Yamaha N-Max 125 2021 - Service Manual-1

2021
SERVICE MANUAL
NMAX
GPD125-A
BAL-F8197-E0
EAS20003
IMPORTANT
This manual was produced by the PT Yamaha Indonesia Motor Manufacturing. primarily for use by Ya-
maha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechan-
ic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on
Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these
types of vehicles. Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic
instructions that must be observed during servicing. Repair and maintenance work attempted by any-
one without this knowledge is likely to render the vehicle unsafe and unfit for use.
PT Yamaha Indonesia Motor Manufacturing. is continually striving to improve all of its models. Modifi-
cations and significant changes in specifications or procedures will be forwarded to all authorized Ya-
maha dealers and will appear in future editions of this manual where applicable.
TIP
• * If the contents of the manual are revised, the last digit of the manual number will be increased by
one.
• Designs and specifications are subject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION

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

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

damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
GPD125-A
SERVICE MANUAL
©2021 by PT Yamaha Indonesia Motor
Manufacturing
First edition, January 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
PT Yamaha Indonesia Motor Manufacturing
is expressly prohibited.
EAS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-
planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
CYLINDER AND PISTON CYLINDER AND PISTON
EAS20046 EAS30289
CYLINDER AND PISTON REMOVING THE PISTON

1. Remove:
Removing the cylinder and piston • Piston pin clips “1”
• Piston pin “2”
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP EAS30291
• Before removing the piston pin clips, cover the CHECKING THE CYLINDER AND PISTON
crankcase opening with a clean rag to prevent 1. Check:
them from falling into the crankcase. • Piston wall
• Before removing the piston pin, deburr the pis- • Cylinder wall
ton pin clip groove and the piston pin bore ar- Vertical scratches → Rebore or replace the
ea. If both areas are deburred and the piston cylinder, and replace the piston and piston
pin is still difficult to remove, remove it with the rings as a set.
piston pin puller set “4”. 2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
Piston pin puller set bore gauge.
90890-01304
TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Bore
52.000–52.010 mm (2.0472–
2.0476 in)
Wear limit
52.060 mm (2.0496 in)
“C” = maximum of D1 - D2
Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-10.
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2 2. Remove:
• Top ring
6 Piston pin 1 b. If out of specification, rebore or replace the
• 2nd ring
7 Piston 1
• Oil ring cylinder, and replace the piston and piston
8 Top ring 1 rings as a set.
TIP
9 2nd ring 1 c. Measure piston skirt diameter P with the mi-
When removing a piston ring, open the end gap crometer.
10 Oil ring 1 with your fingers and lift the other side of the ring
11 Coolant drain bolt (cylinder side) 1 over the piston crown.
5-30 5-31
EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

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

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

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

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

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
MODEL LABEL.......................................................................................... 1-1
1
FEATURES...................................................................................................... 1-2
MULTI-FUNCTION METER UNIT ............................................................. 1-2
SPECIAL TOOLS ............................................................................................ 1-7

IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER

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

The engine serial number “1” is stamped onto
the crankcase.
1
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
• a smartphone battery level meter
FEATURES • a coolant temperature meter
EAS30982
• a multi-function display
MULTI-FUNCTION METER UNIT TIP
Be sure to turn the main switch on before using
Multi-function meter unit the “MENU” switch.
1 2 3 4 5 6 7
App Connect icon
This icon comes on when CCU and smartphone
is connected via MyRide App.
TIP
Even if the smartphone is not connected, when
the vehicle is turned on, this icon should come
8 on for a few seconds. Otherwise have a Yamaha
dealer check the CCU and the electrical circuit.
1. Fuel meter
2. App connect icon
3. VVA (variable valve actuation) indicator Switching the display units
4. Clock The display units can be switched between kilo-
5. Speedometer meters and miles.
6. Smartphone battery level meter
7. Coolant temperature meter To switch the display units
8. Multi-function display 1. Turn the vehicle off.
EWA12423
2. While pushing the “MENU” switch, turn the
WARNING vehicle on.
3. Continue to push the “MENU” switch until the
Be sure to stop the vehicle before making
display unit setting screen comes on (approx-
any setting changes to the multi-function
imately 5 seconds).
meter unit. Changing settings while riding
4. Push the “MENU” switch once to switch the
can distract the operator and increase the
display units.
risk of an accident.
5. Push the “MENU” switch for 1 second to con-
The “MENU” switch is located on the left side of firm the setting.
handlebar. This switch allows you to control or
change the settings of multi-function meter unit.
1. “MENU” switch
The multi-function meter unit is equipped with
the following:
• a speedometer
• a VVA indicator
• a clock
• a fuel meter
• an App connect icon
1-2
FEATURES
Fuel meter TIP

When CCU and smartphone are connected after
1 2 vehicle power on, the clock is automatically ad-
justed.
Coolant temperature meter
1. Fuel meter
2. Fuel level warning indicator “ ”
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as
the fuel level decreases. When approximately 1. Coolant temperature meter
1.7 L (0.45 US gal, 0.37 Imp.gal) of fuel remains,
the last segment starts flashing. Refuel as soon This meter shows the temperature of the cool-
as possible. ant, and thereby the condition of the engine. The
TIP segments come on from “C” (cold) to “H” (hot) as
the engine temperature increases. If the hot seg-
If a problem is detected in the electrical circuit,
ment flashes, stop the engine as soon as possi-
the fuel level segments will flash repeatedly. If
ble, and let the engine cool.
this occurs, have a Yamaha dealer check the ve-
hicle. TIP
If a problem is detected in the electrical circuit, all
segments will flash repeatedly. Have a Yamaha
Clock dealer check the vehicle.
1
VVA indicator
1
1. Clock
The clock uses a 12-hour time system.
1. VVA (variable valve actuation) indicator
To set the clock
1. Push the “MENU” switch until the hour digits This model is equipped with variable valve actu-
start flashing. ation (VVA) for good fuel economy and acceler-
2. Use the “MENU” switch to set the hours. ation in both the low-speed and high-speed
3. Push the “MENU” switch until the minute dig- ranges. The VVA indicator comes on when the
its start flashing. variable valve actuation system has switched to
4. Use the “MENU” switch to set the minutes. the high-speed range.
5. Push the “MENU” switch until the minute dig-
its stop flashing. The setting is confirmed. To turn the VVA indicator on or off
1. Turn the vehicle off.
2. While pushing the “MENU” switch, turn the
vehicle on.
1-3
FEATURES
3. Continue pushing the “MENU” switch. The TIP

display unit setting screen will come on (after • The fuel reserve tripmeter appears only when
5 seconds), and after that (an additional 10 you are low on fuel.
seconds) all segments other than the VVA in- • The oil change tripmeter and V-belt replace-
dicator will start flashing. Now release the ment tripmeter are not displayed while the ve-
“MENU” switch. hicle is moving.
4. Push the “MENU” switch once to change the • There is an average fuel consumption display
on or off setting. for each tripmeter (TRIP 1 and TRIP 2). When
5. Push the “MENU” switch for 1 second to con- a tripmeter is reset, the average fuel consump-
firm the setting. tion display for that tripmeter will also be reset.
TIP
Turning the VVA indicator off does not turn off
Odometer
the variable valve actuation system.
Multi-function display
1
1. Odometer
1 The odometer shows the total distance traveled

by the vehicle.
1. Multi-function display
TIP
The multi-function display is equipped with the The odometer will lock at 999999 and cannot be
following: reset.
• an odometer (ODO)
• two tripmeters (TRIP 1 and TRIP 2)
• a fuel reserve tripmeter (TRIP F) Tripmeters
• an oil change tripmeter (OIL TRIP)
• an oil change indicator
• a V-belt replacement tripmeter (V-BELT TRIP)
• a V-belt replacement indicator
• an instantaneous fuel consumption display (F/
ECO)
• an average fuel consumption display (AVE F/
ECO)
• a battery voltage display (BATT) 1
• a traction control system display (TCS)
Push the “MENU” switch to change the display 1. Tripmeter
in the following order: The tripmeters show the distance traveled since
they were last reset.
ODO and F/ECO → TRIP 1 and AVE F/ECO → To reset a tripmeter, set the display to the trip-
TRIP 2 and AVE F/ECO → TRIP F → BATT → meter you want to reset, and then push the
TCS → OIL TRIP → V-BELT TRIP → ODO and “MENU” switch until it is reset.
F/ECO TIP
The tripmeters will reset and continue counting
after 9999.9 is reached.
1-4
FEATURES
Fuel reserve tripmeter TIP

When the engine oil has been changed, the oil
change tripmeter and the oil change indicator
must be reset. Otherwise, the oil change indica-
tor will not come on at the correct time.
V-belt replacement tripmeter
1
1
1. Fuel reserve tripmeter

If the last segment of the fuel meter starts flash-
ing, the display automatically changes to the fuel
reserve tripmeter “TRIP F” and starts counting
the distance traveled from that point.
To reset the fuel reserve tripmeter, push the 2
“MENU” switch until it is reset. 1. V-belt replacement indicator “V-BELT”
TIP 2. V-belt replacement tripmeter
If you do not reset the fuel reserve tripmeter
This tripmeter shows the distance traveled since
manually, it will reset automatically and disap-
the V-belt was last replaced. The V-belt replace-
pear from the display after refueling and travel-
ment indicator “V-BELT” will flash every 18000
ing 5 km (3 mi).
km (11200 mi) to indicate that the V-belt should
be replaced.
Oil change tripmeter To reset both the tripmeter and the indicator, se-
lect the V-belt replacement tripmeter, and then
1 push the “MENU” switch until “V-BELT” and the
tripmeter start flashing. While “V-BELT” and the
tripmeter are flashing, push the “MENU” switch
until the tripmeter is reset.
TIP
When the V-belt is replaced, the tripmeter and
indicator must be reset. Otherwise, the V-belt re-
2 placement indicator will not come on at the cor-
rect time.
1. Oil change indicator “OIL”
2. Oil change tripmeter
This tripmeter shows the distance traveled since
the last engine oil change. The oil change indi-
cator “OIL” will flash at the initial 1000 km (600
mi), the next 5000 km (3100 mi), and then every
6000 km (3700 mi) thereafter.
To reset the oil change tripmeter and oil change
indicator, select the oil change tripmeter, and
then push the “MENU” switch until “OIL” and the
tripmeter start flashing. While “OIL” and the trip-
meter are flashing, push the “MENU” switch until
the tripmeter is reset.
1-5
FEATURES
Instantaneous fuel consumption display TIP

• To reset the display, push the “MENU” switch
until it resets.
• After resetting, “_ _._” is shown until the vehicle
has traveled some distance.
Battery voltage display
1. Instantaneous fuel consumption display

This display shows fuel consumption under cur-
rent riding conditions. It can be set to either “km/
L” or “L/100 km”, or “MPG” when using miles.
• “km/L”: the distance that can be traveled on 1.0
1
L of fuel.
• “L/100 km”: the amount of fuel necessary to 1. Battery voltage meter
travel 100 km.
• “MPG”: the distance that can be traveled on This display shows the current charge state of
1.0 Imp.gal of fuel. the battery.
TIP • Over 12.8 V = Full charge.
• Under 12.7 V = Charging is required.
When traveling under 10 km/h (6 mi/h), “_ _._” is
displayed. TIP
If the battery voltage is less than 9.0 V, “_ _._” is
displayed.
Average fuel consumption display
1. Average fuel consumption display

This display shows the average fuel consump-
tion since it was last reset. The average fuel con-
sumption display can be set to either “km/L” or
“L/100 km”, or “MPG” when using miles.
• “km/L”: the average distance that can be trav-
eled on 1.0 L of fuel.
• “L/100 km”: the average amount of fuel neces-
sary to travel 100 km.
• “MPG”: the average distance that can be trav-
eled on 1.0 Imp.gal of fuel.
1-6
SPECIAL TOOLS
EAS20012
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
Reference
Tool name/Tool No. Illustration
pages
Yamaha diagnostic tool USB 3-4, 3-7, 4-59,
90890-03267 4-61, 7-15, 7-
16, 9-3, 9-19, 9-
20
Yamaha diagnostic tool (A/I) 3-4, 3-7, 4-59,

90890-03264 4-61, 7-15, 7-
16, 9-3, 9-19, 9-
20
Tappet adjusting tool 3-7

90890-01311
Steering nut wrench 3-15, 4-78

90890-01403
Thickness gauge 4-27

90890-03180
T-handle 4-72, 4-73

90890-01326
Fork seal driver weight 4-73, 4-74

90890-01367
Fork seal driver attachment (ø30) 4-73, 4-74

90890-01400
1-7
SPECIAL TOOLS
Reference
pages
Compression gauge 90890-03081 5-2
90890-03081
Compression gauge extension 122mm 5-2

90890-04136
Camshaft wrench 5-14, 5-18

90890-04162
Yamaha bond No. 1215 5-17, 5-55

90890-85505
Slide hammer bolt (M8) 5-20

90890-01085
Weight 5-20
90890-01084
Valve spring compressor 5-24, 5-28

90890-04019
Valve spring compressor attachment 5-24, 5-28

90890-04108
Valve guide remover (ø5) 5-25

90890-04097
1-8
SPECIAL TOOLS
Reference
pages
Valve guide installer (ø5) 5-25
90890-04098
Valve guide reamer (ø5) 5-25

90890-04099
Piston pin puller set 5-30

90890-01304
Rotor holding tool (including handle and 5-37, 5-42, 5-

3 pins) 44, 5-44
90890-04195
Rotor holding tool attachment 7 x 12 mm 5-37, 5-42

90890-04197
ø7 12
Rotor holding tool 5-37, 5-37, 5-

90890-04166 41, 5-41
Socket wrench (39 mm) 5-37, 5-41

90890-01493
Sheave spring compressor 5-38, 5-40

90890-04134
Sheave fixed block 5-38, 5-40

90890-04135
1-9
SPECIAL TOOLS
Reference
pages
Oil seal guide (37 mm) 5-40
90890-04177
ø37
Rotor holding tool attachment 7 x 5 mm 5-44, 5-44
90890-04198
ø7 5
Flywheel puller 5-44

90890-01189
Crankcase separating tool 5-53

90890-01135
Crankshaft installer pot 5-54

90890-01274
Crankshaft installer bolt 5-54

90890-01275
Adapter (M12) 5-54

90890-01278
Spacer (crankshaft installer) 5-54

90890-04081
Radiator cap tester 6-4, 6-4

90890-01325
1-10
SPECIAL TOOLS
Reference
pages
Radiator cap tester adapter 31mm 6-4, 6-4
90890-05375
Mechanical seal installer 6-10

90890-04145 ø30
ø10
Middle driven shaft bearing driver 6-10

90890-04058
Pressure gauge 7-3

90890-03153
Fuel pressure adapter 6.3mm 7-3

90890-03227
Digital circuit tester (CD732) 8-36, 8-37, 8-

90890-03243 38, 8-39, 8-39,
8-40, 8-40, 8-
41, 8-41, 8-42,
8-42, 8-43
Ignition checker 8-39

90890-06754
1-11
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-6
ELECTRICAL SPECIFICATIONS ...................................................................2-8

2
TIGHTENING TORQUES .............................................................................. 2-10
ENGINE TIGHTENING TORQUES......................................................... 2-10
CHASSIS TIGHTENING TORQUES.......................................................2-11
CABLE ROUTING ......................................................................................... 2-13

GENERAL SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model BAL1
BAL3
Dimensions
Overall length 1935 mm (76.2 in)
Overall width 740 mm (29.1 in)
Overall height 1160 mm (45.7 in)
Wheelbase 1340 mm (52.8 in)
Ground clearance 125 mm (4.92 in)
Minimum turning radius 2.0 m (6.56 ft)
Weight
Curb weight 131 kg (289 lb)
Loading
Maximum load 167 kg (368 lb)
Riding capacity 2 person
2-1
ENGINE SPECIFICATIONS
EAS20014
Engine
Combustion cycle 4-stroke
Cooling system Liquid cooled
Valve train SOHC
Displacement 125 cm³
Number of cylinders Single cylinder
Bore × stroke 52.0 × 58.7 mm (2.05 × 2.31 in)
Number of cylinders Single cylinder
Compression ratio 11.2 : 1
Compression pressure 1583–2038 kPa/1300 r/min (15.8–20.4 kgf/cm²/
1300 r/min, 225.2–289.9 psi/1300 r/min)
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 7.1 L (1.9 US gal, 1.6 Imp.gal)
Fuel reserve amount 1.7 L (0.45 US gal, 0.37 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
SAE viscosity grades 10W-40
Recommended engine oil grade API service SG type or higher, JASO standard
MA or MB
Engine oil quantity
Quantity (disassembled) 1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil change 0.90 L (0.95 US qt, 0.79 Imp.qt)
Final transmission oil

Type Motor oil SAE 10W-40 type SG or higher
Quantity (disassembled) 0.11 L (0.12 US qt, 0.10 Imp.qt)
Quantity 0.10 L (0.11 US qt, 0.09 Imp.qt)
Oil filter
Oil filter type Centrifugal
Cooling system
Coolant quantity
Radiator (including all routes) 0.46 L (0.49 US qt, 0.40 Imp.qt)
Coolant reservoir (up to the maximum level
mark) 0.13 L (0.14 US qt, 0.11 Imp.qt)
Radiator cap valve opening pressure 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9
psi)
Cooling system leak test pressure 137.4 kPa (1.37 kgf/cm², 19.9 psi)
Thermostat
Valve opening temperature 74.0–78.0 °C (165.20–172.40 °F)
Valve full open temperature 90.0 °C (194.00 °F)
2-2
Spark plug(s)
Manufacturer/model NGK/CPR8EA-9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Camshaft lobe dimensions
Lobe height limit (Intake) 32.111 mm (1.2642 in)
Lobe height limit (Intake high speed) 32.487 mm (1.2790 in)
Lobe height limit (Exhaust) 29.124 mm (1.1466 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter limit 10.015 mm (0.3943 in)
Rocker arm shaft outside diameter limit 9.935 mm (0.3911 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm (0.0039–0.0055 in)
Exhaust 0.21–0.25 mm (0.0083–0.0098 in)
Valve dimensions
Valve seat contact width limit (intake) 1.3 mm (0.05 in)
Valve seat contact width limit (exhaust) 1.7 mm (0.07 in)
Valve stem diameter limit (intake) 4.945 mm (0.1947 in)
Valve stem diameter limit (exhaust) 4.930 mm (0.1941 in)
Valve guide inside diameter (intake) 5.000–5.012 mm (0.1969–0.1973 in)
Valve guide inside diameter (exhaust) 5.000–5.012 mm (0.1969–0.1973 in)
Valve-stem-to-valve-guide clearance limit
(intake) 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance limit
(exhaust) 0.100 mm (0.0039 in)
Valve stem runout 0.020 mm (0.0008 in)
Valve spring
Free length limit (intake) 32.10 mm (1.26 in)
Free length limit (exhaust) 32.10 mm (1.26 in)
Cylinder
Bore 52.000–52.010 mm (2.0472–2.0476 in)
Wear limit 52.060 mm (2.0496 in)
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)
Measuring point (from piston skirt bottom) 6.0 mm (0.24 in)
Piston pin bore inside diameter limit 14.043 mm (0.5529 in)
Piston pin outside diameter limit 13.975 mm (0.5502 in)
2-3
Piston ring
Top ring
End gap limit 0.50 mm (0.0197 in)
Side clearance limit 0.115 mm (0.0045 in)
2nd ring
End gap limit 0.85 mm (0.0335 in)
Side clearance limit 0.115 mm (0.0045 in)
Crankshaft
Crank assembly width 51.45–51.50 mm (2.026–2.028 in)
Runout limit 0.050 mm (0.0020 in)
Clutch
Clutch type Dry, centrifugal, shoe
Automatic centrifugal clutch

Clutch shoe thickness limit 2.1 mm (0.08 in)
Clutch housing inside diameter limit 125.5 mm (4.94 in)
Compression spring free length limit 104.7 mm (4.12 in)
Weight outside diameter limit 19.5 mm (0.77 in)
Clutch-in revolution 2600–3000 r/min
Clutch-stall revolution 4700–5300 r/min
V-belt
V-belt width limit 21.6 mm (0.85 in)
Drivetrain
Transmission type V-belt automatic
Primary reduction ratio 1.000
Secondary reduction ratio 10.208 (56/16 x 35/12)
Transmission ratio 2.386–0.748 : 1
Air filter
Air filter element Oil-coated paper element
V-belt filter element Wet element
Fuel injector
Resistance 12.2 Ω
Fuel injection sensor

Intake air temperature sensor resistance 5700–6300 Ω at 0 °C (5700–6300 Ω at 32 °F)
Atmospheric pressure sensor output voltage 3.88–4.12 V at 101.3 kPa (3.88–4.12 V at 1.01
kgf/cm², 3.88–4.12 V at 14.7 psi)
Coolant temperature sensor resistance 2513–2777 Ω at 20 °C (2513–2777 Ω at 68 °F)
Coolant temperature sensor resistance 210–221 Ω at 100 °C (210–221 Ω at 212 °F)
2-4
Idling condition
Engine idling speed 1500–1700 r/min
O2 feedback control Active
Coolant temperature 83 °C (181 °F)
CO% 0.0–1.0 %
Fuel line pressure (at idle) 220–300 kPa (2.2–3.0 kgf/cm², 31.9–43.5 psi)
Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
2-5
CHASSIS SPECIFICATIONS
EAS20015
Chassis
Caster angle 26.5 °
Trail 100 mm (3.9 in)
Front wheel
Wheel type Cast wheel
Rim size J13M/C x MT3.00
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Rear wheel
Wheel type Cast wheel
Rim size J13M/C x MT3.50
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 1.0 mm (0.04 in)
Wheel axle bending limit 0.25 mm (0.01 in)
Front tire
Type Tubeless
Size 110/70-13M/C 48P
Manufacturer/model DUNLOP/SCOOT SMART L
Rear tire
Type Tubeless
Size 130/70-13M/C 63P
Manufacturer/model DUNLOP/SCOOT SMART L
Tire air pressure (measured on cold tires)

1 person
Front 150 kPa (1.50 kgf/cm², 22 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
2 persons
Front 150 kPa (1.50 kgf/cm², 22 psi)
Rear 250 kPa (2.50 kgf/cm², 36 psi)
Front brake
Type Hydraulic single disc brake
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on
wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 0.8 mm (0.03 in)
Master cylinder inside diameter 11.00 mm (0.43 in)
Caliper cylinder inside diameter (Right) 33.34 mm (1.31 in)
Specified brake fluid DOT 4
2-6
Rear brake
Type Hydraulic single disc brake
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on
wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness limit 0.8 mm (0.03 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid DOT 4
Front suspension
Type Telescopic fork
Spring Coil spring
Shock absorber Hydraulic damper
Fork spring free length limit 235.6 mm (9.28 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Yamaha Suspension Oil G10
Quantity (left) 89.0 cm³ (3.01 US oz, 3.14 Imp.oz)
Quantity (right) 89.0 cm³ (3.01 US oz, 3.14 Imp.oz)
Level (left) 77 mm (3.1 in)
Level (right) 77 mm (3.1 in)
Rear suspension
Type Unit swing
Spring Coil spring
Shock absorber Hydraulic damper
Spring preload
Unit for adjustment Cam position
Adjustment value (STD) 1
Adjustment value (Hard) 2
2-7
ELECTRICAL SPECIFICATIONS
EAS20016
Voltage
System voltage 12 V
Engine control unit

Model TBDY49
Ignition system
Ignition timing (B.T.D.C.) 3.0–7.0 °/1600 r/min
Ignition coil
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ
Spark plug cap

Resistance 3.75–6.25 kΩ
Charging system
Charging system Starter generator
Standard output 14.0 V, 50.4 A at 5000 r/min
Stator coil resistance 0.048–0.072 Ω
Rectifier/regulator
Regulated voltage (DC) 14.3–14.7 V
Battery
Model YTZ7V
Voltage, capacity 12 V, 6.0 Ah (10 HR)
Bulb wattage
Headlight LED
Brake/tail light LED
Front turn signal light 10.0 W
Rear turn signal light 10.0 W
Auxiliary light LED
License plate light 5.0 W
Meter lighting LED
Indicator light
Turn signal indicator light LED
High beam indicator light LED
Engine trouble warning light LED
Stop and Start System indicator light LED
ABS warning light LED
Smart key system indicator light LED
Traction control system indicator light LED
Fuel sender unit

Sender unit resistance (full) 10.0–14.0 Ω
Sender unit resistance (empty) 267.0–273.0 Ω
2-8
Fuse(s)
Main fuse 30.0 A
Headlight fuse 7.5 A
Signaling system fuse 7.5 A
Ignition fuse 7.5 A
Fuel injection system fuse 7.5 A
Terminal fuse 1 5.0 A
Backup fuse 7.5 A
ABS motor fuse 30.0 A
ABS solenoid fuse 15.0 A
ABS control unit fuse 2.0 A
Smart key system fuse 2.0 A
2-9
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30016
ENGINE TIGHTENING TORQUES

Threa
Item Q’ty Tightening torque Remarks
d size
Muffler nut M8 2 20 N·m (2.0 kgf·m, 15 lb·ft)
Muffler bolt M10 3 53 N·m (5.3 kgf·m, 39 lb·ft)
Muffler protector bolt M6 2 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
Cylinder head bolt M6 2 10 N·m (1.0 kgf·m, 7.4 lb·ft)

Cylinder head nut M8 4 24 N·m (2.4 kgf·m, 18 lb·ft) M
VVA (variable valve actuator) so-

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

Transmission case cover bolt M8 6 20 N·m (2.0 kgf·m, 15 lb·ft)
Final transmission oil drain bolt M8 1 20 N·m (2.0 kgf·m, 15 lb·ft)
V-belt case bolt M6 10 10 N·m (1.0 kgf·m, 7.4 lb·ft)
Engine oil drain bolt M12 1 20 N·m (2.0 kgf·m, 15 lb·ft)
2-10
TIGHTENING TORQUES
Threa
d size
V-belt case air filter element cov-
M6 6 7 N·m (0.7 kgf·m, 5.2 lb·ft)
er bolt
Primary fixed sheave nut M12 1 76 N·m (7.6 kgf·m, 56 lb·ft)
Clutch housing nut M12 1 45 N·m (4.5 kgf·m, 33 lb·ft)
Secondary sheave nut M28 1 55 N·m (5.5 kgf·m, 41 lb·ft)
Cylinder head tightening sequence:
3 4
1 2
6 5
EAS30017
CHASSIS TIGHTENING TORQUES

Threa
d size
Engine bracket nut M10 1 52 N·m (5.2 kgf·m, 38 lb·ft)
Engine mounting nut (front side) M10 2 50 N·m (5.0 kgf·m, 37 lb·ft)
Engine mounting nut (rear side) M10 2 28 N·m (2.8 kgf·m, 21 lb·ft)
Meter assembly panel bolt M6 2 3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
Grab bar bolt M8 4 17 N·m (1.7 kgf·m, 13 lb·ft)
Seat nut M6 3 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Storage box bolt M6 4 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Front brake master cylinder hold-
M6 2 16 N·m (1.6 kgf·m, 12 lb·ft)
er bolt
Front brake hose union bolt (mas-
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
ter cylinder side)
Rear brake hose union bolt (mas-
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
ter cylinder side)
Throttle cable holder bolt (handle-
M5 1 2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
bar switch side)
Rear brake master cylinder hold-
M6 2 16 N·m (1.6 kgf·m, 12 lb·ft)
er bolt
Brake light switch screw M4 2 1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
Handlebar bracket nut M10 1 53 N·m (5.3 kgf·m, 39 lb·ft)
Lower ring nut M25 1 See TIP.
Upper ring nut M25 1 See TIP.
Lower bracket pinch bolt M10 4 53 N·m (5.3 kgf·m, 39 lb·ft)
Front fork damper rod bolt M10 2 23 N·m (2.3 kgf·m, 17 lb·ft) LT
2-11
TIGHTENING TORQUES
Threa
d size
Ignition coil bolt M6 2 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front wheel sensor bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)
Front brake caliper bolt M10 2 35 N·m (3.5 kgf·m, 26 lb·ft)
Front brake hose union bolt
M10 1 29 N·m (2.9 kgf·m, 21 lb·ft)
(brake caliper side)
Brake caliper bleed screw M8 2 6 N·m (0.6 kgf·m, 4.4 lb·ft)
Front wheel axle nut M10 1 26 N·m (2.6 kgf·m, 19 lb·ft)
Front brake disc bolt M8 3 23 N·m (2.3 kgf·m, 17 lb·ft) LT
Front wheel sensor rotor bolt M5 3 8 N·m (0.8 kgf·m, 5.9 lb·ft) LT
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 axle nut M16 1 125 N·m (12.5 kgf·m, 92 lb·ft)
Rear shock absorber assembly
M10 2 21 N·m (2.1 kgf·m, 15 lb·ft)
nut
M8 2 27 N·m (2.7 kgf·m, 20 lb·ft)
bolt
Swingarm mounting bolt M10 2 57 N·m (5.7 kgf·m, 42 lb·ft)
Fuel tank bolt M6 4 9 N·m (0.9 kgf·m, 6.6 lb·ft)
Coolant reservoir bolt M6 1 11 N·m (1.1 kgf·m, 8.1 lb·ft)
Sidestand switch bolt M5 2 7 N·m (0.7 kgf·m, 5.2 lb·ft) LT
Centerstand spring hook bolt M6 1 7 N·m (0.7 kgf·m, 5.2 lb·ft)

Sidestand nut M8 1 32 N·m (3.2 kgf·m, 24 lb·ft)
TIP
Steering column ring nut
1. Tighten the lower ring nut 38 N·m (3.8 kgf·m, 28 lb·ft) with a torque wrench and the steering nut
wrench, and then loosen the nut 1/4 turn.
2. Tighten the lower ring nut 17 N·m (1.7 kgf·m, 13 lb·ft) with a torque wrench and the steering nut
wrench.
3. Install the rubber washer and the center ring nut.
4. Finger tighten the center ring nut, align the slots of both ring nuts, and then install the lock washer.
5. Hold the lower and center ring nuts, and then tighten the upper ring nut 75 N·m (7.5 kgf·m, 55 lb·ft)
with a torque wrench and the steering nut wrench.
2-12
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
A A
1 2
B 7
5
1 2
1 2
6 5 4 3
2-13
CABLE ROUTING
1. Front brake hose

2. Rear brake hose
3. Rear brake light switch lead
4. Throttle cable (decelerator cable)
5. Throttle cable (accelerator cable)
6. Front brake light switch lead
7. Accessories coupler
A. 15° – 25°
B. Insert the projection on the wire harness
holder into the hole in the lower handlebar
cover.
C. Route the throttle cables through the hole
in the lower handlebar cover.
2-14
CABLE ROUTING
Handlebar (side view)
5
2
1
3
4
2
4 B
2-15
CABLE ROUTING
1. Rear brake hose

4. Wire harness
5. Front brake hose
A. Route the throttle cable (accelerator cable)

to the outside of the throttle cable (deceler-
ator cable).
holder into the hole in the bracket.
2-16
CABLE ROUTING
Front frame (front and left side view)
C 11 12 11 12
9 5
10
3
9 4 13 D
6
14
7
3 4 10
2 3
A 4
1 6 26
15
25
E
F
16
10
9 B
17
5
8
H G
6
6 18
19
7
B 7
20
24 22
23
21
18
20 18 20
26 25
13
8
3
28
6 3
13
7
I
27
26 25
29
2-17
CABLE ROUTING
1. Front side cowling (right) I. Route the headlight lead through the head-
2. Meter assembly lead light lead guide (two places).
3. Headlight lead J. Route the front turn signal light lead (front
left turn signal light) through the guide of
4. Buzzer lead front side panel (left).
5. Fuse box
6. Front wheel sensor lead
7. Front brake hose (hydraulic unit to front
brake caliper)
8. Hydraulic unit assembly
9. SGCU (Starter Generator Control Unit)
10. Front turn signal light lead (front right turn
signal light)
11. Starter charger relay
12. Main relay
13. Front turn signal light lead (front left turn
signal light)
14. Meter assembly
15. Auxiliary DC jack lead
16. Auxiliary DC jack
17. Main switch
18. Seat lock cable
19. Fuel tank cap lid lock cable
20. Frame ground lead
21. Main switch steering lock assy
22. Throttle cable (accelerator)
23. Throttle cable (decelerator)
24. Frame
25. Rear brake hose (rear brake master cylin-
der to hydraulic unit)
26. Front brake hose (front brake master cylin-
27. Wire harness
28. Headlight unit
29. Front turn signal light
A. Insert the projection of clamp wire harness

into the hole of front side cowling (right).
B. Insert the projection of clamp wire harness
into the hole of stay.
C. Make sure the white connector of wire har-
ness shall be connected to relay with white
paint.
D. Make sure the protrusion of wire harness
shall be assembled to the stay.
E. Make sure the auxiliary DC jack coupler
shall be assembled to protrusion of the
front side cowling (left).
F. Insert the projection of clamp wire harness
into the hole of frame.
G. Make sure the stopper of seat lock cable
and fuel tank cap lid lock cable shall be
assembled to the main switch.
H. Insert the projection of clamp front wheel
sensor into the hole of stay.
2-18
CABLE ROUTING
Front fork (rear and right side view)
2 4
B C
2 4
B C
G
4
2
H
A
5
3
4
D
2
6 E
1
2-19
CABLE ROUTING
1. Front wheel sensor

2. Front wheel sensor lead
3. Front brake caliper
4. Front brake hose
5. Horn
6. Front brake hose holder
A. Route the front brake hose through the

guide.
B. Backward
C. Frontward
D. Install the horn fit to the frame.
E. Install the guide fit to the lower bracket.
F. The front brake hose and front wheel sen-
sor lead should be passed through the
vehicle rear side of the guide.
G. Inward
H. Outward
2-20
CABLE ROUTING
Frame (left side view)
F
G
1 8
E 2
1 2 3 4
9 9 10
9
A
J 3
B 1
D 4
2 9
5
13
12
12
I
D
6 11
1 6
2 C
7
7
12
6
7 1 2
1
6 6
2
12
2-21
CABLE ROUTING

3. Fuel tank cap lid lock cable
4. Seat lock cable
5. Fuel tank overflow tray
6. Sidestand switch lead
7. Fuel tank overflow hose
8. Main switch cover
9. Wire harness
11. Fuel hose
12. Frame
13. Horn
A. Insert the projection on the seat lock cable

clamp into the hole in the inner panel.
B. Clamp in the fuel tank cap lid lock cable
shall be assembled into the inner panel.
And the fuel tank cap lid lock cable is fixed
on the front side of the vehicle. Do not
cross the fuel tank cap lid lock cable and
seat lock cable.
C. Install the fuel tank overflow hose so that
this part of the fuel tank overflow hose
comes to the bottom than clamp.
D. Insert the projection on the wire harness
into the hole in the frame.
E. Install the throttle cable grommet into
guide of frame.
F. Pass the wire seat lock and fuel tank lid
lock cable in upper the main switch cover.
G. Push the coupler to forward of vehicle.
H. Insert the projection on the wire harness
clamp into the hole in the main switch
cover.
I. Install the fuel hose grommet into guide of
frame.
J. Install the horn leads in any direction.
2-22
CABLE ROUTING
Frame (left side view)
11 12
12
11
15 16
I
J 16
K
G
13
E
7 8 F O
9 14
M N M L
3
H
4
10
C
B
1 2
4 5 6
2-23
CABLE ROUTING
1. Seat lock cable

2. Smart key unit lead
3. Fuel hose
4. O2 sensor lead
7. Starter generator lead
8. Throttle body sensor assembly
9. Engine ground lead
10. Injector lead
11. Positive battery lead
12. Yamaha diagnostic tool coupler lead
13. Negative battery lead
14. Wire harness
15. Rear brake hose
16. Rear wheel sensor lead
17. Frame
A. Insert the projection on the seat lock cable

clamp into the hole in the storage box.
B. Insert the projection on the seat lock cable
clamp into the hole in the frame.
C. Pass the seat lock cable in groove of the
rear fender.
D. Insert the throttle cable into the clamp.
E. Insert the wire harness clamp into the
plate.
F. Insert the projection on the seat lock cable
clamp into the hole in the bracket.
G. Pass the wire harness inside of frame.
H. Insert the projection on the wire.
I. Insert the projection of clamp wire harness
into the hole of the battery stay.
J. Pass the wire harness in the inside of
frame.
K. Insert the projection of clamp wire harness
into the hole of the ignition coil stay.
L. Pass the coolant reservoir hose in upper
side of the holder.
M. Insert the projection of clamp wire harness
into the hole of the guide.
N. Pass the wire harness in the inside of pillar
guide.
O. Insert the projection of clamp wire harness
into the hole of the frame.
2-24
CABLE ROUTING
Frame (right side view)
5
1 2 3
11
B
10
9 11 10
13 12
7
14 A
10
10
2-25
CABLE ROUTING
1. CCU (Communication Control Unit)

2. Positive battery lead
3. Ignition coil
4. Joint
7. Wire harness
8. Footrest board
9. Coolant reservoir breather hose
10. Frame
11. Fuel pump lead
12. Starter generator lead
13. Wire harness (to battery)
14. Wire harness (to engine)
A. Insert the projection on the wire harness

into the hole in the frame.
B. White paint portion of the coolant reservoir
breather hose and clamp location should
be combined.
2-26
CABLE ROUTING
Frame (right side view)
4 4
B
1
1 2
6 C 5
2-27
CABLE ROUTING

2. Wire harness
3. Coolant temperature sensor lead
4. Frame
5. Rear fender
6. License light lead
A. Pass the wire harness in groove of the rear

fender.
C. Pass the license light lead before assem-
bled the rear fender.
2-28
CABLE ROUTING
Hydraulic unit (top and right side view)

1
3
4
5
1
7 4
2-29
CABLE ROUTING

2. Rear brake hose (hydraulic unit to rear
brake caliper)
3. Rear brake hose (rear brake master cylin-
4. Front brake hose (front brake master cylin-
5. Front brake hose (hydraulic unit to front
brake caliper)
6. Main switch lead
7. Hydraulic unit assembly lead
A. Insert the projection of claim wire harness

into the hole of stay.
2-30
CABLE ROUTING
Rear brake (right side view)
3
D
2
3 2 3
3 B
2
C 2
6 6 7
3 4 5
2
8 9
2 7
2 E
2-31
CABLE ROUTING
1. Rear brake caliper

2. Rear brake hose
4. Radiator
5. Coolant reservoir hose
6. Swingarm
7. Radiator fan cover
8. Rear brake hose bracket
9. Rear brake hose holder
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.
B. Upward
C. Downward
D. Position the clamp within the range shown
in the illustration.
E. The rear brake hose should be passed
through the guide.
2-32
CABLE ROUTING
Fuel tank (top and bottom view)
4
3 2 A
2-33
CABLE ROUTING
1. Rear brake hose

2. Coolant reservoir cap
6. Fuel hose
A. Install the coolant reservoir cap as shown

in the illustration.
2-34
CABLE ROUTING
Fuel tank (right side view)
F 5
4 4
H
E
8 10 5
7 G 3 I
1 2 3
A
5
D
8 6
1 4
C 7 B
3
12
K
6
7 11
2-35
CABLE ROUTING
1. Ignition coil
2. Ignition coil cord
3. Rear brake hose
6. Inner fender
8. Fuel hose
9. Frame
10. Engine
11. Fuel tank overflow hose
12. Coolant reservoir
A. Install the coolant reservoir breather hose

on the frontward of vehicle.
B. Install the fuel hose grommet into guide of
frame.
C. Install the coolant reservoir hose to the
back side guide wire of the frame.
D. Insert the projection on the ignition coil
E. Pass the coolant reservoir hose towards
the outside of the vehicle.
F. Face the white paint mark on the recovery
tank upward.
G. Install the knob of coolant reservoir cap as
shown in illustration.
H. Upward
I. Downward
J. Face the white paint mark on the hose
upward.
K. Install the coolant reservoir hose fit to the
coolant reservoir.
2-36
CABLE ROUTING
Radiator (top and right side view)
2 D
1
E
G F 7
E
3
A
D
4
6 5 A D F
C
M L
5 6 H F D
7 B M L
I A 3 C
F
D
A
I
E
2
J
4
K
A
2-37
CABLE ROUTING
1. Water pump
2. Water pump inlet hose
3. Thermostat assembly
4. Radiator outlet hose
5. Radiator
7. Radiator inlet hose
A. Install the hose completely onto the hose

fitting.
B. Face the white paint mark on the hose to
the left.
C. 45°
D. Upward
E. Downward
F. Frontward
G. Backward
H. To coolant reservoir
I. Face the yellow paint mark on the hose to
the right.
J. Align the yellow paint mark on the hose
with the center of the thermostat assembly.
K. Face the white paint mark on the hose
downward.
L. Outward
M. Inward
2-38
CABLE ROUTING
Air filter case (top and left side view)
A 3
3 2
2
B
A B C
2
C
1 F
A C
2-39
CABLE ROUTING
1. V-belt case breather hose

2. Air filter case
3. Cylinder head breather hose
A. Point the ends of the hose clamp outward.

B. Face the yellow paint mark on the hose
outward.
C. Install the hose completely onto the hose
fitting.
D. Face the white paint mark on the hose out-
ward.
E. 5–6 mm (0.20–0.24 in)
F. 1–5 mm (0.04–0.20 in)
2-40
CABLE ROUTING
2-41
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
REPLACING THE AIR FILTER ELEMENT AND
CLEANING THE CHECK HOSE .............................................................. 3-8
CHECKING THE BREATHER HOSES .....................................................3-9
CLEANING THE V-BELT CASE AIR FILTER ELEMENT AND
3
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................................................. 3-11
CHECKING THE FRONT BRAKE HOSES ............................................. 3-11
CHECKING THE REAR BRAKE HOSES................................................ 3-12
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-12
CHECKING THE WHEELS ..................................................................... 3-13
CHECKING THE TIRES..........................................................................3-13
CHECKING THE WHEEL BEARINGS ....................................................3-15
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-15
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................................................. 3-17
CHECKING THE FRONT FORK ............................................................. 3-17
CHECKING THE REAR SHOCK ABSORBER ASSEMBLIES................ 3-17
CHECKING THE ENGINE OIL LEVEL....................................................3-17
CHANGING THE ENGINE OIL ...............................................................3-18
CHECKING THE COOLANT LEVEL.......................................................3-19
CHECKING THE COOLING SYSTEM ....................................................3-19
CHANGING THE COOLANT................................................................... 3-20
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.
TIP
• The annual checks must be performed every year, except if a distance-based maintenance is
performed instead.
• From 30000 km (17500 mi), repeat the maintenance intervals starting from 6000 km (3500 mi).
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
EAS30614
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
NO. ITEM JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) 10500 mi) (14000 mi)
• Check fuel hoses for cracks or
1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition.
• Adjust gap and clean. √ √
2 Spark plug
• Replace. √ √
3 * Valve clearance • Check and adjust. √ √ √ √
4 * Fuel injection • Check engine idle speed. √ √ √ √ √ √
• Check for leakage.
5 * Exhaust system • Tighten if necessary. √ √ √ √ √
• Replace gasket if necessary.
Evaporative emis- • Check control system for
6 * sion control sys- damage. √ √
tem • Replace if necessary.
EAS30615
GENERAL MAINTENANCE AND LUBRICATION CHART

ODOMETER READING
NO. ITEM CHECK OR MAINTENANCE ANNUAL
JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
Diagnostic sys- • Perform dynamic inspection

1 * using Yamaha diagnostic tool. √ √ √ √ √ √
tem check • Check the error codes.
2 * Air filter element • Replace. Every 18000 km (10500 mi)
Air filter case
3 check hose • Clean. √ √ √ √ √
4 * V-belt case air fil- • Clean. √ √ √ √ √

ter element • Replace if necessary.
• Check voltage.
5 * Battery √ √ √ √ √ √
• Charge if necessary.
• Check operation, fluid level,
and for fluid leakage.
6 * Front brake √ √ √ √ √ √
• Replace brake pads if neces-
sary.
3-1
ODOMETER READING
CHECK OR MAINTENANCE ANNUAL
NO. ITEM
JOB 1000 km 6000 km 12000 km 18000 km 24000 km CHECK
(600 mi) (3500 mi) (7000 mi) (10500 mi) (14000 mi)
• Check operation, fluid level,
7 * Rear brake and for fluid leakage. √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check for cracks or damage. √ √ √ √ √
8 * Brake hose
• Replace. Every 4 years
9 * Brake fluid • Change. Every 2 years
10 * Wheels • Check runout and for damage. √ √ √ √

• Check tread depth and for
damage.
11 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Correct if necessary.
• Check bearing for looseness
12 * Wheel bearings √ √ √ √
or damage.
• Check bearing assemblies for
looseness. √ √ √ √
13 * Steering bearings
• Moderately repack with lithi- √
um-soap-based grease.
• Make sure that all nuts, bolts
14 * Chassis fasteners and screws are properly tight- √ √ √ √ √
ened.
Front and rear
15 brake lever pivot • Lubricate with silicone grease. √ √ √ √ √
shaft
• Check operation.
Sidestand, center-
16 stand • Lubricate with lithium-soap- √ √ √ √ √
based grease.
• Check operation and replace
17 * Sidestand switch √ √ √ √ √ √
if necessary.
• Check operation and for oil
18 * Front fork leakage. √ √ √ √
• Check operation and for oil
19 * Shock absorber leakage. √ √ √ √
assemblies
• Change (warm engine before-
draining). At the initial interval and when the oil change indicator flash-
20 Engine oil √
• Check oil level and vehicle for es or comes on.
oil leakage.
21 * Engine oil strainer • Clean. √
• Check vehicle for oil leakage. √ √ √ √ √
22 * Final transmis-
sion oil • Change. √ √ √
• Check coolant level and vehi-
√ √ √ √ √
23 * Cooling system cle for coolant leakage.
• Change. Every 3 years
24 * V-belt • Replace. When the V-belt replacement indicator flashes or comes on.
25 * Front and rear • Check operation. √ √ √ √ √ √

brake switches
Moving parts and
26 * • Lubricate. √ √ √ √ √
cables
• Check operation and free
play.
27 * Throttle grip • Adjust the throttle cable free √ √ √ √ √
housing and cable play if necessary.
• Lubricate the throttle grip
housing and cable.
Lights, signals • Check operation.
28 * and switches • Adjust headlight beam. √ √ √ √ √ √
3-2
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
5. Install:
CHECKING THE VEHICLE USING THE
• Battery cover
YAMAHA DIAGNOSTIC TOOL
Refer to “GENERAL CHASSIS (1)” on
Use the Yamaha diagnostic tool and check the
page 4-1.
vehicle according to the following procedure.
1. Remove: EAS30619
• Battery cover CHECKING THE FUEL LINE

Refer to “GENERAL CHASSIS (1)” on 1. Remove:
page 4-1. • Front side cover (left)
2. Disconnect the Yamaha diagnostic tool cou- Refer to “GENERAL CHASSIS (2)” on
pler from the CCU (Communication Control page 4-3.
Unit) “1”, and then connect the Yamaha diag- • Footrest board assembly (left)
nostic tool to the coupler. Refer to “GENERAL CHASSIS (5)” on
page 4-12.
Yamaha diagnostic tool USB 2. Check:
90890-03267 • Fuel hose “1”
Yamaha diagnostic tool (A/I) Cracks/damage → Replace.
90890-03264 Loose connections → Connect properly.
3. Install:
3. Check: • Footrest board assembly (left)
• Fault code Refer to “GENERAL CHASSIS (5)” on
TIP page 4-12.
Use the “Diagnosis of malfunction” function of • Front side cover (left)
the Yamaha diagnostic tool to check the fault Refer to “GENERAL CHASSIS (2)” on
codes. For information about using the Yamaha page 4-3.
diagnostic tool, refer to the operation manual EAS30620
that is included with the tool. CHECKING THE SPARK PLUG
Fault code number is displayed → Check and 1. Remove:
repair the probable cause of the malfunction. • Front side cover (right)
Refer to “SELF-DIAGNOSTIC FUNCTION Refer to “GENERAL CHASSIS (2)” on
AND DIAGNOSTIC CODE TABLE” on page 4-3.
page 9-36. • Footrest board assembly (right)
4. Perform: Refer to “GENERAL CHASSIS (5)” on
• Dynamic inspection page 4-12.
2. Remove:
TIP
• Spark plug cap
Use the “Dynamic inspection” function of the Ya- • Spark plug
maha diagnostic tool version 3.0 and after to ECA13330
perform the dynamic inspection. For information NOTICE

about using the Yamaha diagnostic tool, refer to Before removing the spark plug, blow away
the operation manual that is included with the any dirt accumulated in the spark plug well
tool. with compressed air to prevent it from falling
into the cylinder.
3-4
3. Check: TIP
• Spark plug type • Before installing the spark plug, clean the
Incorrect → Change. spark plug and gasket surface.
• When tightening the spark plug, make sure
Manufacturer/model that the inside “a” of the spark plug wrench “2”
NGK/CPR8EA-9 does not contact the portion “b” of the spark
4. Check: plug.
• Electrode “1”
Damage/wear → Replace the spark plug. b
• Insulator “2” a 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
8. Install:
• Footrest board assembly (right)
page 4-12.
• Front side cover (right)
5. Clean: Refer to “GENERAL CHASSIS (2)” on
• Spark plug page 4-3.
(with a spark plug cleaner or wire brush)
EAS30622
6. Measure:
ADJUSTING THE VALVE CLEARANCE
• Spark plug gap “a”
The following procedures are applied to all of the
(with a wire thickness gauge)
valves.
Out of specification → Regap.
TIP
Spark plug gap • Valve clearance adjustment should be made
0.8–0.9 mm (0.031–0.035 in) 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
page 4-1.
• Front side cover
page 4-6.
7. Install: • Fuel tank cover
• Spark plug “1” Refer to “GENERAL CHASSIS (3)” on
• Spark plug cap page 4-6.
• Center lower cover
Spark plug Refer to “GENERAL CHASSIS (5)” on
13 N·m (1.3 kgf·m, 9.6 lb·ft) page 4-12.
T.
R.
• Fuel tank
Refer to “FUEL TANK” on page 7-1.
• Cylinder head cover
Refer to “CYLINDER HEAD” on page 5-9.
3-5
• Radiator cover a. Turn the crankshaft clockwise.

