a good quality re- • Install the tire with the mark pointing in the di-
placement. rection of wheel rotation.
• Align the mark “2” with the valve installation
A B point.
2
1
A. Tire
B. Wheel
EAS30641
Tube wheel Tube tire only CHECKING THE WHEEL BEARINGS
Tubeless wheel Tube or tubeless tire The following procedure applies to all of the
EWA14090
wheel bearings.
WARNING 1. Check:
• Wheel bearings
After extensive tests, the tires listed below
Refer to “CHECKING THE FRONT WHEEL”
have been approved by Yamaha Motor Co.,
on page 4-26.
Ltd. for this model. The front and rear tires
should always be by the same manufacturer EAS30645
and of the same design. No guarantee con- CHECKING AND ADJUSTING THE
cerning handling characteristics can be giv- STEERING HEAD
en if a tire combination other than one 1. Stand the vehicle on a level surface.
EWA13120
approved by Yamaha is used on this vehicle.
WARNING
Securely support the vehicle so that there is
Front tire
no danger of it falling over.
Size
110/70–13M/C 48P TIP
Manufacturer/model Place the vehicle on a suitable stand so that the
DUNLOP/SCOOTSMART
front wheel elevated.
3-14
2. Check:
• Steering head
Grasp the handlebar and gently rock the han-
dlebar.
Binding/looseness → Adjust the steering
head.
3. Remove:
• Front side covers 6
4-3. 5
• Center lower cover c. Loosen the lower ring nut 1/4 of a turn, and
Refer to “GENERAL CHASSIS (5)” on page then tighten it to specification with a steer-
4-11. ing nut wrench.
• Front upper cowling assembly EWA13140
Refer to “GENERAL CHASSIS (6)” on page WARNING

4-15. Do not overtighten the lower ring nut.
• Handlebar
Refer to “HANDLEBAR” on page 4-68. Lower ring nut (final tightening
4. Adjust: torque)
T.
R.
• Steering head 16 N·m (1.6 kgf·m, 12 lb·ft)
a. Remove the upper ring nut “1”, lock wash-
er “2”, center ring nut “3” and rubber wash- d. Check the steering head for looseness or
er “4”. binding by turning the front fork all the way
in both directions. If any binding is felt, re-
move the lower bracket and check the up-
per and lower bearings.
Refer to “STEERING HEAD” on page
1 4-82.
e. Install the rubber washer.
3 f. Install the center ring nut.
4 g. Finger tighten the center ring nut, then
align the slots of both ring nuts. If neces-
2 sary, hold the lower ring nut and tighten
b. Loosen the lower ring nut “5” and then the center ring nut until their slots are
tighten it to specification with a steering aligned.
nut wrench “6”. h. Install the lock washer “2”.
TIP TIP
Set the torque wrench at a right angle to the Make sure the lock washer tabs “a” sit correctly
steering nut wrench. in the ring nut slots “b”.
Steering nut wrench

90890-01403 2
YU-A9472 a
Lower ring nut (initial tightening b

torque)
T.
R.
38 N·m (3.8 kgf·m, 28 lb·ft)
i. Hold the lower and center ring nuts with a

steering nut wrench and tighten the upper
ring nut with a another steering nut
wrench.
3-15
EAS30651
Steering nut wrench LUBRICATING THE SIDESTAND

90890-01403 Lubricate the pivoting point, metal-to-metal mov-
Exhaust flange nut wrench ing parts, and spring contact point of the side-
YU-A9472 stand.
Recommended lubricant
Upper ring nut Lithium-soap-based grease
75 N·m (7.5 kgf·m, 55 lb·ft)
T.
R.
EAS30856
5. Install: CHECKING THE CENTERSTAND

• Handlebar 1. Check:
Refer to “HANDLEBAR” on page 4-68. • Centerstand operation
• Front upper cowling assembly Check that the centerstand moves smoothly.
Refer to “GENERAL CHASSIS (6)” on page Rough movement → Repair or replace.
4-15.
EAS30857
• Center lower cover LUBRICATING THE CENTERSTAND
Refer to “GENERAL CHASSIS (5)” on page Lubricate the pivoting point, metal-to-metal mov-
4-11. ing parts, and spring contact points of the center-
• Front side covers stand.
4-3. Recommended lubricant
Lithium-soap-based grease
EAS30646
LUBRICATING THE STEERING HEAD

EAS30652
1. Lubricate: CHECKING THE SIDESTAND SWITCH
• Upper bearing Refer to “CHECKING THE SWITCHES” on
• Lower bearing page 8-101.
• Lower bearing dust seal
EAS30653
Recommended lubricant CHECKING THE FRONT FORK

Lithium-soap-based grease 1. Stand the vehicle on a level surface.
EWA13120
EAS31186 WARNING
CHECKING THE CHASSIS FASTENERS Securely support the vehicle so that there is
Make sure that all nuts, bolts, and screws are no danger of it falling over.
properly tightened.
Refer to “CHASSIS TIGHTENING TORQUES” 2. Check:
on page 2-14. • Inner tube
Damage/scratches → Replace.
EAS30648 • Oil seal
LUBRICATING THE LEVERS Oil leakage → Replace.
Lubricate the pivoting point and metal-to-metal 3. Hold the vehicle upright and apply the front
moving parts of the levers. brake.
4. Check:
Silicone grease • Front fork operation
Push down hard on the handlebar several
EAS30650
times and check if the front fork rebounds
CHECKING THE SIDESTAND smoothly.
1. Check: Rough movement → Repair.
• Sidestand operation Refer to “FRONT FORK” on page 4-75.
Check that the sidestand moves smoothly.
Rough movement → Repair or replace.
3-16
TIP
• Before checking the engine oil level, wait a few
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
the oil level.
EAS30808
1 1
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLIES b
The following procedure applies to both of the
rear shock absorber assemblies. a
EWA13120
WARNING Recommended brand

Securely support the vehicle so that there is YAMALUBE
no danger of it falling over. SAE viscosity grades
10W-40
2. Check: Recommended engine oil grade
• Rear shock absorber assembly API service SG type or higher,
Oil leaks → Replace the rear shock absorber JASO standard MA or MB
assembly.
ECA13370
Refer to “CHECKING THE REAR SHOCK NOTICE
ABSORBER ASSEMBLY” on page 4-89.
3. Check: Do not allow foreign materials to enter the
• Rear shock absorber assembly operation crankcase.
Push down seat on the vehicle several times 5. Start the engine, warm it up for several min-
and check if the rear shock absorber assem- utes, and then turn it off.
bly rebounds smoothly. 6. Check the engine oil level again.
Rough movement → Replace. TIP
Refer to “REAR SHOCK ABSORBER AS- Before checking the engine oil level, wait a few
SEMBLIES AND SWINGARM” on page minutes until the oil has settled.
4-87.
EAS30656 EAS30657
CHECKING THE ENGINE OIL LEVEL CHANGING THE ENGINE OIL

1. Stand the vehicle on a level surface. 1. Start the engine, warm it up for several min-
TIP utes, and then turn it off.
2. Place a container under the engine oil drain
• Place the vehicle on the centerstand.
bolt.
• Make sure the vehicle is upright.
3. Remove:
2. Start the engine, warm it up for several min- • Dipstick “1”
utes, and then turn it off. • Engine oil drain bolt “2”
3. Remove: (along with the gasket “3”)
• Dipstick “1”
4. Check:
• Engine oil level
The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
3-17
6. Install:
• Engine oil drain bolt
(along with the gasket New )
Engine oil drain bolt

20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
1 7. Fill:
• Crankcase
(with the specified amount of the recom-
mended engine oil)
Engine oil quantity

Quantity (disassembled)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil change
3 2 0.90 L (0.95 US qt, 0.79 Imp.qt)
8. Install:
• Dipstick
9. Start the engine, warm it up for several min-
4. Drain: utes, and then turn it off.
• Engine oil 10.Check:
(completely from the crankcase) • Engine
5. If the oil strainer is also to be cleaned, per- (for engine oil leaks)
form the following procedure. 11.Check:
a. Remove the oil strainer cover “1”, spring • Engine oil level
“2”, and oil strainer “3”. Refer to “CHECKING THE ENGINE OIL
b. Install a new O-ring “4”. LEVEL” on page 3-17.
TIP 12.Remove:
• Front side cover (right)
Lubricate the O-ring with lithium-soap-based
grease.
4-3.
4-11.
3 13.Check:
• Engine oil pressure
2 a. Slightly loosen the oil check bolt “1”.
4 New
1
c. Clean the engine oil strainer with solvent,

and then check it for damage and replace 1
it if necessary.
d. Install the oil strainer, spring, and oil strain-
er cover.
Oil strainer cover b. Start the engine and keep it idling until en-
32 N·m (3.2 kgf·m, 24 lb·ft) gine oil starts to seep from the oil check
T.
R.
bolt. If no engine oil comes out after one

minute, turn the engine off so that it will not
seize.
3-18
c. Check the engine oil passages and the oil TIP

pump for damage or leakage. Refer to Before checking the coolant level, wait a few
“OIL PUMP” on page 5-54. minutes until the coolant has settled.
d. Start the engine after solving the prob-
lem(s) and check the engine oil pressure EAS30812
again. CHECKING THE COOLING SYSTEM
e. Tighten the oil check bolt to specification. 1. Remove:
• Radiator cover
Engine oil check bolt Refer to “RADIATOR” on page 6-1.
7 N·m (0.7 kgf·m, 5.2 lb·ft) 2. Check:
T.
R.
• Radiator “1”
14.Reset:
• Coolant reservoir hose “2”
• Oil change indicator
• Radiator inlet hose “3”
Refer to “INSTRUMENT FUNCTIONS” on
• Radiator outlet hose “4”
page 1-2.
• Thermostat assembly “5”
EAS30811 • Water pump inlet hose “6”
CHECKING THE COOLANT LEVEL Cracks/tears → Replace.
1. Stand the vehicle on a level surface. Refer to “RADIATOR” on page 6-1 and
TIP “THERMOSTAT” on page 6-5.
• Place the vehicle on the centerstand.
3 2
2. Check: 5
• Coolant level
The coolant level should be between the min- 1
imum level mark “a” and maximum level mark
“b”.
Below the minimum level mark → Add the 4 6
recommended coolant to the proper level.
3. Install:
• Radiator cover
b
Refer to “RADIATOR” on page 6-1.
a EAS30813
CHANGING THE COOLANT

1. Remove:
4-3.
ECA13470 • Bottom cover
NOTICE • Footrest board assembly (right)
• Adding water instead of coolant lowers the Refer to “GENERAL CHASSIS (5)” on page
antifreeze content of the coolant. If water is 4-11.
used instead of coolant check, and if nec- 2. Disconnect:
essary, correct the antifreeze concentra- • Coolant reservoir hose “1”
tion of the coolant. • Coolant reservoir breather hose “2”
• Use only distilled water. However, if dis-
tilled water is not available, soft water may
be used.
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Check:
• Coolant level
3-19
EWA13030
WARNING
A hot radiator is under pressure. Therefore,
2 do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
be blown out, which could cause serious in-
jury. When the engine has cooled, open the
radiator cap as follows:
Place a thick rag or a towel over the radiator
1
cap and slowly turn the radiator cap counter-
3. Remove: clockwise toward the detent to allow any re-
• Coolant reservoir cap “1” sidual pressure to escape. When the hissing
• Coolant reservoir “2” sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
7. Remove:
• Coolant drain bolt (radiator side) “1”
1 (along with the O-ring)
• Coolant drain bolt (cylinder side) “2”
(along with the copper washer)
2
4. Drain:
• Coolant
(from the coolant reservoir)
5. Remove:
• Radiator cover “1”
6. Remove:
• Radiator cap “1” 2
1 8. Drain:
• Coolant
(from the engine and radiator)
9. Install:
• Coolant drain bolt (cylinder side)
(along with the copper washer New )
• Coolant drain bolt (radiator side)
(along with the O-ring New )
3-20
• If coolant splashes on your clothes, quickly

Coolant drain bolt (cylinder side) wash it away with water and then with soap
10 N·m (1.0 kgf·m, 7.4 lb·ft) and water.
T.
R.
Coolant drain bolt (radiator side) • If coolant is swallowed, induce vomiting

1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
and get immediate medical attention.
10.Connect: ECA13481
• Coolant reservoir breather hose NOTICE

• Coolant reservoir hose • Adding water instead of coolant lowers the
11.Fill: antifreeze content of the coolant. If water is
• Cooling system used instead of coolant, check, and if nec-
(with the specified amount of the recom- essary, correct the antifreeze concentra-
mended coolant) tion of the coolant.
• Use only distilled water. However, if dis-
Recommended antifreeze tilled water is not available, soft water may
High-quality ethylene glycol an- be used.
tifreeze containing corrosion in- • If coolant comes into contact with painted
hibitors for aluminum engines surfaces, immediately wash them with wa-
Mixing ratio
ter.
1:1 (antifreeze: water)
Radiator (including all routes) • Do not mix different types of antifreeze.
0.46 L (0.49 US qt, 0.40 Imp.qt) 12.Install:
Coolant reservoir (up to the • Radiator cap
maximum level mark) • Coolant reservoir
0.25 L (0.26 US qt, 0.22 Imp.qt)
Coolant reservoir bolt
TIP 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Fill the coolant into the radiator, and then re-

move the air bleed bolt “1” until coolant comes 13.Fill:
out. • Coolant reservoir
• Tighten the air bleed bolt to specification. (with the recommended coolant to the maxi-
mum level mark “a”)
Air bleed bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
a
R.
14.Install:
• Coolant reservoir cap “1”
TIP
Handling notes for coolant Point the tab “a” on the coolant reservoir cap for-
Coolant is potentially harmful and should be ward.
handled with special care.
EWA13040
WARNING
• If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
3-21
1 a
FWD 2
15.Start the engine, warm it up for several min-

utes, and then turn it off.
16.Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-19.
4 3
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
17.Install:
5. Install:
• Radiator cover
• Final transmission oil drain bolt
Radiator cover bolt (along with the copper washer New )
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
Final transmission oil drain bolt

18.Install: 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.

Refer to “GENERAL CHASSIS (5)” on page 6. Fill:
4-11. • Final transmission oil
• Front side cover (right) (with the specified amount of the recom-
Refer to “GENERAL CHASSIS (2)” on page mended final transmission oil)
4-3. Final transmission oil
EAS31187 Type
CHANGING THE FINAL TRANSMISSION OIL Motor oil SAE 10W-30 type SE
1. Stand the vehicle on a level surface. or higher or Gear oil SAE 85W
TIP GL-3
Quantity
• Place the vehicle on the centerstand. 0.15 L (0.16 US qt, 0.13 Imp.qt)
2. Start the engine, warm it up for several min- 7. Install:
utes, and then turn it off. • Final transmission oil filler cap
3. Place a container under the final transmis- (along with the O-ring New )
sion. TIP
4. Remove: Lubricate the O-ring with lithium-soap-based
• Final transmission oil filler cap “1” grease.
(along with the O-ring “2”)
• Final transmission oil drain bolt “3” 8. Start the engine, warm it up for several min-
(along with the copper washer “4”) utes, and then turn it off.
Completely drain the final transmission oil. 9. Check:
• Final transmission oil leakage
3-22
EAS31188
REPLACING THE V-BELT Recommended lubricant

1. Remove: Engine oil or a suitable cable lu-
• Air filter case bricant
Refer to “AIR FILTER CASE” on page 7-7.
• V-belt case TIP
Refer to “V-BELT AUTOMATIC TRANSMIS- Hold the cable end upright and pour a few drops
SION” on page 5-34. of lubricant into the cable sheath or use a suit-
2. Check: able lubricating device.
• V-belt
Damage/wear → Replace. EAS30861
Grease/oil → Clean the primary and second- CHECKING THE THROTTLE GRIP
ary pulleys. OPERATION
Refer to “V-BELT AUTOMATIC TRANSMIS- 1. Check:
SION” on page 5-34. • Throttle cables
TIP Damage/deterioration → Replace.
Replace the V-belt every 25000 km (15500 mi) • Throttle cable installation
of operation. Incorrect → Reinstall the throttle cables.
Refer to “HANDLEBAR” on page 4-68.
3. Install: 2. Check:
• V-belt case • Throttle grip movement
Refer to “V-BELT AUTOMATIC TRANSMIS- Rough movement → Lubricate or replace the
SION” on page 5-34. defective part(s).
• Air filter case
Refer to “AIR FILTER CASE” on page 7-7. Recommended lubricant
Suitable cable lubricant
EAS30658
CHECKING THE BRAKE LIGHT SWITCHES

TIP
1. Check:
• Front brake light switch operation With the engine stopped, turn the throttle grip
• Rear brake light switch operation slowly and release it. Make sure that the throttle
When operating the brake levers, confirm grip turns smoothly and returns properly when
that the brake light comes on. released.
Faulty → Refer to “CHECKING THE Repeat this check with the handlebar turned all
SWITCHES” on page 8-101. the way to the left and right.
EAS30660
3. Check:
CHECKING AND LUBRICATING THE • Throttle grip free play “a”
CABLES Out of specification → Adjust.
The following procedure applies to all of the in-
ner and outer cables. Throttle grip free play
EWA13270 3.0–5.0 mm (0.12–0.20 in)
WARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
• Outer cable
Damage → Replace. a
2. Check:
• Cable operation
Rough movement → Lubricate. 4. Adjust:
• Throttle grip free play
a. Slide back the rubber cover “1”.
3-23
b. Loosen the locknut “2”. a. Turn the adjusting bolt “1” in direction “a”
c. Turn the adjusting nut “3” in direction “a” or or “b”.
“b” until the specified throttle grip free play
is obtained. Direction “a”
Headlight beam is raised.
Direction “a” Direction “b”
Throttle grip free play is increased. Headlight beam is lowered.
Direction “b”
Throttle grip free play is decreased.
1
a b
1
b 3
2
d. Tighten the locknut.
Throttle cable adjusting locknut

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
e. Slide the rubber cover its original position.

TIP
Make sure that the adjusting nut is covered com-
pletely by the rubber cover.
EWA17990
WARNING
After adjusting the throttle grip free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
EAS30663
CHECKING THE SWITCHES, LIGHTS AND

SIGNALS
1. Check that all switches operate and that all
lights come on.
Refer to “Instrument and control functions” in
OWNER’S MANUAL.
Faulty → Refer to “CHECKING THE
SWITCHES” on page 8-101 and “CHECK-
ING THE BULBS AND BULB SOCKETS” on
page 8-104.
EAS30664
ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• Headlight beam (vertically)
3-24
3-25
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE BATTERY COVER .......................................................4-2
INSTALLING THE BATTERY COVER ......................................................4-2
REMOVING THE ECU (engine control unit) .............................................4-2
INSTALLING THE ECU (engine control unit) ............................................4-2
GENERAL CHASSIS (2) ................................................................................. 4-3

REMOVING THE TAIL/BRAKE LIGHT OUTER COVER .......................... 4-4
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER.........................4-4
REMOVING THE FRONT SIDE COVER .................................................. 4-4
INSTALLING THE FRONT SIDE COVER................................................. 4-4
GENERAL CHASSIS (3) ................................................................................. 4-6

REMOVING THE FUEL TANK COVER .................................................... 4-7
INSTALLING THE FUEL TANK COVER................................................... 4-7
GENERAL CHASSIS (4) ................................................................................. 4-8

REMOVING THE REAR SIDE COVER ASSEMBLY ..............................4-10
INSTALLING THE REAR SIDE COVER ASSEMBLY............................. 4-10 4
GENERAL CHASSIS (5) ............................................................................... 4-11
INSTALLING THE SIDESTAND..............................................................4-13
INSTALLING THE CENTER LOWER COVER........................................ 4-13
INSTALLING THE FOOTREST BOARD ASSEMBLY............................. 4-13
INSTALLING THE BOTTOM COVER .....................................................4-13
GENERAL CHASSIS (6) ............................................................................... 4-15

REMOVING THE FRONT UPPER COWLING ASSEMBLY ................... 4-16
INSTALLING THE FRONT UPPER COWLING ASSEMBLY .................. 4-16
DISASSEMBLING THE FRONT UPPER COWLING ASSEMBLY..........4-16
ASSEMBLING THE FRONT UPPER COWLING ASSEMBLY................ 4-16
GENERAL CHASSIS (7) ............................................................................... 4-18

REMOVING THE FRONT COWLING ASSEMBLY.................................4-20
INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-20
REMOVING THE FRONT SIDE COWLING............................................4-20
INSTALLING THE FRONT SIDE COWLING ..........................................4-21
INSTALLING THE FRONT TURN SIGNAL LIGHT .................................4-21
GENERAL CHASSIS (8) ............................................................................... 4-22

INSTALLING THE KEY SHUTTER ......................................................... 4-23
FRONT WHEEL............................................................................................. 4-24
REMOVING THE FRONT WHEEL.......................................................... 4-26
DISASSEMBLING THE FRONT WHEEL................................................ 4-26
CHECKING THE FRONT WHEEL .......................................................... 4-26
MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR
ROTOR................................................................................................... 4-27
ASSEMBLING THE FRONT WHEEL......................................................4-27
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-28
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC).................. 4-29
REAR WHEEL ...............................................................................................4-32

REMOVING THE REAR WHEEL (DISC) ................................................ 4-33
CHECKING THE REAR WHEEL............................................................. 4-33
MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR ................. 4-33
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-33
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-33
FRONT BRAKE ............................................................................................. 4-35

INTRODUCTION .....................................................................................4-41
CHECKING THE FRONT BRAKE DISC ................................................. 4-41
REPLACING THE FRONT BRAKE PADS .............................................. 4-42
REMOVING THE FRONT BRAKE CALIPER..........................................4-43
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-43
CHECKING THE FRONT BRAKE CALIPER ..........................................4-44
ASSEMBLING THE FRONT BRAKE CALIPER ...................................... 4-44
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-44
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-45
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-46
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-46
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-46
REAR BRAKE ...............................................................................................4-48

INTRODUCTION .....................................................................................4-54
CHECKING THE REAR BRAKE DISC....................................................4-54
REPLACING THE REAR BRAKE PADS................................................. 4-54
REMOVING THE REAR BRAKE CALIPER ............................................4-55
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-56
CHECKING THE REAR BRAKE CALIPER............................................. 4-56
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-57
INSTALLING THE REAR BRAKE CALIPER...........................................4-57
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-58
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-58
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-58
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-58
ABS (ANTI-LOCK BRAKE SYSTEM)........................................................... 4-60

REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-62
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-62
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-62
HYDRAULIC UNIT OPERATION TESTS................................................ 4-64
CHECKING THE ABS WARNING LIGHT ............................................... 4-67
HANDLEBAR ................................................................................................4-68
REMOVING THE UPPER HANDLEBAR COVER ASSEMBLY .............. 4-71
DISASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY .... 4-71
REMOVING THE HANDLEBAR..............................................................4-71
CHECKING THE HANDLEBAR ..............................................................4-71
INSTALLING THE HANDLEBAR ............................................................ 4-71
ASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ..........4-74
INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY............. 4-74
FRONT FORK................................................................................................4-75
REMOVING THE FRONT FORK LEGS.................................................. 4-77
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-77
CHECKING THE FRONT FORK LEGS .................................................. 4-78
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-78
INSTALLING THE FRONT FORK LEGS ................................................ 4-81
STEERING HEAD.......................................................................................... 4-82

REMOVING THE LOWER BRACKET.....................................................4-84
CHECKING THE STEERING HEAD .......................................................4-84
INSTALLING THE STEERING HEAD .....................................................4-84
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM................... 4-87

REMOVING THE SWINGARM................................................................4-89
MAINTENANCE OF THE REAR WHEEL SENSOR ...............................4-89
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-89
CHECKING THE SWINGARM ................................................................4-89
INSTALLING THE SWINGARM ..............................................................4-89
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the battery and ECU
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1
Order Job/Parts to remove Q’ty Remarks

Seat Open.
1 Battery cover 1
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery 1
5 ECU coupler 1 Disconnect.
6 ECU (Engine Control Unit) 1
7 Band 1
4-1
GENERAL CHASSIS (1)
EAS31677
REMOVING THE BATTERY COVER

1. Remove: 1
• Battery cover “1”
a
b
b. Install the battery cover screws, and then

tighten the screws to specification.
Battery cover screw

a. Open the seat. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
b. Remove the battery cover screws.
c. Slide the battery cover rearward to re- EAS31679
move the projections “a” on the battery REMOVING THE ECU (engine control unit)
cover from the holes “b” in the storage 1. Disconnect:
box. • ECU coupler “1”
TIP
1 While pushing the portion “a” of the ECU cou-
pler, move the lock lever “b” in the direction of
a the arrow shown to disconnect the coupler.
b
1
EAS31678
INSTALLING THE BATTERY COVER b

1. Install:
• Battery cover “1” a
EAS31680
INSTALLING THE ECU (engine control unit)

1. Connect:
• ECU coupler “1”
TIP
Connect the ECU coupler, and then push the
lock lever “a” of the coupler in the direction of the
arrow shown.
a. Fit the projections “a” on the battery cover 1

into the holes “b” in the storage box, and
then slide the cover forward.
a
4-2
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the grab bar and front side covers
1
17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
2
3
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1 Grab bar 1
2 Tail/brake light outer cover 1
3 Tail/brake light inner cover 1
4 Front side cover (left) 1
5 Front side cover (right) 1
4-3
GENERAL CHASSIS (2)
EAS31681
REMOVING THE TAIL/BRAKE LIGHT OUTER

COVER
a
1. Remove:
• Tail/brake light outer cover “1”
b
b. Install the tail/brake light outer cover

screws, and then tighten the screws to
specification.
Tail/brake light outer cover screw

a. Remove the tail/brake light outer cover 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
screws.
b. Slide the tail/brake light outer cover rear- EAS31683
ward to remove the projection “a” on the REMOVING THE FRONT SIDE COVER
cover from the hole “b” in the tail/brake The following procedure applies to both of the
light. front side cover.
1. Remove:
• Front side cover “1”
a
EAS31682
INSTALLING THE TAIL/BRAKE LIGHT

OUTER COVER a. Remove the front side cover screws.
1. Install: b. Pull the front side cover outward to re-
• Tail/brake light outer cover “1” move the projections “a” from the grom-
mets “b”.
b b
a
1
a. Slide the tail/brake light outer cover for-
ward, fit the projection “a” on the cover into EAS31684
the hole “b” in the tail/brake light. INSTALLING THE FRONT SIDE COVER
front side cover.
1. Install:
• Front side cover “1”
4-4
GENERAL CHASSIS (2)
a. Fit the projections “a” on the front side

cowling into the grommets “b”.
b b
a
1
b. Install the front side cover screws, and

then tighten the screw to specification.
Front side cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
4-5
GENERAL CHASSIS (3)
EAS20156
GENERAL CHASSIS (3)

Removing the fuel tank cover and seat assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
4
3
1 6
2
5
7
(3)
(4)
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

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

Front side covers 4-3.
1 Fuel tank cap 1
2 Fuel tank cover 1
3 Center cover 1
4 Seat assembly 1
5 Owner’s tool kit 1
6 Seat 1
7 Seat hinge 1
4-6
GENERAL CHASSIS (3)
EAS31685
REMOVING THE FUEL TANK COVER

1. Remove:
• Fuel tank cover “1”
a. Slide the fuel tank cover forward and fit the

projections “a” on the cover into the holes
“b” in the leg shield.
b. Fit the projections “c” on the fuel tank cov-
a. Remove the fuel tank cover screws.
er into the holes “d” in the storage box.
b. Pull the fuel tank cover upward to remove
c. Install the fuel tank cover screws, and then
the projections “a” on the cover from the
holes “b” in the storage box.
c. Slide the fuel tank cover rearward to re- Fuel tank cover screw
move the projections “c” on the cover from T. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
R.
the holes “d” in the leg shield.
c a
d b
c a
1 1
a a c c
b d
EAS31686
INSTALLING THE FUEL TANK COVER

1. Install:
• Fuel tank cover “1”
4-7
GENERAL CHASSIS (4)
EAS20157
GENERAL CHASSIS (4)

Removing the rear side covers and storage box
7
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
6
4
5 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
(3)
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
(3) 2 1
7 N•m (0.7 kgf•m, 5.2 lb•ft)

3
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Battery 4-1.
Front side cover 4-3.
Fuel tank cover 4-6.
1 Rear side cover assembly (left) 1
2 Center side cover (left) 1
3 Rear side cover (left) 1
4 Rear side cover assembly (right) 1
5 Center side cover (right) 1
6 Rear side cover (right) 1
7 Brake light coupler 1 Disconnect.
8 Taillight/rear turn signal coupler 1 Disconnect.
4-8
GENERAL CHASSIS (4)
Removing the rear side covers and storage box
13
12
11
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
14
10
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
(3)
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

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

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

9 Tail/brake light assembly 1
10 Starter relay 1
11 Fuse box 1 1
12 Fuse box 2 1
13 Storage box 1
14 Flap 1
4-9
GENERAL CHASSIS (4)
EAS31687
REMOVING THE REAR SIDE COVER 1

ASSEMBLY
The following procedure applies to both of the a
rear side cover assembly.
1. Remove:
• Rear side cover assembly “1” b
b. Install the quick fasteners, screw, and bolt,

and then tighten the screw and bolts to
specification.
Rear side cover assembly screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
Footrest board and rear side cov-
a. Remove the quick fasteners, screw and er bolt
bolt. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
b. Remove the projections “a” on the rear
side cover assembly from the holes “b” in
the storage box.
1
a
EAS31688
INSTALLING THE REAR SIDE COVER

ASSEMBLY
rear side cover assembly.
1. Install:
• Rear side cover assembly “1”
a. Fit the projections “a” on the rear side cov-

er assembly into the holes “b” in the stor-
age box.
4-10
GENERAL CHASSIS (5)
EAS20158
GENERAL CHASSIS (5)

Removing the bottom cover, center lower cover and footrest board
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
3 3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
5
24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
LS
4
LS
1 7

Battery 4-1.
Seat assembly 4-6.
Storage box 4-8.
1 Bottom cover 1
2 Footrest board mat (left) 2
3 Footrest board mat (right) 2
4 Footrest board assembly (left) 1
5 Footrest board assembly (right) 1
6 Center lower cover 1
7 Front lower cover (left) 1
8 Footrest board (left) 1
4-11
GENERAL CHASSIS (5)
Removing the bottom cover, center lower cover and footrest board
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
10
11
3.8 N•m (0.38 kgf•m, 2.8 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft)
T.R
.
LS
9
14
12
13
LS

9 Front lower cover (right) 1
10 Coolant reservoir cap cover 1
11 Footrest board (right) 1
12 Outer spring 1
13 Inner spring 1
14 Sidestand 1
4-12
GENERAL CHASSIS (5)
EAS31732 EAS31690
INSTALLING THE SIDESTAND INSTALLING THE FOOTREST BOARD

1. Install: ASSEMBLY
• Sidestand “1” 1. Install:
• Inner spring “2” • Footrest board assembly “1”
• Outer spring “3”
Sidestand nut
24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
TIP
Make sure that the hooked end “a” of the outer
spring is positions to the outside.
a 2 3
Footrest board assembly bolt
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
TIP
Make sure that the projection “a” on the frame
fits into the hole “b” in the footrest board assem-
1 bly.
EAS31689
INSTALLING THE CENTER LOWER COVER a

1. Install:
• Center lower cover “1”
b
EAS31691
INSTALLING THE BOTTOM COVER

1. Install:
• Bottom cover “1”
TIP
• Fit the end of the fuel tank overflow hose “2”
into the hole “a” in the center lower cover.
• Fit the hole “b” in the center lower cover over
the hook “c” on the frame.
c
b
1
a 2
TIP
Make sure that the projections “a” on the center
lower cover fit into the holes “b” in the bottom
cover.
4-13
GENERAL CHASSIS (5)
a b
4-14
GENERAL CHASSIS (6)
EAS20159
GENERAL CHASSIS (6)

Removing the meter assembly
3.8 N•m (0.38 kgf•m, 2.8 lb•ft) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
T.R
.
.
8
2 5
0.4 N•m (0.04 kgf•m, 0.30 lb•ft)
T.R
.
1
9
7
(4) (4)
3 6
(3) 4
(4)
(6)
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1 Windshield 1
2 Front upper cowling assembly 1
3 Front upper cowling 1
4 Front upper panel 1
5 Meter panel assembly 1
6 Meter assembly coupler 1 Disconnect.
7 Meter assembly 1
8 Meter assembly inner panel 1
9 Meter assembly panel 1
4-15
GENERAL CHASSIS (6)
EAS31692
REMOVING THE FRONT UPPER COWLING c

1
ASSEMBLY
1. Remove: d
• Front upper cowling assembly “1”
a
a
b b
b. Install the front upper cowling assembly

screw, and then tighten the screw to spec-
ification.
Front upper cowling assembly

a. Remove the front upper cowling assembly screw
T.
R.
screw. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
b. Remove the projections “a” on the front
upper cowling assembly from the holes “b” EAS31694
in the leg shield and remove the projec- DISASSEMBLING THE FRONT UPPER
tions “c” from the holes “d” in the headlight COWLING ASSEMBLY
unit. 1. Disassemble:
• Front upper cowling “1”
a
• Front upper panel “2”
1
b TIP
Remove the projections “a” on the front upper
cowling from the holes “b” in the front upper pan-
el, slide the panel in the direction shown in the il-
lustration, and remove the projections “c” on the
c panel from the holes “d” in the cowling.
c
d d
b
EAS31693
INSTALLING THE FRONT UPPER COWLING 2

ASSEMBLY
c
1. Install: a
• Front upper cowling assembly “1” 1
a
d
EAS31695
ASSEMBLING THE FRONT UPPER

COWLING ASSEMBLY
1. Assemble:
• Front upper panel “1”
• Front upper cowling “2”
a. Fit the projections “a” on the front upper Front upper panel screw
cowling assembly into the holes “b” in the 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
headlight unit and fit the projections “c”

into the holes “d” in the leg shield.
4-16
GENERAL CHASSIS (6)
TIP
Slide the front upper panel in the direction
shown in the illustration, fit the projections “a” on
the panel into the holes “b” in the front upper
cowling, and fit the projections “c” on the cowling
into the holes “d” in the panel.
d
1
a
c
2
c
b
4-17
GENERAL CHASSIS (7)
EAS20193
GENERAL CHASSIS (7)

Removing the front cowling assembly
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
(5) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
(3)
(8)
(5)
3
(3)
2 1
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Battery 4-1.
Seat assembly 4-6.
Storage box 4-8.
Center lower cover 4-11.
Meter panel assembly 4-15.
1 Headlight unit coupler 1 Disconnect.
2 Auxiliary light coupler 1 Disconnect.
3 Front turn signal light coupler (left) 1 Disconnect.
4-18
GENERAL CHASSIS (7)
Removing the front cowling assembly

1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
(5) 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)
T.R
.
4
(3)
11 5
(8)
7
(5)
10 (3)
8
6
9
13 1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
12
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

4 Front turn signal light coupler (right) 1 Disconnect.
5 Front cowling assembly 1
6 Front turn signal light (left) 1
7 Front turn signal light (right) 1
8 Front side cowling (left) 1
9 Front side panel (left) 1
10 Front side cowling (right) 1
11 Front side panel (right) 1
12 Front lower cowling 1
13 Headlight unit 1
4-19
GENERAL CHASSIS (7)
EAS31278
REMOVING THE FRONT COWLING b

ASSEMBLY b a
1. Remove: 1
• Front cowling assembly “1”
b. Install the front cowling assembly screws,

and then tighten the screws to specifica-
tion.
Front cowling assembly screw

a. Remove the front cowling assembly (M5 × 15)
T.
R.
screws. 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
b. Pull the front cowling assembly forward to Front cowling assembly screw
remove the projections “a” on the leg (M5 × 11)
shield from the holes “b” in the front cowl- 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
ing assembly.
EAS31696
b REMOVING THE FRONT SIDE COWLING

b a The following procedure applies to both of the
1 front side cowling.
1. Remove:
• Front side cowling “1”
EAS31279
INSTALLING THE FRONT COWLING

ASSEMBLY
1. Install:
• Front cowling assembly “1”
a. Removing the front side cowling screws.
b. Remove the projections “a” on the front
side cowling from the holes “b” in the front
lower cowling.
a. Fit the projections “a” on the leg shield into

the holes “b” in the front cowling assembly. b
a
a
4-20
GENERAL CHASSIS (7)
EAS31697
INSTALLING THE FRONT SIDE COWLING

front side cowling.
1. Install: 2 3
• Front side cowling “1”
a. Fit the projections “a” on the front side

cowling into the holes “b” in the front lower
cowling.
b
a
a
b. Install the front side cowling screws, and
then tighten the screws to specification.
Front side cowling screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
EAS31698
INSTALLING THE FRONT TURN SIGNAL

LIGHT
front turn signal light.
1. Install:
• Turn signal light “1”
Turn signal light screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
TIP
Tighten the turn signal light screw in the proper
tightening sequence as shown.
4-21
GENERAL CHASSIS (8)
EAS20194
GENERAL CHASSIS (8)

Removing the leg shield
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
1
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Battery 4-1.
Seat assembly 4-6.
Storage box 4-8.
Meter panel assembly 4-15.
Front cowling assembly 4-18.
1 Key shutter 1
2 Leg shield 1
4-22
GENERAL CHASSIS (8)
EAS31700
INSTALLING THE KEY SHUTTER

1. Install:
• Key shutter “1”
Key shutter screw

3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
T.
R.
TIP
While holding the key shutter so that it contacts
the leg shield “2”, tighten the key shutter screw
“3” to specification.
4-23
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake disc
40 N•m (4.0 kgf•m, 30 lb•ft)
T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
.
3 8
7
1
4 6 10
LS LT
New
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
New LT
New LT
8 N•m (0.8 kgf•m, 5.9 lb•ft) 23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
T.R
.

1 Front brake hose guide 1
2 Front wheel sensor lead holder 1
3 Front brake caliper 1
4 Front wheel sensor 1
5 Front wheel axle nut 1
6 Front wheel axle 1
7 Collar 2
8 Front wheel 1
9 Front wheel sensor rotor 1
10 Front brake disc 1
4-24
FRONT WHEEL
Disassembling the front wheel
New 1
New 2
LS
3
New 2
New 1
LS

1 Oil seal 2
2 Wheel bearing 2
3 Spacer 1
4-25
FRONT WHEEL
EAS30145
REMOVING THE FRONT WHEEL

ECA20981
NOTICE
• Keep any type of magnets (including mag-
netic pick-up tools, magnetic screwdrivers,
etc.) away from the front wheel sensor or 2
front wheel sensor rotor; otherwise, the
sensor or rotor may be damaged, resulting 1
in improper performance of the ABS sys-
tem.
c. Remove the wheel bearings “3” with a
• Do not drop the front wheel sensor rotor or
subject it to shocks. general bearing puller.
• If any solvent gets on the front wheel sen-
sor rotor, wipe it off immediately.
EWA13120
WARNING
2. Remove:
• Front brake caliper
ECA21830
EAS30147
NOTICE CHECKING THE FRONT WHEEL
Do not apply the brake lever when removing 1. Check:
the brake caliper. • Wheel axle
Roll the wheel axle on a flat surface.
3. Elevate:
Bends → Replace.
• Front wheel EWA13460
TIP WARNING
Place the vehicle on a suitable stand so that the Do not attempt to straighten a bent wheel ax-
front wheel is elevated. le.
EAS30146
DISASSEMBLING THE FRONT WHEEL

1. Remove:
• Oil seals
• Wheel bearings
a. Clean the surface of the front wheel hub.
b. Remove the oil seals “1” with a flat-head
screwdriver.
TIP
To prevent damaging the wheel, place a rag “2” 2. Check:
between the screwdriver and the wheel surface. • Tire
• Front wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-13 and “CHECKING THE WHEELS” on
page 3-13.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
4-26
FRONT WHEEL
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)
2
1
2. Check:
• Front wheel sensor rotor “1”
Cracks/damage/scratches → Replace the
front wheel sensor rotor.
Iron powder/dust/solvent → Clean.
4. Check: TIP
• Wheel bearings When cleaning the wheel sensor rotor, be care-
Front wheel turns roughly or is loose → Re- ful not to damage the surface of the sensor rotor.
place the wheel bearings.
• Oil seals
Damage/wear → Replace. 1
EAS30151
ASSEMBLING THE FRONT WHEEL

1. Lubricate:
EAS30155
• Oil seal lips
MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR Recommended lubricant
ECA21070
NOTICE
• Handle the ABS components with care 2. Install:
since they have been accurately adjusted. • Wheel bearings New
Keep them away from dirt and do not sub-
• Oil seals New
ject them to shocks.
a. Install the new wheel bearing (right side).
• The front wheel sensor cannot be disas- ECA18110
sembled. Do not attempt to disassemble it. NOTICE

If faulty, replace with a new one. Do not contact the wheel bearing inner race
• Keep any type of magnets (including mag- “1” or balls “2”. Contact should be made
netic pick-up tools, magnetic screwdrivers, only with the outer race “3”.
etc.) away from the front wheel sensor or
front wheel sensor rotor. TIP
• Do not drop or shock the wheel sensor or Use a socket “4” that matches the diameter of
the wheel sensor rotor. the wheel bearing outer race.
1. Check:
• Front wheel sensor “1”
Cracks/bends/distortion → Replace.
Iron powder/dust → Clean.
4-27
FRONT WHEEL
b. Install the spacer. c. Turn the front wheel 90° so that the “X1”
c. Install the new wheel bearing (left side). mark is positioned as shown.
TIP d. Release the front wheel.
Place a suitable washer “1” between the socket e. When the wheel stops, put an “X2” mark at
“2” and the bearing so that both the inner race the bottom of the wheel.
“3” and outer race “4” are pressed at the same
time, and then press the bearing until the inner
race makes contact with the spacer “5”.
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
EAS30152
ADJUSTING THE FRONT WHEEL STATIC is the front wheel’s heavy spot “X”.
BALANCE 3. Adjust:
• Front wheel static balance
TIP
TIP
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted. • Install the balancing weights on the rim of the
• Adjust the front wheel static balance with the brake disc side of the wheel.
brake disc installed. • Install up to four balancing weights on the rim.
1. Remove: a. Install a balancing weight “1” onto the rim

• Balancing weight(s) exactly opposite the heavy spot “X”.
2. Find: TIP
• Front wheel’s heavy spot Start with the lightest weight.
TIP
Place the front wheel on a suitable balancing
stand.
a. Spin the front wheel.
b. When the front wheel stops, put an “X1”
mark at the bottom of the wheel.
4-28
FRONT WHEEL
b. Turn the front wheel 90° so that the heavy • Replace the brake disc bolts and wheel
spot is positioned as shown. sensor rotor bolts with new ones.
TIP
• Install the brake disc with its chamfered side
“a” facing inward.
• Install the front wheel sensor rotor with the
stamped mark “b” facing away from the wheel.
• Tighten the bolts in stages.
1
1
c. If the heavy spot does not stay in that po-
sition, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
4. Check:
• Front wheel static balance a
a. Turn the front wheel and make sure it
stays at each position shown.
b. If the front wheel does not remain station- 2. Check:

ary at all of the positions, rebalance it. • Front brake disc
EAS30154
Refer to “CHECKING THE FRONT BRAKE
INSTALLING THE FRONT WHEEL (FRONT DISC” on page 4-41.
BRAKE DISC) 3. Lubricate:
1. Install: • Wheel axle
• Front brake disc “1”
• Front wheel sensor rotor “2” Recommended lubricant
Front wheel sensor rotor bolt
8 N·m (0.8 kgf·m, 5.9 lb·ft) 4. Install:
T.
R.
LOCTITE® • Front wheel

Front brake disc bolt • Collars
23 N·m (2.3 kgf·m, 17 lb·ft) • Front wheel axle
LOCTITE® TIP
ECA21011 Install the front wheel with the mark “a” on the
NOTICE front tire pointing in the direction of wheel rota-
• Do not drop the wheel sensor rotor or sub- tion.
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
4-29
FRONT WHEEL
vice and caught foreign materials). If there is

any defective part, repair or replace the de-
a fective part.
Distance “a” (between the front

wheel sensor rotor and front
wheel sensor)
0.65–1.66 mm (0.026–0.065 in)
TIP
5. Tighten: Measure the distance between the front wheel
• Front wheel axle nut sensor rotor and front wheel sensor in several
places in one rotation of the front wheel. Do not
Front wheel axle nut turn the front wheel while the thickness gauge is
40 N·m (4.0 kgf·m, 30 lb·ft) installed. This may damage the front wheel sen-
T.
R.
sor rotor and the front wheel sensor.

ECA14140
NOTICE
Thickness gauge
Before tightening the wheel axle nut, push
90890-03180
down hard on the handlebar(s) several times Feeler gauge set
and check if the front fork rebounds smooth- YU-26900-9
ly.
6. Install: a
• Front wheel sensor
2
Front wheel sensor bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft) 2
T.
R.
ECA21020
1
NOTICE 1
Make sure there are no foreign materials in
the front wheel sensor rotor and front wheel
sensor. Foreign materials cause damage to 8. Install:
the front wheel sensor rotor and front wheel • Front brake caliper
sensor. • Front wheel sensor lead holder “1”
TIP • Front brake hose guide “2”
• When installing the front wheel sensor, check Front brake caliper bolt
the wheel sensor lead for twists. 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
• To route the front wheel sensor lead, refer to

R.
Front brake hose guide bolt

“CABLE ROUTING” on page 2-27. 7 N·m (0.7 kgf·m, 5.2 lb·ft)
7. Measure: EWA13500
• Distance “a” WARNING

(between the front wheel sensor rotor “1” and Make sure the brake hose is routed properly.
front wheel sensor “2”)
Out of specification → Check the wheel bear- TIP
ing for looseness, and the front wheel sensor While holding the front brake hose guide and
and sensor rotor installation conditions front wheel sensor lead holder so that the por-
(warpage caused by overtorque, wrong in- tions “a” of the guide and holder contact the front
stallation direction, rotor decentering, LOC- fork outer tube, tighten the bolts to specification.
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser-
4-30
FRONT WHEEL
4-31
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel and brake disc
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.
LT
LT
LT
New
1 3
LT
2
LT
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
New
.
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.

Battery 4-1.
Storage box 4-8.
Muffler Refer to “ENGINE REMOVAL” on page 5-3.
Radiator cover Refer to “RADIATOR” on page 6-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-7.
Refer to “REAR SHOCK ABSORBER AS-
Swingarm assembly SEMBLIES AND SWINGARM” on page
4-87.
1 Rear wheel 1
2 Rear wheel sensor rotor 1
3 Rear brake disc 1
4-32
REAR WHEEL
EAS30156
REMOVING THE REAR WHEEL (DISC)
ECA22870
netic pick-up tools, magnetic screwdrivers,
NOTICE etc.) away from the rear wheel sensor rotor.
• Keep any type of magnets (including mag- • Do not drop or shock the wheel sensor ro-
netic pick-up tools, magnetic screwdrivers, tor.
etc.) away from the rear wheel sensor rotor; 1. Check:
otherwise, the rotor may be damaged, re- • Rear wheel sensor rotor
sulting in improper performance of the ABS Refer to “MAINTENANCE OF THE FRONT
system. WHEEL SENSOR AND SENSOR ROTOR”
• Do not drop the rear wheel sensor rotor or on page 4-27.
subject it to shocks.
EAS30164
• If any solvent gets on the rear wheel sensor ADJUSTING THE REAR WHEEL STATIC
rotor, wipe it off immediately. BALANCE
1. Stand the vehicle on a level surface. TIP
EWA13120
• After replacing the tire, wheel or both, the rear
WARNING
wheel static balance should be adjusted.
Securely support the vehicle so that there is • Adjust the rear wheel static balance with the
no danger of it falling over. brake disc installed.
TIP 1. Adjust:
Place the vehicle on the centerstand so that the • Rear wheel static balance
rear wheel is elevated. Refer to “ADJUSTING THE FRONT WHEEL
STATIC BALANCE” on page 4-28.
EAS30159
CHECKING THE REAR WHEEL EAS30165
1. Check: INSTALLING THE REAR WHEEL (REAR

• Tire BRAKE DISC)
• Rear wheel 1. Install:
Damage/wear → Replace. • Rear brake disc “1”
Refer to “CHECKING THE TIRES” on page • Rear wheel sensor rotor “2”
3-13 and “CHECKING THE WHEELS” on Rear wheel sensor rotor bolt
page 3-13. 8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
2. Measure:
R.
LOCTITE®
• Radial wheel runout Rear brake disc bolt
• Lateral wheel runout 23 N·m (2.3 kgf·m, 17 lb·ft)
Refer to “CHECKING THE FRONT WHEEL” LOCTITE®
on page 4-26.
ECA21011
Radial wheel runout limit NOTICE

1.0 mm (0.04 in) • Do not drop the wheel sensor rotor or sub-
Lateral wheel runout limit ject it to shocks.
1.0 mm (0.04 in) • If any solvent gets on the wheel sensor ro-
tor, wipe it off immediately.
EAS31630
• Replace the brake disc bolts and wheel
MAINTENANCE OF THE REAR WHEEL
sensor rotor bolts with new ones.
SENSOR ROTOR
ECA22890
TIP
NOTICE
• Install the brake disc with its chamfered side
• Handle the ABS components with care “a” facing inward.
since they have been accurately adjusted. • Install the front wheel sensor rotor with the
Keep them away from dirt and do not sub- stamped mark “b” facing away from the wheel.
ject them to shocks. • Tighten the bolts in stages.
4-33
REAR WHEEL
1 1
b
2
2. Check:
• Rear brake disc
Refer to “CHECKING THE REAR BRAKE
DISC” on page 4-54.
4-34
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.
2
4
1
7
3
5
35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
.

3 Brake pad clip 2
4 Brake pad pin 1
5 Brake pad (inner) 1
6 Brake pad (outer) 1
7 Brake pad spring 1
8 Brake caliper bleed screw 1
4-35
FRONT BRAKE
Removing the front brake master cylinder
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
3
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
8
6 N•m (0.6 kgf•m, 4.4 lb•ft)
9 New
T.R
.
6
S
5 4
6
6 N•m (0.6 kgf•m, 4.4 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
T.R
.

Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-68.
Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-12.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
2 1
er
3 Brake master cylinder reservoir diaphragm 1
4 Front brake light switch connector 2 Disconnect.
5 Front brake light switch 1
6 Front brake lever pivot bolt/nut 1/1
7 Front brake lever 1
Front brake hose union bolt (master cylinder
8 1
side)
9 Brake hose gasket 2
4-36
FRONT BRAKE
Removing the front brake master cylinder
11 N•m (1.1 kgf•m, 8.1 lb•ft)

11
T.R
.
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
12
.
6 N•m (0.6 kgf•m, 4.4 lb•ft)
New
T.R
.
10
6 N•m (0.6 kgf•m, 4.4 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
T.R
.

Front brake hose (front brake master cylinder to
10 1 Disconnect.
hydraulic unit)
11 Front brake master cylinder holder 1
12 Front brake master cylinder assembly 1
4-37
FRONT BRAKE
Disassembling the front brake master cylinder
BF
S
BF
2
1 New

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
4-38
FRONT BRAKE
Removing the front brake caliper
1 3
2 New
4
5
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.

Drain.
1 Front brake hose union bolt (brake caliper side) 1
Front brake hose (hydraulic unit to front brake
3 1 Disconnect.
caliper)
4-39
FRONT BRAKE
Disassembling the front brake caliper
6
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
S
7
11 New 8
New 9
10
2 5
BF
S 3
4
1

1 Brake pad clip 2
2 Brake pad pin 1
6 Front brake caliper bracket 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
11 Brake caliper body 1
4-40
FRONT BRAKE
EAS30168
e. Measure the runout 1.5 mm (0.06 in) be-
INTRODUCTION
EWA14101
low the edge of the brake disc.
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly. 4. Measure:
• Never use solvents on internal brake com- • Brake disc thickness
ponents. Measure the brake disc thickness at a few dif-
• Use only clean or new brake fluid for clean- ferent locations.
ing brake components. Out of specification → Replace.
• Brake fluid may damage painted surfaces Brake disc thickness limit
and plastic parts. Therefore, always clean 3.5 mm (0.14 in)
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS30169
CHECKING THE FRONT BRAKE DISC

1. Remove:
• Front wheel 5. Adjust:
Refer to “FRONT WHEEL” on page 4-24. • Brake disc runout
2. Check: a. Remove the brake disc.
• Brake disc b. Rotate the brake disc by one bolt hole.
Damage/galling → Replace. c. Install the brake disc.
3. Measure:
• Brake disc runout Front brake disc bolt
Out of specification → Correct the brake disc 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
runout or replace the brake disc. LOCTITE®
Brake disc runout limit (as mea- ECA19150
sured on wheel) NOTICE

0.15 mm (0.0059 in) Replace the brake disc bolts with new ones.
a. Place the vehicle on a suitable stand so TIP

that the front wheel is elevated. • Install the brake disc “1” with its chamfered
b. Before measuring the front brake disc side “a” facing inward.
runout, turn the handlebar to the left or • Tighten the brake disc bolts in stages.
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
4-41
FRONT BRAKE
B
1
1
a
A. Inner
d. Measure the brake disc runout.
B. Outer
e. If out of specification, repeat the adjust-
ment steps until the brake disc runout is 2. Install:
within specification. • Brake pad spring “1”
f. If the brake disc runout cannot be brought • Brake pads
within specification, replace the brake TIP
disc. Always install new brake pads, and new brake
6. Install: pad spring, as a set.
• Front wheel
Refer to “FRONT WHEEL” on page 4-24. a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
EAS30170
the hose into an open container.
REPLACING THE FRONT BRAKE PADS
b. Loosen the bleed screw and push the
TIP brake caliper piston into the brake caliper
When replacing the brake pads, it is not neces- with your finger.
sary to disconnect the brake hose or disassem-
ble the brake caliper.
1
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
2
pads as a set.
Brake pad lining thickness

4.4 mm (0.17 in)
Limit
0.8 mm (0.03 in) c. Tighten the bleed screw.
A
Brake caliper bleed screw
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
d. Install new brake pad spring and new

a
brake pads.
TIP
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
piston.
4-42
FRONT BRAKE
5. Check:
a • Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
1
EAS31328
REMOVING THE FRONT BRAKE CALIPER

TIP
3. Install: Before removing the brake caliper, drain the
• Brake pad pin brake fluid from the entire brake system.
• Brake pad clips 1. Remove:
• Front brake caliper • Brake hose union bolt “1”
• Front wheel sensor lead holder “1” • Brake hose gaskets “2”
• Front brake caliper bolts • Front brake hose “3”
TIP
Front brake caliper bolt
35 N·m (3.5 kgf·m, 26 lb·ft) Put the end of the brake hose into a container
T.
R.
and pump out the brake fluid carefully.

TIP
While holding the front wheel sensor lead holder
3
so that the portion “a” of the holder contacts the
front fork outer tube, tighten the bolt to specifica-
tion.
1
EAS30172
a DISASSEMBLING THE FRONT BRAKE
CALIPER
1 1. Remove:
• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
4. Check:
• Brake caliper piston seal “3”
• Brake fluid level
LEVEL” on page 3-10. 3
2
a 1
a. Blow compressed air into the brake hose

joint opening “a” to force out the piston
from the brake caliper “1”.
4-43
FRONT BRAKE
EWA13550
WARNING
• Cover the brake caliper piston with a rag. 2 3
Be careful not to get injured when the pis- 1
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
2. Check:
• Brake caliper bracket
EAS30174
ASSEMBLING THE FRONT BRAKE CALIPER

1 EWA13621
WARNING
b. Remove the brake caliper piston dust seal • Before installation, all internal brake com-
and brake caliper piston seal. ponents should be cleaned and lubricated
with clean or new brake fluid.
EAS30173
CHECKING THE FRONT BRAKE CALIPER • Never use solvents on internal brake com-
ponents as they will cause the brake caliper
Recommended brake component replacement piston dust seals and brake caliper piston
schedule
seals to swell and distort.
Brake pads If necessary • Whenever a brake caliper is disassembled,
Piston seal Every two years replace the brake caliper piston dust seals
and brake caliper piston seals.
Piston dust seal Every two years
Brake hose Every four years
Every two years and DOT 4
Brake fluid whenever the brake is
disassembled EAS30934
INSTALLING THE FRONT BRAKE CALIPER

1. Check:
1. Install:
• Front brake caliper “1”
Rust/scratches/wear → Replace the brake
(temporarily)
caliper piston.
• Brake caliper cylinder “2” • Brake hose gaskets “2” New
Scratches/wear → Replace the brake caliper • Front brake hose “3”
assembly. • Brake hose union bolt “4”
• Brake caliper body “3”
Front brake hose union bolt
Cracks/damage → Replace the brake caliper
(brake caliper side)
T.
assembly.
R.
29 N·m (2.9 kgf·m, 21 lb·ft)

• Brake fluid delivery passages
(brake caliper body) EWA13531
Obstruction → Blow out with compressed air. WARNING

EWA17070
Proper brake hose routing is essential to in-
WARNING
sure safe vehicle operation.
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.
4-44
FRONT BRAKE
ECA19080
NOTICE not enter the brake master cylinder reser-
When installing the brake hose onto the voir. Water will significantly lower the boil-
brake caliper “1”, make sure the brake pipe ing point of the brake fluid and could cause
“a” passes between the projections “b” on vapor lock.
the brake caliper. ECA13540
NOTICE
3 Brake fluid may damage painted surfaces
1 and plastic parts. Therefore, always clean up
b any spilt brake fluid immediately.
a 5. Bleed:
• Brake system
4 Refer to “BLEEDING THE HYDRAULIC
New 2
6. Check:
2. Remove: Below the minimum level mark “a” → Add the
• Front brake caliper specified brake fluid to the proper level.
3. Install: Refer to “BLEEDING THE HYDRAULIC
• Brake pad spring BRAKE SYSTEM” on page 3-12.
• Brake pads
• Brake pad pin a
• Brake pad clips
• Front brake caliper
• Front wheel sensor lead holder
• Front brake caliper bolts
Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
Refer to “REPLACING THE FRONT BRAKE

PADS” on page 4-42. 7. Check:
4. Fill: • Brake lever operation
• Brake master cylinder reservoir Soft or spongy feeling → Bleed the brake sys-
(with the specified amount of the specified tem.
brake fluid) Refer to “BLEEDING THE HYDRAULIC
EAS30179
DOT 4
REMOVING THE FRONT BRAKE MASTER
EWA13540 CYLINDER
WARNING TIP
• Use only the designated brake fluid. Other Before removing the front brake master cylinder,
brake fluids may cause the rubber seals to drain the brake fluid from the entire brake sys-
deteriorate, causing leakage and poor tem.
brake performance.
1. Remove:
• Brake hose union bolt “1”
is already in the system. Mixing brake fluids
• Brake hose gaskets “2”
• Front brake hose “3”
TIP
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
4-45
FRONT BRAKE

DOT 4
2 EAS30182
INSTALLING THE FRONT BRAKE MASTER

CYLINDER
3 1. Install:
1 • Brake master cylinder
• Brake master cylinder holder “1”
EAS30725 Front brake master cylinder hold-

CHECKING THE FRONT BRAKE MASTER er bolt
T.
R.
CYLINDER 11 N·m (1.1 kgf·m, 8.1 lb·ft)
1. Check:
• Brake master cylinder TIP
Damage/scratches/wear → Replace. • Install the brake master cylinder holder with the
• Brake fluid delivery passages “UP” mark “a” facing up.
(brake master cylinder body) • Align the edge “b” of the brake master cylinder
Obstruction → Blow out with compressed air. holder with the edge “c” of the stay on the han-
2. Check: dlebar as shown in the illustration.
• Brake master cylinder kit • First, tighten the upper bolt, then the lower bolt.
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir “1” b
• Brake master cylinder reservoir cap “2” c
1
• Brake master cylinder reservoir diaphragm
holder “3”
“4”
Damage/wear → Replace. a
2
1 2. Install:
• Brake hose gaskets “1” New
3 • Front brake hose “2”
4 Front brake hose union bolt

(master cylinder side)
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft)

4. Check: EWA13531
• Front brake hose WARNING

Cracks/damage/wear → Replace. Proper brake hose routing is essential to in-
EAS30181
ASSEMBLING THE FRONT BRAKE MASTER
TIP
CYLINDER
EWA13520 • Make sure that the distance “a” between the
WARNING brake hose and the handlebar “4” is 40–44 mm
• Before installation, all internal brake com- (1.57–1.73 in) as shown in the illustration.
ponents should be cleaned and lubricated • Turn the handlebar to the left and right to make
with clean or new brake fluid. sure the brake hose does not touch other parts
• Never use solvents on internal brake com- (e.g., wire harness, cables, leads). Correct if
ponents. necessary.
4-46
FRONT BRAKE
New 1
3
4
2 a
3. Fill: 6. Check:
• Brake master cylinder reservoir • Brake lever operation
(with the specified amount of the specified Soft or spongy feeling → Bleed the brake sys-
brake fluid) tem.
Specified brake fluid BRAKE SYSTEM” on page 3-12.
DOT 4
EWA13540
WARNING
deteriorate, causing leakage and poor
brake performance.
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
4. Bleed:
• Brake system
5. Check:
LEVEL” on page 3-10.
4-47
REAR BRAKE
EAS20031
REAR BRAKE
Removing the rear brake pads
35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
.
4
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
.

1 Rear brake caliper 1
2 Brake pad clip 2
3 Brake pad pin 1
4-48
REAR BRAKE
Removing the rear brake master cylinder
11 N•m (1.1 kgf•m, 8.1 lb•ft)

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
T.R
.
1
2
3
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
6
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
8
.
9 New
5 7
6
4
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

.
T.R
.

Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-68.
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 light switch connector 2 Disconnect.
5 Rear brake light switch 1
6 Rear brake lever pivot bolt/nut 1/1
7 Rear brake lever 1
Rear brake hose union bolt (master cylinder
8 1
side)
4-49
REAR BRAKE
Removing the rear brake master cylinder
11 N•m (1.1 kgf•m, 8.1 lb•ft)

1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
T.R
.
11
6 N•m (0.6 kgf•m, 4.4 lb•ft)
T.R
.
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
New
S
12
10
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)

.
T.R
.

Rear brake hose (rear brake master cylinder to
10 1 Disconnect.
hydraulic unit)
11 Rear brake master cylinder holder 1
12 Rear brake master cylinder assembly 1
4-50
REAR BRAKE
Disassembling the rear brake master cylinder
BF
S
2
BF
1 New

1 Brake master cylinder kit 1
2 Brake master cylinder body 1
4-51
REAR BRAKE
Removing the rear brake caliper
4 35 N•m (3.5 kgf•m, 26 lb•ft)
T.R
.
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
2 New
1
3

Drain.
1 Rear brake hose union bolt (brake caliper side) 1
Rear brake hose (hydraulic unit to rear brake
3 1 Disconnect.
caliper)
4-52
REAR BRAKE
Disassembling the rear brake caliper
6
S
7
S 4
8 New BF
9 New
5
11
10
6 N•m (0.6 kgf•m, 4.4 lb•ft)

T.R
2
.

1 Brake pad clip 2
2 Brake pad pin 1
6 Brake caliper bracket 1
7 Brake caliper piston 1
8 Brake caliper piston dust seal 1
9 Brake caliper piston seal 1
11 Brake caliper body 1
4-53
REAR BRAKE
EAS30183
INTRODUCTION Brake disc thickness limit

EWA14101
4.0 mm (0.16 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc runout
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISC” on page 4-41.
less absolutely necessary.
• If any connection on the hydraulic brake Rear brake disc bolt
system is disconnected, the entire brake 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
sembly. 6. Install:
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-32.
• Use only clean or new brake fluid for clean- EAS30185
ing brake components. REPLACING THE REAR BRAKE PADS

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

EAS30184
CHECKING THE REAR BRAKE DISC 5.3 mm (0.21 in)

Limit
1. Remove:
0.8 mm (0.03 in)
• Rear wheel
Refer to “REAR WHEEL” on page 4-32.
2. Check:
• Brake disc
Damage/galling → Replace.
3. Measure:
• Brake disc runout
Out of specification → Correct the brake disc
runout or replace the brake disc.
Brake disc runout limit (as mea-

sured on wheel)
0.15 mm (0.0059 in)
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification → Replace.
4-54
REAR BRAKE
A TIP
The longer tangs “a” of the brake pad spring
must point in the direction of the brake caliper
a position.
a
3. Install:
• Brake pad pin
• Brake pad clips
• Rear brake caliper
• Rear brake caliper bolts
A. Inner Rear brake caliper bolt
B. Outer 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
2. Install:
4. Check:
• Brake pad spring
• Brake pads
TIP specified brake fluid to the proper level.
Always install new brake pads and brake pad Refer to “CHECKING THE BRAKE FLUID
spring as a set. LEVEL” on page 3-10.
a. Connect a clear plastic hose “1” tightly to
the bleed screw “2”. Put the other end of
the hose into an open container.
b. Loosen the bleed screw and push the
brake caliper piston into the brake caliper a
with your finger.
2
1
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
c. Tighten the bleed screw. EAS30186
REMOVING THE REAR BRAKE CALIPER

Brake caliper bleed screw TIP
6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
Before removing the brake caliper, drain the

R.
d. Install new brake pad spring and new brake fluid from the entire brake system.
brake pads. 1. Remove:
• Rear brake hose union bolt “1”
4-55
REAR BRAKE
• Brake hose gaskets “2” b. Remove the brake caliper piston dust seal
• Rear brake hose “3” and brake caliper piston seal.
TIP EAS30188
Put the end of the brake hose into a container CHECKING THE REAR BRAKE CALIPER
and pump out the brake fluid carefully. Recommended brake component replacement
schedule
Brake pads If necessary
2 Piston seal Every two years
Piston dust seal Every two years
3 Brake hose Every four years
1 Every two years and
Brake fluid whenever the brake is
disassembled
1. Check:
EAS30187
DISASSEMBLING THE REAR BRAKE
Rust/scratches/wear → Replace the brake
CALIPER
caliper piston.
1. Remove:
• Brake caliper cylinder “2”
Scratches/wear → Replace the brake caliper
• Brake caliper piston dust seal “2”
assembly.
• Brake caliper piston seal “3”
• Brake caliper body “3”
Cracks/damage → Replace the brake caliper
assembly.
1
2 3 (brake caliper body)
Obstruction → Blow out with compressed air.
EWA17070
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
and brake caliper piston seal.
a. Blow compressed air into the brake hose
joint opening “a” to force out the piston
from the brake caliper. 3
EWA13550
1 2
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
4-56
REAR BRAKE
EAS30189
3. Install:
ASSEMBLING THE REAR BRAKE CALIPER
EWA17080
• Brake pad spring
WARNING • Brake pads
• Before installation, all internal brake com- • Brake pad pin
ponents should be cleaned and lubricated • Brake pad clips
with clean or new brake fluid. • Rear brake caliper
• Never use solvents on internal brake com- Rear brake caliper bolt
ponents as they will cause the brake caliper 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
piston dust seal and brake caliper piston
seal to swell and distort. Refer to “REPLACING THE REAR BRAKE
• Whenever a brake caliper is disassembled, PADS” on page 4-54.
replace the brake caliper piston dust seal 4. Fill:
and brake caliper piston seal. • Brake master cylinder reservoir
(with the specified amount of the specified
Specified brake fluid brake fluid)
DOT 4
EAS30190 DOT 4
INSTALLING THE REAR BRAKE CALIPER
EWA13540
1. Install:
WARNING
• Rear brake caliper “1”
(temporarily) • Use only the designated brake fluid. Other
• Brake hose gaskets “2” New
• Rear brake hose “3”
brake performance.
Rear brake hose union bolt is already in the system. Mixing brake fluids
(brake caliper side) may result in a harmful chemical reaction,
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft) leading to poor brake performance.

EWA13531
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.
ECA19080
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” passes between the projections “b” on any spilt brake fluid immediately.
the brake caliper.
5. Bleed:
• Brake system
1 BRAKE SYSTEM” on page 3-12.
b 6. Check:
2 New
a Below the minimum level mark “a” → Add the
4 3 LEVEL” on page 3-10.
2. Remove:
• Rear brake caliper
4-57
REAR BRAKE
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake master cylinder reservoir “1”
a
• Brake master cylinder reservoir cap
holder “2”
“3”
7. Check: Damage/wear → Replace.
• Brake lever operation 4. Check:
Soft or spongy feeling → Bleed the brake sys- • Brake hose
tem. Cracks/damage/wear → Replace.
BRAKE SYSTEM” on page 3-12. 2
1
EAS30193
REMOVING THE REAR BRAKE MASTER

CYLINDER 3
TIP
Before removing the rear brake master cylinder,
drain the brake fluid from the entire brake sys-
tem.
1. Remove: EAS30195
• Brake hose union bolt “1” ASSEMBLING THE REAR BRAKE MASTER
• Brake hose gaskets “2” CYLINDER
EWA13520
• Brake hose “3”
WARNING
TIP
• Before installation, all internal brake com-
To collect any remaining brake fluid, place a ponents should be cleaned and lubricated
container under the master cylinder and the end with clean or new brake fluid.
of the brake hose. • Never use solvents on internal brake com-
ponents.
1 2
DOT 4
EAS30196
INSTALLING THE REAR BRAKE MASTER

CYLINDER
1. Install:
3
• Brake master cylinder
EAS30194
• Brake master cylinder holder “1”
CHECKING THE REAR BRAKE MASTER
Rear brake master cylinder hold-
CYLINDER
er bolt
T.
1. Check:
R.
11 N·m (1.1 kgf·m, 8.1 lb·ft)

• Brake master cylinder
Damage/scratches/wear → Replace. TIP
• Install the brake master cylinder holder with the
(brake master cylinder body)
“UP” mark “a” facing up.
Obstruction → Blow out with compressed air.
4-58
REAR BRAKE
• Align the edge “b” of the brake master cylinder EWA13540
holder with the edge “c” of the stay on the han- WARNING
dlebar as shown in the illustration. • Use only the designated brake fluid. Other
• First, tighten the upper bolt, then the lower bolt. brake fluids may cause the rubber seals to
1 brake performance.
b • Refill with the same type of brake fluid that
c may result in a harmful chemical reaction,
a voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
2. Install:
ECA13540
• Brake hose gaskets “1” New NOTICE
• Rear brake hose “2”
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
Rear brake hose union bolt (mas- any spilt brake fluid immediately.
ter cylinder side) 4. Bleed:
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft) • Brake system

EWA13531
WARNING BRAKE SYSTEM” on page 3-12.
5. Check:
Proper brake hose routing is essential to in-
TIP specified brake fluid to the proper level.
• Make sure that the distance “a” between the Refer to “CHECKING THE BRAKE FLUID
brake hose and the handlebar “4” is 5.0–9.0 LEVEL” on page 3-10.
mm (0.20–0.35 in) as shown in the illustration.
• Turn the handlebar to the left and right to make
sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary. a
1 New
4 6. Check:
• Brake lever operation
3 a Soft or spongy feeling → Bleed the brake sys-
tem.
2 Refer to “BLEEDING THE HYDRAULIC
3. Fill:
• Brake master cylinder reservoir
brake fluid)

DOT 4
4-59
ABS (ANTI-LOCK BRAKE SYSTEM)
EAS20032

Removing the hydraulic unit assembly
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
2
5
3
4 New
3
2 New 4
4 New
4 New
New 4
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Drain.
Front side cover (right) 4-3.
Front upper cowling assembly 4-15.
1 ABS ECU coupler 1 Disconnect.
Front brake hose union bolt (hydraulic unit as-
2 2
sembly side)
Rear brake hose union bolt (hydraulic unit as-
3 2
sembly side)
Front brake hose (hydraulic unit to front brake
5 1 Disconnect.
caliper)
4-60
Removing the hydraulic unit assembly

29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
29 N•m (2.9 kgf•m, 21 lb•ft)
T.R
.
New
New
7 8
New
6 New
New
9
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Front brake hose (front brake master cylinder to
6 1 Disconnect.
hydraulic unit)
Rear brake hose (rear brake master cylinder to
7 1 Disconnect.
hydraulic unit)
Rear brake hose (hydraulic unit to rear brake
8 1 Disconnect.
caliper)
9 Hydraulic unit assembly 1
4-61
EAS30197
REMOVING THE HYDRAULIC UNIT TIP

ASSEMBLY Do not operate the brake levers while removing
ECA21091 the brake hoses.
NOTICE ECA14530
Unless necessary, avoid removing and in- NOTICE

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

1. Disconnect: ASSEMBLY
• ABS ECU coupler “1” 1. Check:
TIP • Hydraulic unit assembly
While pushing the portion “a” of the ABS ECU Cracks/damage → Replace the hydraulic unit
coupler, move the lock lever “b” in the direction assembly and the brake hoses that are con-
of the arrow shown to disconnect the coupler. nected to the assembly as a set.
EAS30200
b 1
INSTALLING THE HYDRAULIC UNIT
ASSEMBLY
1. Install:
a • Hydraulic unit assembly
Hydraulic unit assembly bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
2. Remove:
• Brake hoses
4-62
ECA21110
TIP
NOTICE
• Connect the ABS ECU coupler, and then push
Do not remove the rubber plugs or bolts
the lock lever “a” of the coupler in the direction
(M10 × 1.25) installed in the brake hose union
of the arrow shown.
bolt holes before installing the hydraulic unit
• Make sure that the ABS ECU coupler is con-
assembly.
nected in the correct position as shown in illus-
TIP tration “A”.
Do not allow any foreign materials to enter the
hydraulic unit assembly or the brake hoses 1
when installing the hydraulic unit assembly. a
2. Remove:
• Rubber plugs or bolts (M10 × 1.25)
3. Install:
• Rear brake hose (hydraulic unit to rear brake
caliper) “1”
• Rear brake hose (rear brake master cylinder
to hydraulic unit) “2”
• Front brake hose (front brake master cylinder
to hydraulic unit) “3” A B
• Front brake hose (hydraulic unit to front brake
caliper) “4”
Front brake hose union bolt (hy-

draulic unit assembly side)
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft)

Rear brake hose union bolt (hy-
draulic unit assembly side)
29 N·m (2.9 kgf·m, 21 lb·ft)
A. The ABS ECU coupler is connected correctly.
ECA21121 B. The ABS ECU coupler is not connected.
NOTICE
5. Fill:
If the brake hose union bolt does not turn
• Brake master cylinder reservoir
easily, replace the hydraulic unit assembly,
• Brake fluid reservoir
brake hoses, and related parts as a set.
TIP brake fluid)
Position the pipe sections of the brake hoses at
a 30° angle from the line “a” as shown in the il- DOT 4
lustration, and then tighten the brake hose union
bolts to specification. EWA13090
WARNING
4 deteriorate, causing leakage and poor
brake performance.
1 is already in the system. Mixing brake fluids
3
2 may result in a harmful chemical reaction,
a • When refilling, be careful that water does
4. Connect: not enter the brake fluid reservoir. Water
• ABS ECU coupler “1” will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
4-63
ECA13540
1. Place the vehicle on a center stand.
NOTICE 2. Turn the main switch to “OFF”.
Brake fluid may damage painted surfaces 3. Open the seat.
and plastic parts. Therefore, always clean up 4. Remove:
any spilt brake fluid immediately. • Battery cover
6. Bleed: Refer to “GENERAL CHASSIS (1)” on page
• Brake system 4-1.
Refer to “BLEEDING THE HYDRAULIC 5. Check:
BRAKE SYSTEM” on page 3-12. • Battery voltage
7. Check the operation of the hydraulic unit ac- Lower than 12.8 V → Charge or replace the
cording to the brake levers response. (Refer battery.
to “HYDRAULIC UNIT OPERATION TESTS”
Battery voltage
on page 4-64.) Higher than 12.8 V
ECA14550
NOTICE
TIP
Always check the operation of the hydraulic
unit according to the brake lever response. If the battery voltage is lower than 12.8 V, charge
the battery, and then perform brake line routing
8. Delete the fault codes. (Refer to “[B-3] DE- confirmation.
LETING THE FAULT CODES” on page
8-98.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-67.)
EAS30201
HYDRAULIC UNIT OPERATION TESTS

The reaction-force pulsating action generated in
the brake levers when the ABS is activated can
be tested when the vehicle is stopped.
The hydraulic unit operation can be tested using
the following two methods.
6. Removing the protective cap “1”, and then
• Brake line routing confirmation: this test
connect the Yamaha diagnostic tool to the
checks the function of the ABS after the sys-
Yamaha diagnostic tool coupler (4P).
tem was disassembled, adjusted, or serviced.
• ABS reaction-force confirmation: this test gen- Yamaha diagnostic tool USB
erates the same reaction-force pulsating action 90890-03256
that is generated in the front brake lever and Yamaha diagnostic tool (A/I)
rear brake lever when the ABS is front activat- 90890-03254
ed.
Brake line routing confirmation 1

EWA13120
WARNING
TIP
• For the brake line routing confirmation, use the
diagnosis mode of the Yamaha diagnostic tool.
• Before performing the brake line routing confir-
mation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
4-64
7. Start the Yamaha diagnostic tool and display

the diagnosis mode screen.
8. Select code No. 2, “Brake line routing confir-
mation”.
9. Click “Action” “1”, and then operate the front
brake lever “2” and rear brake lever “3” simul-
taneously.
TIP
1 2
• The hydraulic unit operates 1 second after the
front brake lever and rear brake lever are oper-
ated simultaneously and continues for approx- TIP
imately 5 seconds. “ON” and “OFF” on the tool screen indicate
• The operation of the hydraulic unit can be con- when the brakes are being applied and released
firmed using the indicator. respectively.
On: The hydraulic unit is operating. ECA22080
Flashing: The conditions for operating the hy- NOTICE

draulic unit have not been met. • Check that the pulse is felt in the front
Off: The front brake lever and rear brake lever brake lever, rear brake lever, and again in
are not being operated. the front brake lever, in this order.
• If the pulse is felt in the rear brake lever be-
fore it is felt in the front brake lever, check
that the brake hoses and brake pipes are
connected correctly to the hydraulic unit
assembly.
• If the pulse is hardly felt in either the front
1
brake lever or rear brake lever, check that
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
sembly.
11.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
ABS reaction-force confirmation

EWA13120
WARNING
2 3
TIP
• For the ABS reaction-force confirmation, use
10.Check:
the diagnosis mode of the Yamaha diagnostic
• Hydraulic unit operation
tool. For more information, refer to the opera-
Click “Action”, a single pulse will be generat-
tion manual of the Yamaha diagnostic tool.
ed in the front brake lever “1”, rear brake lever
• Before performing the ABS reaction-force con-
“2”, and again in the front brake lever “1”, in
firmation, make sure that no malfunctions have
this order.
been detected in the ABS ECU and that the
wheels are not rotating.
4-65
1. Place the vehicle on a center stand. 7. Start the Yamaha diagnostic tool and display
2. Turn the main switch to “OFF”. the diagnosis mode screen.
3. Open the seat. 8. Select code No. 1, “ABS reaction-force con-
4. Remove: firmation”.
• Battery cover 9. Click “Action” “1”, and then operate the front
Refer to “GENERAL CHASSIS (1)” on page brake lever “2” and rear brake lever “3” simul-
4-1. taneously.
5. Check: TIP
• Battery voltage • The hydraulic unit operates 1 second after the
Lower than 12.8 V → Charge or replace the front brake lever and rear brake lever are oper-
battery. ated simultaneously and continues for approx-
imately 5 seconds.
Battery voltage
Higher than 12.8 V • The operation of the hydraulic unit can be con-
firmed using the indicator.
TIP
On: The hydraulic unit is operating.
Flashing: The conditions for operating the hy-
If the battery voltage is lower than 12.8 V, charge
draulic unit have not been met.
the battery, and then perform ABS reaction-
Off: The front brake lever and rear brake lever
force confirmation.
are not being operated.
6. Removing the protective cap “1”, and then

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

90890-03256
90890-03254
2 3
1
10.A reaction-force pulsating action is generated
in the front brake lever “1” and continues for a
few seconds.
TIP
• The reaction-force pulsating action consists of
quick pulses.
• Be sure to continue operating the front brake
lever and rear brake lever even after the pul-
sating action has stopped.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
4-66
• If the pulse is hardly felt in either the front

brake lever or rear brake lever, check that
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
sembly.
13.Turn the main switch to “OFF”.
14.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
1 stall the protective cap.
15.Turn the main switch to “ON”.
11.After the pulsating action has stopped in the 16.Check for brake fluid leakage around the hy-
front brake lever, it is generated in the rear draulic unit.
brake lever “1” and continues for a few sec- Brake fluid leakage → Replace the hydraulic
onds. unit, brake hoses, and related parts as a set.
TIP 17.If the operation of the hydraulic unit is normal,
• The reaction-force pulsating action consists of delete all of the fault codes.
quick pulses.
EAS30202
• Be sure to continue operating the front brake CHECKING THE ABS WARNING LIGHT
lever and rear brake lever even after the pul- After all checks and servicing are completed, en-
sating action has stopped. sure that the ABS warning light goes off by walk-
• “ON” and “OFF” on the tool screen indicate ing the vehicle at a speed of faster than 10 km/h
when the brakes are being applied and re- (6 mph) or performing a trial run.
1
12.After the pulsating action has stopped in the
rear brake lever, it is generated in the front
brake lever and continues for a few seconds.
TIP
• The reaction-force pulsating action consists of
quick pulses.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
ECA22080
NOTICE
• Check that the pulse is felt in the front
brake lever, rear brake lever, and again in
the front brake lever, in this order.
• If the pulse is felt in the rear brake lever be-
fore it is felt in the front brake lever, check
that the brake hoses and brake pipes are
connected correctly to the hydraulic unit
assembly.
4-67
HANDLEBAR
EAS20033
HANDLEBAR
Removing the rearview mirror and handlebar cover
2
1
3
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
4
22 N•m (2.2 kgf•m, 16 lb•ft)
T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1 Rearview mirror 2
2 Upper handlebar cover assembly 1
3 Upper handlebar panel 1
4 Upper handlebar cover 1
4-68
HANDLEBAR
Removing the handlebar
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
1 S 6 21 N•m (2.1 kgf•m, 15 lb•ft)
T.R
.
LS
LS 8
LS 5
9
LS 11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
7 6
4 3
2
S
2.3 N•m (0.23 kgf•m, 1.7 lb•ft)
T.R
.
11
10
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2.3 N•m (0.23 kgf•m, 1.7 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

1 Grip end (right) 1
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder 1
5 Handlebar switch coupler (right) 1 Disconnect.
6 Handlebar switch (right) 1
7 Throttle cable 2 Disconnect.
8 Throttle grip 1
9 Handlebar weight (right) 1
10 Grip end (left) 1
11 Handlebar grip 1
4-69
HANDLEBAR
Removing the handlebar
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
S 21 N•m (2.1 kgf•m, 15 lb•ft)
T.R
.
LS
LS
LS
LS 20 11 N•m (1.1 kgf•m, 8.1 lb•ft)
T.R
.
13 15 17
16
22 S
2.3 N•m (0.23 kgf•m, 1.7 lb•ft)
T.R
.
21
19 22
12 18
14
17
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
2.3 N•m (0.23 kgf•m, 1.7 lb•ft)

T.R
.
1.8 N•m (0.18 kgf•m, 1.3 lb•ft)

T.R
.