Refer to “RADIATOR” on page 6-2.
2. Move:
• Radiator “1”
TIP
Move the rear of the radiator outward.
b. When the piston is at the Top Dead Center

(TDC) on the compression stroke, align the
mark “a” on the camshaft sprocket with the
match mark “b” on the camshaft stopper
1 plate.
3. Move: a b
• Water pump assembly “1”
TIP
Move the water pump assembly in the direction
shown in the illustration.
1
c. Measure the valve clearance with a thick-
ness gauge “1”.
Out of specification → Adjust.
4. Measure:
• Valve clearance
Valve clearance (cold)

1
Intake
0.10–0.14 mm (0.0039–0.0055
in)
Exhaust
0.21–0.25 mm (0.0083–0.0098
in)
3-6
5. Adjust: EAS31017
CHECKING THE ENGINE IDLING SPEED

• Valve clearance
TIP
a. Loosen the locknut “1”.
b. Insert a thickness gauge “2” between the Prior to checking the engine idling speed, the air
end of the adjusting screw and the valve tip. filter element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2. Check:
1 • Engine idling speed
Out of specification → Go to next step.
Engine idling speed

2 1500–1700 r/min
c. Turn the adjusting screw “3” with the tappet 3. Check:
adjusting tool “4” until the specified valve • ISC (idle speed control) learning value
clearance is obtained. “00” or “01” → Check the intake system.
“02” → Clean the ISC (idle speed control) unit
Tappet adjusting tool and throttle body.
90890-01311 Refer to “CLEANING THE ISC (IDLE SPEED
CONTROL) UNIT AND THROTTLE BODY”
on page 7-13.
a. Connect the Yamaha diagnostic tool.
Use the diagnostic code number “67”.
Refer to “SELF-DIAGNOSTIC FUNCTION
3 AND DIAGNOSTIC CODE TABLE” on
page 9-36.
Yamaha diagnostic tool USB

4 90890-03267
d. Hold the adjusting screw to prevent it from Yamaha diagnostic tool (A/I)
moving and tighten the locknut to specifica- 90890-03264
tion.
EAS30625
Valve clearance adjusting screw CHECKING THE EXHAUST SYSTEM

locknut 1. Check:
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft) • Muffler “1”

Cracks/damage → Replace.
e. Measure the valve clearance again. • Gasket “2”
f. If the valve clearance is still out of specifica- Exhaust gas leaks → Replace.
tion, repeat all of the valve clearance ad-
justment steps until the specified clearance
is obtained.
6. Install:
• All removed parts
TIP
For installation, reverse the removal procedure.
3-7
2. Check: 1
Tightening torque
• Muffler nut “3”
• Muffler bolt “4”
Muffler nut
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
Muffler bolt
53 N·m (5.3 kgf·m, 39 lb·ft)
4
1
2
4
4 3
EAS31130
2. Check:
REPLACING THE AIR FILTER ELEMENT
• Air filter element
AND CLEANING THE CHECK HOSE
Damage → Replace.
TIP
TIP
Check the air filter check hose “1” that is located
• Replace the air filter element every 18000 km
on the rear side of the air filter case. If dust or
(10500 mi) of operation.
water or both collects in the hose, clean the hose
• The air filter needs more frequent service if you
and replace the air filter element.
are riding in unusually wet or dusty areas.
3. Install:
• Air filter element
1 • Air filter case cover
Air filter case cover screw

1.2 N·m (0.12 kgf·m, 0.88 lb·ft)
T.
R.
ECA20480
NOTICE
1. Remove: Never operate the engine without the air filter
• Air filter case cover “1” element installed. Unfiltered air will cause
• Air filter element “2” rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect throttle body
tuning, leading to poor engine performance
and possible overheating.
TIP
When installing the air filter element into the air
filter case, make sure that the sealing surfaces
are aligned to prevent any air leaks.
3-8
EAS31179
CHECKING THE BREATHER HOSES
1. Remove:
page 4-3.
• Battery
• Battery
page 4-1.
page 4-1.
Refer to “GENERAL CHASSIS (2)” on EAS31704
page 4-3. CLEANING THE V-BELT CASE AIR FILTER

• Fuel tank cover ELEMENT AND CLEANING THE CHECK
Refer to “GENERAL CHASSIS (3)” on HOSE
page 4-6. TIP
• Storage box Check the V-belt case air filter check hose “1”
Refer to “GENERAL CHASSIS (4)” on that is located on the rear side of the V-belt case.
page 4-9. If dust or water or both collects in the hose, clean
2. Check: the hose and replace the V-belt case air filter el-
• Cylinder head breather hose “1” ement.
• Transmission case breather hose “2”
Loose connections → Connect properly.
ECA21600
NOTICE
Make sure the cylinder head breather hose
and transmission case breather hose are
routed correctly.
1
1 1. Remove:
• V-belt case air filter element cover “1”
• V-belt case air filter element “2”
2
3. Install:
• Storage box
page 4-9.
• Fuel tank cover
2. Clean:
page 4-6.
• V-belt case air filter element
(with solvent)
3-9
EWA17971
TIP
WARNING
Drive on the road, operate the front and rear
Never use low flash point solvents, such as
brakes separately and check to see if the brakes
gasoline, to clean the V-belt case air filter el-
are operating properly.
ement. Such solvents may cause a fire or an
explosion.
EAS30633
TIP CHECKING THE FRONT BRAKE PADS

• The air filter needs more frequent service if you
brake pads.
are riding in unusually wet or dusty areas.
1. Operate the brake.
• After cleaning, gently squeeze the V-belt case
2. Check:
air filter element to remove the excess solvent.
• Front brake pad
ECA21590
Wear indicator grooves “a” almost disap-
NOTICE peared → Replace the brake pads as a set.
Do not twist the V-belt case air filter element Refer to “FRONT BRAKE” on page 4-31.
when squeezing it.
EAS30634
3. Check: CHECKING THE REAR BRAKE PADS

• V-belt case air filter element The following procedures are applied 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.
Refer to “REAR BRAKE” on page 4-44.
Recommended oil
Engine oil
5. Install:
• V-belt case air filter element
• V-belt case air filter element cover
V-belt case air filter element cov-

er bolt a
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
EAS30801
CHECKING THE BRAKE OPERATION

1. Check:
• Brake operation
Brake not working properly → Check the
brake system.
Refer to “FRONT BRAKE” on page 4-31 and
“REAR BRAKE” on page 4-44.
3-10
EAS30632 EWA13540
CHECKING THE BRAKE FLUID LEVEL WARNING

1. Stand the vehicle on a level surface. • Use only the designated brake fluid. Other
TIP brake fluids may cause the rubber seals to
• Place the vehicle on the centerstand. deteriorate, causing leakage and poor
• Make sure the vehicle is upright. brake performance.
• In order to ensure a correct reading of the • Refill with the same type of brake fluid that
brake fluid level, make sure the top of the brake is already in the system. Mixing brake fluids
fluid reservoir is horizontal. may result in a harmful chemical reaction,
leading to poor brake performance.
2. Check: • When refilling, be careful that water does
• Brake fluid level not enter the brake master cylinder reser-
Below the minimum level mark “a” → Add the voir. Water will significantly lower the boil-
specified brake fluid to the proper level. ing point of the brake fluid and could cause
vapor lock.
Specified brake fluid
DOT 4 ECA13540
NOTICE
A Brake fluid may damage painted surfaces
a and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
EAS30635
CHECKING THE FRONT BRAKE HOSES

1. Check:
• Brake hose “1”
B 1
1
2. Check:
A. Front brake • Brake hose holder
B. Rear brake • Brake hose guide
Loose → Tighten the holder and guide bolt.
3. Hold the vehicle upright and apply the front
brake several times.
4. Check:
• Brake hose
Brake fluid leakage → Replace the damaged
hose.
Refer to “FRONT BRAKE” on page 4-31.
3-11
EAS30636
TIP
CHECKING THE REAR BRAKE HOSES
1. Check: • Be careful not to spill any brake fluid or allow
• Brake hose “1” the brake master cylinder reservoir to overflow.
Cracks/damage/wear → Replace. • When bleeding the ABS, make sure that there
is always enough brake fluid before applying
the brake. Ignoring this precaution could allow
1 air to enter the ABS, considerably lengthening
the bleeding procedure.
• If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours.
1 • Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
1. Bleed:
• ABS
2. Check:
• Brake hose holder a. Fill the brake master cylinder reservoir to
Loose → Tighten the holder bolt. the proper level with the specified brake flu-
3. Hold the vehicle upright and apply the rear id.
brake several times. b. Install the brake master cylinder dia-
4. Check: phragm.
• Brake hose c. Connect a clear plastic hose “1” tightly to
Brake fluid leakage → Replace the brake the bleed screw “2”.
hose. A
Refer to “REAR BRAKE” on page 4-44. 2
EAS30893
BLEEDING THE HYDRAULIC BRAKE 1

SYSTEM
EWA14000
WARNING
Always bleed the brake system when the
brake related parts are removed.
ECA22780
NOTICE B
• Bleed the brake system in the following or-
der.
• 1st step: Front brake caliper
• 2nd step: Rear brake caliper 1
EWA16530
WARNING 2
Bleed the ABS whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or A. Front brake caliper
replaced. B. Rear brake caliper
• the brake fluid level is very low.
d. Place the other end of the hose into a con-
• brake operation is faulty.
tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever and hold it in
position.
g. Loosen the bleed screw.
3-12
TIP 2. Measure:
Loosening the bleed screw will release the pres- • Radial wheel runout
sure and cause the brake lever to contact the • Lateral wheel runout
throttle grip or handlebar grip. Refer to “FRONT WHEEL” on page 4-21 and
“REAR WHEEL” on page 4-28.
h. Tighten the bleed screw and then release
EAS31429
the brake lever.
CHECKING THE TIRES
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
tires.
fluid in the plastic hose.
1. Check:
j. Check the operation of the hydraulic unit.
• Tire pressure
Refer to “HYDRAULIC UNIT OPERATION
Out of specification → Regulate.
TESTS” on page 4-59.
ECA18060
NOTICE
Make sure that the main switch is turned to
“OFF” before checking the operation of the
hydraulic unit.
k. After operating the ABS, repeat steps (e) to
(i), and then fill the brake master cylinder
reservoir to the proper level with the speci-
fied brake fluid.
EWA13181
l. Tighten the bleed screw to specification.
WARNING
Brake caliper bleed screw • The tire pressure should only be checked
6 N·m (0.6 kgf·m, 4.4 lb·ft) and regulated when the tire temperature
T.
equals the ambient air temperature.

R.
m. Fill the brake master cylinder reservoir to • The tire pressure and the suspension must
the proper level with the specified brake flu- be adjusted according to the total weight
id. (including cargo, rider, passenger and ac-
Refer to “CHECKING THE BRAKE FLUID cessories) and the anticipated riding
LEVEL” on page 3-11. speed.
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.
EAS31428
Tire air pressure (measured on
CHECKING THE WHEELS cold tires)
The following procedures are applied to all of the 1 person
wheels. Front
1. Check: 150 kPa (1.50 kgf/cm², 22 psi)
• Wheel Rear
250 kPa (2.50 kgf/cm², 36 psi)
Damage/out-of-round → Replace.
EWA13260
2 persons
WARNING Front
Never attempt to make any repairs to the 150 kPa (1.50 kgf/cm², 22 psi)
wheel. Rear
250 kPa (2.50 kgf/cm², 36 psi)
TIP * Total weight of rider, passenger, cargo
After a tire or wheel has been changed or re- and accessories
placed, always balance the wheel.
3-13
EWA13190
WARNING A B
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
2. Check:
• Tire surfaces
Damage/wear → Replace the tire.
A. Tire
B. Wheel
Tube wheel Tube tire only

Tubeless wheel Tube or tubeless tire
EWA14090
WARNING
After extensive tests, the tires listed below
1. Tire tread depth
have been approved by Yamaha Motor Co.,
2. Side wall
Ltd. for this model. The front and rear tires
3. Wear indicator
should always be by the same manufacturer
and of the same design. No guarantee con-
Wear limit (front) cerning handling characteristics can be giv-
1.0 mm (0.04 in) en if a tire combination other than one
Wear limit (rear) approved by Yamaha is used on this vehicle.
1.0 mm (0.04 in)
EWA14080
Front tire
WARNING Size
• Do not use a tubeless tire on a wheel de- 110/70-13M/C 48P
signed only for tube tires to avoid tire fail- Manufacturer/model
ure and personal injury from sudden DUNLOP/SCOOT SMART L
deflation.
• When using a tube tire, be sure to install the
correct tube. Rear tire
• Always replace a new tube tire and a new Size
130/70-13M/C 63P
tube as a set.
Manufacturer/model
• To avoid pinching the tube, make sure the
DUNLOP/SCOOT SMART L
wheel rim band and tube are centered in the
wheel groove. EWA13210
• Patching a punctured tube is not recom- WARNING

mended. If it is absolutely necessary to do New tires have a relatively low grip on the
so, use great care and replace the tube as road surface until they have been slightly
soon as possible with a good quality re- worn. Therefore, approximately 100 km
placement. should be traveled at normal speed before
any high-speed riding is done.
3-14
TIP • Handlebar
For tires with a direction of rotation mark “1”: Refer to “HANDLEBAR” on page 4-63.
• Install the tire with the mark pointing in the di- 4. Adjust:
rection of wheel rotation. • Steering head
• Align the mark “2” with the valve installation a. Remove the upper ring nut “1”, lock washer
point. “2”, center ring nut “3” and rubber washer
“4”.
2
1
1
3
4
2
EAS30641 b. Loosen the lower ring nut “5” and then tight-
CHECKING THE WHEEL BEARINGS en it to specification with a steering nut
The following procedures are applied to all of the wrench “6”.
wheel bearings. TIP
1. Check:
Set the torque wrench at a right angle to the
• Wheel bearings
steering nut wrench.
Refer to “CHECKING THE FRONT WHEEL”
on page 4-24.
EAS30645
Steering nut wrench
CHECKING AND ADJUSTING THE 90890-01403
STEERING HEAD
1. Stand the vehicle on a level surface. Lower ring nut (initial tightening
EWA13120
torque)
T.
WARNING
R.
38 N·m (3.8 kgf·m, 28 lb·ft)

Securely support the vehicle so that there is
no danger of it falling over.
TIP
Place the vehicle on a suitable stand so that the
front wheel is off ground.
2. Check:
• Steering head 6
Grasp the handlebar and gently rock the han-
dlebar. 5
Binding/looseness → Adjust the steering c. Loosen the lower ring nut 1/4 of a turn, and
head. then tighten it to specification with a steer-
3. Remove: ing nut wrench.
• Front side covers EWA13140
Refer to “GENERAL CHASSIS (2)” on WARNING

page 4-3. Do not overtighten the lower ring nut.
page 4-12. Lower ring nut (final tightening
• Front upper cowling assembly torque)
T.
R.
17 N·m (1.7 kgf·m, 13 lb·ft)

page 4-15.
3-15
d. Check the steering head for looseness or EAS30646
LUBRICATING THE STEERING HEAD

binding by turning the front fork all the way
1. Lubricate:
in both directions. If any binding is felt, re-
• Upper bearing
move the lower bracket and check the up-
• Lower bearing
per and lower bearings.
• Lower bearing dust seal
Refer to “STEERING HEAD” on page 4-76.
e. Install the rubber washer.
Recommended lubricant
f. Install the center ring nut.
Lithium-soap-based grease
g. Finger tighten the center ring nut, then align
the slots of both ring nuts. If necessary, hold EAS31186
the lower ring nut and tighten the center ring CHECKING THE CHASSIS FASTENERS
nut until their slots are aligned. Make sure that all nuts, bolts, and screws are
h. Install the lock washer “2”. properly tightened.
TIP Refer to “TIGHTENING TORQUES” on page 2-
Make sure the lock washer tabs “a” sit correctly 10.
in the ring nut slots “b”. EAS30648
LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
2
a Silicone grease
EAS30650
b CHECKING THE SIDESTAND

1. Check:
• Sidestand operation
i. Hold the lower and center ring nuts with a Check that the sidestand moves smoothly.
steering nut wrench and tighten the upper Rough movement → Repair or replace.
ring nut with another steering nut wrench.
EAS30651
LUBRICATING THE SIDESTAND

Steering nut wrench
90890-01403 Lubricate the pivoting point, metal-to-metal mov-
ing parts and spring contact point of the side-
stand.
Upper ring nut
75 N·m (7.5 kgf·m, 55 lb·ft) Recommended lubricant
T.
R.
5. Install:
EAS30856
• Handlebar
CHECKING THE CENTERSTAND
Refer to “HANDLEBAR” on page 4-63.
1. Check:
• Front upper cowling assembly
• Centerstand operation
Check that the centerstand moves smoothly.
page 4-15.
Rough movement → Repair or replace.
Refer to “GENERAL CHASSIS (5)” on EAS30857
page 4-12. LUBRICATING THE CENTERSTAND

• Front side cover Lubricate the pivoting point, metal-to-metal mov-
Refer to “GENERAL CHASSIS (2)” on ing parts, and spring contact points of the center-
page 4-3. stand.
3-16
EAS30652
3. Check:
CHECKING THE SIDESTAND SWITCH
• Rear shock absorber assembly operation
Refer to “CHECKING THE SWITCHES” on
Push down seat on the vehicle several times
page 8-35.
and check if the rear shock absorber assem-
EAS30653 bly rebounds smoothly.
CHECKING THE FRONT FORK Rough movement → Replace.
1. Stand the vehicle on a level surface. Refer to “REAR SHOCK ABSORBER AS-
EWA13120
SEMBLIES AND SWINGARM” on page 4-
WARNING
80.
no danger of it falling over. EAS30656
CHECKING THE ENGINE OIL LEVEL

2. Check: 1. Stand the vehicle on a level surface.
• Inner tube TIP
Damage/scratches → Replace. • Place the vehicle on the centerstand.
• Oil seal • Make sure the vehicle is upright.
Oil leakage → Replace.
3. Hold the vehicle upright and apply the front 2. Start the engine, warm it up for several min-
brake. utes, and then turn it off.
4. Check: 3. Remove:
• Front fork operation • Dipstick “1”
Push down hard on the handlebar several 4. Check:
times and check if the front fork rebounds • Engine oil level
smoothly. The engine oil level should be between the
Rough movement → Repair. minimum level mark “a” and maximum level
Refer to “FRONT FORK” on page 4-69. mark “b”.
Below the minimum level mark → Add the
recommended engine oil to the proper level.
TIP
• Before checking the engine oil level, wait a few
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
the oil level.
EAS30808
CHECKING THE REAR SHOCK ABSORBER

1
ASSEMBLIES
The following procedures are applied to both of
the rear shock absorber assemblies. 1 b
1. Stand the vehicle on a level surface.
EWA13120
a
WARNING
no danger of it falling over. Recommended brand
YAMALUBE
2. Check: SAE viscosity grades
• Rear shock absorber assembly 10W-40
Oil leaks → Replace the rear shock absorber Recommended engine oil grade
assembly. API service SG type or higher,
Refer to “CHECKING THE REAR SHOCK JASO standard MA or MB
ABSORBER ASSEMBLY” on page 4-82.
3-17
ECA13370
NOTICE
Do not allow foreign materials to enter the
crankcase. 2
5. Start the engine, warm it up for several min- 3
utes, and then turn it off. 4
6. Check the engine oil level again. 1
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled. c. Clean the engine oil strainer with solvent,
and then check it for damage and replace it
EAS30657 if necessary.
CHANGING THE ENGINE OIL d. Install the oil strainer, spring, and oil strain-
1. Start the engine, warm it up for several min- er cover.
utes, and then turn it off.
2. Place a container under the engine oil drain Oil strainer cover
bolt. 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
3. Remove:
• Dipstick “1” 6. Install:
• Engine oil drain bolt “2” • Engine oil drain bolt
(along with the gasket “3”)
(along with the gasket New )
Engine oil drain bolt

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

Quantity (disassembled)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Oil change
0.90 L (0.95 US qt, 0.79 Imp.qt)
3
8. Install:
• Dipstick
2 9. Start the engine, warm it up for several min-
10.Check:
4. Drain: • Engine
• Engine oil (for engine oil leaks)
(completely from the crankcase) 11.Check:
5. If the oil strainer is also to be cleaned, per- • Engine oil level
form the following procedure. Refer to “CHECKING THE ENGINE OIL
a. Remove the oil strainer cover “1”, spring LEVEL” on page 3-17.
“3”, and oil strainer “2”. 12.Remove:
b. Install a new O-ring “4”. • Front side cover (right)
TIP Refer to “GENERAL CHASSIS (2)” on
Lubricate the O-ring with lithium-soap-based page 4-3.
grease.
3-18

page 4-12.
13.Check: b
• Engine oil pressure a
a. Slightly loosen the oil check bolt “1”.
ECA13470
1 NOTICE
• Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
b. Start the engine and keep it idling until en-
• Use only distilled water. However, if dis-
gine oil starts to seep from the oil check
tilled water is not available, soft water may
bolt. If no engine oil comes out after one
be used.
minute, turn the engine off so that it will not
seize. 3. Start the engine, warm it up for several min-
c. Check the engine oil passages and the oil utes, and then turn it off.
pump for damage or leakage. Refer to “OIL 4. Check:
PUMP” on page 5-45. • Coolant level
d. Start the engine after solving the prob- TIP
lem(s) and check the engine oil pressure
Before checking the coolant level, wait a few
again.
minutes until the coolant has settled.
e. Tighten the oil check bolt to specification.
EAS30812
Engine oil check bolt CHECKING THE COOLING SYSTEM
7 N·m (0.7 kgf·m, 5.2 lb·ft) 1. Remove:
T.
R.
• Radiator cover
14.Reset: Refer to “RADIATOR” on page 6-2.
• Oil change indicator 2. Check:
Refer to “MULTI-FUNCTION METER UNIT” • Radiator “1”
on page 1-2. • Coolant reservoir hose “2”
EAS30811
• Radiator inlet hose “3”
CHECKING THE COOLANT LEVEL • Radiator outlet hose “4”
1. Stand the vehicle on a level surface. • Thermostat assembly “5”
TIP • Water pump inlet hose “6”
• Place the vehicle on the centerstand. Cracks/tears → Replace.
• Make sure the vehicle is upright. Refer to “RADIATOR” on page 6-2 and
“THERMOSTAT” on page 6-6.
2. Check:
• Coolant level
The coolant level should be between the min- 3 2
5
imum level mark “a” and maximum level mark
“b”.
Below the minimum level mark → Add the 1
recommended coolant to the proper level.
4 6
3-19
3. Install: 6. Remove:
• Radiator cover • Radiator cap “1”
Refer to “RADIATOR” on page 6-2.
1
EAS30813
CHANGING THE COOLANT

1. Remove:
page 4-3.
• Bottom cover
Refer to “GENERAL CHASSIS (5)” on EWA13030
page 4-12. WARNING

2. Disconnect: A hot radiator is under pressure. Therefore,
• Coolant reservoir hose “1” do not remove the radiator cap when the en-
• Coolant reservoir breather hose “2” 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
2 radiator cap as follows:
Place a thick rag or a towel over the radiator
1 cap and slowly turn the radiator cap counter-
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
3. Remove:
• Coolant reservoir cap “2” 7. Remove:
• Coolant reservoir “1” • Coolant drain bolt (radiator side) “1”
(along with the O-ring)
• Coolant drain bolt (cylinder side) “2”
(along with the copper washer)
1
4. Drain:
• Coolant
(from the coolant reservoir) 1
5. Remove:
• Radiator cover “1”
2
1
3-20
8. Drain: Handling notes for coolant

• Coolant Coolant is potentially harmful and should be
(from the engine and radiator) handled with special care.
9. Install: EWA13040
• Coolant drain bolt (cylinder side) WARNING

(along with the copper washer New ) • If coolant splashes in your eyes, thorough-
• Coolant drain bolt (radiator side) ly wash them with water and consult a doc-
tor.
(along with the O-ring New ) • If coolant splashes on your clothes, quickly
wash it away with water and then with soap
Coolant drain bolt (cylinder side) and water.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
• If coolant is swallowed, induce vomiting
T.
R.
Coolant drain bolt (radiator side)

and get immediate medical attention.
1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
ECA13481
10.Connect: NOTICE
• Coolant reservoir breather hose • Adding water instead of coolant lowers the
• Coolant reservoir hose antifreeze content of the coolant. If water is
11.Fill: used instead of coolant, check, and if nec-
• Cooling system essary, correct the antifreeze concentra-
(with the specified amount of the recom- tion of the coolant.
mended coolant) • Use only distilled water. However, if dis-
tilled water is not available, soft water may
Recommended antifreeze be used.
High-quality ethylene glycol an- • If coolant comes into contact with painted
tifreeze containing corrosion surfaces, immediately wash them with wa-
inhibitors for aluminum enter.
gines
• Do not mix different types of antifreeze.
Mixing ratio
1:1 (antifreeze: water) 12.Install:
Radiator (including all routes) • Radiator cap
0.46 L (0.49 US qt, 0.40 Imp.qt) • Coolant reservoir
Coolant reservoir (up to the
maximum level mark) Coolant reservoir bolt
0.13 L (0.14 US qt, 0.11 Imp.qt) 11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.
R.
TIP 13.Fill:
• Fill the coolant into the radiator, and then re- • Coolant reservoir
move the air bleed bolt “1” until coolant comes (with the recommended coolant to the maxi-
out. mum level mark “b”)
• Tighten the air bleed bolt to specification.
Air bleed bolt b

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
14.Install:
1 • Coolant reservoir cap “1”
3-21
TIP
Point the tab “a” on the coolant reservoir cap for- 1
ward.
a
15.Start the engine, warm it up for several min-
4 3
16.Check:
• Coolant level
Refer to “CHECKING THE COOLANT LEV-
EL” on page 3-19.
TIP 5. Install:
Before checking the coolant level, wait a few • Final transmission oil drain bolt
minutes until the coolant has settled. (along with the copper washer New )
17.Install: Final transmission oil drain bolt

• Radiator cover 20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
Radiator cover bolt 6. Fill:

10 N·m (1.0 kgf·m, 7.4 lb·ft) • Final transmission oil
T.
R.
(with the specified amount of the recom-

18.Install: mended final transmission oil)
Refer to “GENERAL CHASSIS (5)” on Final transmission oil
page 4-12. Type
• Front side cover (right) Motor oil SAE 10W-40 type SG
Refer to “GENERAL CHASSIS (2)” on or higher
page 4-3. Quantity
0.10 L (0.11 US qt, 0.09 Imp.qt)
EAS31187
CHANGING THE FINAL TRANSMISSION OIL

7. Install:
• Final transmission oil filler cap
TIP
(along with the O-ring New )
• Place the vehicle on the centerstand.
TIP
• Make sure the vehicle is upright.
Lubricate the O-ring with lithium-soap-based
2. Start the engine, warm it up for several min- grease.
3. Place a container under the final transmis- 8. Start the engine, warm it up for several min-
sion. utes, and then turn it off.
4. Remove: 9. Check:
• Final transmission oil filler cap “1” • Final transmission oil leakage
(along with the O-ring “2”)
• Final transmission oil drain bolt “3”
(along with the copper washer “4”)
Completely drain the final transmission oil.
3-22
EAS31188
REPLACING THE V-BELT

1. Remove: Engine oil or a suitable cable lu-
• Air filter case bricant
Refer to “AIR FILTER CASE” on page 7-8.
• 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 cable
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 4-63.
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 7-8. Recommended lubricant
EAS30658 Suitable cable lubricant
CHECKING THE BRAKE LIGHT SWITCHES
1. Check: TIP
• 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 8-35. the way to the left and right.
EAS31147 3. Check:
CHECKING AND LUBRICATING THE • Throttle grip free play “a”
CABLES Out of specification → Adjust.
inner 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.
3-23
4. Adjust: EAS30664
ADJUSTING THE HEADLIGHT BEAM

• Throttle grip free play
1. Adjust:
a. Slide back the rubber cover “1”. • Headlight beam (vertically)
b. Loosen the locknut “2”. Turn the adjusting bolts “1” in direction left or
c. Turn the adjusting nut “3” until the specified right.
throttle grip free play is obtained. • Headlight beam (horizontally)
Turn the adjusting bolts “2” in direction left or
right.
1
3
2
d. Tighten the locknut.
1 2
Throttle cable adjusting locknut
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
e. Slide the rubber cover to its original posi-

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

SIGNALS
1. Check that all switches operate and that all
lights come on.
Refer to “Instrument and control functions” in
OWNER’S MANUAL.
Faulty → Refer to “CHECKING THE
SWITCHES” on page 8-35.
3-24
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE BATTERY COVER .......................................................4-2
GENERAL CHASSIS (2) ................................................................................. 4-3

REMOVING THE TAIL/BRAKE LIGHT OUTER COVER .......................... 4-4
INSTALLING THE TAIL/BRAKE LIGHT OUTER COVER.........................4-4
REMOVING THE FRONT SIDE COVER .................................................. 4-4
INSTALLING THE FRONT SIDE COVER................................................. 4-5
GENERAL CHASSIS (3) ................................................................................. 4-6

REMOVING THE FUEL TANK COVER .................................................... 4-7
INSTALLING THE FUEL TANK COVER................................................... 4-7
REMOVING THE FUEL TANK CAP LID COVER ..................................... 4-8
INSTALLING THE FUEL TANK CAP LID COVER....................................4-8
GENERAL CHASSIS (4) ................................................................................. 4-9

REMOVING THE REAR SIDE COVER ASSEMBLY ..............................4-11
INSTALLING THE REAR SIDE COVER ASSEMBLY............................. 4-11 4
GENERAL CHASSIS (5) ............................................................................... 4-12
INSTALLING THE CENTER LOWER COVER........................................ 4-14
INSTALLING THE FOOTREST BOARD ASSEMBLY............................. 4-14
INSTALLING THE BOTTOM COVER .....................................................4-14
GENERAL CHASSIS (6) ............................................................................... 4-15

REMOVING THE FRONT UPPER PANEL ............................................. 4-16
INSTALLING THE FRONT UPPER PANEL............................................4-16
REMOVING THE FRONT COWLING ASSEMBLY.................................4-16
INSTALLING THE FRONT COWLING ASSEMBLY ...............................4-17
REMOVING THE FRONT SIDE COWLING............................................4-17
INSTALLING THE FRONT SIDE COWLING ..........................................4-17
GENERAL CHASSIS (7) ............................................................................... 4-18

REMOVING THE UPPER CENTER COVER..........................................4-20
INSTALLING THE UPPER CENTER COVER ........................................ 4-20
FRONT WHEEL............................................................................................. 4-21

REMOVING THE FRONT WHEEL.......................................................... 4-23
DISASSEMBLING THE FRONT WHEEL................................................ 4-23
CHECKING THE FRONT WHEEL .......................................................... 4-24
MAINTENANCE OF THE FRONT WHEEL SENSOR AND
SENSOR ROTOR .................................................................................. 4-24
ASSEMBLING THE FRONT WHEEL......................................................4-25
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-25
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC).................. 4-25
REAR WHEEL ...............................................................................................4-28
REMOVING THE REAR WHEEL (DISC) ................................................ 4-29
CHECKING THE REAR WHEEL............................................................. 4-29
MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR ................. 4-29
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-29
INSTALLING THE REAR WHEEL (REAR BRAKE DISC) ......................4-30
FRONT BRAKE ............................................................................................. 4-31

INTRODUCTION .....................................................................................4-37
CHECKING THE FRONT BRAKE DISC ................................................. 4-37
REPLACING THE FRONT BRAKE PADS .............................................. 4-38
REMOVING THE FRONT BRAKE CALIPER..........................................4-39
DISASSEMBLING THE FRONT BRAKE CALIPER ................................4-39
CHECKING THE FRONT BRAKE CALIPER ..........................................4-40
ASSEMBLING THE FRONT BRAKE CALIPER ...................................... 4-40
INSTALLING THE FRONT BRAKE CALIPER ........................................ 4-40
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-41
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-41
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-42
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-42
REAR BRAKE ...............................................................................................4-44

INTRODUCTION .....................................................................................4-49
CHECKING THE REAR BRAKE DISC....................................................4-49
REPLACING THE REAR BRAKE PADS................................................. 4-49
REMOVING THE REAR BRAKE CALIPER ............................................4-50
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-51
CHECKING THE REAR BRAKE CALIPER............................................. 4-51
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-52
INSTALLING THE REAR BRAKE CALIPER...........................................4-52
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-53
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-53
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-53
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-53
ABS (Anti-lock Brake System) .................................................................... 4-55

REMOVING THE HYDRAULIC UNIT ASSEMBLY .................................4-57
CHECKING THE HYDRAULIC UNIT ASSEMBLY..................................4-57
INSTALLING THE HYDRAULIC UNIT ASSEMBLY................................4-58
HYDRAULIC UNIT OPERATION TESTS................................................ 4-59
CHECKING THE ABS WARNING LIGHT ............................................... 4-62
HANDLEBAR ................................................................................................4-63
REMOVING THE UPPER HANDLEBAR COVER ASSEMBLY .............. 4-66
DISASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY .... 4-66
REMOVING THE HANDLEBAR..............................................................4-66
CHECKING THE HANDLEBAR ..............................................................4-66
INSTALLING THE HANDLEBAR ............................................................ 4-66
ASSEMBLING THE UPPER HANDLEBAR COVER ASSEMBLY ..........4-68
INSTALLING THE UPPER HANDLEBAR COVER ASSEMBLY............. 4-68
FRONT FORK................................................................................................4-69
REMOVING THE FRONT FORK LEGS.................................................. 4-71
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-71
CHECKING THE FRONT FORK LEGS .................................................. 4-72
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-72
INSTALLING THE FRONT FORK LEGS ................................................ 4-75
STEERING HEAD.......................................................................................... 4-76

REMOVING THE LOWER BRACKET.....................................................4-78
CHECKING THE STEERING HEAD .......................................................4-78
INSTALLING THE STEERING HEAD .....................................................4-79
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM................... 4-80

REMOVING THE SWINGARM................................................................4-82
MAINTENANCE OF THE REAR WHEEL SENSOR ...............................4-82
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-82
CHECKING THE SWINGARM ................................................................4-83
INSTALLING THE SWINGARM ..............................................................4-83
GENERAL CHASSIS (1)
EAS20026
GENERAL CHASSIS (1)

Removing the battery
3 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
2 1
6
5

Seat Open.
1 Battery cover 1
2 Negative battery lead 1 Disconnect.
3 Positive battery lead 1 Disconnect.
4 Battery 1
5 CCU (Communication Control Unit) 1
6 Smart key unit 1
4-1
GENERAL CHASSIS (1)
EAS31677
REMOVING THE BATTERY COVER

1. Remove:
• Battery cover “1”
a. Open the seat.

b. Remove the battery cover screws.
c. Slide the battery cover “1” rearward to re-
move from the storage box.
4-2
GENERAL CHASSIS (2)
EAS20155
GENERAL CHASSIS (2)

Removing the grab bar and front side covers
17 N•m (1.7 kgf•m, 13 lb•ft) 17 N•m (1.7 kgf•m, 13 lb•ft)
T.R
.
T.R
.
T.R
. 1.8 N•m (0.18 kgf•m, 1.3 lb•ft) 1
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 upper cover 1
3 Front side cover (left) 1
4 Front side cover (right) 1
4-3
GENERAL CHASSIS (2)
EAS31681
REMOVING THE TAIL/BRAKE LIGHT OUTER a 1

COVER
1. Remove:
• Tail/brake light outer cover “1”
a
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 light. The following procedures are applied to both of
the front side covers.
a 1 1. Remove:
• Front side cover “1”
EAS31682 1
INSTALLING THE TAIL/BRAKE LIGHT
OUTER COVER
1. Install: a. Remove the front side cover screws.
• Tail/brake light outer cover “1” b. Pull the front side cover outward to remove
the projections “a” from the grommets “b”.
1
b a
b a
a. Slide the tail/brake light outer cover for-
ward, fit the projection “a” on the cover into
the hole “b” in the tail/brake light.
4-4
GENERAL CHASSIS (2)
EAS31684
INSTALLING THE FRONT SIDE COVER

the front side covers.
1. Install:
• Front side cover “1”
a. Fit the projections “a” on the front side cover

into the grommets “b”.
b a
b a
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
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
.
1
2
6
8
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.

Front side cover page 4-3.
1 Fuel tank cover 1
2 Fuel tank cap lid lock cable 1 Disconnect.
3 Fuel tank cap lid cover 1
4 Fuel tank cap lid 1
5 Center cover 1
6 Seat assembly 1
7 Owner’s tool kit 1
8 Seat 1
4-6
GENERAL CHASSIS (3)
EAS31685 EAS31686
REMOVING THE FUEL TANK COVER INSTALLING THE FUEL TANK COVER
1. Remove: 1. Install:
• Fuel tank cover “1” • Fuel tank cover “1”
1 1
a. Remove the fuel tank cover screws. a. Slide the fuel tank cover forward and fit the
b. Slide the fuel tank cover rearward to re- projections “a” on the cover into the holes
move the projections “a” on the cover from “b” in the leg shield.
the holes “b” in the leg shield. b. Install the fuel tank cover screws, and then
tighten the screws to specification.
Fuel tank cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
b a
b a
4-7
GENERAL CHASSIS (3)
EAS32349 EAS32350
REMOVING THE FUEL TANK CAP LID INSTALLING THE FUEL TANK CAP LID
COVER COVER
• Fuel tank cap lid cover “1” • Fuel tank cap lid cover “1”
1 1
a. Remove the screw. a. Fit the projections “a” on the fuel tank cap
b. Remove the projections “a” on the fuel tank lid cover into the holes “b” in the fuel tank
cap lid cover from the holes “b” in the fuel cap lid.
tank cap lid.
a
a b
b 1
1
b. Install the fuel tank cap lid cover screw, and

then tighten the screw to specification.
Fuel tank cap lid cover screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
4-8
GENERAL CHASSIS (4)
EAS20157
GENERAL CHASSIS (4)

Removing the rear side covers and storage box
9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.R
.
10
11
13
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 9
12
6
8
4
3
1
2

Battery page 4-1.
Fuel tank cover page 4-6.
1 Rear side cover assembly (left) 1
2 Center side cover (left) 1
3 Rear side cover (left) 1
4 Rear side cover assembly (right) 1
5 Center side cover (right) 1
6 Rear side cover (right) 1
7 Brake light coupler 1 Disconnect.
8 Taillight/rear turn signal coupler 1 Disconnect.
9 Tail/brake light lower cover 1
4-9
GENERAL CHASSIS (4)
Removing the rear side covers and storage box

9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.R
.
10
11
13
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 9
12
6
8
4
3
1
2

10 Tail/brake light assembly 1
11 Storage box 1
12 Flap 1
13 Seat hinge 1
4-10
GENERAL CHASSIS (4)
EAS31687 EAS31688
REMOVING THE REAR SIDE COVER INSTALLING THE REAR SIDE COVER
ASSEMBLY ASSEMBLY
The following procedures are applied to both of The following procedures are applied to both of
the rear side cover assembly. the rear side cover assembly.
• Rear side cover assembly “1” • Rear side cover assembly “1”
1 1
a. Remove the quick fasteners, screw and a. Fit the projections “a” on the rear side cover
bolt. assembly into the holes “b” in the storage
b. Remove the projections “a” on the rear side box.
cover assembly from the holes “b” in the
storage box. 1
b
1
b
a
b. Install the quick fasteners, screw, and bolt,
and then tighten the screw and bolts to
specification.
4-11
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
.
3.8 N·m (0.38 kgf·m, 2.8 lb·ft) 32 N·m (3.2 kgf·m, 24 lb·ft)
T.R
T.R
.
.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.
4
11
9
12 2
LS
13
14
10 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

T.R
.
LS
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.
2
5 6
8
1
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 7 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
T.R
.

Battery page 4-1.
Seat assembly page 4-6.
Storage box page 4-9.
1 Bottom cover 1
2 Clamp 3
3 Footrest board mat (left) 2
4 Footrest board mat (right) 2
5 Center lower cover 1
6 Footrest board assembly (left) 1
7 Front lower cover (left) 1
8 Footrest board (left) 1
4-12
GENERAL CHASSIS (5)
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) 32 N·m (3.2 kgf·m, 24 lb·ft)
T.R
T.R
.
.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.
4
11
9
12 2
LS
13
14
10 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.
3.8 N·m (0.38 kgf·m, 2.8 lb·ft)

T.R
.
LS
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.
2
5 6
8
1
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 7 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
T.R
.

9 Footrest board assembly (right) 1
10 Front lower cover (right) 1
11 Coolant reservoir cap cover 1
12 Footrest board (right) 1
13 Sidestand spring 1
14 Sidestand 1
4-13
GENERAL CHASSIS (5)
EAS31689
INSTALLING THE CENTER LOWER COVER

1. Install: a
• Center lower cover “1”
b
1
1
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.
2 1
a
TIP
Make sure that the projections “a” on the center
lower cover fit into the holes “b” in the bottom
EAS31690
cover.
INSTALLING THE FOOTREST BOARD
ASSEMBLY
1. Install:
• Footrest board assembly “1”
a b
Footrest board assembly bolt

3.8 N·m (0.38 kgf·m, 2.8 lb·ft)
T.
R.
TIP
Make sure that the projection “a” on the frame
fits into the hole “b” in the footrest board assem-
bly.
4-14
GENERAL CHASSIS (6)
EAS20159
GENERAL CHASSIS (6)

Removing the front cowling assembly
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
2
T.R
.
.
1
3
0.4 N·m (0.04 kgf·m, 0.30 lb·ft)
T.R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)

T.R
.
8 4
6 11
14 4 5
7 16
13 4
4
12
(6)
10
9
15
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) 1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
T.R
.

1 Windshield 1
2 Front upper cowling 1
3 Front upper panel 1
4 Clamp 3
5 Headlight unit coupler 1 Disconnect.
6 Front turn signal light coupler (left) 1 Disconnect.
7 Front turn signal light coupler (right) 1 Disconnect.
8 Front cowling assembly 1
9 Front turn signal light (left) 1
10 Front turn signal light (right) 1
11 Front side cowling (left) 1
12 Front side panel (left) 1
13 Front side cowling (right) 1
14 Front side panel (right) 1
15 Front lower cowling 1
16 Headlight unit 1
4-15
GENERAL CHASSIS (6)
EAS31197
a. Fit the projections “a” on the front upper
REMOVING THE FRONT UPPER PANEL
panel into the holes “b” in the headlight unit
1. Remove:
and fit the projections “c” into the holes “d”
• Front upper panel “1”
in the leg shield.
1
a
1
d
c c
b
a. Remove the front upper panel screw. b. Install the front upper panel screw, and then
b. Remove the projections “a” on the front up- tighten the screw to specification.
per panel from the holes “b” in the leg shield
and remove the projections “c” from the Front upper cowling assembly
holes “d” in the headlight unit. screw
T.
R.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
1
a EAS31278
REMOVING THE FRONT COWLING

ASSEMBLY
d 1. Remove:
c c • Front cowling assembly “1”
b
EAS31198
INSTALLING THE FRONT UPPER PANEL

1. Install:
• Front upper panel “1”
1
a. Remove the front cowling assembly

1 screws.
b. Pull the front cowling assembly forward to
remove the projections “a” on the leg shield
from the holes “b” in the front cowling as-
sembly.
a a
b
b
4-16
GENERAL CHASSIS (6)
EAS31279
a. Removing the front side cowling screws.
INSTALLING THE FRONT COWLING
b. Remove the projections “a” on the front side
ASSEMBLY
cowling from the holes “b” in the front lower
1. Install:
cowling.
• Front cowling assembly “1”
1 b
b
1
a. Fit the projections “a” on the leg shield into EAS31697
INSTALLING THE FRONT SIDE COWLING

the holes “b” in the front cowling assembly.
a the front side cowling.
a
b 1. Install:
• Front side cowling “1”
b
1
b. Install the front cowling assembly screws,
and then tighten the screws to specification. 1
Front cowling assembly screw
(M5 × 15) a. Fit the projections “a” on the front side cowl-
T.
R.
1.8 N·m (0.18 kgf·m, 1.3 lb·ft) ing into the holes “b” in the front lower cowl-
Front cowling assembly screw ing.
(M5 × 11)
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
a
EAS31696
REMOVING THE FRONT SIDE COWLING a

the front side cowling. b
1
1. Remove:
• Front side cowling “1” b
b. Install the front side cowling screws, and

then tighten the screws to specification.
Front side cowling screw

1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.
R.
4-17
GENERAL CHASSIS (7)
EAS20193
GENERAL CHASSIS (7)

Removing the meter assembly
7 N·m (0.7 kgf·m, 5.2 lb·ft)

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

11
T.R
.
7
6
2
9
12
3 4
8 10
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
.

Battery page 4-1.
Seat assembly page 4-6.
Center lower cover page 4-12.
Front cowling assembly page 4-15.
1 Upper center cover 1
2 Meter panel assembly 1
3 Meter assembly coupler 1 Disconnect.
4 Clamp 1
5 Buzzer coupler 1 Disconnect.
6 Meter assembly 1
7 Meter assembly inner panel 1
4-18
GENERAL CHASSIS (7)
Removing the meter assembly
7 N·m (0.7 kgf·m, 5.2 lb·ft)

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

11
T.R
.
7
6
2
9
12
3 4
8 10
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
.

8 Meter assembly panel 1
9 Auxiliary DC jack coupler 1 Disconnect.
10 Auxiliary DC jack 1
11 Leg shield assembly 1
12 Clamp 2
4-19
GENERAL CHASSIS (7)
EAS32329 EAS32330
REMOVING THE UPPER CENTER COVER INSTALLING THE UPPER CENTER COVER
• Upper center cover “1” • Upper center cover “1”
1 1
a. Remove the quick fasteners. a. Fit the projections “a” on the upper center
b. Pull the upper center cover outward to re- cover into the holes “b” in the leg shield.
move the projections “a” on the cover from
the holes “b” in the leg shield.
b a
1
b a
1 b. Install the quick fasteners.
4-20
FRONT WHEEL
EAS20028
FRONT WHEEL
Removing the front wheel and brake disc
26 N·m (2.6 kgf·m, 19 lb·ft)
T.R
.
35 N·m (3.5 kgf·m, 26 lb·ft)
T.R
.
LS
2 7
6
1
3 5 9
LS LT
7 N·m (0.7 kgf·m, 5.2 lb·ft)

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

1 Front brake hose guide 1
2 Front brake caliper 1
3 Front wheel sensor 1
4 Front wheel axle nut 1
5 Front wheel axle 1
6 Collar 2
7 Front wheel 1
8 Front wheel sensor rotor 1
9 Front brake disc 1
4-21
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
4-22
FRONT WHEEL
EAS30145 EAS30146
REMOVING THE FRONT WHEEL DISASSEMBLING THE FRONT WHEEL

ECA22340
1. Remove:
NOTICE • Oil seal
• Keep any type of magnets (including mag- • Wheel bearing
netic pick-up tools, magnetic screwdrivers,
a. Clean the surface of the front wheel hub.
etc.) away from the speed sensor or speed
b. Remove the oil seals “1” with a flat-head
sensor rotor; otherwise, the sensor or rotor
screwdriver.
may be damaged, resulting in improper op-
TIP
eration.
• Do not drop the speed sensor rotor or sub- To prevent damaging the wheel, place a rag “2”
ject it to shocks. between the screwdriver and the wheel surface.
• If any solvent gets on the speed sensor ro-
tor, wipe it off immediately.
EWA13120
WARNING
2
2. Remove: 1
• Front brake caliper
ECA21830
c. Remove the wheel bearings “3” with a gen-
NOTICE
eral bearing puller.
Do not apply the brake lever when removing
the brake caliper.
3. Lift up:
• Front wheel
TIP 3
front wheel is elevated.
4-23
FRONT WHEEL
EAS30147
CHECKING THE FRONT WHEEL

1. Check:
• Wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
EWA13460
WARNING
Do not attempt to straighten a bent wheel ax-
le.
EAS30155
MAINTENANCE OF THE FRONT WHEEL

SENSOR AND SENSOR ROTOR
ECA21630
NOTICE
• The speed sensor cannot be disassembled.
Do not attempt to disassemble it. If faulty,
replace with a new one.
• Keep magnets (including magnetic pick-up
tools, magnetic screwdrivers, etc.) away
2. Check: from the speed sensor.
• Tire • Do not drop or shock the speed sensor or
• Front wheel the speed sensor rotor.
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on 1. Check:
page 3-13 and “CHECKING THE WHEELS” • Front wheel sensor “1”
on page 3-13. Cracks/bends/distortion → Replace.
3. Measure: Iron powder/dust → Clean.
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)
2
1
4. Check:
• Wheel bearing
Front wheel turns roughly or is loose → Re-
place the wheel bearings.
• Oil seal
4-24
FRONT WHEEL
2. Check: TIP
• Front wheel sensor rotor “1” Place a suitable washer “1” between the socket
Cracks/damage/scratches → Replace the “2” and the bearing so that both the inner race
front wheel sensor rotor. “3” and outer race “4” are pressed at the same
Iron powder/dust/solvent → Clean. time, and then press the bearing until the inner
TIP race makes contact with the spacer “5”.
When cleaning the wheel sensor rotor, be care-
ful not to damage the surface of the sensor rotor.
EAS30152
ADJUSTING THE FRONT WHEEL STATIC

EAS30151 BALANCE
ASSEMBLING THE FRONT WHEEL TIP
1. Lubricate:
• After replacing the tire, wheel or both, the front
• Oil seal lips
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
2. Install: • Balancing weight(s)
• Wheel bearing New 2. Find:
• Oil seal New • Front wheel’s heavy spot
a. Install the new wheel bearing (right side). 3. Adjust:
ECA18110 • Front wheel static balance
NOTICE 4. Check:
Do not contact the wheel bearing inner race • Front wheel static balance
“1” or balls “2”. Contact should be made EAS30932
only with the outer race “3”. INSTALLING THE FRONT WHEEL (FRONT
BRAKE DISC)
TIP
1. Install:
Use a socket “4” that matches the diameter of • Front brake disc “1”
the wheel bearing outer race. • Front wheel sensor rotor “2”
Front wheel sensor rotor bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
LOCTITE®
Front brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
LOCTITE®
b. Install the spacer.

c. Install the new wheel bearing (left side).
4-25
FRONT WHEEL
ECA21011
TIP
NOTICE
Install the front wheel with the mark “a” on the
• Do not drop the wheel sensor rotor or sub-
front tire pointing in the direction of wheel rota-
ject it to shocks.
tion.
• If any solvent gets on the wheel sensor ro-
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones. a
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.
5. Tighten:
• Front wheel axle nut
1
1
Front wheel axle nut
T.
R.
26 N·m (2.6 kgf·m, 19 lb·ft)
ECA14140
NOTICE
a Before tightening the wheel axle nut, push
down hard on the handlebar(s) several times
and check if the front fork rebounds smooth-
ly.
b 6. Install:
• Front wheel sensor
Front wheel sensor bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
2 ECA21020
NOTICE
Make sure there are no foreign materials in
2. Check: the front wheel sensor rotor and front wheel
• Front brake disc sensor. Foreign materials cause damage to
Refer to “CHECKING THE FRONT BRAKE the front wheel sensor rotor and front wheel
DISC” on page 4-37. sensor.
3. Lubricate:
TIP
• Wheel axle
• When installing the front wheel sensor, check
Recommended lubricant the front wheel sensor lead for twists.
Lithium-soap-based grease • To route the front wheel sensor lead, refer to
“CABLE ROUTING” on page 2-13.
4. Install:
• Front wheel
• Collar
• Front wheel axle
4-26
FRONT WHEEL
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”)
TIP
Out of specification → Check the wheel bear-
ing for looseness, and the front wheel sensor While holding the front brake hose guide so that
and sensor rotor installation conditions the portions “a” of the guide and holder contact
(warpage caused by overtorque, wrong in- the front fork outer tube, tighten the bolts to
stallation direction, rotor decentering, LOC- specification.
TITE® on the mounting surface of the rotor,
deformation caused by an impact during ser- a
vice and caught foreign materials). If there is
any defective part, repair or replace the de- 1
fective part.
Distance “a” (between the front

wheel sensor rotor and front
wheel sensor)
0.65–1.66 mm (0.026–0.065 in)
TIP
Measure the distance between the front wheel
sensor rotor and front wheel sensor in several
places in one rotation of the front wheel. Do not
turn the front wheel while the thickness gauge is
installed. This may damage the front wheel sen-
sor rotor and the front wheel sensor.
Thickness gauge
90890-03180
a
2
2
1
1
8. Install:
• Front brake hose guide “1”
Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
Front brake hose guide bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
4-27
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 page 4-1.
Muffler Refer to “ENGINE REMOVAL” on page 5-4.
Radiator cover Refer to “RADIATOR” on page 6-2.
Refer to “REAR SHOCK ABSORBER
Swingarm assembly ASSEMBLIES AND SWINGARM” on
page 4-80.
1 Rear wheel 1
2 Rear wheel sensor rotor 1
3 Rear brake disc 1
4-28
REAR WHEEL
EAS30156 EAS30167
REMOVING THE REAR WHEEL (DISC) MAINTENANCE OF THE REAR WHEEL

ECA22870
SENSOR ROTOR
NOTICE ECA22890
• Keep any type of magnets (including mag- NOTICE

netic pick-up tools, magnetic screwdrivers, • Handle the ABS components with care
etc.) away from the rear wheel sensor rotor; since they have been accurately adjusted.
otherwise, the rotor may be damaged, re- Keep them away from dirt and do not sub-
sulting in improper performance of the ABS ject them to shocks.
system. • Keep any type of magnets (including mag-
• Do not drop the rear wheel sensor rotor or netic pick-up tools, magnetic screwdrivers,
subject it to shocks. etc.) away from the rear wheel sensor rotor.
• If any solvent gets on the rear wheel sensor • Do not drop or shock the wheel sensor ro-
rotor, wipe it off immediately. tor.
1. Stand the vehicle on a level surface. 1. Check:
EWA13120
• Rear wheel sensor rotor
WARNING Refer to “MAINTENANCE OF THE FRONT
Securely support the vehicle so that there is WHEEL SENSOR AND SENSOR ROTOR”
no danger of it falling over. on page 4-24.
TIP EAS30164
Place the vehicle on the centerstand so that the ADJUSTING THE REAR WHEEL STATIC
rear wheel is off ground. BALANCE
TIP
EAS30159 • After replacing the tire, wheel or both, the rear
CHECKING THE REAR WHEEL wheel static balance should be adjusted.
1. Check: • Adjust the rear wheel static balance with the
• Tire brake disc installed.
• Rear wheel
Damage/wear → Replace. 1. Adjust:
Refer to “CHECKING THE TIRES” on • Rear wheel static balance
page 3-13 and “CHECKING THE WHEELS” Refer to “ADJUSTING THE FRONT WHEEL
on page 3-13. STATIC BALANCE” on page 4-25.
2. Measure:
• Radial wheel runout
• Lateral wheel runout
Refer to “CHECKING THE FRONT WHEEL”
on page 4-24.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
1.0 mm (0.04 in)
4-29
REAR WHEEL
EAS30911
INSTALLING THE REAR WHEEL (REAR

BRAKE DISC)
1. Install:
• Rear brake disc “1”
• Rear wheel sensor rotor “2”
Rear wheel sensor rotor bolt

8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.
R.
LOCTITE®
Rear brake disc bolt
23 N·m (2.3 kgf·m, 17 lb·ft)
LOCTITE®
ECA21011
NOTICE
• Do not drop the wheel sensor rotor or sub-
ject it to shocks.
• If any solvent gets on the wheel sensor ro-
• Replace the brake disc bolts and wheel
sensor rotor bolts with new ones.
TIP
• Install the brake disc with its chamfered side
“a” facing inward.
• Install the rear wheel sensor rotor with the
stamped mark “b” facing away from the wheel.
• Tighten the bolts in stages.
1 1
b
2
2. Check:
• Rear brake disc
Refer to “CHECKING THE REAR BRAKE
DISC” on page 4-49.
4-30
FRONT BRAKE
EAS20030
FRONT BRAKE
Removing the front brake pads
6 N·m (0.6 kgf·m, 4.4 lb·ft)
1
3
6
2
4
5 35 N·m (3.5 kgf·m, 26 lb·ft)

2 Brake pad clip 2
3 Brake pad pin 1
4 Brake pad (inner) 1
5 Brake pad (outer) 1
6 Brake pad spring 1
7 Brake caliper bleed screw 1
4-31
FRONT BRAKE
Removing the front brake master cylinder
16 N·m (1.6 kgf·m, 12 lb·ft)

11
T.R
.
1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.R
.
3
29 N·m (2.9 kgf·m, 21 lb·ft)
T.R
12
.
8
6 N·m (0.6 kgf·m, 4.4 lb·ft)
9 New
T.R
.
6
S
7 10
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 4-63.
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
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Front brake light switch connector 2 Disconnect.
5 Front brake light switch 1
6 Front brake lever pivot bolt/nut 1/1
7 Front brake lever 1
8 Front brake hose union bolt 1
9 Brake hose gasket 2
4-32
FRONT BRAKE
Removing the front brake master cylinder
16 N·m (1.6 kgf·m, 12 lb·ft)

11
T.R
.
1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
T.R
.
3
29 N·m (2.9 kgf·m, 21 lb·ft)
T.R
12
.
8
6 N·m (0.6 kgf·m, 4.4 lb·ft)
9 New
T.R
.
6
S
7 10
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
.