12 Rear brake light switch connector 2 Disconnect.
13 Rear brake master cylinder holder 1
14 Rear brake master cylinder 1
15 Handlebar switch connector 1 Disconnect.
16 Handlebar switch coupler (left) 1 Disconnect.
17 Handlebar switch (left) 1
18 Handlebar weight (left) 1
19 Lower handlebar cover 1
20 Upper handlebar holder 2
21 Handlebar 1
22 Lower handlebar holder 2
4-70
HANDLEBAR
EAS31622
3. Remove:
REMOVING THE UPPER HANDLEBAR
• Handlebar grip “1”
COVER ASSEMBLY
1. Remove: TIP
• Upper handlebar cover assembly “1” Blow compressed air between the handlebar
a. Remove the quick fastener and upper and the handlebar grip, and gradually push the
handlebar cover assembly screws. grip off the handlebar.
b. Unhook the projections “a” on the upper
handlebar cover assembly from the slots
“b” in the lower handlebar cover.
a a
b
a
b
EAS30204
b CHECKING THE HANDLEBAR

1. Check:
EAS31701 • Handlebar
DISASSEMBLING THE UPPER HANDLEBAR Bends/cracks/damage → Replace.
COVER ASSEMBLY EWA13690
1. Disassemble: WARNING
• Upper handlebar panel “1” Do not attempt to straighten a bent handle-
• Upper handlebar cover “2” bar as this may dangerously weaken it.
TIP
EAS30205
Unhook the projections “a” on the upper handle- INSTALLING THE HANDLEBAR
bar panel from the slots “b” in the upper handle- 1. Stand the vehicle on a level surface.
bar cover. EWA13120
WARNING
a Securely support the vehicle so that there is
1 no danger of it falling over.
2. Install:
a b • Lower handlebar holders “1”
2 • Handlebar “2”
• Upper handlebar holders “3”
Upper handlebar holder bolt

b 21 N·m (2.1 kgf·m, 15 lb·ft)
T.
R.
EAS30203
ECA18300
REMOVING THE HANDLEBAR NOTICE
EWA13120 First, tighten the bolts on the front side of the
WARNING handlebar holder, and then on the rear side.
Securely support the vehicle so that there is TIP
no danger of it falling over. • Make sure that the projection “a” of the handle-
2. Remove: bar contacts the lower handlebar holder.
• Grip end • The upper handlebar holders should be in-
TIP stalled with the punch mark “b” facing forward.
While holding the grip end, loosen the grip end
bolt.
4-71
HANDLEBAR
3 TIP
b
b • Install the brake master cylinder holder with the
“UP” mark “a” facing up.
• Align the edge “b” of the brake master cylinder
holder with the edge “c” of the stay on the han-
a 2
dlebar as shown in the illustration.
• First, tighten the upper bolt, then the lower bolt.
1 1
b
3. Install:
• Handlebar weight (left) “1”
c
TIP
Fit the projections “a” on the handlebar weight
into the holes “b” in the handlebar.
a
1
6. Install:
b
• Handlebar grip “1”
a • Grip end (left) “2”
a. Apply a thin coat of a rubber adhesive to
the left end of the handlebar.
1
b b. Slide the handlebar grip over the left end
of the handlebar.
a TIP
4. Install: Make sure that the distance “a” between the end
• Handlebar switch (left) “1” of the left handlebar switch and the end of the
handlebar grip is 0 mm (0 in).
Handlebar switch screw (left)
2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.
R.
a
1
TIP
Align the projection “a” on the left handlebar
switch with the hole “b” in the handlebar.
1 c. Wipe off any excess rubber adhesive with

a clean rag.
EWA13700
b a
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
5. Install:
• Rear brake master cylinder d. Install the left grip end.
• Rear brake master cylinder holder “1”
Grip end bolt (left)
Rear brake master cylinder hold- 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
er bolt
T.
R.
11 N·m (1.1 kgf·m, 8.1 lb·ft)
4-72
HANDLEBAR
TIP
Handlebar switch screw (right)
• Align the projection “a” on the grip end with the 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.
slot “b” in the handlebar weight.
R.
Throttle cable holder bolt (han-
• There should be 1.0–3.0 mm (0.04–0.12 in) of dlebar switch side)
clearance “c” between the handlebar grip and 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
the grip end. Grip end bolt (right)
7 N·m (0.7 kgf·m, 5.2 lb·ft)
TIP
b • Lubricate the end of the throttle cables and the
2 inside of the throttle grip with a thin coat of lith-
1
ium-soap-based grease.
• Align the projection “a” on the right handlebar
switch with the hole “b” in the handlebar.
a • Align the projection “c” on the grip end with the
slot “d” in the handlebar weight.
• There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “e” between the throttle grip and the
c 1 grip end.
3 LS
LS
2
1
2
1 b
7. Install:
• Handlebar weight (right) “1” a
2
TIP
Fit the projections “a” on the handlebar weight
3
into the holes “b” in the handlebar.
b
a
d
4
c
1
b
a
8. Install: e
• Handlebar switch (right) “1”
• Throttle cables “2”
• Throttle grip “3”
• Grip end (right) “4”
3 4
9. Install:
• Front brake master cylinder
• Front brake master cylinder holder “1”
4-73
HANDLEBAR
EAS31623
Front brake master cylinder hold- INSTALLING THE UPPER HANDLEBAR

er bolt COVER ASSEMBLY
T.
R.

• Upper handlebar cover assembly “1”
TIP a. Fit the projections “a” on the upper handle-
• Install the brake master cylinder holder with the bar cover into the slots “b” in the lower
“UP” mark “a” facing up. handlebar cover.
• Align the edge “b” of the brake master cylinder a a
holder with the edge “c” of the stay on the han-
dlebar as shown in the illustration.
1
• First, tighten the upper bolt, then the lower bolt.
b
a
b
b
c
1
b
TIP
There should be 2.0–4.0 mm (0.08–0.16 in) of
a
clearance “c” between the upper handlebar cov-
er assembly and the right handlebar switch “2”
10.Adjust: and between the cover assembly and the left
• Throttle grip free play handlebar switch “3”.
Refer to “CHECKING THE THROTTLE GRIP
OPERATION” on page 3-23.
1
Throttle grip free play
3.0–5.0 mm (0.12–0.20 in) 3 2
EAS31702
ASSEMBLING THE UPPER HANDLEBAR

COVER ASSEMBLY c c
1. Assemble:
• Upper handlebar cover “1”
• Upper handlebar panel “2” b. Install the upper handlebar cover assem-
TIP bly screws and quick fasteners, and then
Fit the projections “a” on the upper handlebar
panel into the slots “b” in the upper handlebar Upper handlebar cover assembly
cover. screw
T.
R.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

a
1
a b
2
4-74
FRONT FORK
EAS20034
FRONT FORK
Removing the front fork legs
53 N•m (5.3 kgf•m, 39 lb•ft)

T.R
.
2
2
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
1 8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.

The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-24.
1 Front fender 1
2 Lower bracket pinch bolt 2
3 Front fork leg 1
4-75
FRONT FORK
Disassembling the front fork legs
9
12
New 14
LS 1 New
10
15 2
LS
3 New
11
13
LT 8 New
5 New
7
6 New
23 N•m (2.3 kgf•m, 17 lb•ft)
T.R
.

The following procedure applies to both of
the front fork legs.
1 Front fork cap clip 1
2 Front fork cap 1
3 O-ring 1
4 Fork spring 1
5 Dust seal 1
6 Oil seal clip 1
7 Front fork damper rod bolt 1
8 Copper washer 1
9 Oil flow stopper 1
10 Damper rod 1
11 Rebound spring 1
12 Damper rod ring 1
13 Inner tube 1
14 Oil seal 1
15 Outer tube 1
4-76
FRONT FORK
EAS30206
REMOVING THE FRONT FORK LEGS

front fork legs. 1
EWA13120
2
WARNING
TIP
Place the vehicle on a suitable stand so that the 2. Drain:
front wheels are elevated. • Fork oil
TIP
2. Loosen:
• Lower bracket pinch bolts “1” Stroke the outer tube several times while drain-
EWA18000 ing the fork oil.
WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg.
1
1
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
EAS30207 (with a flathead screwdriver)
DISASSEMBLING THE FRONT FORK LEGS ECA14180
The following procedure applies to both of the NOTICE

front fork legs. Do not scratch the inner tube.
ECA19110
NOTICE
1
• The front fork leg has a very sophisticated
internal construction, which are particular-
ly sensitive to foreign material. 2
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
1. Remove:
• Front fork cap clip “1”
• Front fork cap “2” 4. Remove:
TIP • Front fork damper rod bolt “1”
Push the front fork cap in the direction of the ar- • Copper washer
row shown in the illustration to remove the front TIP
fork cap clip. While holding the damper rod with the hexagon
bit socket (14 mm) “2” and T-handle “3”, loosen
the front fork damper rod bolt.
4-77
FRONT FORK
EAS30209
T-handle ASSEMBLING THE FRONT FORK LEGS

90890-01326 The following procedure applies to both of the
T-handle 3/8" drive 60 cm long front fork legs.
YM-01326 EWA13660
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
1 2 3 dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
–Front fork cap clip
–Oil seal
EAS30208
–Oil seal clip
CHECKING THE FRONT FORK LEGS –Dust seal
The following procedure applies to both of the –Copper washer
front fork legs. –O-ring
1. Check: • Before assembling the front fork leg, make
• Inner tube sure all of the components are clean.
• Outer tube 1. Install:
Bends/damage/scratches → Replace. • Damper rod ring “1”
EWA13650
WARNING • Damper rod “2”

• Rebound spring “3”
Do not attempt to straighten a bent inner
(in the inner tube “4”)
tube as this may dangerously weaken it.
• Oil flow stopper “5”
2. Measure: ECA22740
• Fork spring free length “a” NOTICE

Out of specification → Replace. Allow the damper rod to slide slowly down
the inner tube until it protrudes from the bot-
Fork spring free length tom of the inner tube. Be careful not to dam-
245.3 mm (9.66 in) age the inner tube.
Limit
240.3 mm (9.46 in) TIP
Fit the damper rod ring into the damper rod
groove so that the side of the ring with the pro-
jections is facing in the direction shown in the il-
lustration.
a
2
1
3. Check:
• Damper rod
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage → Replace.
4-78
FRONT FORK
3. Lubricate:
• Inner tube’s outer surface
Recommended oil
Yamaha Suspension Oil G10
4. Install:
• Inner tube
5 4 3 1 2 (in the outer tube)
5. Install:
• Copper washer New
2. Install:
• Front fork damper rod bolt “1”
• Oil seal “1” New
(with the fork seal driver attachment “2” and Front fork damper rod bolt
fork seal driver weight “3”) 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
ECA14220
LOCTITE®
NOTICE
Make sure the numbered side of the oil seal TIP
faces up. While holding the damper rod assembly with the
TIP hexagon bit socket (14 mm) “2” and T-handle
“3”, tighten the front fork damper rod bolt.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of T-handle
the front fork leg with a plastic bag to protect 90890-01326
T-handle 3/8" drive 60 cm long
the oil seal during installation.
YM-01326
Fork seal driver weight

90890-01367
Replacement hammer
YM-A9409-7 1 2 3
Fork seal driver attachment (ø30)
90890-01400
6. Install:
• Oil seal clip “1” New
TIP
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
2 1 New
1 New
4-79
FRONT FORK
7. Install:
• Dust seal “1” New
(with the fork seal driver attachment “2” and
fork seal driver weight “3”)
1
Fork seal driver weight
90890-01367
Replacement hammer
YM-A9409-7
Fork seal driver attachment (ø30)
90890-01400 10.Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
TIP
3 Be sure to bleed the front fork leg of any residual
air.
2 11.Measure:
• Front fork leg oil level “a”
1 New (from the top of the inner tube, with the inner
tube fully compressed and without the fork
spring)
8. Fill: Out of specification → Correct.
• Front fork leg
(with the specified amount of the recom- Level
mended fork oil) 78.0 mm (3.07 in)
Recommended oil TIP

Yamaha Suspension Oil G10
Quantity • While filling the front fork leg, keep it upright.
86.0 cm³ (2.91 US oz, 3.03 • After filling, slowly pump the front fork leg up
Imp.oz) and down to distribute the fork oil.
ECA14230
NOTICE
• Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
9. After filling the front fork leg, slowly stroke the
inner tube “1” up and down (at least ten
12.Install:
times) to distribute the fork oil.
• Fork spring “1”
TIP
• O-ring New
Be sure to stroke the inner tube slowly because
• Front fork cap
the fork oil may spurt out.
• Front fork cap clip New
TIP
Install the fork spring with its smaller pitch down-
ward.
4-80
FRONT FORK
1 1
1
EAS30210
INSTALLING THE FRONT FORK LEGS

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

53 N·m (5.3 kgf·m, 39 lb·ft)
T.
R.
TIP
Tighten the lower bracket pinch bolts to specifi-
cation twice. Tighten the upper and lower bolts
alternately, starting with the upper bolts.
4-81
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
63 N•m (6.3 kgf•m, 47 lb•ft) 1
T.R
.
LS
LS
75 N•m (7.5 kgf•m, 55 lb•ft)
T.R
.
1st 38 N•m (3.8 kgf•m, 28 lb•ft)
*2nd 16 N•m (1.6 kgf•m, 12 lb•ft)
T.R
.
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
3 2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
* Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.

Front upper cowling assembly 4-15.
Front wheel Refer to “FRONT WHEEL” on page 4-24.
Handlebar Refer to “HANDLEBAR” on page 4-68.
Front fork legs Refer to “FRONT FORK” on page 4-75.
1 Handlebar bracket 1
2 Horn connector 2 Disconnect.
3 Horn 1
4 Horn bracket 1
5 Front brake hose holder 1
4-82
STEERING HEAD
Removing the lower bracket

63 N•m (6.3 kgf•m, 47 lb•ft)
T.R
.
LS
19
16
6
LS 17
75 N•m (7.5 kgf•m, 55 lb•ft) 7
T.R
.
18
1st 38 N•m (3.8 kgf•m, 28 lb•ft)
*2nd 16 N•m (1.6 kgf•m, 12 lb•ft) 8
T.R
.
9
10
LS
11
12 13
14
15
7 N•m (0.7 kgf•m, 5.2 lb•ft) 20
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

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

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

• Lower ring nut If the bearing race is not installed properly,
• Lower bracket the steering head pipe could be damaged.
EWA13730
WARNING TIP
Securely support the lower bracket so that • Always replace the bearings and bearing races
there is no danger of it falling. as a set.
• Whenever the steering head is disassembled,
TIP replace the dust seal.
Remove the upper ring nut and lower ring nut
with the steering nut wrench “2”.
Steering nut wrench

90890-01403
YU-A9472
1
EAS30214
CHECKING THE STEERING HEAD

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

• Bearings 1. Install:
• Bearing races • Upper bearing “1”
Damage/pitting → Replace the bearings and • Lower bearing
bearing races as a set. • Lower bearing dust seal
4-84
STEERING HEAD
TIP 4. Install:
• Apply lithium-soap-based grease to each part. • Horn bracket “1”
• Be sure to install the upper bearing so that the • Horn “2”
marks “a” on the bearing are facing upward.
Horn bracket bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
a Horn bolt
7 N·m (0.7 kgf·m, 5.2 lb·ft)
TIP
1 • While holding the horn bracket so that the
bracket contacts the portion “a” of the lower
bracket “3”, tighten the bolt to specification.
• While holding the horn so that the horn con-
tacts the portion “b” of the horn bracket, tighten
2. Install: the bolt to specification.
• Lower ring nut “1”
• Rubber washer “2”
a
• Center ring nut “3”
• Lock washer “4” 3
• Upper ring nut “5”
Refer to “CHECKING AND ADJUSTING 1
THE STEERING HEAD” on page 3-14.
5
4 3
2
1 1
3. Install:
• Front brake hose holder “1” b
2
Front brake hose holder bolt
T.
R.
• Handlebar bracket “1”

TIP
Handlebar bracket nut
While holding the front brake hose holder so that
63 N·m (6.3 kgf·m, 47 lb·ft)
T.
the holder contacts the projection “a” on the low-

R.
er bracket, tighten the bolt to specification.

TIP
Align the slots “a” in the lower bracket with the
pin “b” on the handlebar bracket.
a
4-85
STEERING HEAD
b
a
4-86
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
EAS20189

Removing the rear shock absorber assemblies and swingarm
3
2
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
LS
LS New
57 N•m (5.7 kgf•m, 42 lb•ft)
T.R
.
LS
21 N•m (2.1 kgf•m, 15 lb•ft)
New
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

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

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

T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
21 N•m (2.1 kgf•m, 15 lb•ft)

T.R
.

Battery 4-1.
Storage box 4-8.
1 Rear wheel axle nut 1
2 Rear brake hose holder (rear side) 1
3 Rear wheel sensor 1
4-87
Removing the rear shock absorber assemblies and swingarm
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
13
LS
LS New
10 57 N•m (5.7 kgf•m, 42 lb•ft)
T.R
.
LS
21 N•m (2.1 kgf•m, 15 lb•ft)
New
T.R
.
6
12 7
11
5 8
9
10
7 N•m (0.7 kgf•m, 5.2 lb•ft)

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

T.R
.
35 N•m (3.5 kgf•m, 26 lb•ft)

T.R
.
21 N•m (2.1 kgf•m, 15 lb•ft)

T.R
.

5 Rear shock absorber assembly 2
6 Swingarm assembly 1
7 Rear brake hose guide 1
8 Spacer 1
9 Bearing retaining plate 1
10 Oil seal 2
11 Bearing 1
12 Swingarm 1
13 Collar 1
4-88
EAS31228
1. Check:
REMOVING THE SWINGARM
ECA22880
• Rear wheel sensor
NOTICE Refer to “MAINTENANCE OF THE FRONT
Keep any type of magnets (including mag- WHEEL SENSOR AND SENSOR ROTOR”
netic pick-up tools, magnetic screwdrivers, on page 4-27.
etc.) away from the rear wheel sensor; other- 2. Check:
wise, the sensor may be damaged, resulting • Rear wheel sensor rotor
in improper performance of the ABS system. Refer to “MAINTENANCE OF THE FRONT
WHEEL SENSOR AND SENSOR ROTOR”
1. Stand the vehicle on a level surface. on page 4-27.
EWA13120
WARNING EAS31229
Securely support the vehicle so that there is CHECKING THE REAR SHOCK ABSORBER
no danger of it falling over. ASSEMBLY
1. Check:
TIP • Rear shock absorber rod
Place the vehicle on the centerstand so that the Bends/damage → Replace the rear shock
rear wheel is elevated. absorber assembly.
• Rear shock absorber assembly
2. Remove:
Oil leaks → Replace the rear shock absorber
• Rear wheel axle nut “1”
assembly.
• Rear brake hose holder (rear side) “2”
• Spring
• Rear wheel sensor “3”
Damage/wear → Replace the rear shock ab-
• Rear brake caliper “4”
ECA21830
sorber assembly.
NOTICE • Bushings
Damage/wear → Replace the rear shock ab-
Do not apply the brake lever when removing
sorber assembly.
the brake caliper.
• Bolts
Bends/damage/wear → Replace.
2
EAS31230
CHECKING THE SWINGARM

4 1. Check:
• Swingarm
Bends/cracks/damage → Replace.
3
2. Check:
1 • Spacer
• Collar
• Oil seal
EAS31734
• Bearing
MAINTENANCE OF THE REAR WHEEL
SENSOR
ECA22900
EAS31231
NOTICE INSTALLING THE SWINGARM
• Handle the ABS components with care 1. Lubricate:
since they have been accurately adjusted. • Oil seal lips
Keep them away from dirt and do not sub-
ject them to shocks. Recommended lubricant
• The rear wheel sensor cannot be disassem- Lithium-soap-based grease
bled. Do not attempt to disassemble it. If
2. Assemble:
faulty, replace with a new one.
• Bearing “1”
netic pick-up tools, magnetic screwdrivers, • Oil seals “2” New
etc.) away from the rear wheel sensor. • Bearing retaining plate “3”
• Do not drop or shock the wheel sensor. • Rear brake hose guide “4”
4-89
• Spacer “5” • Swingarm mounting bolt (lower side) “4”

(to the swingarm “6”) (temporarily tighten)
4. Tighten:
Bearing retaining plate bolt • Rear wheel axle nut “2”
7 N·m (0.7 kgf·m, 5.2 lb·ft) • Swingarm mounting bolt (upper side) “3”
T.
R.
• Swingarm mounting bolt (lower side) “4”

TIP
• Install the oil seal until it is flush with the sur- Rear wheel axle nut
face “a” of the swingarm. 125 N·m (12.5 kgf·m, 92 lb·ft)
T.
R.
• Install the oil seal until it is flush with the sur- Swingarm mounting bolt
face “b” of the bearing retaining plate. 57 N·m (5.7 kgf·m, 42 lb·ft)
• Install the bearing retaining plate with the
punch mark “c” facing outward. TIP
• While holding the rear brake hose guide so that Tighten the rear wheel axle nut “2”, then the
the portion “d” of the guide contacts the bearing swingarm mounting bolts “3”, “4”.
retaining plate.
1
3
6
2 4
3
1
2 New 5. Install:
New 2
5 • Rear shock absorber assemblies
LS
Rear shock absorber assembly
2 New nut
T.
R.
LS 21 N·m (2.1 kgf·m, 15 lb·ft)

Rear shock absorber assembly
2 New bolt
21 N·m (2.1 kgf·m, 15 lb·ft)
b
a TIP
Tighten the rear shock absorber assembly nuts
and bolts temporarily, and then tighten them to
specification.
3
6. Measure:
TIP
Measure the distance “a” only if the wheel bear-
c ings, wheel sensor rotor, or both were replaced.
• Distance “a”
4 (between the wheel sensor rotor “1” and
d swingarm “2” (edge of the wheel sensor in-
stallation hole “b”))
3. Install:
Out of specification → Reinstall the bearing
• Swingarm assembly “1”
or replace the wheel sensor rotor.
• Rear wheel axle nut “2”
(temporarily tighten)
• Swingarm mounting bolt (upper side) “3”
(temporarily tighten)
4-90
Distance “a” (between the wheel

sensor rotor and swingarm (edge
of the wheel sensor installation
hole))
18.92–19.60 mm (0.74–0.77 in)
b
1
2
a
7. Install:
• Rear wheel sensor
Rear wheel sensor bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
ECA22910
NOTICE
Make sure there are no foreign materials in
the rear wheel sensor. Foreign materials
cause damage to the rear wheel sensor.
TIP
To route the rear wheel sensor lead, refer to
“CABLE ROUTING” on page 2-27.
8. Install:
• Rear brake hose holder (rear side) “1”
Rear brake hose holder bolt (rear

side)
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
TIP
Fit the projection “a” on the rear brake hose hold-
er into the hole “b” in the swingarm.
a
b
4-91
ENGINE
ENGINE INSPECTION .................................................................................... 5-1

MEASURING THE COMPRESSION PRESSURE....................................5-1
ENGINE REMOVAL ........................................................................................5-3

INSTALLING THE ENGINE....................................................................... 5-7
CONNECTING THE LEADS ..................................................................... 5-8
INSTALLING THE MUFFLER ...................................................................5-8
CYLINDER HEAD............................................................................................ 5-9

REMOVING THE CYLINDER HEAD.......................................................5-13
CHECKING THE CYLINDER HEAD .......................................................5-13
CHECKING THE CAMSHAFT SPROCKET............................................5-14
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-14
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-14
CHECKING THE VVA SOLENOID.......................................................... 5-15
INSTALLING THE CYLINDER HEAD .....................................................5-15
CAMSHAFT ................................................................................................... 5-18

REMOVING THE CAMSHAFT ................................................................5-19
CHECKING THE CAMSHAFT.................................................................5-19
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-20
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-20
VALVES AND VALVE SPRINGS.................................................................. 5-22

5
REMOVING THE VALVES...................................................................... 5-23
CHECKING THE VALVES AND VALVE GUIDES ..................................5-23
CHECKING THE VALVE SEATS ............................................................ 5-25
CHECKING THE VALVE SPRINGS........................................................ 5-26
INSTALLING THE VALVES .................................................................... 5-27
CYLINDER AND PISTON.............................................................................. 5-29

REMOVING THE PISTON ...................................................................... 5-30
CHECKING THE CYLINDER AND PISTON ...........................................5-30
CHECKING THE PISTON RINGS........................................................... 5-31
CHECKING THE PISTON PIN ................................................................5-32
CHECKING THE TIMING CHAIN GUIDE (EXHAUST SIDE) ................. 5-32
INSTALLING THE PISTON AND CYLINDER .........................................5-32
V-BELT AUTOMATIC TRANSMISSION .......................................................5-34
REMOVING THE PRIMARY SHEAVE....................................................5-38
REMOVING THE SECONDARY SHEAVE ............................................. 5-38
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-38
CHECKING THE CLUTCH HOUSING ....................................................5-39
CHECKING THE CLUTCH SHOES ........................................................ 5-39
CHECKING THE V-BELT........................................................................5-39
CHECKING THE PRIMARY SHEAVE ....................................................5-39
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-40
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-40
CHECKING THE SECONDARY SHEAVE .............................................. 5-40
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-40
ASSEMBLING THE SECONDARY SHEAVE..........................................5-40
INSTALLING THE PRIMARY SHEAVE, V-BELT AND SECONDARY
SHEAVE .................................................................................................5-41
STARTER CLUTCH ......................................................................................5-44

CHECKING THE STARTER WHEEL......................................................5-46
CHECKING THE STARTER CLUTCH ....................................................5-46
CHECKING THE TIMING CHAIN............................................................ 5-46
CHECKING THE TIMING CHAIN GUIDE (INTAKE SIDE) .....................5-46
INSTALLING THE STARTER CLUTCH .................................................. 5-46
AC MAGNETO...............................................................................................5-47
REMOVING THE AC MAGNETO............................................................ 5-49
INSTALLING THE AC MAGNETO .......................................................... 5-49
ELECTRIC STARTER ...................................................................................5-50

CHECKING THE STARTER MOTOR .....................................................5-52
ASSEMBLING THE STARTER MOTOR................................................. 5-53
INSTALLING THE STARTER MOTOR ...................................................5-53
OIL PUMP...................................................................................................... 5-54

CHECKING THE OIL STRAINER ........................................................... 5-56
CHECKING THE OIL PUMP ................................................................... 5-56
ASSEMBLING THE OIL PUMP...............................................................5-56
TRANSMISSION............................................................................................ 5-57
CHECKING THE TRANSMISSION ......................................................... 5-59
INSTALLING THE TRANSMISSION .......................................................5-59
CRANKSHAFT ..............................................................................................5-60
DISASSEMBLING THE CRANKCASE....................................................5-62
REMOVING THE CRANKSHAFT ASSEMBLY ....................................... 5-62
CHECKING THE CRANKSHAFT ASSEMBLY........................................ 5-62
CHECKING THE CRANKCASE ..............................................................5-63
CHECKING THE BEARING .................................................................... 5-63
CHECKING THE OIL PUMP DRIVE GEAR ............................................5-63
INSTALLING THE CRANKSHAFT .......................................................... 5-63
ASSEMBLING THE CRANKCASE.......................................................... 5-63
INSTALLING THE CENTERSTAND .......................................................5-64
ENGINE INSPECTION
EAS20041
7. Measure:
ENGINE INSPECTION • Compression pressure
EAS30249
Out of specification → Refer to steps (c) and
MEASURING THE COMPRESSION (d).
PRESSURE
Compression pressure
TIP 1609–2072 kPa/840 r/min (16.1–
Insufficient compression pressure will result in a 20.7 kgf/cm²/840 r/min, 228.9–
loss of performance. 294.7 psi/840 r/min) (GPD125-A)
1566–2016 kPa/860 r/min (15.7–
1. Measure:
20.2 kgf/cm²/860 r/min, 222.7–
• Valve clearance 286.7 psi/860 r/min) (GPD150-A)
Refer to “ADJUSTING THE VALVE CLEAR- a. Turn the main switch to “ON”.
ANCE” on page 3-5. b. With the throttle wide open, crank the en-
2. Start the engine, warm it up for several min- gine until the reading on the compression
utes, and then turn it off. gauge stabilizes.
3. Remove: EWA12960
• Front side cover (right) WARNING

Refer to “GENERAL CHASSIS (2)” on page To prevent sparking, ground the spark plug
4-3. lead before cranking the engine.
c. If the compression pressure is above the
maximum specification, check the cylinder
4-11.
head, valve surfaces and piston crown for
4. Disconnect:
carbon deposits.
• Spark plug cap
Carbon deposits → Eliminate.
5. Remove:
d. If the compression pressure is below the
• Spark plug
ECA20470
minimum specification, pour a teaspoonful
NOTICE of engine oil into the spark plug bore and
Before removing the spark plug, use com- measure again.
pressed air to blow away any dirt accumulat- Refer to the following table.
ed in the spark plug well to prevent it from Compression pressure (with oil applied into the
falling into the cylinder. cylinder)
Reading Diagnosis
6. Install:
• Compression gauge “1” Piston ring(s) wear or
Higher than without oil
damage → Repair.
• Extension “2”
Piston, valves, cylinder
Compression gauge head gasket or piston
Same as without oil
90890-03081 ring(s) possibly defec-
Engine compression tester tive → Repair.
YU-33223
8. Install:
Extension
90890-04136 • Spark plug “1”
Spark plug
1 13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
TIP
When tightening the spark plug, make sure that
the inside “a” of the spark plug wrench “2” does
not contact the portion “b” of the spark plug.
5-1
ENGINE INSPECTION
b
a 2
9. Connect:
• Spark plug cap
TIP
To route the spark plug lead, refer to “CON-
NECTING THE LEADS” on page 5-8.
10.Install:
4-11.
4-3.
5-2
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler
8 N•m (0.8 kgf•m, 5.9 lb•ft)

T.R
.
53 N•m (5.3 kgf•m, 39 lb•ft)

T.R
.
LT New 3
2
1 53 N•m (5.3 kgf•m, 39 lb•ft)

T.R
.
LT

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

T.R
.

1 Muffler protector 1
2 Muffler 1
3 Exhaust gasket 1
5-3
ENGINE REMOVAL
Disconnecting the leads
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-17.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
Battery 4-1.
Storage box 4-8.
Refer to “V-BELT AUTOMATIC TRANSMIS-
V-belt case air duct SION” on page 5-34.
Fuel injector Refer to “FUEL INJECTOR” on page 7-5.
Throttle body Refer to “THROTTLE BODY” on page 7-10.
5-4
ENGINE REMOVAL
Disconnecting the leads
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
8
7
2
6 5

Rear brake caliper Refer to “REAR BRAKE” on page 4-48.
Rear wheel sensor SEMBLIES AND SWINGARM” on page
4-87.
1 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 AC magneto lead coupler 1 Disconnect.
4 O2 sensor coupler 1 Disconnect.
5 Spark plug cap 1 Disconnect.

6 Coolant temperature sensor coupler 1 Disconnect.
7 Starter motor sub-wire harness coupler 1 Disconnect.
8 Engine ground lead 1 Disconnect.
5-5
ENGINE REMOVAL
Removing the engine
21 N•m (2.1 kgf•m, 15 lb•ft)
T.R
.
68 N•m (6.8 kgf•m, 50 lb•ft)
T.R
.
1
21 N•m (2.1 kgf•m, 15 lb•ft)
T.R
.
1
2
4
6 68 N•m (6.8 kgf•m, 50 lb•ft)
T.R
.
6 8 3
4
2 9
5
52 N•m (5.2 kgf•m, 38 lb•ft) 9

T.R
.

1 Rear shock absorber assembly 2
2 Engine bracket nut/bolt 1/1
3 Engine 1
4 Engine mounting nut/bolt (rear side) 1/1
5 Engine mounting nut/bolt (front left side) 1/1
6 Engine mounting nut/bolt (front right side) 1/1
7 Engine bracket 1
8 Stopper 1
9 Collar 2
5-6
ENGINE REMOVAL
EAS30251
INSTALLING THE ENGINE Rear shock absorber assembly

1. Install: nut
T.
R.
• Collars “1” 21 N·m (2.1 kgf·m, 15 lb·ft)
• Stopper “2” Rear shock absorber assembly
(to the engine “3”) bolt
2. Install: 21 N·m (2.1 kgf·m, 15 lb·ft)
• Engine bracket “4”
• Engine mounting bolt/nut (front right side) “5” TIP
• Engine mounting bolt/nut (front left side) “6” Tighten the rear shock absorber assembly nuts
• Engine mounting bolt/nut (rear side) “7” and bolts temporarily, and then tighten them to
TIP specification.
Do not fully tighten the nuts and bolts. 7. Tighten:
3. Tighten: • Engine bracket nut
• Engine mounting nut (front right side)
Engine bracket nut
• Engine mounting bolt (front left side) 52 N·m (5.2 kgf·m, 38 lb·ft)
T.
R.
Engine mounting nut (front right
side) TIP
T.
R.
68 N·m (6.8 kgf·m, 50 lb·ft) Before tightening the engine bracket nut, place
Engine mounting bolt (front left the vehicle on the centerstand so that the rear
side) wheel is elevated.
68 N·m (6.8 kgf·m, 50 lb·ft)
8. Check:
TIP • Stopper installation
a. Raise the centerstand so that the rear
Tighten the engine mounting nut, and then tight-
wheel is on the ground.
en the engine mounting bolt.
b. Make sure that the stopper “2” is not
touching the engine “3”.
1 1 4 3 2
6 6 5 5
2
7
7
4. Tighten:
• Engine mounting nut (rear side)
Engine mounting nut (rear side)

68 N·m (6.8 kgf·m, 50 lb·ft)
T.
R.
5. Install:
• Engine bracket bolt/nut “8”
TIP
Do not fully tighten the nut.
6. Install:
• Rear shock absorber assemblies “9”
5-7
ENGINE REMOVAL
9 1
3
8
2
EAS31588
INSTALLING THE MUFFLER

1 1. Install:
7
5
5 • Exhaust gaskets “1” New
7 (to the cylinder head)
1
8 6 6 TIP
3 Install the exhaust gasket with its projections “a”
4 facing toward the cylinder head.
EAS31717
CONNECTING THE LEADS

1. Connect: a
• Engine ground lead “1”
Engine ground lead bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
a
R.
1 New
TIP
Make sure that the engine ground lead terminal
“a” contacts the stopper “b” on the crankcase.
b
1
2. Connect:
• Spark plug cap “1”
TIP
Route the spark plug lead between the VVA
(variable valve actuator) solenoid “2” and the
water pump inlet hose “3”. Make sure that the
spark plug lead does not contact the VVA (vari-
able valve actuator) solenoid or water pump inlet
hose.
5-8
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
New
New
New New *
(4)
LS LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
(4) New
M
7 N•m (0.7 kgf•m, 5.2 lb•ft)
(4) New
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)

T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft)

New
T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)

New
T.R
.

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

Battery 4-1.
Storage box 4-8.
Drain.
page 3-19.
Radiator Refer to “RADIATOR” on page 6-1.
Thermostat assembly Refer to “THERMOSTAT” on page 6-5.
Water pump Refer to “WATER PUMP” on page 6-7.
5-9
CYLINDER HEAD
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
New
New
New New *
(4)
LS LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
(4) New
M
7 N•m (0.7 kgf•m, 5.2 lb•ft)
(4) New
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)

T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft)

New
T.R
.
M
1 2
13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.
3
10 N•m (1.0 kgf•m, 7.4 lb•ft) 5
T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)

New
T.R
.
4
T.R
T.R
.

Fuel tank Refer to “FUEL TANK” on page 7-1.
Intake manifold Refer to “THROTTLE BODY” on page 7-10.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3 O2 sensor coupler 1 Disconnect.
TIP
4 O2 sensor 1 Remove the O2 sensor only when neces-
sary.
5 Coolant temperature sensor coupler 1 Disconnect.
5-10
CYLINDER HEAD
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

10 N•m (1.0 kgf•m, 7.4 lb•ft) 12
T.R
.
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
8
9 New
14 New
7 10 New New
*
(4)
LS LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
11 13 (4) New
M 15
7 N•m (0.7 kgf•m, 5.2 lb•ft)
(4) New
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)

T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft)

New
T.R
.
13 N•m (1.3 kgf•m, 9.6 lb•ft)

T.R
.
15
6
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)

New
T.R
.

T.R
T.R
.

6 Coolant temperature sensor 1
7 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
8 VVA (variable valve actuator) solenoid 1
9 VVA (variable valve actuator) solenoid gasket 1
10 VVA (variable valve actuator) solenoid rod 1
11 Fuel hose holder 1
12 Cylinder head breather hose 1
13 Cylinder head cover 1
14 Cylinder head cover gasket 1
15 Dowel pin 2
5-11
CYLINDER HEAD
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)

10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
19
New
New 16 20
17 New New 21 *
18
(4)
LS LT
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
28
(4) New 27
M
7 N•m (0.7 kgf•m, 5.2 lb•ft)
(4) 26 New
T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft) (4)

T.R
.
24 N•m (2.4 kgf•m, 18 lb•ft)

New
T.R
.
27
M
22
13 N•m (1.3 kgf•m, 9.6 lb•ft)
25 24
T.R
.
23
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
30 N•m (3.0 kgf•m, 22 lb•ft)

New
T.R
.

T.R
T.R
.