10 Front brake hose 1 Disconnect.
11 Front brake master cylinder holder 1
12 Front brake master cylinder assembly 1
4-33
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
4-34
FRONT BRAKE
Removing the front brake caliper
1 3
2 New
4
29 N·m (2.9 kgf·m, 21 lb·ft)
T.R
.
35 N·m (3.5 kgf·m, 26 lb·ft)

T.R
.

Drain.
1 Front brake hose union bolt 1
3 Front brake hose 1 Disconnect.
4-35
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
4-36
FRONT BRAKE
EAS30168
e. Measure the runout 1.5 mm (0.06 in) below
INTRODUCTION
EWA14101
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
and plastic parts. Therefore, always clean Brake disc thickness limit
up any spilt brake fluid immediately. 3.5 mm (0.14 in)
• 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 4-21.
• Brake disc runout
2. Check:
• Brake disc a. Remove the brake disc.
Damage/galling → Replace. b. Rotate the brake disc by one bolt hole.
3. Measure: c. Install the brake disc.
Out of specification → Correct the brake disc Front brake disc bolt
runout or replace the brake disc. 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
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 that TIP

the front wheel is off ground. • 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 right • Tighten the brake disc bolts in stages.
to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
4-37
FRONT BRAKE
A. Inner
1 B. Outer
1
2. Install:
• Brake pad spring
• Brake pads
TIP
a Always install new brake pads, and new brake
pad spring, as a set.
d. Measure the brake disc runout. a. Connect a clear plastic hose “1” tightly to
e. If out of specification, repeat the adjustment the bleed screw “2”. Put the other end of the
steps until the brake disc runout is within hose into an open container.
specification. b. Loosen the bleed screw and push the brake
f. If the brake disc runout cannot be brought caliper piston into the brake caliper with
within specification, replace the brake disc. your finger.
6. Install:
• Front wheel 1
Refer to “FRONT WHEEL” on page 4-21
EAS30170
REPLACING THE FRONT BRAKE PADS 2

TIP
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.
c. Tighten the bleed screw.
1. Measure:
• Brake pad wear limit “a” Brake caliper bleed screw
Out of specification → Replace the brake 6 N·m (0.6 kgf·m, 4.4 lb·ft)
T.
R.
pads as a set.
d. Install new brake pad spring and new brake
Brake pad lining thickness limit pads.
0.8 mm (0.03 in) TIP
The longer tangs “a” of the brake pad spring “1”
A must point in the direction of the brake caliper
piston.
a
a
1
B
a 3. Install:
• Brake pad pin
• Brake pad clips
• Front brake caliper bolt
4-38
FRONT BRAKE
TIP
Front brake caliper bolt Put the end of the brake hose into a container
35 N·m (3.5 kgf·m, 26 lb·ft) and pump out the brake fluid carefully.
T.
R.
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. Remove:
• Brake caliper piston “1”
• Brake caliper piston dust seal “2”
4. Check:
• Brake caliper piston seal “3”
• Brake fluid level
Below the minimum level mark “a” → Add the
specified brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-11. 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”.
EWA13550
WARNING
5. Check:
• Cover the brake caliper piston with a rag.
• Brake lever operation
Be careful not to get injured when the pis-
Soft or spongy feeling → Bleed the brake sys-
ton is expelled from the brake caliper.
tem.
• Never try to pry out the brake caliper pis-
Refer to “BLEEDING THE HYDRAULIC
ton.
EAS31328
a
REMOVING THE FRONT BRAKE CALIPER
TIP
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
• Brake hose union bolt “1”
• Brake hose gasket “2” 1
• Front brake hose “3”
b. Remove the brake caliper piston dust seal
and brake caliper piston seal.
4-39
FRONT BRAKE
EAS30173 EAS30174
CHECKING THE FRONT BRAKE CALIPER ASSEMBLING THE FRONT BRAKE CALIPER
EWA16560
Recommended brake component WARNING

replacement schedule • Before installation, all internal brake com-
Brake pads If necessary ponents should be cleaned and lubricated
Piston seal Every two years with clean or new brake fluid.
• Never use solvents on internal brake com-
Piston dust seal Every two years ponents as they will cause the brake caliper
Brake hose Every four years piston dust seals and brake caliper piston
Every two years and seals to swell and distort.
Brake fluid whenever the brake is • Whenever a brake caliper is disassembled,
disassembled replace the brake caliper piston dust seals
and brake caliper piston seals.
1. Check:
Rust/scratches/wear → Replace the brake DOT 4
caliper piston.
• Brake caliper cylinder “2” EAS30934
Scratches/wear → Replace the brake caliper INSTALLING THE FRONT BRAKE CALIPER
assembly. 1. Install:
• Brake caliper body “3” • Front brake caliper “1”
Cracks/damage → Replace the brake caliper (temporarily)
assembly. • Brake hose gasket “2” New
• Brake fluid delivery passages • Front brake hose “3”
(brake caliper body) • Brake hose union bolt “4”
Obstruction → Blow out with compressed air.
EWA17070
Front brake hose union bolt
WARNING (brake caliper side)
T.
Whenever a brake caliper is disassembled,

R.
29 N·m (2.9 kgf·m, 21 lb·ft)

replace the brake caliper piston dust seal
EWA13531
WARNING
Proper brake hose routing is essential to in-
sure safe vehicle operation.
2 3
ECA19080
1
NOTICE
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” passes between the projections “b” on
the brake caliper.
2. Check:
3
• Brake caliper bracket 1
Cracks/damage → Replace. b
a
4
New 2
2. Remove:
4-40
FRONT BRAKE
3. Install:
• Brake pad spring a
• Brake pads
• Brake pad pin
• Brake pad clips
• Front wheel sensor lead holder
• Front brake caliper bolt
Front brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft) 7. Check:
T.
R.

Refer to “REPLACING THE FRONT BRAKE Soft or spongy feeling → Bleed the brake sys-
PADS” on page 4-38. tem.
4. Fill: Refer to “BLEEDING THE HYDRAULIC
• Brake master cylinder reservoir BRAKE SYSTEM” on page 3-12.
(with the specified amount of the specified
EAS30179
brake fluid) REMOVING THE FRONT BRAKE MASTER
CYLINDER
DOT 4 TIP
Before removing the front brake master cylinder,
EWA13540
drain the brake fluid from the entire brake sys-
WARNING tem.
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to 1. Remove:
deteriorate, causing leakage and poor • Brake hose union bolt “1”
brake performance. • Brake hose gasket “2”
• Refill with the same type of brake fluid that • Front brake hose “3”
is already in the system. Mixing brake fluids TIP
may result in a harmful chemical reaction, To collect any remaining brake fluid, place a
leading to poor brake performance. container under the master cylinder and the end
• When refilling, be careful that water does of the brake hose.
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA13540
2
NOTICE
Brake fluid may damage painted surfaces 3
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately. 1
5. Bleed:
• Brake system EAS30725
Refer to “BLEEDING THE HYDRAULIC CHECKING THE FRONT BRAKE MASTER

BRAKE SYSTEM” on page 3-12. CYLINDER
6. Check: 1. Check:
• Brake fluid level • Brake master cylinder
Below the minimum level mark “a” → Add the Damage/scratches/wear → Replace.
specified brake fluid to the proper level. • Brake fluid delivery passages
Refer to “BLEEDING THE HYDRAULIC (Brake master cylinder body)
BRAKE SYSTEM” on page 3-12. Obstruction → Blow out with compressed air.
4-41
FRONT BRAKE
2. Check: TIP
• Brake master cylinder kit • Install the brake master cylinder holder with the
Damage/scratches/wear → Replace. “UP” mark “a” facing up.
3. Check: • Align the edge “b” of the brake master cylinder
• Brake master cylinder reservoir “1” holder with the edge “c” of the stay on the han-
• Brake master cylinder reservoir cap “2” dlebar as shown in the illustration.
• Brake master cylinder reservoir diaphragm • First, tighten the upper bolt, then the lower bolt.
holder “3”
• Brake master cylinder reservoir diaphragm
“4” b
Damage/wear → Replace. c
1
2
1
3 a
4 2. Install:
• Brake hose gasket “1” New
• Front brake hose “2”
4. Check: • Brake hose union bolt “3”
• Front brake hose
Cracks/damage/wear → Replace. Front brake hose union bolt
(master cylinder side)
T.
R.
EAS30181
ASSEMBLING THE FRONT BRAKE MASTER 29 N·m (2.9 kgf·m, 21 lb·ft)

CYLINDER EWA13531
EWA13520
WARNING
WARNING
• Before installation, all internal brake com- sure safe vehicle operation.
ponents should be cleaned and lubricated
with clean or new brake fluid. TIP
• Never use solvents on internal brake com- • Make sure that the distance “a” between the
ponents. brake hose and the handlebar “4” is 40–44 mm
(1.57–1.73 in) as shown in the illustration.
Specified brake fluid • Turn the handlebar to the left and right to make
DOT 4 sure the brake hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
EAS30182 necessary.
INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1. Install:
• Brake master cylinder
• Brake master cylinder holder “1” New 1
3
Front brake master cylinder hold- 4
er bolt
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft) 2 a
4-42
FRONT BRAKE
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
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
• When refilling, be careful that water does
voir. Water will significantly lower the boil-
vapor lock.
ECA13540
NOTICE
Brake fluid may damage painted surfaces
any spilt brake fluid immediately.
4. Bleed:
• Brake system
5. Check:
Below the minimum level mark “a” → Add the
LEVEL” on page 3-11.
4-43
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
4-44
REAR BRAKE
Removing the rear brake master cylinder
16 N·m (1.6 kgf·m, 12 lb·ft) 1.5 N·m (0.15 kgf·m, 1.1 lb·ft)
11
3
6 N·m (0.6 kgf·m, 4.4 lb·ft)
29 N·m (2.9 kgf·m, 21 lb·ft)

8 6
9 New
12
10
7
5
6
4
1.2 N·m (0.12 kgf·m, 0.88 lb·ft) 6 N·m (0.6 kgf·m, 4.4 lb·ft)

Upper handlebar cover assembly Refer to “HANDLEBAR” on page 4-63.
Drain.
1 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm
2 1
holder
3 Brake master cylinder reservoir diaphragm 1
4 Rear brake light switch connector 2 Disconnect.
5 Rear brake light switch 1
6 Rear brake lever pivot bolt/nut 1/1
7 Rear brake lever 1
8 Rear brake hose union bolt 1
10 Rear brake hose 1 Disconnect.
11 Rear brake master cylinder holder 1
12 Rear brake master cylinder assembly 1
4-45
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
4-46
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
3 Rear brake hose 1 Disconnect.
4-47
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
4-48
REAR BRAKE
EAS30183
INTRODUCTION
EWA14101
Brake disc thickness limit
WARNING 4.0 mm (0.16 in)
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 4-37.
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 4-28.
• 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.
EAS30184 Brake pad lining thickness limit

CHECKING THE REAR BRAKE DISC 0.8 mm (0.03 in)
1. Remove:
• Rear wheel A
Refer to “REAR WHEEL” on page 4-28.
2. Check:
• Brake disc a
Damage/galling → Replace.
3. Measure:
Out of specification → Correct the brake disc
runout or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISC” on page 4-37. B
Brake disc runout limit (as mea-

sured on wheel) a
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. A. Inner
Refer to “CHECKING THE FRONT BRAKE B. Outer
4-49
REAR BRAKE
2. Install: 4. Check:
• Brake pad spring • Brake fluid level
• Brake pads Below the minimum level mark “a” → Add the
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 3-11.
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 a
caliper piston into the brake caliper with
your finger.
2
1
5. Check:
tem.
EAS30186
c. Tighten the bleed screw. REMOVING THE REAR BRAKE CALIPER

TIP
Brake caliper bleed screw Before removing the brake caliper, drain the
6 N·m (0.6 kgf·m, 4.4 lb·ft) brake fluid from the entire brake system.
T.
R.
d. Install new brake pad spring and new brake 1. Remove:

pads. • Rear brake hose union bolt “1”
TIP • Brake hose gasket “2”
The longer tangs “a” of the brake pad spring • Rear brake hose “3”
must point in the direction of the brake caliper TIP
position. Put the end of the brake hose into a container
and pump out the brake fluid carefully.
a
2
a
3
1
3. Install:
• Brake pad pin
• Brake pad clips
• Rear brake caliper
• Rear brake caliper bolt
Rear brake caliper bolt

35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
4-50
REAR BRAKE
EAS30187 EAS30188
DISASSEMBLING THE REAR BRAKE CHECKING THE REAR BRAKE CALIPER

CALIPER
Recommended brake component
1. Remove:
replacement schedule
• Brake caliper piston dust seal “2” Brake pad If necessary
• Brake caliper piston seal “3” Piston seal Every two years
Piston dust seal Every two years
Brake hose Every four years
1 Every two years and
2 3 Brake fluid whenever the brake is
disassembled
1. Check:
Rust/scratches/wear → Replace the brake
a. Blow compressed air into the brake hose caliper piston.
joint opening “a” to force out the piston from • Brake caliper cylinder “2”
the brake caliper. Scratches/wear → Replace the brake caliper
EWA13550
assembly.
WARNING • Brake caliper body “3”
• Cover the brake caliper piston with a rag. Cracks/damage → Replace the brake caliper
Be careful not to get injured when the pis- assembly.
ton is expelled from the brake caliper. • Brake fluid delivery passages
• Never try to pry out the brake caliper pis- (brake caliper body)
ton. Obstruction → Blow out with compressed air.
EWA17070
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston dust seal
a 3
1 2
b. Remove the brake caliper piston dust seal

2. Check:
• Brake caliper bracket
4-51
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
ponents as they will cause the brake caliper Rear brake caliper bolt
piston dust seal and brake caliper piston 35 N·m (3.5 kgf·m, 26 lb·ft)
T.
R.
seal to swell and distort. Refer to “REPLACING THE REAR BRAKE
• Whenever a brake caliper is disassembled, PADS” on page 4-49.
replace the brake caliper piston dust seal 4. Fill:
and brake caliper piston seal. • Brake master cylinder reservoir
Specified brake fluid brake fluid)
DOT 4
EAS30190 DOT 4
INSTALLING THE REAR BRAKE CALIPER
EWA13540
1. Install:
• Rear brake caliper “1” WARNING
(temporarily) • Use only the designated brake fluid. Other
• Brake hose gasket “2” New
• Rear brake hose “3”
brake performance.
• Brake hose union bolt “4”
Rear brake hose union bolt
(brake caliper side)
T.

R.
29 N·m (2.9 kgf·m, 21 lb·ft)

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 LEVEL” on page 3-11.
3
2. Remove:
• Rear brake caliper
4-52
REAR BRAKE
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
a • Brake master cylinder reservoir “1”
• Brake master cylinder reservoir cap
holder “2”
7. Check: “3”
• Brake lever operation Damage/wear → Replace.
Soft or spongy feeling → Bleed the brake sys- 4. Check:
tem. • Brake hose
Refer to “BLEEDING THE HYDRAULIC Cracks/damage/wear → Replace.
2
EAS30193
1
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 gasket “2” CYLINDER
• Brake hose “3” EWA13520
TIP WARNING
To collect any remaining brake fluid, place a • Before installation, all internal brake com-
container under the master cylinder and the end ponents should be cleaned and lubricated
of the brake hose. with clean or new brake fluid.
2 ponents.
1

DOT 4
EAS30196
INSTALLING THE REAR BRAKE MASTER

3 CYLINDER
1. Install:
EAS30194
• Brake master cylinder holder “1”
CHECKING THE REAR BRAKE MASTER
CYLINDER
Rear brake master cylinder hold-
1. Check:
er bolt
T.

R.
16 N·m (1.6 kgf·m, 12 lb·ft)

Damage/scratches/wear → Replace.
• Brake fluid delivery passages
(brake master cylinder body)
4-53
REAR BRAKE
EWA13540
TIP
WARNING
• 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-
brake performance.
dlebar as shown in the illustration.
• First, tighten the upper bolt, then the lower bolt.
1 leading to poor brake performance.
b
c voir. Water will significantly lower the boil-
vapor lock.
ECA13540
a
NOTICE
Brake fluid may damage painted surfaces
2. Install:
• Brake hose gasket “1” New any spilt brake fluid immediately.
• Rear brake hose “2”
• Brake hose union bolt “3” 4. Bleed:
• Brake system
Rear brake hose union bolt (mas- Refer to “BLEEDING THE HYDRAULIC
ter cylinder side) BRAKE SYSTEM” on page 3-12.
T.
R.
29 N·m (2.9 kgf·m, 21 lb·ft) 5. Check:

EWA13531
WARNING Below the minimum level mark “a” → Add the
sure safe vehicle operation.
LEVEL” on page 3-11.
3. Fill:
• Brake master cylinder reservoir
brake fluid)
a
DOT 4
6. Check:
tem.
4-54
ABS (Anti-lock Brake System)
EAS20032

Removing the hydraulic unit assembly
29 N•m (2.9 kgf•m, 21 lb•ft)
T .R
.
2
4
New 5
3
7 3
2 8
4
New 4
6 New
4
New
1 9
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T .R
.

Drain.
Front side cover (right) page 4-3.
Front upper cowling assembly page 4-15.
1 ABS ECU coupler 1 Disconnect.
Front brake hose union bolt (hydraulic unit
2 2
assembly side)
Rear brake hose union bolt (hydraulic unit
3 2
assembly side)
Front brake hose (hydraulic unit to front brake
5 1 Disconnect.
caliper)
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)
4-55
Removing the hydraulic unit assembly
29 N•m (2.9 kgf•m, 21 lb•ft)
T .R
.
2
4
New 5
3
7 3
2 8
4
New 4
6 New
4
New
1 9
7 N•m (0.7 kgf•m, 5.2 lb•ft)

T .R
.
8 Rear brake hose (hydraulic unit to rear brake 1 Disconnect.

caliper)
9 Hydraulic unit assembly 1
4-56
EAS30197
TIP
REMOVING THE HYDRAULIC UNIT
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
to poor braking performance. TIP
• To avoid brake fluid leakage and to prevent for-
ECA18241
eign materials from entering the hydraulic unit
NOTICE
assembly, insert a rubber plug “a” or a bolt
• Handle the ABS components with care (M10 × 1.25) into each brake hose union bolt
since they have been accurately adjusted. hole.
Keep them away from dirt and do not sub- • When using a bolt, do not tighten the bolt until
ject them to shocks. the bolt head touches the hydraulic unit. Other-
• Do not turn the main switch to “ON” when wise, the brake hose union bolt seating surface
removing the hydraulic unit assembly. could be deformed.
• Do not clean with compressed air.
• Do not reuse the brake fluid.
• Brake fluid may damage painted surfaces 1
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.
b 1
2. Remove:
• Brake hose
4-57
EAS30200
INSTALLING THE HYDRAULIC UNIT a

ASSEMBLY
1. Install: a
4
• Hydraulic unit assembly
4 1
Hydraulic unit assembly bolt 3 2
7 N·m (0.7 kgf·m, 5.2 lb·ft) 1
T.
R.
ECA21110 2
NOTICE a 3 a
Do not remove the rubber plugs or bolts 4. Connect:
(M10 × 1.25) installed in the brake hose union • ABS ECU coupler “1”
bolt holes before installing the hydraulic unit TIP
assembly. • Connect the ABS ECU coupler, and then push
the lock lever “a” of the coupler in the direction
TIP of the arrow shown.
Do not allow any foreign materials to enter the • Make sure that the ABS ECU coupler is con-
hydraulic unit assembly or the brake hoses nected in the correct position as shown in illus-
when installing the hydraulic unit assembly. tration “A”.
2. Remove:
• Rubber plugs or bolt (M10 × 1.25) 1
3. Install: a
• Rear brake hose (hydraulic unit to rear brake
caliper) “1”
• Rear brake hose (rear brake master cylinder
to hydraulic unit) “2”
• Front brake hose (front brake master cylinder
to hydraulic unit) “3”
• Front brake hose (hydraulic unit to front brake
caliper) “4”
A B
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)
ECA21121
NOTICE
A. The ABS ECU coupler is connected cor-
If the brake hose union bolt does not turn rectly.
easily, replace the hydraulic unit assembly, B. The ABS ECU coupler is not connected.
brake hoses, and related parts as a set.
5. Fill:
TIP • Brake master cylinder reservoir
As shown in the picture, when the brake hose is • Brake fluid reservoir
assembled, the steel pipe touches the convex. (with the specified amount of the specified
After the position of edge “a”, follow the se- brake fluid)
quence of 1 → 2 → 3 → 4. Tighten the connect-
ing bolts to the specified torque value. Specified brake fluid
DOT 4
4-58
EWA13090
Brake line routing confirmation
WARNING EWA13120
• Use only the designated brake fluid. Other WARNING

brake fluids may cause the rubber seals to Securely support the vehicle so that there is
deteriorate, causing leakage and poor no danger of it falling over.
brake performance.
• Refill with the same type of brake fluid that TIP
is already in the system. Mixing brake fluids • For the brake line routing confirmation, use the
may result in a harmful chemical reaction, diagnosis mode of the Yamaha diagnostic tool.
leading to poor brake performance. • Before performing the brake line routing confir-
• When refilling, be careful that water does mation, make sure that no malfunctions have
not enter the brake fluid reservoir. Water been detected in the ABS ECU and that the
will significantly lower the boiling point of wheels are not rotating.
the brake fluid and could cause vapor lock.
1. Place the vehicle on the centerstand.
ECA13540 2. Turn the main switch to “OFF”.
NOTICE 3. Open the seat.
Brake fluid may damage painted surfaces 4. Remove:
and plastic parts. Therefore, always clean up • Battery cover
any spilt brake fluid immediately. Refer to “GENERAL CHASSIS (1)” on
page 4-1.
6. Bleed:
5. Check:
• Brake system
• Battery voltage
Lower than 12.8 V → Charge or replace the
battery.
7. Check the operation of the hydraulic unit ac-
cording to the brake levers response. (Refer
Battery voltage
to “HYDRAULIC UNIT OPERATION TESTS” Higher than 12.8 V
on page 4-59.)
ECA14550
TIP
NOTICE
Always check the operation of the hydraulic If the battery voltage is lower than 12.8 V, charge
unit according to the brake lever response. the battery, and then perform brake line routing
confirmation.
8. Delete the fault codes. (Refer to “[B-3] DE-
LETING THE FAULT CODES” on page 9-
20.)
9. Perform a trial run. (Refer to “CHECKING
THE ABS WARNING LIGHT” on page 4-62.)
EAS30201
HYDRAULIC UNIT OPERATION TESTS

The reaction-force pulsating action generated in
the brake levers when the ABS is activated can
be tested when the vehicle is stopped.
The hydraulic unit operation can be tested using 6. Disconnect the Yamaha diagnostic tool cou-
the following two methods. pler from the CCU (Communication Control
• Brake line routing confirmation: this test Unit) “1”, and then connect the Yamaha diag-
checks the function of the ABS after the sys- nostic tool to the coupler.
tem was disassembled, adjusted, or serviced.
• ABS reaction-force confirmation: this test gen- Yamaha diagnostic tool USB
erates the same reaction-force pulsating action 90890-03267
that is generated in the front brake lever and Yamaha diagnostic tool (A/I)
rear brake lever when the ABS is front activat- 90890-03264
ed.
4-59
1 2
7. Start the Yamaha diagnostic tool and display TIP

the diagnosis mode screen. “ON” and “OFF” on the tool screen indicate
8. Select code No. 2, “Brake line routing confir- when the brakes are being applied and released
mation”. respectively.
9. Click “Actuator Check”, and then operate the
ECA22080
front brake lever “1” and rear brake lever “2”
NOTICE
simultaneously.
• Check that the pulse is felt in the front
TIP
brake lever, rear brake lever, and again in
• The hydraulic unit operates 1 second after the the front brake lever, in this order.
front brake lever and rear brake lever are oper- • If the pulse is felt in the rear brake lever be-
ated simultaneously and continues for approx- fore it is felt in the front brake lever, check
imately 5 seconds. that the brake hoses and brake pipes are
• The operation of the hydraulic unit can be con- connected correctly to the hydraulic unit
firmed using the indicator. assembly.
On: The hydraulic unit is operating. • If the pulse is hardly felt in either the front
Flashing: The conditions for operating the hy- brake lever or rear brake lever, check that
draulic unit have not been met. the brake hoses and brake pipes are con-
Off: The front brake lever and rear brake lever nected correctly to the hydraulic unit as-
are not being operated. sembly.
11.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
1 2
10.Check:
• Hydraulic unit operation
Click “Actuator Check”, a single pulse will be
generated in the front brake lever “1”, rear
brake lever “2”, and again in the front brake
lever “1”, in this order.
4-60
ABS reaction-force confirmation

EWA13120
WARNING 90890-03267
Securely support the vehicle so that there is Yamaha diagnostic tool (A/I)
no danger of it falling over. 90890-03264
TIP
1
• For the ABS reaction-force confirmation, use
the diagnosis mode of the Yamaha diagnostic
tool. For more information, refer to the opera-
tion manual of the Yamaha diagnostic tool.
• Before performing the ABS reaction-force con-
firmation, make sure that no malfunctions have
been detected in the ABS ECU and that the
wheels are not rotating.
1. Place the vehicle on a centerstand. 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 “Actuator Check”, and then operate the
Refer to “GENERAL CHASSIS (1)” on front brake lever “1” and rear brake lever “2”
page 4-1. simultaneously.
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 • The operation of the hydraulic unit can be con-
Higher than 12.8 V
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.
1 2
6. Disconnect the Yamaha diagnostic tool cou-
10.A reaction-force pulsating action is generated
pler from the CCU (Communication Control
in the front brake lever “1” and continues for a
Unit) “1”, and then connect the Yamaha diag-
few seconds.
nostic tool to the coupler.
4-61
ECA22080
TIP
NOTICE
• The reaction-force pulsating action consists of
• Check that the pulse is felt in the front
quick pulses.
brake lever, rear brake lever, and again in
• Be sure to continue operating the front brake
the front brake lever, in this order.
lever and rear brake lever even after the pul-
• If the pulse is felt in the rear brake lever be-
sating action has stopped.
fore it is felt in the front brake lever, check
• “ON” and “OFF” on the tool screen indicate
that the brake hoses and brake pipes are
when the brakes are being applied and re-
connected correctly to the hydraulic unit
leased respectively.
assembly.
• If the pulse is hardly felt in either the front
brake lever or rear brake lever, check that
the brake hoses and brake pipes are con-
nected correctly to the hydraulic unit as-
sembly.
13.Turn the main switch to “OFF”.
14.Remove the Yamaha diagnostic tool from the
Yamaha diagnostic tool coupler, and then in-
1 stall the protective cap.
11.After the pulsating action has stopped in the 15.Turn the main switch to “ON”.
front brake lever, it is generated in the rear 16.Check for brake fluid leakage around the hy-
brake lever “1” and continues for a few sec- draulic unit.
onds. Brake fluid leakage → Replace the hydraulic
TIP
unit, brake hoses, and related parts as a set.
17.If the operation of the hydraulic unit is normal,
delete all of the fault codes.
quick pulses.
• Be sure to continue operating the front brake EAS30202
lever and rear brake lever even after the pul- CHECKING THE ABS WARNING LIGHT
sating action has stopped. After all checks and servicing are completed, en-
• “ON” and “OFF” on the tool screen indicate sure that the ABS warning light goes off by walk-
when the brakes are being applied and re- ing the vehicle at a speed of faster than 10 km/h
leased respectively. (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
quick pulses.
• “ON” and “OFF” on the tool screen indicate
when the brakes are being applied and re-
leased respectively.
4-62
HANDLEBAR
EAS20033
HANDLEBAR
Removing the rearview mirror and handlebar cover
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)
T.R
.
2 1
22 N·m (2.2 kgf·m, 16 lb·ft) 3

T.R
.
4
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.
22 N·m (2.2 kgf·m, 16 lb·ft)
T.R
.
(2)
(2)

1 Rearview mirror 2
2 Upper handlebar cover assembly 1
3 Upper handlebar panel 1
4 Upper handlebar cover 1
4-63
HANDLEBAR
Removing the handlebar
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

T.R
.
LS 6
1 LS
16 N·m (1.6 kgf·m, 12 lb·ft)
T.R
LS
.
8
5
LS 53 N·m (5.3 kgf·m, 39 lb·ft)
T.R
.
7 16 N·m (1.6 kgf·m, 12 lb·ft)
6
T.R
.
4 3
12
10
2
16
2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.R
.
9 11 13 1
12
15 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.R
.
14
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

Front cowling assembly page 4-15
1 Grip end (left and right) 2
2 Front brake light switch connector 2 Disconnect.
3 Front brake master cylinder holder 1
4 Front brake master cylinder 1
5 Handlebar switch coupler (right) 2 Disconnect.
6 Handlebar switch (right) 1
7 Throttle cable 2 Disconnect.
8 Throttle grip 1
9 Rear brake light switch connector 2 Disconnect.
4-64
HANDLEBAR
Removing the handlebar
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)

T.R
.
LS 6
1 LS
16 N·m (1.6 kgf·m, 12 lb·ft)
T.R
LS
.
8
5
LS 53 N·m (5.3 kgf·m, 39 lb·ft)
T.R
.
7 16 N·m (1.6 kgf·m, 12 lb·ft)
6
T.R
.
4 3
12
10
2
16
2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.R
.
9 11 13 1
12
15 2.3 N·m (0.23 kgf·m, 1.7 lb·ft)
T.R
.
14
1.8 N·m (0.18 kgf·m, 1.3 lb·ft)
T.R
.

10 Rear brake master cylinder holder 1
11 Rear brake master cylinder 1
12 Handlebar switch (left) 1
13 Handlebar grip 1
14 Clamp 1
15 Upper handlebar cover 1
16 Handlebar 1
4-65
HANDLEBAR
EAS31622
TIP
REMOVING THE UPPER HANDLEBAR
COVER ASSEMBLY Blow compressed air between the handlebar
1. Remove: and the handlebar grip, and gradually push the
• Upper handlebar cover assembly “1” grip off the handlebar.
a. Remove the quick fastener and upper han-
dlebar cover assembly screws.
b. Unhook the projections “a” on the upper
handlebar cover assembly from the slots
“b” in the lower handlebar cover.
1
a
EAS30204
CHECKING THE HANDLEBAR

1. Check:
• Handlebar
b
Bends/cracks/damage → Replace.
EWA13690
EAS31701
DISASSEMBLING THE UPPER HANDLEBAR WARNING

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

TIP
Unhook the projections “a” on the front handle- EWA13120
bar cover from the slots “b” in the front handlebar WARNING
cover. Securely support the vehicle so that there is
1 2. Install:
• Handlebar “1”
b
a Handlebar bracket nut
53 N·m (5.3 kgf·m, 39 lb·ft)
T.
R.
EAS30203
REMOVING THE HANDLEBAR 1

EWA13120
WARNING
2. Remove:
• Grip end
3. Remove:
• Handlebar grip “1”
4-66
HANDLEBAR
3. Install:
• Handlebar switch (left) “1” 1
TIP
2
Align the projection “a” on the left handlebar
switch with the hole “b” in the rear handlebar 1
cover.
2
a
1
5. Install:
1 • Handlebar switch (right) “1”
• Throttle cables “2”
b a • Throttle grip “3”
• Grip end (right)
4. Install: Throttle cable holder bolt (han-

dlebar switch side)
• Handlebar grip “1”
T.
R.
2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
• Grip end (left) “2”
a. Apply a thin coat of a rubber adhesive to the TIP
left end of the handlebar. • Lubricate the end of the throttle cables and the
b. Slide the handlebar grip over the left end of inside of the throttle grip with a thin coat of lith-
the handlebar. ium-soap-based grease.
TIP • Align the projection “a” on the right handlebar
Make sure that the distance “a” between the end switch with the hole “b” in the rear handlebar
of the left handlebar switch and the end of the cover.
handlebar grip is 0 mm (0 in). • There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance between the throttle grip and the grip
end.
1 a
3 LS
LS
1
2
1 b
c. Wipe off any excess rubber adhesive with a a

2
clean rag.
EWA13700
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
d. Install the left grip end.
TIP
There should be 1.0–3.0 mm (0.04–0.12 in) of
clearance “a” between the handlebar grip and
the grip end.
4-67
HANDLEBAR
6. Install: EAS31623
INSTALLING THE UPPER HANDLEBAR

• Front brake master cylinder
COVER ASSEMBLY
• Front brake master cylinder holder “1”
1. Install:
• Upper handlebar cover assembly “1”
Front brake master cylinder hold-
er bolt a. Fit the projections “a” on the upper handle-
T.
R.
16 N·m (1.6 kgf·m, 12 lb·ft) bar cover into the slots “b” in the lower han-
dlebar cover.
TIP
1
• 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
dlebar as shown in the illustration.
• First, tighten the upper bolt, then the lower bolt.
b b
c b. Install the upper handlebar cover assembly
screws, and then tighten the screws to
1 specification.
UP
a Upper handlebar cover assembly

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

3.0–5.0 mm (0.12–0.20 in)
EAS31702
ASSEMBLING THE UPPER HANDLEBAR

COVER ASSEMBLY
1. Assemble:
• Upper handlebar cover “1”
• Upper handlebar cover “2”
TIP
Fit the projections “a” on the front handlebar cov-
er into the slots “b” in the front handlebar cover.
b
a
4-68
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 procedures are applied to both
of the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-21.
1 Front fender 1
2 Lower bracket pinch bolt 2
3 Front fork leg 1
4-69
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 procedures are applied 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
4-70
FRONT FORK
EAS30206
REMOVING THE FRONT FORK LEGS

the front fork legs. 1
EWA13120
2
WARNING
TIP
2. Drain:
• Fork oil
front wheels are off ground.
TIP
2. Loosen: Stroke the outer tube several times while drain-
• Lower bracket pinch bolts “1” ing the fork oil.
EWA18000
WARNING
Before loosening the lower bracket pinch
bolts, support the front fork leg.
1
1
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flathead screwdriver)
EAS30207 ECA14180
DISASSEMBLING THE FRONT FORK LEGS NOTICE

The following procedures are applied to both of Do not scratch the inner tube.
the front fork legs.
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” 4. Remove:
• Front fork cap “2” • Front fork damper rod bolt “1”
TIP • Copper washer
Push the front fork cap in the direction of the ar- TIP
row shown in the illustration to remove the front While holding the damper rod with the hexagon
fork cap clip. bit socket (14 mm) “2” and T-handle “3”, loosen
the front fork damper rod bolt.
4-71
FRONT FORK
EAS30209
ASSEMBLING THE FRONT FORK LEGS

T-handle
90890-01326 The following procedures are applied to both of
EWA13660
WARNING
• Make sure the oil levels in both front fork
1 2 3 legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
TIP
• When assembling the front fork leg, be sure to
replace the following parts:
– Front fork cap clip
EAS30208
CHECKING THE FRONT FORK LEGS – Oil seal

The following procedures are applied to both of – Oil seal clip
the front fork legs. – Dust seal
1. Check: – Copper washer
• Inner tube – O-ring
• Outer tube • Before assembling the front fork leg, make
Bends/damage/scratches → Replace. sure all of the components are clean.
EWA13650
1. Install:
WARNING
• Damper rod ring “1”
Do not attempt to straighten a bent inner • Damper rod “2”
tube as this may dangerously weaken it. • Rebound spring “3”
2. Measure: (in the inner tube “4”)
• Fork spring free length “a” • Oil flow stopper “5”
Out of specification → Replace.
ECA22740
NOTICE
Fork spring free length limit Allow the damper rod to slide slowly down
235.6 mm (9.28 in) the inner tube until it protrudes from the bot-
tom of the inner tube. Be careful not to dam-
age the inner tube.
TIP
a 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.
2
1
3. Check:
• Damper rod
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper
Damage → Replace.
4-72
FRONT FORK
Recommended oil
Yamaha Suspension Oil G10
4. Install:
• Inner tube
(in the outer tube)
5. Install:
5 4 3 1 2 • Copper washer New
• Front fork damper rod bolt “1”
2. Install:
• Oil seal “1” New Front fork damper rod bolt
(with the fork seal driver attachment “2” and 23 N·m (2.3 kgf·m, 17 lb·ft)
T.
R.
fork seal driver weight “3”) LOCTITE®
ECA14220
NOTICE TIP
Make sure the numbered side of the oil seal While holding the damper rod assembly with the
faces up. hexagon bit socket (14 mm) “2” and T-handle
“3”, tighten the front fork damper rod bolt.
TIP
• Lubricate the outer surface of the inner tube
with fork oil. T-handle
• Before installing the oil seal, cover the top of 90890-01326
the front fork leg with a plastic bag to protect
the oil seal during installation.
Fork seal driver weight 1 2 3

90890-01367
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
7. Install:
• Dust seal “1” New
3. Lubricate:
(with the fork seal driver attachment “2” and
• Inner tube’s outer surface
fork seal driver weight “3”)
4-73
FRONT FORK
TIP
Fork seal driver weight Be sure to bleed the front fork leg of any residual
90890-01367 air.
Fork seal driver attachment (ø30)
90890-01400 11.Measure:
• Front fork leg oil level “a”
(from the top of the inner tube, with the inner
tube fully compressed and without the fork
3 spring)
Out of specification → Correct.
2 Level (left)
77 mm (3.1 in)
1 New Level (right)
77 mm (3.1 in)
8. Fill: TIP
• Front fork leg • While filling the front fork leg, keep it upright.
(with the specified amount of the recom- • After filling, slowly pump the front fork leg up
mended fork oil) and down to distribute the fork oil.
Recommended oil
Yamaha Suspension Oil G10
Quantity
89.0 cm³ (3.01 US oz, 3.14 Imp.oz)
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 12.Install:
front fork leg, do not allow any foreign ma- • Fork spring “1”
terial to enter the front fork.
• O-ring New
9. After filling the front fork leg, slowly stroke the • Front fork cap
inner tube “1” up and down (at least ten • Front fork cap clip New
times) to distribute the fork oil. TIP
TIP Install the fork spring with its smaller pitch down-
Be sure to stroke the inner tube slowly because ward.
the fork oil may spurt out.
1
1
10.Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
4-74
FRONT FORK
EAS30210
INSTALLING THE FRONT FORK LEGS

1. Remove:
• 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.
1
1
4-75
STEERING HEAD
EAS20035
STEERING HEAD
Removing the lower bracket
1st 38 N·m (3.8 kgf·m, 28 lb·ft)

*2nd 17 N·m (1.7 kgf·m, 13 lb·ft) 75 N·m (7.5 kgf·m, 55 lb·ft)
LS 15
12
13 2
LS
14 4 3
LS 5
9 6
7
16
8 10
11
7 N·m (0.7 kgf·m, 5.2 lb·ft)
*Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.
Front upper cowling assembly page 4-15.
Front wheel Refer to “FRONT WHEEL” on page 4-21.
Handlebar Refer to “HANDLEBAR” on page 4-63.
Front fork legs Refer to “FRONT FORK” on page 4-69.
1 Front brake hose holder 1
2 Ring nut cover 1
3 Upper ring nut 1
4 Lock washer 1
4-76
STEERING HEAD
Removing the lower bracket
1st 38 N·m (3.8 kgf·m, 28 lb·ft)

*2nd 17 N·m (1.7 kgf·m, 13 lb·ft) 75 N·m (7.5 kgf·m, 55 lb·ft)
LS 15
12
13 2
LS
14 4 3
LS 5
9 6
7
16
8 10
11
7 N·m (0.7 kgf·m, 5.2 lb·ft)
*Loosen the lower ring nut 1/4 of a turn, and then tighten it to specification.
5 Center ring nut 1
6 Rubber washer 1
7 Lower ring nut 1
8 Lower bracket 1
9 Bearing cover 1
10 Upper bearing inner race 1
11 Upper bearing 1
12 Lower bearing 1
13 Lower bearing inner race 1
14 Dust seal 1
15 Lower bearing outer race 1
16 Upper bearing outer race 1
4-77
STEERING HEAD
EAS30213
3. Replace:
REMOVING THE LOWER BRACKET
• Bearing
EWA13120
• Bearing race
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 lower
2. Remove: bracket with a floor chisel “4” and hammer.
• Ring nut cover c. Install a new dust seal and new bearing rac-
• Upper ring nut “1” es.
• Lock washer ECA14270
• Center ring nut NOTICE

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

90890-01403
1
EAS30214
CHECKING THE STEERING HEAD

1. Wash:
• Bearing
• Bearing race 4. Check:
• Lower bracket
Recommended cleaning solvent (along with the steering stem)
Kerosene Bends/cracks/damage → Replace.
2. Check:
• Bearing
• Bearing race
Damage/pitting → Replace the bearings and
bearing races as a set.
4-78
STEERING HEAD
EAS30216
TIP
INSTALLING THE STEERING HEAD
1. Install: While holding the front brake hose holder so that
• Upper bearing “1” the holder contacts the projection “a” on the low-
• Lower bearing er bracket, tighten the bolt to specification.
• Lower bearing dust seal
TIP
• Apply lithium-soap-based grease to each part. a
• Be sure to install the upper bearing so that the
marks “a” on the bearing are facing upward.
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
• Center ring nut “3”
• Lock washer “4”
• Upper ring nut “5”
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-15.
5
4 3
2
1
3. Install:
• Front brake hose holder “1”
Front brake hose holder bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
4-79
REAR SHOCK ABSORBER ASSEMBLIES AND SWINGARM
EAS20189

Removing the rear shock absorber assemblies and swingarm
2
4 3
7 N m (0.7 kgf m, 5.2 lb ft)
T.R
.
13
New
10 57 N m (5.7 kgf m, 42 lb ft)
T.R
.
12
New
6
11
5 9 10
7
8 1
5 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
.

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

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

T.R
27 N•m (2.7 kgf•m, 20 lb•ft)

.
T.R
.

Battery page 4-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-8.
1 Rear wheel axle nut 1
2 Rear brake hose holder (rear side) 1
3 Rear wheel sensor 1
4-80
Removing the rear shock absorber assemblies and swingarm
2
4 3
7 N m (0.7 kgf m, 5.2 lb ft)
T.R
.
13
New
10 57 N m (5.7 kgf m, 42 lb ft)
T.R
.
12
New
6
11
5 9 10
7
8 1
5 T.R
. 7 N•m (0.7 kgf•m, 5.2 lb•ft)
T.R
T.R
.
.
21 N•m (2.1 kgf•m, 15 lb•ft) 7 N•m (0.7 kgf•m, 5.2 lb•ft)

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

T.R
27 N•m (2.7 kgf•m, 20 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
4-81
EAS31228 EAS31734
REMOVING THE SWINGARM MAINTENANCE OF THE REAR WHEEL

ECA22880
SENSOR
NOTICE ECA22900
Keep any type of magnets (including mag- NOTICE

netic pick-up tools, magnetic screwdrivers, • Handle the ABS components with care
etc.) away from the rear wheel sensor; other- since they have been accurately adjusted.
wise, the sensor may be damaged, resulting Keep them away from dirt and do not sub-
in improper performance of the ABS system. ject them to shocks.
• The rear wheel sensor cannot be disassem-
EWA13120
bled. Do not attempt to disassemble it. If
WARNING faulty, replace with a new one.
Securely support the vehicle so that there is • Keep any type of magnets (including mag-
no danger of it falling over. netic pick-up tools, magnetic screwdrivers,
etc.) away from the rear wheel sensor.
TIP • Do not drop or shock the wheel sensor.
Place the vehicle on the centerstand so that the 1. Check:
rear wheel is off ground. • Rear wheel sensor
2. Remove: Refer to “MAINTENANCE OF THE FRONT
• Rear wheel axle nut “1” WHEEL SENSOR AND SENSOR ROTOR”
• Rear brake hose holder (rear side) “2” on page 4-24.
• Rear wheel sensor “3” 2. Check:
• Rear brake caliper “4” • Rear wheel sensor rotor
ECA21830 Refer to “MAINTENANCE OF THE FRONT
NOTICE WHEEL SENSOR AND SENSOR ROTOR”
Do not apply the brake lever when removing on page 4-24.
the brake caliper. EAS31229
CHECKING THE REAR SHOCK ABSORBER

2 ASSEMBLY
1. Check:
• Rear shock absorber rod
4 Bends/damage → Replace the rear shock
absorber assembly.
3 • Rear shock absorber assembly
Oil leaks → Replace the rear shock absorber
1 assembly.
• Spring
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bushings
Damage/wear → Replace the rear shock ab-
sorber assembly.
• Bolt
Bends/damage/wear → Replace.
4-82
EAS30227
CHECKING THE SWINGARM

1. Check:
• Swingarm
Bends/cracks/damage → Replace.
2. Check: 6
• Spacer
• Collar
• Oil seal 3
• Bearing 1
Damage/wear → Replace. 2 New
New 2
EAS30228
5
INSTALLING THE SWINGARM LS
1. Lubricate:
• Oil seal lips 2 New
LS
Recommended lubricant 2 New

b
2. Assemble:
• Bearing “1” a
• Oil seals “2” New
• Bearing retaining plate “3”
• Rear brake hose guide “4” 3
• Spacer “5”
(to the swingarm “6”) d
Bearing retaining plate bolt

7 N·m (0.7 kgf·m, 5.2 lb·ft) c
T.
R.
TIP
• Install the oil seal until it is flush with the sur- 4
face “a” of the swingarm.
• Install the oil seal until it is flush with the sur-
3. Install:
face “b” of the bearing retaining plate.
• Swingarm assembly “1”
• Install the bearing retaining plate with the
• Rear wheel axle nut “2”
punch mark “c” facing outward.
(temporarily tighten)
• While holding the rear brake hose guide so that
• Swingarm mounting bolt (upper side) “3”
the portion “d” of the guide contacts the bearing
retaining plate.
• Swingarm mounting bolt (lower side) “4”
4. Tighten:
• Rear wheel axle nut “2”
• Swingarm mounting bolt (upper side) “3”
• Swingarm mounting bolt (lower side) “4”
Rear wheel axle nut

125 N·m (12.5 kgf·m, 92 lb·ft)
T.
R.
Swingarm mounting bolt

57 N·m (5.7 kgf·m, 42 lb·ft)
4-83
TIP
Tighten the rear wheel axle nut “2”, then the
swingarm mounting bolts “3”, “4”.
1 b
1
2
3
a
7. Install:
• Rear wheel sensor
2 4
Rear wheel sensor bolt
5. Install: 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.
R.
• Rear shock absorber assembly
ECA22910
NOTICE
nut Make sure there are no foreign materials in
T.
the rear wheel sensor. Foreign materials

R.
21 N·m (2.1 kgf·m, 15 lb·ft)

Rear shock absorber assembly cause damage to the rear wheel sensor.
bolt
27 N·m (2.7 kgf·m, 20 lb·ft) TIP
To route the rear wheel sensor lead, refer to
TIP “CABLE ROUTING” on page 2-13.
Tighten the rear shock absorber assembly nuts 8. Install:
and bolts temporarily, and then tighten them to • Rear brake hose holder (rear side) “1”
specification.
6. Measure: Rear brake hose holder bolt (rear
side)
T.
TIP
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)

Measure the distance “a” only if the wheel bear-
ings, wheel sensor rotor, or both were replaced. TIP
• Distance “a” Fit the projection “a” on the rear brake hose hold-
(between the wheel sensor rotor “1” and er into the hole “b” in the swingarm.
swingarm “2” (edge of the wheel sensor in-
stallation hole “b”))
Out of specification → Reinstall the bearing
or replace the wheel sensor rotor. 1
Distance “a” (between the wheel

sensor rotor and swingarm (edge a
of the wheel sensor installation
hole)) b
18.92–19.60 mm (0.74–0.77 in)
4-84
4-85
ENGINE
LUBRICATION SYSTEM CHART AND DIAGRAMS...................................... 5-1

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

MEASURING THE COMPRESSION PRESSURE....................................5-2
ENGINE REMOVAL ........................................................................................5-4

INSTALLING THE ENGINE....................................................................... 5-8
CYLINDER HEAD............................................................................................ 5-9

REMOVING THE CYLINDER HEAD.......................................................5-14
CHECKING THE CYLINDER HEAD .......................................................5-14
CHECKING THE CAMSHAFT SPROCKET............................................5-15
CHECKING THE TIMING CHAIN TENSIONER...................................... 5-15
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-16
CHECKING THE VVA SOLENOID.......................................................... 5-16
INSTALLING THE CYLINDER HEAD .....................................................5-16
CAMSHAFT ................................................................................................... 5-19

REMOVING THE CAMSHAFT ................................................................5-20
CHECKING THE CAMSHAFT.................................................................5-20
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-21
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-21
5
VALVES AND VALVE SPRINGS.................................................................. 5-23
REMOVING THE VALVES...................................................................... 5-24
CHECKING THE VALVES AND VALVE GUIDES ..................................5-24
CHECKING THE VALVE SEATS ............................................................ 5-26
CHECKING THE VALVE SPRINGS........................................................ 5-27
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....................................................5-37
REMOVING THE SECONDARY SHEAVE ............................................. 5-37
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-38
CHECKING THE CLUTCH HOUSING ....................................................5-38
CHECKING THE CLUTCH SHOES ........................................................ 5-38
CHECKING THE V-BELT........................................................................5-38
CHECKING THE PRIMARY SHEAVE ....................................................5-39
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-39
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-39
CHECKING THE SECONDARY SHEAVE .............................................. 5-39
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-39
ASSEMBLING THE SECONDARY SHEAVE..........................................5-40
INSTALLING THE PRIMARY SHEAVE, V-BELT AND
SECONDARY SHEAVE .........................................................................5-41
STARTER GENERATOR .............................................................................. 5-43

REMOVING THE STARTER GENERATOR ...........................................5-44
INSTALLING THE STARTER GENERATOR..........................................5-44
OIL PUMP...................................................................................................... 5-45

CHECKING THE OIL STRAINER ........................................................... 5-47
CHECKING THE OIL PUMP ................................................................... 5-47
ASSEMBLING THE OIL PUMP...............................................................5-47
TRANSMISSION............................................................................................ 5-48
CHECKING THE TRANSMISSION ......................................................... 5-50
INSTALLING THE TRANSMISSION .......................................................5-50
CRANKSHAFT ..............................................................................................5-51
DISASSEMBLING THE CRANKCASE....................................................5-53
REMOVING THE CRANKSHAFT ASSEMBLY ....................................... 5-53
CHECKING THE CRANKSHAFT ASSEMBLY........................................ 5-53
CHECKING THE CRANKCASE ..............................................................5-54
CHECKING THE BEARING .................................................................... 5-54
CHECKING THE OIL PUMP DRIVE GEAR ............................................5-54
INSTALLING THE CRANKSHAFT .......................................................... 5-54
ASSEMBLING THE CRANKCASE.......................................................... 5-55
INSTALLING THE CENTERSTAND .......................................................5-55
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20298
LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS32362
ENGINE OIL LUBRICATION CHART
Rocker arm
Camshaft Oil Nozzle
Crankshaft
Oil pump
Oil pan Oil strainer
3
Lubricant System Diagram
4
5 2 A-A
A
1. Engine oil port

2. Oil drain plug
3. Oil filter
4. Compression spring
5. O-ring
A
5-1
ENGINE INSPECTION
EAS20041
7. Measure:
ENGINE INSPECTION • Compression pressure
EAS30249
Out of specification → Refer to steps (c) and
MEASURING THE COMPRESSION (d).
PRESSURE
TIP Compression pressure
1583–2038 kPa/1300 r/min
Insufficient compression pressure will result in a (15.8–20.4 kgf/cm²/1300 r/min,
loss of performance. 225.2–289.9 psi/1300 r/min)
1. Measure:
• Valve clearance a. Turn the main switch to “ON”.
Out of specification → Adjust. b. With the throttle wide open, crank the en-
Refer to “ADJUSTING THE VALVE CLEAR- gine until the reading on the compression
ANCE” on page 3-5. gauge stabilizes.
EWA12960
2. Start the engine, warm it up for several min-
WARNING
To prevent sparking, ground the spark plug
3. Remove:
lead before cranking the engine.
Refer to “GENERAL CHASSIS (2)” on c. If the compression pressure is above the
page 4-3. maximum specification, check the cylinder
• Footrest board assembly (right) head, valve surfaces and piston crown for
Refer to “GENERAL CHASSIS (5)” on carbon deposits.
page 4-12. Carbon deposits → Eliminate.
4. Disconnect: d. If the compression pressure is below the
• Spark plug cap minimum specification, pour a teaspoonful
5. Remove: of engine oil into the spark plug bore and
• Spark plug measure again.
ECA20470
Refer to the following table.
NOTICE
Before removing the spark plug, use com- Compression pressure (with oil applied into
pressed air to blow away any dirt accumulat- the cylinder)
ed in the spark plug well to prevent it from Reading Diagnosis
falling into the cylinder. Higher than without Piston ring(s) wear or
oil damage → Repair.
6. Install:
• Compression gauge “1” Piston, valves, cylin-
• Extension “2” der head gasket or
Same as without oil
piston ring(s) possibly
Compression gauge defective → Repair.
90890-03081
Compression gauge extension
122mm
90890-04136
5-2
ENGINE INSPECTION
8. Install:
• Spark plug “1”
Spark plug
13 N·m (1.3 kgf·m, 9.6 lb·ft)
T.
R.
TIP
When tightening the spark plug, make sure that
the inside “a” of the spark plug wrench “2” does
not contact the portion “b” of the spark plug.
b
a 2
9. Connect:
• Spark plug cap
10.Install:
page 4-12.
page 4-3.
5-3
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler
25 N•m (2.5 kgf•m, 18 lb•ft)
T.R
.
8 N·m (0.8 kgf·m, 5.9 lb·ft)
T.R
.
53 N·m (5.3 kgf·m, 39 lb·ft)

T.R
.
1
LT
3 5
4 New
LT 2 53 N·m (5.3 kgf·m, 39 lb·ft)

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

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

T.R
.

1 O2 sensor coupler 1 Disconnect.
2 Muffler protector 1
3 Muffler 1
4 Exhaust gasket 1
5 O2 sensor 1
5-4
ENGINE REMOVAL
Disconnecting the leads
5
6

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-18.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-20.
Battery page 4-1.
Front cowling assembly page 4-3.
Side cover assembly page 4-6.
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 7-11.
5-5
ENGINE REMOVAL
Disconnecting the leads
5
6

Rear wheel Refer to “REAR WHEEL” on page 4-28.
1 Coolant reservoir hose 1 Disconnect.
2 Coolant temperature sensor coupler 1 Disconnect.
3 Crankshaft position sensor coupler 1 Disconnect.
4 Starter generator lead coupler 1 Disconnect.
5 Spark plug cap 1 Disconnect.
6 Engine ground lead 1 Disconnect.
7 VVA (variable valve actuator) solenoid coupler 1 Disconnect.
5-6
ENGINE REMOVAL
Removing the engine
52 N·m (5.2 kgf·m, 38 lb·ft) 21 N·m (2.1 kgf·m, 15 lb·ft)
T.R
T.R
.
.
28 N·m (2.8 kgf·m, 21 lb·ft)

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

1 Rear shock absorber assembly 2
2 Engine bracket nut/bolt 1
3 Engine bracket fixed nut/bolt (upper) 2/2
4 Engine mount bracket nut/bolt 2/2
5 Engine bracket 1
6 Stopper 2
7 Collar 2
5-7
ENGINE REMOVAL
EAS30251
d. Temporarily install the engine bracket fixed
INSTALLING THE ENGINE
bolt “9” in the engine mount bracket “10”.
1. Install:
a. Temporarily put the stopper “1” and collar
“2” on the engine assembly “3”.
1
3
9
2 10
e. Tighten the engine bracket nut (front) “10”.
Engine bracket nut (front)

b. Install the engine bracket “4” to the engine 52 N·m (5.2 kgf·m, 38 lb·ft)
T.
R.
assembly, then install fixing bolt “5” and nut
(below) “6” and use the pin ø3 mm to insert
in the hole of the engine bracket and the
collar “a”, then tighten. Fix the nut to the
specified torque (first lock the right and then
the left side).
a
4
A A 10
f. After the installation is complete, confirm
2 1 that the stopper “1” will not touch the engine
assembly “3” with the main bracket upright.
6 5
4 a
A-A 1
Engine bracket nut (center)

50 N·m (5.0 kgf·m, 37 lb·ft)
T.
R.
c. Remove the ø3 pin, insert the engine mount

bracket nut “7”, and then tighten the nut “8”.
Engine mount bracket nut 3

28 N·m (2.8 kgf·m, 21 lb·ft)
T.
R.
5-8
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
10
T.R
.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
New
6 17
7 New New 18 TB1215
New 14 New
8 12
16 19
5 15
(4)
LS LT
9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
11 26 25
M
New
13
(4) (4) (4) 24 New
10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R
M
.
1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.
23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.
T.R
4
.
New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

Battery page 4-1.
Front side covers page 4-3.
Drain.
page 3-20.
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
.
10
T.R
.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
New
6 17
7 New New 18 TB1215
New 14 New
8 12
16 19
5 15
(4)
LS LT
9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
11 26 25
M
New
13
(4) (4) (4) 24 New
10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R
M
.
1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.
23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.
T.R
4
.
New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

Radiator Refer to “RADIATOR” on page 6-2.
Thermostat assembly Refer to “THERMOSTAT” on page 6-6.
Water pump Refer to “WATER PUMP” on page 6-8.
5-10
CYLINDER HEAD
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
10
T.R
.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
New
6 17
7 New New 18 TB1215
New 14 New
8 12
16 19
5 15
(4)
LS LT
9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
11 26 25
M
New
13
(4) (4) (4) 24 New
10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R
M
.
1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.
23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.
T.R
4
.
New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

Fuel tank Refer to “FUEL TANK” on page 7-1.
Intake manifold Refer to “THROTTLE BODY” on page 7-11.
1 Spark plug cap 1 Disconnect.
2 Spark plug 1
3 Coolant temperature sensor coupler 1 Disconnect.
5-11
CYLINDER HEAD
4.0 N·m (0.40 kgf·m, 3.0 lb·ft)

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
10
T.R
.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
New
6 17
7 New New 18 TB1215
New 14 New
8 12
16 19
5 15
(4)
LS LT
9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
11 26 25
M
New
13
(4) (4) (4) 24 New
10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R
M
.
1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.
23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.
T.R
4
.
New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

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

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
10
T.R
.
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
New
6 17
7 New New 18 TB1215
New 14 New
8 12
16 19
5 15
(4)
LS LT
9 7 N·m (0.7 kgf·m, 5.2 lb·ft)

T.R
.
11 26 25
M
New
13
(4) (4) (4) 24 New
10 N·m (1.0 kgf·m, 7.4 lb·ft) New

T.R
M
.
1st 10 N·m (1.0 kgf·m, 7.4 lb·ft) 25

M
2nd 24 N·m (2.4 kgf·m, 18 lb·ft) 1 2
13 N·m (1.3 kgf·m, 9.6 lb·ft) 20
T.R
.
23 22
13
3 21
10 N·m (1.0 kgf·m, 7.4 lb·ft)
30 N·m (3.0 kgf·m, 22 lb·ft)
T.R
.
T.R
4
.
New
15 N·m (1.5 kgf·m, 11 lb·ft)
T.R
.

14 Cylinder head cover breather plate 1
15 Cylinder head cover breather plate gasket 1
16 Oil seal 1
17 Timing chain tensioner plug 1
18 Timing chain tensioner 1
19 Timing chain tensioner gasket 1
20 Camshaft sprocket bolt 1
21 Camshaft sprocket 1
22 Decompression cam 1
23 Cylinder head 1
24 Cylinder head gasket 1
25 Dowel pin 2
26 Engine oil check bolt 1
5-13
CYLINDER HEAD
EAS30276
3. Remove:
REMOVING THE CYLINDER HEAD
• Cylinder head
1. Align:
TIP
• “I” mark “a” on the AC magneto rotor
(with the match mark “b” on the right crank- • Loosen the bolts and nuts in the proper se-
case) quence as shown.
• Loosen each bolt and nuts 1/2 of a turn at a
a. Turn the crankshaft clockwise.
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 compres-
1 2
sion stroke, align the “I” mark “c” on the
camshaft sprocket with the match mark “d” EAS30277
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
2. Check:
• Cylinder head
Damage/scratches → Replace.
1 • Cylinder head water jacket
2 Mineral deposits/rust → Eliminate.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
head.
Warpage limit
0.05 mm (0.0020 in)
5-14
CYLINDER HEAD
EAS30266
a. Place a straightedge “1” and a thickness 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 screw-
driver counterclockwise, remove the screw-
b. Measure the warpage. driver, and slowly release the timing chain
c. If the limit is exceeded, resurface the cylin- tensioner rod.
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.
EAS30936
CHECKING THE CAMSHAFT SPROCKET d. Make sure that the timing chain tensioner
1. Check: rod comes out of the timing chain tensioner
• Camshaft sprocket housing smoothly. If there is rough move-
More than 1/4 tooth wear “a” → Replace the ment, replace the timing chain tensioner.
camshaft sprocket, timing chain and crank- e. Install the timing chain tensioner plug.
shaft as a set.
a. 1/4 tooth
b. Correct
1. Timing chain roller

2. Camshaft sprocket
5-15
CYLINDER HEAD
EAS30280 EAS30282
CHECKING THE DECOMPRESSION SYSTEM INSTALLING THE CYLINDER HEAD

1. Check: 1. Tighten:
• Decompression system • Cylinder head nuts “1”
TIP • Cylinder head bolts “2”
• Check that the decompression lever moves
smoothly. Cylinder head nut
• Check that the operating range “a” of the de- 24 N·m (2.4 kgf·m, 18 lb·ft)
T.
R.
compression lever is the same as the range Cylinder head bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
shown in the illustration.
TIP
a
• Lubricate the cylinder head nuts and thread of
bolt and washers with molybdenum disulfide
grease.
• Tighten the cylinder head nuts and bolts in the
proper tightening sequence as shown and
torque them in two stages.
×
3 4 4
a. 20.88°
EAS31624
1 1 ×
CHECKING THE VVA SOLENOID 2
1. Check: 1 2
2 2
• VVA (variable valve actuator) solenoid “1”
6 5
1 2. Install:
• Decompression cam “1”
• Camshaft sprocket “2”
• Timing chain
• Camshaft sprocket bolt
a. Turn the crankshaft clockwise.
b. Align the “I” mark “a” on the AC magneto ro-
tor with the match mark “b” on the right
crankcase.
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.
5-16
CYLINDER HEAD
ECA20600
TIP
NOTICE
• Install the timing chain tensioner gasket so that
Do not turn the crankshaft when installing
the tabs “a” on the gasket are protruding in the
the camshaft sprocket to avoid damage or
directions shown in the illustration.
improper valve timing.
• Apply Yamaha bond No. 1215 to the threads of
TIP the timing chain tensioner bolts.
• Fit the pin on the decompression cam into the
slot “c” in the decompression lever on the cam- Yamaha bond No. 1215
shaft sprocket. 90890-85505
• Align the “I” mark “d” on the camshaft sprocket
with the match mark “e” on the camshaft stop-
per plate. Timing chain tensioner bolt
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
2
e a
a
1
d
c 2
e. While holding the camshaft, temporarily

tighten the camshaft sprocket bolt. d. Turn the timing chain tensioner rod counter-
clockwise with a thin screwdriver “1”, make
3. Install: sure it releases, and then install the timing
• Timing chain tensioner gasket New chain tensioner plug.
• Timing chain tensioner
a. Remove the timing chain tensioner plug. 1
b. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod
fully clockwise with a thin screwdriver “1”.
TIP
Make sure that the tensioner rod has been fully
turned clockwise.
4. Turn:
• Crankshaft
(several turns clockwise)
5. Check:
• “I” mark “a”
Make sure the “I” mark “a” on the AC magne-
to rotor is aligned with the match mark “b” on
1
the right crankcase.
• “I” mark “c”
c. Install the gasket and the timing chain ten- Make sure the “I” mark “c” on the camshaft
sioner “2” onto the cylinder. sprocket is aligned with the match mark “d”
EWA17620
WARNING on the camshaft stopper plate.

Always use a new gasket. Out of alignment → Correct.
Refer to the installation steps above.
5-17
CYLINDER HEAD
7. Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-5.
b 8. Install:
• Oil seal “1”
(into the cylinder head cover “2”)
TIP
a
Install the oil seal so that it is facing in the direc-
tion shown in the illustration. Press the oil seal
c into the cylinder head cover using a suitable di-
d
ameter socket “3”.
3 2
1
6. Tighten:
• Camshaft sprocket bolt “1”
Camshaft sprocket bolt

30 N·m (3.0 kgf·m, 22 lb·ft) 9. Install:
T.
R.
• VVA (variable valve actuator) solenoid “1”

Camshaft wrench
90890-04162 VVA (variable valve actuator) so-
lenoid bolt
T.
R.
ECA20610 10 N·m (1.0 kgf·m, 7.4 lb·ft)

NOTICE
Be sure to tighten the camshaft sprocket bolt TIP
to the specified torque to avoid the possibil- While holding the VVA (variable valve actuator)
ity of the bolt coming loose and damaging solenoid so that it is contacting the cylinder head
the engine. cover “2”, tighten the bolts to specification.
TIP
Tighten the camshaft sprocket bolt with the cam-
shaft wrench “2”.
1
2
1
2
5-18
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 9 4 New
M
M E
8
6 7
E 3
E 5
2 M
7 E
M
2 M 5
M
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T .R
.

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
5-19
CAMSHAFT
EAS30256 EAS30257
REMOVING THE CAMSHAFT CHECKING THE CAMSHAFT

1. Loosen: 1. Check:
• Adjusting screw (intake/exhaust) • Camshaft lobe
2. Remove: Blue discoloration/pitting/scratches → Re-
• Camshaft assembly “1” place the camshaft.
2. Measure:
Slide hammer bolt (M8) • Camshaft lobe dimensions “a”
90890-01085 Out of specification → Replace the camshaft.
Weight
90890-01084 Camshaft lobe dimensions
Lobe height limit (Intake)
a. Align the holes “a” in intake rocker arm 1 “2” 32.111 mm (1.2642 in)
and intake rocker arm 2 “3”, and then push Lobe height limit (Intake high
the intake rocker arm stopper pin “4” in the speed)
direction of the arrow shown in the illustra- 32.487 mm (1.2790 in)
tion. Lobe height limit (Exhaust)
29.124 mm (1.1466 in)
4 a
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 3. Measure:
camshaft assembly using a slide hammer • Camshaft runout
bolt “5” and weight “6”. Out of specification → Replace the camshaft.
3
1
5
6
4. Check:
• Camshaft oil passage
5-20
CAMSHAFT
EAS30259
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
• Rocker arm
• Rocker arm roller “1”
1 5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
TIP
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.
1 1 Out of specification → Replace the defective
part(s).
2. Check:
• Rocker arm shaft Rocker-arm-to-rocker-arm-shaft
Blue discoloration/excessive wear/pitting/ clearance limit
scratches → Replace or check the lubrication 0.080 mm (0.0032 in)
system.
3. Measure: EAS30270
• Rocker arm inside diameter “a” INSTALLING THE CAMSHAFT AND ROCKER
Out of specification → Replace. ARMS
1. Lubricate:
Rocker arm inside diameter limit • Camshaft assembly
10.015 mm (0.3943 in)
Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
a
2. Lubricate:
• Rocker arms
• Rocker arm shafts
• Spring
• Intake rocker arm stopper pin
4. Measure:
• Rocker arm shaft outside diameter “a” Recommended lubricant
Out of specification → Replace. Rocker arm shaft
Intake rocker arm stopper pin
Rocker arm shaft outside diame- Molybdenum disulfide oil
ter limit Spring
9.935 mm (0.3911 in) Rocker arm roller
Engine oil
5-21
CAMSHAFT
3. Install: 5. Install:
• Spring “1” • Camshaft stopper plate
TIP
Install the spring so that the ends “a” of the Camshaft stopper plate bolt (M5
spring are positioned at the locations shown in × 16)
T.
R.
8 N·m (0.8 kgf·m, 5.9 lb·ft)
the illustration.
Camshaft stopper plate bolt (M6
× 14)
a 1 8 N·m (0.8 kgf·m, 5.9 lb·ft)
TIP
Before installing the camshaft stopper plate,
make sure that the slots “a” in the rocker arm
shafts “2” are parallel with the edge “b” of the cyl-
inder head and that the camshaft stopper plate
bolt holes in the cylinder head and rocker arm
shafts are aligned.
4. Install:
• Camshaft assembly “1” b
a. Align the holes “a” in intake rocker arm 1 “2” 2 a
and intake rocker arm 2 “3”, and then push
the intake rocker arm stopper pin “4” in the a
direction of the arrow shown in the illustra-
tion.
4
a
b. While pushing intake rocker arm 1 “2” and

intake rocker arm 2 “3” in the direction of the
arrow shown in the illustration, install the
camshaft assembly.
TIP
Install the camshaft with the punch mark “a” fac-
ing upward.
5-22
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 arm Refer to “CAMSHAFT” on page 5-19.
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
5-23
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 3. Remove:
Leakage at the valve seat → Check the valve • Valve spring retainer “1”
face, valve seat, and valve seat width. • Valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Valve “3”
on page 5-26. • Valve stem seal “4”
a. Pour a clean solvent “a” into the intake and • Valve spring seat “5”
exhaust ports. TIP
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
1
5
2
3
4
EAS30284
2. Remove: CHECKING THE VALVES AND VALVE

• Valve cotters “1” GUIDES
TIP The following procedures are applied to all of the
valves and valve guides.
Remove the valve cotters by compressing the
1. Measure:
valve spring with the valve spring compressor
• Valve-stem-to-valve-guide clearance
and the valve spring compressor attachment “2”.
Out of specification → Replace the valve
guide.
Valve spring compressor Valve-stem-to-valve-guide clearance =
90890-04019 Valve guide inside diameter “a” -
Valve spring compressor attach- Valve stem diameter “b”
ment
90890-04108
Valve-stem-to-valve-guide clear-
ance limit (intake)
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance limit (exhaust)
0.100 mm (0.0039 in)
5-24
a
a
a. Valve guide position

c. After installing the valve guide, bore the
valve guide with the valve guide reamer “3”
to obtain the proper valve-stem-to-valve-
guide clearance.
2. Replace:
• Valve guide New 3
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
a. Remove the valve guide with the valve

guide remover “1”.
TIP
After replacing the valve guide, reface the valve
seat.
1
Valve guide remover (ø5)

90890-04097
Valve guide installer (ø5)
90890-04098
Valve guide reamer (ø5)
b. Install the new valve guide with the valve 90890-04099
guide installer “2” and valve guide remover
“1”. 3. Eliminate:
• Carbon deposits
Valve guide position (from the valve face and valve seat)
9.9–10.3 mm (0.39–0.41 in) 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.
5-25
TIP a. Apply blue layout fluid “b” onto the valve

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

0.020 mm (0.0008 in)
b
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
EAS30285
CHECKING THE VALVE SEATS removed.

valves and valve seats. 4. Lap:
1. Eliminate: • Valve face
• Carbon deposits • Valve seat
(from the valve face and valve seat) TIP
2. Check: After replacing the cylinder head or replacing the
• Valve seat valve and valve guide, the valve seat and valve
Pitting/wear → Replace the cylinder head. face should be lapped.
3. Measure:
• Valve seat width “a” a. Apply a coarse lapping compound “a” to the
Out of specification → Replace the cylinder valve face.
ECA13790
head.
NOTICE
Do not let the lapping compound enter the
Valve seat contact width limit (in-
take) gap between the valve stem and the valve
1.3 mm (0.05 in) guide.
Valve seat contact width limit
(exhaust)
1.7 mm (0.07 in)
a
b. Apply molybdenum disulfide oil onto the
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, and then clean off
all of the lapping compound.
5-26
TIP
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hands.
a
EAS30288
INSTALLING THE VALVES

valves and related components.
• Valve stem end
e. Apply a fine lapping compound to the valve (with an oil stone)
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply blue layout fluid “b” onto the valve
face.
1. Lubricate:
• Valve stem “1”
b
Molybdenum disulfide oil
h. Install the valve into the cylinder head. • Valve stem seal “2”
i. Press the valve through the valve guide and (with the recommended lubricant)
onto the valve seat to make a clear impres-
sion. Recommended lubricant
j. Measure the valve seat width again. If the Engine oil
valve seat width is out of specification, re-
face and lap the valve seat.
EAS30286
CHECKING THE VALVE SPRINGS

The following procedures are applied to all of the E
valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
spring.
Free length limit (intake)

32.10 mm (1.26 in)
Free length limit (exhaust)
32.10 mm (1.26 in)
5-27
2. Install:
• Valve spring seat “1” 2
• Valve stem seal “2” New
• Valve “3”
• Valve spring “4”
• Valve spring retainer “5”
(into the cylinder head)
TIP
• Make sure each valve is installed in its original 1
place. 4. To secure the valve cotters onto the valve
• Install the valve springs with the larger pitch “a” stem, lightly tap the valve tip with a soft-face
facing up. hammer.
5.ECA13800
NOTICE
5
Hitting the valve tip with excessive force
1 could damage the valve.
4
3
2 New
b. Smaller pitch
3. Install:
• Valve cotters “1”
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.
Valve spring compressor

90890-04019
Valve spring compressor attach-
ment
90890-04108
5-28
CYLINDER AND PISTON
EAS20046
CYLINDER AND PISTON

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

1. Remove:
• Piston pin clips “1”
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP EAS30291
• Before removing the piston pin clips, cover the CHECKING THE CYLINDER AND PISTON
crankcase opening with a clean rag to prevent 1. Check:
them from falling into the crankcase. • Piston wall
• Before removing the piston pin, deburr the pis- • Cylinder wall
ton pin clip groove and the piston pin bore ar- Vertical scratches → Rebore or replace the
ea. If both areas are deburred and the piston cylinder, and replace the piston and piston
pin is still difficult to remove, remove it with the rings as a set.
piston pin puller set “4”. 2. Measure:
• Piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
Piston pin puller set bore gauge.
90890-01304
TIP
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
2 1 Bore
52.000–52.010 mm (2.0472–
2.0476 in)
Wear limit
52.060 mm (2.0496 in)
3
“C” = maximum of D1 - D2
2. Remove:
• Top ring
• 2nd ring b. If out of specification, rebore or replace the
• Oil ring cylinder, and replace the piston and piston
rings as a set.
TIP
c. Measure piston skirt diameter P with the mi-
When removing a piston ring, open the end gap crometer.
with your fingers and lift the other side of the ring
over the piston crown.
5-30
CYLINDER AND PISTON
a. 6.0 mm (0.24 in) from the bottom edge of 2. Install:

the piston • Piston ring
(into the cylinder)
Piston TIP
Diameter Use the piston crown to level the piston ring near
51.962–51.985 mm (2.0457– the bottom of the cylinder where the cylinder
2.0466 in) wear is lowest.
d. If out of specification, replace the piston and 3. Measure:
piston rings as a set. • Piston ring end gap
e. Calculate the piston-to-cylinder clearance Out of specification → Replace the piston
with the following formula. ring.
Piston-to-cylinder clearance = TIP
Cylinder bore - The oil ring expander spacer end gap cannot be
Piston skirt diameter measured. If the oil ring rail gap is excessive, re-
place all three piston rings.
Piston-to-cylinder clearance
0.015–0.048 mm (0.0006–0.0019 Piston ring
in) Top ring
End gap limit
f. If out of specification, rebore or replace the 0.50 mm (0.0197 in)
cylinder, and replace the piston and piston 2nd ring
rings as a set. End gap limit
0.85 mm (0.0335 in)
EAS30292
CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance a
Out of specification → Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston b
ring grooves and piston rings.
a. Bottom of cylinder
Piston ring b. Upper of cylinder
Top ring
Side clearance limit
0.115 mm (0.0045 in)
2nd ring
Side clearance limit
0.115 mm (0.0045 in)
5-31
CYLINDER AND PISTON
EAS30293 EAS30290
CHECKING THE PISTON PIN CHECKING THE TIMING CHAIN GUIDE

1. Check: (EXHAUST SIDE)
• Piston pin 1. Check:
Blue discoloration/grooves → Replace the • Timing chain guide (exhaust side)
piston pin, and then check the lubrication sys- Damage/wear → Replace.
tem.
EAS30294
2. Measure: INSTALLING THE PISTON AND CYLINDER
• Piston pin outside diameter “a” 1. Install:
Out of specification → Replace the piston pin. • Lower oil ring rail “1”
• Oil ring expander “2”
Piston pin outside diameter limit • Upper oil ring rail “3”
13.975 mm (0.5502 in) • 2nd ring “4”
• Top ring “5”
TIP
Be sure to install the piston rings so that the
manufacturer marks face up.
4
3. Measure: 3
• Piston pin bore diameter “b”
2
Out of specification → Replace the piston.
1
Piston pin bore inside diameter
limit 2. Install:
14.043 mm (0.5529 in) • Piston “1”
• Piston pin clips “3” New
TIP
• Apply engine oil to the piston pin.
• Make sure the punch mark “a” on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase.
• When installing a piston pin clip, make sure
4. Calculate: that the clip ends “b” are positioned away from
• Piston-pin-to-piston-pin-bore clearance the cutout “c” in the piston as shown in the illus-
Out of specification → Replace the piston pin tration.
and piston as a set.
Piston-pin-to-piston-pin-bore clearance = New 3
Piston pin bore diameter “b” - 2
Piston pin outside diameter “a”
5-32
CYLINDER AND PISTON
3 New 2 1 2
1
b
3. Lubricate:
• Piston
• Piston rings
• Cylinder
(with the recommended lubricant)
Engine oil
4. Offset:
• Piston ring end gaps
c
b a
135˚
45˚ 45˚
e 45˚ 45˚ d
A
a. Top ring
b. 2nd ring
c. Upper oil ring rail
d. Oil ring expander
e. Lower oil ring rail
A. Exhaust side
5. Install:
• Dowel pins
• Cylinder gasket New
• Cylinder “1”
TIP
• While holding the piston “2” with one hand, in-
stall the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
5-33
V-BELT AUTOMATIC TRANSMISSION
EAS20050

Removing the V-belt case
10 5 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
New 9
(10)
8
7
New 1
New 6
2
3
4
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
.

1 V-belt case air filter element cover 1
2 V-belt case air filter element 1
3 V-belt case air filter element support 1
4 O-ring 1
5 V-belt case 1
6 V-belt case gasket 1
7 Dowel pin 1
8 V-belt case check hose 1
9 Clip 1
10 Bearing 1
5-34
Removing the V-belt, primary sheave and secondary sheave
45 N·m (4.5 kgf·m, 33 lb·ft)
T.R
.
13
14
12
10
10
11 8
LS 9
10
7 6
LS
4
5
3
1
2
76 N·m (7.6 kgf·m, 56 lb·ft)
T.R
.

1 Primary fixed sheave nut 1
2 Conical spring washer 1
3 Primary fixed sheave 1
4 Washer 1
5 V-belt 1
6 Collar 1
7 Primary sliding sheave 1
8 Primary sheave weight 6
9 Cam 1
10 Slider 3
11 Washer 1
12 Clutch housing nut 1
13 Clutch housing 1
14 Secondary sheave assembly 1
5-35
Disassembling the secondary sheave
E
7
6
3
4 55 N·m (5.5 kgf·m, 41 lb·ft)
T .R
.
13
14 16 5
15 New 2
8
9
12 New 10
1
12 New
E 11 New

1 Secondary sheave nut 1
2 Clutch carrier assembly 1
3 Circlip 3
4 Clutch puller fixed plate 1
5 Clutch shoe spring 3
6 Compression spring 1
7 Spring seat 1
8 Guide pin 3
9 Collar 3
10 Secondary sliding sheave 1
11 O-ring 2
12 Oil seal 2
13 Bearing 1
14 Circlip 1
15 Bearing 1
16 Secondary fixed sheave 1
5-36
EAS30310
2. Loosen:
REMOVING THE PRIMARY SHEAVE
• Secondary sheave nut “1”
1. Remove: ECA21820
• Primary fixed sheave nut “1” NOTICE

• Conical spring washer Do not remove the secondary sheave nut at
• Washer this stage.
• Primary fixed sheave “2”
TIP TIP
While holding the primary fixed sheave with the While holding the secondary sheave with the ro-
rotor holding tool “3”, loosen the primary fixed tor holding tool “2”, loosen the secondary
sheave nut. sheave nut one full turn with the socket wrench
“3”.
Rotor holding tool (including

handle and 3 pins) Rotor holding tool
90890-04195 90890-04166
Rotor holding tool attachment 7 x Socket wrench (39 mm)
12 mm 90890-01493
90890-04197
3
1
3 2
1
EAS30311
REMOVING THE SECONDARY SHEAVE

1. Remove:
• Clutch housing nut “1”
• Clutch housing “2”
TIP
While holding the clutch housing with the rotor
holding tool “3”, loosen the clutch housing nut.
Rotor holding tool

90890-04166
3
2
1
5-37
EAS31619 EAS30314
DISASSEMBLING THE SECONDARY CHECKING THE CLUTCH SHOES

SHEAVE The following procedures are applied to all of the
1. Remove: clutch shoes.
• Secondary sheave nut “1” 1. Check:
TIP • Clutch shoe
Install the sheave spring compressor “2” and Damage/wear → Replace the clutch shoes
sheave fixed block “3” onto the secondary and springs as a set.
sheave as shown. Then, compress the spring, Glazed areas → Sand with coarse sandpa-
and remove the secondary sheave nut. per.
TIP
After sanding the glazed areas, clean the clutch
Sheave spring compressor
with a cloth.
90890-04134
Sheave fixed block 2. Measure:
90890-04135 • Clutch shoe thickness “a”
Out of specification → Replace the clutch
shoes and springs as a set.
2
1 Clutch shoe thickness limit

2.1 mm (0.08 in)
a a
a
3
a
EAS30352
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing
Damage/wear → Replace. a a
2. Measure: EAS30315
• Clutch housing inside diameter “a” CHECKING THE V-BELT
Out of specification → Replace the clutch 1. Check:
housing. • V-belt “1”
Cracks/damage/wear → Replace.
Clutch housing inside diameter Grease/oil → Clean the primary and second-
limit ary sheave.
125.5 mm (4.94 in) 2. Measure:
• V-belt width “a”
V-belt width limit

a 21.6 mm (0.85 in)
5-38
EAS30319
a 2 1 CHECKING THE SECONDARY SHEAVE

1. Check:
• Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear → Replace the sec-
3 ondary fixed and sliding sheaves as a set.
2. Check:
• Torque cam groove “a”
Damage/wear → Replace the secondary
2. Plastic board fixed and sliding sheaves as a set.
3. Ruler 3. Check:
• Guide pin “1”
EAS30316
Damage/wear → Replace the secondary
CHECKING THE PRIMARY SHEAVE fixed and sliding sheaves as a set.
1. Check:
• Primary sliding sheave
• Primary fixed sheave 1
• Collar
Cracks/damage/wear → Replace the primary
sliding sheave, primary fixed sheave, and
collar as a set.
a
EAS30317
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedures are applied to all of the 4. Check:
primary sheave weights. • Spring free length
1. Check: Out of specification → Replace the spring.
• Primary sheave weight
Cracks/damage/wear → Replace. Compression spring free length
2. Measure: limit
• Primary sheave weight outside diameter “a” 104.7 mm (4.12 in)
Weight outside diameter limit

19.5 mm (0.77 in)
EAS30320
ASSEMBLING THE PRIMARY SHEAVE

1. Clean:
• Primary fixed sheave
EAS31233
• Primary sliding sheave
CHECKING THE PRIMARY SHEAVE • Primary sheave weight
SLIDERS • Cam
1. Check:
• Primary sheave slider
5-39
EAS30321
ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate: Shell dolium grease R®
• Secondary sliding sheave inner surface
• Oil seal “1”
(with the recommended lubricant) 1
New 2
a
Shell dolium grease R®
TIP
Do not apply grease to the inner surface “a” of
the secondary fixed sheave “2”. If any grease
gets on the inner surface of the secondary fixed
sheave, be sure to wipe it off thoroughly. 5. Install:
• Spring seat
• 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
a 1 sheave as shown. Then, compress the spring,
and install the secondary sheave nut.
• Install the secondary sheave nut “1” with its ta-
2. Install: pered side facing the clutch carrier.
• Oil seal New
• Secondary sliding sheave “1” Sheave spring compressor
TIP 90890-04134
Install the secondary sliding sheave onto the Sheave fixed block
secondary fixed sheave “2” with the oil seal 90890-04135
guide “3”.
2
Oil seal guide (37 mm)
90890-04177 1
3 3
3. Install:
• Guide pin “1”
4. Lubricate:
• Guide pin grooves “a”
• O-rings “2” New
(with the recommended lubricant)
5-40
EAS31234
TIP
INSTALLING THE PRIMARY SHEAVE, V-
BELT AND SECONDARY SHEAVE While holding the clutch housing with the rotor
1. Install: holding tool “3”, tighten the clutch housing nut.
• Secondary sheave assembly
TIP Rotor holding tool
Before installing the secondary sheave assem- 90890-04166
bly, check that there is no grease on the splines
“a” of the primary drive gear. If there is any
grease on the splines, be sure to wipe it off thor- 3
oughly.
1
2
a 4. Install:
• Primary sliding sheave assembly “1”
• Washer
TIP
2. Tighten: When installing the primary sliding sheave as-
• Secondary sheave nut “1” sembly, hold the cam to prevent the primary
sheave weights from falling out of the primary
Secondary sheave nut sliding sheave.
55 N·m (5.5 kgf·m, 41 lb·ft)
T.
R.
TIP
While holding the secondary sheave with the ro-
tor holding tool “2”, tighten the secondary
1
sheave nut with the socket wrench “3”.
Rotor holding tool

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

45 N·m (4.5 kgf·m, 33 lb·ft)
T.
R.
5-41

handle and 3 pins)
90890-04195
Rotor holding tool attachment 7 x
12 mm
1 90890-04197
6. Install:
• Primary fixed sheave “1”
• Washer
• Conical spring washer “2”
• Primary fixed sheave nut 1
ECA21730
NOTICE
Do not allow grease to contact the primary
sheave assembly.
TIP
• Apply lithium-soap-based grease to the prima-
ry fixed sheave nut side of the conical spring
washer and to the threaded portion of the
crankshaft.
• Install the conical spring washer with the mark
“a” facing outward.
• Install the V-belt in the primary sheave (when
the pulley is at its widest position) and in the
secondary sheave (when the pulley is at its
narrowest position), and make sure the V-belt
is tight.
2
7. Tighten:
• Primary fixed sheave nut “1”
Primary fixed sheave nut

76 N·m (7.6 kgf·m, 56 lb·ft)
T.
R.
TIP
While holding the primary fixed sheave with the
rotor holding tool “2”, tighten the primary fixed
sheave nut.
5-42
STARTER GENERATOR
EAS20714
STARTER GENERATOR
Removing the starter generator assembly
4
LT
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
3
5
2
LT
70 N·m (7.0 kgf·m, 52 lb·ft)

T.R
.

Drain.
page 3-20.
Battery page 4-1.
Side cover (right) page 4-3.
Radiator fan Refer to “RADIATOR” on page 6-2.
Crankshaft position sensor coupler/Starter gen-
1 1/1 Disconnect.
erator coupler
2 Starter generator rotor nut 1
3 Starter generator rotor 1
4 Woodruff key 1
5 Starter generator/Crankshaft position sensor 1
5-43
STARTER GENERATOR
EAS33382 EAS33383
REMOVING THE STARTER GENERATOR INSTALLING THE STARTER GENERATOR

• Starter generator rotor nut “1” • Woodruff key
• Washer • Starter generator rotor
TIP • Washer
While holding the starter generator rotor “2” with • Starter generator rotor nut
the rotor holding tool “3”, loosen the starter gen- TIP
erator rotor nut. • Clean the tapered portion of the crankshaft and
the starter generator rotor hub.
• When installing the starter generator rotor,
make sure the woodruff key is properly seated
handle and 3 pins)
90890-04195 in the keyway of the crankshaft.
Rotor holding tool attachment 7 x 2. Tighten:
5 mm • Starter generator rotor nut “1”
90890-04198
Starter generator rotor nut
70 N·m (7.0 kgf·m, 52 lb·ft)
T.
R.
TIP
While holding the starter generator rotor “2” with
3 the rotor holding tool “3”, tighten the starter gen-
2
erator rotor nut.
1 Rotor holding tool (including

handle and 3 pins)
2. Remove: 90890-04195
• Starter generator rotor “1” Rotor holding tool attachment 7 x
(with the flywheel puller “2”) 5 mm
• Woodruff key 90890-04198
ECA21740
NOTICE
To protect the end of the crankshaft, place an
appropriate sized socket between the fly-
wheel puller center bolt and the crankshaft.
3
2
Flywheel puller
90890-01189
5-44
OIL PUMP
EAS20054
OIL PUMP
Removing the oil pump
3 New
2
4
5 4
1 New
4.0 N·m (0.40 kgf·m, 3.0 lb·ft) LS

T.R
.
10 N·m (1.0 kgf·m, 7.4 lb·ft)

T.R
.

V-belt automatic transmission SION” on page 5-34.
1 Oil seal 1
2 Oil pump cover 1
3 Gasket 1
4 Dowel pin 2
5 Oil pump assembly 1
5-45
OIL PUMP
Disassembling the oil pump
10 N·m (1.0 kgf·m, 7.4 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
5-46
OIL PUMP
EAS30340
TIP
CHECKING THE OIL STRAINER
1. Check: When installing the inner rotor, align the pin in
• Oil strainer the oil pump driven gear with the groove “a” in
Damage → Replace. the inner rotor.
Contaminants → Clean with solvent.
4
EAS30337
5 3
CHECKING THE OIL PUMP
1. Check: 2
• Oil pump drive gear
• Oil pump driven gear
• Oil pump housing
• Oil pump housing cover a 1
Cracks/damage/wear → Replace the oil
pump.
2. Check: 3. Check:
• Oil pump operation • Oil pump operation
Rough movement → Repeat steps (1) and Refer to “CHECKING THE OIL PUMP” on
(2) or replace the oil pump. page 5-47.
EAS30342
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
• Oil pump shaft
Engine oil
2. Install:
• Oil pump housing “1”
• Oil pump outer rotor “2”
• Oil pump inner rotor “3”
• Oil pump driven gear “4”
• Pin “5”
• Oil pump housing cover
Oil pump housing cover screw

1.0 N·m (0.10 kgf·m, 0.73 lb·ft)
T.
R.
5-47
TRANSMISSION
EAS20062
TRANSMISSION
Removing the transmission
20 N·m (2.0 kgf·m, 15 lb·ft)

T.R
.
LS
New 11
New 12
10
2
12
5 12
6 E
E
E
(5)
12 13
12
E
E
7
9 New 1
E
8
LS
LS New 11 3
New 4
LS 12 New
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

Secondary sheave assembly SION” on page 5-34.
Refer to “REAR SHOCK ABSORBER
Swingarm ASSEMBLIES AND SWINGARM” on
page 4-80.
Rear wheel Refer to “REAR WHEEL” on page 4-28.
1 Final transmission oil filler cap 1
2 Final transmission oil drain bolt 1
3 Transmission case cover 1
4 Transmission case cover gasket 1
5 Dowel pin 2
5-48
TRANSMISSION
Removing the transmission
20 N·m (2.0 kgf·m, 15 lb·ft)

T.R
.
LS
New 11
New 12
10
2
12
5 12
6 E
E
E
(5)
12 13
12
E
E
7
9 New 1
E
8
LS
LS New 11 3
New 4
LS 12 New
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

6 Main axle assembly 1
7 Drive axle 1
8 1st wheel gear 1
9 Circlip 1
10 Primary drive gear 1
11 Oil seal 2
12 Bearing 6
13 Transmission breather pipe 1
5-49
TRANSMISSION
EAS30433
CHECKING THE TRANSMISSION

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

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

21.7–21.8 mm (0.85–0.86 in) • Transmission case cover “1”
Installed depth “b”
0.25–0.75 mm (0.01–0.03 in) Transmission case cover bolt
20 N·m (2.0 kgf·m, 15 lb·ft)
T.
R.
New 1 2 TIP
Tighten the transmission case cover bolts in the
proper tightening sequence as shown.
a
1 5
4
3 New
6
b 4
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.
5-50
CRANKSHAFT
EAS20061
CRANKSHAFT
Removing the crankshaft
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
1 E
LS
New
(11) 11
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
10
10
12
LS
7
New
8 LS
New
6 2
4
5
LS
New 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.
3
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

Engine Refer to “ENGINE REMOVAL” on page 5-4.
Refer to “CYLINDER AND PISTON” on
Piston page 5-29.
Secondary sheave assembly SION” on page 5-34.
Refer to “STARTER GENERATOR” on
Starter clutch page 5-43.
1 Dipstick 1
2 Engine oil drain bolt 1
3 Oil strainer cover 1
4 Spring 1
5-51
CRANKSHAFT
Removing the crankshaft

10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
1 E
LS
New
(11) 11
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
10
10
12
LS
7
New
8 LS
New
6 2
4
5
LS
New 7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.
3
20 N·m (2.0 kgf·m, 15 lb·ft)
T.R
.

5 Centerstand shaft 1
6 Centerstand 1
7 Timing chain guide (intake side) 1
8 Timing chain 1
9 Crankcase (left) 1
10 Dowel pin 2
11 Crankshaft assembly 1
12 Crankcase (right) 1
5-52
CRANKSHAFT
EAS30389 ECA20630
DISASSEMBLING THE CRANKCASE NOTICE

1. Remove: • To protect the end of the crankshaft, place
• Crankcase bolts an appropriate sized socket between the
TIP crankcase separating tool bolt and the
Loosen each bolt 1/4 of a turn at a time, in stag- crankshaft.
es and in a crisscross pattern. After all of the • Do not tap on the crankshaft.
bolts are fully loosened, remove them.
Crankcase separating tool
90890-01135
1
2. Remove:
• Crankcase (left) “1” 3
ECA13900
NOTICE EAS31242
Tap on one side of the crankcase with a soft- CHECKING THE CRANKSHAFT ASSEMBLY
face hammer. Tap only on reinforced por- 1. Measure:
tions of the crankcase, not on the crankcase • Crankshaft runout
mating surfaces. Work slowly and carefully Out of specification → Replace the crank-
and make sure the crankcase halves sepa- shaft assembly.
rate evenly. TIP
Turn the crankshaft slowly.
Runout limit
0.050 mm (0.0020 in)
EAS30414
REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:
• Crankshaft assembly “1”
TIP
2. Measure:
• Remove the crankshaft assembly with the
• Crankshaft width
crankcase separating tool “2” and M6 bolts “3”.
Out of specification → Replace the crank-
• Make sure that the crankcase separating tool
shaft assembly.
is centered over the crankshaft assembly.
Crank assembly width
51.45–51.50 mm (2.026–2.028
in)
5-53
CRANKSHAFT
EAS30791
INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft assembly “1”
TIP
• Install the crankshaft assembly with the crank-
shaft installer pot “2”, crankshaft installer bolt
“3”, adapter “4”, and crankshaft installer spacer
“5”.
• Hold the connecting rod at top dead center
3. Check: (TDC) with one hand while turning the nut of
• Crankshaft sprocket “1” the crankshaft installer bolt with the other. Turn
Damage/wear → Replace the crankshaft as- the crankshaft installer bolt until the crankshaft
sembly. assembly bottoms against the bearing.
• Bearing “2”
Cracks/damage/wear → Replace the crank-
shaft assembly. Crankshaft installer pot
90890-01274
2 Crankshaft installer bolt
90890-01275
Adapter (M12)
1 90890-01278
Spacer (crankshaft installer)
90890-04081
5
EAS30390 1 4
CHECKING THE CRANKCASE 2
1. Thoroughly wash the crankcase halves in a
mild solvent. 3
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
• Crankcase
EAS31244
CHECKING THE BEARING

1. Check:
• Bearing
Clean and lubricate the bearings, and then
rotate the inner race with your finger.
Rough movement → Replace.
EAS31245
CHECKING THE OIL PUMP DRIVE GEAR

1. Check:
• Oil pump drive gear
5-54
CRANKSHAFT
EAS30397 EAS31247
ASSEMBLING THE CRANKCASE INSTALLING THE CENTERSTAND

1. Thoroughly clean all the gasket mating sur- 1. Install:
faces and crankcase mating surfaces. • Centerstand “1”
2. Apply: • Spring “2”
• Sealant TIP
(onto the crankcase mating surfaces) • Make sure that the hooked end “a” of the spring
is positioned to the outside.
Yamaha bond No. 1215 • Make sure that the hooked end “b” of the spring
90890-85505 is positioned to the outside.
TIP
Do not allow any sealant to come into contact
with the oil gallery.
1
2 b
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.
5-55
CRANKSHAFT
5-56
COOLING SYSTEM
COOLING SYSTEM DIAGRAMS .................................................................... 6-1
RADIATOR ...................................................................................................... 6-2

CHECKING THE RADIATOR.................................................................... 6-4
INSTALLING THE RADIATOR..................................................................6-4
THERMOSTAT ................................................................................................6-6
CHECKING THE THERMOSTAT ASSEMBLY ......................................... 6-7
INSTALLING THE THERMOSTAT ASSEMBLY ....................................... 6-7
WATER PUMP.................................................................................................6-8
DISASSEMBLING THE WATER PUMP.................................................. 6-10
CHECKING THE WATER PUMP ............................................................ 6-10
ASSEMBLING THE WATER PUMP........................................................ 6-10
INSTALLING THE WATER PUMP .......................................................... 6-11
6
COOLING SYSTEM DIAGRAMS
EAS20299
COOLING SYSTEM DIAGRAMS
8
1 2 3 4 7 5
1 2 3 4 5
1. Radiator cap 5. Thermostat assembly

2. Coolant reservoir hose 6. Radiator outlet hose
3. Radiator 7. Water pump inlet hose
4. Radiator inlet hose 8. Water pump assembly
6-1
RADIATOR
EAS20063
RADIATOR
Removing the radiator
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.
4
11
5 12
(3)
(5) 9
10 N·m (1.0 kgf·m, 7.4 lb·ft) 7

T.R
.
10
(4) 8 6
LS 11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.R
1 New
.
1.0 N·m (0.10 kgf·m, 0.73 lb·ft)

T.R
.
(3)

Drain.
page 3-20.
Side cover (right) page 4-3.
Footrest board assembly (right)/Bottom cover page 4-12.
1 Radiator cover 1
2 Coolant reservoir breather hose 1
3 Coolant reservoir hose 1
4 Rear brake hose bracket 1
5 Rear brake hose holder (front side) 1
6 Coolant reservoir 1
6-2
RADIATOR
Removing the radiator
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
T.R
.
4
11
5 12
(3)
(5) 9
10 N·m (1.0 kgf·m, 7.4 lb·ft) 7

T.R
.
10
(4) 8 6
LS 11 N·m (1.1 kgf·m, 8.1 lb·ft)
T.R
1 New
.
1.0 N·m (0.10 kgf·m, 0.73 lb·ft)

T.R
.
(3)

7 Radiator inlet hose 1
8 Radiator outlet hose 1
9 Radiator cap 1
10 Radiator 1
11 Radiator fan case 1
12 Radiator fan 1
6-3
RADIATOR
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
2. Check: mended coolant)
• Radiator hose Refer to “CHANGING THE COOLANT” on
• Coolant reservoir hose page 3-20.
Cracks/damage → Replace. 2. Check:
3. Measure: • Cooling system
• Radiator cap valve opening pressure Leaks → Repair or replace any faulty part.
Below the specified pressure → Replace the
radiator cap. a. Attach the radiator cap tester “1” to the radi-
ator.
Radiator cap valve opening pres-
sure Radiator cap tester
108.0–137.4 kPa (1.08–1.37 kgf/ 90890-01325
cm², 15.7–19.9 psi)
a. Install the radiator cap tester “1” and radia-

tor cap tester adapter “2” to the radiator cap
“3”.
Radiator cap tester

90890-01325 1
Radiator cap tester adapter
31mm
90890-05375
b. Apply 137.4 kPa (1.37 kgf/cm2, 19.9 psi) of
pressure.
c. Measure the pressure to check its maintain-
ing applied pressure.
6-4
RADIATOR
3. Measure:
• Radiator cap opening pressure
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-4.
4. Install:
• Rear brake hose holder (front side) “1”
Rear brake hose holder bolt

(front side)
T.
R.
7 N·m (0.7 kgf·m, 5.2 lb·ft)
6-5
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat assembly
* New
2 3
9 N•m (0.9 kgf•m, 6.6 lb•ft)

T .R
.
*: Apply water
Drain.
page 3-20.
Front side cover (right) page 4-3.
Footrest board assembly (right)/Bottom cover page 4-12.
1 Radiator inlet hose 1 Disconnect.
2 Radiator outlet hose 1 Disconnect.
3 Water pump inlet hose 1 Disconnect.
4 Thermostat assembly 1
6-6
THERMOSTAT
EAS31248
CHECKING THE THERMOSTAT ASSEMBLY B

1. Check:
• Thermostat “1”
0.5 mm
Do not open at 74–78°C (165–172 °F) → Re- (0.02 in) 7 mm
place. (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-
place it. A faulty thermostat could cause serious
a. Suspend the thermostat “1” in a container overheating or overcooling.
“2” filled with water.
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
mended coolant)
3 Refer to “CHANGING THE COOLANT” on
page 3-20.
2. Check:
4 • Cooling system
1 Leaks → Repair or replace any faulty part.
2 Refer to “INSTALLING THE RADIATOR” on
page 6-4.
3. Measure:
e. Check the thermostat element position “5”. • Radiator cap opening pressure
Same level for the thermostat element up- Below the specified pressure → Replace the
per end and the hole lower line “a” at 90° C radiator cap.
(194°F) Refer to “CHECKING THE RADIATOR” on
page 6-4.
6-7
WATER PUMP
EAS20066
WATER PUMP
Removing the water pump
3
2
New 4 3
10 N•m (1.0 kgf•m, 7.4 lb•ft)

T.R
.