16 Cylinder head cover breather plate 1
17 Cylinder head cover breather plate gasket 1
18 Oil seal 1
19 Timing chain tensioner plug 1
20 Timing chain tensioner 1
21 Timing chain tensioner gasket 1
22 Camshaft sprocket bolt 1
23 Camshaft sprocket 1
24 Decompression cam 1
25 Cylinder head 1
26 Cylinder head gasket 1
27 Dowel pin 2
28 Engine oil check bolt 1
5-12
CYLINDER HEAD
EAS30276
3. Remove:
REMOVING THE CYLINDER HEAD
• Cylinder head
1. Align:
• “I” mark “a” on the AC magneto rotor TIP
(with the match mark “b” on the right crank- • Loosen the bolts and nuts in the proper se-
case) quence as shown.
a. Turn the crankshaft clockwise. • Loosen each bolt and nuts 1/2 of a turn at a
time. After all of the bolts and nuts are fully
loosened, remove them.
×
4 3 4
b
×
2
6 5
a
b. When the piston is at TDC on the com- 1 2
pression stroke, align the “I” mark “c” on
the camshaft sprocket with the match EAS30277
mark “d” on the camshaft stopper plate. CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
c d (with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
• Valve seats
2. Loosen:
• Camshaft sprocket bolt “1”
TIP
Use the camshaft wrench “2” and loosen the
camshaft sprocket bolt.
Camshaft wrench
90890-04162
Camshaft wrench
YM-04162 2. Check:
• Cylinder head
Damage/scratches → Replace.
• Cylinder head water jacket
1 Mineral deposits/rust → Eliminate.
2 3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
Warpage limit
0.05 mm (0.0020 in)
5-13
CYLINDER HEAD
a. Place a straightedge “1” and a thickness EAS30279
CHECKING THE TIMING CHAIN TENSIONER

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

rod in place with your hand, turn the
screwdriver counterclockwise, remove the
screwdriver, and slowly release the timing
b. Measure the warpage. chain tensioner rod.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.
EAS31232
CHECKING THE CAMSHAFT SPROCKET d. Make sure that the timing chain tensioner
1. Check: rod comes out of the timing chain tension-
• Camshaft sprocket er housing smoothly. If there is rough
More than 1/4 tooth wear “a” → Replace the movement, replace the timing chain ten-
camshaft sprocket, timing chain and crank- sioner.
shaft as a set. e. Install the timing chain tensioner plug.
EAS30280
CHECKING THE DECOMPRESSION SYSTEM

1. Check:
• Decompression system
TIP
• Check that the decompression lever moves
smoothly.
• Check that the operating range “a” of the de-
compression lever is the same as the range
a. 1/4 tooth shown in the illustration.
b. Correct
1. Timing chain roller
2. Camshaft sprocket
5-14
CYLINDER HEAD
2. Install:
a • Decompression cam “1”
• Camshaft sprocket “2”
• Timing chain
• Camshaft sprocket bolt
a. Turn the crankshaft clockwise.
b. Align the “I” mark “a” on the AC magneto
rotor with the match mark “b” on the right
crankcase.
a. 20.88°
EAS31624
CHECKING THE VVA SOLENOID

1. Check:
• VVA (variable valve actuator) solenoid “1” b
1 a
c. Install the decompression cam.
d. Install the timing chain onto the camshaft
sprocket, then the camshaft sprocket onto
the camshaft, and then finger tighten the
camshaft sprocket bolt.
ECA20600
NOTICE
Do not turn the crankshaft when installing
EAS30282
the camshaft sprocket to avoid damage or
INSTALLING THE CYLINDER HEAD
improper valve timing.
1. Tighten:
• Cylinder head nuts “1” TIP
• Cylinder head bolts “2” • Fit the pin on the decompression cam into the
slot “c” in the decompression lever on the cam-
Cylinder head nut
shaft sprocket.
24 N·m (2.4 kgf·m, 18 lb·ft)
T.
• Align the “I” mark “d” on the camshaft sprocket

R.
Cylinder head bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft) with the match mark “e” on the camshaft stop-
per plate.
TIP
• Lubricate the cylinder head nuts and washers
2
with molybdenum disulfide grease. e
• Tighten the cylinder head nuts and bolts in the
proper tightening sequence as shown and 1
torque them in two stages. d
× c
3 4 4
1 1 × e. While holding the camshaft, temporarily

2 tighten the camshaft sprocket bolt.
1 2 3. Install:
2 2
• Timing chain tensioner gasket New
6 5 • Timing chain tensioner
a. Remove the timing chain tensioner plug.
5-15
CYLINDER HEAD
b. While lightly pressing the timing chain ten-

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

90890-85505
(Three bond No.1215®)
a
Timing chain tensioner bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
c d
a
a
2
6. Tighten:
• Camshaft sprocket bolt “1”
d. Turn the timing chain tensioner rod coun- Camshaft sprocket bolt
terclockwise with a thin screwdriver “1”, 30 N·m (3.0 kgf·m, 22 lb·ft)
T.
R.
make sure it releases, and then install the

timing chain tensioner plug.
5-16
CYLINDER HEAD
Camshaft wrench VVA (variable valve actuator) so-

90890-04162 lenoid bolt
T.
R.
Camshaft wrench 10 N·m (1.0 kgf·m, 7.4 lb·ft)
YM-04162
TIP
ECA20610
NOTICE While holding the VVA (variable valve actuator)

solenoid so that it is contacting the cylinder head
Be sure to tighten the camshaft sprocket bolt
cover “2”, tighten the bolts to specification.
to the specified torque to avoid the possibil-
ity of the bolt coming loose and damaging
the engine.
TIP
1
Tighten the camshaft sprocket bolt with the cam- 2
shaft wrench “2”.
1
2
7. Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
8. Install:
• Oil seal “1”
(into the cylinder head cover “2”)
TIP
Install the oil seal so that it is facing in the direc-
tion shown in the illustration. Press the oil seal
into the cylinder head cover using a suitable di-
ameter socket “3”.
3 2
9. Install:
• VVA (variable valve actuator) solenoid “1”
5-17
CAMSHAFT
EAS20043
CAMSHAFT
Removing the rocker arms and camshaft
8 N•m (0.8 kgf•m, 5.9 lb•ft)
T.R
.
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
2
New M
11 14
14
12 10
13 4 New
9
M
3
M
M E
8
6 7
E
E 5
2 M
7 E
M
2 M 5
M
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

Cylinder head Refer to “CYLINDER HEAD” on page 5-9.
1 Camshaft stopper plate 1
2 Locknut 4
3 Camshaft assembly 1
4 Bearing 1
5 Rocker arm shaft 2
6 Exhaust rocker arm 1
7 Adjusting screw (exhaust side) 2
8 Plate 1
9 Spring 1
10 Intake rocker arm 1 1
11 Intake rocker arm stopper pin 1
12 Spring 1
13 Intake rocker arm 2 1
14 Adjusting screw (intake side) 2
5-18
CAMSHAFT
EAS30256
REMOVING THE CAMSHAFT Camshaft lobe dimensions

1. Loosen: Lobe height (Intake)
• Adjusting screws (intake/exhaust) 32.211–32.311 mm (1.2681–
2. Remove: 1.2721 in)
• Camshaft assembly “1” Limit
32.111 mm (1.2642 in)
Slide hammer bolt (M8) Lobe height (Intake high speed)
90890-01085 32.587–32.687 mm (1.2830–
Slide hammer bolt 8 mm 1.2869 in)
YU-01083-2 Limit (Intake high speed)
Weight 32.487 mm (1.2790 in)
90890-01084 Lobe height (Exhaust)
Weight 29.224–29.324 mm (1.1505–
YU-01083-3 1.1545 in) (GPD125-A)
29.420–29.520 mm (1.1583–
a. Align the holes “a” in intake rocker arm 1 1.1622 in) (GPD150-A)
“2” and intake rocker arm 2 “3”, and then Limit
push the intake rocker arm stopper pin “4” 29.124 mm (1.1466 in) (GPD125-
in the direction of the arrow shown in the A)
illustration. 29.320 mm (1.1543 in) (GPD150-
A)
4
a
b. While pushing intake rocker arm 1 “2” and

intake rocker arm 2 “3” in the direction of
the arrow shown in the illustration, remove
the camshaft assembly using a slide ham-
mer bolt “5” and weight “6”.
3
1
5
6 3. Measure:
• Camshaft runout
Out of specification → Replace the camshaft.
EAS30257
Camshaft runout limit
CHECKING THE CAMSHAFT
0.030 mm (0.0012 in)
1. Check:
• Camshaft lobes
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the camshaft.
5-19
CAMSHAFT
4. Check: 4. Measure:
• Camshaft oil passage • Rocker arm shaft outside diameter “a”
Obstruction → Blow out with compressed air. Out of specification → Replace.
EAS30259
Rocker arm shaft outside diame-
CHECKING THE ROCKER ARMS AND ter
ROCKER ARM SHAFTS 9.966–9.976 mm (0.3924–0.3928
The following procedure applies to all of the in)
rocker arms and rocker arm shafts. Limit
1. Check: 9.935 mm (0.3911 in)
• Rocker arm
• Rocker arm roller “1”
1 1 5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
2. Check: TIP
• Rocker arm shaft Calculate the clearance by subtracting the rock-
Blue discoloration/excessive wear/pitting/ er arm shaft outside diameter from the rocker
scratches → Replace or check the lubrication arm inside diameter.
system.
3. Measure: Out of specification → Replace the defective
• Rocker arm inside diameter “a” part(s).
Rocker-arm-to-rocker-arm-shaft
Rocker arm inside diameter clearance
9.985–10.000 mm (0.3931– 0.009–0.034 mm (0.0004–0.0013
0.3937 in) in)
Limit Limit
10.015 mm (0.3943 in) 0.080 mm (0.0032 in)
EAS30270
INSTALLING THE CAMSHAFT AND ROCKER

ARMS
1. Lubricate:
• Camshaft assembly
5-20
CAMSHAFT
b. While pushing intake rocker arm 1 “2” and

Recommended lubricant intake rocker arm 2 “3” in the direction of
Camshaft the arrow shown in the illustration, install
Molybdenum disulfide oil the camshaft assembly.
Camshaft bearing
Engine oil TIP
Install the camshaft with the punch mark “a” fac-
2. Lubricate: ing upward.
• Rocker arms
• Rocker arm shafts
• Spring 2
• Intake rocker arm stopper pin
3
Rocker arm shaft
Intake rocker arm stopper pin
Molybdenum disulfide oil
Spring a
Rocker arm roller
Engine oil 5. Install:
• Camshaft stopper plate
3. Install:
• Spring “1” Camshaft stopper plate bolt
TIP (M5×16)
T.
R.
Install the spring so that the ends “a” of the 8 N·m (0.8 kgf·m, 5.9 lb·ft)
Camshaft stopper plate bolt
spring are positioned at the locations shown in
(M6×14)
the illustration. 8 N·m (0.8 kgf·m, 5.9 lb·ft)
a 1 TIP
Before installing the camshaft stopper plate,
make sure that the slots “a” in the rocker arm
shafts “2” are parallel with the edge “b” of the cyl-
inder head and that the camshaft stopper plate
bolt holes in the cylinder head and rocker arm
shafts are aligned.
b
4. Install: 2 a
• Camshaft assembly “1”
a. Align the holes “a” in intake rocker arm 1
a
“2” and intake rocker arm 2 “3”, and then
push the intake rocker arm stopper pin “4”
in the direction of the arrow shown in the
illustration.
4
a
5-21
VALVES AND VALVE SPRINGS
EAS20045

Removing the valves and valve springs
1 2 3 8 New
6 New
8 New
4
7
E
7
M
M
6 New
1
E

Camshaft/Rocker arms Refer to “CAMSHAFT” on page 5-18.
1 Valve cotter 8
2 Valve spring retainer 4
3 Valve spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Valve spring seat 4
8 Valve guide 4
5-22
EAS30283
REMOVING THE VALVES 2

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

GUIDES
TIP
Remove the valve cotters by compressing the valves and valve guides.
valve spring with the valve spring compressor 1. Measure:
and the valve spring compressor attachment “2”. • Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
Valve spring compressor guide.
90890-04019 Valve-stem-to-valve-guide clearance =
Valve spring compressor Valve guide inside diameter “a” -
YM-04019 Valve stem diameter “b”
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
5-23
b. Install the new valve guide with the valve

Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remov-
ance (intake) er “1”.
0.010–0.037 mm (0.0004–0.0015
in) Valve guide position
Limit 9.9–10.3 mm (0.39–0.41 in)
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)
a. Valve guide position

c. After installing the valve guide, bore the
valve guide with the valve guide reamer
“3” to obtain the proper valve-stem-to-
valve-guide clearance.
TIP
2. Replace: After replacing the valve guide, reface the valve
seat.
• Valve guide New
TIP
Valve guide remover (ø5)
To ease valve guide removal and installation, 90890-04097
and to maintain the correct fit, heat the cylinder Valve guide remover (5.0 mm)
head to 100 °C (212 °F) in an oven. YM-04097
a. Remove the valve guide with the valve Valve guide installer (ø5)
guide remover “1”. 90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5)
90890-04099
Valve guide reamer (5.0 mm)
YM-04099
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
5-24
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
5. Measure:
• Valve stem runout
Out of specification → Replace the valve.
TIP
• When installing a new valve, always replace a. Apply Blue layout fluid “b” onto the valve
the valve guide. face.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.010 mm (0.0004 in)
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
d. Measure the valve seat width.
TIP
EAS30285 Where the valve seat and valve face contacted
CHECKING THE VALVE SEATS one another, the blue layout fluid will have been
The following procedure applies to all of the removed.
valves and valve seats.
4. Lap:
1. Eliminate:
• Valve face
• Carbon deposits
• Valve seat
(from the valve face and valve seat)
2. Check: TIP
• Valve seat After replacing the cylinder head or replacing the
Pitting/wear → Replace the cylinder head. valve and valve guide, the valve seat and valve
3. Measure: face should be lapped.
• Valve seat width “a” a. Apply a coarse lapping compound “a” to
Out of specification → Replace the cylinder the valve face.
head. ECA13790
NOTICE
Valve seat contact width (intake)
Do not let the lapping compound enter the
0.90–1.20 mm (0.0354–0.0472 in)
Limit gap between the valve stem and the valve
1.7 mm (0.07 in) guide.
Valve seat contact width (ex-
haust)
0.90–1.20 mm (0.0354–0.0472 in)
Limit
1.7 mm (0.07 in)
5-25
j. Measure the valve seat width again. If the

valve seat width is out of specification, re-
face and lap the valve seat.
EAS30286
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
• Valve spring free length “a”
b. Apply molybdenum disulfide oil onto the spring.
valve stem.
c. Install the valve into the cylinder head. Free length (intake)
d. Turn the valve until the valve face and 33.79 mm (1.33 in)
valve seat are evenly polished, and then Limit
clean off all of the lapping compound. 32.10 mm (1.26 in)
TIP
Free length (exhaust)
33.80 mm (1.33 in) (GPD125-A)
For the best lapping results, lightly tap the valve 33.79 mm (1.33 in) (GPD150-A)
seat while rotating the valve back and forth be- Limit
tween your hands. 32.06 mm (1.26 in) (GPD125-A)
32.10 mm (1.26 in) (GPD150-A)
e. Apply a fine lapping compound to the

valve face and repeat the above steps.
2. Measure:
f. After every lapping procedure, be sure to
• Valve spring tilt “a”
clean off all of the lapping compound from
the valve face and valve seat.
spring.
g. Apply blue layout fluid “b” onto the valve
face. Spring tilt (intake)
1.5 mm (0.06 in) (GPD125-A)
1.7 mm (0.07 in) (GPD150-A)
Spring tilt (exhaust)
1.5 mm (0.06 in) (GPD125-A)
1.7 mm (0.07 in) (GPD150-A)
h. Install the valve into the cylinder head.

i. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
5-26
EAS30288
INSTALLING THE VALVES 5

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

E 90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
2. Install: er 22 mm
• Valve spring seat “1” YM-04108
• Valve stem seal “2” New
• Valve “3” 2
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
TIP
• Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
1
facing up.
5-27
4. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-28
CYLINDER AND PISTON
EAS20046
CYLINDER AND PISTON

Removing the cylinder and piston
3 New
4
2
E
1 5 New
7
New
10
9
11 6
10 N•m (1.0 kgf•m, 7.4 lb•ft) 5 New
T.R
.
8 E

1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
11 Coolant drain bolt (cylinder side) 1
5-29
CYLINDER AND PISTON
EAS30289
REMOVING THE PISTON TIP

1. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore ar- EAS30291
ea. If both areas are deburred and the piston CHECKING THE CYLINDER AND PISTON
pin is still difficult to remove, remove it with the 1. Check:
• Piston wall
piston pin puller set “4”.
• Cylinder wall
Vertical scratches → Rebore or replace the
Piston pin puller set cylinder, and replace the piston and piston
90890-01304 rings as a set.
Piston pin puller
2. Measure:
YU-01304
• Piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylin-
der bore gauge.
TIP
Measure cylinder bore “C” by taking side-to-side
2 1 and front-to-back measurements of the cylinder.
Bore
52.000–52.010 mm (2.0472–
3 2.0476 in) (GPD125-A)
58.000–58.010 mm (2.2835–
2.2839 in) (GPD150-A)
Wear limit
52.060 mm (2.0496 in) (GPD125-
A)
58.060 mm (2.2858 in) (GPD150-
A)
“C” = maximum of D1 - D2
2. Remove:
• Top ring
• 2nd ring
• Oil ring
5-30
CYLINDER AND PISTON
b. If out of specification, rebore or replace the

cylinder, and replace the piston and piston Piston ring
rings as a set. Top ring
c. Measure piston skirt diameter P with the Ring side clearance
0.030–0.065 mm (0.0012–
micrometer.
0.0026 in)
Side clearance limit
0.115 mm (0.0045 in)
a 2nd ring
Ring side clearance
0.020–0.055 mm (0.0008–
0.0022 in)
P Side clearance limit
0.115 mm (0.0045 in)
a. 6.0 mm (0.24 in) from the bottom edge of the

piston
Piston
Diameter
51.962–51.985 mm (2.0457–
2.0466 in) (GPD125-A)
57.962–57.985 mm (2.2820–
2.2829 in) (GPD150-A)
2. Install:
d. If out of specification, replace the piston • Piston ring
and piston rings as a set. (into the cylinder)
e. Calculate the piston-to-cylinder clearance TIP
with the following formula. Use the piston crown to level the piston ring near
Piston-to-cylinder clearance = the bottom of the cylinder where the cylinder
Cylinder bore - wear is lowest.
Piston skirt diameter
3. Measure:
• Piston ring end gap
Piston-to-cylinder clearance
Out of specification → Replace the piston
0.015–0.048 mm (0.0006–0.0019
in) ring.
TIP
f. If out of specification, rebore or replace the The oil ring expander spacer end gap cannot be
cylinder, and replace the piston and piston measured. If the oil ring rail gap is excessive, re-
rings as a set. place all three piston rings.
EAS30292
CHECKING THE PISTON RINGS Piston ring

1. Measure: Top ring
• Piston ring side clearance End gap limit
Out of specification → Replace the piston 0.50 mm (0.0197 in)
and piston rings as a set. 2nd ring
End gap limit
TIP
0.85 mm (0.0335 in)
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
5-31
CYLINDER AND PISTON
a. Bottom of cylinder 4. Calculate:

b. Upper of cylinder • Piston-pin-to-piston-pin-bore clearance
Out of specification → Replace the piston pin
EAS30293
and piston as a set.
CHECKING THE PISTON PIN
1. Check: Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter “b” -
• Piston pin Piston pin outside diameter “a”
Blue discoloration/grooves → Replace the
piston pin, and then check the lubrication sys-
tem. Piston-pin-to-piston-pin-bore
2. Measure: clearance
• Piston pin outside diameter “a” 0.002–0.018 mm (0.0001–0.0007
Out of specification → Replace the piston pin. in)
Piston pin outside diameter EAS30290
13.995–14.000 mm (0.5510– CHECKING THE TIMING CHAIN GUIDE

0.5512 in) (EXHAUST SIDE)
Limit 1. Check:
13.975 mm (0.5502 in) • Timing chain guide (exhaust side)
EAS30294
INSTALLING THE PISTON AND CYLINDER

1. Install:
• Lower oil ring rail “1”
• Oil ring expander “2”
• Upper oil ring rail “3”
• 2nd ring “4”
• Top ring “5”
TIP
3. Measure: Be sure to install the piston rings so that the
• Piston pin bore diameter “b” manufacturer marks face up.
Out of specification → Replace the piston.
5
Piston pin bore inside diameter
14.002–14.013 mm (0.5513–
0.5517 in)
Limit 4
14.043 mm (0.5529 in) 3
2. Install:
• Piston “1”
5-32
CYLINDER AND PISTON
• Piston pin “2” c

• Piston pin clips “3” New
TIP
• Apply engine oil to the piston pin. b a
• Make sure the punch mark “a” on the piston
135˚
points towards the exhaust side of the cylinder. 45˚ 45˚
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent e 45˚ 45˚ d
the clips from falling into the crankcase. A
• When installing a piston pin clip, make sure
that the clip ends “b” are positioned away from a. Top ring
the cutout “c” in the piston as shown in the illus- b. 2nd ring
tration. c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
New 3 A. Exhaust side
2 5. Install:
• Dowel pins
• Cylinder gasket New
• Cylinder “1”
1
TIP
a • While holding the piston “2” with one hand, in-
stall the cylinder with the other hand.
• Pass the timing chain and timing chain guide
3 New 2 (intake side) through the timing chain cavity.
1
b
1 2
3. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
Engine oil
4. Offset:
• Piston ring end gaps
5-33
V-BELT AUTOMATIC TRANSMISSION
EAS20050

Removing the V-belt case
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
(10)
5
New 1
New
3
2
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
(6)
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.

Battery 4-1.
Storage box 4-8.
1 V-belt case air filter element cover 1
2 V-belt case air filter element 1
3 V-belt case air filter element support 1
4 V-belt case air duct 1
5 V-belt case 1
5-34
Removing the V-belt case
9
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
(10)
7 8
New
New 6
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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

T.R
.
TIP
When removing the V-belt case gasket, cut
the center portion of the gasket. Before in-
6 V-belt case gasket 1 stalling a new V-belt case gasket, remove
the V-belt.
Refer to “Removing the V-belt, primary
sheave and secondary sheave”.
7 Dowel pin 1
8 V-belt case check hose 1
9 Bearing 1
5-35
Removing the V-belt, primary sheave and secondary sheave
45 N•m (4.5 kgf•m, 33 lb•ft)
T.R
.
14
13
11
10 12
11
LS 9
11 6
8 7
LS
5 3
4 1
2
49 N•m (4.9 kgf•m, 36 lb•ft)
T.R
.

1 Primary fixed sheave nut 1
2 Conical spring washer 1
3 Washer 1
4 Primary fixed sheave 1
5 Washer 1 GPD125-A only
6 V-belt 1
7 Collar 1
8 Primary sliding sheave 1
9 Primary sheave weight 6
10 Cam 1
11 Slider 3
12 Clutch housing nut 1
13 Clutch housing 1
14 Secondary sheave assembly 1
5-36
Disassembling the secondary sheave
* 55 N•m (5.5 kgf•m, 41 lb•ft)
T.R
.
4
3
2
10
11 New 13
12
5 1
6
9 New 7
9 New
* 8 New
* Apply Shell dolium grease R®.

1 Secondary sheave nut 1
2 Clutch carrier assembly 1
3 Compression spring 1
4 Spring seat 1
5 Guide pin 3
6 Collar 3
7 Secondary sliding sheave 1
8 O-ring 2
9 Oil seal 2
10 Bearing 1
11 Circlip 1
12 Bearing 1
13 Secondary fixed sheave 1
5-37
EAS30310
2. Loosen:
REMOVING THE PRIMARY SHEAVE
• Secondary sheave nut “1”
1. Remove: ECA21820
• Primary fixed sheave nut “1” NOTICE

• Conical spring washer Do not remove the secondary sheave nut at
• Washer this stage.
• Primary fixed sheave “2”
TIP TIP
While holding the primary fixed sheave with the While holding the secondary sheave with the ro-
rotor holding tool “3”, loosen the primary fixed tor holding tool “2”, loosen the secondary
sheave nut. sheave nut one full turn with the socket wrench
“3”.
Rotor holding tool
90890-01235 Rotor holding tool
Universal magneto and rotor 90890-04166
holder Rotor holding tool
YU-01235 YM-04166
Socket wrench (39 mm)
90890-01493
3
1
1
3 2
2
EAS30311
REMOVING THE SECONDARY SHEAVE

1. Remove: EAS30312
• Clutch housing nut “1” DISASSEMBLING THE SECONDARY

• Clutch housing “2” SHEAVE
1. Remove:
TIP
• Secondary sheave nut “1”
While holding the clutch housing with the rotor
TIP
holding tool “3”, loosen the clutch housing nut.
Install the sheave spring compressor “2” and
sheave fixed block “3” onto the secondary
Rotor holding tool
sheave as shown. Then, compress the spring,
90890-04166
Rotor holding tool and remove the secondary sheave nut.
YM-04166
90890-04134
YM-04134
Sheave fixed block
90890-04135
3 YM-04135
2
1
5-38
2 Clutch shoe thickness

2.5 mm (0.10 in) (GPD125-A)
1 4.0 mm (0.16 in) (GPD150-A)
Limit
1.0 mm (0.04 in) (GPD125-A)
2.5 mm (0.10 in) (GPD150-A)
a a
3
EAS30313 a
CHECKING THE CLUTCH HOUSING
a
1. Check:
• Clutch housing
2. Measure:
• Clutch housing inside diameter “a” a a
Out of specification → Replace the clutch
EAS30315
housing. CHECKING THE V-BELT
1. Check:
Clutch housing inside diameter
125.0 mm (4.92 in) • V-belt “1”
Limit Cracks/damage/wear → Replace.
125.5 mm (4.94 in) Grease/oil → Clean the primary and second-
ary sheave.
2. Measure:
• V-belt width “a”
a V-belt width
25.5 mm (1.00 in)
Limit
23.0 mm (0.91 in)
EAS30314
CHECKING THE CLUTCH SHOES

clutch shoes.
1. Check:
• Clutch shoe
Damage/wear → Replace the clutch shoes
and springs as a set.
Glazed areas → Sand with coarse sandpa-
EAS30316
per. CHECKING THE PRIMARY SHEAVE
TIP 1. Check:
After sanding the glazed areas, clean the clutch • Primary sliding sheave
with a cloth. • Primary fixed sheave
• Collar
2. Measure:
Cracks/damage/wear → Replace the primary
• Clutch shoe thickness “a”
sliding sheave, primary fixed sheave, and
Out of specification → Replace the clutch
collar as a set.
shoes and springs as a set.
5-39
EAS30317
CHECKING THE PRIMARY SHEAVE

WEIGHTS 1
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
• Primary sheave weight
Cracks/damage/wear → Replace. a
2. Measure:
• Primary sheave weight outside diameter “a”
4. Check:
Weight outside diameter • Spring free length
20.0 mm (0.79 in) Out of specification → Replace the spring.
Limit
19.5 mm (0.77 in) Compression spring free length
95.0 mm (3.74 in)
Limit
85.5 mm (3.37 in)
EAS31233
CHECKING THE PRIMARY SHEAVE

SLIDERS
EAS30320
1. Check:
ASSEMBLING THE PRIMARY SHEAVE
• Primary sheave slider
1. Clean:
Cracks/damage/wear → Replace.
• Primary fixed sheave
EAS30319 • Primary sliding sheave
CHECKING THE SECONDARY SHEAVE • Primary sheave weights
1. Check: • Cam
• Secondary fixed sheave
EAS30321
• Secondary sliding sheave
ASSEMBLING THE SECONDARY SHEAVE
Cracks/damage/wear → Replace the sec-
1. Lubricate:
ondary fixed and sliding sheaves as a set.
• Secondary sliding sheave inner surface
2. Check:
• Oil seals “1”
• Torque cam groove “a”
(with the recommended lubricant)
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set. Recommended lubricant
3. Check: Shell dolium grease R®
• Guide pin “1”
Damage/wear → Replace the secondary TIP
fixed and sliding sheaves as a set. Do not apply grease to the inner surface “a” of
the secondary fixed sheave “2”. If any grease
gets on the inner surface of the secondary fixed
sheave, be sure to wipe it off thoroughly.
5-40
• Compression spring
2 * • Clutch carrier assembly
1 • Secondary sheave nut “1”
TIP
• Install the sheave spring compressor “2” and
* sheave fixed block “3” onto the secondary
sheave as shown. Then, compress the spring,
a 1
and install the secondary sheave nut.
• Install the secondary sheave nut “1” with its ta-
pered side facing the clutch carrier.
2. Install:
• Oil seals New Sheave spring compressor
• Secondary sliding sheave “1” 90890-04134
TIP Sheave spring compressor
Install the secondary sliding sheave onto the YM-04134
secondary fixed sheave “2” with the oil seal Sheave fixed block
guide “3”. 90890-04135
YM-04135
Oil seal guide (37 mm)
90890-04177
2
1
1
2
3
EAS31234
INSTALLING THE PRIMARY SHEAVE, V-

3. Install: BELT AND SECONDARY SHEAVE
• Guide pins “1” 1. Install:
4. Lubricate: • Secondary sheave assembly
• Guide pin grooves “a” TIP
• O-rings “2” New Before installing the secondary sheave assem-
(with the recommended lubricant) bly, check that there is no grease on the splines
“a” of the primary drive gear. If there is any
Shell dolium grease R® grease on the splines, be sure to wipe it off thor-
oughly.
1
New 2
a
5. Install: 2. Tighten:
• Spring seat • Secondary sheave nut “1”
5-41
• Washer
Secondary sheave nut TIP
55 N·m (5.5 kgf·m, 41 lb·ft)
T.
When installing the primary sliding sheave as-

R.
TIP
sembly, hold the cam to prevent the primary
sheave weights from falling out of the primary
While holding the secondary sheave with the ro-
sliding sheave.
tor holding tool “2”, tighten the secondary
sheave nut with the socket wrench “3”.
Rotor holding tool

90890-04166 1
Rotor holding tool
YM-04166
Socket wrench (39 mm)
90890-01493
2 5. Install:
• V-belt “1”
ECA21720
NOTICE
1 Do not allow grease to come in contact with
the V-belt.
TIP
3
• Install the V-belt with the printed arrow mark on
3. Install: the V-belt facing in the direction shown in the il-
• Clutch housing “1” lustration.
• Clutch housing nut “2” • Install the V-belt onto the primary sheave side.
Clutch housing nut

45 N·m (4.5 kgf·m, 33 lb·ft)
T.
R.
TIP
While holding the clutch housing with the rotor
holding tool “3”, tighten the clutch housing nut.
1
Rotor holding tool
90890-04166
Rotor holding tool 6. Install:
YM-04166
• Primary fixed sheave “1”
• Washer
• Conical spring washer “2”
3 • Primary fixed sheave nut
ECA21730
NOTICE
Do not allow grease to contact the primary
sheave assembly.
TIP
1 • Apply lithium-soap-based grease to the prima-
2 ry fixed sheave nut side of the conical spring
4. Install: washer and to the threaded portion of the
• Primary sliding sheave assembly “1” crankshaft.
5-42
• Install the conical spring washer with the mark

“a” facing outward.
• Install the V-belt in the primary sheave (when
the pulley is at its widest position) and in the
secondary sheave (when the pulley is at its
narrowest position), and make sure the V-belt
is tight.
2
7. Tighten:
• Primary fixed sheave nut “1”
Primary fixed sheave nut

49 N·m (4.9 kgf·m, 36 lb·ft)
T.
R.
TIP
While holding the primary fixed sheave with the
rotor holding tool “2”, tighten the primary fixed
sheave nut.
Rotor holding tool

90890-01235
Universal magneto and rotor
holder
YU-01235
5-43
STARTER CLUTCH
EAS20049
STARTER CLUTCH
Removing the starter clutch
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
M
10 N•m (1.0 kgf•m, 7.4 lb•ft)

LT
T.R
3 LT
.
5
10 N•m (1.0 kgf•m, 7.4 lb•ft)
4
T.R
.
3
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
New
LS (3)
New
E 6
8
9 2 New
7 New
1
*
10 N•m (1.0 kgf•m, 7.4 lb•ft) LS
T.R
.
*Apply Yamaha bond No. 1215 (90890-85505).

Secondary sheave assembly SION” on page 5-34.
1 Starter clutch cover 1
2 Oil seal 1
3 Dowel pin 2
4 Starter clutch idle gear 1
5 Starter clutch idle gear shaft 1
6 Collar 1
7 Starter clutch 1
8 Collar 1
9 Starter wheel 1
5-44
STARTER CLUTCH
Removing the starter clutch
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
14
10 N•m (1.0 kgf•m, 7.4 lb•ft)

LT
T.R
LT
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
12 T.R
.
10 N•m (1.0 kgf•m, 7.4 lb•ft)
New
LS (3)
New 10 11
13
E
New
New
*
10 N•m (1.0 kgf•m, 7.4 lb•ft) LS
T.R
.
*Apply Yamaha bond No. 1215 (90890-85505).

10 Circlip 1
11 Bearing 1
12 Timing chain guide stopper 1
13 Timing chain 1
14 Timing chain guide (intake side) 1
5-45
STARTER CLUTCH
EAS31236 EAS31237
CHECKING THE STARTER WHEEL CHECKING THE TIMING CHAIN

1. Check: 1. Check:
• Bearing • Timing chain
Damage/wear → Replace. Damage/stiffness → Replace the timing
2. Check: chain and camshaft sprocket as a set.
• Starter clutch idle gear
• Starter wheel “1”
Burrs/chips/roughness/wear → Replace the
defective part(s).
3. Check:
• Starter wheel’s contacting surfaces
Damage/pitting/wear → Replace the starter
wheel.
1
EAS31238
CHECKING THE TIMING CHAIN GUIDE

(INTAKE SIDE)
1. Check:
• Timing chain guide (intake side)
EAS30309
INSTALLING THE STARTER CLUTCH

EAS30306 1. Install:
CHECKING THE STARTER CLUTCH
1. Check:
(to the starter clutch cover)
• Starter clutch operation
a. Install the starter wheel “1” onto the starter Installed depth “a”
clutch “2” and hold the starter clutch. 1.0–1.5 mm (0.04–0.06 in)
b. When turning the starter wheel counter-
clockwise “A”, the starter clutch and the TIP
starter wheel should engage, otherwise Lubricate the oil seal with lithium-soap-based
the starter clutch is faulty and must be re- grease.
placed.
c. When turning the starter wheel clockwise
“B”, it should turn freely, otherwise the
starter clutch is faulty and must be re-
placed.
1
1 New
B a
5-46
AC MAGNETO
EAS20190
AC MAGNETO
Removing the stator coil assembly
1
1
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
LT
LT 2
LT

T.R
T.R
.

Drain.
page 3-19.
Battery 4-1.
Storage box 4-8.
Footrest board assembly (right)/Bottom cover 4-11.
Radiator fan Refer to “RADIATOR” on page 6-1.
Crankshaft position sensor coupler/Stator coil
1 1/1 Disconnect.
assembly coupler
2 AC magneto rotor nut 1
5-47
AC MAGNETO
Removing the stator coil assembly
6
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
5
LT
3
4
7
LT
LT

T.R
T.R
.

3 AC magneto rotor 1
4 Woodruff key 1
5 Crankshaft position sensor holder 1
6 Crankshaft position sensor 1
7 Stator coil assembly 1
5-48
AC MAGNETO
EAS31239
REMOVING THE AC MAGNETO

1. Remove:
• AC magneto rotor nut “1”
• Washer
TIP
While holding the AC magneto rotor “2” with the
rotor holding tool “3”, loosen the AC magneto ro- 1
tor nut.
2
Rotor holding tool EAS31240
90890-01235 INSTALLING THE AC MAGNETO

Universal magneto and rotor 1. Install:
holder • Woodruff key
YU-01235 • AC magneto rotor
• Washer
• AC magneto rotor nut
TIP
3
• Clean the tapered portion of the crankshaft and
the AC magneto rotor hub.
• When installing the AC magneto rotor, make
sure the woodruff key is properly seated in the
1
keyway of the crankshaft.
2 2. Tighten:
• AC magneto rotor nut “1”
2. Remove:
• AC magneto rotor “1” AC magneto rotor nut
(with the flywheel puller “2”) 80 N·m (8.0 kgf·m, 59 lb·ft)
T.
R.
• Woodruff key
ECA21740 TIP
NOTICE While holding the AC magneto rotor “2” with the
To protect the end of the crankshaft, place an rotor holding tool “3”, tighten the AC magneto ro-
appropriate sized socket between the fly- tor nut.
wheel puller center bolt and the crankshaft.
TIP Rotor holding tool
90890-01235
Make sure the flywheel puller is centered over Universal magneto and rotor
the AC magneto rotor. holder
YU-01235
Flywheel puller
90890-01189
Flywheel puller
YM-01189 3
1
2
5-49
ELECTRIC STARTER
EAS20052
ELECTRIC STARTER
Removing the starter motor
3.5 N•m (0.35 kgf•m, 2.6 lb•ft)
T.R
.
LS
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Flap 4-8.
1 Starter motor lead 1 Disconnect.
2 Starter motor 1
3 Starter motor sub-wire harness 1
5-50
ELECTRIC STARTER
Disassembling the starter motor
1 4
1.5 N•m (0.15 kgf•m, 1.1 lb•ft)
T.R
.
3
New 2
5 New
2.5 N•m (0.25 kgf•m, 1.8 lb•ft)

T.R
.

1 Starter motor front cover 1
2 Gasket 1
3 Armature assembly 1
4 Brush holder set 1
5 Starter motor rear cover 1
5-51
ELECTRIC STARTER
EAS30325
CHECKING THE STARTER MOTOR Digital circuit tester (CD732)

1. Check: 90890-03243
• Commutator Model 88 Multimeter with ta-
Dirt → Clean with 600 grit sandpaper. chometer
2. Measure: YU-A1927
• Commutator diameter “a”
Out of specification → Replace the starter
Armature coil resistance
motor.
0.0279–0.0341 Ω
Commutator diameter Insulation resistance “2”
17.6 mm (0.69 in) No continuity (Above 1 MΩ at 20
Limit °C (68 °F))
16.6 mm (0.65 in)
a
b. If any resistance is out of specification, re-
3. Measure: place the starter motor.
• Mica undercut “a” 5. Measure:
Out of specification → Scrape the mica to the • Brush length “a”
proper measurement with a hacksaw blade Out of specification → Replace the brushes
that has been grounded to fit the commutator. as a set.
Mica undercut (depth) Brush overall length

1.35 mm (0.05 in) 7.0 mm (0.28 in)
Limit
TIP
3.50 mm (0.14 in)
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
6. Measure:
• Brush spring force
4. Measure: Out of specification → Replace the brush
• Armature assembly resistances (commutator springs as a set.
and insulation) “1”
Brush spring force
Out of specification → Replace the starter
3.92–5.88 N (400–600 gf, 14.11–
motor.
21.17 oz)
a. Measure the armature assembly resis-
tances with the digital circuit tester.
5-52
ELECTRIC STARTER
TIP
Install the starter motor sub-wire harness to the
starter motor so that the harness is parallel to the
starter motor axis “a”.
2
7. Check:
• Gear teeth a
Damage/wear → Replace the gear.
8. Check:
• Bearing
• Oil seal
Damage/wear → Replace the defective
part(s).
EAS30326
ASSEMBLING THE STARTER MOTOR

1. Assemble:
• Starter motor front cover “1”
• Starter motor rear cover “2”
Starter motor cover bolt

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.
TIP
Align the match mark “a” on the starter motor
rear cover with the match mark “b” on the starter
motor front cover.
2
b
EAS30327
INSTALLING THE STARTER MOTOR

1. Install:
• Starter motor sub-wire harness “1”
(to the starter motor “2”)
Starter motor sub-wire harness

bolt
T.
R.
3.5 N·m (0.35 kgf·m, 2.6 lb·ft)
5-53
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump
5 New
6
7 New
LS
6 4
*
*
3 8
4.0 N•m (0.40 kgf•m, 3.0 lb•ft) (4)

T.R
2
.
LS
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
New
32 N•m (3.2 kgf•m, 24 lb•ft)
T.R
.
* Apply Yamaha bond No. 1215 (90890-85505).

Stator coil assembly Refer to “AC MAGNETO” on page 5-47.
1 Oil strainer cover 1
2 Spring 1
3 Oil strainer 1
4 Crankcase cover (right) 1
5 Gasket 1
6 Dowel pin 2
7 Oil seal 1
8 Oil pump assembly 1
5-54
OIL PUMP
Disassembling the oil pump
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)
T.R
.
7
5
3
6

1 Oil pump housing cover 1
2 Pin 1
3 Oil pump driven gear 1
4 Oil pump rotor assembly 1
5 Oil pump inner rotor 1
6 Oil pump outer rotor 1
7 Oil pump housing 1
5-55
OIL PUMP
EAS30340
CHECKING THE OIL STRAINER

1. Check:
• Oil strainer
Damage → Replace.
Contaminants → Clean with solvent.
EAS30337
CHECKING THE OIL PUMP

1. Check:
• Oil pump drive gear
• Oil pump driven gear EAS30342
• Oil pump housing ASSEMBLING THE OIL PUMP

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

1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
T.
R.
1. Inner rotor TIP

2. Outer rotor When installing the inner rotor, align the pin in
3. Oil pump housing the oil pump driven gear with the groove “a” in
the inner rotor.
Inner-rotor-to-outer-rotor-tip
clearance
4
Less than 0.15 mm (0.006 in) 3
5
Limit
0.23 mm (0.0091 in) 2
Outer-rotor-to-oil-pump-housing
clearance
0.13–0.18 mm (0.0051–0.0071 in)
Limit 1
a
0.25 mm (0.0098 in)
3. Check: 3. Check:
• Oil pump operation • Oil pump operation
Rough movement → Repeat steps (1) and Refer to “CHECKING THE OIL PUMP” on
(2) or replace the oil pump. page 5-56.
5-56
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission
20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
.
LS
New
2
New
1
New 5
E
LS E
4 New
E
E
E New
3
LS
New
LS (6)
19 N•m (1.9 kgf•m, 14 lb•ft)
T.R
.