Drain.
page 3-20.
Front side cover (left) page 4-3.
Footrest board assembly (left)/Bottom cover page 4-9.
1 Water pump inlet hose 1 Disconnect.
2 Water pump assembly 1
3 Dowel pin 2
4 O-ring 2
6-8
WATER PUMP
Disassembling the water pump
3 New
7 8
6 New
2 New
New 6
1
New 5 New
4
LS
10 N·m (1.0 kgf·m, 7.4 lb·ft)

1 Water pump housing cover 1
2 Water pump housing gasket 1
3 Circlip 1
4 Impeller shaft 1
5 Water pump seal 1
6 O-ring 2
7 Bearing 2
8 Water pump housing 1
6-9
WATER PUMP
EAS30446
DISASSEMBLING THE WATER PUMP Mechanical seal installer

1. Remove: 90890-04145
• Water pump seal “1” Middle driven shaft bearing driv-
TIP er
Remove the water pump seal from the inside of 90890-04058
the water pump housing “2”.
• Water pump bearing “3” A
TIP 4
Remove the water pump bearing from the out-
side of the water pump housing “2”. 3
2 1 New
3
1
2
A. Push down
3. Mechanical seal installer

4. Middle driven shaft bearing driver
1
EAS30447 a
CHECKING THE WATER PUMP
1. Check:
• Water pump housing cover 2
• Water pump housing
• Impeller shaft
• Impeller a. Installed depth of water pump seal
• Water pump seal • Bearing
Cracks/damage/wear → Replace. Install the bearing as same as water pump
2. Check: seal installation procedure.
• Bearing 2. Lubricate:
Rough movement → Replace • Water pump seal and bearing.
EAS30448
ASSEMBLING THE WATER PUMP Recommended lubricant

1. Install: Lithium-soap-based grease
• Water pump seal “1” New
(into the water pump housing “2”)
TIP
Install the water pump seal with the special tools
to the specified depth as shown in the illustra-
tion.
Installed depth of water pump

seal
0–0.5 mm (0–0.02 in)
6-10
WATER PUMP
3. Install: EAS30449
INSTALLING THE WATER PUMP

• Impeller shaft “1”
1. Install:
• Circlip New
• O-rings “1” New
TIP
• Water pump assembly “2”
After installation, check that the impeller shaft ro-
tates smoothly. 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.
1 a b
2
New 1
LS
2. Fill:
• Cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” on
page 3-20.
3. Check:
• Cooling system
Leaks → Repair or replace any faulty part.
Refer to “INSTALLING THE RADIATOR” on
page 6-4.
4. Measure:
• Radiator cap opening pressure
radiator cap.
Refer to “CHECKING THE RADIATOR” on
page 6-4.
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 ................................................................7-7
AIR FILTER CASE .......................................................................................... 7-8

INSTALLING THE AIR FILTER CASE ....................................................7-10
THROTTLE BODY......................................................................................... 7-11

REMOVING THE THROTTLE BODY......................................................7-13
CHECKING THE THROTTLE BODY ......................................................7-13
CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND
THROTTLE BODY ................................................................................. 7-13
REPLACING THE THROTTLE BODY ....................................................7-16
INSTALLING THE THROTTLE BODY ....................................................7-16
7
FUEL TANK
EAS20067
FUEL TANK
Removing the fuel tank
9 N·m (0.9 kgf·m, 6.6 lb·ft)
T.R
.
4
5
8
6
1 11
New
7 2
10
3
9
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
Fuel tank breather hose (fuel tank to rollover
4 1
valve)
5 Fuel sender coupler 1 Disconnect.
6 Fuel pump coupler 1 Disconnect.
7 Fuel hose 1 Disconnect.
8 Fuel tank 1
9 Fuel pump bracket 1
10 Fuel pump 1
11 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 an appropriate pump. • Fuel pump body
2. Disconnect: Obstruction → Clean.
• Fuel sender coupler Cracks/damage → Replace the fuel pump
• Fuel pump coupler assembly.
• 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.
Although the fuel has been removed from
R.
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.
• Always use a new fuel pump gasket.
TIP
• Face the gasket lip “a” toward the fuel pump.
• To remove the fuel hose from the fuel pump, • Align the projections “b” (two locations) on the
slide the fuel hose connector cover “1” on the fuel pump gasket with the slots “c” in the fuel
end of the hose in the direction of the arrow pump.
shown, and then remove the hose. • Align the projection “d” on the fuel pump with
• Before removing the hose, place a few rags in the slot in the fuel pump bracket.
the area under where it will be removed. • Tighten the fuel pump bolts in the proper tight-
ening sequence as shown.
1
a
c
1 New
b
3. Remove:
• Fuel tank
EAS30451 1
REMOVING THE FUEL PUMP d
1. Remove:
• Fuel pump
ECA14721 4
NOTICE 3
• Do not drop the fuel pump or give it a
strong shock.
• Do not touch the base section of the fuel
2
sender.
7-2
FUEL TANK
EAS30457 EAS30703
INSTALLING THE FUEL TANK CHECKING THE FUEL PRESSURE

1. Install: 1. Remove:
• Fuel tank “1” • Front side cover assembly (left)
a. Temporarily install the fuel tank. Refer to “GENERAL CHASSIS (2)” on
TIP page 4-3.
• Footrest board (left)
Make sure that the flanges of the fuel tank bolts
“2” do not contact the fuel tank.
page 4-12.
b. Install the fuel tank overflow tray and fuel 2. Check:
tank cover “3”. To install the fuel tank cover, • Pressure regulator operation
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
9 N·m (0.9 kgf·m, 6.6 lb·ft) when disconnecting it. Residual pressure in
T.
R.
the fuel lines could cause fuel to spurt out

when removing the hose.
3
ECA20020
NOTICE
2 Although the fuel has been removed from
the fuel tank, be careful when removing the
2 fuel hose, since there may be fuel remaining
in it.
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 Fuel pressure adapter 6.3mm
will not be properly installed. 90890-03227
TIP 1
• Install the fuel hose securely onto the fuel YAMA
H
pump until a distinct “click” is heard.

• To install the fuel hose, slide the fuel hose con-
nector cover “1” on each end of the hose in the
direction of the arrow shown.
2 3
c. Start the engine.

1
7-3
FUEL TANK
d. Measure the fuel pressure.
Fuel line pressure (at idle)

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

e. Connect the fuel hose.
Refer to “INSTALLING THE FUEL TANK”
on page 7-3.
3. Install:
• Footrest board (left)
page 4-12.
• Front side cover assembly (left)
page 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
.
5
1
3
New 8 E
2 6
New 7

Battery page 4-1.
1 Fuel hose 1
2 Fuel injector coupler 1 Disconnect.
3 Fuel injector connector 1
4 Fuel injector gasket 1
5 Clamp ring 1
6 Fuel injector 1
7 O-ring 1
8 O-ring 1
7-5
FUEL INJECTOR
EAS31250 EAS31617
REMOVING THE FUEL HOSE INSTALLING THE FUEL INJECTOR

1. Disconnect: 1. Install:
• Fuel hose • Fuel injector adaptor “1”
EWA17610
• O-ring “2” New
WARNING
(to the fuel injector)
Cover fuel hose connections with a cloth • Fuel injector “3”
when disconnecting them. Residual pres-
sure in the fuel lines could cause fuel to Fuel injector bolt
spurt out when removing the hoses. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
ECA20020
NOTICE TIP
Although the fuel has been removed from • Lubricate the O-ring with engine oil.
the fuel tank, be careful when removing the • Align the projection “a” on the fuel injector
fuel hose, since there may be fuel remaining adapter with the hole “b” in the intake manifold.
in it. • Align the projection “c” on the fuel injector with
the hole “d” in the fuel injector adapter.
TIP
• To remove the fuel hose from the fuel injector,
slide the fuel hose connector cover “1” on the 3
end of the hose in the direction of the arrow New 2
shown, and then remove the hose. a c
• Before removing the hose, place a few rags in
b 1
the area under where it will be removed.
d
EAS31251
CHECKING THE FUEL INJECTOR

1. Check:
• Injector
Obstruction → Replace and check the fuel
pump/fuel supply system.
Deposit → Replace.
Damage → Replace.
2. Check:
• Injector resistance
Refer to “INSTALLING THE FUEL INJEC-
TOR” on page 7-6.
7-6
FUEL INJECTOR
EAS31253
INSTALLING THE FUEL HOSE

1. Install:
• Fuel hose
ECA17500
NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel in-
jector until a distinct “click” is heard.
• To install the fuel hose onto the fuel injector,
slide the fuel hose connector cover “1” on the
end of the hose in the direction of the arrow
shown.
7-7
AIR FILTER CASE
EAS20068
AIR FILTER CASE

Removing the air filter case
4
7
8
New
3
New
9 1
5
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 2

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

T.R
.

Battery page 4-1.
1 Air filter case cover 1
2 Air filter case duct 1
3 Air filter element 1
4 Transmission case breather hose 1
7-8
AIR FILTER CASE
Removing the air filter case
4
7
8
New
3
New
9 1
5
10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.R
.
2.5 N·m (0.25 kgf·m, 1.8 lb·ft) 2

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

T.R
.

5 Cylinder head breather hose 1 Disconnect.
6 Air filter case joint clamp screw 1 Loosen.
7 Air filter case 1
8 Air filter check hose 1
9 Air filter case joint 1
7-9
AIR FILTER CASE
EAS31618
3. Install:
INSTALLING THE AIR FILTER CASE
• Air filter case duct “1”
1. Install:
TIP
• Hose “1”
(to the air filter case joint “2”) Fit the projection “a” on the air filter case duct be-
TIP
tween the projections “b” on the air filter case
cover “2”.
• Apply Three bond 1521 “3” onto the mating
surfaces of the hose and air filter case joint.
• Align the slot “b” on the air filter case joint with
the projection “a” in the hose.
2 b
b
a
1 2 1 a
3
2. Install:
• Air filter case joint clamp “1”
(to the air filter case joint “2”)
Air filter case joint clamp screw

2.5 N·m (0.25 kgf·m, 1.8 lb·ft)
T.
R.
TIP
Align the projection “a” on the air filter case joint
with the slot “b” in the air filter case joint clamp.
1 2
b a
7-10
THROTTLE BODY
EAS20070
THROTTLE BODY
Removing the throttle body
8
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.R
.
10 N·m (1.0 kgf·m, 7.4 lb·ft) 1 3

T.R
.
7 9 10 N·m (1.0 kgf·m, 7.4 lb·ft)

2
T.R
.
New
6
5
4
New
4.5 N·m (0.45 kgf·m, 3.3 lb·ft)

T.R
.

Battery page 4-1.
Side covers page 4-3.
Air filter case joint Refer to “AIR FILTER CASE” on page 7-8.
1 ISC (Idle Speed Control) unit coupler 1 Disconnect.
2 Throttle body sensor assembly coupler 1 Disconnect.
7-11
THROTTLE BODY
Removing the throttle body

8
5 N·m (0.5 kgf·m, 3.7 lb·ft)
T.R
.
10 N·m (1.0 kgf·m, 7.4 lb·ft) 1 3

T.R
.
7 9 10 N·m (1.0 kgf·m, 7.4 lb·ft)

2
T.R
.
New
6
5
4
New
4.5 N·m (0.45 kgf·m, 3.3 lb·ft)

T.R
.

3 Canister purge hose 1 Disconnect.
4 Throttle cable holder 1
5 Throttle body 1 Loosen.
6 Intake manifold 1
7 ISC (Idle Speed Control) unit holder 1
8 ISC (Idle Speed Control) unit 1
9 Spring 1
7-12
THROTTLE BODY
EAS30979 EAS31254
REMOVING THE THROTTLE BODY CLEANING THE ISC (IDLE SPEED

1. Remove: CONTROL) UNIT AND THROTTLE BODY
• Throttle body 1. Remove the throttle body from the vehicle.
ECA20500
TIP
NOTICE
Before removing the throttle body, disconnect
Do not remove the throttle body sensor as-
the throttle cables and couplers.
sembly from the throttle body.
2. Remove:
EAS30479 • Screw “1”
CHECKING THE THROTTLE BODY • ISC (Idle Speed Control) unit holder “2”
TIP • ISC (Idle Speed Control) unit “3”
ECA21780
Before checking the throttle body, check the fol-
NOTICE
lowing items:
• Valve clearance Because the force of the spring may push
• Spark plug out the ISC unit unexpectedly, be sure to
• Air filter element hold the ISC unit when removing the compo-
• Intake manifold nents.
• Fuel hose
• Exhaust system 2
• Cylinder head breather hose 3 1
EWA18030
WARNING
If the throttle body is subjected to strong
shocks or dropped during, replace it.
1. Check:
• Throttle body
Cracks/damage → Replace the throttle body. 3. Remove:
2. Check: • Spring “1”
• Butterfly valve • O-ring “2”
Damage/scratches/wear → Replace the
throttle body.
ECA21770
NOTICE 1
Do not adjust the stop screw “1”. 2
7-13
THROTTLE BODY
4. Check: a. Use a rag soaked in the recommended

• ISC (Idle Speed Control) unit cleaning agent to wipe off any deposits and
Plunger “1” does not rotate smoothly/plunger foreign materials.
rotates together with the motor shaft “2” →
Replace. Recommended cleaning agent
Yamaha oil & brake cleaner
ECA21790
1 NOTICE
• Be sure to use the recommended cleaning
agent.
• Do not spray the cleaning agent directly
onto the ISC unit or throttle body and do
2 not immerse them in the cleaning agent.
• To prevent scratching the components, do
5. Check: not use a brush, metal file, or other abra-
• Spring sive tool.
Damage/bent → Replace. • Do not clean with compressed air.
6. Clean: • Do not allow the removed deposits or for-
• Area “a” of the ISC unit eign materials to adhere to the sealing sur-
• Areas “b” and “c” of the throttle body faces of the O-ring.
Clogs or foreign materials cannot be re- • Do not scratch or deform the ISC valve or
moved → Replace. air passage; otherwise, poor starting per-
formance, an unstable engine idling speed,
or uncontrollable engine speed could re-
a sult.
• Do not clean any areas other than the areas
“a”, “b”, and “c”. If the cleaning agent en-
ters the ISC unit or throttle body, thorough-
ly wipe it off.
7. Adjust the ISC unit plunger to the specified

distance “a” from the motor assembly body.
Distance “a”
0.0–3.0 mm (0.0–0.12 in)
a
b
8. Install:
• Spring
• O-ring “1” New
• ISC (Idle Speed Control) unit “2”
c
7-14
THROTTLE BODY
ECA21800
NOTICE 1
• Do not use the ISC unit if it was dropped. 2
• Do not allow water to enter the ISC unit and
do not allow foreign materials to adhere to
the assembly.
a
• Do not touch the terminals of the coupler
directly. b
• Because the force of the spring may push
out the ISC unit unexpectedly, be sure to
hold the motor assembly when installing 10.Install the throttle body to the vehicle.
the components. 11.Reset:
• ISC learning valves
TIP Use the diagnostic code number “67”.
• Install the new O-ring until it contacts the raised Refer to “SELF-DIAGNOSTIC FUNCTION
portion of the ISC unit body. AND DIAGNOSTIC CODE TABLE” on
• When installing the ISC unit, be sure to align page 9-36.
the oval portion “a” of the ISC unit with the oval • ISC valve position
hole “b” in the throttle body. Use the diagnostic code number “54”.
AND DIAGNOSTIC CODE TABLE” on
page 9-36.
2 1 New
90890-03267
Yamaha diagnostic tool (A/I)
90890-03264
12.Place the vehicle on the centerstand so that

the rear wheel is off ground.
13.Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed. Within specifi-
cation → Service is finished.
b Out of specification → Replace the throttle
body.
a Refer to “REPLACING THE THROTTLE
BODY” on page 7-16.
9. Install:
• ISC (Idle Speed Control) unit holder “1” Engine idling speed
1500–1700 r/min
• Screw
ISC (Idle Speed Control) unit

holder screw
T.
R.
5 N·m (0.5 kgf·m, 3.7 lb·ft)
TIP
Align the slot “a” in the ISC unit holder with the
projection “b” on the ISC unit “2”.
7-15
THROTTLE BODY
EAS31160 EAS30980
REPLACING THE THROTTLE BODY INSTALLING THE THROTTLE BODY

1. Remove the throttle body from the vehicle. 1. Install:
2. Install a new throttle body to the vehicle. • Throttle body
3. Reset:
• ISC learning valves Throttle body bolt
Use the diagnostic code number “67”. 10 N·m (1.0 kgf·m, 7.4 lb·ft)
T.
R.
AND DIAGNOSTIC CODE TABLE” on TIP
page 9-36. • Align the projection “a” on the O-ring with the
• ISC valve position slot “b” in the throttle body.
Use the diagnostic code number “54”
AND DIAGNOSTIC CODE TABLE” on
page 9-36.

90890-03267 b a
90890-03264
4. Place the vehicle on the centerstand so that

the rear wheel is off ground.
5. Check:
• Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed.
Engine idling speed

1500–1700 r/min
7-16
THROTTLE BODY
7-17
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 8-1

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

CIRCUIT DIAGRAM .................................................................................. 8-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 8-7
TROUBLESHOOTING ..............................................................................8-8
STOP AND START SYSTEM........................................................................8-11

CIRCUIT DIAGRAM ................................................................................ 8-11
STOP AND START SYSTEM OPERATION ...........................................8-13
TROUBLESHOOTING ............................................................................8-14
CHARGING SYSTEM....................................................................................8-17
CIRCUIT DIAGRAM ................................................................................ 8-17
LIGHTING SYSTEM ......................................................................................8-21

CIRCUIT DIAGRAM ................................................................................ 8-21
SIGNALING SYSTEM ...................................................................................8-25

CIRCUIT DIAGRAM ................................................................................ 8-25
FUEL PUMP SYSTEM...................................................................................8-31

CIRCUIT DIAGRAM ................................................................................ 8-31
ELECTRICAL COMPONENTS...................................................................... 8-34

CHECKING THE SWITCHES .................................................................8-35
CHECKING THE FUSES ........................................................................8-36
REPLACING THE SGCU (starter generator control unit)........................ 8-36
CHECKING AND CHARGING THE BATTERY....................................... 8-36
CHECKING THE RELAYS ...................................................................... 8-37
CHECKING THE SPARK PLUG CAP .....................................................8-38
8
CHECKING THE IGNITION COIL ........................................................... 8-39
CHECKING THE IGNITION SPARK GAP............................................... 8-39
CHECKING THE STARTER GENERATOR............................................8-40
CHECKING THE FUEL SENDER ........................................................... 8-40
CHECKING THE COOLANT TEMPERATURE SENSOR.......................8-41
CHECKING THE FUEL INJECTOR ........................................................ 8-41
CHECKING THE VVA SOLENOID.......................................................... 8-42
CHECKING THE SMART KEY BATTERY .............................................. 8-42
CHECKING THE BUZZER ...................................................................... 8-42
CHECKING THE MAIN SWITCH SOLENOID.........................................8-43
EAS30490
EAS20072
RR
R
R
Br Br
9 Br
Br Br
CIRCUIT DIAGRAM
10
R R 13
R
ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
IGNITION SYSTEM
LOCK L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Br Br/R
(B)
Br
O O
44
45
Br
Br
Br
W/R W/R G
W/L W/L G W/R W/R B/L
W/B W/B L/Y Br/B W/L W/L Br/B
W/Y W/Y 51
Br/B Br/B L/Y W/B W/B W/Y
43 B/L B/L
(B)
(B)
8-1
B B L/Y L/Y L/Y L/Y
R
L/Y B 36
B B
(L) (L)
1
B
B
B
B B
B B
B B
B B
B
B
BB
B
72
72
IGNITION SYSTEM
IGNITION SYSTEM
1. Battery
9. Main fuse
10. Ignition fuse
13. Main switch
36. Sidestand switch
43. SGCU (starter generator control unit)
44. Ignition coil
45. Spark plug
51. Crankshaft position sensor
72. Frame ground
8-2
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 cover
3. Fuel tank cover
4. Storage box
5. Footrest board assembly
6. Front cowling assembly
1. Check the fuse.

(Main and ignition)
NG→ Replace the fuse.
Refer to “CHECKING THE FUS-
ES” on page 8-36.
OK↓
2. Check the battery.

Refer to “CHECKING AND
• Clean the battery terminals.
CHARGING THE BATTERY” in NG→
• Recharge or replace the battery.
SERVICE MANUAL BASIC IN-
FORMATION.
OK↓
3. Check the spark plug.

Refer to “CHECKING THE SPARK NG→ Re-gap or replace the spark plug.
PLUG” on page 3-4.
OK↓
4. Check the ignition spark gap.

Refer to “CHECKING THE IGNI- OK→ Ignition system is OK.
TION SPARK GAP” on page 8-39.
NG↓
5. Check the spark plug cap.

Refer to “CHECKING THE SPARK NG→ Replace the spark plug cap.
PLUG CAP” on page 8-38.
OK↓
6. Check the ignition coil.

Refer to “CHECKING THE IGNI- NG→ Replace the ignition coil.
TION COIL” on page 8-39.
OK↓
7. Check the main switch.

Refer to “CHECKING THE NG→ Replace the main switch.
OK↓
8-3
IGNITION SYSTEM
8. Check the sidestand switch.

Refer to “CHECKING THE NG→ Replace the sidestand switch.
OK↓
9. Check the entire ignition system

wiring. Properly connect or replace the wire har-
NG→
Refer to “CIRCUIT DIAGRAM” on ness.
page 8-1.
OK↓
Replace the starter generator assem-

bly or the SGCU. Refer to “REPLAC-
ING THE SGCU (starter generator
control unit)” on page 8-36.
8-4
EAS30493
EAS20073
R
RR
6
Br/R Br
7
R
R
Br
9
CIRCUIT DIAGRAM
Br Br
Br Br
10
R R 13
R R W G
R/Y R/Y OPEN
Br Br/R OFF
LOCK Y/R Y/B B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Br Br/R
(B)
Br/R R
Br/R
Br/R Br B
(B)
31
R
Br/R Br
B Br R
Br
ELECTRIC STARTING SYSTEM
27 L/W
Br 33 L/W
Br Br B/Y B/Y
28 Br W/R W/R G
G W/R W/R B/L
L/W W/L W/L
PUSH B/Y W/B W/B L/Y Br/B W/L W/L Br/B
FREE 34 W/Y W/Y 51
B Br B/Y L/B
B 40 43 B/L B/L
(B)
(B)
L/B L/B L/B
L/W
Y/R
L/B R 35
R/B Br/R Br Y/R Y/R
8-5
R
Br R/B R/B
B B L/Y L/Y L/Y L/Y

B
R
R L/Y B 36
B B
(L) (L)
1
B B
B
B
G G R/L
R R R/Y 55
W W R/W
R/Y R/W R/L
R W G
B
B B
B B
B B
B B
B
B
B BB BB
B B B
73 72 72
72 72
1. Battery
6. Terminal fuse
7. Fuel injection system fuse
9. Main fuse
10. Ignition fuse
13. Main switch
27. Handlebar switch (right)
28. Start switch
31. Main relay
33. Front brake light switch
34. Rear brake light switch
35. Starter charge relay
40. Joint 3
55. Starter generator
72. Frame ground
73. Engine ground
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 generator can only op-
erate if at least one of the following conditions is met:
• The front brake lever is pulled to the handlebar (the front brake light switch is closed) and the side-
stand is up (the sidestand switch is closed).
• The rear brake lever is pulled to the handlebar (the rear brake light switch is closed) and the sidestand
is up (the sidestand switch is closed).
7
14
1 13 15
2
5
6
3 8
4 9 10 11 12
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
6. Main relay
8. Signaling system fuse
11. Start switch
8-7
EAS30495
TROUBLESHOOTING
The starter generator fails to turn.
TIP
1. Battery cover
2. Center cover
3. Side cover
4. Storage box
1. Check the fuses.

(Main, ignition, fuel injection sys-
tem, and signaling system) NG→ Replace the fuse(s).
ES” on page 8-36.
OK↓

FORMATION.
OK↓
3. Check the starter generator.

Refer to “CHECKING THE START- NG→ Replace the starter generator assembly.
ER GENERATOR” on page 8-40.
OK↓
4. Check the main relay.

Refer to “CHECKING THE RE- NG→ Replace the main relay.
LAYS” on page 8-37.
OK↓
5. Check the starter charge relay.

Refer to “CHECKING THE RE- NG→ Replace the starter charge relay.
OK↓

OK↓

OK↓
8-8
8. Check the start switch.

The start switch is faulty. Replace the right
Refer to “CHECKING THE NG→
handlebar switch.
OK↓
9. Check the brake light switches.

(Front and rear)
NG→ Replace the brake light switch(es).
Refer to “CHECKING THE
OK↓
10.Check the entire starting system

NG→
page 8-5.
OK↓

bly or SGCU. Refer to “REPLACING
THE SGCU (starter generator control
unit)” on page 8-36.
8-9
8-10
RR
EAS33384
EAS20715
7
R
R
Br
9 Br
Br Br
Br Br
10
R R 13
12 R R W G
Br ON Lg/L G/Y P W/L Ch G B/L B O/B W/R B/Y O
R/Y R/Y OPEN
Br Br/R OFF
CIRCUIT DIAGRAM
Br Br/R
(B)
Br
Br
R
Br
47 48
49 B/L Y L P/W Br/W
B/L B/L
Y Y
L L
50 (B)
Y/W 39 W/G
27 Y/W
W/G
STOP AND START SYSTEM
29 W/R W/R G
G W/R W/R B/L
Y/W W/L W/L
ON W/B W/B L/Y Br/B W/L W/L Br/B
OFF W/Y W/Y 51
B/W 43 B/L B/L
(B)
(B)
B/W
Y/W
Y/R
G/R G/R G/R B/L
B/W R 35 B/L B/L 52
R/B Br/R Br Y/R Y/R (B)
(B)
B/W R
Br R/B R/B
B
B B L/Y L/Y L/Y L/Y

B
R
R L/Y B 36
B B
(L) (L)
8-11
1
B B
B
B
G G R/L
R R R/Y 55
W W R/W
W/B R/Y R/W R/L
W
R W G
W
Br W/B
Br Br B
Y Y W 56 W B Br Y
59
B B B/W
B
B 60
B R Br Y G L W W/L W/B B/W
B Br R/L Y L/G L/G Br Lg/L Lg/W B/W B

B B
B B
B B (B)
B B B/W 61
B B B
B
B
B BB BB
B
B B
73 72 72
72
68
R/W L/W Br/W Y/W Dg Ch Br R
L/R G/B W/L Br/R W/R G B R
(Gy)
1. Battery
9. Main fuse
10. Ignition fuse
12. ABS control unit fuse
13. Main switch
29. Stop and Start System switch
39. Joint 2
48. Intake air pressure sensor
49. Intake air temperature sensor
50. Throttle position sensor
52. Coolant temperature sensor
59. ABS ECU
60. Meter assembly
61. Multi-function meter
68. Stop and Start System indicator light
72. Frame ground
73. Engine ground
8-12
EAS33385
STOP AND START SYSTEM OPERATION

If the main switch is turned to “ON” and the Stop and Start System switch is set to “ON” (both switches
are closed), the following functions operate when the conditions for each function are met.
Engine stop function:
When all of the following conditions are met, this function cuts off the fuel after 5 seconds (or 0 seconds
depending on the circumstances) to stop the engine.
• Vehicle speed: stopped
• Engine speed: idling
• Throttle valve: fully closed
• Coolant temperature: 70°C or more
• Operating condition: vehicle has traveled at a speed of more than 10 km/h after the engine was started
TIP
The engine stop function may not operate when the vehicle is traveling at a speed of 10 km/h or less,
such as when traveling in heavy traffic. This, however, does not indicate a malfunction.
Engine start function:
When all of the following conditions are met, this function restarts the engine.
• Sidestand: UP
• Throttle valve: opened
12
7
13
11
1 2 14
6
15
8 16
3 17
18 19
9
4 5 10
1. Battery 15. Throttle position sensor

2. Main fuse 16. Front wheel sensor
3. Main switch 17. ABS ECU
4. ABS control unit fuse 18. Sidestand switch
5. Ignition fuse 19. Stop and Start System switch
8. Yamaha diagnostic tool coupler
10. Stop and Start System indicator light
8-13
EAS33386
TROUBLESHOOTING
• The engine stop function does not operate.
• The engine start function does not operate.
• The Stop and Start System indicator light fails to come on.
TIP
1. Battery cover
2. Center cover
3. Side cover
4. Storage box
1. Check the fuses.

(Main, ignition, fuel injection sys-
tem, and ABS control unit) NG→ Replace the fuse(s).
ES” on page 8-36.
OK↓

FORMATION.
OK↓

OK↓
4. Check the Stop and Start System

switch. The Stop and Start System switch is
NG→
Refer to “CHECKING THE faulty. Replace the right handlebar switch.
OK↓
5. Check the entire starting system

NG→
page 8-11.
OK↓
Check the condition of each of the

Stop and Start System circuits. Refer
to “Checking the Stop and Start Sys-
tem” on page 8-14.
8-14
Checking the Stop and Start System
The engine stop function does not operate.
1. Check the coolant temperature

sensor.
Refer to “CHECKING THE COOL- NG→ Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-41.
OK↓
The throttle position sensor is faulty. Re-

2. Check the throttle position sensor. NG→
place the throttle body assembly.
OK↓
3. Check the front wheel sensor. NG→ Replace the front wheel sensor.
OK↓
4. Check the entire wiring. Properly connect or replace the wiring har-
NG→
Refer to TIP. ness.
OK↓
Replace the SGCU. Refer to “RE-

PLACING THE SGCU (starter gener-
ator control unit)” on page 8-36.
TIP
Replace the wire harness if there is an open or short circuit.
The engine start function does not operate.

OK↓

OK↓
3. Check the start charge relay.

Refer to “CHECKING THE RE- NG→ Replace the start charge relay.
OK↓
The throttle position sensor is faulty. Re-

4. Check the throttle position sensor. NG→
place the throttle body assembly.
OK↓
8-15
5. Check the entire Stop and Start

System wiring. Properly connect or replace the wiring har-
NG→
page 8-11.
OK↓

The Stop and Start System indicator light fails to come on.
NG→
Refer to TIP. ness.
OK↓
Replace the SGCU or meter assem-

bly. Refer to “REPLACING THE
SGCU (starter generator control unit)”
on page 8-36.
TIP
• Between SGCU coupler and meter assembly coupler.
(Blue/Red–Blue/Red)
8-16
EAS30496
EAS20074
R
RR
R
R
Br
9 Br Br
Br Br
CIRCUIT DIAGRAM
10
R R 13
R R W G
R/Y R/Y OPEN
Br Br/R OFF
Br Br/R
(B)
CHARGING SYSTEM
R
Br/R Br/R
Br/R Br B
(B)
31
R
Br/R Br
B Br
Br
43
Y/R
R 35
R/B Br/R Br
R Br/R
Br R/B R/B
8-17
B
R
R
B B
B
B
G G R/L
R R R/Y 55
W W R/W
R/Y R/W R/L
R W G
B
B B
B B
B
B
B BB BB
B B
73 72 72
72 72
CHARGING SYSTEM
CHARGING SYSTEM
1. Battery
9. Main fuse
10. Ignition fuse
13. Main switch
31. Main relay
72. Frame ground
73. Engine ground
8-18
CHARGING SYSTEM
EAS30497
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Battery cover
2. Center cover
3. Side cover
4. Storage box
5. Front side cover
1. Check the fuses.

(Main and ignition)
NG→ Replace the fuse(s).
ES” on page 8-36.
OK↓

FORMATION.
OK↓

OK↓
4. Check the main relay.

Refer to “CHECKING THE RE- NG→ Replace the main relay.
OK↓
5. Check the starter charge relay.

Refer to “CHECKING THE RE- NG→ Replace the starter charge relay.
OK↓

OK↓
7. Check the entire charging system

NG→
page 8-17.
OK↓
8-19
CHARGING SYSTEM

8-20
RR
EAS30498
EAS20075
8
R R
R
Br
9 Br
Br
Br Br
10
Br R R 13
Br
11 R R W G
R/Y R/Y OPEN
Br Br/R OFF
R
Br Br/R
R (B)
CIRCUIT DIAGRAM
Br
LIGHTING SYSTEM
B Br
Br Br B
L/B Br
22 L/B
L/B P
25
Y Y
Y/W
B B 43
Ch Dg
L/W B
(B)
Y
P L/B
Y/W
R/W L/W
(B)
R Y/B
Br
Br
8-21
1 Br
B
75 Br Br B
L
82 Y Br 76 74
B Y L
84 Br B
85 86 Br Y Y Br
G B B Y/B B Br B
Y B
Gy Br/R B
Br
83 85
G Y/B
Gy Br/R
B B
B
B
B B 60
B
B
B Br
B Br/R
B B
R
B B R R 61
B B B
B
B
B BB BB
B
B B B 62
73 72 72
72 72

(Gy)
LIGHTING SYSTEM
LIGHTING SYSTEM
1. Battery
8. Backup fuse
9. Main fuse
10. Ignition fuse
11. Headlight fuse
13. Main switch
22. Handlebar switch (left)
25. Dimmer switch
60. Meter assembly
62. ABS warning light
72. Frame ground
73. Engine ground
74. License plate light
75. Tail/brake light assembly
76. Taillight
82. Headlight assembly
83. Headlight control unit
84. High beam
85. Low beam
86. Auxiliary light
8-22
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
2. Front side cover
5. Leg shield
6. Upper handlebar cover assembly
1. Check the condition of each bulb

and bulb socket.
Refer to “CHECKING THE BULBS
NG→ Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” in “BASIC
INFORMATION” (separate vol-
ume).
OK↓
2. Check the fuses.

(Main, ignition, and headlight)
ES” on page 8-36.
OK↓

FORMATION.
OK↓

OK↓
5. Check the dimmer switch.

The dimmer switch is faulty. Replace the
left handlebar switch.
OK↓
6. Check the entire lighting system

NG→
page 8-21.
OK↓
8-23
LIGHTING SYSTEM
Replace the SGCU, meter assembly,

tail/brake light assembly or headlight
unit. Refer to “REPLACING THE
on page 8-36.
8-24
R
EAS30500
EAS20076
RR
6
Br/R Br
Br
8
R R
R
Br
9 Br
Br
Br Br
10
R R 13
12 R
R/Y R/Y OPEN
Br Br/R OFF
CIRCUIT DIAGRAM
R
Br Br/R
R (B)
Br/R R
Br/R
Br/R Br B
(B)
31
R
Br/R Br
Br
SIGNALING SYSTEM
Br
20 Br
P Br Br
P 21
P P Br
27 Br/W
22 P L/W R/W Br 33
Dg Br Br B/Y B/Y
Ch Dg
30 Br B/Y
Dg Br/W
24 26 OFF B/Y
L/B P Br/W
Y Y 34 37
Y/W FREE
PUSH PUSH B B Ch B Br B/Y B/Y
Ch 43
Ch Dg (R)
L/W B Y
(B) B
L/W
B B L/R L/R
P L/B G/R G/R G/R B/L
L/R B/L B/L 52
Y/W (B)
R/W L/W B
B
(B) B
B
Ch Ch
Ch
R
Dg Dg
Dg
8-25
1
B
G 42 B G
B (Gy)
Ch Dg Ch Dg B
B
75 Y B
G
81 80 79 78
B
B B Ch 76 77
W/B
Ch Dg G
(Br) (G) (Br) B Y
W
Br
B B B B B
B
Ch Dg Ch B
Y B
(Br) (G) Dg Br W
(Br) Br W/B
Br Br B
Y Y W 56 W B Br Y
59
B B B B/W
W/L
B
B
B B B 60
B
W/L
B G
B R Br Y G L W W/L W/B B/W

B B
B B B (B)
R
B B B/W R R 61
B B B L/W
R/W
B Ch
B Dg
Br/W
L/R
B BB BB
B
B B B
73 72 72
72 72
65
66

(Gy)
SIGNALING SYSTEM
SIGNALING SYSTEM
1. Battery
6. Terminal fuse
8. Backup fuse
9. Main fuse
10. Ignition fuse
13. Main switch
20. Horn
21. Diode
22. Handlebar switch (left)
24. Horn switch
26. Turn signal switch
30. Hazard switch
31. Main relay
37. Joint 1
42. Fuel sender
59. ABS ECU
60. Meter assembly
65. Turn signal indicator light (left)
66. Turn signal indicator light (right)
72. Frame ground
73. Engine ground
76. Taillight
77. Brake light
78. Front turn signal light (left)
79. Front turn signal light (right)
80. Rear turn signal light (left)
81. Rear turn signal light (right)
8-26
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
2. Front side cover
3. Fuel tank cover
4. Storage box
5. Center lower cover
6. Upper handlebar cover assembly
1. Check the fuses.

(Main, ignition, signaling system
ABS control unit) NG→ Replace the fuse(s).
ES” on page 8-36.
OK↓

FORMATION.
OK↓

OK↓
4. Check the entire signaling system

NG→
page 8-25.
OK↓
Check the condition of each of the sig-

naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system
The horn fails to sound.
1. Check the horn switch.

The horn switch is faulty. Replace the left
handlebar switch.
8-27
SIGNALING SYSTEM
OK↓

NG→
page 8-25.
OK↓
Replace the horn.
The brake light fails to come on.
1. Check the front brake light switch.

Refer to “CHECKING THE NG→ Replace the front brake light switch.
OK↓
2. Check the rear brake light switch.

Refer to “CHECKING THE NG→ Replace the rear brake light switch.
OK↓

NG→
page 8-25.
OK↓
Replace the tail/brake light assembly.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the turn signal light bulbs

and sockets.
Refer to “CHECKING THE BULBS Replace the turn signal light bulb, socket
NG→
AND BULB SOCKETS” in “BASIC or both.
ume).
OK↓
2. Check the turn signal switch.

The turn signal switch is faulty. Replace
the left handlebar switch.
OK↓

NG→
page 8-25.
OK↓
8-28
SIGNALING SYSTEM
Replace the meter assembly.
The coolant temperature warning light fails to come on.
1. Check the coolant temperature

sensor.
Refer to “CHECKING THE COOL- NG→ Replace the coolant temperature sensor.
ANT TEMPERATURE SENSOR”
on page 8-41.
OK↓

NG→
page 8-25.
OK↓
Replace the meter assembly or

SGCU. Refer to “REPLACING THE
on page 8-36.
The fuel meter, fuel level warning light, or both fails to come on.
1. Check the fuel sender.

Refer to “CHECKING THE FUEL NG→ Replace the fuel pump.
SENDER” on page 8-40.
OK↓

NG→
page 8-25.
OK↓
Replace the meter assembly.
The speedometer, V-belt replacement indicator, engine oil change indicator, instantaneous fuel
consumption meter fails to operate.
1. Check the front wheel sensor.

Refer to “MAINTENANCE OF THE
NG→ Replace the front wheel sensor.
FRONT WHEEL SENSOR AND
SENSOR ROTOR” on page 4-24.
OK↓
NG→
Refer to TIP. ness.
OK↓
8-29
SIGNALING SYSTEM
Replace the SGCU, or meter assem-

bly. Refer to “REPLACING THE
on page 8-36.
TIP
• Between front speed sensor coupler and SGCU coupler.
(Brown–Brown)
(Yellow–Yellow)
• Between SGCU coupler and meter assembly coupler.
(Blue/Red–Blue/Red)
8-30
EAS30513
RR EAS20081
7
R
R
Br
9 Br
Br Br
10
R R 13
CIRCUIT DIAGRAM
R
R/Y R/Y OPEN
Br Br/R OFF
Br Br/R
(B)
FUEL PUMP SYSTEM
Br
Br
Br
43
8-31
R
B/Y R
41 (B)
1 R B/Y B/Y
B
B
B
B B
B B
B
B
BB
72
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
1. Battery
9. Main fuse
10. Ignition fuse
13. Main switch
41. Fuel pump
72. Frame ground
8-32
FUEL PUMP SYSTEM
EAS30514
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Battery cover
2. Front side cover
4. Fuel tank
1. Check the fuses.

(Main, ignition and fuel injection)
ES” on page 8-36.
OK↓

Refer to “CHECKING AND • Clean the battery terminals.
NG→
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-36.
OK↓

OK↓
4. Check the fuel pump.

Refer to “CHECKING THE FUEL NG→ Replace the fuel pump.
PRESSURE” on page 7-3.
OK↓
5. Check the entire fuel pump system

wiring. Properly connect or replace the wiring har-
NG→
page 8-31.
OK↓
Replace the SGCU. Refer to “RE-

PLACING THE SGCU (starter gener-
ator control unit)” on page 8-36.
8-33
ELECTRICAL COMPONENTS
EAS20089
2
1
3 4
5
32
6
31
7
30
10
8
29
9
28 11
24,25,26,27
23 12
13
22 14
21 20
15
19 18 17 16
1. Battery 19. Spark plug
2. Main switch 20. Coolant temperature sensor
3. Front brake light switch 21. Starter generator
4. Rear brake light switch 22. Crankshaft position sensor
5. Auxiliary DC jack 23. Rear wheel sensor
6. Buzzer 24. Throttle body sensor assembly
7. SGCU (starter generator control unit) 25. Intake air pressure sensor
8. Main relay 26. Intake air temperature sensor
9. Starter charge relay 27. Throttle position sensor
10. Fuse box 28. ISC (Idle Speed Control) unit
11. ABS ECU 29. Fuel injector
12. Horn 30. Ignition coil
13. Front wheel sensor 31. CCU (Communication Control Unit)
14. Fuel pump 32. Smart key unit
15. Fuel sender
17. VVA (variable valve actuator) solenoid
18. O2 sensor
8-34
EAS30549
CHECKING THE SWITCHES
11 1
R R R/Y Br/R
B Y/W ON
L/B P
FREE OPEN
PUSH Y/W OFF
R/Y LOCK
Ch Dg
10 Br/R
Y L/B
Y
B
2
9 L/W
L/W B L/W
P B
PUSH
FREE
B
8
Ch B/W Dg 3
Y/W B/W
Y/W
ON
OFF
B/W
7
4
Dg Dg Br/W Ch
Br/W
Ch
6
B
B
B
1. Main switch
2. Start switch
3. Start and Stop System switch
4. Hazard switch
6. Sidestand switch
8. Turn signal light switch
9. Horn switch
10. Dimmer switch
11. Menu switch
8-35
EAS30551
CHECKING THE FUSES Amper-

Fuses Q’ty
The following procedures are applied to all of the age rating
fuses. Spare 5A 1
ECA20520
NOTICE EWA13310
To avoid a short circuit, always turn the main WARNING

switch to “OFF” when checking or replacing Never use a fuse with an amperage rating
a fuse. other than that specified. Improvising or us-
ing a fuse with the wrong amperage rating
1. Remove:
may cause extensive damage to the electri-
• Battery cover
cal system, cause the lighting and ignition
systems to malfunction and could possibly
page 4-1.
cause a fire.
2. Check:
• Fuse
4. Install:
a. Connect the digital circuit tester to the fuse • Battery cover
and check the continuity. Refer to “GENERAL CHASSIS (1)” on
page 4-1.
Digital circuit tester (CD732)
90890-03243 EAS33388
REPLACING THE SGCU (starter generator

b. If the digital circuit tester indicates “∞”, re- control unit)
place the fuse. 1. Turn the main switch to “OFF”.
2. Replace the SGCU (starter generator control
3. Replace:
unit).
• Blown fuse
3. Clean the throttle body.
a. Turn the main switch to “OFF”. Refer to “CLEANING THE ISC (IDLE SPEED
b. Install a new fuse of the correct amperage CONTROL) UNIT AND THROTTLE BODY”
rating. on page 7-13.
c. Set on the switches to verify if the electrical 4. Check:
circuit is operational. • Engine idling speed
d. If the fuse immediately blows again, check Start the engine, warm it up, and then mea-
the electrical circuit. sure the engine idling speed.
Amper-
Fuses Q’ty Engine idling speed
age rating
1500–1700 r/min
Main fuse 30 A 1
Headlight fuse 7.5 A 1 EAS30552
CHECKING AND CHARGING THE BATTERY

Backup fuse 7.5 A 1
TIP
Ignition fuse 7.5 A 1 Refer to “CHECKING AND CHARGING THE
Fuel injection system 7.5 A 1 BATTERY” in “BASIC INFORMATION” (sepa-
fuse rate volume).
Signaling system fuse 7.5 A 1 1. Remove:
Terminal fuse 5A 1 • Battery cover
ABS motor fuse 30.0 A 1 Refer to “GENERAL CHASSIS (1)” on
page 4-1.
ABS solenoid fuse 15.0 A 1
ABS control unit fuse 2.0 A 1
Smart key system fuse 2.0 A 1
Spare 30 A 1
Spare 7.5 A 1
8-36
2. Disconnect: 8. Lubricate:
• Battery lead • Battery terminals
(from the battery terminals)
ECA13640
NOTICE Dielectric grease
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”. 9. Install:
• Battery cover
page 4-1.
EAS30553
CHECKING THE RELAYS

1 Check each switch for continuity with the digital
circuit tester. If the continuity reading is incor-
rect, replace the relay.
2
3. Remove: 90890-03243
• Battery
1. Disconnect the relay from the wire harness.
4. Check:
2. Connect the digital circuit tester and battery
• Battery charge
(12 V) to the relay terminals as shown.
a. Connect a digital circuit tester to the battery Check the relay operation.
terminals. Out of specification → Replace.
• Positive tester probe →
positive battery terminal 1
• Negative tester probe → 3 +
4
negative battery terminal
2
5. Install:
B Br
• Battery
Br/R
6. Connect: R
• Battery leads
(to the battery terminals) 1. Positive battery terminal
ECA13630
NOTICE 2. Negative battery terminal

3. Positive tester probe
First, connect the positive battery lead “1”,
4. Negative tester probe
and then the negative battery lead “2”.
Result
Continuity
(between “3” and “4”)
7. Check:
• Battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
8-37
Starter charge relay EAS30557
CHECKING THE SPARK PLUG CAP

First step: 1. Check:
• Spark plug cap resistance
1 Out of specification → Replace.
3
Resistance
2
3.75–6.25 kΩ
Br Br/R R/B
a. Remove the spark plug cap from the spark
R
plug lead.
Y/R
b. Connect the digital circuit tester to the spark
plug cap as shown.
90890-03243
Result
Continuity
No continuity
Second step:
3 2
5 +
4 c. Measure the spark plug cap resistance.
1
Br Br/R R/B
R
Y/R
1. Positive battery terminal

2. Negative battery terminal
Result
No continuity
Continuity
8-38
EAS30558
CHECKING THE IGNITION COIL

1. Check: 2
• Primary coil resistance
Primary coil resistance

2.16–2.64 Ω
a. Disconnect the ignition coil connectors from 1

the ignition coil terminals. b. Measure the secondary coil resistance.
b. Connect the digital circuit tester to the igni-
tion coil as shown. EAS30556
CHECKING THE IGNITION SPARK GAP

Digital circuit tester (CD732) 1. Check:
90890-03243 • Ignition spark gap
Out of specification → Perform the ignition
• Positive tester probe → system troubleshooting, starting with step 5.
Brown “1” Refer to “TROUBLESHOOTING” on page 8-
• Negative tester probe → 3.
Orange “2”
Minimum ignition spark gap
6.0 mm (0.24 in)
TIP
If the ignition spark gap is within specification,
2 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.
1
c. Measure the primary coil resistance. Ignition checker
90890-06754
2. Check:
• 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 2. Ignition coil
• Positive tester probe → c. Turn the main switch to “ON”.

Orange “1” d. Measure the ignition spark gap “a”.
• Negative tester probe → e. Crank the engine by pushing the “ ” of the
High tension cord “2” start switch and gradually increase the
spark gap until a misfire occurs.
8-39
EAS33389 EAS30573
CHECKING THE STARTER GENERATOR CHECKING THE FUEL SENDER

1. Disconnect: 1. Remove:
• Starter generator coupler • Fuel pump
(from the wire harness) (from the fuel tank)
2. Check: 2. Check:
• Starter generator resistance • Fuel sender resistance
Out of specification → Replace the starter Out of specification → Replace the fuel pump
generator assembly. assembly.
Starter generator resistance Fuel sender

0.048–0.072 Ω Sender unit resistance (full)
10.0–14.0 Ω
a. Connect the digital circuit tester to the start- Sender unit resistance (empty)
er generator coupler as shown. 267.0–273.0 Ω
Digital circuit tester (CD732) a. Connect the digital circuit tester to the fuel
90890-03243 sender terminals as shown.
• Positive tester probe → Digital circuit tester (CD732)

Red/Yellow “1” 90890-03243
• Negative tester probe →
Red/Blue “3” • Positive tester probe →
Green “1”
• Positive tester probe → • Negative tester probe →
Red/Yellow “1” Black “2”
Red/White “2”
2
Red/Blue “3”
• Negative tester probe → B/Y B
Red/White “2” R G
b. Move the fuel sender float to minimum “3”

and maximum “4” level position.
R/Y R/W R/L
4
1 2 3
b. Measure the starter generator resistance. 3
c. Measure the fuel sender resistance.
8-40
EAS30578
3. Install:
CHECKING THE COOLANT TEMPERATURE
• Coolant temperature sensor
SENSOR
1. Remove:
Coolant temperature sensor
• Coolant temperature sensor 15 N·m (1.5 kgf·m, 11 lb·ft)
T.
R.
EWA14130
EAS30681
WARNING CHECKING THE FUEL INJECTOR
• Handle the coolant temperature sensor 1. Check:
with special care. • Fuel injector resistance
• Never subject the coolant temperature sen- Out of specification → Replace the fuel injec-
sor to strong shocks. If the coolant tem- tor.
perature sensor is dropped, replace it.
Resistance
2. Check:
12.2 Ω
• Coolant temperature sensor resistance
a. Disconnect the fuel injector coupler from
fuel injector.
Coolant temperature sensor re-
b. Connect the digital circuit tester to the fuel
sistance
2513–2777 Ω at 20 °C (2513– injector terminals as shown.
2777 Ω at 68 °F)
Coolant temperature sensor re- Digital circuit tester (CD732)
sistance 90890-03243
210–221 Ω at 100 °C (210–221 Ω
at 212 °F) • Positive tester probe →
Injector terminal “1”
a. Connect the digital circuit tester to the cool- • Negative tester probe →
ant temperature sensor terminals as Injector terminal “2”
shown.
Digital circuit tester (CD732) 2 1

90890-03243
b. Immerse the coolant temperature sensor

“1” in a container filled with coolant “2”.
TIP
Make sure that the coolant temperature sensor
terminals do not get wet.
c. Place a thermometer “3” in the coolant. c. Measure the fuel injector resistance.
3
1
d. Heat the coolant or let it cool down to the

specified temperatures.
e. Measure the coolant temperature sensor
resistance.
8-41
EAS31612
CHECKING THE VVA SOLENOID • Positive tester probe →

1. Check: Positive battery terminal “1”
• VVA solenoid resistance
Negative battery terminal “2”
Resistance
1.8–2.2 Ω at 20 °C (1.8–2.2 Ω at 68
°F) 1
a. Disconnect the VVA solenoid coupler from
the VVA solenoid. 2
b. Connect the digital circuit tester to the VVA
solenoid terminal as shown.
Digital circuit tester (CD732) c. Measure the smart key battery voltage.
90890-03243
EAS31555
• Positive tester probe CHECKING THE BUZZER

Solenoid terminal “1” 1. Check:
• Negative tester probe • Buzzer operation
Solenoid terminal “2” Buzzer does not sound → Replace.
a. Disconnect the buzzer coupler from the
wire harness.
1 2 b. Connect the battery (12 V) to the buzzer
coupler as shown.
• Positive battery lead →
Red “1”
• Negative battery lead →
Black “2”
2 1
c. Measure the VVA solenoid resistance.
EAS31553
B R
CHECKING THE SMART KEY BATTERY
1. Check:
• Smart key battery voltage
Out of specification → Replace the smart key
battery.
Smart key battery voltage c. Check that the buzzer sounds.