Swingarm SEMBLIES AND SWINGARM” on page
4-87.
Rear wheel Refer to “REAR WHEEL” on page 4-32.
1 Final transmission oil filler cap 1
2 Final transmission oil drain bolt 1
3 Transmission case cover 1
4 Transmission case cover gasket 1
5 Dowel pin 2
5-57
TRANSMISSION
Removing the transmission
20 N•m (2.0 kgf•m, 15 lb•ft)

T.R
.
LS
13 New
14
New
12
14
8 6
New
7 E
LS 14 E
New
14
E
E
14
10
E 11 New
9
LS
New 13
LS
14 (6)
19 N•m (1.9 kgf•m, 14 lb•ft)
T.R
.

6 Main axle assembly 1
7 Primary driven gear 1
8 Main axle 1
9 Drive axle 1
10 1st wheel gear 1
11 Circlip 1
12 Primary drive gear 1
13 Oil seal 2
14 Bearing 6
5-58
TRANSMISSION
EAS30433
CHECKING THE TRANSMISSION

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

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

21.7–21.8 mm (0.85–0.86 in)
• Transmission case cover “1”
Installed depth “b”
0.25–0.75 mm (0.01–0.03 in) Transmission case cover bolt
19 N·m (1.9 kgf·m, 14 lb·ft)
T.
R.
New 1 2 TIP
Tighten the transmission case cover bolts in the
a proper tightening sequence as shown.
1 5
3 New 4
b 4 6
2. Install:
3 1
• Circlip “1” New
(to the drive axle “2”)
2 7
TIP 8
Install the circlip with its chamfered side facing
as shown.
5-59
CRANKSHAFT
EAS20061
CRANKSHAFT
Removing the crankshaft
1
10 N•m (1.0 kgf•m, 7.4 lb•ft) E
T.R
.
LS
New
(8)
LS
LS 7 N•m (0.7 kgf•m, 5.2 lb•ft)

T.R
.
New
2
New LS
4 5
3 20 N•m (2.0 kgf•m, 15 lb•ft)
LS
T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-3.
Refer to “CYLINDER AND PISTON” on page
Piston 5-29.
Starter clutch Refer to “STARTER CLUTCH” on page 5-44.
1 Dipstick 1
2 Engine oil drain bolt 1
3 Outer spring 1
4 Inner spring 1
5 Centerstand shaft 1
5-60
CRANKSHAFT
Removing the crankshaft
10 N•m (1.0 kgf•m, 7.4 lb•ft) E

T.R
.
LS
New
(8)
9
8
10
LS
LS 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
6 New
7 New LS
LS
20 N•m (2.0 kgf•m, 15 lb•ft)
T.R
.

6 Centerstand 1
7 Crankcase (left) 1
8 Dowel pin 2
9 Crankshaft assembly 1
10 Crankcase (right) 1
5-61
CRANKSHAFT
EAS31241 ECA20630
DISASSEMBLING THE CRANKCASE NOTICE

1. Remove: • To protect the end of the crankshaft, place
• Crankcase bolts an appropriate sized socket between the
TIP crankcase separating tool bolt and the
Loosen each bolt 1/4 of a turn at a time, in stag- crankshaft.
es and in a crisscross pattern. After all of the • Do not tap on the crankshaft.
bolts are fully loosened, remove them.
Crankcase separating tool
90890-01135
Crankcase separator
YU-01135-B
2
2. Remove:
• Crankcase (left) “1” 1
ECA13900
NOTICE 3
Tap on one side of the crankcase with a soft-
EAS31242
face hammer. Tap only on reinforced por- CHECKING THE CRANKSHAFT ASSEMBLY
tions of the crankcase, not on the crankcase 1. Measure:
mating surfaces. Work slowly and carefully • Crankshaft runout
and make sure the crankcase halves sepa- Out of specification → Replace the crank-
rate evenly. shaft assembly.
TIP
Turn the crankshaft slowly.
Runout limit
0.030 mm (0.0012 in)
EAS30414
REMOVING THE CRANKSHAFT ASSEMBLY

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

51.45–51.50 mm (2.026–2.028 in)
5-62
CRANKSHAFT
TIP
• Install the crankshaft assembly with the crank-
shaft installer pot “2”, crankshaft installer bolt
“3”, adapter “4”, and crankshaft installer spacer
“5”.
• Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of
the crankshaft installer bolt with the other. Turn
the crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.
3. Check:
• Crankshaft sprocket “1”
Crankshaft installer pot
Damage/wear → Replace the crankshaft as-
90890-01274
sembly. Installing pot
• Bearing “2” YU-90058
Cracks/damage/wear → Replace the crank- Crankshaft installer bolt
shaft assembly. 90890-01275
Bolt
2 YU-90060
Adapter (M12)
90890-01278
1
Adapter #3
YU-90063
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
EAS31243
CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a 5
mild solvent. 1 4
2. Thoroughly clean all the gasket surfaces and 2
crankcase mating surfaces.
3. Check: 3
• Crankcase
EAS31244
CHECKING THE BEARING EAS31246
1. Check: ASSEMBLING THE CRANKCASE

• Bearing 1. Thoroughly clean all the gasket mating sur-
Clean and lubricate the bearings, and then faces and crankcase mating surfaces.
rotate the inner race with your finger. 2. Apply:
Rough movement → Replace. • Sealant
(onto the crankcase mating surfaces)
EAS31245
CHECKING THE OIL PUMP DRIVE GEAR Yamaha bond No. 1215
1. Check: 90890-85505
• Oil pump drive gear (Three bond No.1215®)
EAS30791
TIP
INSTALLING THE CRANKSHAFT Do not allow any sealant to come into contact
1. Install: with the oil gallery.
• Crankshaft assembly “1”
5-63
CRANKSHAFT
3. Install:
• Crankcase (right)
(onto the crankcase (left))
• Crankcase bolts
Crankcase bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Thoroughly wipe off any sealant that protrudes
from between the left crankcase and the right
crankcase.
• Tighten the crankcase bolts in stages and in a
crisscross pattern.
EAS31247
INSTALLING THE CENTERSTAND

1. Install:
• Centerstand “1”
• Inner spring “2”
• Outer spring “3”
TIP
• Make sure that the hooked end “a” of the inner
spring is positioned to the outside.
• Make sure that the hooked end “b” of the outer
spring is positioned to the outside.
a 2 3
5-64
CRANKSHAFT
5-65
COOLING SYSTEM
RADIATOR ...................................................................................................... 6-1

CHECKING THE RADIATOR.................................................................... 6-3
INSTALLING THE RADIATOR..................................................................6-3
THERMOSTAT ................................................................................................6-5
CHECKING THE THERMOSTAT ASSEMBLY ......................................... 6-6
INSTALLING THE THERMOSTAT ASSEMBLY ....................................... 6-6
WATER PUMP.................................................................................................6-7
DISASSEMBLING THE WATER PUMP.................................................... 6-9
CHECKING THE WATER PUMP .............................................................. 6-9
ASSEMBLING THE WATER PUMP.......................................................... 6-9
INSTALLING THE WATER PUMP ............................................................ 6-9
6
RADIATOR
EAS20063
RADIATOR
Removing the radiator
7 N•m (0.7 kgf•m, 5.2 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
T.R
.
.
(3)
(5)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
(4)
LS New
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.
T.R
.
T.R
.

Drain.
page 3-19.
1 Radiator cover 1
2 Coolant reservoir breather hose 1
3 Coolant reservoir hose 1
4 Rear brake hose bracket 1
5 Rear brake hose holder (front side) 1
6-1
RADIATOR
Removing the radiator
T.R
T.R
.
.
11
(3) 12
9
7
(5)
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.
(4)
8 6
10
LS New
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
1.0 N•m (0.10 kgf•m, 0.73 lb•ft)

T.R
.
T.R
.
T.R
.

6 Coolant reservoir 1
7 Radiator inlet hose 1
8 Radiator outlet hose 1
9 Radiator cap 1
10 Radiator 1
11 Radiator fan case 1
12 Radiator fan 1
6-2
RADIATOR
EAS30439
CHECKING THE RADIATOR

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

1. Fill:
• Cooling system
mended coolant)
2. Check:
Refer to “CHANGING THE COOLANT” on
• Radiator hoses
page 3-19.
• Coolant reservoir hose
2. Check:
• Cooling system
3. Measure:
Leaks → Repair or replace any faulty part.
• Radiator cap valve opening pressure
a. Attach the radiator cap tester “1” and radi-
Below the specified pressure → Replace the
ator cap tester adapter “2” to the radiator.
radiator cap.
Radiator cap tester
Radiator cap valve opening pres-
90890-01325
sure
78.6–137.4 kPa (0.79–1.37 kgf/
YU-24460-A
cm², 11.4–19.9 psi)
Radiator cap tester adapter
31mm
a. Install the radiator cap tester “1” and radi-
90890-05375
ator cap tester adapter “2” to the radiator Radiator cap tester adapter
cap “3”. 31mm
YM-05375
Radiator cap tester
90890-01325
YU-24460-A
31mm
90890-05375
31mm 1
YM-05375
b. Apply 196 kPa (1.96 kg/cm², 27.87 psi) of

pressure.
6-3
RADIATOR
c. Measure the pressure to check its main-

taining applied pressure.
3. Measure:
• Radiator cap opening pressure
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
4. Install:
• Rear brake hose holder (front side) “1”
Rear brake hose holder bolt

(front side)
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
TIP
Make sure that the projection “a” on the radiator
fan case “2” fits into the hole “b” in the rear brake
hose holder.
a
2
b
6-4
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat assembly
* New
1
4
2 3
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T.R
.
*: Apply water

Drain.
page 3-19.
1 Radiator inlet hose 1 Disconnect.
2 Radiator outlet hose 1 Disconnect.
3 Water pump inlet hose 1 Disconnect.
4 Thermostat assembly 1
6-5
THERMOSTAT
EAS31248
CHECKING THE THERMOSTAT ASSEMBLY

B
1. Check:
• Thermostat “1”
Does not open at 74–78°C (165–172°F) → 0.5 mm
(0.02 in) 7 mm
Replace.
(0.28 in)
A
74 – 78˚C 90˚C
(165 – 172˚F) (194˚F)
1
A. Fully closed
B. Fully open
TIP
If the accuracy of the thermostat is in doubt, re-
a. Suspend the thermostat “1” in a container place it. A faulty thermostat could cause serious
“2” filled with water. overheating or overcooling.
b. Slowly heat the water.
EAS30445
c. Place a thermometer “3” in the water. INSTALLING THE THERMOSTAT
d. While stirring the water “4”, observe the ASSEMBLY
thermostat and thermometer’s indicated 1. Fill:
temperature. • Cooling system
3 mended coolant)
page 3-19.
2. Check:
4 • Cooling system
1
2 Refer to “INSTALLING THE RADIATOR” on
page 6-3.
3. Measure:
e. Check the thermostat element position • Radiator cap opening pressure
“5”. Below the specified pressure → Replace the
Same level for the thermostat element up- radiator cap.
per end and the hole lower line “a” at 90 °C Refer to “CHECKING THE RADIATOR” on
(194 °F) page 6-3.
6-6
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
3 2
LS
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Drain.
page 3-19.
Front side cover (left) 4-3.
Footrest board assembly (left)/Bottom cover 4-8.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1
3 Dowel pin 2
6-7
WATER PUMP
Disassembling the water pump

7
3 New
6
5 New
4 10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
2 New
New
LS
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

1 Water pump housing cover 1
2 Water pump housing gasket 1
3 Circlip 1
4 Impeller shaft 1
5 Water pump seal 1
6 Bearing 1
7 Water pump housing 1
6-8
WATER PUMP
EAS30446
DISASSEMBLING THE WATER PUMP A

1. Remove:
• Water pump seal “1” 4
TIP
3
Remove the water pump seal from the inside of
the water pump housing “2”. 2 1 New
1
2 A. Push down
3. Mechanical seal installer
4. Middle driven shaft bearing driver
1
a
EAS30447
CHECKING THE WATER PUMP 2

1. Check:
• Water pump housing cover
• Water pump housing
• Impeller shaft
Cracks/damage/wear → Replace.
a. Installed depth of water pump seal
EAS30448
ASSEMBLING THE WATER PUMP 2. Lubricate:

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

90890-04145
Middle driven shaft bearing driv-
er
90890-04058
Middle drive bearing installer 40
& 50 mm
YM-04058 1
EAS30449
INSTALLING THE WATER PUMP

1. Install:
• O-rings “1” New
• Water pump assembly “2”
6-9
WATER PUMP
Water pump assembly bolt

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
TIP
• Align the projection “a” on the impeller shaft
with the slit “b” on the camshaft sprocket bolt.
• Lubricate the O-ring with a thin coat of lithium-
soap-based grease.
a b
2
New 1
LS
2. Fill:
• Cooling system
mended coolant)
page 3-19.
3. Check:
• Cooling system
Refer to “INSTALLING THE RADIATOR” on
page 6-3.
4. Measure:
• Radiator cap opening pressure
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-3.
6-10
WATER PUMP
6-11
FUEL SYSTEM
FUEL TANK..................................................................................................... 7-1

REMOVING THE FUEL TANK ..................................................................7-2
REMOVING THE FUEL PUMP .................................................................7-2
CHECKING THE FUEL PUMP BODY.......................................................7-2
INSTALLING THE FUEL PUMP................................................................7-2
INSTALLING THE FUEL TANK.................................................................7-3
CHECKING THE FUEL PRESSURE ........................................................7-3
FUEL INJECTOR............................................................................................. 7-5

REMOVING THE FUEL HOSE .................................................................7-6
CHECKING THE FUEL INJECTOR .......................................................... 7-6
INSTALLING THE FUEL INJECTOR ........................................................7-6
INSTALLING THE FUEL HOSE ................................................................7-6
AIR FILTER CASE .......................................................................................... 7-7

INSTALLING THE AIR FILTER CASE ......................................................7-9
THROTTLE BODY......................................................................................... 7-10

REMOVING THE THROTTLE BODY......................................................7-12
CHECKING THE THROTTLE BODY ......................................................7-12
CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND
THROTTLE BODY ................................................................................. 7-12
REPLACING THE THROTTLE BODY ....................................................7-14
INSTALLING THE THROTTLE BODY ....................................................7-15
7
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank
1
2
5
4
6
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.
3
(4) 7
10 New
(4)
4.0 N•m (0.40 kgf•m, 3.0 lb•ft)
T.R
.

1 Fuel tank cap 1
2 Fuel tank overflow tray 1
3 Fuel tank overflow hose 1
4 Fuel sender coupler 1 Disconnect.
5 Fuel pump coupler 1 Disconnect.
6 Fuel hose 1 Disconnect.
7 Fuel tank 1
8 Fuel pump bracket 1
9 Fuel pump 1
10 Fuel pump gasket 1
7-1
FUEL TANK
EAS30450 EAS30454
REMOVING THE FUEL TANK CHECKING THE FUEL PUMP BODY

1. Extract the fuel in the fuel tank through the 1. Check:
fuel tank cap with a pump. • Fuel pump body
2. Disconnect: Obstruction → Clean.
• Fuel sender coupler Cracks/damage → Replace fuel pump as-
• Fuel pump coupler sembly.
• Fuel hose
EAS30456
EWA18020
WARNING INSTALLING THE FUEL PUMP

1. Install:
Cover the fuel hose connection with a cloth
when disconnecting it. Residual pressure in • Fuel pump gasket “1” New
the fuel lines could cause fuel to spurt out • Fuel pump
when removing the hose. • Fuel pump bracket
ECA20020
Fuel pump bracket bolt
NOTICE 4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.
R.
Although the fuel has been removed from
the fuel tank, be careful when removing the TIP
fuel hose, since there may be fuel remaining • Do not damage the installation surfaces of the
in it. fuel tank when installing the fuel pump.
TIP • Always use a new fuel pump gasket.
• The gasket lip “a” shall face toward the fuel
• To remove the fuel hose from the fuel pump,
pump.
slide the fuel hose connector cover “1” on the
• Align the projections “b” (two locations) on the
end of the hose in the direction of the arrow
fuel pump gasket with the slots “c” in the fuel
shown, and then remove the hose.
pump.
• Before removing the hose, place a few rags in
• Align the projection “d” on the fuel pump with
the area under where it will be removed.
the slot in the fuel pump bracket.
• Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
1
c
3. Remove: 1 New
• Fuel tank b
EAS30451
REMOVING THE FUEL PUMP 1

d
1. Remove:
• Fuel pump
ECA14721
NOTICE 4
• Do not drop the fuel pump or give it a 3
strong shock.
• Do not touch the base section of the fuel
sender. 2
7-2
FUEL TANK
EAS30457 EAS30703
INSTALLING THE FUEL TANK CHECKING THE FUEL PRESSURE

1. Install: 1. Remove:
• Fuel tank “1” • Front side cover (right)
a. Temporarily install the fuel tank. Refer to “GENERAL CHASSIS (2)” on page
TIP 4-3.
Make sure that the flanges of the fuel tank bolts • Footrest board assembly (right)
“2” do not contact the fuel tank. Refer to “GENERAL CHASSIS (5)” on page
4-11.
b. Install the fuel tank overflow tray and fuel 2. Check:
tank cover “3”. To install the fuel tank cov- • Pressure regulator operation
er, refer to “GENERAL CHASSIS (3)” on a. Disconnect the fuel hose from the fuel
page 4-6. pump.
c. Tighten the fuel tank bolts to specification. EWA18020
WARNING
Fuel tank bolt Cover the fuel hose connection with a cloth
7 N·m (0.7 kgf·m, 5.2 lb·ft) when disconnecting it. Residual pressure in
T.
R.
the fuel lines could cause fuel to spurt out

3 when removing the hose.
ECA20020
NOTICE
2 Although the fuel has been removed from

the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
2 1
TIP
Before removing the hose, place a few rags in
2. Install:
the area under where it will be removed.
• Fuel hose
ECA17500
b. Connect the pressure gauge “1” and fuel
NOTICE pressure adapter “2” to the fuel hose “3”.
When installing the fuel hose, make sure that
it is securely connected, and that the fuel Pressure gauge
hose connector cover on the fuel hose is in 90890-03153
the correct position, otherwise the fuel hose Pressure gauge
will not be properly installed. YU-03153
Fuel pressure adapter 6.3mm
TIP 90890-03227
• Install the fuel hose securely onto the fuel
pump until a distinct “click” is heard.
• To install the fuel hose, slide the fuel hose con- 2
nector cover “1” on each end of the hose in the 1
direction of the arrow shown.
3
1
c. Start the engine.
d. Measure the fuel pressure.
7-3
FUEL TANK
Fuel line pressure (at idle)

220–300 kPa (2.2–3.0 kgf/cm²,
31.9–43.5 psi)
Faulty → Replace the fuel pump.

e. Connect the fuel hose.
Refer to “INSTALLING THE FUEL TANK”
on page 7-3.
3. Install:
4-11.
4-3.
7-4
FUEL INJECTOR
EAS20191
FUEL INJECTOR
Removing the fuel injector
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
3
1
2
4
New
E

Battery 4-1.
Storage box 4-8.
1 Fuel hose 1
2 Fuel injector coupler 1 Disconnect.
3 Fuel injector 1
4 Fuel injector adaptor 1
7-5
FUEL INJECTOR
EAS31250
REMOVING THE FUEL HOSE Fuel injector bolt

1. Disconnect: 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
• Fuel hose
EWA17610
TIP
WARNING
• Lubricate the O-ring with engine oil.
Cover fuel hose connections with a cloth
• Align the projection “a” on the fuel injector
when disconnecting them. Residual pres-
adapter with the hole “b” in the intake manifold.
sure in the fuel lines could cause fuel to
• Align the projection “c” on the fuel injector with
spurt out when removing the hoses.
the hole “d” in the fuel injector adapter.
ECA20020
NOTICE
Although the fuel has been removed from 3
the fuel tank, be careful when removing the New 2
fuel hose, since there may be fuel remaining c
a
in it.
b 1
TIP
• To remove the fuel hose from the fuel injector, d
slide the fuel hose connector cover “1”on the
end of the hose in the direction of the arrow
shown, and then remove the hose. EAS31253
• Before removing the hose, place a few rags in INSTALLING THE FUEL HOSE
the area under where it will be removed. 1. Install:
• Fuel hose
ECA17500
NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
1
the correct position, otherwise the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel in-
EAS31251 jector until a distinct “click” is heard.
CHECKING THE FUEL INJECTOR • To install the fuel hose onto the fuel injector,
1. Check: slide the fuel hose connector cover “1” on the
• Injector end of the hose in the direction of the arrow
Obstruction → Replace and check the fuel shown.
pump/fuel supply system.
Deposit → Replace.
Damage → Replace.
2. Check:
• Injector resistance
Refer to “CHECKING THE FUEL INJEC- 1
TOR” on page 7-6.
EAS31617
INSTALLING THE FUEL INJECTOR

1. Install:
• Fuel injector adaptor “1”
• O-ring “2” New
(to the fuel injector)
• Fuel injector “3”
7-6
AIR FILTER CASE
EAS20068
AIR FILTER CASE

Removing the air filter case
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
.
New
4
New
(6)
3
3.0 N•m (0.30 kgf•m, 2.2 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
T.R
T.R
.

Battery 4-1.
Storage box 4-8.
1 Air filter case cover 1
2 Air filter case duct cover 1
3 Air filter case duct 1
4 Air filter element 1
5 Transmission case breather hose 1
7-7
AIR FILTER CASE
Removing the air filter case
8
1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
9
T.R
.
New
New
10
7
(6)
11
3.0 N•m (0.30 kgf•m, 2.2 lb•ft) 10 N•m (1.0 kgf•m, 7.4 lb•ft) 1.2 N•m (0.12 kgf•m, 0.88 lb•ft)
T.R
T.R
T.R
.

6 Cylinder head breather hose 1 Disconnect.
7 Air filter case joint clamp screw 1 Loosen.
8 Air filter case 1
9 Air filter check hose 1
10 Air filter case joint 1
11 Hose 1
7-8
AIR FILTER CASE
EAS31618
INSTALLING THE AIR FILTER CASE

1. Install: 2
• Hose “1” 1
(to the air filter case joint “2”)
• Clamp “3”
TIP
• Apply Three bond 1521 “4” onto the mating
surfaces of the hose and air filter case joint. b
a
• Align the slot “a” on the air filter case joint with
the projection “b” in the hose. 4. Install:
• Air filter case duct “1”
TIP
1 2
Fit the projection “a” on the air filter case duct be-
tween the projections “b” on the air filter case
3 a cover “2”.
b
2
4
2. Install: b
• Air filter case joint “1”
(to the air filter case “2”)
TIP 1
• Apply Three Bond 1521 “3” onto the mating a
surfaces of the air filter case joint and air filter
case.
• Fit the projection “a” on the air filter case joint
between the projections “b” on the air filter
case.
b 2
a
1
3. Install:
• Air filter case joint clamp “1”
(to the air filter case joint “2”)
Air filter case joint clamp screw

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
TIP
Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.
7-9
THROTTLE BODY
EAS20070
THROTTLE BODY
Removing the throttle body
5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
3.0 N•m (0.30 kgf•m, 2.2 lb•ft)
T.R
.
1
New
10 N•m (1.0 kgf•m, 7.4 lb•ft)

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

Battery 4-1.
Storage box 4-8.
Air filter case joint Refer to “AIR FILTER CASE” on page 7-7.
1 ISC (Idle Speed Control) unit coupler 1 Disconnect.
2 Throttle body sensor assembly coupler 1 Disconnect.
7-10
THROTTLE BODY
Removing the throttle body
5 N•m (0.5 kgf•m, 3.7 lb•ft)

T.R
.
8 3.0 N•m (0.30 kgf•m, 2.2 lb•ft)
T.R
.
9
New 6
10
10 N•m (1.0 kgf•m, 7.4 lb•ft)
T.R
.
5
New 7
4
LS
7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

3 Throttle cable 2 Disconnect.
4 Throttle cable holder 1
5 Intake manifold clamp screw 1 Loosen.
6 Throttle body 1
7 Intake manifold 1
8 ISC (Idle Speed Control) unit holder 1
9 ISC (Idle Speed Control) unit 1
10 Spring 1
7-11
THROTTLE BODY
EAS30979
2. Remove:
REMOVING THE THROTTLE BODY
• Screw “1”
1. Remove:
• ISC (Idle Speed Control) unit holder “2”
• Throttle body
ECA20500
• ISC (Idle Speed Control) unit “3”
ECA21780
NOTICE
NOTICE
Do not remove the throttle body sensor as-
Because the force of the spring may push
sembly from the throttle body.
out the ISC unit unexpectedly, be sure to
EAS30479
hold the ISC unit when removing the compo-
CHECKING THE THROTTLE BODY nents.
TIP
Before checking the throttle body, check the fol-
lowing items: 2 3
• Valve clearance
• Spark plug
• Air filter element
• Intake manifold 1
• Fuel hose
• Exhaust system
• Cylinder head breather hose
EWA18030
3. Remove:
WARNING • Spring “1”
• O-ring “2”
If the throttle body is subjected to strong
shocks or dropped during, replace it.
1. Check:
1
• Throttle body
Cracks/damage → Replace the throttle body. 2
2. Check:
• Butterfly valve
Damage/scratches/wear → Replace the
throttle body.
ECA21770
NOTICE
4. Check:
Do not adjust the stop screw “1”. • ISC (Idle Speed Control) unit
Plunger “1” does not rotate smoothly/plunger
rotates together with the motor shaft “2” →
Replace.
1
1
EAS31254 2
CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY
1. Remove the throttle body from the vehicle. 5. Check:
TIP • Spring
Damage/bent → Replace.
Before removing the throttle body, disconnect
6. Clean:
the throttle cables and couplers.
• Area “a” of the ISC unit
7-12
THROTTLE BODY
• Areas “b” and “c” of the throttle body • Do not allow the removed deposits or for-
Clogs or foreign materials cannot be re- eign materials to adhere to the sealing sur-
moved → Replace. faces of the O-ring.
• Do not scratch or deform the ISC valve or
air passage; otherwise, poor starting per-
a formance, an unstable engine idling speed,
or uncontrollable engine speed could re-
sult.
• Do not clean any areas other than the areas
“a”, “b”, and “c”. If the cleaning agent en-
ters the ISC unit or throttle body, thorough-
ly wipe it off.
7. Adjust the ISC unit plunger to the specified
distance “a” from the motor assembly body.
b Distance “a”
0.0–3.0 mm (0.0–0.12 in)
8. Install:
• Spring
• O-ring “1” New
• ISC (Idle Speed Control) unit “2”
ECA21800
NOTICE
a. Use a rag soaked in the recommended
cleaning agent to wipe off any deposits • Do not use the ISC unit if it was dropped.
and foreign materials. • Do not allow water to enter the ISC unit and
do not allow foreign materials to adhere to
Recommended cleaning agent the assembly.
Yamaha oil & brake cleaner • Do not touch the terminals of the coupler
directly.
ECA21790
• Because the force of the spring may push
NOTICE
out the ISC unit unexpectedly, be sure to
• Be sure to use the recommended cleaning hold the motor assembly when installing
agent. the components.
• Do not spray the cleaning agent directly
onto the ISC unit or throttle body and do TIP
not immerse them in the cleaning agent. • Install the new O-ring until it contacts the raised
• To prevent scratching the components, do portion of the ISC unit body.
not use a brush, metal file, or other abra- • When installing the ISC unit, be sure to align
sive tool. the oval portion “a” of the ISC unit with the oval
• Do not clean with compressed air. hole “b” in the throttle body.
7-13
THROTTLE BODY

90890-03256
2 1 New Yamaha diagnostic tool (A/I)
90890-03254
12.Reset:
• A/F control learning values
Refer to “SELF-DIAGNOSTIC FUNCTION
AND DIAGNOSTIC CODE TABLE” on page
9-5.

90890-03256
90890-03254
13.Place the vehicle on the centerstand so that

the rear wheel is elevated.
b a 14.Check:
9. Install:
Start the engine, warm it up, and then mea-
• ISC (Idle Speed Control) unit holder “1”
sure the engine idling speed. Within specifi-
• Screw
cation → Service is finished.
ISC (Idle Speed Control) unit Out of specification → Replace the throttle
holder screw body.
T.
R.
5 N·m (0.5 kgf·m, 3.7 lb·ft) Refer to “REPLACING THE THROTTLE

BODY” on page 7-14.
TIP
Engine idling speed
Align the slot “a” in the ISC unit holder with the
1500–1700 r/min
projection “b” on the ISC unit “2”.
EAS31160
b REPLACING THE THROTTLE BODY

2 1. Remove the throttle body from the vehicle.
a
2. Install a new throttle body to the vehicle.
3. Reset:
1 • ISC learning valves
9-5.
10.Install the throttle body to the vehicle. • ISC valve position
11.Reset: Use the diagnostic code number “54”
• ISC learning valves Refer to “SELF-DIAGNOSTIC FUNCTION
Use the diagnostic code number “67”. AND DIAGNOSTIC CODE TABLE” on page
Refer to “SELF-DIAGNOSTIC FUNCTION 9-5.
9-5. 90890-03256
• ISC valve position Yamaha diagnostic tool (A/I)
Use the diagnostic code number “54”. 90890-03254
9-5.
7-14
THROTTLE BODY
4. Place the vehicle on the centerstand so that

the rear wheel is elevated.
5. Check:
sure the engine idling speed.
Engine idling speed

1500–1700 r/min
EAS30980
INSTALLING THE THROTTLE BODY

1. Install:
• Throttle body
Intake manifold clamp screw

3.0 N·m (0.30 kgf·m, 2.2 lb·ft)
T.
R.
TIP
• Align the projection “a” on the throttle body with
the slot “b” in the intake manifold.
• Align the projection “c” on the intake manifold
“1” with slot “d” in the intake manifold clamp “2”.
a
b
c
1
7-15
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

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

CIRCUIT DIAGRAM .................................................................................. 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-7
TROUBLESHOOTING ..............................................................................8-8
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
FUEL INJECTION SYSTEM..........................................................................8-25

CIRCUIT DIAGRAM ................................................................................ 8-25
ECU SELF-DIAGNOSTIC FUNCTION....................................................8-27
TROUBLESHOOTING METHOD............................................................ 8-27
YAMAHA DIAGNOSTIC TOOL ...............................................................8-28
TROUBLESHOOTING DETAILS (FAULT CODE) ..................................8-28
FUEL PUMP SYSTEM...................................................................................8-65

CIRCUIT DIAGRAM ................................................................................ 8-65
8
ABS (ANTI-LOCK BRAKE SYSTEM)........................................................... 8-69
CIRCUIT DIAGRAM ................................................................................ 8-69
ABS COUPLER LOCATION CHART ......................................................8-71
MAINTENANCE OF THE ABS ECU .......................................................8-73
ABS TROUBLESHOOTING OUTLINE....................................................8-73
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 8-74
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 8-75
[A] CHECKING THE ABS WARNING LIGHT..........................................8-76
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............. 8-76
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................8-76
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 8-76
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................... 8-77
[B-2] DIAGNOSIS USING THE FAULT CODES ..................................... 8-77
[B-3] DELETING THE FAULT CODES....................................................8-98
[C-1] FINAL CHECK ................................................................................ 8-98
ELECTRICAL COMPONENTS...................................................................... 8-99

CHECKING THE SWITCHES ...............................................................8-101
CHECKING THE BULBS AND BULB SOCKETS .................................8-104
CHECKING THE FUSES ......................................................................8-105
REPLACING THE ECU (engine control unit) ........................................8-105
CHECKING AND CHARGING THE BATTERY.....................................8-106
CHECKING THE RELAYS ....................................................................8-109
CHECKING THE TURN SIGNAL RELAY .............................................8-109
CHECKING THE DIODE .......................................................................8-110
CHECKING THE SPARK PLUG CAP ...................................................8-110
CHECKING THE IGNITION COIL .........................................................8-110
CHECKING THE IGNITION SPARK GAP.............................................8-111
CHECKING THE CRANKSHAFT POSITION SENSOR........................8-111
CHECKING THE STARTER MOTOR OPERATION .............................8-112
CHECKING THE STATOR COIL ..........................................................8-112
CHECKING THE RECTIFIER/REGULATOR ........................................8-112
CHECKING THE FUEL SENDER .........................................................8-113
CHECKING THE COOLANT TEMPERATURE SENSOR.....................8-113
CHECKING THE FUEL INJECTOR ......................................................8-114
CHECKING THE VVA SOLENOID........................................................8-114
EAS30490
EAS20072
G/Y G P Ch L W R/W B/L O/B Y/B B/W

Sb Gy L/Y G/R Y L/R B/L
B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L B/L
W/R W/R
(B)
R/L
30
CIRCUIT DIAGRAM
W/R O O
R
B/L
R R R/W
31
12
IGNITION SYSTEM
10 B
B
ON
OFF
3
R
Br
R 29
L/Y
L/Y L/Y
B L/Y
Br
L/Y B B
Br Br R/L
B B 18
Br Br R/W
(L) (L)
B B
B
B
B/W
B/W
8-1
B
B/W
B/W
53
52
IGNITION SYSTEM
IGNITION SYSTEM
1. Crankshaft position sensor

3. Main fuse 1
10.Main switch
12.Battery
18.Sidestand switch
29.ECU (Engine Control Unit)
30.Ignition coil
31.Spark plug
52.Engine ground
53.Frame ground
8-2
IGNITION SYSTEM
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Battery cover
2. Front side covers
3. Fuel tank cover
4. Storage box
5. Footrest board assemblies
6. Front cowling assembly
1. Check the fuse. NG →

(Main 1)
Replace the fuse.
Refer to “CHECKING THE FUS-
ES” on page 8-105.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-106.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” 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 8-111.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 8-110.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 8-110.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the stator coil assembly.
SHAFT POSITION SENSOR” on
page 8-111.
OK ↓
8-3
IGNITION SYSTEM
8. Check the main switch. NG →

Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 8-101.
OK ↓
9. Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
10.Check the entire ignition system NG →
wiring. Properly connect or replace the wire har-
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-1.
OK ↓
Replace the ECU. Refer to “REPLAC-
ING THE ECU (engine control unit)”
on page 8-105.
8-4
EAS30493
EAS20073
A
B B
A B
R B
Y L/W
CIRCUIT DIAGRAM
R
13
R Y
R R R
L/W
12 B 15 L/W
R
16
B
L/W L/W
10 B
B A L/W B B
ON
OFF B
L/W
3 L/W
R B
Br
L/Y
R 17
L/W
14
L/Y
B L/Y
7 Br
L/Y B B
Br Br Br
B B 18
(L) (L)
ELECTRIC STARTING SYSTEM
B B
B
B
Br
Br
Br
8-5
Br Br
40 39
G/Y G/Y
Y
53
3. Main fuse 1
7. Signaling system fuse
10.Main switch
12.Battery
13.Starter relay
14.Starter motor
15.Handlebar switch (right)
16.Start switch
17.Diode
18.Sidestand switch
39.Rear brake light switch
40.Front brake light switch
53.Frame ground
A. Wire harness
B. Starter motor sub-wire harness
8-6
EAS30494
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the main switch is turned to “ON” and the start switch “ ” is pushed, the starter motor can only oper-
ate 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).
11
10
1 7
2
5 6 8
3
4 9
1. Battery
2. Main fuse 1
3. Main switch
5. Rear brake light switch
6. Front brake light switch
7. Start switch
8. Diode
9. Sidestand switch
10. Starter relay
11. Starter motor
8-7
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Battery cover
3. Fuel tank cover
4. Storage box
1. Check the fuses. NG →

(Main 1 and signaling system)
Replace the fuse(s).
OK ↓
page 8-106.
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.
8-112.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-52.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
LAYS” on page 8-109.
OK ↓
6. Check the diode. NG →
Refer to “CHECKING THE DIODE” Replace the diode.
on page 8-110.
OK ↓
OK ↓
8-8
8. Check the sidestand switch. NG →

Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
9. Check the start switch. NG →
The start switch is faulty. Replace the right
Refer to “CHECKING THE
handlebar switch.
OK ↓
10.Check the brake light switches. NG →
(Front and rear)
Replace the brake light switch(es).
OK ↓
11.Check the entire starting system NG →
page 8-5.
OK ↓
The starting system circuit is OK.
8-9
8-10
CHARGING SYSTEM
EAS20074
CHARGING SYSTEM
EAS30496
CIRCUIT DIAGRAM
B
B
B
53
B
R
B
B
B
12
B
W
R
R
B/W,B
W
B
W
W
W
R
W/L
3
W
R
W
W
8-11
CHARGING SYSTEM
2. AC magneto
3. Main fuse 1
12.Battery
53.Frame ground
8-12
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Battery cover
4. Front upper cowling assembly
1. Check the fuse. NG →

(Main 1)
Replace the fuse.
OK ↓
page 8-106.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator coil assembly.
COIL” on page 8-112.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI-
Replace the rectifier/regulator.
FIER/REGULATOR” on page
8-112.
OK ↓
5. Check the entire charging system NG →
page 8-11.
OK ↓
The charging system circuit is OK.
8-13
CHARGING SYSTEM
8-14
EAS30498
EAS20075

B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
(B)
CIRCUIT DIAGRAM
R
R R R/W
12
R
LIGHTING SYSTEM
10 B
B
ON
OFF
3
R
Br
R 29
6 B
Br B
Br
Br Br
L/B
Br Br R/W
G
B
B
B Y/B
B
B
B
Br
B/W
L
8-15
Br Br
43 L/B
44 B Dg
Dg B
Br/W Ch Ch Br/W
L/B P P L/B
Y
Y Y
Ch Dg Y/B Y/B B W/L
Br R/B G L/R B Y
Br Y Br Y G L
59 (Gy) 56 47
57 49
60 58
Ch Dg
64 67 Br G Y B L
B Y/B
B Dg Ch
B Y/B L B
Br Y G
B Y/B
Y/B
B Y/B
B
B B
B
B
B B/W
53
52
LIGHTING SYSTEM
LIGHTING SYSTEM
3. Main fuse 1
6. Taillight fuse
10.Main switch
12.Battery
43.Handlebar switch (left)
44.Dimmer switch
47.Tail/brake light assembly
49.Taillight
52.Engine ground
53.Frame ground
56.Headlight unit
57.Auxiliary light
58.Headlight
59.Meter assembly
60.Multi-function meter
64.Meter light
67.High beam indicator light
8-16
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary lights or meter
light.
TIP
1. Battery cover
3. Footrest board assembly
5. Leg shield
6. Upper handlebar cover assembly
1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
8-104.
OK ↓
(Main 1 and taillight)
OK ↓
page 8-106.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
left handlebar switch.
OK ↓
6. Check the entire lighting system NG →
page 8-15.
OK ↓
Replace the ECU, meter assembly,
tail/brake light assembly or headlight
unit. Refer to “REPLACING THE ECU
(engine control unit)” on page 8-105.
8-17
LIGHTING SYSTEM
8-18
EAS30500
EAS20076

(B)
CIRCUIT DIAGRAM
R
Y
R R R Y R/W
G/R G/R
12 G/R B/L 22
R (B) B/L B/L
B B G
SIGNALING SYSTEM
10 B
ON
OFF
19
3
R
Br
B
R 29
B G
(Gy)
6 B
Br B
7 Br
Br Br Br
8 Br Br R/W
Br/W
B L/R
B
B
B
W
B
Br
Br
Br
Br Br Br
B/W
Br Br
Br Br
8-19
Br
42 Br/W
41 Br
40 39
Br/W
P
43 P Br/W
45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B
Y
B Ch Dg Y
R G L Br Y W W/L B/W
Dg
Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Br R/B G L/R B Y (B)
Ch Ch
L/R
G Br Dg Ch Ch Y Ch Dg
59 (Gy) 47
Ch Dg
55 54 48 50 51
B B Br/W
Ch Dg
60
(Br) (G) Y B Ch Dg
G G B
61 65 66 W B G L
B L 34
L L W
B B B B
Ch Dg B B Dg Ch 38
B Y L B
(Br) (G)
(B)
B
B B
B
B B
B
B B
B B
B
B/W
53
52
SIGNALING SYSTEM
SIGNALING SYSTEM
3. Main fuse 1
6. Taillight fuse
8. ABS control unit fuse
10.Main switch
12.Battery
19.Fuel sender
22.Coolant temperature sensor
34.Front wheel sensor
38.ABS ECU
41.Turn signal relay
42.Horn
45.Horn switch
46.Turn signal switch
48.Brake light
50.Rear turn signal light (left)
51.Rear turn signal light (right)
52.Engine ground
53.Frame ground
54.Front turn signal light (right)
55.Front turn signal light (left)
59.Meter assembly
61.Coolant temperature warning light
65.Turn signal indicator light (right)
66.Turn signal indicator light (left)
8-20
SIGNALING SYSTEM
EAS30501
TROUBLESHOOTING
• Any of the following fail to light: turn signal lights, brake light, warning lights or indicator lights.
• The horn fails to sound.
• The fuel meter fails to come on.
• The speedometer fails to operate.
• The instantaneous fuel consumption meter fails to operation.
TIP
1. Battery cover
3. Fuel tank cover
4. Storage box
5. Center lower cover
6. Upper handlebar cover assembly

(Main 1, taillight, signaling system,
and ABS control unit) Replace the fuse(s).
OK ↓
page 8-106.
OK ↓
OK ↓
4. Check the entire signaling system NG →
page 8-19.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

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

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

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
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.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulbs NG →
and sockets.
Replace the turn signal light bulb, socket or
Refer to “CHECKING THE BULBS
both.
AND BULB SOCKETS” on page
8-104.
OK ↓
2. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
3. Check the turn signal relay. NG →
Refer to “CHECKING THE TURN Replace the turn signal relay.
SIGNAL RELAY” on page 8-109.
OK ↓
8-22
SIGNALING SYSTEM

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

1. Check the coolant temperature sen- NG →
sor.
Refer to “CHECKING THE COOL- Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-113.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly or ECU.
Refer to “REPLACING THE ECU (en-
gine control unit)” on page 8-105.
The fuel meter, fuel level warning light, or both fails to come on.
1. Check the fuel sender. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
SENDER” on page 8-113.
OK ↓
page 8-19.
OK ↓
Replace the meter assembly.
The speedometer, V-belt replacement indicator, engine oil change indicator, instantaneous fuel con-
sumption meter fails to operate.
1. Check the front wheel sensor. NG →
Refer to “MAINTENANCE OF THE
Replace the front wheel sensor.
FRONT WHEEL SENSOR AND
SENSOR ROTOR” on page 4-27.
OK ↓
8-23
SIGNALING SYSTEM
2. Check the entire wiring. NG → Properly connect or replace the wiring har-
Refer to TIP. ness.
OK ↓
Replace the ECU, ABS ECU, or meter
assembly. Refer to “REPLACING THE
ECU (engine control unit)” on page
8-105.
TIP
Replace the wire harness if there is an open or short circuit.
• Between front wheel sensor coupler and ABS ECU coupler.
(Green–Green)
(Blue–Blue)
• Between ABS ECU coupler and ECU coupler.
(White–White)
• Between ECU coupler and meter assembly coupler.
(Yellow/Blue–Yellow/Blue)
8-24
EAS30504
EAS20078

B/L W/L 1
W/R B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/L
W/R W/R
(B)
R/L
30
CIRCUIT DIAGRAM
W/R O O
R
B/L
R R R/W
R/B 31
B G/R G/R
B/W 12 G/R B/L 22
R (B) B/L B/L
R/L
23 24 P/W P/W
10 B B 32
B Br/W Br/W B Gy/R
ON 25 Gy/R Gy/R B
OFF B/L Y L P/W Br/W B/L B/L (B) (B)
20 26 Y Y
(B)
R/B 3 L L
R
Br
P P G G
L/B G/Y G/Y
R P G/Y Sb Gy
L/B R/L 29
27 Gy Gy 33 G Ch
R/L 5 Sb Sb Ch Ch
FUEL INJECTION SYSTEM
(B) (B)
L/Y
L/Y L/Y (Gy)
6 B L/Y
Br B O/B R/L
Br (B) 28
L/Y B B R/L O/B O/B
Br Br R/L
B B 18 L/B
8 L/B
Br Br R/W
Br/W (L) (L)
G R/L
B
B L/R
B
B B Y/B
B
W
B
B/Y
B/W B/W
Br
B/W
B/W
8-25
Br
43 L/B
44 B Dg
Dg B
Br/W Ch Ch Br/W
L/B P P L/B
Y
Y
Y Y R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L
W
L/R
Br Y Y G
59 (Gy) 56
Br/W
60 58
G G B
63 67 W B G L
G Y L L W
34
Y/B
38
Y/B
Y G
Y/B
Y/B
B Y/B
B
B B
B/W
B/W
B/Y B/W
53
52

3. Main fuse 1
5. Main fuse 2
6. Taillight fuse
10.Main switch
12.Battery
18.Sidestand switch
20.Fuel pump
22.Coolant temperature sensor
23.Throttle body sensor assembly
24.Intake air pressure sensor
25.Intake air temperature sensor
26.Throttle position sensor
27.ISC (Idle Speed Control) unit
28.Fuel injector
30.Ignition coil
31.Spark plug
32.O2 sensor
33.VVA (variable valve actuator) solenoid
38.ABS ECU
44.Dimmer switch
52.Engine ground
53.Frame ground
56.Headlight unit
58.Headlight
59.Meter assembly
63.Engine trouble warning light
67.High beam indicator light
8-26
EAS30505
ECU SELF-DIAGNOSTIC FUNCTION

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

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

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue operating or stop operating, depending on the conditions.
EAS30506
TROUBLESHOOTING METHOD
The engine operation is not normal and the engine trouble warning light comes on.
1. Check:
• Fault code number
a. Check the fault code numbers that have a condition of “Detected” using the Yamaha diagnostic
tool.
b. Identify the faulty system with the fault code number.
c. Identify the probable cause of the malfunction.
2. Check and repair the probable cause of the malfunction.
Fault code No. No fault code No.
Check and repair. Check and repair.
Refer to “TROUBLESHOOTING DETAILS (FAULT
CODE)” on page 8-28.
Monitor the operation of the sensors and actuators in
the diagnostic mode.
Refer to “TROUBLESHOOTING DETAILS (FAULT
CODE)” on page 8-28 and “SELF-DIAGNOSTIC
FUNCTION AND DIAGNOSTIC CODE TABLE” on
page 9-5.
3. Perform the reinstatement action for the fuel injection system.