2.7–3.2 V
a. Remove the smart key battery from the

smart key.
b. Connect the digital circuit tester to the smart
key battery as shown.

90890-03243
8-42
EAS31257
CHECKING THE MAIN SWITCH SOLENOID

1. Check:
• Main switch solenoid
a. Disconnect the main switch solenoid cou-
pler from the wire harness.
b. Connect the digital circuit tester to the main
switch solenoid as shown.

90890-03243

Red/White “1”
Black “2”
1 2
R/W B
c. Check the main switch solenoid continuity.

d. If there is no continuity, replace the main
switch assembly.
8-43
SELF DIAGNOSTIC
SELF-DIAGNOSTIC FUNCTION..................................................................... 9-1

GLOSSARY............................................................................................... 9-1
OUTLINE ...................................................................................................9-1
CHECKING THE WARNING LIGHT .........................................................9-2
YDT ...........................................................................................................9-3
PARTS CONNECTED TO THE SGCU .....................................................9-3
PARTS CONNECTED TO THE ABS ECU................................................ 9-4
SYSTEM DIAGRAM ........................................................................................9-5

ECU CIRCUIT DIAGRAM..........................................................................9-5
ECU COUPLER LAYOUT ......................................................................... 9-6
FUEL INJECTION SYSTEM............................................................................9-8

CIRCUIT DIAGRAM .................................................................................. 9-8
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-10
[A] THE MIL COMES ON/FLASHES AND
ENGINE OPERATION IS NOT NORMAL .............................................. 9-11
[B] THE MIL DOES NOT COME ON,
BUT THE ENGINE OPERATION IS NOT NORMAL ..............................9-11
ABS (Anti-lock Brake System) .................................................................... 9-12

CIRCUIT DIAGRAM ................................................................................ 9-12
ABS COUPLER LOCATION CHART ......................................................9-14
MAINTENANCE OF THE ABS ECU .......................................................9-15
ABS TROUBLESHOOTING OUTLINE....................................................9-15
BASIC INSTRUCTIONS FOR TROUBLESHOOTING ............................ 9-16
BASIC PROCESS FOR TROUBLESHOOTING ..................................... 9-17
[A] CHECKING THE ABS WARNING LIGHT..........................................9-18
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON............. 9-18
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON ..............................9-18
[A-3] THE ABS WARNING LIGHT COMES ON ...................................... 9-18
[B-1] MALFUNCTION ARE CURRENTLY DETECTED .......................... 9-19
[B-2] DIAGNOSIS USING THE FAULT CODES ..................................... 9-19
[B-3] DELETING THE FAULT CODES....................................................9-20
[C-1] FINAL CHECK ................................................................................ 9-20
SMART KEY SYSTEM .................................................................................. 9-22

CIRCUIT DIAGRAM ................................................................................ 9-22
SMART KEY SYSTEM SELF-DIAGNOSIS............................................. 9-27
SMART KEY SYSTEM EMERGENCY MODE ........................................ 9-30
REGISTERING A SMART KEY...............................................................9-32
DISABLING A SMART KEY .................................................................... 9-33
DISABLING THE POWER-ON ALARM...................................................9-34
9
REPLACEMENT PARTS LIST ................................................................9-35
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE..........9-36
DTC TABLE............................................................................................. 9-36
COMMUNICATION ERROR WITH
THE YAMAHA DIAGNOSTIC TOOL ......................................................9-39
SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 9-40
SELF-DIAGNOSTIC FUNCTION TABLE
(FOR ABS (Anti-lock Brake System)) .....................................................9-51
DIAGNOSTIC CODE: SENSOR OPERATION TABLE ........................... 9-56
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE ......................9-58
EVENT CODE TABLE...................................................................................9-60
P0030............................................................................................................. 9-62
P00D1, P2195................................................................................................9-65
P0105............................................................................................................. 9-69
P0106............................................................................................................. 9-71
P0107, P0108 ................................................................................................9-73

P0110............................................................................................................. 9-77
P0111............................................................................................................. 9-79
P0112, P0113 ................................................................................................9-82

P0115............................................................................................................. 9-86
P0116............................................................................................................. 9-87
P0117, P0118 ................................................................................................9-90

P0122, P0123 ................................................................................................9-94
P0132............................................................................................................. 9-98
P0133...........................................................................................................9-101
OUTLINE ...............................................................................................9-101
FAIL-SAFE SYSTEM.............................................................................9-101
TROUBLESHOOTING ..........................................................................9-102
P0134...........................................................................................................9-103
P0201...........................................................................................................9-106
P0301...........................................................................................................9-109
OUTLINE ...............................................................................................9-109
FAIL-SAFE SYSTEM.............................................................................9-110
P0335...........................................................................................................9-113
P0351...........................................................................................................9-117
P0500...........................................................................................................9-121
P0507...........................................................................................................9-125
P0511...........................................................................................................9-132
P0560, P0563 ..............................................................................................9-136

P0601...........................................................................................................9-137
P062F ..........................................................................................................9-138
P1602........................................................................................................... 9-140
P2158........................................................................................................... 9-145
P2645........................................................................................................... 9-150
Er-1, Er-2, Er-3, Er-4 ...................................................................................9-154

11, 25_ABS ................................................................................................. 9-158

12_ABS .......................................................................................................9-159
13, 26_ABS ................................................................................................. 9-160

14, 27_ABS ................................................................................................. 9-161

15_ABS .......................................................................................................9-162
16_ABS .......................................................................................................9-164
17, 45_ABS ................................................................................................. 9-166

18, 46_ABS ................................................................................................. 9-167

21_ABS .......................................................................................................9-168
31_ABS .......................................................................................................9-169
32_ABS .......................................................................................................9-171
33_ABS .......................................................................................................9-172
34_ABS .......................................................................................................9-174
41_ABS .......................................................................................................9-175
42, 47_ABS .................................................................................................9-176

43_ABS .......................................................................................................9-177
44_ABS .......................................................................................................9-178
51, 52_ABS .................................................................................................9-179

53_ABS .......................................................................................................9-180
54_ABS .......................................................................................................9-182
55_ABS .......................................................................................................9-184
56_ABS .......................................................................................................9-185
63_ABS .......................................................................................................9-186
64_ABS .......................................................................................................9-188
SELF-DIAGNOSTIC FUNCTION
EAS20437
EAS33142
GLOSSARY
Word Description
MIL
MIL is an indicator light that comes on when a control unit determines a
(Malfunction indica-
malfunction.
tor light)
DTC
DTC is a code that is saved within a control unit’s memory when the control
(Diagnostic trouble
unit determines a malfunction.
code)
Pending DTC Pending DTC is a code that is saved within a control unit’s memory when
(Pending diagnostic the control unit detects an abnormal condition. If the abnormal condition
trouble code) continues, a malfunction may be determined.
Driving cycle is the duration from the ON/start switch is pushed, OBD re-
Driving cycle
quirements are met, and until the OFF/lock switch is pushed.
FFD FFD is the data of all signal sensors saved at the moment a malfunction is
(Freeze frame data) determined.
Current malfunction A DTC for an unrecovered, current malfunction.
Recovered malfunc-
A DTC for a previously determined but now recovered malfunction.
tion
Abnormal condition that is detected but not yet determined to be a malfunc-
Pending abnormality
tion.
Threshold is a point set to detect if the output from sensors are abnormal or
Threshold
not.
OBD
Self-diagnostic system is equipped in a control unit for the emission control
(On-board diagnos-
system.
tics)
GST
Generic diagnostic tool that complies with OBD standards.
(Generic scan tool)
YDT
(Yamaha diagnostic Diagnostic tool developed especially for Yamaha vehicles.
tool)
EAS32858
OUTLINE
The control unit is equipped with a self-diagnostic function in order to ensure that the system is operat-
ing normally. If this function detects a malfunction in the system, it immediately operates the system un-
der substitute characteristics and illuminates the warning light to alert the rider that a malfunction has
occurred in the system. Once a malfunction has been detected, a DTC is stored in the memory of the
control unit.
9-1
EAS32859
CHECKING THE WARNING LIGHT

The warning light comes on after the ON/start switch has been pushed on. Refer to the following table
for lighting up time.
If the warning light still comes on, refer to a check item of a troubleshooting of each system, check and
repair it. If the warning light does not come on, the warning light (LED) may be defective.
TIP
• This engine equips self-diagnostic function. It’s controlled delicately for detecting defective and mal-
function of the exhaust emission control system. Therefore, the vehicle modifying, poor maintenance,
and improper using of the vehicle may also become the cause of the MIL come on. These events may
cause the occurrence of the warning light coming on without malfunction.
• Reprogramming of the SGCU software.
• Using the electrical accessory which may affect the SGCU.
• Using the incorrect specification of spark plug and fuel injector. Using the third party accessories such
as suspension and exhaust system.
• Removing or modifying the O2 sensor, the exhaust system part (catalyst, etc.).
1 2
System Lighting up warning light Lighting time

FUEL INJECTION SYSTEM MIL “2” 2.0 seconds
ABS (Anti-lock Brake Sys-
ABS warning light “1” *1
tem)
TIP
*1: The ABS warning light goes off when the vehicle is judged to normal with running.
9-2
EAS32806
YDT
This model uses the YDT to identify malfunctions.
For information about using the YDT, refer to the operation manual that is included with the tool.

90890-03267
90890-03264
TIP
• Yamaha diagnostic tool (A/I) (90890-03264) includes YDT sub harness (6P) (90890-03266).
• If you already have Yamaha diagnostic tool (A/I) (90890-03262), YDT sub harness (6P) (90890-
03266) is separately required.
• A GST can also be used to identify malfunctions.
Disconnect the YDT
Disconnect the YDT coupler from the CCU (Communication Control Unit) “1”, and then connect the
YDT to the coupler.
1
EAS33550
PARTS CONNECTED TO THE SGCU

The following parts are connected to the SGCU.
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• Crankshaft position sensor • Fuel pump
• Injector • Starter generator
• Ignition coil • ABS ECU (Electronic Control Unit)
• Throttle position sensor • Starter charge relay
• Intake air pressure sensor • ISC (Idle Speed Control)
• Coolant temperature sensor • VVA (Variable Valve Actuation) solenoid
• Intake air temperature sensor • CCU (Communication Control Unit)
• O2 sensor • Meter assembly
9-3
EAS32918
PARTS CONNECTED TO THE ABS ECU

The following parts are connected to the hydraulic unit assembly (ABS ECU).
When checking for a power short circuit, the couplers must be disconnected from all of the following
parts beforehand.
• ABS solenoid fuse • Rear wheel sensor
• ABS motor fuse • Meter assembly
• ABS ECU fuse • SGCU (Starter Generator Control Unit)
• Front wheel sensor
9-4
SYSTEM DIAGRAM
EAS20387
SYSTEM DIAGRAM
EAS32920
ECU CIRCUIT DIAGRAM
METER ASSEMBLY
EFI FUSE BACKUP FUSE
IGNITION COIL
40
47 1
33
IGNITION
LOW BEAM FUEL INJECTOR
FUSE
43 5
FUEL PUMP
FRONT WHEEL
DIMMER HIGH BEAM SENSOR 3
SWITCH O2 SENSOR HEATER
25
ABS ECU
HEADLIGHT
SWITCH 38
MAIN OS SENSOR
REAR WHEEL
RELAY
SENSOR
8
HEADLIGHT
FUSE
48
START SWITCH
13
44
SSS SWITCH
MAIN
SWITCH
SGCU 15
(STARTER ISC (IDLE SPEED CONTROL)
GENERATOR
CONTROL
UNIT)
29
MAIN FUSE
SIDESTAND SWITCH
SIGNALING FUSE BRAKE LIGHT 42 31

SWITCH
TERMINAL FUSE
7 THROTTLE BODY SENSOR ASSEMBLY
23
35
THROTTLE POSITION S
20
17
STARTER CHARGER RELAY
34 INTAKE AIR TEMPERAT
50
36
51 INTAKE AIR PRESSURE
BATTERY
21
49
52 46
COOLANT TEMPERATURE SENSOR
STARTER GENERATOR 54 45
53
9
VVA (VARIABLE VALVE ACTUATION)
18
11
4
39
CRANKSHAFT 12
POSITION
SENSOR
24 16
YAMAHA DIAGNOSTIC TOOL
26 32
19
9-5
SYSTEM DIAGRAM
EAS33369
ECU COUPLER LAYOUT
1 3 4 5 7 8 9 11 12 13 15 16
17 18 19 20 21 23 24 25 26 29 31 32
33 34 35 36 37 38 39 41 42 43 44 45 46 47 48 49 50 51 52 5354
Wire harness Wire harness

No. Connected parts No. Connected parts
color color
1 Ignition coil O Throttle body sen-
23 L
2 — — sor assemblies
3 Fuel pump B/Y Crankshaft position

24 W/B
sensor
Crankshaft position
4 W/R 25 O2 sensor P/B
sensor
5 Fuel injector O/B Crankshaft position
26 W/Y
sensor
6 — —
27 — —
7 Ground B
28 — —
8 O2 sensor B/L
ISC (Idle Speed
VVA (Variable valve 29 Gy
9 G Control)
actuation) solenoid
30 — —
10 — —
ISC (Idle Speed
VVA (Variable valve 31 Sb
11 Ch Control)
actuation) solenoid
Yamaha diagnostic
Crankshaft position 32 Lg/W
12 W/L tool
sensor
33 Main relay Br
ISC (Idle Speed
13 Ch Throttle body sen-
Control) 34 P/W
sor assemblies
14 — —
35 Ground B
ISC (Idle Speed
15 G/Y Throttle body sen-
Control) 36 Br/W
sor assemblies
Yamaha diagnostic
16 Lg/L 37 ABS ECU W/B
tool
17 Starter charge relay R/B 38 O2 sensor Gy/R
Crankshaft position 39 Ground B
18 Br/B
sensor 40 Meter assembly L/R
Crankshaft position 41 — —
19 B/L
sensor
42 Sidestand switch L/Y
Throttle body sen-
20 Y 43 ABS ECU W
sor assemblies
Stop Start System
Throttle body sen- 44 Y/W
21 B/L switch
sor assemblies
Coolant tempera-
22 — — 45 B/L
ture sensor
9-6
SYSTEM DIAGRAM
Wire harness
No. Connected parts
color
Coolant tempera-
46 G/R
ture sensor
Fuel injection sys-
47 R
tem fuse
48 Starter switch L/B
49 Starter charge relay Y/R
50 Headlight unit Y/B
51 Battery B
52 Starter generator G
53 Starter generator W
54 Starter generator R
9-7
RR
EAS32871
EAS20440
R
R
7 8 R
R
R Br Br
Br Br
9 Br Br/R Br
Br
Br Br
10
R R 13 R
R
12 R
R/Y R/Y OPEN
Br Br/R OFF
CIRCUIT DIAGRAM
Br Br/R
(B)
Br
38 O O
44
Br O/B O/B
45
O/B Br
Br (B)
Br P P
R G/Y G/Y P G/Y Sb Gy
Gy Gy 46
Lg/L B Sb Sb
Br (B)
R Lg/W
Lg/W
(R) R Lg/L
Lg/W
47 48
Lg/L 32 B P/W P/W
Br/W Br/W 49 B/L Y L P/W Br/W
B/L B/L
Y Y
L L
50 (B)
FUEL INJECTION SYSTEM
W/R W/R G
W/L W/L G W/R W/R B/L
W/B W/B L/Y Br/B W/L W/L Br/B
W/Y W/Y 51
43 B/L B/L
(B)
(B)
L/R L/R G/R G/R G/R B/L

L/R B/L B/L 52
(B)
G G G Ch
Ch Ch 53
B B L/Y L/Y L/Y L/Y (Gy)
B
R
L/Y B 36 Gy/R Br/R B B P/B
B B
B/Y R B/L B/L W L Gy/R
(L) (L)
9-8
41 P/B
(B)
1 R B/Y B/Y
B B Br/R P/B
54 W L Gy/R B/L
(B) (B)
B B
B
B
B
W/B
W
Br W/B
Br Br B
Y Y W 56 W B Br Y
59
Lg/W
B B B/W
Lg/W W/L
B
B 60
Lg/L W/L
B Lg/L R Br Y G L W W/L W/B B/W

B
B B
B B B (B)
B B B/W 61
B B B
B
B
L/R
B BB BB
B
B B B
73 72 72
72 72
67

(Gy)
1. Battery
8. Backup fuse
9. Main fuse
10. Ignition fuse
13. Main switch
38. Injector
41. Fuel pump
44. Ignition coil
45. Spark plug
46. ISC (Idle Speed Control) unit
53. VVA (variable valve actuator) solenoid
54. O2 sensor
59. ABS ECU
60. Meter assembly
67. Engine trouble warning light
72. Frame ground
73. Engine ground
9-9
EAS32917
BASIC PROCESS FOR TROUBLESHOOTING

This section describes the basic process about fuel injection system troubleshooting.
But because a work procedure varies depending to symptom and DTC, check and repair it according
to applicable troubleshooting.
When pushing the ON/start switch, No Does the MIL (LED) work No
Check the MIL (LED).
does the MIL come on? properly?
Yes Yes
Yes [B] Perform the checking with the

The MIL goes off after 2 seconds?
diagnostic mode.
No
Still on/flash.
[A] Check the DTC.
Do the troubleshooting according

to the DTCs of "malfunction".
Check the DTCs of "malfunction"

are not displayed on the screen.
Finished.
9-10
EAS33147
[A] THE MIL COMES ON/FLASHES AND ENGINE OPERATION IS NOT NORMAL
1. Check the DTC of “malfunction” using the YDT.
2. Delete the DTC using the YDT. (Only for *1)
3. Check and repair the malfunction according to applicable DTC troubleshooting.
4. Push the OFF/LOCK switch, and then push the ON/start switch, and then check the DTC of “mal-
function” is not displayed.
TIP
• If another DTC is displayed, repeat steps (1) to (4) until no DTC is displayed.
• Push the OFF/LOCK switch will not erase the malfunction history.
EAS33148
[B] THE MIL DOES NOT COME ON, BUT THE ENGINE OPERATION IS NOT NORMAL
1. Monitor the operation of these sensors and actuators by using the YDT in the diagnostic mode.
Refer to “DIAGNOSTIC CODE: SENSOR OPERATION TABLE” on page 9-56 and “DIAGNOSTIC
CODE: ACTUATOR OPERATION TABLE” on page 9-58.
D01: Throttle position sensor signal
D30: Ignition coil
D36: Injector
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the en-
gine.
9-11
R R
2 3 R
EAS32890
EAS20443
R/L
RR
6
Br/R Br
8 R
R
R
Br
9 Br
Br
Br Br
10
R R 13 R
R
12 R
R/Y R/Y OPEN
Br Br/R OFF
CIRCUIT DIAGRAM
Br Br/R
(B)
Br/R R
Br/R
Br/R Br B
(B)
31
R
Br/R Br
B Br
Lg/L B Br
R Lg/W
Lg/W
(R) R Lg/L
Lg/W
Lg/L 32 B
Br 33
Br Br B/Y B/Y
Br B/Y
B/Y
34 37
Br B/Y B/Y Y 43
Y
R
R
9-12
1
B
B
B
75 Y B
77
W/B
B Y
W
Br
B
Y B
Br R W
Br W/B
R/L
Y Br Br B
Lg/W Y Y W 56 W B Br Y
Lg/L
B
59
L/G G G B
L/G L L W 57 W B G L
Lg/W
B B B/W B/W
Lg/W W/L B/W
B
B Lg/W
B B 60
Lg/L W/L 58 B/W
B
B Lg/L R Br Y G L W W/L W/B B/W
B/W
Lg/L
Br R/L Y L/G L/G Br Lg/L Lg/W B/W B
B
B (B)
B B B/W 61
B B B
B
B
B BB BB
B
B B B 62
73 72 72
72 72

(Gy)
1. Battery
2. ABS solenoid fuse
3. ABS motor fuse
6. Terminal fuse
8. Backup fuse
9. Main fuse
10. Ignition fuse
13. Main switch
31. Main relay
37. Joint 1
57. Rear wheel sensor
58. Joint 4
59. ABS ECU
60. Meter assembly
72. Frame ground
73. Engine ground
77. Brake light
9-13
EAS32892
ABS COUPLER LOCATION CHART
R Br Y G L W W/L B/W
R/L Y Br L/R L/B B/W B
(B)
Br Y W B
G L W B
3
Lg/L B
R Lg/W
4

(Gy)
1. ABS ECU coupler

2. Rear wheel sensor coupler
4. Meter assembly coupler
5. Front wheel sensor coupler
9-14
EAS32893
MAINTENANCE OF THE ABS ECU
Checking the ABS ECU

1. Check:
• Terminals “1” of the ABS ECU
Cracks/damages → Replace the hydraulic unit assembly, brake hoses, and brake pipes that are
connected to the assembly as a set.
• Terminals “2” of the ABS ECU coupler
Connection defective, contaminated, come-off → Correct or clean.
TIP
If the ABS ECU coupler is clogged with mud or dirt, clean with compressed air.
1
2
EAS33284
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 Yama-
ha diagnostic tool. For information about using the Yamaha diagnostic tool, refer to “[B-2] DIAGNOSIS
USING THE FAULT CODES” on page 9-19. For troubleshooting items other than the following items,
follow the normal service method.
EWA16710
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 9-20.
ABS operation when the ABS warning light comes on

1. The ABS warning light remains on → ABS operates as a normal brake system.
• A malfunction was detected using the ABS self-diagnosis function.
• The ABS self-diagnosis has not been completed.
The ABS self-diagnosis starts when the main switch is turned to “ON” and finishes when the vehicle
has traveled at a speed of approximately 10 km/h (6 mi/h).
2. The ABS warning light comes on after the engine starts, and then goes off when the vehicle starts
moving (traveling at a speed of approximately 10 km/h (6 mi/h)). → ABS operation is normal.
3. The ABS warning light flashes → ABS operation is normal.
• Refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-16.
9-15
Self-diagnosis and servicing

The ABS ECU has a self-diagnosis function. By utilizing this function, quick problem identification and
service are possible. Previous malfunctions can be checked since the ABS ECU also stores the mal-
function history.
The fault codes recorded in the ABS ECU can be checked using the Yamaha diagnostic tool. When the
service is finished, check the normal operation of the vehicle, and then delete the fault code(s). For in-
formation about deleting the fault codes, refer to “[B-3] DELETING THE FAULT CODES” on page 9-20.
By deleting the fault codes stored in the ABS ECU memory, it is possible to pursue the cause correctly
if another malfunction occurs.
TIP
The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the
main switch was turned to “ON”. During this test, a “clicking” noise can be heard from front side, and if
the front brake lever or rear brake lever are even slightly applied, a vibration can be felt at the levers, but
these do not indicate a malfunction.
Self-diagnosis using the ABS ECU

The ABS ECU performs a static check of the entire system when the main switch is turned to “ON”.
It also checks for malfunctions while the vehicle is ridden. Since all malfunctions are recorded after
they are detected, it is possible to check the recorded malfunction data by utilizing the Yamaha di-
agnostic tool when the ABS ECU has entered the self-diagnosis mode.
Special precautions for handling and servicing a vehicle equipped with ABS
ECA17620
NOTICE
Care should be taken not to damage components by subjecting them to shocks or pulling on
them with too much force since the ABS components are precisely adjusted.
• The ABS ECU and hydraulic unit are united assemblies and cannot be disassembled.
• The malfunction history is stored in the memory of the ABS ECU. Delete the fault codes when the ser-
vice is finished. (This is because the past fault codes will be displayed again if another malfunction oc-
curs.)
EAS32895
BASIC INSTRUCTIONS FOR TROUBLESHOOTING

EWA17420
WARNING
• Perform the troubleshooting [A]→[B]→[C] in order. Be sure to follow the order since a wrong
diagnosis could result if the steps are followed in a different order or omitted.
• Use sufficiently charged regular batteries only.
[A] Malfunction check using the ABS warning light
[B] Use the Yamaha diagnostic tool and determine the location of the malfunction and the cause from
the recorded fault code.
Determine the cause of the malfunction from the condition and place where the malfunction occurred.
[C] Servicing the ABS
Execute the final check after disassembly and assembly.
9-16
EAS32878
BASIC PROCESS FOR TROUBLESHOOTING
Fails to
[A] Turn the main switch to “ON”, [A-1] Does only the ABS • The ABS warning light (LED) is
come on Yes
and check the ABS warning warning light fail to defective. Return to [A].
light. come on? • The wire harness is grounded
between the ABS ECU and the
Comes on meter assembly.
• The meter assembly circuit is
defective.
• The hydraulic unit assembly is
defective.
No
• The main switch is defective.
Yes • The battery voltage is low.
[A-2] Do all indicator lights
• The taillight fuse is blown. Return to [A].
fail to come on?
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 • The wire harness is defective.
with the ABS ECU? • The hydraulic unit assembly
is defective.
Can communicate • 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.
codes in the screen for the Return to [A].
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. pipes are not connected
No
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.
defective.
• The ABS warning light circuit in
the hydraulic unit assembly is
defective.
Finished.
9-17
EWA16710
WARNING
When maintenance or checks have been performed on components related to the ABS, be sure
to perform a final check before delivering the vehicle to the customer.
TIP
To final check, refer to “[C-1] FINAL CHECK” on page 9-20.
EAS32897
[A] CHECKING THE ABS WARNING LIGHT

Turn the main switch to “ON”. (Do not start the engine.)
1. The ABS warning light does not come on.
• Only the ABS warning light fails to come on. [A-1]
• The ABS warning light and all other indicator lights fail to come on. [A-2]
2. The ABS warning light comes on. [A-3]
EAS32898
[A-1] ONLY THE ABS WARNING LIGHT FAILS TO COME ON

1. Check for a short circuit to the ground between the White/Blue terminal of the ABS ECU coupler and
White/Blue terminal of the meter assembly.
• If there is short circuit to the ground, the wire harness is defective. Replace the wire harness.
2. Disconnect the ABS ECU coupler and check that the ABS warning light comes on when the main
switch is turned to “ON”.
• If the ABS warning light does not come on, the meter assembly circuit (including the ABS warning
light [LED]) is defective. Replace the meter assembly.
• If the ABS warning light comes on, the ABS ECU is defective. Replace the hydraulic unit assembly.
EAS32899
[A-2] ALL INDICATOR LIGHTS FAIL TO COME ON

1. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES” on page 8-35.
• If there is no continuity, replace the main switch.
2. Battery
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-36.
• If the battery is defective, clean the battery terminals and recharge it, or replace the battery.
3. Taillight fuse
• Check the fuse for continuity.
Refer to “CHECKING THE FUSES” on page 8-36.
• If the taillight fuse is blown, replace the fuse.
4. Circuit
• Check the meter assembly circuit.
Refer to “CIRCUIT DIAGRAM” on page 9-12.
• If the meter assembly circuit is open, replace the wire harness.
EAS32900
[A-3] THE ABS WARNING LIGHT COMES ON

Connect the Yamaha diagnostic tool to the Yamaha diagnostic tool coupler and execute functional di-
agnosis. (For information about how to execute functional diagnosis, refer to the operation manual that
is included with the tool.)
Check that communication with the ABS ECU is possible.
• Only the ABS ECU fails to communicate. [A-4]
• ABS ECU and FI ECU fail to communicate. [A-5]
• Communication is possible with the ABS ECU. [B-1] (The ABS is displayed on the select unit screen.)
9-18
EAS32903
[B-1] MALFUNCTION ARE CURRENTLY DETECTED

When the Yamaha diagnostic tool is connected to the Yamaha diagnostic tool coupler, the fault codes
will be displayed on the computer screen.
• A fault code is displayed. [B-2]
• A fault code is not displayed. [C-1]
EAS32904
[B-2] DIAGNOSIS USING THE FAULT CODES

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

90890-03267
90890-03264
Connecting the Yamaha diagnostic tool

Removing the battery cover. Refer to “GENERAL CHASSIS (1)” on page 4-1.
Disconnect the Yamaha diagnostic tool coupler from the CCU (Communication Control Unit) “1”, and
then connect the Yamaha diagnostic tool to the coupler.
1
Details about the displayed fault codes are shown in the following chart. Refer to this chart and check-
the vehicle.
Once all the work is complete, delete the fault codes. [B-3]
TIP
Check the inspection points after terminating the connection with the Yamaha diagnostic tool and turn-
ing the main switch off.
9-19
EAS33339
[B-3] DELETING THE FAULT CODES

To delete the fault codes, use the YDT. For information about deleting the fault codes, refer to the op-
eration manual of the YDT.
Check that all the displayed fault codes are deleted.

90890-03267
90890-03264
Connecting the Yamaha diagnostic tool

Disconnect the YDT coupler from the CCU (Communication Control Unit) “1”, and then connect the
YDT to the coupler.
1
EAS32905
[C-1] FINAL CHECK

Check all the following items to complete the inspection.
If the process is not completed properly, start again from the beginning.
Checking procedures
1. Check the brake fluid level in the front brake master cylinder reservoir and the rear brake master cyl-
inder reservoir.
Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-11.
2. Check the wheel sensors for proper installation.
Refer to “INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)” on page 4-25 and “INSTALL-
ING THE REAR WHEEL (REAR BRAKE DISC)” on page 4-30.
3. Perform brake line routing confirmation.
Refer to “HYDRAULIC UNIT OPERATION TESTS” on page 4-59.
If it does not have reaction-force properly, the brake hose is not properly routed or connected.
4. Delete the fault codes.
Refer to “[B-3] DELETING THE FAULT CODES” on page 9-20.
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 4-62.
If the ABS warning light does not turn off, the possible causes are following:
• The problem is not solved.
• Open circuit between the ABS ECU and the meter assembly.
Check for continuity between White/Blue terminal of the ABS ECU coupler and White/Blue terminal
of the meter assembly coupler.
• Malfunction in the meter assembly circuit.
• Malfunction in the ABS warning light circuit in the hydraulic unit assembly.
9-20
9-21
EAS33403
EAS20717
R/Y G/W RR
8 R
R R
R Br
Br Br
9 Br Br/R Br
Br
Br Br
10
R R 13 R
G/W R R
R Br
R/Y R/Y R/W B B R/W
OPEN
B R/B Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
OFF
CIRCUIT DIAGRAM
Br Br/R (B) (B) G/W L/R R/B L/Y B/W G/B 19
LOCK R R L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
R/Y R L W/R Br R/W R
Br Br/R B L
18 R/B B R R
L B (B)
B (B) R
L/R
14 15 L L W/R
B R/W R/W L/Y
G/B
B/W
Br
Br
SMART KEY SYSTEM
Br
43
L/R
L/R L/R
L/R
L/Y
Ch Ch B B L/Y L/Y L/Y L/Y
Ch
R
L/Y B 36
Dg Dg
Dg B B
9-22
(L) (L)
1
B
Ch Dg Ch Dg
B
B
81 80 79 78 G
B
B B Ch
Ch Dg G
(Br) (G) (Br)
B B B B B
B
Ch Dg Ch
(Br) (G) Dg
(Br)
B B
B
B B 60
B
B
B/W B G/B
B
B B B B Br
B B
B W/R
B R
B B R R 61
B B B
B Ch
B Dg
L/R
B BB BB
B
B B B B
73 72 72
72 72
65 64
66

(Gy)
SMART KEY SYSTEM
SMART KEY SYSTEM
1. Battery
4. Signaling system fuse
8. Backup fuse
9. Main fuse
10. Ignition fuse
13. Main switch
14. Request switch
15. Main switch solenoid
18. Smart key unit
19. Buzzer
60. Meter assembly
64. Smart key system indicator light
72. Frame ground
73. Engine ground
9-23
SMART KEY SYSTEM
EAS33404
TROUBLESHOOTING
Vehicle power does not turn on. (Meter light and tail/brake light do not come on.)
Engine does not start even though vehicle power is turned on.
Seat does not open. (Vehicle power is turned on.)
Left front storage box does not open. (Vehicle power is turned on.)
Fuel tank cap lid does not open.
Answer back function does not operate.
TIP
Before troubleshooting, remove the following part(s):
1. Battery cover
2. Windshield
3. Front panel
Checking the vehicle power
1. Check the smart key.

→ The smart key indicator light
comes on when the smart key but-
Replace the button cell battery of the
ton is pushed. NG→
smart key. Standard battery: CR2032
→ Check the button cell battery.
Refer to “CHECKING THE SMART
KEY BATTERY” on page 8-42.
OK↓
2. Check the fuses.

(Main, backup, ignition, and smart
key system) NG→ Replace the fuse(s).
ES” on page 8-36.
OK↓

Refer to “CHECKING AND • Clean the battery terminals.
NG→
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 8-36.
OK↓
4. Check the main switch and request

switch.
NG→ Replace the main switch.
Refer to “CHECKING THE
OK↓
5. Check the main switch solenoid.

Refer to “CHECKING THE MAIN
NG→ Replace the main switch.
SWITCH SOLENOID” on page 8-
43.
OK↓
9-24
SMART KEY SYSTEM
6. Check the entire smart key sys-

tem’s wiring. Properly connect or replace the wire har-
NG→
page 9-22.
OK↓
Replace the smart key unit.
Checking the smart key system

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

Refer to “Checking the vehicle NG→ Repair or replace any defective parts.
power” on page 9-24.
OK↓
• There are sources of strong electro-

magnetic waves in the vicinity →
Move the vehicle.
• Smart key malfunction → Register
and use a different smart key.
• Smart key unit malfunction → Re-
place the smart key unit.
Engine does not start even though vehicle power is turned on.
1. When the vehicle power is turned

on, the smart key indicator light “ ” Check and repair the electric starting sys-
flashes 4 times. NO→ tem. Refer to “ELECTRIC STARTING
Refer to “SMART KEY SYSTEM SYSTEM” on page 8-5.
SELF-DIAGNOSIS” on page 9-27.
YES↓
2. Turn the main switch to “OFF”, and

Repair or replace any defective parts. Re-
then push the main switch and
NG→ fer to “Checking the vehicle power” on
check that it can be turned back to
page 9-24.
“ON”.
OK↓
3. Check for continuity in the commu-

nication line between the SGCU
NG→ Replace the wire harness.
and the smart key unit (blue/red –
blue/red).
9-25
SMART KEY SYSTEM
OK↓
• Replace the SGCU.

Refer to “REPLACING THE SGCU
(starter generator control unit)” on
page 8-36.
• Replace the smart key unit.
Seat does not open. (Vehicle power is turned on.)

OK↓
• Check the mechanical components

of the lock for malfunctions. Repair
or replace any defective parts.
• Adjust or replace the seat lock cable.
Left front storage box does not open. (Vehicle power is turned on.)

OK↓

• Adjust or replace the left front stor-
age box lock cable.
Fuel tank cap lid does not open.
1. Check that the main switch can be

NG→ Repair or replace any defective parts.
turned counterclockwise.
OK↓

• Adjust or replace the fuel tank cap lid
lock cable.
Answer back function does not operate.

OK↓
9-26
SMART KEY SYSTEM
2. Check the buzzer operation.

Refer to “CHECKING THE BUZZ- NG→ Replace the buzzer.
ER” on page 8-42.
OK↓
3. Check the turn signal light bulbs

and sockets.
Refer to “CHECKING THE BULBS Replace the turn signal light bulb, socket
NG→
AND BULB SOCKETS” in “BASIC or both.
ume).
OK↓
Replace the smart key unit.
EAS33405
SMART KEY SYSTEM SELF-DIAGNOSIS

The smart key system is equipped with a self-diagnostic function. If a malfunction is detected in the sys-
tem, the malfunction will be indicated by the flash pattern of the smart key indicator light “ ”.
TIP
The smart key indicator light “ ” comes on for about 2 seconds when the vehicle power is on. If one of
the following malfunctions is detected, the indicator light starts flashing.
Flashing time/num- Malfunction and

Item Flash pattern
ber of flashes check point
0.5 (s) Replace the button

a cell battery of the
Low voltage of smart b smart key.
0.5 (s)
20 (seconds)
key button cell battery Refer to “SMART
KEY SYSTEM” on
a.LED on page 9-22.
b.LED off
The smart key cannot
be recognized.
0.15 (s)
Check that there are
a
no sources of strong
Vehicle power off ver- b
0.15 (s)
30 (seconds) electromagnetic
ification error
waves in the vicinity,
a.LED on the smart key is not
b.LED off lost, and the battery is
not discharged.
The smart key cannot
be recognized.
0.15 (s)
Check that there are
a
Flashes continuously no sources of strong
Running detection er- b
0.15 (s)
until the error is re- electromagnetic
ror*
solved. waves in the vicinity,
a.LED on the smart key is not
b.LED off lost, and the battery is
not discharged.
9-27
SMART KEY SYSTEM
Flashing time/num- Malfunction and

Item Flash pattern
ber of flashes check point
0.3 (s) Flashes continuously Check the wire har-

• SGCU communica- a until the error is re- ness.
tion error b solved/flashes 4 Check the SGCU.
• Data error 0.3 (s) 1.0 (s)
times in a repeating Check the smart key
• SGCU malfunction
a.LED on cycle. unit.
b.LED off
* The running detection error

If the smart key is dropped or can no longer be recognized while the vehicle is traveling. If the vehicle
travels while the smart key cannot be recognized, the smart key indicator light “ ” flashes in 0.15-sec-
ond intervals.
The vehicle can be ridden, but the vehicle power cannot be turned off.
Although a forced shutdown can be performed to turn off the vehicle power (the main switch is pushed
for 4 times within 2 seconds while the smart key indicator light “ ” is flashing in 0.15-second inter-
vals), the vehicle power cannot be turned back on.
9-28
SMART KEY SYSTEM
SMART KEY SYSTEM SELF-DIAGNOSIS

If a communication error between the SGCU and the smart key unit is detected, the following fault code
numbers will be displayed on the meter to indicate the location of the malfunction.
TIP
These fault code numbers are not stored in the memory of the SGCU. Note all of the displayed fault
code numbers, and then check the vehicle.
Device that de-

Fault Check or mainte-
tected the mal- Symptom Cause
code No. nance job
function
51 Smart key unit Communication error Radio wave noise in- Perform the checks
between the smart terference. and maintenance job
key and the smart key • Lock condition in the for “Engine does not
unit. smart key start even though ve-
• Defective smart key hicle power is turned
• Defective smart key on.”
unit
53 Smart key unit Communication error Radio wave noise in- Perform the checks
between the SGCU terference or discon- and maintenance job
and the smart key nected lead. for “Engine does not
unit. • Obstruction due to start even though ve-
radio wave noise hicle power is turned
• Disconnection in the on.”
wire harness
• Defective SGCU
• Defective smart key
unit
54 Smart key unit Codes transmitted Radio wave noise in- Perform the checks
between the SGCU terference or discon- and maintenance job
and the smart key unit nected lead. for “Engine does not
do not match. • Obstruction due to start even though ve-
radio wave noise. hicle power is turned
wire harness
• Defective SGCU
(when the SGCU or
smart key unit is re-
placed with a unit
from a different ve-
hicle)
unit
56 SGCU Unidentified code is Radio wave noise in- Perform the checks
received. terference or discon- and maintenance job
nected lead. for “Engine does not
• Obstruction due to start even though ve-
radio wave noise hicle power is turned
wire harness
• Defective SGCU
unit
9-29
SMART KEY SYSTEM
EAS33406
SMART KEY SYSTEM EMERGENCY MODE

If the smart key is lost or if it cannot be used due a discharged battery or malfunction, this mode can be
used to turn on the smart key system.
TIP
The emergency mode operation will be canceled if the respective steps are not carried out within the
time set for each operation.
1. Stop the vehicle in a safe place and turn the main switch to “OFF”.
2. Push the main switch for 5 seconds until the smart key indicator light flashes once, then release it.
Repeat two more times. The smart key indicator light “1” will come on for 3 seconds to indicate the
transition to emergency mode.
3. After the smart key indicator light “ ” goes off, use the main switch to enter the identification number
“1” located on the identification number card. (Refer to the following procedure on how to input the
identification number.)
868588
4. The input identification number is indicated by the number of flashes of the smart key indicator light
“ ” while the main switch is pushed.
For example, if the smart key identification number is 123456:
Push and hold the main switch. →
The smart key indicator light “ ” will start to flash. →
9-30
SMART KEY SYSTEM
Release the main switch after the smart key indicator light “ ” flashes 1 time. →
The first digit of the identification number has been set as 1. →
Push and hold the main switch again. →
Release the main switch after the smart key indicator light “ ” flashes 2 times. →
The second digit of the identification number has been set as 2. →
Repeat the above procedure until all 6 digits of the identification number have been set.
5. The smart key indicator light “ ” will come on for 10 seconds if the correct 6-digit identification num-
ber was entered.
TIP
When one of the following situations applies, emergency mode will be terminated and the smart key in-
dicator light will flash quickly for 3 seconds. In this case, start over again from step 2.
• When there are no main switch operations for 10 seconds during the identification number input pro-
cess.
• When the smart key indicator light is allowed to flash nine or more times.
• The identification number is not entered correctly.
6. While the smart key indicator light is on, push the main switch once more to complete emergency
mode access. The smart key indicator light will go off and then come back on for approximately 4
seconds.
7. While the smart key indicator light is on, turn the main switch to “ON”. The vehicle can now be oper-
ated normally.
9-31
SMART KEY SYSTEM
EAS33407
REGISTERING A SMART KEY

The following procedure can be used to register additional smart keys or a new smart key in case the
original smart key is lost.
TIP
• A maximum of 6 smart keys can be registered to the smart key unit.
• Be sure to register the smart keys one at a time. Do not register multiple smart keys at the same time.
1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.
1
2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 9-30.
3. While the smart key indicator light “ ” is on for 10 seconds, push the main switch “1” for 5 seconds
until buzzer sounds once.
4. The smart key indicator light (red) “1” on the new smart key comes on for 10 seconds.
TIP
While the smart key indicator light on the smart key is on, the smart key indicator light “ ” flashes ac-
cording to the number of currently registered smart keys. (For example, if 5 smart keys are registered,
the indicator light flashes 5 times.)
5. While the smart key indicator light is on for 10 seconds, push the button on the smart key to transmit
a signal from the smart key to the smart key unit.
9-32
SMART KEY SYSTEM
6. If the smart key is registered successfully, the smart key indicator light “ ” will come on for 3 sec-
onds, and then the smart key system will turn off.
If the smart key was not registered successfully, the smart key indicator light “ ” will flash for 3 sec-
onds, and then the smart key system will turn off.
TIP
If this registration procedure is performed for a smart key that is already registered, the smart key indi-
cator light “ ” will flash for 7 seconds (on for 0.2 second and off for 0.8 second).
EAS33408
DISABLING A SMART KEY

If a smart key is lost or stolen, the smart key can be disabled.
1. Place all of the smart keys “1” 300 cm (118.1 in) “a” or more away from the vehicle or lock the com-
munication.
1
2. Perform steps 1–5 in “SMART KEY SYSTEM EMERGENCY MODE” on page 9-30.
3. While the smart key indicator light “ ” is on for 10 seconds, perform the following procedure.
a. Push the main switch “1” 5 times or more until buzzer sounds 3 times.
4. Check that the smart key indicator light “ ” goes off (the smart key disable mode is activated).
5. Turn on (unlocked setting) the smart keys that you want to enable and place them within 80 cm (31.5
in) of the smart key unit.
6. Push the main switch for 5 seconds or more to start the communication between the smart key unit
and the smart keys that are located within 80 cm (31.5 in) of the unit.
TIP
The number of smart keys that currently can be used will be indicated.
Number of flashes = Number of verified smart keys. (1 cycle of on for 0.3 second and off for 0.3 second
= 1 smart key)
7. Push the main switch for 5 seconds or more. The use of only the verified smart keys will be enabled.
The use of all other smart keys will be disabled.
TIP
• If the procedure was not completed successfully, repeat the procedure from step 1.
• To enable a smart key after its use has been disabled, perform this procedure again.
9-33
SMART KEY SYSTEM
EAS33409
DISABLING THE POWER-ON ALARM

1. Place the smart key “1” that will be registered within 80 cm (31.5 in) “a” of the main switch.
1
2. Push the main switch and the smart key indicator light will come on for approximately 4 seconds.
3. While the smart key indicator light is on, turn the main switch to “ON”.
4. Extend and retract the sidestand by hand for 10 times or more within 15 seconds from vehicle power
on.
5. When the buzzer sounds, the setting is complete.
• If the buzzer sounds 2 times: The power-on alarm is turned off.
• If the buzzer sounds 1 times: The power-on alarm is turned on.
9-34
SMART KEY SYSTEM
EAS33410
REPLACEMENT PARTS LIST

TIP
When replacing the parts, refer to the following sections.
• Refer to “SMART KEY SYSTEM EMERGENCY MODE” on page 9-30.
• Refer to “REGISTERING A SMART KEY” on page 9-32.
• Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
Required item Replacement parts (when

when replacing an item is required in or-
parts der to replace parts)
○ : Required. ○ : Replace.
Smart key
identifica-
△ : tion number × : Do not replace.
or smart key
Faulty part is required. Remarks
This part must be re-
× : Not required. *: placed even if it is
not faulty.
Smart
key Smart
Smart Smart
identifi- key SGCU
key key
cation unit
number
Register the smart key identi-
Smart key ○ × ○ × × fication number in the emer-
gency mode.
Replace the smart key, smart
Smart key unit × × ○* ○ ○*
key unit, and SGCU as a set.
When the vehicle system is
turned on, the smart key iden-
SGCU △ △ × × ○
tification number is automati-
cally registered to the SGCU.
Smart key unit/ Replace the smart key, smart
× × ○* ○ ○
SGCU key unit, and SGCU as a set.
Smart key/Smart Replace the smart key, smart
× × ○ ○ ○*
key unit key unit, and SGCU as a set.
Register the smart key identi-
fication number in the emer-
gency mode.
Smart key/SGCU ○ × ○ × ○ When the vehicle system is
turned on, the smart key iden-
tification number is automati-
cally registered to the SGCU.
Smart key/Smart Replace the smart key, smart
× × ○ ○ ○
key unit/SGCU key unit, and SGCU as a set.
9-35
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20551

EAS33149
DTC TABLE
Fail-safe system
Diagnos-
DTC Symptom Starting the Driving the tic code
engine vehicle
“11, Front wheel sensor (intermittent pulses
— — —
25_ABS” or no pulses)
Rear wheel sensor (intermittent pulses or
“12_ABS” — — —
no pulses)
“13, Front wheel sensor (abnormal pulse pe-
— — —
26_ABS” riod)
“14, Rear wheel sensor (abnormal pulse peri-
— — —
27_ABS” od)
“15_ABS” Front wheel sensor (open or short circuit) — — —
“16_ABS” Rear wheel sensor (open or short circuit) — — —
“17,
Front wheel sensor (missing pulses) — — —
45_ABS”
“18,
Rear wheel sensor (missing pulses) — — —
46_ABS”
Hydraulic unit assembly (defective sole-
“21_ABS” — — —
noid drive circuit)
Hydraulic unit assembly (abnormal ABS
“31_ABS” — — —
solenoid power supply)
Hydraulic unit assembly (short circuit in
“32_ABS” — — —
ABS solenoid power supply circuit)
Hydraulic unit assembly (abnormal ABS
“33_ABS” — — —
motor power supply)
Hydraulic unit assembly (short circuit in
“34_ABS” — — —
ABS motor power supply circuit)
Front wheel ABS (intermittent wheel
“41_ABS” speed pulses or incorrect depressuriza- — — —
tion)
Rear wheel ABS (intermittent wheel
“42,
speed pulses or incorrect depressuriza- — — —
47_ABS”
tion)
“43_ABS” Front wheel sensor (missing pulses) — — —
“44_ABS” Rear wheel sensor (missing pulses) — — —
• Vehicle system power supply (voltage
of ABS ECU power supply is high)
“51, (DTC No. 51)
— — —
52_ABS” • Vehicle system power supply (voltage
of wheel sensor power supply is high)
(DTC No. 52)
Vehicle system power supply (voltage of
“53_ABS” — — —
ABS ECU power supply is low)
9-36
Fail-safe system
Diagnos-
engine vehicle
Hydraulic unit assembly (defective ABS
“54_ABS” solenoid and ABS motor power supply — — —
circuits)
Hydraulic unit assembly (defective ABS
“55_ABS” — — —
ECU)
Hydraulic unit assembly (abnormal pow-
“56_ABS” — — —
er supply)
Front wheel sensor power supply (volt-
“63_ABS” — — —
age of power supply is low)
Rear wheel sensor power supply (volt-
“64_ABS” — — —
age of power supply is low)
O2 sensor heater: defective heater or
“P0030” heater driver ON / OFF command and er- Able Able —
ror signal is mismatching.
• [P00D1] O2 sensor: heater perfor-
mance deteriorated. Normal signal is
“P00D1, not received from the O2 sensor while
Able Able —
P2195” driving the O2 sensor.
• [P2195] O2 sensor: open circuit is de-
tected.
• [P0105] Intake air pressure sensor: sig-
“P0105” Able Able D03
nal out of range.
• [P0106] Intake air pressure sensor:
“P0106” clogging hole or sensor installation im- Able Able D03
properly.
• [P0107] Intake air pressure sensor:
short to ground circuit is detected.
“P0107,
• [P0108] Intake air pressure sensor: Able Able D03
P0108”
open or short to power circuit is detect-
ed.
Intake air temperature sensor: signal
stuck.
Intake air temperature sensor: signal
without of range.
• [P0112] Intake air temperature sensor:
“P0112,
• [P0113] Intake air temperature sensor: Able Able D05
P0113”
ed.
Coolant temperature sensor: signal
stuck.
Coolant temperature sensor: signal out
of range.
9-37
Fail-safe system
Diagnos-
engine vehicle
• [P0117] Coolant temperature sensor:
“P0117,
• [P0118] Coolant temperature sensor: Able Able D06
P0118”
ed.
• [P0122] Throttle position sensor: open
“P0122, or short to ground circuit is detected.
Able Able D01
P0123” • [P0123] Throttle position sensor: short
to power circuit is detected.
O2 sensor: short to power circuit is de-
“P0132” Able Able —
tected.
O2 sensor: response delay of sensor out-
“P0133” Able Able —
put signal.
“P0134” O2 sensor: signal stuck. Able Able —
“P0201” Fuel injector: malfunction in fuel injector. Unable Unable D36
Able / Un- Able / Un-
able (De- able (De-
Misfire is detected or malfunction in fuel
“P0301” pends on the pends on the —
injector.
situation of situation of
misfire.) misfire.)
Crankshaft position sensor: normal sig-
“P0335” nal is not received from the crankshaft Unable Unable —
position sensor.
Ignition coil: open or short circuit is de-
“P0351” tected in the primary lead of the ignition Unable Unable D30
coil.
Front wheel sensor: normal signal is not
“P0500” received from the front wheel speed sen- Able Able D07
sor.
“P0507” Engine idling speed is too high. Able Able D54
“P0511” ISC valve malfunction is detected. Able Able —
Charging voltage is abnormal.
“P0560,
[P0560] Discharged condition / [P0563] Able Able —
P0563”
Overcharged condition.
Internal malfunction in SGCU. (When this
malfunction is detected in the SGCU, the
“P0601” Unable Unable —
DTC might not appear on the tool dis-
play.)
EEPROM DTC: an error is detected
“P062F” Able Able D60
while reading or writing on EEPROM.
Malfunction in SGCU internal circuit
“P1602” (malfunction of SGCU power cut-off func- Able Able —
tion).
Rear wheel sensor: normal signal is not
“P2158” received from the rear wheel speed sen- Able Able —
sor.
9-38
Fail-safe system
Diagnos-
engine vehicle
Normal signal is not received from the
“P2645” VVA solenoid circuit while driving the Able Able D45
VVA solenoid.
EAS33030
COMMUNICATION ERROR WITH THE YAMAHA DIAGNOSTIC TOOL