Refer to “Confirmation of service completion” in the appropriate table in “TROUBLESHOOTING DE-
TAILS (FAULT CODE)” on page 8-28.
TIP
• If another fault code number is displayed, repeat steps (1) to (3) until no fault code number is dis-
played.
• Turning the main switch to “OFF” will not erase the malfunction history.
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 “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-11 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-12.
8-27
01: Throttle position sensor signal (throttle angle)

30: Ignition coil
36: Fuel injector
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
EAS30951
YAMAHA DIAGNOSTIC TOOL

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

90890-03256
90890-03254
TIP
A generic scan tool can also be used to identify malfunctions.
OBD/ GST Leadwire kit

90890-03249
Connecting the Yamaha diagnostic tool

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

This section describes the measures per fault code number displayed on the Yamaha diagnostic tool.
Check and service the items or components that are the probable cause of the malfunction following
the order given.
After the check and service of the malfunctioning part have been completed, delete the fault codes dis-
played on the Yamaha diagnostic tool according to the reinstatement method.
Fault code No.:
Fault code number displayed on the Yamaha diagnostic tool when the engine failed to work normally.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “SELF-DIAGNOS-
TIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 9-5.
8-28
Parts connected to the ECU

The following parts are connected to the ECU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • ABS ECU
• Fuel injector • Sidestand switch
• Fuel pump • Main switch
• Ignition coil • Handlebar switch (left and right)
• ISC (Idle Speed Control) unit • Headlight
• Coolant temperature sensor • Meter assembly
• Throttle body sensor assembly • VVA (variable valve actuator) solenoid
• O2 sensor • Rectifier/regulator
Fault code No. P0106

ECA20500
NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
TIP
If fault code numbers “P0106” and “P0107/P0108” are both indicated, take the actions specified for fault
code number “P0107/P0108” first.
Intake air pressure sensor: system malfunction (clogged hole or de-

Item
tached).
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. 03
Tool display Displays the intake air pressure.
Operate the throttle while pushing the start switch “ ”. (If the display val-
Procedure
ue changes, the performance is OK.)
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Installed condition of throttle Improperly installed sensor → Start the engine and let it idle for
body sensor assembly. Check Reinstall the throttle body. approximately 5 seconds.
for looseness or pinching. Fault code number is not dis-
played → Go to item 3 and fin-
ish the service.
Fault code number is displayed
→ Go to item 2.
8-29
Intake air pressure sensor: system malfunction (clogged hole or de-

Item
tached).
2 Defective intake air pressure Execute the diagnostic mode. Service is finished.
sensor. (Code No. 03)
When engine is stopped:
Atmospheric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 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.
The value does not change
when engine is cranking. → Re-
place the throttle body.
3 Delete the fault code and check Confirm that the fault code has
that the engine trouble warning a condition of “Recovered” us-
light goes off. ing the Yamaha diagnostic tool,
and then delete the fault code.
Fault code No. P0107, P0108

ECA20500
NOTICE
TIP
If fault code numbers “P0106” and “P0107/P0108” are both indicated, take the actions specified for fault
code number “P0107/P0108” first.
[P0107] Intake air pressure sensor: open or ground short circuit de-
tected.
Item
[P0108] Intake air pressure sensor: open or power short circuit de-
tected.
Fail-safe system
Tool display Displays the intake air pressure.
Operate the throttle while pushing the start switch “ ”. (If the display val-
Procedure
ue changes, the performance is OK.)
8-30
tected.
Item
tected.
1 Connection of throttle body sen- Improperly connected → Con- Turn the main switch to “ON”,
sor assembly coupler. nect the coupler securely or re- and then check the condition of
Check the locking condition of place the wire harness. the fault code using the mal-
the coupler. function mode of the Yamaha di-
Disconnect the coupler and agnostic tool.
check the pins (bent or broken Condition is “Recovered” → Go
terminals and locking condition to item 7 and finish the service.
of the pins). Condition is “Detected” → Go to
item 2.
2 Connection of ECU coupler. Improperly connected → Con- Turn the main switch to “ON”,
Check the locking condition of nect the coupler securely or re- and then check the condition of
the coupler. place the wire harness. the fault code using the mal-
Disconnect the coupler and function mode of the Yamaha di-
check the pins (bent or broken agnostic tool.
terminals and locking condition Condition is “Recovered” → Go
of the pins). to item 7 and finish the service.
Condition is “Detected” → Go to
item 3.
3 Wire harness continuity. Open or short circuit → Replace Turn the main switch to “ON”,
the wire harness. and then check the condition of
the fault code using the mal-
function mode of the Yamaha di-
agnostic tool.
Condition is “Recovered” → Go
to item 7 and finish the service.
item 4.
3-1
3
1 5V
L
4 L
Y Y
5
2 P/W P/W
5V
Br/W Br/W
B/L B/L
6
1. Throttle body sensor assembly

2. Intake air pressure sensor
3. ECU
4. Sensor input lead
5. Sensor output lead
6. Sensor ground lead
3-2 Disconnect the ECU coupler from the ECU.
Disconnect the throttle body sensor assembly coupler from the throttle body.
8-31
tected.
Item
tected.
3-3 [For P0107] Ground short circuit
Between throttle body sensor assembly coupler and ground: pink/white–ground
If there is continuity, replace the wire harness.
B/L Y L P/W Br/W
3-4 [For P0107] Open circuit

Between throttle body sensor assembly coupler and ECU coupler: blue–blue
If there is no continuity, replace the wire harness.

B/L Y L P/W Br/W

Between throttle body sensor assembly coupler and ECU coupler: pink/white–pink/white

B/L Y L P/W Br/W
8-32
tected.
Item
tected.
Between throttle body sensor assembly coupler and ECU coupler: black/blue–black/blue

B/L Y L P/W Br/W
3-7 Disconnect the couplers from the parts that are connected to the ECU.
Refer to “Parts connected to the ECU” on page 8-29.
3-8 [For P0107, P0108] Short circuit
Between intake air pressure sensor output terminal (pink/white) “a” of ECU coupler and any other
ECU coupler terminal “b”.

4 Installed condition of throttle Check for looseness or pinch- Turn the main switch to “ON”,
body sensor assembly. ing. and then check the condition of
Improperly installed sensor → the fault code using the mal-
Reinstall the throttle body. function mode of the Yamaha di-
agnostic tool.
item 5.
8-33
tected.
Item
tected.
5 Defective intake air pressure Execute the diagnostic mode. Turn the main switch to “ON”,
sensor. (Code No. 03) and then check the condition of
When engine is stopped: the fault code using the mal-
Atmospheric pressure at the function mode of the Yamaha di-
current altitude and weather agnostic tool.
conditions is indicated. Condition is “Recovered” → Go
At sea level: Approx. 101 kPa to item 7 and finish the service.
(757.6 mmHg, 29.8 inHg) Condition is “Detected” → Go to
1000 m (3300 ft) above sea lev- item 6.
mmHg, 26.6 inHg)
mmHg, 23.6 inHg)
mmHg, 20.7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking. → Re-
place the throttle body.
6 Malfunction in ECU. Replace the ECU. Service is finished.
Refer to “REPLACING THE
ECU (engine control unit)” on
page 8-105.

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

Item [P0113] Intake air temperature sensor: open or power short circuit
detected.
Fail-safe system
Tool display Displays the air temperature.
Compare the actually measured air temperature with the tool display val-
Procedure
ue.
8-34

detected.
1 Connection of throttle body sen- Improperly connected → Con- Turn the main switch to “ON”,
sor assembly coupler. nect the coupler securely or re- and then check the condition of
item 2.
item 3.
agnostic tool.
item 4.
3-1
3
1 5V
L L
Y Y
P/W P/W
5V
2 4
Br/W Br/W
B/L B/L
5

2. Intake air temperature sensor
3. ECU
8-35

detected.
Between throttle body sensor assembly coupler and ground: brown/white–ground
B/L Y L P/W Br/W

Between throttle body sensor assembly coupler and ECU coupler: brown/white–brown/white

B/L Y L P/W Br/W


B/L Y L P/W Br/W
8-36

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

agnostic tool.
item 5.
5 Defective intake air tempera- Execute the diagnostic mode. Turn the main switch to “ON”,
ture sensor. (Code No. 05) and then check the condition of
When engine is cold: the fault code using the mal-
Displayed temperature is close function mode of the Yamaha di-
to the ambient temperature. agnostic tool.
The displayed temperature is Condition is “Recovered” → Go
not close to the ambient tem- to item 7 and finish the service.
perature. → Replace the throttle Condition is “Detected” → Go to
body. item 6.
page 8-105.
8-37

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

Item [P0118] Coolant temperature sensor: open or power short circuit de-
tected.
Fail-safe system
When engine is cold: Displays temperature closer to air temperature.
Tool display
When engine is hot: Displays current coolant temperature.
Compare the actually measured coolant temperature with the tool display
Procedure
value.
1 Connection of coolant tempera- Improperly connected → Con- Turn the main switch to “ON”,
ture sensor coupler. nect the coupler securely or re- and then check the condition of
item 2.
item 3.
agnostic tool.
item 4.
8-38

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

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

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

G/R B/L Sb Gy L/Y G/R Y L/R B/L
8-39

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

G/R B/L Sb Gy L/Y G/R Y L/R B/L
Between coolant temperature sensor output terminal (green/red) “a” of ECU coupler and any other
ECU coupler terminal “b”.

4 Installed condition of coolant Check for looseness or pinch- Turn the main switch to “ON”,
temperature sensor. ing. and then check the condition of
Reinstall or replace the sensor. function mode of the Yamaha di-
agnostic tool.
item 5.
5 Defective coolant temperature Execute the diagnostic mode. Turn the main switch to “ON”,
sensor. (Code No. 06) and then check the condition of
When engine is cold: the fault code using the mal-
Displayed temperature is close function mode of the Yamaha di-
to the ambient temperature. agnostic tool.
The displayed temperature is Condition is “Recovered” → Go
not close to the ambient tem- to item 7 and finish the service.
perature. → Replace the cool- Condition is “Detected” → Go to
ant temperature sensor. item 6.
page 8-105.
8-40

tected.

ECA20500
NOTICE
[P0122] Throttle position sensor: open or ground short circuit de-

tected.
Item
[P0123] Throttle position sensor: open or power short circuit detect-
ed.
Fail-safe system
Throttle position sensor signal
Tool display • 13–21 (fully closed position)
• 92–102 (fully open position)
• Check with throttle valves fully closed.
Procedure
• Check with throttle valves fully open.
1 Connection of throttle position Improperly connected → Con- Turn the main switch to “ON”,
sensor coupler. nect the coupler securely or re- and then check the condition of
item 2.
item 3.
8-41

tected.
Item
ed.
agnostic tool.
item 4.
3-1
3
1 5V
L
4 L
2 Y Y
5
P/W P/W
5V
Br/W Br/W
B/L B/L
6

2. Throttle position sensor
3. ECU
4. Sensor input lead
Between throttle body sensor assembly coupler and ground: yellow–ground
B/L Y L P/W Br/W
8-42

tected.
Item
ed.
Between throttle body sensor assembly coupler and ECU coupler: blue–blue

B/L Y L P/W Br/W

Between throttle body sensor assembly coupler and ECU coupler: yellow–yellow

B/L Y L P/W Br/W


B/L Y L P/W Br/W
8-43

tected.
Item
ed.
Between throttle position sensor output terminal (yellow) “a” of ECU coupler and any other ECU cou-
pler terminal “b”

agnostic tool.
item 5.
5 Defective throttle position sen- Check throttle position sensor Turn the main switch to “ON”,
sor. signal. and then check the condition of
Execute the diagnostic mode. the fault code using the mal-
(Code No. 01) function mode of the Yamaha di-
When the throttle valves are ful- agnostic tool.
ly closed: Condition is “Recovered” → Go
A value of 13–21 is indicated. to item 7 and finish the service.
When throttle valves are fully Condition is “Detected” → Go to
open: item 6.
A value of 92–102 is indicated.
An indicated value is out of the
specified range. → Replace the
throttle body.
page 8-105.
8-44

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

Fail-safe system
Diagnostic code No. —
Tool display —
Procedure —
1 Installed condition of O2 sensor. Check for looseness or pinch- Turn the main switch to “ON”,
ing. and then check the condition of
Reinstall or replace the sensor. function mode of the Yamaha di-
agnostic tool.
item 2.
2 Connection of O2 sensor cou- Improperly connected → Con- Turn the main switch to “ON”,
pler. nect the coupler securely or re- and then check the condition of
item 3.
3 Connection of wire harness Improperly connected → Con- Turn the main switch to “ON”,
ECU coupler. nect the coupler securely or re- and then check the condition of
item 4.
4 Wire harness continuity. Open or short circuit → Properly Turn the main switch to “ON”,
connect or replace the wire har- and then check the condition of
ness. the fault code using the mal-
Between O2 sensor coupler and function mode of the Yamaha di-
ECU coupler. agnostic tool.
gray/red–gray/red Condition is “Recovered” → Go
item 5.
5 Defective O2 sensor. Check the O2 sensor. Turn the main switch to “ON”,
Defective → Replace the O2 and then check the condition of
sensor. the fault code using the mal-
Refer to “CYLINDER HEAD” on function mode of the Yamaha di-
page 5-9. agnostic tool.
item 6.
8-45
Item O2 sensor: short circuit detected (power short circuit).

6 Malfunction in ECU. Replace the ECU.
page 8-105.

Item Fuel injector: malfunction in fuel injector.

Unable to start engine
Fail-safe system
Unable to drive vehicle
Actuates fuel injector five times at one-second intervals.
Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on
each time the fuel injector is actuated.
Disconnect the fuel pump coupler. Check that fuel injector is actuated
Procedure
five times by listening for the operating sound.
1 Connection of fuel injector cou- Improperly connected → Con- Execute the diagnostic mode.
pler. nect the coupler securely or re- (Code No. 36)
Check the locking condition of place the wire harness. Operating sound → Go to item
the coupler. 6.
Disconnect the coupler and No operating sound → Go to
check the pins (bent or broken item 2.
terminals and locking condition
of the pins).
2 Defective fuel injector. Measure the fuel injector resis- Execute the diagnostic mode.
tance. (Code No. 36)
Replace if out of specification. Operating sound → Go to item
Refer to “CHECKING THE 6.
FUEL INJECTOR” on page No operating sound → Go to
8-114. item 3.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
Check the locking condition of nect the coupler securely or re- (Code No. 36)
the coupler. place the wire harness. Operating sound → Go to item
Disconnect the coupler and 6.
check the pins (bent or broken No operating sound → Go to
terminals and locking condition item 4.
of the pins).
4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 36)
Between fuel injector coupler Operating sound → Go to item
and ECU coupler. 6.
orange/black–orange/black No operating sound → Go to
Between fuel injector coupler item 5.
and main switch coupler.
brown–red/blue
8-46
Item Fuel injector: malfunction in fuel injector.

5 Malfunction in ECU. Replace the ECU.
page 8-105.
6 Delete the fault code and check Start the engine and let it idle for
that the engine trouble warning approximately 5 seconds.
light goes off. Confirm that the fault code has
a condition of “Recovered” us-
ing the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.

Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
Fail-safe system
Tool display —
Procedure —
1 Connection of crankshaft posi- Improperly connected → Con- Crank the engine, and then
tion sensor coupler. nect the coupler securely or re- check the condition of the fault
Check the locking condition of place the wire harness. code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler and tool.
item 2.
2 Connection of ECU coupler. Improperly connected → Con- Crank the engine, and then
Check the locking condition of nect the coupler securely or re- check the condition of the fault
the coupler. place the wire harness. code using the malfunction
Disconnect the coupler and mode of the Yamaha diagnostic
check the pins (bent or broken tool.
item 3.
3 Wire harness continuity. Open or short circuit → Replace Crank the engine, and then
the wire harness. check the condition of the fault
Between crankshaft position code using the malfunction
sensor coupler and ECU cou- mode of the Yamaha diagnostic
pler. tool.
white/red–white/red Condition is “Recovered” → Go
black/blue–black/blue to item 7 and finish the service.
item 4.
8-47
Crankshaft position sensor: no normal signals are received from the

Item
crankshaft position sensor.
4 Installed condition of crankshaft Improperly installed sensor → Crank the engine, and then
position sensor. Reinstall or replace the sensor. check the condition of the fault
Check for looseness or pinch- Refer to “AC MAGNETO” on code using the malfunction
ing. page 5-47. mode of the Yamaha diagnostic
tool.
item 5.
5 Defective crankshaft position Check the crankshaft position Crank the engine, and then
sensor. sensor. check the condition of the fault
Refer to “CHECKING THE code using the malfunction
CRANKSHAFT POSITION mode of the Yamaha diagnostic
SENSOR” on page 8-111. tool.
Replace if defective. Condition is “Recovered” → Go
item 6.
page 8-105.

Ignition coil: open or short circuit detected in the primary lead of the
Item
ignition coil.
Fail-safe system
Actuates the ignition coil five times at one-second intervals.
Actuation The “check” indicator on the Yamaha diagnostic tool screen comes on
each time the ignition coil is actuated.
Check that a spark is generated five times.
Procedure
• Connect an ignition checker.
1 Connection of ignition coil cou- Improperly connected → Con- Start the engine and let it idle for
pler. nect the coupler securely or re- approximately 5 seconds.
Check the locking condition of place the wire harness. Check the condition of the fault
the coupler. code using the malfunction
item 2.
8-48
Ignition coil: open or short circuit detected in the primary lead of the
Item
ignition coil.
2 Connection of ECU coupler. Improperly connected → Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
the coupler. place the wire harness. Check the condition of the fault
Disconnect the coupler and code using the malfunction
check the pins (bent or broken mode of the Yamaha diagnostic
terminals and locking condition tool.
of the pins). Condition is “Recovered” → Go
item 3.
3 Wire harness continuity. Open or short circuit → Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between ignition coil coupler Check the condition of the fault
and ECU coupler. code using the malfunction
orange–orange mode of the Yamaha diagnostic
Between ignition coil coupler tool.
and main switch coupler. Condition is “Recovered” → Go
Red/Blue–brown to item 7 and finish the service.
item 4.
4 Installed condition of ignition Check for looseness or pinch- Start the engine and let it idle for
coil. ing. approximately 5 seconds.
Improperly installed ignition coil Check the condition of the fault
→ Reinstall or replace the igni- code using the malfunction
tion coil. mode of the Yamaha diagnostic
tool.
item 5.
5 Defective ignition coil. Measure the primary coil resis- Start the engine and let it idle for
tance of the ignition coil. approximately 5 seconds.
Replace if out of specification. Check the condition of the fault
Refer to “CHECKING THE IG- code using the malfunction
NITION COIL” on page 8-110. mode of the Yamaha diagnostic
tool.
item 6.
6 Malfunction in ECU. Execute the diagnostic mode. Service is finished.
(Code No. 30)
No spark → Replace the ECU.
page 8-105.
8-49

Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
Fail-safe system
Front wheel speed pulse
Tool display
0–999
Check that the number increases when the front wheel is rotated. The
Procedure
number is cumulative and does not reset each time the wheel is stopped.
1 Connection of front wheel sen- Improperly connected → Con- Execute the diagnostic mode.
sor coupler. nect the coupler securely or re- (Code No. 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 → Go to item 7.
terminals and locking condition Value does not increase → Go
of the pins). to item 2.
2 Connection of ABS ECU cou- Improperly connected → Con- Execute the diagnostic mode.
pler. nect the coupler securely or re- (Code No. 07)
Check the locking condition of place the wire harness. Rotate the 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 → Go to item 7.
terminals and locking condition Value does not increase → Go
of the pins). to item 3.
3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
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 → Go to item 7.
of the pins). Value does not increase → Go
to item 4.
4 Front wheel sensor lead conti- Open or short circuit, or defec- Execute the diagnostic mode.
nuity, or defective front wheel tive sensor → Replace the front (Code No. 07)
sensor. wheel sensor. Rotate the front wheel by hand
Between front wheel sensor and check that the indicated val-
coupler and ABS ECU coupler. ue increases.
green–green Value increases → Go to item 7.
blue–blue Value does not increase → Go
Between ABS ECU coupler and to item 5.
ECU coupler.
white–white
5 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
Refer to “REPLACING THE (Code No. 07)
ECU (engine control unit)” on Rotate the front wheel by hand
page 8-105. and check that the indicated val-
ue increases.
Value increases → Go to item 7.
Value does not increase → Go
to item 6.
8-50
Front wheel sensor: no normal signals are received from the front
Item
wheel sensor.
6 Malfunction in ABS ECU. Replace the ABS ECU. Go to item 7.
7 Delete the fault code and check Turn the main switch to “ON”,
that the engine trouble warning and then rotate the front wheel
light goes off. by hand.
Confirm that the fault code has
ing the malfunction mode of the
Yamaha diagnostic tool, and
then delete the fault code.

TIP
• If fault code numbers “P0507” and “P0560” are both indicated, take the actions specified for fault code
number “P0560” first.
Component other than ISC (Idle Speed Control) unit is defec-

A
tive (ISC operating sound is heard).
Item
Defective ISC (Idle Speed Control) unit (ISC operating sound is
B
not heard).
Fail-safe system
Fully closes the ISC valve, and then opens the valve. This operation
Tool display takes approximately 3 seconds. The “check” indicator on the Yamaha di-
agnostic tool screen comes on during the operation.
Procedure The ISC unit vibrates when the ISC valve operates.
A-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard →
(Code No. 54) Go to item A-2.
Fully closes the ISC (Idle Speed ISC operating sound is not
Control) valve, and then fully heard → Go to item B-2 for the
opens the valve. This operation defective ISC (Idle Speed Con-
takes approximately 3 seconds. trol) unit.
A-2 Incorrect front wheel sensor sig- Check the front wheel sensor. Start the engine and let it idle for
nal. Execute the diagnostic mode. approximately 10 seconds.
(Code No. 07) Check the condition of the fault
Rotate the front wheel by hand code using the malfunction
and check that the indicated val- mode of the Yamaha diagnostic
ue increases. tool.
Value does not increase → Go Condition is “Recover” → Go to
to fault code No. P0500. item A-9 and finish the service.
item A-3.
8-51

A
Item
B
not heard).
A-3 Throttle valve does not fully Check the throttle grip free play. Start the engine and let it idle for
close due to malfunction in Refer to “CHECKING THE approximately 10 seconds.
throttle cables. THROTTLE GRIP OPERA- Check the condition of the fault
TION” on page 3-23. code using the malfunction
mode of the Yamaha diagnostic
tool.
to item A-9 and finish the ser-
vice.
item A-4.
A-4 Air leak from the throttle body. Check the throttle body. Start the engine and let it idle for
Refer to “CHECKING THE approximately 10 seconds.
THROTTLE BODY” on page Check the condition of the fault
7-12. code using the malfunction
tool.
vice.
item A-5.
A-5 Air leak from the ISC (Idle Improperly installed ISC (Idle Start the engine and let it idle for
Speed Control) unit. Speed Control) unit → Reinstall approximately 10 seconds.
the ISC (Idle Speed Control) Check the condition of the fault
unit. code using the malfunction
Check the intake air passages mode of the Yamaha diagnostic
for air leaks. tool.
vice.
item A-6.
A-6 The air volume for the throttle Clean the throttle body and ISC Start the engine and let it idle for
body and ISC (Idle Speed Con- (Idle Speed Control) unit. approximately 10 seconds.
trol) unit is excessive. Refer to “CLEANING THE ISC Check the condition of the fault
(IDLE SPEED CONTROL) UNIT code using the malfunction
AND THROTTLE BODY” on mode of the Yamaha diagnostic
page 7-12. tool.
vice.
item A-7.
8-52

A
Item
B
not heard).
A-7 ISC (Idle Speed Control) is not Replace the ISC (Idle Speed Start the engine and let it idle for
moving correctly. Control) unit. approximately 10 seconds.
Refer to “CLEANING THE ISC Check the condition of the fault
(IDLE SPEED CONTROL) UNIT code using the malfunction
AND THROTTLE BODY” on mode of the Yamaha diagnostic
page 7-12. tool.
vice.
item A-8.
A-8 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
ECU (engine control unit)” on Return the ISC (Idle Speed
page 8-105. Control) valve to the initial open-
ing position.
A-9 Delete the fault code and check Confirm that the fault code has

A
Item
B
not heard).
Fail-safe system
Fully closes the ISC valve, and then opens the valve. This operation
Tool display takes approximately 3 seconds. The “check” indicator on the Yamaha di-
agnostic tool screen comes on during the operation.
Check that the ISC unit is actuated three times by listening for the operat-
Procedure
ing sound.
B-1 Locate the malfunction. Execute the diagnostic mode. ISC operating sound is heard →
(Code No. 54) Go to item A-2 for the compo-
Fully closes the ISC (Idle Speed nent other than ISC (Idle Speed
Control) valve, and then fully Control) unit is defective.
opens the valve. This operation ISC operating sound is not
takes approximately 3 seconds. heard → Go to item B-2.
8-53

A
Item
B
not heard).
B-2 Connection of ISC (Idle Speed Improperly connected → Con- Execute the diagnostic mode.
Control) unit coupler. nect the coupler securely or re- (Code No. 54)
Check the locking condition of place the wire harness. ISC operating sound is heard →
the coupler. Go to item B-9 and delete the
Disconnect the coupler and fault code.
check the pins (bent or broken ISC operating sound is not
terminals and locking condition heard → Go to item B-3.
of the pins).
B-3 Connection of ECU coupler. Improperly connected → Con- Execute the diagnostic mode.
the coupler. place the wire harness. ISC operating sound is heard →
Disconnect the coupler and Go to item B-9 and delete the
check the pins (bent or broken fault code.
terminals and locking condition ISC operating sound is not
of the pins). heard → Go to item B-4.
B-4 Wire harness continuity. Open or short circuit → Replace Execute the diagnostic mode.
the wire harness. (Code No. 54)
Between ISC (Idle Speed Con- ISC operating sound is heard →
trol) unit coupler and ECU cou- Go to item B-9 and delete the
pler. fault code.
pink–pink ISC operating sound is not
green/yellow–green/yellow heard → Go to item B-5.
gray–gray
sky blue–sky blue
B-5 Installed condition of ISC (Idle Check for looseness or pinch- Execute the diagnostic mode.
Speed Control) unit. ing. (Code No. 54)
Improperly installed ISC (Idle ISC operating sound is heard →
Speed Control) unit → Reinstall Go to item B-9 and delete the
the ISC (Idle Speed Control) fault code.
unit. ISC operating sound is not
Check the intake air passages heard → Go to item B-6.
for air leaks.
B-6 Battery malfunction Check the battery voltage. Execute the diagnostic mode.
Refer to “CHECKING AND (Code No. 54)
CHARGING THE BATTERY” on ISC operating sound is heard →
page 8-106. Go to item B-9 and delete the
fault code.
ISC operating sound is not
heard → Go to item B-7.
B-7 ISC (Idle Speed Control) unit is Replace the ISC (Idle Speed Execute the diagnostic mode.
not moving correctly. Control) unit. (Code No. 54)
Refer to “CLEANING THE ISC ISC operating sound is heard →
(IDLE SPEED CONTROL) UNIT Go to item B-9 and delete the
AND THROTTLE BODY” on fault code.
page 7-12. ISC operating sound is not
heard → Go to item B-8.
B-8 Malfunction in ECU. Replace the ECU. Execute the diagnostic mode.
ECU (engine control unit)” on Return the ISC (Idle Speed
page 8-105. Control) valve to the initial open-
ing position.
8-54

A
Item
B
not heard).
B-9 Delete the fault code and check Start the engine and let it idle for
that the engine trouble warning approximately 10 seconds.
light goes off. Confirm that the fault code has
ing the Yamaha diagnostic tool,

Item ISC (Idle Speed Control) unit: malfunction in ISC unit.

Fail-safe system
Action —
Procedure —
1 Connection of ISC unit coupler. Improperly connected → Con- Set the main switch to “ON”.
Check the locking condition of nect the coupler securely or re- Check the condition of the fault
the coupler. place the wire harness. code using the malfunction
item 2.
2 Connection of wire harness Improperly connected → Con- Set the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Check the condition of the fault
Check the locking condition of place the wire harness. code using the malfunction
the coupler. mode of the Yamaha diagnostic
Disconnect the coupler and tool.
item 3.
3 Wire harness continuity. Open or short circuit → Replace Set the main switch to “ON”.
the wire harness. Check the condition of the fault
Between ISC unit coupler and code using the malfunction
ECU coupler. mode of the Yamaha diagnostic
pink–pink tool.
green/yellow–green/yellow Condition is “Recovered” → Go
gray–gray to item 6 and finish the service.
sky blue–sky blue Condition is “Detected” → Go to
item 4.
8-55
Item ISC (Idle Speed Control) unit: malfunction in ISC unit.

4 Faulty ISC unit operation. Execute the diagnostic mode. Set the main switch to “ON”.
(Code No. D54) Check the condition of the fault
ISC unit operation sound is not code using the malfunction
heard. → Replace the ISC unit. mode of the Yamaha diagnostic
Refer to “CLEANING THE ISC tool.
(IDLE SPEED CONTROL) Condition is “Recovered” → Go
UNIT AND THROTTLE BODY” to item 6 and finish the service.
on page 7-12. Condition is “Detected” → Go to
item 5.
5 Malfunction in ECU Replace the ECU. Service is finished.
page 8-105.

Item Charging voltage is abnormal.

Fail-safe system
Tool display —
Procedure —
1 Malfunction in charging system. Check the charging system. Start the engine and let it idle for
Refer to “CHARGING SYSTEM” approximately 5 seconds.
on page 8-11. Check the condition of the fault
Defective rectifier/regulator or code using the malfunction
AC magneto → Replace. mode of the Yamaha diagnostic
Defective connection in the tool.
charging system circuit → Prop- Condition is “Recovered” → Go
erly connect or replace the wire to item 2 and finish the service.
harness. Condition is “Detected” → Re-
peat item 1.

Faulty ECU memory. (When this malfunction is detected in the ECU,

Item
the fault code number might not appear on the tool display.)
Fail-safe system
8-56
Faulty ECU memory. (When this malfunction is detected in the ECU,

Item
the fault code number might not appear on the tool display.)
Tool display —
Procedure —
1 Malfunction in ECU. Replace the ECU. Turn the main switch to “ON”.
Refer to “REPLACING THE Check that the engine trouble
ECU (engine control unit)” on warning light does not come on.
page 8-105.
Fault code No. P062F

EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
Fail-safe system
00
• No malfunctions detected (If the self-diagnosis fault code P062F is indi-
cated, the ECU is defective.)
Tool display 01 (CO adjustment value)
11 (Data error for ISC (Idle Speed Control) learning values)
12 (O2 feedback learning value)
Procedure —
1 Locate the malfunction Execute the diagnostic mode.
(Code No. 60)
00: Go to item 4.
01: Go to item 2.
11–12: Go to item 3.
2 “01” is indicated in diagnostic Change the CO concentration, Set the main switch to “ON”,
mode (code No. 60). EEPROM and rewrite in EEPROM. and then check the condition of
data error for adjustment of CO Refer to “ADJUSTING THE EX- the fault code using the mal-
concentration. HAUST GAS VOLUME” on function mode of the Yamaha di-
page 3-8. agnostic tool.
After this adjustment is made, Condition is “Recovered” → Go
turn the main switch to “OFF”. to item 5 and finish the service.
Condition is “Detected” → Re-
peat item 1.
If the same number is indicated,
go to item 4.
8-57
EEPROM fault code number: an error is detected while reading or

Item
writing on EEPROM.
3 “11” is indicated in diagnostic Turn the main switch to “OFF”. Set the main switch to “ON”,
mode (code No. 60). EEPROM and then check the condition of
data error for ISC (Idle Speed the fault code using the mal-
Control) learning values. function mode of the Yamaha di-
“12” is indicated in the diagnos- agnostic tool.
tic mode. (Code No. 60) EE- Condition is “Recovered” → Go
PROM data error for O2 to item 5 and finish the service.
feedback learning values. Condition is “Detected” → Re-
peat item 1.
If the same number is indicated,
go to item 4.
page 8-105.

Sidestand switch: open or short circuit of the blue/yellow lead of the

Item
ECU is detected.
Fail-safe system
Sidestand switch
Tool display • “ON” (sidestand retracted)
• “OFF” (sidestand extended)
Procedure Extend and retract the sidestand.
1 Connection of sidestand switch Improperly connected → Con- Turn the main switch to “ON”,
coupler. nect the coupler securely or re- and then extend and retract the
Check the locking condition of place the wire harness. sidestand.
the coupler. Check the condition of the fault
item 2.
8-58
Sidestand switch: open or short circuit of the blue/yellow lead of the

Item
ECU is detected.
Check the locking condition of nect the coupler securely or re- and then extend and retract the
the coupler. place the wire harness. sidestand.
Disconnect the coupler and Check the condition of the fault
check the pins (bent or broken code using the malfunction
terminals and locking condition mode of the Yamaha diagnostic
of the pins). tool.
item 3.
3 Connection of main switch cou- Improperly connected → Con- Turn the main switch to “ON”,
pler. nect the coupler securely or re- and then retract and extend the
Check the locking condition of place the wire harness. sidestand.
check the pins mode of the Yamaha diagnostic
(bent or broken terminals and tool.
locking condition of the pins). Condition is “Recovered” → Go
item 4.
the wire harness. and then extend and retract the
Between sidestand switch cou- sidestand.
pler and ECU coupler. Check the condition of the fault
blue/yellow–blue/yellow code using the malfunction
tool.
item 5.
5 Defective sidestand switch. Execute the diagnostic mode. Turn the main switch to “ON”,
(Code No. 20) and then extend and retract the
Sidestand retracted: “ON” sidestand.
Sidestand extended: “OFF” Check the condition of the fault
Replace if defective. code using the malfunction
tool.
item 6.
page 8-105.
8-59

Item O2 sensor: Open circuit detected.

Fail-safe system
Tool display —
Procedure —
1 Installed condition of O2 sensor. Check for looseness or pinch- Start the engine, warm it up,
ing. and then race it.
Improperly installed sensor → Check the condition of the fault
Reinstall or replace the sensor. code using the malfunction
tool.
item 2.
Also, delete this fault code,
which has a condition of “De-
tected”.
2 Connection of O2 sensor cou- Improperly connected → Con- Start the engine, warm it up,
pler. nect the coupler securely or re- and then race it.
Check the locking condition of place the wire harness. Check the condition of the fault
the coupler. code using the malfunction
item 3.
tected”.
3 Connection of ECU coupler. Improperly connected → Con- Start the engine, warm it up,
Check the locking condition of nect the coupler securely or re- and then race it.
the coupler. place the wire harness. Check the condition of the fault
item 4.
tected”.
8-60
Item O2 sensor: Open circuit detected.

4 Wire harness continuity. Open or short circuit → Replace Start the engine, warm it up,
the wire harness. and then race it.
Between O2 sensor coupler and Check the condition of the fault
ECU coupler. code using the malfunction
gray/red–gray/red mode of the Yamaha diagnostic
tool.
item 5.
tected”.
5 Check fuel pressure. Refer to “CHECKING THE Start the engine, warm it up,
FUEL PRESSURE” on page and then race it.
7-3. Check the condition of the fault
code using the malfunction
tool.
item 6.
tected”.
6 Defective O2 sensor. Check the O2 sensor. Start the engine, warm it up,
Replace if defective. and then race it.
Refer to “CYLINDER HEAD” on Check the condition of the fault
page 5-9. code using the malfunction
tool.
item 7.
tected”.
page 8-105.

VVA (variable valve actuator) solenoid: malfunction in VVA (variable

Item
valve actuator) solenoid.
Fail-safe system
8-61

Item
Actuates the VVA (variable valve actuator) solenoid five times at five-sec-
ond intervals. The “check” indicator on the Yamaha diagnostic tool
Action
screen come on each time the VVA (variable valve actuator) solenoid is
actuated.
Procedure Check that VVA solenoid is actuated five times.
1 Connection of VVA (variable Improperly connected → Con- Set the main switch to “ON”.
valve actuator) solenoid coupler. nect the coupler securely or re- Start the engine and accelerate
Check the locking condition of place the wire harness. to 6000 r/min.
the coupler. Disconnect the cou- Check the condition of the fault
pler and check the pins (bent or code using the malfunction
broken terminals and locking mode of the Yamaha diagnostic
condition of the pins). tool.
item 2.
2 Connection of wire harness Improperly connected → Con- Set the main switch to “ON”.
ECU coupler. nect the coupler securely or re- Start the engine and accelerate
Check the locking condition of place the wire harness. to 6000 r/min.
item 3.
3 Wire harness continuity. Open or short circuit → Replace Set the main switch to “ON”.
the wire harness. Start the engine and accelerate
Between VVA (variable valve to 6000 r/min.
actuator) solenoid coupler and Check the condition of the fault
ECU coupler. code using the malfunction
green–green mode of the Yamaha diagnostic
chocolate-chocolate tool.
Between ECU coupler and en- Condition is “Recovered” → Go
gine ground. to item 6 and finish the service.
black/yellow–black/yellow Condition is “Detected” → Go to
item 4.
4 Defective VVA (variable valve Measure the VVA (variable Set the main switch to “ON”.
actuator) solenoid. valve actuator) solenoid resis- Start the engine and accelerate
tance. to 6000 r/min.
Replace it out of specification. Check the condition of the fault
Refer to “CHECKING THE VVA code using the malfunction
SOLENOID” on page 8-114. mode of the Yamaha diagnostic
tool.
item 5.
8-62

Item
page 8-105.
8-63
8-64
EAS30513
EAS20081

(B)
CIRCUIT DIAGRAM
R
R R R/W
12
R
10 B R/L
B
FUEL PUMP SYSTEM
ON
OFF
20
3
R
Br
L/B
R
L/B R/L 29
R/L 5
(B)
Br
Br Br
L/B
Br Br R/W
B
B
B
B/W
B/W
8-65
B
B/W
B/W
53
52
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
3. Main fuse 1
5. Main fuse 2
10.Main switch
12.Battery
20.Fuel pump
52.Engine ground
53.Frame ground
8-66
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Battery cover
4. Fuel tank

(Main 1 and main 2)
OK ↓
page 8-106.
OK ↓
OK ↓
4. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump.
PRESSURE” on page 7-3.
OK ↓
5. Check the entire fuel pump system NG →
wiring. Properly connect or replace the wiring har-
page 8-65.
OK ↓
Replace the ECU. Refer to “REPLAC-
ING THE ECU (engine control unit)”
on page 8-105.
8-67
FUEL PUMP SYSTEM
8-68
EAS30843
EAS20085

(B)
CIRCUIT DIAGRAM
R
Y
R R R Y R/W
B
B/W 12
R
10 B
B
ON
OFF
3
R
Br
R/B 4
R R 29
11
6 R/L R
B
Br B
7 Br
Br Br Br
8 Br Br R/W
Br/W
B L/R
B
W
Br B/W B/W
Br
Br B
Br
B/W
B/W
Br Br
8-69
Br
40 39
G/Y G/Y
Y
Y
Y
R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L
W
L/R
Br Y
59 (Gy) 47
R/L
48 R
Br/W
60
Y B
G G B
62 W B G L
L L W
34
B 38 Br Br B
B Y W B Br Y
Y Y W 35
(B)
B/W
B W/L
B/W B/W
W/L 36 R/B
Y L/R L/B
R/B B
37
B B/W L/B L/B B
B/W L/R L/R
B/W
53
52
3. Main fuse 1
4. ABS solenoid fuse
6. Taillight fuse
10.Main switch
11.ABS motor fuse
12.Battery
35.Rear wheel sensor
36.Joint connector
37.ABS test coupler
38.ABS ECU
48.Brake light
52.Engine ground
53.Frame ground
59.Meter assembly
62.ABS warning light
8-70
EAS30844
ABS COUPLER LOCATION CHART
(B)
G L W B
Br Y W B
3
L/R L/B
R/B B
4
Ch Dg Y/B Y/B B W/L

Br R/B G Y/L B Y
(Gy)
8-71
1. ABS ECU coupler

2. Rear wheel sensor coupler
3. ABS test coupler
4. Meter assembly coupler
5. Front wheel sensor coupler
8-72
EAS30845
MAINTENANCE OF THE ABS ECU
Checking the ABS ECU

1. Check:
• Terminals “1” of the ABS ECU
Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off → Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
1
2
EAS30528
ABS TROUBLESHOOTING OUTLINE

This section describes the troubleshooting for the ABS in detail. Read this service manual carefully and
make sure you fully understand the information provided before repairing any malfunctions or perform-
ing service.
The ABS ECU (electronic control unit) has a self-diagnosis function. When failures occur in the system,
the ABS warning light on the meter assembly indicates a malfunction.
The following troubleshooting describes the problem identification and service method using the
Yamaha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAG-
NOSIS USING THE FAULT CODES” on page 8-77. For troubleshooting items other than the following
items, follow the normal service method.
EWA16710
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-98.
ABS operation when the ABS warning light comes on

1. The ABS warning light remains on → ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 10 km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h)). → ABS operation is normal.
3. The ABS warning light flashes → ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 8-74.
8-73
Self-diagnosis and servicing

The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page 8-98.
By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause correctly
if another malfunction occurs.
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned to “ON”. During this test, a “clicking” noise can be heard from front side, and if
the front brake lever or rear brake lever are even slightly applied, a vibration can be felt at the levers,
but these do not indicate a malfunction.
Self-diagnosis using the ABS ECU
The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”. It also
checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after they are detect-
ed, it is possible to check the recorded malfunction data by utilizing the Yamaha diagnostic tool when the
ABS ECU has entered the self-diagnosis mode.
Special precautions for handling and servicing a vehicle equipped with ABS
ECA18490
NOTICE
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction
occurs.)
EAS30529
BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420
WARNING
• Perform the troubleshooting [A]→[B]→[C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.
8-74
EAS30530
BASIC PROCESS FOR TROUBLESHOOTING
[A] Turn the main switch to “ ON ”, Fails to • The ABS warning light (LED)
come on [A-1] Does only the ABS
and check the ABS warning Yes is defective.
warning light fail to Return to [A].
light. • The wire harness is grounded
come on?
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.
No
• The main switch is defective.
[A-2] Do all indicator lights Yes • The battery voltage is low. Return to [A].
fail to come on? • The taillight fuse is blown.
• The meter assembly circuit is
defective.
[A-3] The ABS warning light comes Cannot communicate • The connection with the Yamaha
on. diagnostic tool is defective. Return to [A].
Connect the Yamaha • The ABS control unit fuse is blown.
diagnostic tool, and then • The ABS ECU coupler is
execute functional diagnosis. disconnected.
Can the tool communicate with
the ABS ECU?
• The wire harness is defective.
• The hydraulic unit assembly
Can communicate is defective.
• The ABS solenoid fuse is blown.
Refer to “ Troubleshooting details
of fault code No. 31 ”.
[B-1] Check for ABS fault Yes [B-2] Diagnose by the fault [B-3] Delete the fault codes.
Return to [A].
codes in the screen for the code.
Yamaha diagnostic tool.
Execute fault diagnosis.
Are fault codes displayed on
the screen?
The reaction force generated
No during brake line routing
confirmation is incorrect.
• The brake hoses and brake
[C-1] Perform the final checks. No pipes are not connected
Were all of the final checks correctly. Return to [A].
completed normally? The ABS warning light does
not go off when the light is
Yes checked.
(Check that the ABS warning • The malfunction is not
light goes off during the ABS
corrected.
warning light check.)
• There is a break in the wire
harness between the ABS ECU
and the meter assembly.
• The meter assembly circuit
is defective.
• The ABS warning light circuit
in the hydraulic unit assembly
is defective.
Finished.
8-75
EWA16710
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 8-98.
EAS30531
[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS30532
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the White/Blue terminal of the ABS ECU coupler and
White/Blue terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS30964
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-101.
• If there is no continuity, replace the main switch.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-106.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Taillight fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-105.
• If the taillight fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 8-69.
• If the meter assembly circuit is open, replace the wire harness.
EAS31162
[A-3] THE ABS WARNING LIGHT COMES ON

Connect the Yamaha diagnostic tool to the ABS test coupler and execute functional diagnosis. (For in-
formation about how to execute functional diagnosis, refer to the operation manual that is included with
the tool.)
Check that communication with the ABS ECU is possible.
• Only the ABS ECU fails to communicate. [A-4]
• ABS ECU and FI ECU fail to communicate. [A-5]
• Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
8-76
EAS31165
[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the Yamaha diagnostic tool is connected to the ABS test coupler, the fault codes will be displayed
on the computer screen.
• A fault code is displayed. [B-2]
• A fault code is not displayed. [C-1]
EAS31166
[B-2] DIAGNOSIS USING THE FAULT CODES

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

90890-03256
90890-03254

Removing the battery cover. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Removing the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
Details about the displayed fault codes are shown in the following chart. Refer to this chart and check
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.
Fault code table

TIP
Record all of the fault codes displayed and inspect the check points.
Fault code No. Item Symptom Check point

11* Front wheel sensor (intermit- Front wheel sensor signal is • Foreign material adhered
25* tent pulses or no pulses) not received properly. (Puls- around the front wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) front wheel
• Defective sensor rotor or
incorrect installation of the
rotor
• Defective front wheel sen-
sor or incorrect installation
of the sensor
8-77

12 Rear wheel sensor (intermit- Rear wheel sensor signal is • Foreign material adhered
tent pulses or no pulses) not received properly. (Puls- around the rear wheel sen-
es are not received or are re- sor
ceived intermittently while • Incorrect installation of the
the vehicle is traveling.) rear wheel
rotor
• Defective rear wheel sen-
of the sensor
13* Front wheel sensor (abnor- Front wheel sensor signal is • Foreign material adhered
26* mal pulse period) not received properly. (The around the front wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
front wheel
rotor
of the sensor
14* Rear wheel sensor (abnor- Rear wheel sensor signal is • Foreign material adhered
27* mal pulse period) not received properly. (The around the rear wheel sen-
pulse period is abnormal sor
while the vehicle is traveling.) • Incorrect installation of the
rear wheel
rotor
of the sensor
15 Front wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the front wheel sen- the front wheel sensor and
sor. the hydraulic unit assembly
• Open or short circuit in the
wire harness between the
front wheel sensor and the
hydraulic unit assembly
sor or hydraulic unit as-
sembly
16 Rear wheel sensor (open or Open or short circuit is de- • Defective coupler between
short circuit) tected in the rear wheel sen- the rear wheel sensor and
sor. the hydraulic unit assembly
rear wheel sensor and the
hydraulic unit assembly
sor or hydraulic unit as-
sembly
8-78

17* Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
45* pulses) not received properly. (Miss- around the front wheel sen-
ing pulses are detected in sor
the signal while the vehicle is • Incorrect installation of the
traveling.) front wheel
rotor
of the sensor
18* Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
46* pulses) not received properly. (Miss- around the rear wheel sen-
traveling.) rear wheel
rotor
of the sensor
21 Hydraulic unit assembly (de- Solenoid drive circuit in the • Defective hydraulic unit as-
fective solenoid drive circuit) hydraulic unit assembly is sembly
open or short-circuited.
24 Brake light switch or brake Brake light signal is not re- • Defective signaling system
light ceived properly while the ve- (brake light or brake light
hicle is traveling. (Brake light switch)
circuit, or front or rear brake • Defective coupler between
light switch circuit) the signaling system (brake
light or brake light switch)
and the hydraulic unit as-
sembly
signaling system (brake
light or brake light switch)
and the hydraulic unit as-
sembly
• Defective hydraulic unit as-
sembly
31 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS solenoid fuse
normal ABS solenoid power solenoid circuit in the hy- • Defective coupler between
supply) draulic unit assembly. the battery and the hydrau-
lic unit assembly
battery and the hydraulic
unit assembly
sembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS solenoid the solenoid power supply sembly
power supply circuit) circuit in the hydraulic unit
assembly.
8-79

33 Hydraulic unit assembly (ab- Power is not supplied to the • Blown ABS motor fuse
normal ABS motor power motor circuit in the hydraulic • Defective coupler between
supply) unit assembly. the battery and the hydrau-
lic unit assembly
unit assembly
sembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit as-
(short circuit in ABS motor the motor power supply cir- sembly
power supply circuit) cuit in the hydraulic unit as-
sembly.
41 Front wheel ABS (intermit- • Pulses from the front wheel • Incorrect installation of the
tent wheel speed pulses or sensor are received inter- front wheel sensor
incorrect depressurization) mittently while the vehicle • Incorrect rotation of the
is traveling. front wheel
• Front wheel will not recover • Front brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
42 Rear wheel ABS (intermit- • Pulses from the rear wheel • Incorrect installation of the
47 tent wheel speed pulses or sensor are received inter- rear wheel sensor (for fault
incorrect depressurization) mittently while the vehicle code No. 42)
is traveling. (for fault code • Incorrect rotation of the
No. 42) rear wheel
• Rear wheel will not recover • Rear brake dragging
from the locking tendency • Defective hydraulic unit as-
even though the signal is sembly
transmitted from the ABS
ECU to reduce the hydrau-
lic pressure.
43 Front wheel sensor (missing Front wheel sensor signal is • Foreign material adhered
pulses) not received properly. (Miss- around the front wheel sen-
traveling.) front wheel
rotor
of the sensor
44 Rear wheel sensor (missing Rear wheel sensor signal is • Foreign material adhered
pulses) not received properly. (Miss- around the rear wheel sen-
traveling.) rear wheel
rotor
of the sensor
8-80

51 • Vehicle system power sup- • Power voltage supplied to • Defective battery
52 ply (voltage of ABS ECU the ABS ECU in the hy- • Disconnected battery ter-
power supply is high) (for draulic unit assembly is too minal
fault code No. 51) high. (for fault code No. 51) • Defective charging system
• Vehicle system power sup- • Power voltage supplied to
ply (voltage of wheel sen- the wheel sensor is too
sor power supply is high) high. (for fault code No. 52)
(for fault code No. 52)
53 Vehicle system power supply Power voltage supplied to • Defective battery
(voltage of ABS ECU power the ABS ECU in the hydrau- • Defective coupler between
supply is low) lic unit assembly is too low. the battery and the hydrau-
lic unit assembly
unit assembly
• Defective charging system
54 Hydraulic unit assembly (de- Abnormality is detected in • Defective battery
fective ABS solenoid and the solenoid or motor power • Defective coupler between
ABS motor power supply cir- supply circuit in the hydraulic the battery and the hydrau-
cuits) unit assembly. lic unit assembly
unit assembly
• Defective charging system
sembly
55 Hydraulic unit assembly (de- Abnormal data is detected in • Defective hydraulic unit as-
fective ABS ECU) the hydraulic unit assembly. sembly
56 Hydraulic unit assembly (ab- Abnormality is detected in • Defective hydraulic unit as-
normal internal power sup- the power supply circuit in sembly
ply) the hydraulic unit assembly.
63 Front wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the front ness between the front
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
sor
sembly
64 Rear wheel sensor power Power voltage supplied from • Short circuit in the wire har-
supply (voltage of power the ABS ECU to the rear ness between the rear
supply is low) wheel sensor is too low. wheel sensor and the hy-
draulic unit assembly
sor
sembly
* The fault code number varies according to the vehicle conditions.
8-81
Fault code No. 11, 25

TIP
With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (fault code
No. 11) or for longer than about 2 seconds (fault code No. 25).
11
Fault code No.
25
Item Front wheel sensor (intermittent pulses or no pulses)
Front wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)
Order Item/components and probable cause Check or maintenance job

1 Foreign material adhered around the front Check the surface of the sensor rotor and wheel sensor
wheel sensor for foreign material, such as metal particles.
Clean the sensor rotor and wheel sensor if necessary.
2 Incorrect installation of the front wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE FRONT WHEEL” on page
4-26.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage.
lation of the rotor Replace the sensor rotor if there is visible damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL
SENSOR AND SENSOR ROTOR” on page 4-27.
4 Defective front wheel sensor or incorrect Check the wheel sensor for damage and the installed
installation of the sensor condition of the sensor. Repair or replace the wheel
sensor if necessary.
Fault code No. 12

Fault code No. 12
Item Rear wheel sensor (intermittent pulses or no pulses)
Rear wheel sensor signal is not received properly. (Pulses are not re-
Symptom
ceived or are received intermittently while the vehicle is traveling.)

1 Foreign material adhered around the rear Check the surface of the sensor rotor and wheel sensor
2 Incorrect installation of the rear wheel Check the components for looseness, distortion, and
bends.
Refer to “CHECKING THE REAR WHEEL” on page
4-33.
Refer to “MAINTENANCE OF THE REAR WHEEL
4 Defective rear wheel sensor or incorrect Check the wheel sensor for damage and the installed
8-82

TIP
• If the front brake ABS operates continuously for 20 seconds or more, fault code No. 26 will be record-
ed. If the front brake ABS operates continuously for 36 seconds or more, fault code No. 13 will be re-
corded.
• Vehicle possibly ridden on uneven roads.
13
Fault code No.
26
Item Front wheel sensor (abnormal pulse period)
Front wheel sensor signal is not received properly. (The pulse period
Symptom
is abnormal while the vehicle is traveling.)

bends.
4-26.
3 Defective sensor rotor or incorrect instal- Check the surface of the sensor rotor for damage. Re-
lation of the rotor place the sensor rotor if there is visible damage.

TIP
• If the rear brake ABS operates continuously for 20 seconds or more, fault code No. 27 will be record-
ed. If the rear brake ABS operates continuously for 36 seconds or more, fault code No. 14 will be re-
corded.
• Vehicle possibly ridden on uneven roads.
14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)
Rear wheel sensor signal is not received properly. (The pulse period
Symptom

bends.
4-33.
8-83
14
Fault code No.
27
Item Rear wheel sensor (abnormal pulse period)
Rear wheel sensor signal is not received properly. (The pulse period
Symptom

Fault code No. 15

TIP
Turn the main switch to “OFF” before disconnecting or connecting a coupler.
Fault code No. 15
Item Front wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the front wheel sensor.

1 Defective coupler between the front wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
• If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
8-84
Fault code No. 15
Item Front wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the front wheel sensor.

2 Open or short circuit in the wire harness • Check for continuity between the Green terminal “1”
between the front wheel sensor and the and the Green terminal “4” and between the Blue ter-
hydraulic unit assembly minal “2” and the Blue terminal “5”.
• If there is no continuity, the wire harness is defective.
Replace the wire harness.
• Check that there is no short circuit between the Green
terminal “1” and the Blue terminal “2” and between the
Green terminal “4” and the Blue terminal “5”.
• If there is short circuit, the wire harness is defective.
• Check that there is no short circuit between the Black/
White terminal “3” and the Green terminal “4” and be-
tween the Black/White terminal “3” and the Blue termi-
nal “5”.
1 2 3
4 5
G L W B
6
7
6. ABS ECU
3 Defective front wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “FRONT WHEEL” on page 4-24 and “ABS (AN-
TI-LOCK BRAKE SYSTEM)” on page 4-60.
Fault code No. 16

TIP
Fault code No. 16
Item Rear wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the rear wheel sensor.

1 Defective coupler between the rear wheel • Check the coupler for any pins that may be pulled out.
sensor and the hydraulic unit assembly • Check the locking condition of the coupler.
pler securely.
See TIP.
8-85
Fault code No. 16
Item Rear wheel sensor (open or short circuit)
Symptom Open or short circuit is detected in the rear wheel sensor.

2 Open or short circuit in the wire harness • Check for continuity between the Brown terminal “1”
between the rear wheel sensor and the and the Brown terminal “4” and between the Yellow
hydraulic unit assembly terminal “2” and the Yellow terminal “5”.
• If there is no continuity, the wire harness is defective.
• Check that there is no short circuit between the Brown
terminal “1” and the Yellow terminal “2” and between
the Brown terminal “4” and the Yellow terminal “5”.
• Check that there is no short circuit between the Black/
White terminal “3” and the Brown terminal “4” and be-
tween the Black/White terminal “3” and the Yellow ter-
minal “5”.
1 2 3
4 5
Br Y W B
6
7
6. ABS ECU
3 Defective rear wheel sensor or hydraulic If the above items were performed and no malfunctions
unit assembly were found, the wheel sensor or hydraulic unit assembly
is defective. Replace the wheel sensor or hydraulic unit
assembly.
Refer to “REAR WHEEL” on page 4-32 and “ABS (ANTI-
LOCK BRAKE SYSTEM)” on page 4-60.
8-86

TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 45 will be recorded first and fault code No. 17 will be recorded if the condition continues.
17
Fault code No.
45
Item Front wheel sensor (missing pulses)
Front wheel sensor signal is not received properly. (Missing pulses

Symptom
are detected in the signal while the vehicle is traveling.)

bends.
4-26.

TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, fault
code No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, fault code
No. 46 will be recorded first and fault code No. 18 will be recorded if the condition continues.
18
Fault code No.
46
Item Rear wheel sensor (missing pulses)
Rear wheel sensor signal is not received properly. (Missing pulses are
Symptom
detected in the signal while the vehicle is traveling.)

bends.
4-33.
8-87
18
Fault code No.
46
Symptom

Fault code No. 21

Fault code No. 21
Item Hydraulic unit assembly (defective solenoid drive circuit)
Solenoid drive circuit in the hydraulic unit assembly is open or short-

Symptom
circuited.

1 Defective hydraulic unit assembly Replace the hydraulic unit assembly.
Refer to “ABS (ANTI-LOCK BRAKE SYSTEM)” on page
4-60.
Fault code No. 24

Fault code No. 24
Item Brake light switch or brake light
Brake light signal is not received properly while the vehicle is travel-
Symptom
ing (Brake light circuit, or front or rear brake light switch circuit).

1 Defective signaling system (brake light or Check the brake light switches.
brake light switch) Refer to “CHECKING THE SWITCHES” on page 8-101.
2 Defective coupler between the signaling • Check the coupler for any pins that may be pulled out.
system (brake light or brake light switch) • Check the locking condition of the coupler.
and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
3 Open or short circuit in the wire harness • Between front brake light switch connector and rear
between the signaling system (brake light brake light switch connector.
or brake light switch) and the hydraulic (Green/Yellow–Green/Yellow)
unit assembly • Between ABS ECU coupler and rear brake light switch
connector.
(Yellow–Yellow)
4 Defective hydraulic unit assembly If the above items were performed and no malfunctions
were found, replace the hydraulic unit assembly.
4-60.
8-88
Fault code No. 31

TIP
Fault code No. 31
Item Hydraulic unit assembly (abnormal ABS solenoid power supply)
Power is not supplied to the solenoid circuit in the hydraulic unit as-
Symptom
sembly.

1 Blown ABS solenoid fuse Check the ABS solenoid fuse. If the ABS solenoid fuse
is blown, replace the fuse and check the wire harness.
2 Defective coupler between the battery • Check the locking condition of the coupler.
and the hydraulic unit assembly • If there is a malfunction, repair it and connect the cou-
pler securely.
See TIP.
3 Open or short circuit in the wire harness • Replace if there is an open or short circuit.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS solenoid fuse.
assembly (Red–Red)
4-60.
Fault code No. 32

Fault code No. 32
Hydraulic unit assembly (short circuit in ABS solenoid power supply

Item
circuit)
Short circuit is detected in the solenoid power supply circuit in the hy-
Symptom
draulic unit assembly.

4-60.
Fault code No. 33

TIP
Fault code No. 33
Item Hydraulic unit assembly (abnormal ABS motor power supply)
Power is not supplied to the motor circuit in the hydraulic unit assem-
Symptom
bly.

1 Blown ABS motor fuse Check the ABS motor fuse. If the ABS motor fuse is
blown, replace the fuse and check the wire harness.
8-89
Fault code No. 33
Item Hydraulic unit assembly (abnormal ABS motor power supply)
Power is not supplied to the motor circuit in the hydraulic unit assem-
Symptom
bly.

2 Defective coupler between the battery • Check the coupler for any pins that may be pulled out.
and the hydraulic unit assembly • Check the locking condition of the coupler.
pler securely.
See TIP.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS motor fuse.
assembly (Red/Blue–Red/Blue)
• Between ABS ECU coupler and ground.
(Black–Black)
4-60.
Fault code No. 34

Fault code No. 34
Hydraulic unit assembly (short circuit in ABS motor power supply cir-
Item
cuit)
Short circuit is detected in the motor power supply circuit in the hy-
Symptom
draulic unit assembly.

4-60.
Fault code No. 41

Fault code No. 41
Front wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)
• Pulses from the front wheel sensor are received intermittently while
the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
the signal is transmitted from the ABS ECU to reduce the hydraulic
pressure.

sensor bends.
4-26.
8-90
Fault code No. 41
Front wheel ABS (intermittent wheel speed pulses or incorrect de-

Item
pressurization)
• Pulses from the front wheel sensor are received intermittently while
the vehicle is traveling.
Symptom • Front wheel will not recover from the locking tendency even though
pressure.

2 Incorrect rotation of the front wheel Check that there is no brake disc drag on the front wheel
and make sure that it rotates smoothly.
4-26 and “CHECKING THE FRONT BRAKE DISC” on
page 4-41.
3 Front brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake lever is operated
and that the pressure decreases when the lever is re-
leased.
Refer to “CHECKING THE FRONT BRAKE DISC” on
page 4-41.
4-60.

42
Fault code No.
47
Rear wheel ABS (intermittent wheel speed pulses or incorrect depres-

Item
surization)
• Pulses from the rear wheel sensor are received intermittently while
the vehicle is traveling. (for fault code No. 42)
Symptom • Rear wheel will not recover from the locking tendency even though
pressure.

sensor (for fault code No. 42) bends.
4-33.
2 Incorrect rotation of the rear wheel Check that there is no brake disc drag on the wheel and
make sure that it rotates smoothly.
4-33.
3 Rear brake dragging Check that the brake fluid pressure is correctly transmit-
ted to the brake caliper when the brake lever is operated
and that the pressure decreases when the lever is re-
leased.
Refer to “CHECKING THE REAR BRAKE DISC” on
page 4-54.
8-91
42
Fault code No.
47
Rear wheel ABS (intermittent wheel speed pulses or incorrect depres-

Item
surization)
• Pulses from the rear wheel sensor are received intermittently while
the vehicle is traveling. (for fault code No. 42)
Symptom • Rear wheel will not recover from the locking tendency even though
pressure.

4-60.
Fault code No. 43

Fault code No. 43
Item Front wheel sensor (missing pulses)
Front wheel sensor signal is not received properly. (Missing pulses

Symptom
are detected in the signal while the vehicle is traveling.)

bends.
4-26.
Fault code No. 44

Fault code No. 44
Symptom

8-92
Fault code No. 44
Symptom

bends.
4-33.

51
Fault code No.
52
• Vehicle system power supply (voltage of ABS ECU power supply is

high) (for fault code No. 51)
Item
• Vehicle system power supply (voltage of wheel sensor power supply
is high) (for fault code No. 52)
• Power voltage supplied to the ABS ECU in the hydraulic unit assem-
bly is too high. (for fault code No. 51)
Symptom
• Power voltage supplied to the wheel sensor is too high. (for fault
code No. 52)

1 Defective battery Recharge or replace the battery.
Refer to “CHECKING AND CHARGING THE BATTERY”
on page 8-106.
2 Disconnected battery terminal Check the connection. Replace or reconnect the termi-
nal if necessary.
3 Defective charging system Check the charging system.
8-93
Fault code No. 53

TIP
Fault code No. 53
Vehicle system power supply (voltage of ABS ECU power supply is

Item
low)
Power voltage supplied to the ABS ECU in the hydraulic unit assem-
Symptom
bly is too low.

on page 8-106.
pler securely.
See TIP.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS control unit fuse.
assembly (Brown/White–Brown/White)
Fault code No. 54

TIP
Fault code No. 54
Hydraulic unit assembly (defective ABS solenoid and ABS motor

Item
power supply circuits)
Abnormality is detected in the solenoid or motor power supply circuit

Symptom
in the hydraulic unit assembly.

on page 8-106.
pler securely.
See TIP.
between the battery and the hydraulic unit • Between ABS ECU coupler and ABS motor fuse.
assembly (Red/Blue–Red/Blue)
• Between ABS ECU coupler and ABS solenoid fuse.
(Red–Red)
Refer to “CHARGING SYSTEM” on page 8-11.
8-94
Fault code No. 54
Hydraulic unit assembly (defective ABS solenoid and ABS motor

Item
power supply circuits)
Abnormality is detected in the solenoid or motor power supply circuit

Symptom
in the hydraulic unit assembly.

4-60.
Fault code No. 55

Fault code No. 55
Item Hydraulic unit assembly (defective ABS ECU)
Symptom Abnormal data is detected in the hydraulic unit assembly.

4-60.
Fault code No. 56

Fault code No. 56
Item Hydraulic unit assembly (abnormal internal power supply)
Abnormality is detected in the power supply circuit in the hydraulic

Symptom
unit assembly.

4-60.
8-95
Fault code No. 63

Fault code No. 63
Item Front wheel sensor power supply (voltage of power supply is low)
Power voltage supplied from the ABS ECU to the front wheel sensor is
Symptom
too low.

1 Short circuit in the wire harness between • Check that there is no short circuit between the Green
the front wheel sensor and the hydraulic terminal “1” and the Blue terminal “2”.
unit assembly • Check that there is no short circuit between the Black/
White terminal “3” and the Green terminal “1”.
• If there is a short circuit, the wire harness is defective.
3
1 2
G L W B
4
5
4. ABS ECU
2 Defective front wheel sensor • Check that there is no short circuit between the Black
terminal “1” and the White terminal “2”.
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.
2 1
G L W B
3
4
3. ABS ECU
4-60.
8-96
Fault code No. 64

Fault code No. 64
Item Rear wheel sensor power supply (voltage of power supply is low)
Power voltage supplied from the ABS ECU to the rear wheel sensor is
Symptom
too low.

1 Short circuit in the wire harness between • Check that there is no short circuit between the Yellow
the rear wheel sensor and the hydraulic terminal “1” and the Brown terminal “2”.
unit assembly • Check that there is no short circuit between the Black/
White terminal “3” and the Yellow terminal “1”.
• If there is a short circuit, the wire harness is defective.
3
2 1
Br Y W B
4
5
4. ABS ECU
2 Defective rear wheel sensor • Check that there is no short circuit between the Black
terminal “1” and the White terminal “2”.
• If there is a short circuit, the wheel sensor is defective.
Repair or replace the wheel sensor.
2 1
Br Y W B
3
4
3. ABS ECU
4-60.
8-97
EAS31167
[B-3] DELETING THE FAULT CODES

To delete the fault codes, use the Yamaha diagnostic tool. For information about deleting the fault
codes, refer to the operation manual of the Yamaha diagnostic tool.
Check that all the displayed fault codes are deleted.

90890-03256
90890-03254

Remove the protective cap “1”, and then connect the Yamaha diagnostic tool to the coupler.
EAS31168
[C-1] FINAL CHECK

Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.
Checking procedures
1. Check the brake fluid level in the front brake master cylinder reservoir and rear brake master cylinder
reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-10.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)” on page 4-29 and “INSTALL-
ING THE REAR WHEEL (REAR BRAKE DISC)” on page 4-33.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-64.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 8-98.
5. Checking the ABS warning light.
Check that the ABS warning light goes off.
If the ABS warning light does not come on or if it does not go off, refer to “CHECKING THE ABS
WARNING LIGHT” on page 4-67.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between White/Blue terminal of the ABS ECU coupler and White/Blue terminal
of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.
8-98
ELECTRICAL COMPONENTS
EAS20089
3 4
2 5
6
7
8
1
9
32 10
11
31
27,28,29,30
12
13
14
26
25
15
17
24
16
18
22
23 21 19
20
8-99
1. Starter relay
2. Battery
3. ECU (Engine Control Unit)
4. Fuse box 1
7. Fuse box 2
8. Main switch
11. ABS ECU
12. Horn
13. Diode
14. Ignition coil
16. Fuel sender
17. Fuel pump
18. Sidestand switch
19. Spark plug
20. O2 sensor
21. Coolant temperature sensor
22. VVA (variable valve actuator) solenoid
23. AC magneto
26. Starter motor
28. Intake air pressure sensor
29. Intake air temperature sensor
30. Throttle position sensor
31. ISC (Idle Speed Control) unit
32. Fuel injector
8-100
EAS30549
CHECKING THE SWITCHES
1 2
R Br
ON
OFF
3
8
Y L/B
7
P B
6
Ch Br/W Dg
Dg B
Br/W Ch
L/B P
4
L/W B
5 L/W
B
B
B
B
8-101

2. Main switch
4. Start switch
5. Sidestand switch
6. Turn signal switch
7. Horn switch
8. Dimmer switch
8-102
Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check
the wiring connections and if necessary, replace the switch.
ECA14371
NOTICE
Never insert the tester probes into the coupler terminal slots. Always insert the probes from the
opposite end “a” of the coupler, taking care not to loosen or damage the leads.

90890-03243
chometer
YU-A1927
TIP
• Before checking for continuity, set the digital circuit tester to “0”.
• 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 main
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 red and brown when the switch is turned to “ON”.
R Br
ON
a
OFF
8-103
EAS30550
CHECKING THE BULBS AND BULB Digital circuit tester (CD732)

SOCKETS 90890-03243
TIP Model 88 Multimeter with ta-
Do not check any of the lights that use LEDs. chometer
YU-A1927
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continuity TIP
between the terminals. Before checking for continuity, set the digital cir-
Damage/wear → Repair or replace the bulb, cuit tester to “0”.
bulb socket or both.
Improperly connected → Properly connect. a. Connect the positive tester probe to termi-
No continuity → Repair or replace the bulb, bulb nal “1” and the negative tester probe to ter-
socket or both. minal “2”, and check the continuity.
b. Connect the positive tester probe to termi-
Types of bulbs nal “1” and the negative tester probe to ter-
The bulbs used on this vehicle are shown in the minal “3”, and check the continuity.
illustration. c. If either of the readings indicate no conti-
• Bulbs “a” are used for turn signal and taillights nuity, replace the bulb.
and can be removed from the socket by push-
ing and turning the bulb counterclockwise.
• Bulbs “b” are used for auxiliary lights and can
be removed from their respective sockets by
carefully pulling them out.
Checking the condition of the bulb sockets

The following procedure applies to all of the bulb
sockets.
1. Check:
• Bulb socket (for continuity)
Checking the condition of the bulbs (with the digital circuit tester)
The following procedure applies to all of the No continuity → Replace.
bulbs.
1. Remove: Digital circuit tester (CD732)
90890-03243
• Bulb
ECA22810
NOTICE chometer
YU-A1927
Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
TIP
wise it may be pulled out of the terminal in
Check each bulb socket for continuity in the
the coupler.
same manner as described in the bulb section;
2. Check: however, note the following.
• Bulb (for continuity)
(with the digital circuit tester) a. Install a good bulb into the bulb socket.
No continuity → Replace. b. Connect the digital circuit tester probes to
the respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity, re-
place the bulb socket.
8-104
EAS30551 EWA13310
CHECKING THE FUSES WARNING

The following procedure applies to all of the fus- Never use a fuse with an amperage rating
es. other than that specified. Improvising or us-
ECA20520
NOTICE ing a fuse with the wrong amperage rating

may cause extensive damage to the electri-
To avoid a short circuit, always turn the main
cal system, cause the lighting and ignition
switch to “OFF” when checking or replacing
systems to malfunction and could possibly
a fuse.
cause a fire.
1. Remove:
4. Install:
• Battery cover
• Battery cover
4-1.
4-1.
2. Check:
• Fuse EAS31006
a. Connect the digital circuit tester to the fuse REPLACING THE ECU (engine control unit)
and check the continuity. 1. Turn the main switch to “OFF”.
2. Replace the ECU (engine control unit).
Digital circuit tester (CD732) 3. Clean the throttle body.
90890-03243 Refer to “CLEANING THE ISC (IDLE SPEED
Model 88 Multimeter with ta- CONTROL) UNIT AND THROTTLE BODY”
chometer on page 7-12.
YU-A1927 4. Reset:
• ISC learning values
b. If the digital circuit tester indicates “∞”, re-
place the fuse.
3. Replace:
• Blown fuse
9-5.
a. Turn the main switch to “OFF”.
• ISC valve position
b. Install a new fuse of the correct amperage
rating.
c. Set on the switches to verify if the electri-
cal circuit is operational.
9-5.
d. If the fuse immediately blows again, check
the electrical circuit. Yamaha diagnostic tool USB
Amperage 90890-03256
Fuses Q’ty Yamaha diagnostic tool (A/I)
rating
90890-03254
ABS motor 30 A 1
Main 1 15 A 1 5. Reset:
ABS solenoid 15 A 1 • A/F control learning values
Main 2 7.5 A 1
Taillight 7.5 A 1 AND DIAGNOSTIC CODE TABLE” on page
Signaling system 7.5 A 1 9-5.
ABS control unit 7.5 A 1
Spare 30 A 1 90890-03256
Spare 15 A 1 Yamaha diagnostic tool (A/I)
Spare 7.5 A 1 90890-03254
6. Check:
sure the engine idling speed.
8-105
TIP
Engine idling speed
1500–1700 r/min Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check the
EAS30552
charge state of the battery by measuring the
CHECKING AND CHARGING THE BATTERY specific gravity of the electrolyte. Therefore, the
EWA13290
charge of the battery has to be checked by mea-
WARNING suring the voltage at the battery terminals.
Batteries generate explosive hydrogen gas
1. Remove:
and contain electrolyte which is made of poi-
• Battery cover
sonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
4-1.
measures:
2. Disconnect:
• Wear protective eye gear when handling or
• Battery leads
working near batteries.
(from the battery terminals)
• Charge batteries in a well-ventilated area. ECA13640
• Keep batteries away from fire, sparks or NOTICE
open flames (e.g., welding equipment, First, disconnect the negative battery lead
lighted cigarettes). “1”, and then positive battery lead “2”.
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE 2
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
1
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention. 3. Remove:
INTERNAL • Battery
• Drink large quantities of water or milk fol- 4. Check:
lowed with milk of magnesia, beaten egg or • Battery charge
vegetable oil. Get immediate medical atten- a. Connect a digital circuit tester to the bat-
tion. tery terminals.
ECA20530 • Positive tester probe →
NOTICE positive battery terminal
• Negative tester probe →
• This is a VRLA (Valve Regulated Lead Acid) negative battery terminal
battery. Never remove the sealing caps be-
cause the balance between cells will not be TIP
maintained and battery performance will • The charge state of an VRLA (Valve Regulated
deteriorate. Lead Acid) battery can be checked by measur-
• Charging time, charging amperage and ing its open-circuit voltage (i.e., the voltage
charging voltage for a VRLA (Valve Regu- when the positive battery terminal is discon-
lated Lead Acid) battery are different from nected).
those of conventional batteries. The VRLA • No charging is necessary when the open-cir-
(Valve Regulated Lead Acid) battery should cuit voltage equals or exceeds 12.8 V.
be charged according to the appropriate
charging method. If the battery is over- b. Check the charge of the battery, as shown
charged, the electrolyte level will drop con- in the charts and the following example.
siderably. Therefore, take special care
when charging the battery.
8-106
Example • When charging a battery, be sure to remove

Open-circuit voltage = 12.0 V it from the vehicle. (If charging has to be
Charging time = 6.5 hours done with the battery mounted on the vehi-
Charge of the battery = 20–30% cle, disconnect the negative battery lead
from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the battery
charger leads are connected to the battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips are
in full contact with the battery terminal and
that they are not shorted. A corroded bat-
tery charger lead clip may generate heat in
A. Open-circuit voltage (V)
the contact area and a weak clip spring may
B. Charging time (hours)
cause sparks.
C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F) • If the battery becomes hot to the touch at
D. These values vary with the temperature, the any time during the charging process, dis-
condition of the battery plates, and the connect the battery charger and let the bat-
electrolyte level. 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.