Fail-safe system
Diagnos-
engine vehicle
SGCU internal malfunction (Output sig-
Er-1 Able Able —
nal error)
Er-2 Able Able —
nal error)
Er-3 Able Able —
nal error)
SGCU internal malfunction (Input signal
Er-4 Able Able —
error)
9-39
EAS33028
SELF-DIAGNOSTIC FUNCTION TABLE

TIP
For details of the fault code, refer to “TROUBLESHOOTING” on page 8-33.
Probable cause of Fail-safe system

DTC Item Vehicle symptom
malfunction operation
P0030 O2 sensor heater: • Open or short cir- When the O2 sensor Display only (If O2
defective heater or cuit in wire har- does not operate sensor does not op-
heater driver ON / ness. due to the exhaust erate, O2 feedback
OFF command and • Disconnected cou- temperature is low is not carried out.)
error signal is mis- pler condition.
matching. • Defective O2 sen- Increased exhaust
sor heater driver emissions.
(Malfunction in
SGCU)
• Broken or discon-
nected lead in O2
sensor heater.
P00D1 O2 sensor: heater • Open or short cir- Increased exhaust O2 feedback is not
performance deteri- cuit in wire har- emissions. carried out.
orated. (Normal sig- ness between O2
nal is not received sensor and SGCU.
from the O2 sensor • Defective coupler
while driving the O2 between O2 sen-
sensor.) sor and SGCU.
• Disconnected cou-
pler
• Improperly in-
stalled O2 sensor.
• Defective O2 sen-
sor.
• Malfunction in
SGCU.
9-40

P0105 Intake air pressure • Defective coupler Engine idling speed Intake air pressure
sensor: normal sig- between intake air is unstable or high. difference is fixed to
nal is not received pressure sensor Engine response is 0 [kPa].
from the intake air and SGCU. poor. Load is detected ac-
pressure sensor. • Open or short cir- Idling does not stop. cording to the throt-
(Signal without of cuit in wire har- Loss of engine pow- tle opening.
range.) ness between er. Intake manifold
intake air pressure Increased exhaust pressure is calculat-
sensor and SGCU. emissions. ed using the throttle
• Defective intake Stop and start sys- position sensor.
air pressure sen- tem is not operated. Transient control
sor. according to the in-
• Malfunction in take air pressure is
SGCU. not carried out.
Intake air pressure
is fixed to 101.3
[kPa].
O2 feedback is not
carried out.
Stop and start sys-
tem is not carried
out.
P0106 Intake air pressure • Detached throttle Engine idling speed Intake air pressure
sensor (clogged body sensor as- is high. difference is fixed to
hole or loose) sembly. Engine idling speed 0 [kPa].
• Improperly in- is unstable. Load is detected ac-
stalled throttle Engine response is cording to the throt-
body. poor. tle opening.
• Clogged intake air Loss of engine pow- Intake manifold
pressure sensor er. pressure is calculat-
hole. Increased exhaust ed using the throttle
emissions. position sensor.
Stop and start sys- Transient control
tem is not operated. according to the in-
Idling does not stop. take air pressure is
not carried out.
Intake air pressure
is fixed to 101.3
[kPa].
O2 feedback is not
carried out.
Stop and start sys-
tem is not carried
out.
9-41

P0107 [P0107] Intake air [P0107] Low voltage Engine idling speed Intake air pressure
P0108 pressure sensor of the intake air is high. difference is fixed to
(short to ground cir- pressure sensor cir- Engine idling speed 0 [kPa].
cuit is detected) cuit (0.2 V or less) is unstable. Load is detected ac-
[P0108] Intake air [P0108] High volt- Engine response is cording to the throt-
pressure sensor age of the intake air poor. tle opening.
(open or short to pressure sensor cir- Loss of engine pow- Intake manifold
power circuit is de- cuit (4.9 V or more) er. pressure is calculat-
tected) • Defective coupler Increased exhaust ed using the throttle
between throttle emissions. position sensor.
body sensor as- Stop and start sys- Transient control
sembly and tem is not operated. according to the in-
SGCU. Idling does not stop. take air pressure is
• Open or short cir- not carried out.
cuit in wire har- Intake air pressure
ness between is fixed to 101.3
throttle body sen- [kPa].
sor assembly and O2 feedback is not
SGCU. carried out.
• Defective intake Stop and start sys-
air pressure sen- tem is not carried
sor. out.
• Malfunction in
SGCU.
P0110 Intake air tempera- • Improperly in- Engine is difficult to The intake air tem-
ture sensor: signal stalled intake air start. perature is fixed to
stuck. temperature sen- Increased exhaust 20 [°C].
sor. emissions. O2 feedback is not
• Defective intake Engine idling speed carried out.
air temperature is unstable.
sensor. Idling does not stop.
• Malfunction in
SGCU.
P0111 Intake air tempera- • Defective coupler Engine is difficult to The intake air tem-
ture sensor: signal between intake air start. perature is fixed to
without of range. temperature sen- Increased exhaust 20 [°C].
sor and SGCU. emissions. O2 feedback is not
• Open or short cir- Engine idling speed carried out.
cuit in wire har- is unstable.
ness between Idling does not stop.
intake air tempera-
ture sensor and
SGCU.
• Improperly in-
stalled intake air
temperature sen-
sor.
• Defective intake
air temperature
sensor.
• Malfunction in
SGCU.
9-42

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
(short to ground cir- perature sensor cir- Increased exhaust 20 [°C].
cuit is detected) cuit (0.2 V or less) emissions. O2 feedback is not
[P0113] Intake air [P0113] High volt- Engine idling speed carried out.
temperature sensor age of the intake air is unstable. Stop and start sys-
(open or short to temperature sensor Stop and start system is not carried
power circuit is de- circuit (4.8 V or tem is not operated. out.
tected) more) Idling does not stop.
• Defective coupler
between throttle
body sensor as-
sembly and
SGCU.
• Open or short cir-
cuit in wire har-
ness between
throttle body sen-
sor assembly and
SGCU.
• Improperly in-
stalled throttle
body sensor as-
sembly.
air temperature
sensor.
• Malfunction in
SGCU.
P0115 Coolant tempera- • Improperly in- Engine is difficult to The intake air tem-
ture sensor: signal stalled intake air start. perature is fixed to
stuck. temperature sen- Increased exhaust 20 [°C].
sor. emissions. O2 feedback is not
• Defective intake Engine idling speed carried out.
air temperature is unstable.
sensor. Idling does not stop.
• Malfunction in
SGCU.
9-43

P0116 Coolant tempera- • Defective coupler Engine is difficult to The intake air tem-
ture sensor: signal between intake air start. perature is fixed to
without of range. temperature sen- Increased exhaust 20 [°C].
sor and SGCU. emissions. O2 feedback is not
• Open or short cir- Engine idling speed carried out.
cuit in wire har- is unstable.
ness between Idling does not stop.
intake air tempera-
ture sensor and
SGCU.
• Improperly in-
stalled intake air
temperature sen-
sor.
air temperature
sensor.
• Malfunction in
SGCU.
P0117 [P0117] Coolant [P0117] Low voltage Engine is difficult to O2 feedback is not
P0118 temperature sensor of the coolant tem- start. carried out.
(short to ground cir- perature sensor cir- Increased exhaust The coolant tem-
cuit is detected) cuit (0.1 V or less) emissions. perature is fixed to
[P0118] Coolant [P0118] High volt- Engine idling speed 30 [°C] (when key is
temperature sensor age of the coolant is unstable. ON) or 80 [°C]
(open or short to temperature sensor Stop and start sys- (when riding).
power circuit is de- circuit (4.8 V or tem is not operated. Stop and start sys-
tected) more) Idling does not stop. tem is not carried
• Defective coupler out.
between coolant
temperature sen-
sor and SGCU.
cuit in wire har-
ness between
coolant tempera-
ture sensor and
SGCU.
• Improperly in-
stalled coolant
temperature sen-
sor.
• Defective coolant
temperature sen-
sor.
• Malfunction in
SGCU.
9-44

P0122 [P0122] Throttle po- [P0122] Low voltage Engine idling speed Change in the throt-
P0123 sition sensor (open of the throttle posi- is high. tle valve opening is
or short to ground tion sensor circuit Engine idling speed 0 (transient control
circuit is detected) (0.2 V or less) is unstable. is not carried out).
[P0123] Throttle po- [P0123] High volt- Engine response is Throttle valve open-
sition sensor (short age of the throttle poor. ing is fixed to 15 [°].
to power circuit is position sensor cir- Loss of engine pow- Intake air pressure
detected) cuit (4.8 V or more) er. is fixed to 101.3
• Defective coupler Deceleration is [kPa].
between throttle poor. Fuel is not cut off
body sensor as- Increased exhaust due to the throttle
sembly and emissions. opening.
SGCU. Stop and start sys- O2 feedback is not
• Open or short cir- tem is not operated. carried out.
cuit in wire har- Idling does not stop. Stop and start sys-
ness between tem is not carried
throttle body sen- out.
sor assembly and
SGCU.
• Improperly in-
stalled throttle
body sensor as-
sembly.
• Defective throttle
position sensor.
• Malfunction in
SGCU.
P0132 O2 sensor (short to High voltage of the Increased exhaust O2 feedback is not
power circuit is de- O2 sensor circuit emissions. carried out.
tected) (4.8 V or more)
• Improperly in-
stalled O2 sensor.
between O2 sen-
sor and SGCU.
• Power short circuit
in wire harness be-
tween O2 sensor
and SGCU.
sor.
• Malfunction in
SGCU.
P0133 O2 sensor: re- • Defective O2 sen- Increased exhaust —
sponse delay of sor. emissions.
sensor output sig- • Malfunction in fuel
nal. system.
• Malfunction in ex-
haust system.
9-45

P0134 O2 sensor: signal • Defective engine Increased exhaust Idle stop is not car-
stuck. condition. emissions. ried out.
• Incorrect fuel pres- O2 feedback is not
sure. carried out.
• Improperly in-
stalled O2 sensor.
sor.
• Malfunction in
SGCU.
P0201 Fuel injector (Nor- • Defective coupler Loss of engine pow- When engine is run-
mal signal is not re- between fuel injec- er. ning: Engine is
ceived from the fuel tor and SGCU. Engine is difficult to forcefully stopped.
injector circuit) • Open or short cir- start. When engine is
cuit in wire har- Engine cannot be stopped: Engine
ness between fuel started. cannot be started.
injector and Engine stops. Injection is not car-
SGCU. ried out.
• Defective fuel in-
jector.
• Malfunction in
SGCU.
• Improperly in-
stalled fuel injec-
tor.
P0335 Crankshaft position • Defective coupler Engine cannot be Does not operate.
sensor (no normal between crank- started.
signals are received shaft position sen-
from the crankshaft sor and SGCU.
position sensor) • Open or short cir-
cuit in wire har-
ness between
crankshaft position
sensor and SGCU.
• Improperly in-
stalled crankshaft
position sensor.
• Defective starter
generator rotor.
• Defective crank-
shaft position sen-
sor.
• Malfunction in
SGCU.
9-46

P0351 Ignition system • Defective coupler Engine stops. When engine is run-
(Normal signal is not between ignition Loss of engine pow- ning: Engine is
received from the ig- coil and SGCU. er. forcefully stopped.
nition circuit) • Open or short cir- Engine is difficult to When engine is
cuit in wire har- start. stopped: Engine
ness between Engine cannot be cannot be started.
ignition coil and started. Injection is not car-
SGCU. ried out.
• Improperly in-
stalled ignition coil.
• Defective ignition
coil.
• Malfunction in
SGCU.
P0500 Front wheel sensor • Open or short cir- Vehicle speed is not O2 feedback is not
(Normal signal is not cuit in wire har- displayed on the carried out.
received from the ness between meter. Stop and start sys-
front wheel sensor) front wheel sensor Engine stalls when tem is not carried
and ABS unit. the vehicle is decel- out.
• Open or short cir- erating to a stop.
cuit in wire har- Engine idling speed
ness between is high.
ABS unit and Engine idling speed
SGCU. is unstable.
• Defective front Increased exhaust
wheel sensor. emissions.
• Malfunction in Stop and start sys-
SGCU. tem is not operated.
Idling does not stop.
P0507 ISC valve (stuck ful- • Defective front Engine idling speed ISC is stopped.
ly open) wheel sensor. is high. Stop and start sys-
• Defective coupler Stop and start system is not carried
between ISC unit tem is not operated. out.
and SGCU. Idling does not stop.
cuit in wire har-
ness between ISC
unit and SGCU.
• Improperly in-
stalled ISC unit.
• Air sucking from
intake air passage.
• Defective throttle
valve or throttle ca-
bles.
• Defective ISC unit
(ISC valve stuck
fully open).
• Malfunction in
SGCU.
9-47

P0511 ISC valve (ISC • Defective coupler Engine is difficult to Power is not sup-
valve malfunction is between ISC valve start. plied to the ISC unit.
detected. ISC valve and SGCU. Engine idling speed Stop and start sys-
does not operate) • Open or short cir- is unstable. tem is not carried
cuit in wire har- Engine idling speed out.
ness between ISC is high.
valve and SGCU. Stop and start sys-
• Defective ISC tem is not operated.
stepping motor. Idling does not stop.
• Malfunction in
SGCU.
P0560 Vehicle system • Battery discharg- Engine is difficult to O2 feedback learn-
power voltage per- ing. start. ing is not carried
formance: Charging • Battery discharg- Increased exhaust out.
voltage is abnormal. ing (broken rectifi- emissions. Stop and start sys-
(Discharged condi- er / regulator or Battery perfor- tem is not carried
tion) disconnected lead mance has deterio- out.
in rectifier / regula- rated or battery is
tor system). defective.
Stop and start sys-
tem is not operated.
P0563 Vehicle system • Battery overcharg- Engine is difficult to O2 feedback learn-
power voltage out of ing. start. ing is not carried
range: charging • Battery overcharg- Increased exhaust out.
voltage is abnormal. ing (broken rectifi- emissions. Stop and start sys-
(Overcharged con- er / regulator or Battery perfor- tem is not carried
dition) disconnected lead mance has deterio- out.
in rectifier / regula- rated or battery is
tor system). defective.
Stop and start sys-
tem is not operated.
P0601 Faulty SGCU mem- • Malfunction in Engine cannot be Engine cannot be
ory. (When this mal- SGCU. started. started.
function is detected Ignition and injec-
in the SGCU, the tion are not carried
DTC might not ap- out.
pear on the tool dis- Judgment for other
play.) DTCs are not car-
ried out.
Writing to EEPROM
is not carried out.
9-48

P062F EEPROM fault code • Malfunction in Increased exhaust O2 feedback learn-
number (an error is SGCU. emissions. ing value is initial-
detected while read- • O2 feedback learn- Engine cannot be ized.
ing or writing on EE- ing value is not started or is difficult CO adjustment val-
PROM) properly written. to start. ue is initialized.
• CO adjustment Engine idling speed OBD memory value
value is not prop- is unstable. is initialized.
erly written. OBD memory value Stop and start sys-
• OBD memory val- is not correct. tem is not carried
ue is not properly Stop and start sys- out.
written. tem is not operated.
P1602 Malfunction in • Improperly con- Engine idling speed —
SGCU internal cir- nected battery is high.
cuit (normal backup lead. Engine idling speed
voltage is not sup- • Defective coupler is unstable.
plied to the SGCU) between main Increased exhaust
switch and SGCU. emissions.
• Open circuit in wire Engine is difficult to
harness between start.
main switch and
SGCU.
• Malfunction in
SGCU.
P2195 O2 sensor (open cir- • Improperly in- Increased exhaust O2 feedback is not
cuit is detected) stalled O2 sensor. emissions. carried out.
between O2 sen-
sor and SGCU.
cuit in wire har-
ness between O2
sensor and SGCU.
sor.
• Malfunction in
SGCU.
• Normal signal is
not received from
O2 sensor.
EU3 specified volt-
age:
(0.25 V or more to
0.53 V or less )
EU4/5 specified
voltage:
(0.25 V or more to
0.40 V or less )
9-49

P2645 VVA solenoid mal- • Defective coupler Decreased engine Fixed to the low
function (normal sig- between VVA so- torque in the high speed cam position.
nal is not received lenoid and SGCU. speed range. Upper limit for the
from the VVA sole- • Open or short cir- engine speed is de-
noid circuit while cuit in wire har- creased.
driving the VVA so- ness between
lenoid) VVA solenoid and
SGCU.
• Open circuit in
VVA solenoid.
Er-1 SGCU internal mal- • Open or short cir- Signals cannot be Normally operated
function (Output sig- cuit in wire har- transmitted between except for the me-
nal error) ness between the SGCU and the ter.
meter and SGCU. meter.
• Defective coupler Signals cannot be
between meter transmitted between
and SGCU. the SGCU and the
• Defective meter YDT (Yamaha Diag-
unit. nostic Tool).
• Malfunction in Meter operation is
SGCU. impossible.
Er-2 SGCU internal mal- • Open or short cir- Signals are not re- Normally operated
function (Output sig- cuit in wire har- ceived from the except for the me-
nal error) ness between SGCU within the ter.
meter and SGCU. specified duration.
• Defective coupler Meter operation is
between meter impossible.
and SGCU.
• Defective meter
unit.
• Malfunction in
SGCU.
Er-3 SGCU internal mal- • Open or short cir- Sending data from Normally operated
function (Output sig- cuit in wire har- the SGCU cannot except for the me-
nal error) ness between be received correct- ter.
meter and SGCU. ly.
• Defective coupler Meter operation is
between meter impossible.
and SGCU.
• Defective meter
unit.
• Malfunction in
SGCU.
9-50

Er-4 SGCU internal mal- • Open or short cir- Registered data is Normally operated
function (Input sig- cuit in wire har- not received from except for the me-
nal error) ness between the meter. ter.
meter and SGCU. Normal signals are
• Defective coupler not received from
between meter the YDT (Yamaha
and SGCU. Diagnostic Tool).
• Defective meter Meter operation is
unit. impossible.
• Malfunction in
SGCU.
EAS33286
SELF-DIAGNOSTIC FUNCTION TABLE (FOR ABS (Anti-lock Brake System))

TIP
For details of the DTC, refer to “BASIC INSTRUCTIONS FOR TROUBLESHOOTING” on page 9-16.
DTC Item Symptom Check point

11* Front wheel sensor (inter- Front wheel sensor signal • Foreign material ad-
25* mittent pulses or no puls- is not received properly. hered around the front
es) (Pulses are not received wheel sensor
or are received intermit- • Incorrect installation of
tently while the vehicle is the front wheel
traveling.) • Defective sensor rotor or
incorrect installation of
the rotor
• Defective front wheel
sensor or incorrect in-
stallation of the sensor
12 Rear wheel sensor (inter- Rear wheel sensor signal • Foreign material ad-
mittent pulses or no puls- is not received properly. hered around the rear
es) (Pulses are not received wheel sensor
or are received intermit- • Incorrect installation of
tently while the vehicle is the rear wheel
traveling.) • Defective sensor rotor or
the rotor
• Defective rear wheel
13* Front wheel sensor (ab- Front wheel sensor signal • Foreign material ad-
26* normal pulse period) is not received properly. hered around the front
(The pulse period is ab- wheel sensor
normal while the vehicle is • Incorrect installation of
traveling.) the front wheel
• Defective sensor rotor or
the rotor
9-51

14* Rear wheel sensor (abnor- Rear wheel sensor signal • Foreign material ad-
27* mal pulse period) is not received properly. hered around the rear
(The pulse period is ab- wheel sensor
normal while the vehicle is • Incorrect installation of
traveling.) the rear wheel
the rotor
15 Front wheel sensor (open Open or short circuit is de- • Defective coupler be-
or short circuit) tected in the front wheel tween the front wheel
sensor. sensor and the hydraulic
unit assembly
• Open or short circuit in
the wire harness be-
tween the front wheel
sensor and the hydraulic
unit assembly
sensor or hydraulic unit
assembly
16 Rear wheel sensor (open Open or short circuit is de- • Defective coupler be-
or short circuit) tected in the rear wheel tween the rear wheel
sensor. sensor and the hydraulic
unit assembly
tween the rear wheel
sensor and the hydraulic
unit assembly
sensor or hydraulic unit
assembly
17* Front wheel sensor (miss- Front wheel sensor signal • Foreign material ad-
45* ing pulses) is not received properly. hered around the front
(Missing pulses are de- wheel sensor
tected in the signal while • Incorrect installation of
the vehicle is traveling.) the front wheel
the rotor
9-52

18* Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad-
46* ing pulses) is not received properly. hered around the rear
the vehicle is traveling.) the rear wheel
the rotor
21 Hydraulic unit assembly Solenoid drive circuit in • Defective hydraulic unit
(defective solenoid drive the hydraulic unit assem- assembly
circuit) bly is open or short-circuit-
ed.
24 Brake light switch or tail/ Brake light signal is not re- • Defective signaling sys-
brake light ceived properly while the tem (tail/brake light or
vehicle is traveling. (Brake brake light switch)
light circuit, or front or rear • Defective coupler be-
brake light switch circuit.) tween the signaling sys-
tem (tail/brake light or
brake light switch) and
the hydraulic unit assem-
bly
tween the signaling sys-
tem (tail/brake light or
brake light switch) and
the hydraulic unit assem-
bly
• Defective hydraulic unit
assembly
31 Hydraulic unit assembly Power is not supplied to • Blown ABS solenoid fuse
(abnormal ABS solenoid the solenoid circuit in the • Defective coupler be-
power supply) hydraulic unit assembly. tween the battery and the
hydraulic unit assembly
tween the battery and the
assembly
32 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS sole- the solenoid power supply assembly
noid power supply circuit) circuit in the hydraulic unit
assembly.
9-53

33 Hydraulic unit assembly Power is not supplied to • Blown ABS motor fuse
(abnormal ABS motor the motor circuit in the hy- • Defective coupler be-
power supply) draulic unit assembly. tween the battery and the
assembly
34 Hydraulic unit assembly Short circuit is detected in • Defective hydraulic unit
(short circuit in ABS motor the motor power supply assembly
power supply circuit) circuit in the hydraulic unit
assembly.
41 Front wheel ABS (intermit- • Pulses from the front • Incorrect installation of
tent wheel speed pulses or wheel sensor are re- the front wheel sensor
incorrect depressuriza- ceived intermittently • Incorrect rotation of the
tion) while the vehicle is trav- front wheel
eling. • Front brake dragging
• Front wheel will not re- • Defective hydraulic unit
cover from the locking assembly
tendency even though
the signal is transmitted
from the ABS ECU to re-
duce the hydraulic pres-
sure.
42 Rear wheel ABS (intermit- • Pulses from the rear • Incorrect installation of
47 tent wheel speed pulses or wheel sensor are re- the rear wheel sensor
incorrect depressuriza- ceived intermittently (for DTC No. 42)
tion) while the vehicle is trav- • Incorrect rotation of the
eling. (for DTC No. 42) rear wheel
• Rear wheel will not re- • Rear brake dragging
cover from the locking • Defective hydraulic unit
tendency even though assembly
the signal is transmitted
from the ABS ECU to re-
duce the hydraulic pres-
sure.
43 Front wheel sensor (miss- Front wheel sensor signal • Foreign material ad-
ing pulses) is not received properly. hered around the front
the vehicle is traveling.) the front wheel
the rotor
9-54

44 Rear wheel sensor (miss- Rear wheel sensor signal • Foreign material ad-
ing pulses) is not received properly. hered around the rear
the vehicle is traveling.) the rear wheel
the rotor
51 • Vehicle system power • Power voltage supplied • Defective battery
52 supply (voltage of ABS to the ABS ECU in the • Disconnected battery
ECU power supply is hydraulic unit assembly terminal
high) (for DTC No. 51) is too high. (for DTC No. • Defective charging sys-
• Vehicle system power 51) tem
supply (voltage of wheel • Power voltage supplied
sensor power supply is to the wheel sensor is too
high) (for DTC No. 52) high. (for DTC No. 52)
53 Vehicle system power Power voltage supplied to • Defective battery
supply (voltage of ABS the ABS ECU in the hy- • Defective coupler be-
ECU power supply is low) draulic unit assembly is tween the battery and the
too low. hydraulic unit assembly
• Defective charging sys-
tem
54 Hydraulic unit assembly Abnormality is detected in • Defective battery
(defective ABS solenoid the solenoid or motor pow- • Defective coupler be-
and ABS motor power er supply circuit in the hy- tween the battery and the
supply circuits) draulic unit assembly. hydraulic unit assembly
• Defective charging sys-
tem
assembly
55 Hydraulic unit assembly Abnormal data is detected • Defective hydraulic unit
(defective ABS ECU) in the hydraulic unit as- assembly
sembly.
56 Hydraulic unit assembly Abnormality is detected in • Defective hydraulic unit
(abnormal internal power the power supply circuit in assembly
supply) the hydraulic unit assem-
bly.
9-55

63 Front wheel sensor power Power voltage supplied • Short circuit in the wire
supply (voltage of power from the ABS ECU to the harness between the
supply is low) front wheel sensor is too front wheel sensor and
low. the hydraulic unit assem-
bly
sensor
assembly
64 Rear wheel sensor power Power voltage supplied • Short circuit in the wire
supply (voltage of power from the ABS ECU to the harness between the
supply is low) rear wheel sensor is too rear wheel sensor and
low. the hydraulic unit assem-
bly
sensor
assembly
* The DTC No. varies according to the vehicle conditions.

EAS33031
DIAGNOSTIC CODE: SENSOR OPERATION TABLE

Diagnostic
Item Tool display Procedure
code No.
01 Throttle position sensor 0–125
signal
• Fully closed position 12–22 Check the fully closed
throttle valve.
• Fully opened position 94–110 Check the fully opened
throttle valve.
03 Intake air pressure Displays the intake air Check the intake air pres-
pressure. sure when cranking the
When engine is stopped: engine. (If the displaying
Atmospheric pressure at value changes, the perfor-
the current altitude and mance is OK.)
weather conditions is indi-
cated.
At sea level: Approx. 101
kPa 3000 m above sea
level: Approx. 70 kPa
05 Intake air temperature Displays the intake air Compare the actually
temperature. measured air temperature
-30–120 [°C] with the tool displayed val-
When engine is cold: Dis- ue.
plays temperature closer
to air temperature
When engine is hot: Air
temperature + approx. 20
[°C]
9-56
Diagnostic
code No.
06 Coolant temperature Displays the coolant tem- Compare the actually
perature. measured coolant tem-
-30–120 [°C] perature with the tool dis-
When engine is cold: Dis- played value.
plays temperature closer
to air temperature
When engine is hot: Dis-
plays current coolant tem-
perature.
07 Vehicle speed pulse Front wheel speed pulse Check that the number in-
0–999 creases when the front
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
09 Fuel system voltage Displays the fuel system Compare the actually
(battery voltage) voltage 0–18.7 [V] measured battery voltage
Standard voltage: Approxi- with the tool displayed val-
mately 12.0 [V] ue. (If the actually mea-
sured battery voltage is
low, recharge the battery.)
20 Sidestand switch Check the sidestand
• Stand retracted ON switch condition.
• Stand extended OFF

60 EEPROM DTC display —
• Defective EEPROM DTC 00
is indicated. • No malfunctions detect-
ed (If the self-diagnosis
fault code P062F is indi-
cated, the SGCU is de-
fective.)
• DTCs are indicated 2- 01 (CO adjustment value) —
second interval. 11 (ISC learning values)
Display the EEPROM 12 (O2 feedback learning
writing error for fault code value)
No. P062F. 14 (Wheel diameter learn-
If more than one item is ing value)
defective, the displays al-
ternates every two sec-
onds to show all the
detected numbers.
67 ISC learning condition dis- 00 To erase the ISC learning
play ISC learning data has data, click “ON / OFF but-
ISC learning data erasure been erased. ton” on the Yamaha diag-
01 nostic tool screen 3 times
It is not necessary to erase in 5 seconds.
the ISC learning data.
02
It is necessary to erase the
ISC learning data.
9-57
Diagnostic
code No.
70 Programmed unit Ver. 0–254 [-] Check the programmed
number unit Ver. number
87 A/F learning data erasure 00 To erase the A / F learning
A/F learning data has been data, click “ON / OFF but-
erased. ton” on the Yamaha diag-
01 nostic tool screen 3 times
A/F learning data has not in 5 seconds.
been erased
90 Idle stop selection switch Check the idle stop selec-
• Set to “ON” position Indicated ON tion switch is turned ON /
OFF.
• Set to “OFF” position Indicated OFF
EAS33032
DIAGNOSTIC CODE: ACTUATOR OPERATION TABLE

Diagnostic
Item Actuation Procedure
code No.
30 Ignition coil Actuates the ignition coil Check the energization of
five times at one–second the ignition coil.
intervals. • Check the sparking per-
The “CHECK” indicator formance on the spark
“ ” on the Yamaha diag- plug.
nostic tool screen comes
on each time the ignition
coil is actuated.
36 Fuel injector Actuates the fuel injector Disconnect the fuel pump
five times at one–second coupler.
intervals. Check that the injector is
The “CHECK” indicator actuated five times by lis-
“ ” on the Yamaha diag- tening for the operating
nostic tool screen comes sound.
on each time the fuel injec-
tor is actuated.
45 VVA solenoid Actuates the VVA solenoid Check that the VVA sole-
five times at five-second noid is operated five times.
intervals.
The “CHECK” indicator
“ ” on the Yamaha diag-
on each time the VVA so-
lenoid is actuated.
52 Headlight Actuates the headlight five Check that the headlight
times at five-second inter- comes on five times.
vals.
on each time the headlight
is actuated.
9-58
Diagnostic
Item Actuation Procedure
code No.
54 ISC unit Fully closes the ISC valve, Check that the ISC unit
and then opens the valve operates by listening for
to the standby opening po- the operating sound while
sition. the ISC unit operates for 3
This operation takes ap- seconds.
proximately 3 seconds
each time.
on during the operation.
9-59
EVENT CODE TABLE
EAS20707
EVENT CODE TABLE

Fuel injection system
No. Item Symptom Possible cause Remarks
192 Intake air pres- Brief abnormality Same as for DTC Perform the checks and
sure sensor detected in intake P0107 and P0108 maintenance jobs for
air pressure sensor DTC P0107 and P0108.
193 Throttle position Brief abnormality Same as for DTC Perform the checks and
sensor detected in throttle P0122 and P0123 maintenance jobs for
position sensor DTC P0122 and P0123.
196 Coolant tem- Brief abnormality Same as for DTC Perform the checks and
perature sensor detected in coolant P0117 and P0118 maintenance jobs for
temperature sensor DTC P0117 and P0118.
197 Intake air tem- Brief abnormality Same as for DTC Perform the checks and
perature sensor detected in intake P0112 and P0113 maintenance jobs for
air temperature DTC P0112 and P0113.
sensor
218 Crankshaft posi- Brief abnormality Same as for DTC Perform the checks and
tion sensor detected in crank- P0335 maintenance jobs for
shaft position sen- DTC P0335.
sor
240 O2 sensor Correction value re- • Open or short circuit • If a DTC is indicated,
(Correction val- mains at upper limit in the wire harness perform the checks and
ue remains at during O2 feedback between the sensor maintenance jobs for
upper limit) and the SGCU gray/ the DTC first.
red–gray/red * Event code number 240
• Low fuel pressure may be indicated even if
• Clogged fuel injector the system is normal.
• Sensor malfunction
• Defective SGCU
• Defective fuel injec-
tion system
241 O2 sensor Correction value re- • Open or short circuit • If a DTC is indicated,
(Correction val- mains at lower limit in the wire harness perform the checks and
ue remains at during O 2 feedback between the sensor maintenance jobs for
lower limit) and the SGCU gray/ the DTC first.
red–gray/red * Event code number 241
• Low fuel pressure may be indicated even if
• Clogged fuel injector the system is normal.
• Sensor malfunction
• Defective SGCU
• Defective fuel injec-
tion system
9-60
EVENT CODE TABLE
No. Item Symptom Possible cause Remarks

242 ISC During idling, the Idling engine speed is • Implement diagnosis
(Stuck at the up- adjustment is main- slow mode D67, and check
per limit for ad- tained at the upper • Clogged throttle body the ISC maintenance
justment) limit • Poorly adjusted throt- request.
tle cable • If a DTC is indicated,
• Poorly adjusted perform to that first.
clutch cable * Event code number 242
• Malfunction in the may be indicated even if
fuel injection system the system is normal.
• Dirty or worn spark
plug
• Malfunction in the
battery
• Malfunction in SGCU
243 ISC During idling, the Idling engine speed is • If a DTC is indicated,
(Stuck at the adjustment is main- fast perform to that first.
lower limit for tained at the lower • Poorly adjusted throt- * Event code number 243
adjustment) limit tle cable may be indicated even if
• Poorly adjusted the system is normal.
clutch cable
fuel injection system
plug
battery
• Malfunction in SGCU
244 Difficult/unable Engine starting diffi- • Empty fuel tank • If a DTC is indicated,
to start engine cult/unable condi- • Defective fuel injec- perform the checks and
tion detected tion system maintenance jobs for
• Dirty or worn spark the DTC first.
plug * Event code number 244
• Defective battery may be indicated even if
• Defective SGCU the system is normal.
245 Engine stall Engine stall detect- • Empty fuel tank • If a DTC is indicated,
ed • Improperly adjusted perform the checks and
throttle cable maintenance jobs for
• Improperly adjusted the DTC first.
clutch cable * Event code number 245
• Defective fuel injec- may be indicated even if
tion system the system is normal.
plug
• Defective battery
• Defective SGCU
9-61
P0030
EAS20397
P0030
EAS33134
TROUBLESHOOTING
Item
O2 sensor heater: defective heater or heater driver ON/OFF command and error signal is mismatching.
Fail-safe system
• Able to start engine
• Able to drive vehicle
Procedure
1. Connection of O2 sensor coupler.
• Check the locking condition of the coupler.
• Disconnect the coupler and check the pins (bent or broken terminals and locking condition of the
pins).
Is the coupler condition normal?

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness.
b. Push the ON/start switch, and then check the DTC using the malfunction mode of the YDT.
Is it in the “Recovered” condition?

YES
→ Go to step 6, and complete the service.
NO
→ Go to step 2.
2. Connection of SGCU coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-62
P0030
3. Wire harness continuity.

• Disconnect the O2 sensor coupler, SGCU coupler and fuse box (ignition fuse) coupler.
• Open circuit check
Between O2 sensor coupler “1” and SGCU cou-
pink/black–pink/black
pler “2”
Between O2 sensor coupler “1” and fuse box (ig-
brown/red–brown
nition fuse) coupler “3”
3
2
1
Br/R P/B Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
Gy/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Is resistance 0 Ω?
YES
→ Go to “Short circuit check”.
NO
a. Replace the wire harness.

YES
NO
• Short circuit check
TIP
Disconnect the SGCU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3.
Ground short circuit check “A”
pink/black–ground
Between O2 sensor coupler “1” and ground
brown/red–ground
Lines short circuit check “B”

pink/black–any other coupler terminal
O2 sensor coupler “1”
brown/red–any other coupler terminal
SGCU coupler “2” pink/black–any other coupler terminal
Fuel box (ignition fuse) coupler “3” brown–any other coupler terminal
9-63
P0030
A B
1 1 2
Br/R P/B
Gy/R B/L
Br/R P/B
Gy/R B/L Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
Is resistance ∞ Ω?
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Defective O2 sensor heater.
• Replace the O2 sensor.
Refer to “ENGINE REMOVAL” on page 5-4.
• Push the ON/start switch, and then check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 5.
5. Malfunction in SGCU.
• Replace the SGCU, and complete the service.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36.
6. Delete the DTC and check that the MIL goes off.
• Confirm that the DTC has a condition of “Recovered” using the YDT, and then delete the DTC.
9-64
P00D1, P2195
EAS20660
P00D1, P2195
EAS33115
TROUBLESHOOTING
Item
• [P00D1] O2 sensor: heater performance deteriorated. Normal signal is not received from the O2 sen-
sor while driving the O2 sensor.
• [P2195] O2 sensor: open circuit is detected.
Fail-safe system
Procedure
1. Installed condition of O2 sensor.
• Check for looseness or pinching.
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall the O2 sensor.
b. Start the engine and warm up it. And then, racing the engine.
c. Check the DTC using the malfunction mode of the YDT.

YES
NO
→ Delete the DTC, and then go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
pins).
9-65
P00D1, P2195

YES
→ Go to step 4.
NO

YES
NO
• Disconnect the O2 sensor coupler, SGCU coupler and fuse box (ignition fuse) coupler.
pink/black–pink/black
Between O2 sensor coupler “1” and SGCU cou-
gray/red–gray/red
pler “2”
black/blue–black/blue
Between O2 sensor coupler “1” and fuse box (ig-
brown/red–brown
nition fuse) coupler “3”
3
2
1
Br/R P/B Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
Gy/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Is resistance 0 Ω?
YES
[P00D1]
[P2195]
→ Go to step 5.
NO

YES
NO
9-66
P00D1, P2195

TIP
pink/black–ground
brown/red–ground
Between O2 sensor coupler “1” and ground
gray/red–ground
black/blue–ground

brown/red–any other coupler terminal
O2 sensor coupler “1”
gray/red–any other coupler terminal
black/blue–any other coupler terminal
SGCU coupler “2” gray/red–any other coupler terminal
Fuel box (ignition fuse) coupler “3” brown/red–any other coupler terminal
A B
1 2 3
1
Br/R P/B Br/R P/B
Gy/R B/L Gy/R B/L Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-67
P00D1, P2195
5. Check fuel pressure.

• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-3.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-2.

YES
NO
→ Go to step 6.
6. Defective O2 sensor.
• Check the O2 sensor.
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the O2 sensor.

YES
NO
→ Go to step 7.
9-68
P0105
EAS20420
P0105
EAS32838
TROUBLESHOOTING
Item
Intake air pressure sensor: signal out of range
Fail-safe system
Procedure
TIP
If more than one DTC is detected at the same time, perform troubleshooting of DTC listed below first.
• P0107, P0108
1. Connection of intake air pressure sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
2. Defective intake air pressure sensor.
• Replace the intake air pressure sensor.
Refer to “THROTTLE BODY” on page 7-11.

YES
NO
→ Go to step 3.
3. Defective wire harness.
• Replace the wire harness.

YES
NO
→ Go to step 4.
9-69
P0105
9-70
P0106
EAS20421
P0106
EAS32840
TROUBLESHOOTING
Item
Intake air pressure sensor: clogging of hole or sensor installation improperly.
Fail-safe system
Procedure
ECA20500
NOTICE
Do not remove the throttle body sensor assembly from the throttle body.
TIP
If the DTC “P0107/P0108” or “P0106” are detected at the same time, perform the check and service for
DTC listed below first.
• P0107, P0108
1. Installed condition of throttle body sensor assembly.
• Check for detached or clogged.
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall the throttle body sensor assembly.
b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then
check the condition of the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
• Execute the diagnostic mode. (Code 03)
• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
101 kPa (757.6 mmHg, 29.8 inHg), approx. 3.99
At sea level
V
Approx. 90 kPa (675.1 mmHg, 26.6 inHg), ap-
1000 m (3300 ft) above sea level
prox. 3.55 V
prox. 3.16 V
prox. 2.76 V
9-71
P0106
• When engine is cranking: Make sure that the indication value changes.
Is check result OK?

YES
NO
a. Replace the throttle body assembly.
b. Start the engine and let it idle for approximately 5 seconds with the throttle fully closed, and then
check the DTC using the malfunction mode of the YDT.
c. Confirm the “Recovered” condition, then go to step 3.
9-72
P0107, P0108
EAS20567
P0107, P0108
EAS33047
TROUBLESHOOTING
Item
• [P0107] Intake air pressure sensor: open or short to ground circuit is detected.
• [P0108] Intake air pressure sensor: short to power circuit is detected.
Fail-safe system
Procedure
ECA20500
NOTICE
TIP
If the DTC “P0107/P0108” or “P0106” are detected at the same time, perform the check and service for
DTC listed below first.
• P0107, P0108
1. Connection of throttle body sensor assembly coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
9-73
P0107, P0108

pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
• Disconnect the throttle body sensor assembly coupler and SGCU coupler.
[P0108] black/blue–black/blue
Between throttle body sensor assembly coupler
[P0107] pink/white–pink/white
“1” and SGCU coupler “2”
[P0107] blue–blue
2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
Or/B W/R B/Y Or
B/L Y B/L Br/B R/B
B/L Y L P/W Br/W L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Is resistance 0 Ω?
YES
NO

YES
NO
9-74
P0107, P0108

TIP
[P0107] pink/white–ground
“1” and ground

Throttle body sensor assembly coupler “1” [P0108] pink/white–any other coupler terminal
SGCU coupler “2” [P0108] pink/white–any other coupler terminal
A B
1 1 2
B/L Y L P/W Br/W
B/L Y L P/W Br/W
Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-75
P0107, P0108

• When engine is stopped: Atmospheric pressure at the current altitude and weather conditions is in-
dicated.
At sea level
prox. 3.99 V
prox. 3.55 V
prox. 3.16 V
prox. 2.76 V
• When engine is cranking: Make sure that the indication value changes.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the throttle body.

YES
NO
→ Go to step 6.
9-76
P0110
EAS20426
P0110
EAS32845
TROUBLESHOOTING
Item
Intake air temperature sensor: signal stuck
Fail-safe system
Procedure
TIP
• Perform this procedure when the engine is cold.
• If the DTCs P0112 or P0113 are detected at the same time, perform the check and service for DTC
listed below first.
• P0112, P0113
1. Installed condition of intake air temperature sensor.
Refer to “GENERAL CHASSIS (3)” on page 4-6.
• Check the dirt around the intake air temperature sensor.
Is check result OK?

YES
→ Go to step 2.
NO
a. Clean around the intake air temperature sensor, then reinstall it.
b. Push the ON/start switch, then heat the intake air temperature sensor using hair dryer.

YES
NO
→ Go to step 2.
2. Defective intake air temperature sensor.
• Measure and note the intake air temperature sensor resistance at ambient temperature.
• Heat the intake air temperature sensor using hair dryer, and measure the intake air temperature sen-
sor resistance, then compare the noted resistance at ambient temperature.
Is the resistance change?

YES
→ Go to step 3.
NO
a. Replace the intake air temperature sensor.
b. Push the ON/start switch, then heat the intake air temperature sensor using hair dryer.

YES
NO
→ Go to step 3.
9-77
P0110
9-78
P0111
EAS20425
P0111
EAS32844
TROUBLESHOOTING
Item
Intake air temperature sensor: signal out of range
Fail-safe system
Procedure
TIP
listed below first.
• P0112, P0113
pins).

YES
→ Go to step 2.
NO
b. Execute the diagnostic mode. (Code 05)
• When engine is cold: Displayed temperature is close to the ambient temperature.
Is check result OK?

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
Is check result OK?

YES
NO
→ Go to step 3.
9-79
P0111
3. Installed condition of throttle body sensor assembly coupler.

Is check result OK?

YES
→ Go to step 4.
NO
a. Reinstall the throttle body sensor assembly coupler.
Is check result OK?

YES
NO
→ Go to step 4.
• Check the intake air temperature sensor.
6.0 ± 0.3 kΩ at 0 °C (6.0 ± 0.3 kΩ at 32 °F)
Intake air temperature sensor resistance 0.36 ± 0.02 kΩ at 80 °C (0.36 ± 0.02 kΩ at 176
°F)
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the throttle body sensor assembly coupler.
c. Submerge the throttle body sensor assembly coupler in a container filled with water at 0 °C (32
°F).
• The displayed temperature is close to the 0 °C (32 °F)
Is check result OK?

YES
NO
→ Go to step 5.
• Submerge the throttle body sensor assembly coupler in a container of 0 °C (32 °F) water.
• The displayed temperature is close to the 0 °C (32 °F)
Is check result OK?

YES
NO
→ Go to step 6.
9-80
P0111
9-81
P0112, P0113
EAS20568
P0112, P0113
EAS33048
TROUBLESHOOTING
Item
• [P0112] Intake air temperature sensor: short to ground circuit is detected.
• [P0113] Intake air temperature sensor: open or short to power circuit is detected.
Fail-safe system
Procedure
ECA20500
NOTICE
TIP
Perform this procedure when the engine is cold.
pins).

YES
→ Go to step 2.
NO
a. Connect the coupler securely or replace the wire harness and/or sub-wire harness.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-82
P0112, P0113

• Disconnect the throttle body sensor assembly coupler and SGCU coupler.
Is DTC P0112 displayed?

YES
NO
→ Go to “Open circuit check”.
Between throttle body sensor assembly coupler [P0113] brown/white–brown/white
“1” and SGCU coupler “2” [P0113] black/blue–black/blue
2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
Or/B W/R B/Y Or
B/L Y B/L Br/B R/B
Is resistance 0 Ω?
YES
NO

YES
NO
9-83
P0112, P0113

TIP
[P0112] brown/white–ground
“1” and ground

SGCU coupler “2” [P0113] brown/white–any other coupler terminal
A B
2
1
B/L Y L P/W Br/W Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Check for looseness.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-84
P0112, P0113

• The displayed temperature is not close to the ambient temperature → Replace the throttle body.
Refer to “REPLACING THE THROTTLE BODY” on page 7-16.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the intake air temperature sensor.
b. Turn the main switch to “ON”, and then check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 6.
9-85
P0115
EAS20424
P0115
EAS32843
TROUBLESHOOTING
Item
Coolant temperature sensor: signal stuck
Fail-safe system
Procedure
TIP
• If the follwing DTCs are detected at the same time, perform the check and service for DTC listed below
first.
• P0116, P0117, P0118, P0335, P0500, P2122, P2123
1. Defective coolant temperature sensor.
• Measure and note the coolant temperature sensor resistance at ambient temperature.
• Start the engine and warm-up it.
• Measure the coolant temperature sensor resistance at engine warmed-up, then compare the noted
resistance at ambient temperature.
Is the resistance change?

YES
→ Go to step 2.
NO
a. Allow the engine to cool to ambient temperature, then replace the coolant temperature sensor.
b. Push the ON/start switch, then start the engine and warm-up it.

YES
NO
→ Go to step 2.
9-86
P0116
EAS20423
P0116
EAS32842
TROUBLESHOOTING
Item
Coolant temperature sensor: signal out of range
Fail-safe system
Procedure
TIP
listed below first.
• P0117, P0118
1. Connection of coolant temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO
Is check result OK?

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO
Is check result OK?

YES
NO
→ Go to step 3.
9-87
P0116
3. Installed condition of coolant temperature sensor.

Is check result OK?

YES
→ Go to step 4.
NO
a. Reinstall the sensor.
Is check result OK?

YES
NO
→ Go to step 4.
• Check the coolant temperature sensor resistance.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR” on page 8-41.
2.645 kΩ ± 132.25 Ω at 20 °C (2.645 kΩ ±
132.25 Ω at 68 °F)
Coolant temperature sensor resistance
0.216 kΩ ± 5.4 Ω at 100 °C (0.216 kΩ ± 5.4 Ω at
212 °F)
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the coolant temperature sensor.
c. Submerge the coolant temperature sensor in a container filled with water at 20 °C (68 °F) and
100 °C (212 °F).
• Displayed temperature is close to the 20 °C (68 °F) and 100 °C (212 °F).
Is check result OK?

YES
NO
→ Go to step 5.
9-88
P0116

• Submerge the coolant temperature sensor in a container filled with water at 20 °C (68 °F) and 100
°C (212 °F).
• Displayed temperature is close to the 20 °C (68 °F) and 100 °C (212 °F).
Is check result OK?

YES
NO
→ Go to step 6.
9-89
P0117, P0118
EAS20569
P0117, P0118
EAS33049
TROUBLESHOOTING
Item
• [P0117] Coolant temperature sensor: short to ground circuit is detected.
• [P0118] Coolant temperature sensor: open or short to power circuit is detected.
Fail-safe system
Procedure
TIP
Perform this procedure when the engine is cold.
1. Connection of coolant temperature sensor coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-90
P0117, P0118

• Disconnect the coolant temperature sensor coupler and SGCU coupler.
Is DTC P0117 displayed?

YES
NO
→ Go to “Open circuit check”.
Between coolant temperature sensor coupler [P0118] green/red–green/red
“1” and SGCU coupler “2” [P0118] black/blue–black/blue
1 2
G/R B/L
Is resistance 0 Ω?
YES
→ Go to step “Short circuit check”.
NO

YES
NO
9-91
P0117, P0118

TIP
Between coolant temperature sensor coupler
[P0117] green/red–ground
“1” and ground

Coolant temperature sensor coupler “1” [P0118] green/red–any other coupler terminal
SGCU coupler “2” [P0118] green/red–any other coupler terminal
A B
1 1 2
G/R B/L
G/R B/L Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of coolant temperature sensor.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the sensor.

YES
NO
→ Go to step 5.
9-92
P0117, P0118

• The displayed temperature is not close to the ambient temperature → Check the coolant tempera-
ture sensor.
Refer to “CHECKING THE COOLANT TEMPERATURE SENSOR” on page 8-41.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the coolant temperature sensor.

YES
NO
→ Go to step 6.
9-93
P0122, P0123
EAS20757
P0122, P0123
EAS33050
TROUBLESHOOTING
Item
• [P0122] Throttle position sensor: open or short to ground circuit is detected.
• [P0123] Throttle position sensor: short to power circuit is detected.
Fail-safe system
Procedure
ECA20500
NOTICE
1. Connection of throttle body sensor assembly.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-94
P0122, P0123

• Disconnect the throttle position sensor coupler and SGCU coupler.
[P0122] blue–blue
Between throttle position sensor coupler “1” and
[P0122] yellow–yellow
SGCU coupler “2”
[P0123] black/blue–black/blue
2
1 Lg/L G/Y
Lg/W Sb
P W/L Ch
Gy
G B/L B
W/Y P/B W/B L
Or/B W/R B/Y Or
B/L Y B/L Br/B R/B
Is resistance 0 Ω?
YES
NO

YES
NO
9-95
P0122, P0123

TIP
Between throttle position sensor coupler “1” and
[P0122] yellow–ground
ground

Throttle position sensor coupler “1” [P0123] yellow–any other coupler terminal
SGCU coupler “2” [P0123] yellow–any other coupler terminal
A B
1 1 2

B/L Y L P/W Br/W B/L Y L P/W Br/W
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-96
P0122, P0123
5. Defective throttle position sensor.

• Check throttle position sensor signal 1.
When the throttle valves are fully closed 12–22
When throttle valves are fully open 94–110
Is check result OK?

YES
→ Go to step 7.
NO
a. Replace the throttle body assembly.
Refer to “REPLACING THE THROTTLE BODY” on page 7-16.

YES
NO
→ Go to step 6.
9-97
P0132
EAS20571
P0132
EAS33051
TROUBLESHOOTING
Item
O2 sensor: short to power circuit is detected.
Fail-safe system
Procedure
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the sensor.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-98
P0132

pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
• Disconnect the O2 sensor coupler and SGCU coupler.
TIP
Lines short circuit check
SGCU coupler “1” gray/red–any other coupler terminal

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-99
P0132
Is check result OK?