B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
5. Charge:
• Battery
(refer to the appropriate charging method)
EWA13300
WARNING
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- Charging method using a variable-current
tery overheating and battery plate damage. (voltage) charger
• If it is impossible to regulate the charging a. Measure the open-circuit voltage prior to
current on the battery charger, be careful charging.
not to overcharge the battery. TIP
Voltage should be measured 30 minutes after
the engine is stopped.
8-107
b. Connect a charger and ammeter to the TIP

battery and start charging. If the current is lower than the standard charging
TIP current written on the battery, this type of battery
Set the charging voltage to 16–17 V. If the set- charger cannot charge the VRLA (Valve Regu-
ting is lower, charging will be insufficient. If too lated Lead Acid) battery. A variable voltage
high, the battery will be over-charged. charger is recommended.
c. Make sure that the current is higher than d. Charge the battery until the battery’s
the standard charging current written on charging voltage is 15 V.
the battery. TIP
TIP Set the charging time at 20 hours (maximum).
If the current is lower than the standard charging
e. Measure the battery open-circuit voltage
current written on the battery, set the charging
after leaving the battery unused for more
voltage adjust dial at 20–24 V and monitor the
than 30 minutes.
amperage for 3–5 minutes to check the battery.
12.8 V or more --- Charging is complete.
• Standard charging current is reached 12.7 V or less --- Recharging is required.
Battery is good. Under 12.0 V --- Replace the battery.
• Standard charging current is not reached
Replace the battery. 6. Install:
• Battery
d. Adjust the voltage so that the current is at 7. Connect:
the standard charging level. • Battery leads
e. Set the time according to the charging (to the battery terminals)
time suitable for the open-circuit voltage. ECA13630
f. If charging requires more than 5 hours, it is NOTICE

advisable to check the charging current af- First, connect the positive battery lead “1”,
ter a lapse of 5 hours. If there is any and then the negative battery lead “2”.
change in the amperage, readjust the volt-
age to obtain the standard charging cur-
rent. 1
g. Measure the battery open-circuit voltage
after leaving the battery unused for more
than 30 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
Charging method using a constant volt-

8. Check:
age charger
• Battery terminals
a. Measure the open-circuit voltage prior to
Dirt → Clean with a wire brush.
charging.
Loose connection → Connect properly.
TIP 9. Lubricate:
Voltage should be measured 30 minutes after • Battery terminals
the engine is stopped.
b. Connect a charger and ammeter to the Dielectric grease
battery and start charging.
c. Make sure that the current is higher than 10.Install:
the standard charging current written on • Battery cover
the battery. Refer to “GENERAL CHASSIS (1)” on page
4-1.
8-108
EAS30553
CHECKING THE RELAYS Digital circuit tester (CD732)

Check each switch for continuity with the digital 90890-03243
circuit tester. If the continuity reading is incor- Model 88 Multimeter with ta-
rect, replace the relay. chometer
YU-A1927
90890-03243 • Positive tester probe
Model 88 Multimeter with ta- Brown “1”
chometer • Negative tester probe
YU-A1927 Ground
1. Disconnect the relay from the wire harness.

2. Connect the digital circuit tester and battery
(12 V) to the relay terminals as shown.
Check the relay operation. 1
Out of specification → Replace. Br/W
Br
Starter relay
4 3
b. Turn the main switch to “ON”.
R B c. Measure the turn signal relay input volt-
Y L/W age.
2. Check:
2 1 • Turn signal relay output voltage
Turn signal relay output voltage

1. Positive battery terminal
DC 12V
2. Negative battery terminal
3. Positive tester probe a. Connect the digital circuit tester to the turn
4. Negative tester probe signal relay terminal as shown.
Result Digital circuit tester (CD732)

Continuity 90890-03243
(between “3” and “4”) Model 88 Multimeter with ta-
chometer
EAS30554 YU-A1927
CHECKING THE TURN SIGNAL RELAY
1. Check: • Positive tester probe
• Turn signal relay input voltage Brown/White “1”
Out of specification → The wiring circuit from • Negative tester probe
Ground
the main switch to the turn signal relay cou-
pler is faulty and replace the wire harness.
Turn signal relay input voltage

DC 12V
a. Connect the digital circuit tester to the turn

signal relay terminal as shown.
8-109
EAS30557
CHECKING THE SPARK PLUG CAP

1 1. Check:
• Spark plug cap resistance
Br/W
Br Resistance
3.75–6.25 kΩ
a. Remove the spark plug cap from the spark

plug lead.
b. Turn the main switch to “ON”. b. Connect the digital circuit tester to the
c. Measure the turn signal relay output volt- spark plug cap as shown.
age.
EAS30555
90890-03243
CHECKING THE DIODE Model 88 Multimeter with ta-
1. Check: chometer
• Diode YU-A1927

90890-03243
chometer
YU-A1927
Continuity
Positive tester probe → Blue/
Yellow “1”
Negative tester probe → Blue/ c. Measure the spark plug cap resistance.
White “2”
No continuity EAS30558
Positive tester probe → Blue/ CHECKING THE IGNITION COIL

White “2” 1. Check:
Negative tester probe → Blue/ • Primary coil resistance
Yellow “1” Out of specification → Replace.
Primary coil resistance

2.16–2.64 Ω
1
a. Disconnect the ignition coil connectors
L/Y from the ignition coil terminals.
L/W
b. Connect the digital circuit tester to the igni-
tion coil as shown.
2 Digital circuit tester (CD732)

90890-03243
a. Disconnect the diode from the wire har- chometer
ness. YU-A1927
b. Connect the digital circuit tester to the di-
ode terminals. • Positive tester probe →
c. Check the diode for continuity. Red/Blue “1”
d. Check the diode for no continuity. • Negative tester probe →
Orange “2”
8-110
TIP
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
a. Disconnect the spark plug cap from the
spark plug.
b. Connect the ignition checker “1” as
shown.
Ignition checker
90890-06754
c. Measure the primary coil resistance. Oppama pet–4000 spark checker
2. Check: YM-34487
• Secondary coil resistance
Secondary coil resistance

8.64–12.96 kΩ
a. Connect the digital circuit tester to the igni-

tion coil as shown.

90890-03243
chometer 2. Ignition coil
YU-A1927
c. Turn the main switch to “ON”.
• Positive tester probe → d. Measure the ignition spark gap “a”.
Red/Blue “1” e. Crank the engine by pushing the “ ” of
• Negative tester probe → the start switch and gradually increase the
High tension cord “2” spark gap until a misfire occurs.
EAS30560
CHECKING THE CRANKSHAFT POSITION

SENSOR
1. Disconnect:
• Crankshaft position sensor coupler
(from the wire harness)
2. Check:
• Crankshaft position sensor resistance
Out of specification → Replace the crank-
shaft position sensor/stator assembly.
b. Measure the secondary coil resistance.
Crankshaft position sensor resis-
EAS30556 tance
CHECKING THE IGNITION SPARK GAP 228–342 Ω
1. Check:
• Ignition spark gap a. Connect the digital circuit tester to the
Out of specification → Perform the ignition crankshaft position sensor coupler as
system troubleshooting, starting with step 5. shown.
Refer to “TROUBLESHOOTING” on page
8-3. Digital circuit tester (CD732)
90890-03243
Minimum ignition spark gap Model 88 Multimeter with ta-
6.0 mm (0.24 in) chometer
YU-A1927
8-111
EAS30566
• Positive tester probe → CHECKING THE STATOR COIL
White/Red “1”
• Negative tester probe → 1. Disconnect:
White/Blue “2” • Stator coil coupler
(from the wire harness)
2. Check:
• Stator coil resistance
2
Out of specification → Replace the stator coil.
W/L
Stator coil resistance
0.496–0.744 Ω
W/R
a. Connect the digital circuit tester to the sta-
1 tor coil coupler as shown.

b. Measure the crankshaft position sensor 90890-03243
resistance. Model 88 Multimeter with ta-
EAS30562
chometer
CHECKING THE STARTER MOTOR YU-A1927
OPERATION
1. Check: • Positive tester probe →
• Starter motor operation White “1”
Does not operate → Perform the electric White “2”
starting system troubleshooting, starting with
step 4.
Refer to “TROUBLESHOOTING” on page
8-8. 1
a. Connect the positive battery terminal “1”
and starter motor lead “2” with a jumper W
lead “3”. W
EWA13810
WARNING 2
• A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may b. Measure the stator coil resistance.
burn.
EAS30680
• This check is likely to produce sparks,
CHECKING THE RECTIFIER/REGULATOR
therefore, make sure no flammable gas or
1. Check:
fluid is in the vicinity.
• Charging voltage
Out of specification → Replace the rectifier/
regulator.
Charging voltage
14 V at 5000 r/min
a. Connect the engine tachometer to the

spark plug lead.
b. Connect the digital circuit tester to the bat-
tery terminals as shown.
b. Check the starter motor operation.
8-112

90890-03243 2
chometer
YU-A1927 R/L B
L/B G
• Positive tester probe →
positive battery terminal “1” 1
negative battery terminal “2”
b. Move the fuel sender float to minimum “3”
and maximum “4” level position.
1
4
3
2
c. Start the engine and let it run at approxi-

mately 5000 r/min. c. Measure the fuel sender resistance.
d. Measure the charging voltage.
EAS30578
EAS30573 CHECKING THE COOLANT TEMPERATURE

CHECKING THE FUEL SENDER SENSOR
1. Remove: 1. Remove:
• Fuel pump • Coolant temperature sensor
(from the fuel tank) Refer to “CYLINDER HEAD” on page 5-9.
2. Check: EWA14130
• Fuel sender resistance WARNING

Out of specification → Replace the fuel pump • Handle the coolant temperature sensor
assembly. with special care.
• Never subject the coolant temperature sen-
Fuel sender sor to strong shocks. If the coolant tem-
Sender unit resistance (full) perature sensor is dropped, replace it.
10.0–14.0 Ω
Sender unit resistance (empty) 2. Check:
267.0–273.0 Ω • Coolant temperature sensor resistance
a. Connect the digital circuit tester to the fuel
sender terminals as shown. Coolant temperature sensor re-
sistance
Digital circuit tester (CD732) 2512–2777 Ω at 20 °C (2512–
90890-03243 2777 Ω at 68 °F)
Model 88 Multimeter with ta- Coolant temperature sensor re-
chometer sistance
YU-A1927 210–220 Ω at 100 °C (210–220 Ω
at 212 °F)
• Positive tester probe →
Green “1” a. Connect the digital circuit tester to the
• Negative tester probe → coolant temperature sensor terminals as
Black “2” shown.
8-113
• Positive tester probe

Digital circuit tester (CD732) Injector terminal “1”
90890-03243 • Negative tester probe
Model 88 Multimeter with ta- Injector terminal “2”
chometer
YU-A1927
2 1
b. Immerse the coolant temperature sensor
“1” in a container filled with coolant “2”.
TIP
Make sure that the coolant temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the coolant.
c. Measure the fuel injector resistance.

3
1 EAS31612
CHECKING THE VVA SOLENOID

1. Check:
• VVA solenoid resistance
2
Resistance
1.8–2.2 Ω at 20 °C (12.0 Ω at 68
d. Heat the coolant or let it cool down to the °F)
specified temperatures.
e. Measure the coolant temperature sensor a. Disconnect the VVA solenoid coupler from
resistance. the VVA solenoid.
3. Install: b. Connect the digital circuit tester to the
• Coolant temperature sensor VVA solenoid terminal as shown.
Coolant temperature sensor Digital circuit tester (CD732)

15 N·m (1.5 kgf·m, 11 lb·ft) 90890-03243
T.
R.

EAS30681 chometer
CHECKING THE FUEL INJECTOR YU-A1927
1. Check:
• Fuel injector resistance • Positive tester probe
Out of specification → Replace the fuel injec- Solenoid terminal “1”
tor. • Negative tester probe
Solenoid terminal “2”
Resistance
12.0 Ω at 20 °C (12.0 Ω at 68 °F)
1 2
a. Disconnect the fuel injector coupler from
fuel injector.
b. Connect the digital circuit tester to the fuel
injector terminals as shown.

90890-03243
chometer c. Measure the VVA solenoid resistance.
YU-A1927
8-114
8-115
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 ........................................ 9-3
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE............9-5

SELF-DIAGNOSTIC FUNCTION TABLE .................................................. 9-5
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 9-11
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................9-12
9
TROUBLESHOOTING
EAS20090
Electrical system
TROUBLESHOOTING 1. Battery
EAS30599
• Discharged battery
GENERAL INFORMATION • Faulty battery
TIP 2. Fuse(s)
• Blown, damaged or incorrect fuse
The following guide for troubleshooting does not
• Improperly installed fuse
cover all the possible causes of trouble. It should
3. Spark plug
be helpful, however, as a guide to basic trouble-
• Incorrect spark plug gap
shooting. Refer to the relative procedure in this
• Incorrect spark plug heat range
manual for checks, adjustments, and replace-
• Fouled spark plug
ment of parts.
• Worn or damaged electrode
EAS31258
• Worn or damaged insulator
STARTING FAILURE/HARD STARTING • Faulty spark plug cap
4. Ignition coil
Engine • Cracked or broken ignition coil body
1. Cylinder and cylinder head • Broken or shorted primary or secondary coils
• Loose spark plug • Faulty spark plug lead
• Loose cylinder head or cylinder 5. Ignition system
• Damaged cylinder head gasket • Faulty ECU
• Damaged cylinder gasket • Faulty crankshaft position sensor
• Worn or damaged cylinder • Broken AC magneto rotor woodruff key
• Incorrect valve clearance 6. Switches and wiring
• Improperly sealed valve • Faulty main switch
• Incorrect valve-to-valve-seat contact • Broken or shorted wiring
• Incorrect valve timing • Faulty front, rear or both brake light switches
• Faulty valve spring • Faulty start switch
• Seized valve • Faulty sidestand switch
2. Piston and piston ring(s) • Improperly grounded circuit
• Improperly installed piston ring • Loose connections
• Damaged, worn or fatigued piston ring 7. Starting system
• Seized piston ring • Faulty starter motor
• Seized or damaged piston • Faulty starter relay
3. Air filter • Faulty starter clutch
• Improperly installed air filter EAS30601
• Clogged air filter element INCORRECT ENGINE IDLING SPEED
4. Crankcase and crankshaft
• Improperly assembled crankcase Engine
• Seized crankshaft 1. Cylinder and cylinder head
• Incorrect valve clearance
Fuel system • Damaged valve train components
1. Fuel tank 2. Air filter
• Empty fuel tank • Clogged air filter element
• Clogged fuel tank cap breather hole
• Deteriorated or contaminated fuel Fuel system
• Clogged or damaged fuel hose 1. Throttle body
2. Fuel pump • Damaged or loose throttle body joint
• Faulty fuel pump • Faulty ISC (Idle Speed Control) unit
• Clogged fuel pump filter • Improper throttle grip free play
3. Throttle body
• Deteriorated or contaminated fuel Electrical system
• Sucked-in air 1. Battery
• Discharged battery
9-1
TROUBLESHOOTING
• Faulty battery Poor starting performance

2. Spark plug 1. V-belt
• Incorrect spark plug gap • Slipping V-belt
• Incorrect spark plug heat range • Oil or grease on the V-belt
• Fouled spark plug 2. Primary sliding sheave
• Worn or damaged electrode • Faulty operation
• Worn or damaged insulator 3. Clutch shoe(s)
• Faulty spark plug cap • Bent, damaged or worn clutch shoe
3. Ignition coil
• Broken or shorted primary or secondary coil Poor speed performance
• Faulty spark plug lead 1. V-belt
4. Ignition system • Slipping V-belt
• Faulty ECU • Oil or grease on the V-belt
• Faulty crankshaft position sensor 2. Primary sheave weight(s)
• Faulty operation
EAS30602
POOR MEDIUM-AND-HIGH-SPEED • Worn primary sheave weight

PERFORMANCE 3. Primary fixed sheave
Refer to “STARTING FAILURE/HARD START- • Worn primary fixed sheave
ING” on page 9-1. 4. Primary sliding sheave
• Worn primary sliding sheave
Engine 5. Secondary fixed sheave
1. Air filter • Worn secondary fixed sheave
• Clogged air filter element 6. Secondary sliding sheave
• Worn secondary sliding sheave
Fuel system EAS30607
1. Throttle body OVERHEATING

• Faulty throttle body
2. Fuel pump Engine
• Faulty fuel pump 1. Clogged coolant passages
2. Cylinder head and piston
EAS30849
FAULTY CLUTCH • Heavy carbon buildup

3. Engine oil
Engine operates but vehicle will not move • Incorrect oil level
1. V-belt • Incorrect oil viscosity
• Bent, damaged or worn V-belt • Inferior oil quality
• Slipping V-belt
2. Primary sheave cam and primary sheave Cooling system
slider(s) 1. Coolant
• Damaged or worn primary sheave cam • Low coolant level
• Damaged or worn primary sheave slider 2. Radiator
3. Clutch spring • Damaged or leaking radiator
• Damaged clutch spring • Faulty radiator cap
4. Transmission gear(s) • Bent or damaged radiator fin
• Damaged transmission gear 3. Water pump
• Damaged or faulty water pump
Clutch slips 4. Thermostat
1. Clutch shoe spring(s) • Thermostat stays closed
• Damaged, loose or worn clutch shoe spring 5. Hose(s) and pipe(s)
2. Clutch shoe(s) • Damaged hose
• Damaged or worn clutch shoe • Improperly connected hose
3. Primary sliding sheave • Damaged pipe
• Seized primary sliding sheave • Improperly connected pipe
9-2
TROUBLESHOOTING
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
EAS30611
• Clogged air filter element UNSTABLE HANDLING
1. Handlebar
Chassis • Bent or improperly installed handlebar
1. Brake(s) 2. Steering head components
• Dragging brake • Improperly installed lower bracket
(improperly tightened ring nut)
Electrical system
• Damaged ball bearing or bearing race
1. Spark plug
3. Front fork leg(s)
• Incorrect spark plug gap
• Uneven oil levels (both front fork legs)
• Incorrect spark plug heat range
• Unevenly tensioned fork spring (both front
2. Ignition system
fork legs)
• Faulty ECU
• Broken fork spring
EAS30608 • Bent or damaged inner tube
OVERCOOLING • Bent or damaged outer tube
4. Swingarm
Cooling system • Worn bearing or bushing
1. Thermostat • Bent or damaged swingarm
• Thermostat stays open 5. Rear shock absorber assembly(-ies)
EAS30609
• Faulty rear shock absorber spring
POOR BRAKING PERFORMANCE • Leaking oil
• Worn brake pad 6. Tire(s)
• Worn brake disc • Uneven tire pressures (front and rear)
• Air in hydraulic brake system • Incorrect tire pressure
• Leaking brake fluid • Uneven tire wear
• Faulty brake caliper kit 7. Wheel(s)
• Faulty brake caliper seal • Incorrect wheel balance
• Loose union bolt • Deformed cast wheel
• Damaged brake hose • Damaged wheel bearing
• Oil or grease on the brake disc • Bent or loose wheel axle
• Oil or grease on the brake pad • Excessive wheel runout
• Incorrect brake fluid level 8. Frame
• Bent frame
EAS30610
FAULTY FRONT FORK LEGS • Damaged steering head pipe

• Improperly installed bearing race
Leaking oil EAS30612
• Bent, damaged or rusty inner tube FAULTY LIGHTING OR SIGNALING SYSTEM

• Cracked or damaged outer tube
• Improperly installed oil seal Headlight does not come on
• Damaged oil seal lip • Faulty headlight unit
• Incorrect oil level (high) • Too many electrical accessories
• Loose damper rod bolt • Hard charging
• Damaged damper rod bolt copper washer • Incorrect connection
• Cracked or damaged front fork cap O-ring • Improperly grounded circuit
• Poor contacts (main switch)
Malfunction
• Bent or damaged inner tube Tail/brake light does not come on
• Bent or damaged outer tube • Wrong tail/brake light LED
• Damaged fork spring • Too many electrical accessories
• Worn or damaged outer tube bushing • Incorrect connection
9-3
TROUBLESHOOTING
Turn signal does not come on

• Faulty turn signal switch
• Faulty turn signal relay
• Burnt-out turn signal light bulb
• Incorrect connection
• Damaged or faulty wire harness
• Improperly grounded circuit
• Faulty battery
Turn signal blinks slowly

• Faulty main switch
• Faulty turn signal switch
• Incorrect turn signal light bulb
Turn signal remains lit

Turn signal blinks quickly

• Incorrect turn signal light bulb
Horn does not sound

• Damaged or faulty horn
• Faulty main switch
• Faulty horn switch
• Faulty battery
• Faulty wire harness
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 8-27.
Fault code Probable cause of Fail-safe system

Item Vehicle symptom
No. malfunction operation
P0106 Intake air pressure • Disconnected sen- Engine idling speed is Intake air pressure
sensor (system mal- sor module. unstable. difference is fixed to 0
function (clogged hole • Improperly installed Engine response is [kPa].
or detached)) throttle body. poor. α–N is fixed.
• Defective intake air Loss of engine power. Fuel is not cut off due
pressure sensor. Increased exhaust to the intake air pres-
emissions. sure difference.
Intake air pressure is
fixed to 101.3 [kPa].
O2 feedback is not
carried out.
P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed is Intake air pressure
P0108 pressure sensor of the intake air pres- unstable. difference is fixed to 0
(open or ground short sure sensor circuit Engine response is [kPa].
circuit detected) (0.2 V or less) poor. α–N is fixed.
[P0108] Intake air [P0108] High voltage Loss of engine power. Fuel is not cut off due
pressure sensor of the intake air pres- Increased exhaust to the intake air pres-
(power short circuit sure sensor circuit emissions. sure difference.
detected) (4.9 V or more) Intake air pressure is
• Defective coupler fixed to 101.3 [kPa].
between intake air O2 feedback is not
pressure sensor and carried out.
ECU.
• Open or short cir-
cuit in wire harness
between intake air
pressure sensor and
ECU.
• Defective intake air
pressure sensor.
• Malfunction in ECU.
9-5

P0112 [P0112] Intake air [P0112] Low voltage Engine is difficult to The intake air tem-
P0113 temperature sensor of the intake air tem- start. perature is fixed to 20
(ground short circuit perature sensor circuit Increased exhaust [°C].
detected) (0.2 V or less) emissions. O2 feedback is not
[P0113] Intake air [P0113] High voltage Engine idling speed is carried out.
temperature sensor of the intake air tem- unstable. ISC learning is not
(open or power short perature sensor circuit carried out.
circuit detected) (4.8 V or more)
• Defective coupler
between intake air
temperature sensor
and ECU.
between intake air
temperature sensor
and ECU.
• Improperly installed
intake air tempera-
ture sensor.
• Defective intake air
temperature sensor.
P0117 [P0117] Coolant tem- [P0117] Low voltage Engine is difficult to O2 feedback is not
P0118 perature sensor of the coolant tem- start. carried out.
(ground short circuit perature sensor circuit Increased exhaust ISC learning is not
detected) (0.2 V or less) emissions. carried out.
[P0118] Coolant tem- [P0118] High voltage Engine idling speed is The coolant tempera-
perature sensor (open of the coolant tem- unstable. ture is fixed to 80 [°C].
or power short circuit perature sensor circuit
detected) (4.8 V or more)
between coolant
temperature sensor
and ECU.
between coolant
temperature sensor
and ECU.
coolant temperature
sensor.
• Defective coolant
temperature sensor.
9-6

P0122 [P0122] Throttle posi- [P0122] Low voltage Engine idling speed is Change in the throttle
P0123 tion sensor (open or of the throttle position high. opening is 0 (transient
ground short circuit sensor circuit (0.2 V Engine idling speed is control is not carried
detected) or less) unstable. out).
[P0123] Throttle posi- [P0123] High voltage Engine response is D–j is fixed.
tion sensor (power of the throttle position poor. Throttle opening is
short circuit detected) sensor circuit (4.8 V Loss of engine power. fixed to 15 [°].
or more) Deceleration is poor. O2 feedback is not
• Defective coupler Increased exhaust carried out.
between throttle po- emissions. Fuel is not cut off due
sition sensor and to the throttle open-
ECU. ing.
• Open or short cir- Output is restricted.
between throttle po-
sition sensor and
ECU.
throttle position sen-
sor.
• Defective throttle po-
sition sensor.
P0132 O2 sensor (power [P0132] High voltage Increased exhaust O2 feedback is not
short circuit detected) of the O2 sensor cir- emissions. carried out.
cuit (4.8 V or more)
O2 sensor.
between O2 sensor
and ECU.
between O2 sensor
and ECU.
• Defective O2 sensor.
P0201 [P0201] Fuel injector • Defective coupler Loss of engine power. Injection is cut off.
(malfunction in fuel in- between injector Engine is difficult to
jector) and ECU. start.
• Open or short cir- Engine cannot be
cuit in wire harness started.
between injector Engine stops.
and ECU. Engine idling speed is
• Defective injector. unstable.
• Malfunction in ECU. Increased exhaust
• Improperly installed emissions.
injector.
9-7

P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor between crankshaft started.
(no normal signals are position sensor and
received from the ECU.
crankshaft position • Open or short cir-
sensor) cuit in wire harness
between crankshaft
position sensor and
ECU.
crankshaft position
sensor.
• Defective generator
rotor.
• Defective crank-
shaft position sen-
sor.
P0351 [P0351] Ignition coil • Defective coupler Engine stops. Injection is cut off.
(open or short circuit between ignition coil Loss of engine power.
detected in the lead of and ECU. Engine is difficult to
the ignition coil) • Open or short cir- start.
cuit in wire harness Engine cannot be
between ignition coil started.
• Improperly installed unstable.
ignition coil. Increased exhaust
• Defective ignition emissions.
coil.
P0500 Front wheel sensor • Open or short cir- Vehicle speed is not O2 feedback is not
(no normal signals are cuit in wire harness displayed on the me- carried out.
received from the between front wheel ter. ISC feedback is not
front wheel sensor) sensor and ABS Engine stalls when carried out.
unit. the vehicle is deceler- ISC learning is not
• Open or short cir- ating to a stop. carried out.
cuit in wire harness Engine idling speed is
between ABS unit high.
• Defective front unstable.
wheel sensor. Increased exhaust
• Malfunction in ECU. emissions.
9-8

P0507 • Component other • Defective speed Engine idling speed is ISC learning is not
than ISC (idle speed sensor. high. carried out.
control) unit is de- • Defective coupler
fective (ISC operat- between ISC unit
ing sound is heard). and ECU.
• Defective ISC (idle • Open or short cir-
speed control) unit cuit in wire harness
(ISC operating between ISC unit
sound is not heard). and ECU.
ISC unit.
• Disconnected ISC
unit hose or air leak
from intake air pas-
sage.
• Defective throttle
valve or throttle ca-
ble.
• Defective ISC unit
(ISC valve stuck ful-
ly open).
P0511 ISC unit (malfunction • Defective coupler Engine is difficult to Power is not supplied
in ISC unit) between ISC unit start. to the ISC unit.
• Open or short cir- unstable.
cuit in wire harness Engine idling speed is
between ISC unit high.
and ECU.
• Defective ISC step-
ping motor.
P0560 Charging voltage is • Battery overcharg- Engine is difficult to O2 feedback is not
abnormal. ing (defective rectifi- start. carried out.
er/regulator). Increased exhaust
• Battery overcharg- emissions.
ing (broken or dis- Battery performance
connected rectifier/ has deteriorated or
regulator lead). battery is defective.
• Battery over-dis-
charging (broken or
disconnected lead in
charging system).
• Battery over-dis-
charging (defective
rectifier/regulator).
P0601 Faulty ECU memory. • Malfunction in ECU. Engine cannot be Engine cannot be
(When this malfunc- started. started.
tion is detected in the
ECU, the fault code
number might not ap-
pear on the tool dis-
play.)
9-9

P062F EEPROM fault code • CO adjustment val- Increased exhaust CO adjustment value
number ue is not properly emissions. for the faulty cylinder
(an error is detected written. Engine cannot be =0
while reading or writ- • ISC learning value is started or is difficult to (default value)
ing on EEPROM) not properly written. start. ISC learning values =
• OBD memory value Engine idling speed is Default values
is not properly writ- unstable. OBD memory value is
ten. OBD memory value is initialized.
• Malfunction in ECU. not correct. O2 feedback learning
value is initialized.
P1601 Sidestand switch • Defective coupler Engine cannot be Engine is forcefully
(open or short circuit between relay unit started. stopped (the injector
of the blue/yellow lead and ECU. output is stopped).
of the ECU is detect- • Open or short cir-
ed) cuit in wire harness
between relay unit
and ECU.
between sidestand
switch and relay
unit.
between sidestand
switch and relay
unit.
• Defective sidestand
switch.
P2195 O2 sensor (open cir- • Signal voltage is Increased exhaust O2 feedback is not
cuit detected) 0.25–0.53 V. emissions. carried out.
O2 sensor.
between O2 sensor
and ECU.
between O2 sensor
and ECU.
• Defective O2 sensor.
P2645 Malfunction in VVA • Defective coupler EG torque goes down Low speed cam is
system between VVA sole- in high EG revolution fixed.
noid and ECU. speed range. EG revolution speed
• Open or short cir- limiter is lowered.
between VVA sole-
noid and ECU.
• Open circuit in in-
side of VVA sole-
noid.
9-10
EAS31120
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor sig-
nal
• Fully closed position 13–21 Check with throttle valve fully
closed.
• Fully open position 92–102 Check with throttle valve fully
open.
03 Intake air pressure Displays the intake air pres- Operate the throttle while
sure. pushing the start switch “ ”.
(If the display value changes,
the performance is OK.)
05 Intake air temperature Displays the intake air tem- Compare the actually mea-
perature. sured air temperature with
the computer display value.
06 Coolant temperature When engine is cold: Dis- Compare the actually mea-
plays temperature closer to sured coolant temperature
air temperature. with the computer display
When engine is hot: Displays value.
current coolant temperature.
07 Vehicle speed pulse Front wheel speed pulse Check that the number in-
0–999 creases when the front wheel
is rotated. The number is cu-
mulative and does not reset
each time the wheel is
stopped.
09 Fuel system voltage Approximately 12.0 Compare the actually mea-
(battery voltage) sured battery voltage with
the computer display value.
(If the actually measured bat-
tery voltage is low, recharge
the battery.)
20 Sidestand switch Extend and retract the side-
stand.
• Stand retracted ON
• Stand extended OFF
60 EEPROM fault code display —
• No history 00
• No malfunctions detected
(If the self-diagnosis fault
code P062F is indicated,
the ECU is defective.)
• History exists 01 (CO adjustment value)
Display the EEPROM writ- 11 (Data error for ISC (idle
ing error for fault code No. speed control) learning val-
P062F. ues)
If more than one item is de- 12 (O2 feedback learning val-
fective, the displays alter- ue)
nates every two seconds to
show all the detected num-
bers.
9-11
Diagnostic
Item Tool display Procedure
code No.
67 ISC (idle speed control) 00 To erase the ISC (idle speed
learning condition display ISC (idle speed control) control) learning data, click
ISC (idle speed control) learning data has been “Actuator Check” on the
learning data erasure erased. Yamaha diagnostic tool
01 screen 3 times in 5 seconds.
It is not necessary to erase
the ISC (idle speed control)
learning data.
02
It is necessary to erase the
ISC (idle speed control)
learning data.
70 Control number 0–254 [-] —
87 A/F control learning data era- 00 To erase the ECU learning
sure ECU learning data has been data, click the Yamaha diag-
erased. nostic tool “Actuator Check”
01 button three times in 5 sec-
ECU learning data has not onds.
been erased.
EAS31121
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates 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 on the er.
Yamaha diagnostic tool
screen come on each time
the ignition coil is actuated.
36 Fuel injector Actuates fuel injector five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that injector is actuat-
The “check” indicator on the ed five times by listening for
Yamaha diagnostic tool the operating sound.
the fuel injector is actuated.
45 VVA (variable valve actuator) Actuates the VVA solenoid Check that VVA solenoid is
solenoid five times at five-second in- actuated five times.
tervals.
The “check” indicator on the
the VVA solenoid is actuat-
ed.
52 Headlight Actuates the headlight five Check that the headlight is
times at five-second inter- on five times.
vals.
the headlight is actuated.
9-12
Diagnostic
Item Actuation Procedure
code No.
54 ISC valve Fully closes the ISC valve, Check that the ISC unit oper-
and then opens the valve. ates by listening for the oper-
This operation takes approxi- ating sound while the ISC
mately 3 seconds each time. unit operates for 3 seconds.
screen come on during the
operation.
9-13
9-14
EAS20091
57. Auxiliary light EAS30613
WIRING DIAGRAM 58. Headlight COLOR CODE

GPD125-A/GPD150-A 2017 59. Meter assembly B Black
1. Crankshaft position sensor 60. Multi-function meter Br Brown
2. AC magneto 61. Coolant temperature warning Ch Chocolate
3. Main fuse 1 light Dg Dark green
4. ABS solenoid fuse 62. ABS warning light G Green
5. Main fuse 2 63. Engine trouble warning light Gy Gray
64. Meter light L Blue
6. Taillight fuse
65. Turn signal indicator light (right) O Orange
P Pink
8. ABS control unit fuse 66. Turn signal indicator light (left)
R Red
9. Rectifier/regulator 67. High beam indicator light
Sb Sky blue
10. Main switch 68. Option coupler
W White
11. ABS motor fuse A. Wire harness Y Yellow
12. Battery B. Starter motor sub-wire harness B/L Black/Blue
13. Starter relay B/W Black/White
14. Starter motor B/Y Black/Yellow
15. Handlebar switch (right) Br/W Brown/White
16. Start switch G/R Green/Red
17. Diode G/Y Green/Yellow
18. Sidestand switch Gy/R Gray/Red
19. Fuel sender L/B Blue/Black
20. Fuel pump L/R Blue/Red
21. Yamaha diagnostic tool coupler L/W Blue/White
22. Coolant temperature sensor L/Y Blue/Yellow
23. Throttle body sensor assembly O/B Orange/Black
24. Intake air pressure sensor P/W Pink/White
25. Intake air temperature sensor R/B Red/Black
26. Throttle position sensor R/L Red/Blue
27. ISC (Idle Speed Control) unit R/W Red/White
W/L White/Blue
28. Fuel injector
W/R White/Red
29. ECU (Engine Control Unit)
Y/B Yellow/Black
30. Ignition coil
Y/L Yellow/Blue
31. Spark plug
32. O2 sensor
33. VVA (variable valve actuator)
solenoid
36. Joint connector
37. ABS test coupler
38. ABS ECU
42. Horn
43. Handlebar switch (left)
44. Dimmer switch
45. Horn switch
46. Turn signal switch
47. Tail/brake light assembly
48. Brake light
49. Taillight
50. Rear turn signal light (left)
51. Rear turn signal light (right)
52. Engine ground
53. Frame ground
54. Front turn signal light (right)
55. Front turn signal light (left)
56. Headlight unit
GPD125-A/GPD150-A 2017 GPD125-A/GPD150-A 2017 GPD125-A/GPD150-A 2017 GPD125-A/GPD150-A 2017 GPD125-A/GPD150-A 2017
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
B B
A B

B/L W/L 1 B/Y L/B Y/L B/W P/W Br/W Gy/R R/B B/L W/R B O
W/R
W/L B/L
W/R W/R
(B)
B/W,B R
W W W W
R
Y L/W
B R/L
30
W W
2 9 R
13 W/R O O
W W R Y B/L
W W R R R Y R/W
R
R/B 31
L/W
B
B/W 12 15 L/W G/R B/L 22 G/R G/R
B
R (B) B/L B/L
16
10 B B
B
L/W L/W G R/L
23 24 P/W P/W
32
B A
ON
OFF
L/W B B
B/L Y L P/W Br/W
25 Br/W Br/W Gy/R Gy/R B
(B)
B Gy/R
B B/L B/L (B)

L/W 19 20 26 Y Y
R/B 3 L/W
(B)
L L
R B
R/B 4 Br
L/Y
B L/B
P P G G
R R
L/W 17 B G L/B R/L P G/Y Sb Gy
27
G/Y G/Y
29 33
R/L 5 14
Gy
Sb Sb
Gy
Ch Ch
G Ch
R/B 11 L/Y (Gy) (B) (B)

L/Y
Br/W 6 R/L R
B L/Y
L/Y (Gy)
Br B O/B R/L
7 Br B (B) 28
L/Y B B R/L O/B O/B
Br Br Br R/L
8 L/B B B 18 L/B
Br Br R/W
Br/W (L) (L)
G R/L B R/B
B 21 Y/L
R/B
Y/L Y/L
B
B L/R
B B
B B Y/B
B
B B W
B
B/Y
Br B/W B/W
Br
Br B
Br Br Br
B/W
L
Br Br B/W
Br Br
Br Br
42 41 Br/W
Br/W B Br
40 39
Br/W
68 B Br/W
P
43 L/B P Br/W
44 45 46 B Dg
Dg B G/Y G/Y
Y
Br/W Ch Ch Br/W
L/B P P L/B
Y
B Ch Dg Y
Y
Y
Dg
Y
Y Y Dg Dg R/L Y Br/W L/R L/B B/W B
Ch Dg Y/B Y/B B W/L Dg
Ch W
Ch Ch
L/R
59 R/B G Br (Gy)
Dg Ch Y
56 Br Y G Ch
Ch Dg
47 Y L Ch Dg
R/L
57 48 49 50 51
B
55 B
54 R
Br/W
60 58 Ch Dg
(Br) (G) Y B Ch Dg
G G B
61 62 63 64 65 66 67 Br G Y B L
L L W
34 W B G L
B B B B
B Y/B
Ch Dg B B Dg Ch 38 Br Br B
Br
B Y/B
Y G
(Br) (G)
B Y L B Y Y W
35 W B Br Y
Y/B (B)
B B/W
Y/B B
B B W/L Y/B
B B
B B
B/W B/W
B
B B
W/L 36 R/B
Y L/R L/B
R/B B
B B 37
B B/W L/B L/B B
B B/W L/R L/R
B/Y B/W
53
52
GPD125-A/GPD150-A 2017 GPD125-A/GPD150-A 2017 GPD125-A/GPD150-A 2017 GPD125-A/GPD150-A 2017 GPD125-A/GPD150-A 2017
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN SCHEMA ELETTRICO DIAGRAMA ELÉCTRICO
A B
1
(B)
30
2 9 13
31
12 15 22
(B)
16
10 23 24 32
A
ON
OFF
25 (B) (B)
19 20 26
3 (B)
4
17 27 29 33
5 14
11 (Gy) (B) (B)
6 (Gy)
7 (B) 28
8 18
(L) (L)
21
42 41
40 39
68
43
44 45 46
(B)
59 (Gy) 56 47
57 48 49 50 51
55 54
60 58
(Br) (G)
61 62 63 64 65 66 67 34
38
(Br) (G) 35
(B)
36
37
53
52

Yamaha Gpd-A 125 150 Nmax (2017)

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Yamaha Gpd-A 125 150 Nmax (2017)

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2017

IMPORTANT MANUAL INFORMATION

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

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

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

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

IMPORTANT INFORMATION ......................................................................... 1-6

BASIC SERVICE INFORMATION...................................................................1-8

SPECIAL TOOLS .......................................................................................... 1-13

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

Multi-function meter unit

7 6 5 [To set the clock]

then go off for approximately 3 seconds. If this • a V-belt replacement tripmeter

ODO → TRIP 1 → TRIP 2 → OIL TRIP → V-

If the fuel level warning indicator “ ” and last

TIP Average fuel consumption mode

V-belt replacement tripmeter mode

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 Turn the main switch to “OFF” before dis-

NOTICE Checking the electrical system

Digital circuit tester (CD732)

Digital circuit tester (CD732) Coolant temperature sensor re-

Yamaha diagnostic tool (A/I) 3-4, 3-7, 3-8,

Tappet adjusting tool 3-7

T-handle 4-78, 4-79

Fork seal driver weight 4-79, 4-80

Fork seal driver attachment (ø30) 4-79, 4-80

Compression gauge 90890-03081 5-1

Camshaft wrench 5-13, 5-17

Slide hammer bolt (M8) 5-19

Valve spring compressor 5-23, 5-27

Valve spring compressor attachment 5-23, 5-27

Valve guide remover (ø5) 5-24

Valve guide installer (ø5) 5-24

Valve guide reamer (ø5) 5-24

Rotor holding tool 5-38, 5-43, 5-49,

Rotor holding tool 5-38, 5-38, 5-42,

Socket wrench (39 mm) 5-38, 5-42

Sheave spring compressor 5-38, 5-41

Oil seal guide (37 mm) 5-41

Crankcase separating tool 5-62

Crankshaft installer pot 5-63

Adapter (M12) 5-63

Spacer (crankshaft installer) 5-63

Radiator cap tester 6-3, 6-3

Radiator cap tester adapter 31mm 6-3, 6-3

Mechanical seal installer 6-9

Middle driven shaft bearing driver 6-9