YES
→ Go to step 6.
NO

YES
NO
→ Go to step 6.
9-100
P0133
EAS20411
P0133
O2 sensor: deterioration detected
EAS33291
OUTLINE
Explanation of detection method
The O2 sensor detects the oxygen concentration in the exhaust gas, converts it into an electrical signal,
and sends it to the SGCU. The SGCU determines whether there is any deterioration by comparing the
output value from the O2 sensor with a predetermined threshold value such as response time. When
the SGCU determines that there is an O2 sensor deterioration, the DTC is stored in SGCU and MIL
comes on.
Frequency of detection Once per driving cycle
Malfunction determination If an abnormality is detected in three consecutive driving cycles, the
method malfunction is confirmed and the MIL comes on.
Driving condition Flat road, no overloading, and no acceleration or deceleration
Type of detection result Complete, Incomplete
Requirement for detection

Duration 400 seconds or more
O2 feedback Carried out
Vehicle speed 40–60 km/h (25–37 mph)
Gear position No condition specified
Engine speed No condition specified
Fuel correction value The O2 feedback correction amount is within a certain range.
Related sensor for detection

O2 sensor, intake air pressure sensor, coolant temperature sensor, front wheel sensor, rear wheel sen-
sor, crankshaft position sensor, and throttle position sensor
Storing DTC
Once an abnormality has been detected, a pending DTC is stored in the memory of the SGCU. Then,
if the abnormality is detected in the next two driving cycles, the MIL comes on and the DTC and FFD
are stored. If the vehicle is judged to be operating normally for three consecutive driving cycles, the MIL
goes off. However, the DTC, pending DTC, and FFD will not be deleted even if a battery terminal is dis-
connected.
Reproduction test
Perform the test using the driving pattern according to the detecting method.
EWA20860
WARNING
When test riding the vehicle, always comply with local traffic regulations.
EAS33153
FAIL-SAFE SYSTEM
9-101
P0133
EAS32813
TROUBLESHOOTING
TIP
If the follwing DTCs are detected at the same time, perform the check and service for DTC listed below
first.
• DTC except P0133
1. Connect the YDT to check and delete the DTC stored in the SGCU.
2. Perform the reproduction test under the following conditions, then go to step 3.
Reproduction test conditions
60
40
D
B
E F
C
G
A. Speed [km/h] E. 5 min.
B. Time [min] F. Total: 15 min.
C. Start the engine G. Stop the engine
D. Idle (warm up)
3. Connect the YDT and check if the pending DTC is displayed.
Is pending DTC displayed?

Yes
→ Delete the pending DTC, then go to step 4.
No
→ Check the readiness status.
Readiness status is “Complete”.
→ Check the coupler between the SGCU and O2 sensor for any abnormality. If there is no abnor-
mality, temporary connection failure is considered to be the cause, so finish the troubleshooting.
Readiness status is “Incomplete”.
→ Reproduction test is required again because the reproduction is not completed.
Go to step 2.
4. Replace the O2 sensor, then go to step 5.
5. Perform reproduction test and connect the YDT.
Check that the pending DTC is not detected and readiness status is “Complete”. Then complete the
troubleshooting.
9-102
P0134
EAS20414
P0134
EAS32834
TROUBLESHOOTING
Item
O2 sensor: signal stuck
Fail-safe system
Procedure
TIP
If the follwing DTCs are detected at the same time, perform the check and service for DTC listed below
first.
1. P0030
2. P00D1, P2195
3. P0105, P0106, P0107, P0108, P0110, P0111, P0112, P0113, P0115, P0116, P0117, P0118,
P0122, P0123, P0132, P0201, P0335, P0351
4. P0301
1. Engine condition.
• Check the idling condition and check the engine sound while racing the engine.
Is check result OK?

YES
→ Go to step 2.
NO
a. Check the ignition spark gap.
Refer to “CHECKING THE IGNITION SPARK GAP” on page 8-39.
b. Test ride the vehicle according to the test-ride conditions for the O2 deterioration diagnosis.
Refer to step 2 in “TROUBLESHOOTING” on page 9-102.
At this time, do not check the malfunction diagnosis status (readiness).

YES
NO
→ Go to step 2.
9-103
P0134

Is check result OK?

YES
→ Go to step 3.
NO
a. Reinstall the O2 sensor.

YES
NO
→ Go to step 3.
3. Check fuel pressure.
• Check the fuel pressure.
Refer to “CHECKING THE FUEL PRESSURE” on page 7-3.
Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the fuel pump.
Refer to “REMOVING THE FUEL PUMP” on page 7-2.

YES
NO
→ Go to step 4.
9-104
P0134
Is check result OK?

YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-105
P0201
EAS20574
P0201
EAS33054
TROUBLESHOOTING
Item
Fuel injector: malfunction in fuel injector.
Fail-safe system
• Unable to start engine
• Unable to drive vehicle
Procedure
1. Connection of fuel injector coupler.
pins).

YES
→ Go to step 2.
NO
Is operating sound heard?

YES
→ Go to step 6.
NO
→ Go to step 2.
2. Defective fuel injector.
• Measure the injector resistance.
Refer to “CHECKING THE FUEL INJECTOR” on page 8-41.
Is check result OK?

YES
→ Go to step 3.
NO
a. Replace the fuel injector.

YES
→ Go to step 6.
NO
→ Go to step 3.
9-106
P0201

pins).

YES
→ Go to step 4.
NO

YES
→ Go to step 6.
NO
→ Go to step 4.
• Disconnect the fuel injector coupler and SGCU coupler
Between fuse box (ignition fuse) terminal “1”
brown–brown
and fuel injector coupler “2”
Between fuel injector coupler “2” and SGCU
orange/black–orange/black
coupler “3”
1
3
2
Or/B Br Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 6.
NO
9-107
P0201

TIP
orange/black–ground
Between fuel injector coupler “2” and ground
brown–ground

orange/black–any other coupler terminal
Fuel injector coupler “2”
brown–any other coupler terminal
SGCU coupler “1” orange/black–any other coupler terminal
A B
2 2 1
Or/B Br
Or/B Br
YES
→ Go to step 5.
NO

YES
→ Go to step 6.
NO
→ Go to step 5.
• Start the engine and let it idle for approximately 5 seconds.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT, and
then delete the DTC.
9-108
P0301
EAS20713
P0301
• Misfire in cylinder #1
EAS33318
OUTLINE
Explanation of detection method

The SGCU monitors the consistency of the crankshaft rotation by crankshaft position sensor, and if the
angular velocity fluctuates irregularly, the SGCU determines that there is a misfire. Two kinds of misfire
judgment are performed according to the number of misfire occurrences and the threshold value.
* Catalyst damage
• The number of misfires per 200 revolutions of the crankshaft exceeds the threshold value, and it is de-
tected that the exhaust gas damages the catalyst, the DTC is stored in the SGCU and the MIL starts
flashing.
* Exhaust gas deterioration
• The number of misfires per 1000 revolutions of the crankshaft exceeds the threshold value, and it is
detected that the exhaust gas does not damage the catalyst but affect the exhaust gas emission level,
the DTC is stored in the SGCU and the MIL comes on.
Frequency of detection Always
Time required for detection Always
• Catalyst damage
When an abnormality is detected three times in one driving cycle, it
is determined to be a pending abnormality and the MIL starts flash-
ing. If this cycle occurs in three consecutive driving cycles, the mal-
Malfunction determination function is determined and the MIL comes on.
method • Exhaust gas deterioration
If an abnormality is detected four times within one driving cycle, it is
determined to be a pending abnormality. The MIL does not flash at
this time. If this cycle occurs in three consecutive driving cycles, the
malfunction is determined and the MIL comes on.
Driving condition No excessive acceleration or deceleration
Type of detection result Complete, Incomplete
Requirement for detection

Duration Refer to the conversion table of steady driving time.
Engine starting time No condition specified
O2 feedback No condition specified
Vehicle speed No condition specified
Gear position No condition specified
Engine speed 2500–7000 r/min
Related sensors for detection

Intake air pressure sensor, coolant temperature sensor, front wheel sensor, rear wheel sensor, crank-
shaft position sensor, throttle position sensor
9-109
P0301
Storing DTC
Once an abnormality has been detected, a pending DTC is stored in the memory of the ECU. Then, if
the abnormality is detected in the next two driving cycles, the MIL comes on and the DTC and FFD are
stored. If the vehicle is judged to be operating normally for three consecutive driving cycles, the MIL
goes off. However, the DTC, pending DTC, and FFD will not be deleted even if a battery terminal is dis-
connected.
Reproduction test
Operate the vehicle according to the engine speed and vehicle speed in the FFD. Confirm the operating
time in the conversion table of steady driving time according to the engine speed in the FFD. Do not ac-
celerate or decelerate excessively during the reproduction test. Continue to operate the vehicle even if
the vehicle cannot be operated at a constant speed due to the operating environment.
EWA20860
WARNING
When test riding the vehicle, always comply with local traffic regulations.
EAS33154
FAIL-SAFE SYSTEM
• Able/Unable to start engine
• Able/Unable to drive vehicle
EAS32820
TROUBLESHOOTING
1. Connect the YDT and check the DTC stored in the SGCU.
DTC is displayed
→ Check the engine speed and vehicle speed of FFD.
Delete DTC, then go to step 2.
Pending DTC is displayed
→ Confirm the engine speed and vehicle speed to the customer when the customer feels an abnor-
mality.
Delete pending DTC, then go to step 2.
DTC and pending DTC are not displayed.
mality
Go to step 2.
9-110
P0301
2. Perform the reproduction test under the following conditions, then go to step 3.
ECA26950
NOTICE
If the MIL flashes during the reproduction test, immediately decelerate or reduce the engine
speed. Otherwise, the catalyst could be damaged.
Reproduction test condition
B
D F
E
A. Speed [km/h] E. Steady driving time

B. Time [min] F. Stop the engine
C. Vehicle speed of FFD
D. Start the engine
Conversion table of steady driving time

Engine speed (r/min) Time (sec.)
2000 240
3000 160
4000 120
5000 96
6000 80
7000 70
8000 60
9000 54
10000 48
9-111
P0301
3. Connect the YDT and check if the pending DTC is displayed.
Is the pending DTC displayed?

Yes
→ Delete the pending DTC, then go to step 4.
No
mality.
Go to step 2.
If the pending DTC is not displayed after several reproduction test, go to step 4.
4. Check the ignition system
Is the inspection result OK?

Yes
→ Go to step 5.
No
→Repair or replace the defective part, then go to step 6.
5. Check the following parts. If defective, replace the parts and go to step 6.
• Intake air pressure sensor
• Coolant temperature sensor
• Speed sensor
• Crankshaft position sensor
• Throttle position sensor
6. Perform a reproduction test and connect the YDT.
Check that the pending DTC is not detected, then complete the troubleshooting.
9-112
P0335
EAS20578
P0335
EAS33058
TROUBLESHOOTING
Item
Crankshaft position sensor: normal signals are not received from the crankshaft position sensor.
Fail-safe system
Procedure
1. Connection of crankshaft position sensor coupler.
pins).

YES
→ Go to step 2.
NO
b. Crank the engine, and then check the DTC using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
2. Connection of wire harness SGCU coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-113
P0335

• Disconnect the crankshaft position sensor coupler and SGCU coupler.
white/red–white/red
white/blue–white/blue
Between crankshaft position sensor coupler “1” white/black–white/black
and SGCU coupler “2” white/yellow–white/yellow
brown/black–brown/black
black/blue–black//blue
1
W/R B/L
2
W/L Br/B Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
W/B W/Y Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Is resistance 0 Ω?
YES
NO

YES
NO
9-114
P0335

TIP
white/red–ground
white/blue–ground
Between crankshaft position sensor coupler “1” white/black–ground
and ground white/yellow–ground
brown/black–ground
black/blue–ground

white/red–any other coupler terminal
white/blue–any other coupler terminal
white/black–any other coupler terminal
Crankshaft position sensor coupler “1”
white/yellow–any other coupler terminal
brown/black–any other coupler terminal
white/red–any other coupler terminal
white/blue–any other coupler terminal
white/yellow–any other coupler terminal
brown/black–any other coupler terminal
A B
1 1 2
W/R B/L W/R B/L

W/L Br/B W/L Br/B
W/B W/Y W/B W/Y Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
9-115
P0335
4. Installed condition of crankshaft position sensor.

• Check the gap (1.15 mm (0.05 in)) between the crankshaft position sensor and the generator rotor.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall or replace the sensor.

YES
NO
→ Go to step 5.
5. Defective crankshaft position sensor.
a. Replace the crankshaft position sensor.

YES
NO
→ Go to step 6.
9-116
P0351
EAS20580
P0351
EAS33060
TROUBLESHOOTING
Item
Ignition coil: open or short circuit is detected in the primary lead of the ignition coil.
Fail-safe system
Procedure
1. Connection of ignition coil coupler.
pins).

YES
→ Go to step 2.
NO
b. Start the engine and let it idle for approximately 5 seconds.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-117
P0351

• Disconnect the ignition coil coupler and SGCU coupler.
Between ignition coil coupler “1” and SGCU
orange–orange
coupler “2”
2 1

Is resistance 0 Ω?
YES
NO

YES
NO
TIP
Between ignition coil coupler “1” and ground orange–ground

Ignition coil coupler “1” orange–any other coupler terminal
SGCU coupler “2” orange–any other coupler terminal
A B
1 2 1

9-118
P0351
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Installed condition of ignition coil.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall.

YES
NO
→ Go to step 5.
5. Defective ignition coil.
• Measure the primary coil resistance of the ignition coil.
Refer to “CHECKING THE IGNITION COIL” on page 8-39.
Is check result OK?

YES
→ Go to step 6.
NO
a. Replace the ignition coil.

YES
NO
→ Go to step 6.
9-119
P0351
• Confirm that spark plug does not spark.
9-120
P0500
EAS20674
P0500
EAS33303
TROUBLESHOOTING
Item
Front wheel sensor: normal signal is not received from the front wheel sensor.
Fail-safe system
Procedure
1. Connection of front wheel sensor coupler.
pins).

YES
→ Go to step 2.
NO
c. Rotate the front wheel by hand and check that the indicated value increases.
Is that value increased?

YES
→ Go to step 8.
NO
→ Go to step 2.
2. Connection of ABS ECU coupler.
pins).

YES
→ Go to step 3.
NO

YES
→ Go to step 8.
NO
→ Go to step 3.
9-121
P0500

pins).

YES
→ Go to step 4.
NO

YES
→ Go to step 7.
NO
→ Go to step 4.
• Disconnect the front wheel sensor coupler, ABS ECU coupler and SGCU coupler.
Between front wheel sensor coupler “1” and brown–brown
ABS ECU coupler “2” yellow–yellow
Between ABS ECU coupler “2” and SGCU cou-
white–white
pler “3”
1 2 3
Br Y G L W W/L W/B B/W Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
R
Br Y R/L Y L/G L/G Br Lg/L Lg/W B/W B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Is resistance 0 Ω?
YES
NO

YES
→ Go to step 8.
NO
9-122
P0500

TIP
brown–ground
Between ABS ECU coupler “2” and ground
yellow–ground

Front wheel sensor coupler “1”
yellow–any other coupler terminal
ABS ECU coupler “2”
SGCU coupler “3” white–any other coupler terminal
A B
2 1
R Br Y G L W W/L W/B B/W Br Y
R/L Y L/G L/G Br Lg/L Lg/W B/W B
2 3
R Br Y G L W W/L W/B B/W Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
R/L Y L/G L/G Br Lg/L Lg/W B/W B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
YES
→ Go to step 5.
NO

YES
→ Go to step 8.
NO
→ Go to step 5.
9-123
P0500
5. Defective front wheel sensor.

• Check the installed condition of front wheel sensor.
Is check result OK?

YES
→ Go to step 8.
NO
a. Reinstall or replace the front wheel sensor.
Refer to “FRONT WHEEL” on page 4-21.

YES
NO
→ Go to step 8.
Refer to “REPLACING THE SGCU (starter generator control unit)” on page 8-36
• Rotate the front wheel by hand and check that the indicated value increases.

YES
→ Go to step 8.
NO
→ Go to step 7.
7. Malfunction in ABS ECU.
• Replace the ABS ECU and go to step 8.
• Push the ON/start switch, and then rotate the front wheel by hand.
then delete the DTC. Delete this DTC even if it has a condition of “Detected”.
9-124
P0507
EAS20589
P0507
EAS33069
TROUBLESHOOTING
Item
Engine idling speed is too high.
A. Component other than ISC unit is defective (ISC unit operating sound is heard).
B. Defective ISC unit (ISC unit operating sound is not heard).
Fail-safe system
TIP
If the DTCs P0507, P0560 are detected at the same time, perform the checked service for DTC listed
below first.
• P0560
below first.
• P0500
below first.
• P0511
Procedure
1. Locate the malfunction.
• Fully close the ISC valve, and then open the valve to the standby opening position.
• This operation takes approximately 3 seconds.
Is ISC operating sound heard?

YES
→ Go to step 2.
NO
→ Go to step 10.
2. Incorrect front wheel sensor signal.
• Front wheel stopped: Check that the cumulative pulse value does not increase.
• Front wheel is rotated several turns by hand: Check that the cumulative pulse value increases
Is check result OK?

YES
→ Go to step 3.
NO
a. Go to the section for the defective front wheel sensor for DTC P0500.
c. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

YES
NO
→ Go to step 3.
9-125
P0507
3. Throttle valve does not fully close due to malfunction in throttle cables.
• Check the throttle grip free play.
Refer to “CHECKING THE THROTTLE GRIP OPERATION” on page 3-23.
Is check result OK?

YES
→ Go to step 4.
NO
a. Replace the throttle bodies.

YES
NO
→ Go to step 4.
4. Air sucking from the throttle body.
• Check the throttle body.
Is check result OK?

YES
→ Go to step 5.
NO
a. Reinstall the throttle body.

YES
NO
→ Go to step 5.
5. Air sucking from the ISC unit.
• Check the intake air passages for air sucking.
Is check result OK?

YES
→ Go to step 6.
NO
a. Reinstall the ISC unit.

YES
NO
→ Go to step 6.
9-126
P0507
6. The air volume for the throttle body and ISC unit is excessive.
• Clean the throttle body and ISC unit.
Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on
page 7-13.
Is check result OK?

YES
→ Go to step 7.
NO
a. Start the engine and let it idle for approximately 10 seconds.
b. Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

YES
NO
→ Go to step 7.
7. The ISC valve is not moving correctly.
• Replace the ISC unit.
• Confirm that the DTC has a condition of “Recovered” using the malfunction mode of the YDT.

YES
NO
→ Go to step 8.
• Return the ISC valve to the initial opening position.
10.Connection of ISC unit coupler.
pins).
Is check result OK?

YES
→ Go to step 11.
NO
Is check result OK?

YES
→ Go to step 17.
NO
9-127
P0507
11.Connection of SGCU coupler.

pins).

YES
→ Go to step 12.
NO
Is ISC operating sound heard ?

YES
NO
→ Go to step 12.
12.Wire harness continuity.
• Disconnect the ISC unit coupler and SGCU coupler.
pink–pink
Between ISC unit coupler “1” and SGCU cou- green/yellow–green/yellow
pler “2” gray–gray
sky blue–sky blue
2
1 Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
P G/Y Sb Gy L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Is resistance 0 Ω?
YES
NO
Is hear operating sound?

YES
NO
9-128
P0507

TIP
pink–ground
green/yellow–ground
Between ISC unit coupler “1” and ground
gray–ground
sky blue–ground

pink–any other coupler terminal
green/yellow–any other coupler terminal
ISC unit coupler “1”
gray–any other coupler terminal
sky blue–any other coupler terminal
A B
1 1 2
P G/Y Sb Gy P G/Y Sb Gy
YES
→ Go to step 13.
NO
Is hear operating sound?

YES
→ Go to step 17.
NO
→ Go to step 13.
9-129
P0507
13.Installed condition of ISC unit.

Is check result OK?

YES
→ Go to step 14.
NO
a. Reinstall the ISC unit.

YES
NO
→ Go to step 14.
14.Battery malfunction.
• Check the battery voltage.
Is check result OK?

YES
→ Go to step 15.
NO
→ Execute the diagnostic mode. (Code 54)

YES
NO
→ Go to step 15.
15.ISC valve is not moving correctly.
• Replace the ISC unit.
Refer to “CLEANING THE ISC (IDLE SPEED CONTROL) UNIT AND THROTTLE BODY” on
page 7-13.
Is check result OK?

YES
→ Go to step 16.
NO
→ Execute the diagnostic mode. (Code 54)

YES
NO
→ Go to step 16.
9-130
P0507
16.Malfunction in SGCU.
• Return the ISC valve to the standby opening position.
17.Delete the DTC and check that the MIL goes off.
9-131
P0511
EAS20590
P0511
EAS33070
TROUBLESHOOTING
Item
ISC unit: ISC valve malfunction is detected. (Open or short circuit is detected between ISC valve and
SGCU.)
Fail-safe system
Procedure
1. Connection of ISC unit coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-132
P0511

• Disconnect the ISC unit coupler and SGCU coupler.
pink–pink
Between ISC unit coupler “1” and SGCU cou- green/yellow–green/yellow
pler “2” gray–gray
sky blue–sky blue
2
P G/Y Sb Gy L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Is resistance 0 Ω?
YES
NO

YES
NO
9-133
P0511

TIP
pink–ground
green/yellow–ground
Between ISC unit coupler “1” and ground
gray–ground
sky blue–ground

ISC unit coupler “1”
A B
1 1 2
P G/Y Sb Gy
P G/Y Sb Gy
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
9-134
P0511
4. Faulty the ISC unit operation

• Check the operating sound of the relay.

YES
→ Go to step 5.
NO
a. Replace the ISC unit.

YES
NO
→ Go to step 5.
9-135
P0560, P0563
EAS20434
P0560, P0563
EAS33138
TROUBLESHOOTING
Item
• [P0560] Battery charging voltage is abnormal. (Discharged condition)
• [P0563] Battery charging voltage is abnormal. (Overcharged condition)
Fail-safe system
Procedure
1. Malfunction in charging system.
• Check the charging system.
Refer to “CHARGING SYSTEM” on page 8-17.
Is check result OK?

YES
→ Repeat step 1.
NO
a. Defective connection in the charging system circuit → Properly connect or replace the wire har-
ness.

YES
NO
→ Repeat step 1.
9-136
P0601
EAS20676
P0601
EAS33305
TROUBLESHOOTING
Item
Internal malfunction in SGCU. (When this malfunction is detected in the SGCU, the DTC might not ap-
pear on the tool display.)
Fail-safe system
Procedure
• Push the ON/start switch.
• Check that the MIL does not come on.
9-137
P062F
EAS20598
P062F
EAS33078
TROUBLESHOOTING
Item
EEPROM DTC: an error is detected while reading or writing on EEPROM.
Fail-safe system
Procedure
• Execute the diagnostic mode (Code 60)
00
Go to step 5.
01
Go to step 2.
11
Go to step 3.
12
Go to step 3.
14
Go to step 4.
2. “01” is indicated in diagnostic mode (Code 60). EEPROM data error for adjustment of CO adjust-
ment value.
• Activate the CO volume adjustment mode using the YDT.
• Click the “Step up” or “Step down” button 1 time. (Clicking the “Step up” or “Step down” button during
this procedure does not change the CO volume.)
• After this adjustment is made, push the OFF/LOCK switch.

YES
NO
a. Repeat step 1.
b. If the same number is indicated, go to step 5.
3. “11” is indicated in diagnostic mode (Code 60). EEPROM data error for ISC learning value and/or
“12” is indicated in the diagnostic mode (Code 60). EEPROM data error for A/F learning values.
• After this adjustment is made, push the OFF/LOCK switch.

YES
NO
a. Repeat step 1.
b. If the same number is indicated, go to step 5.
9-138
P062F
4. “14” is indicated in the diagnostic mode (Code 60). EEPROM data error for outside diameter of tire
learning value.
• Push the OFF/LOCK switch.

YES
NO
a. Execute the diagnostic mode (Code 87)
b. Repeat step 1.
c. If the same number is indicated, go to step 5.
9-139
P1602
EAS20615
P1602
EAS33095
TROUBLESHOOTING
Item
Malfunction in SGCU internal circuit (malfunction of SGCU power cut-off function).
Fail-safe system
Procedure
1. Installed condition of battery leads.
• Check the installed condition of the battery and battery leads (loose bolts).
Is check result OK?

YES
→ Go to step 2.
NO
a. Reinstall or replace the battery leads.

YES
NO
→ Go to step 2.
2. Connection of starter charge coupler.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-140
P1602

• Disconnect the fuse box (main fuse and ignition fuse) terminal and SGCU coupler.
Between battery “1” and fuse box (main fuse)
red–red
terminal “2”
Between fuse box (EFI fuse) terminal “2” and
red–red
2 3
1
Is resistance 0 Ω?
YES
NO

YES
NO
9-141
P1602

TIP
Between SGCU coupler “3” and ground red–ground

SGCU coupler “3” red–any other coupler terminal
A B
3 3
Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-142
P1602

• Disconnect the main switch coupler, fuse box (ignition fuse) terminal, starter charge relay coupler
and SGCU coupler.
Between main switch coupler “1” and fuse box
brown–brown
(ignition fuse) terminal “2”
Between fuse box (ignition fuse) terminal “2”
brown–brown
and starter charger relay coupler “3”
Between starter charge relay “3” and SGCU red/black–red/black
coupler “4”
4
1 3
Y/R
R/Y R Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
Br R/B Br/R Br Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/B R G/R B/L W/G W L/Y L/R B Gy/RW/B Br/W B P/W Br
Is resistance 0 Ω?
YES
NO

YES
NO
9-143
P1602

TIP
Between starter charge relay coupler “3” and
red/black–ground
ground

Starter charge relay coupler “3” red/black–any other coupler terminal
SGCU coupler “4” red/black–any other coupler terminal
A B 3 4
3
Y/R Y/R
R R
R/B Br/R Br R/B Br/R Br
L/B R G/R B/L W/G W L/Y L/R B Gy/RW/B Br/W B P/W Br
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 5.
9-144
P2158
EAS20633
P2158
EAS33113
TROUBLESHOOTING
Item
Rear wheel sensor: normal signals are not received from the rear wheel sensor.
Fail-safe system
Procedure
• Check the ABS warning light.
Is the ABS warning light on?

YES
→ Refer to “ABS TROUBLESHOOTING OUTLINE” on page 9-15.
NO
→ Go to step 2.
2. Connection of rear wheel sensor coupler.
pins).

YES
→ Go to step 2.
NO
b. Check the rear wheel speed with YDT monitor item.
c. Rotate the rear wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 3.
9-145
P2158
3. Connection of ABS ECU coupler.

pins).

YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
pins).

YES
→ Go to step 5.
NO
b. Check the rear wheel speed by YDT monitor item.

YES
NO
→ Go to step 5.
9-146
P2158

• Disconnect the rear wheel sensor coupler, ABS ECU coupler and SGCU coupler.
Between rear wheel sensor coupler “1” and green–green
ABS ECU coupler “2” blue–blue
Between ABS ECU coupler “2” and SGCU cou-
white/black–white/black
pler “3”
1 2 3
R Br Y G L W W/L W/B B/W
G L R/L Y L/G L/G Br Lg/L Lg/W B/W B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Is resistance 0 Ω?
YES
NO

YES
NO
9-147
P2158

TIP
Disconnect the SGCU and ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE SGCU” on page 9-3 and “PARTS CONNECTED TO THE
ABS ECU” on page 9-4.
green–ground
Between ABS ECU coupler “2” and ground blue–ground
white/black–ground

green–any other coupler terminal
blue–any other coupler terminal
ABS ECU coupler “2” blue–any other coupler terminal
ECU coupler “3” white/black–any other coupler terminal
A B
1 3
2
G L
R Br Y G L W W/L W/B B/W Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
R/L B L/B R G/R B/L W/G W L/Y L/R B Gy/RW/B Br/W B P/W Br
Y L/G L/G Br Lg/L Lg/W B/W
YES
→ Go to step 5.
NO

YES
NO
→ Go to step 6.
9-148
P2158
6. Defective rear wheel sensor.

• Check the installed condition of rear wheel sensor.
Is check result OK?

YES
→ Go to step 7.
NO
a. Reinstall or replace the rear wheel sensor.
Refer to “REAR WHEEL” on page 4-28.

YES
NO
→ Go to step 7.
• Check the rear wheel speed with YDT monitor item.
• Rotate the rear wheel by hand and check that the indicated value increases.

YES
NO
→ Go to step 8.
8. Malfunction in ABS ECU.
• Replace the ABS ECU.
Refer to “REMOVING THE HYDRAULIC UNIT ASSEMBLY” on page 4-57.
• Go to step 9, and complete the service.
• Push the ON/start switch, and then rotate the rear wheel by hand.
then delete the DTC.
• Delete this DTC even if it has a condition of “Detected”.
9-149
P2645
EAS20642
P2645
EAS33122
TROUBLESHOOTING
Item
VVA solenoid: Normal signal is not received from the VVA solenoid circuit while driving the VVA sole-
noid.
Fail-safe system
Procedure
1. Connection of VVA solenoid coupler.
pins).

YES
→ Go to step 2.
NO
b. Push the ON/start switch, start the engine and accelerate to 6000 r/min and then check the DTC
using the malfunction mode of the YDT.

YES
NO
→ Go to step 2.
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3.
9-150
P2645

• Disconnect the VVA solenoid coupler and SGCU coupler.
Between VVA solenoid coupler “1” and SGCU green–green
coupler “2” chocolate–chocolate
Between SGCU coupler “2” and ground black–ground
2
G Ch
Is resistance 0 Ω?
YES
NO

YES
NO
9-151
P2645

TIP
green–ground
Between VVA solenoid coupler “1” and ground
chocolate–ground

VVA solenoid coupler “1”
chocolate–any other coupler terminal
chocolate–any other coupler terminal
A B
1 1 2
G Ch
G Ch
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
9-152
P2645
4. Faulty the VVA solenoid operation

• Check the VVA solenoid resistance.
Refer to “CHECKING THE VVA SOLENOID” on page 8-42.
Is check result OK?

YES
→ Go to step 5.
NO
a. Replace the VVA solenoid.

YES
NO
→ Go to step 5.
9-153
Er-1, Er-2, Er-3, Er-4
EAS20776
Er-1, Er-2, Er-3, Er-4

EAS33508
TROUBLESHOOTING
Item
• [Er-1] SGCU internal malfunction (output signal error): signals cannot be transmitted between the
SGCU and the multi-function meter.
• [Er-2] SGCU internal malfunction (output signal error): signals are not received from the SGCU within
the specified duration
• [Er-3] SGCU internal malfunction (output signal error): data from the SGCU cannot be received cor-
rectly.
• [Er-4] SGCU internal malfunction (input signal error): registered data is not received from the meter.
Procedure
1. Connection of meter assembly coupler.
pins).

YES
→ Go to step 2.
NO

YES
NO
→ Go to step 2
pins).

YES
→ Go to step 3.
NO

YES
NO
→ Go to step 3
9-154
Er-1, Er-2, Er-3, Er-4
3. Meter assembly wire harness continuity.

• Disconnect the meter assembly coupler and SGCU coupler.
Between meter assembly coupler “1” and
blue/red–blue/red
1 2

R/W L/W Br/W Y/W Dg Ch Br R Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
L/R G/B W/L Br/R W/R G B R L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
Is resistance 0 Ω?
YES
NO

YES
NO
→ Go to “Short circuit check”
9-155
Er-1, Er-2, Er-3, Er-4

TIP
Between meter assembly coupler “1” and
blue/red –ground
ground

Meter assembly coupler “1” blue/red –any other coupler terminal
SGCU coupler “2” blue/red–any other coupler terminal
A B
1 1 2
R/W L/W Br/W Y/W Dg Ch Br R R/W L/W Br/W Y/W Dg Ch Br R Lg/L G/Y P W/L Ch G B/L B Or/B W/R B/Y Or
L/R G/B W/L Br/R W/R G B R L/R G/B W/L Br/R W/R G B R Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
YES
→ Go to step 4.
NO

YES
NO
→ Go to step 4.
4. Defective meter assembly
• Check that the installed condition of meter assembly.
Is check result OK?

YES
NO
a. Replace the meter assembly.
YES
NO
→ Go to step 5.
9-156
Er-1, Er-2, Er-3, Er-4
9-157
11, 25_ABS
EAS20685
11, 25_ABS
EAS33314
TROUBLESHOOTING
Item
Front wheel sensor (intermittent pulses or no pulses)
Procedure
TIP
With the front wheel stopped, the rear wheel was rotated for longer than about 20 seconds (DTC No.
11) or for longer than about 2 seconds (DTC No. 25).
1. Foreign material adhered around the front wheel sensor
• Check the surface of the sensor rotor and wheel sensor for foreign material, such as metal particles.
Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and wheel sensor.
2. Incorrect installation of the front wheel
• Check the components for looseness, distortion, and bends.
Refer to “CHECKING THE FRONT WHEEL” on page 4-24.
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, front wheel, wheel bearings or oil seals.
3. Defective sensor rotor or incorrect installation of the rotor
• Check the surface of the sensor rotor for damage.
Refer to “MAINTENANCE OF THE FRONT WHEEL SENSOR AND SENSOR ROTOR” on page 4-
24.
Is check result OK?

YES
→ Go to step 4.
NO
→ Replace the sensor rotor.
4. Defective front wheel sensor or incorrect installation of the sensor
• Check the wheel sensor for damage and the installed condition of the sensor.
24.
Is check result OK?

YES
→ Replace the hydraulic unit assembly (ABS ECU).
NO
→ Repair or replace the wheel sensor.
9-158
12_ABS
EAS20686
12_ABS
EAS33315
TROUBLESHOOTING
Item
Rear wheel sensor (intermittent pulses or no pulses)
Procedure
1. Foreign material adhered around the rear wheel sensor
Is check result OK?

YES
→ Go to step 2.
NO
2. Incorrect installation of the rear wheel
Refer to “CHECKING THE REAR WHEEL” on page 4-29.
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace the wheel axle, tire, rear wheel, wheel bearings or oil seals.
Refer to “MAINTENANCE OF THE REAR WHEEL SENSOR ROTOR” on page 4-29.
Is check result OK?

YES
→ Go to step 4.
NO
4. Defective rear wheel sensor or incorrect installation of the sensor
Is check result OK?

YES
NO
9-159
13, 26_ABS
EAS20687
13, 26_ABS
EAS33316
TROUBLESHOOTING
Item
Front wheel sensor (abnormal pulse period)
Procedure
TIP
• If the front brake ABS operates continuously for 20 seconds or more, DTC No. 26 will be recorded. If
the front brake ABS operates continuously for 36 seconds or more, DTC No. 13 will be recorded.
• Vehicle possibly ridden on uneven roads.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
24.
Is check result OK?

YES
→ Go to step 4.
NO
24.
Is check result OK?

YES
NO
9-160
14, 27_ABS
EAS20688
14, 27_ABS
EAS33317
TROUBLESHOOTING
Item
Rear wheel sensor (abnormal pulse period)
Procedure
TIP
• If the rear brake ABS operates continuously for 20 seconds or more, DTC No. 27 will be recorded. If
the rear brake ABS operates continuously for 36 seconds or more, DTC No. 14 will be recorded.
• Vehicle possibly ridden on uneven roads.
Is check result OK?

YES
→ Go to step 2.
NO
→ Clean the sensor rotor and rear sensor.
Is check result OK?

YES
→ Go to step 3.
NO
Is check result OK?

YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
9-161
15_ABS
EAS20662
15_ABS
EAS33040
TROUBLESHOOTING
Item
Front wheel sensor (open or short circuit)
Procedure
1. Defective coupler between the front wheel sensor and the hydraulic unit assembly
• Check the coupler for any pins that may be pulled out.
TIP
Push the OFF/LOCK switch before disconnecting or connecting a coupler.
Is check result OK?

YES
→ Go to step 2.
NO
→ If there is a malfunction, repair it and connect the coupler securely.
2. Wire harness continuity
• Disconnect the ABS ECU coupler and front wheel sensor coupler.
Between ABS ECU coupler “1” and front wheel brown–brown
sensor coupler “2” yellow–yellow
1
2
R/L Y L/G L/G Br Lg/L Lg/W B/W B Br Y
Is resistance 0 Ω?
YES
NO
→ Replace the wire harness.
9-162
15_ABS

TIP
Disconnect the ABS ECU related connectors before checking.
Refer to “PARTS CONNECTED TO THE ABS ECU” on page 9-4.
brown–ground
yellow–ground

Front wheel sensor “2”
A B
2 2
R
R/L
Br Y G L W W/L W/B B/W
B
1
Br Y
YES
→ Go to step 3.
NO
3. Defective front wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions were found, the wheel sensor or hydraulic
unit assembly is defective.
• Replace the wheel sensor or hydraulic unit assembly.
Refer to “FRONT WHEEL” on page 4-21 and “ABS (Anti-lock Brake System)” on page 4-55.
9-163
16_ABS
EAS20663
16_ABS
EAS33285
TROUBLESHOOTING
Item
Rear wheel sensor (open or short circuit)
Procedure
1. Defective coupler between the rear wheel sensor and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 2.
NO
• Disconnect the ABS ECU coupler and rear wheel sensor coupler.
Between ABS ECU coupler “1” and rear wheel green–green
sensor coupler “2” blue–blue
1
2
R/L Y L/G L/G Br Lg/L Lg/W B/W B G L
Is resistance 0 Ω?
YES
NO
9-164
16_ABS

TIP
green–ground
blue–ground

Rear wheel sensor “2”
A B
2 2
1

G L
YES
→ Go to step 3.
NO
3. Defective rear wheel sensor or hydraulic unit assembly
• If the above items were performed and no malfunctions were found, the wheel sensor or hydraulic
unit assembly is defective.
• Replace the wheel sensor or hydraulic unit assembly.
Refer to “REAR WHEEL” on page 4-28 and “ABS (Anti-lock Brake System)” on page 4-55.
9-165
17, 45_ABS
EAS20708
17, 45_ABS
EAS33372
TROUBLESHOOTING
Item
Front wheel sensor (missing pulses)
Procedure
TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC
No. 17 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 45
will be recorded first and DTC No. 17 will be recorded if the condition continues.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
24.
Is check result OK?

YES
→ Go to step 4.
NO
24.
Is check result OK?

YES
NO
9-166
18, 46_ABS
EAS20709
18, 46_ABS
EAS33373
TROUBLESHOOTING
Item
Rear wheel sensor (missing pulses)
Procedure
TIP
If pulse gaps are detected when the vehicle is traveling at a speed of 30 km/h (19 mi/h) or more, DTC
No. 18 will be recorded. If the vehicle is traveling at a speed of 29 km/h (18 mi/h) or less, DTC No. 46
will be recorded first and DTC No. 18 will be recorded if the condition continues.
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
Is check result OK?

YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
9-167
21_ABS
EAS20690
21_ABS
EAS33320
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective solenoid drive circuit)
Procedure
1. Defective hydraulic unit assembly
• Replace the hydraulic unit assembly.
Refer to “ABS (Anti-lock Brake System)” on page 4-55.
9-168
31_ABS
EAS20691
31_ABS
EAS33321
TROUBLESHOOTING
Hydraulic unit assembly (defective ABS solenoid power supply)
Procedure
1. Blown ABS solenoid fuse
• Check the ABS solenoid fuse.
Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
2. Defective coupler between the battery and the hydraulic unit assembly
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS solenoid fuse and ABS ECU coupler.
Between ABS solenoid fuse holder “1” and ABS
red–red
ECU coupler “2”
2
1
Is resistance 0 Ω?
YES
NO
9-169
31_ABS

TIP
Between ABS ECU coupler “2” and ground red–ground

ABS ECU coupler “2” red–any other coupler terminal
A B
2 2
R Br Y G L W W/L W/B B/W Br Y G L W W/L W/B B/W
R
R/L Y L/G L/G Br Lg/L Lg/W B/W B R/L B
YES
→ Go to step 4.
NO
9-170
32_ABS
EAS20712
32_ABS
EAS33376
TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS solenoid power supply circuit)
Procedure
9-171
33_ABS
EAS20692
33_ABS
EAS33322
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal ABS motor power supply)
Procedure
1. Blown ABS motor fuse
• Check the ABS motor fuse.
Is check result OK?

YES
→ Go to step 2.
NO
→ Replace the fuse and check the wire harness.
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS motor fuse and ABS ECU coupler.
Between ABS motor fuse holder “1” and ABS
red/blue–red/blue
ECU coupler “2”
2
1
Is resistance 0 Ω?
YES
NO
9-172
33_ABS

TIP
Between ABS ECU coupler “2” and ground red/blue–ground

ABS ECU coupler “2” red/blue–any other coupler terminal
A B
2 2
YES
→ Go to step 4.
NO
9-173
34_ABS
EAS20693
34_ABS
EAS33323
TROUBLESHOOTING
Item
Hydraulic unit assembly (short circuit in ABS motor power supply circuit)
Procedure
9-174
41_ABS
EAS20694
41_ABS
EAS33331
TROUBLESHOOTING
Item
Front wheel ABS (intermittent wheel speed pulses or incorrect depressurization)
Procedure
1. Incorrect installation of the front wheel sensor
24.
Is check result OK?

YES
→ Go to step 2.
NO
→ Repair or replace the defective part.
2. Incorrect rotation of the front wheel
• Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE FRONT WHEEL” on page 4-24 and “CHECKING THE FRONT BRAKE
Is check result OK?

YES
→ Go to step 3.
NO
3. Front brake dragging
• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever
is operated and that the pressure decreases when the lever is released.
Refer to “CHECKING THE FRONT BRAKE DISC” on page 4-37.
Is check result OK?

YES
→ Go to step 4.
NO
9-175
42, 47_ABS
EAS20695
42, 47_ABS
EAS33324
TROUBLESHOOTING
Item
Rear wheel ABS (intermittent wheel speed pulses or incorrect depressurization)
Procedure
1. Incorrect installation of the rear wheel sensor (DTC No. 42)
Is check result OK?

YES
→ Go to step 2.
NO
2. Incorrect rotation of the rear wheel
• Check that there is no brake disc drag on the wheel and make sure that it rotates smoothly.
Refer to “CHECKING THE REAR WHEEL” on page 4-29 and “CHECKING THE REAR BRAKE
Is check result OK?

YES
→ Go to step 3.
NO
3. Rear brake dragging
• Check that the brake fluid pressure is correctly transmitted to the brake caliper when the brake lever
is operated and that the pressure decreases when the lever is released.
Refer to “CHECKING THE REAR BRAKE DISC” on page 4-49.
Is check result OK?

YES
→ Go to step 4.
NO
9-176
43_ABS
EAS20696
43_ABS
EAS33330
TROUBLESHOOTING
Item
Front wheel sensor (missing pulses)
Procedure
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
24.
Is check result OK?

YES
→ Go to step 4.
NO
24.
Is check result OK?

YES
NO
9-177
44_ABS
EAS20697
44_ABS
EAS33325
TROUBLESHOOTING
Item
Rear wheel sensor (missing pulses)
Procedure
Is check result OK?

YES
→ Go to step 2.
NO
Is check result OK?

YES
→ Go to step 3.
NO
Is check result OK?

YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
9-178
51, 52_ABS
EAS20698
51, 52_ABS
EAS33326
TROUBLESHOOTING
Item
• Vehicle system power supply (voltage of ABS ECU power supply is high) (DTC No. 51)
• Vehicle system power supply (voltage of wheel sensor power supply is high) (DTC No. 52)
Procedure
1. Defective battery
• Recharge or replace the battery, and check again.
2. Disconnected battery terminal
• Check the connection.
Is check result OK?

YES
→ Go to step 3.
NO
→ Replace or reconnect the terminal.
3. Defective charging system
Is check result OK?

YES
NO
→ Confirm the cause of the problem and repair it, and check again.
9-179
53_ABS
EAS20699
53_ABS
EAS33327
TROUBLESHOOTING
Item
Vehicle system power supply (voltage of ABS ECU power supply is low)
Procedure
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS ECU fuse and ABS ECU coupler.
Between ABS ECU fuse holder “1” and ABS
brown
ECU coupler “2”
1 2
Is resistance 0 Ω?
YES
NO
9-180
53_ABS

TIP
Between ABS ECU coupler “2” and ground brown–ground

ABS ECU coupler “2” brown–any other coupler terminal
A B
2
2
R Br Y G L W W/L W/B B/W R Br Y G L W W/L W/B B/W

R/L Y L/G L/G Br Lg/L Lg/W B/W B R/L B
YES
→ Go to step 4.
NO
Is check result OK?

YES
NO
9-181
54_ABS
EAS20711
54_ABS
EAS33375
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS solenoid and ABS motor power supply circuits)
Procedure
TIP
Is check result OK?

YES
→ Go to step 3.
NO
• Disconnect the ABS ECU fuse, ABS motor fuse and ABS ECU coupler.
Between ABS ECU fuse holder “1” and ABS
brown
ECU coupler “3”
Between ABS motor fuse holder “2” and ABS
red/blue–red/blue
ECU coupler “3”
3

2
Is resistance 0 Ω?
YES
NO
9-182
54_ABS

TIP
brown–ground
red/blue–ground

red/blue–any other coupler terminal
A B
3 3
R Br Y G L W W/L W/B B/W R Br Y G L W W/L W/B B/W
R/L Y L/G L/G Br Lg/L Lg/W B/W B R/L Y L/G L/G Br Lg/L Lg/W B/W B
YES
→ Go to step 4.
NO
Is check result OK?

YES
→ Go to step 5.
NO
9-183
55_ABS
EAS20700
55_ABS
EAS33328
TROUBLESHOOTING
Item
Hydraulic unit assembly (defective ABS ECU)
Procedure
9-184
56_ABS
EAS20701
56_ABS
EAS33329
TROUBLESHOOTING
Item
Hydraulic unit assembly (abnormal internal power supply)
Procedure
9-185
63_ABS
EAS20703
63_ABS
EAS33334
TROUBLESHOOTING
Item
Front wheel sensor power supply (voltage of power supply is low)
Procedure
TIP
Between front wheel sensor coupler “1” and brown–ground
ground yellow–ground

A B
1 1 2
Br Y Br Y
YES
→ Go to step 2.
NO
9-186
63_ABS
2. Defective front wheel sensor

brown–ground
Between front wheel sensor “1” and ground
yellow–ground

Front wheel sensor “1”
A B
1 1
Br Y Br Y
YES
→ Go to step 3.
NO
9-187
64_ABS
EAS20704
64_ABS
EAS33335
TROUBLESHOOTING
Item
Rear wheel sensor power supply (voltage of power supply is low)
Procedure
TIP
Between rear wheel sensor coupler “1” and green–ground
ground blue–ground

Rear wheel sensor coupler “1”
A B
1 1 2
G L G L
YES
→ Go to step 2.
NO
9-188
64_ABS
2. Defective rear wheel sensor

Between rear wheel sensor coupler “1” and green–ground
ground blue–ground

Rear wheel sensor coupler “1”
A B
1 1
G L G L
YES
→ Go to step 3.
NO
9-189
EAS20091
55. Starter generator EAS30613
WIRING DIAGRAM 56. Front wheel sensor COLOR CODE

57. Rear wheel sensor B Black
GPD125-A 2021 Br Brown
58. Joint 4
1. Battery Ch Chocolate
59. ABS ECU
2. ABS solenoid fuse Dg Dark green
60. Meter assembly
3. ABS motor fuse G Green
4. Signaling system fuse Gy Gray
5. Smart key system fuse L Blue
63. High beam indicator light
6. Terminal fuse O Orange
64. Smart key system indicator
7. Fuel injection system fuse P Pink
light
8. Backup fuse R Red
9. Main fuse Sb Sky blue
10. Ignition fuse W White
67. Engine trouble warning light Y Yellow
11. Headlight fuse
68. Stop and Start System indica- B/L Black/Blue
tor light B/R Black/Red
13. Main switch
69. Traction control system indica- B/W Black/White
14. Request switch
tor light B/Y Black/Yellow
15. Main switch solenoid
70. Notification indicator light 1 Br/R Brown/Red
16. Auxiliary DC jack
71. Notification indicator light 2 Br/W Brown/White
17. DC outlet
72. Frame ground G/B Green/Black
18. Smart unit
73. Engine ground G/R Green/Red
19. Buzzer
74. License plate light G/W Green/White
20. Horn
75. Tail/brake light assembly G/Y Green/Yellow
21. Diode
76. Taillight Gy/G Gray/Green
22. Handlebar switch (left) Gy/R Gray/Red
77. Brake light
23. Menu switch L/B Blue/Black
24. Horn switch L/R Blue/Red
25. Dimmer switch L/W Blue/White
26. Turn signal switch L/Y Blue/Yellow
27. Handlebar switch (right) P/B Pink/Black
82. Headlight assembly
28. Start switch P/L Pink/Blue
83. Headlight control unit
29. Stop and Start System switch P/W Pink/White
84. High beam
30. Hazard switch R/B Red/Black
85. Low beam
31. Main relay R/G Red/Green
86. Auxiliary light
32. Yamaha diagnostic tool cou- R/L Red/Blue
pler R/W Red/White
33. Front brake light switch R/Y Red/Yellow
34. Rear brake light switch Sb/W Sky blue/White
35. Starter charge relay W/R White/Red
36. Sidestand switch W/Y White/Yellow
37. Joint 1 Y/B Yellow/Black
38. Injector Y/G Yellow/Green
39. Joint 2 Y/L Yellow/Blue
Y/R Yellow/Red
40. Joint 3
Y/W Yellow/White
41. Fuel pump
42. Fuel sender
43. SGCU (starter generator con-
trol unit)
44. Ignition coil
45. Spark plug
46. ISC (idle speed control) unit
53. VVA (variable valve actuator)
solenoid
54. O2 sensor
GPD125-A 2021
WIRING DIAGRAM
R R
2 3 R
R/L
R/Y G/W RR W/R Br B
4 5 17 Br W/R
W/R
W/R W/R
6 B 16 B B
Br/R Br
Br W/R B
R
R
7 8 R
R R
R Br Br
Br Br
9 Br
Br
Br/R Br Br
Br
Br Br
10
Br
Br
R R 13 R
11 12 R
G/W
Br
R R R
R W G
R/Y R/Y R/W B B R/W
OPEN
B R/B Lg/W Sb Gy W/Y P/B W/B L B/L Y B/L Br/B R/B
Br Br/R OFF
LOCK
(B) (B) G/W L/R R/B L/Y B/W G/B 19 R R Y/R Y/B B L/B R G/R B/L W/G W L/Y L/R B Gy/R W/B Br/W B P/W Br
R L W/R Br R/W R
R/Y
Br Br/R
L B B L
18 R/B B R R
(B)
B (B) R
14 15 L L
L/R
W/R Br
Br/R B R/W R/W L/Y
G/B
R 38 O O
44
Br/R Br/R
B/W Br O/B O/B
Br/R Br B
31 45
(B) O/B Br
R
Br/R Br (B)
B Br P P
R
Br Br B
G/Y
Gy
Sb
G/Y
Gy
Sb
46 P G/Y Sb Gy
L/B Lg/L B Br (B)

20 Br R Lg/W
P Br Br Lg/W
21
(R)
Lg/W
R Lg/L 47 48
P
Lg/L 32
P P Br B P/W
Br/W
P/W
Br/W 49 B/L Y L P/W Br/W
B/L B/L
Y
L
Y
L
50 (B)
Y/W 39 W/G
27 L/W Y/W Br/W
22 Y/W P L/B L/W R/W Br 33 L/W
W/G
Ch Dg
28 29 30 Dg
Br
Br Br B/Y B/Y
W/R W/R G
23 24 25 26 L/W PUSH Y/W ON OFF
Dg Br/W B/Y W/L W/L G W/R W/R B/L
L/B P
FREE FREE Y Y FREE OFF Br/W 34 B/Y
37 W/B
W/Y
W/B
W/Y
L/Y
51 Br/B W/L W/L Br/B
W/B W/Y
Ch Dg
Y/W
PUSH PUSH PUSH B B B B B/W Ch
Ch B
(R)
Br B/Y B/Y Y L/B 40 43 Br/B
B/L
Br/B
B/L
L/Y W/B
L/W B Y (B)
(B) (B)
L/W L/B B/W B L/B L/B
L/W Y/W
L/R
B Y B Y/R L/R L/R
P L/B L/B B/W R 35 L/R
G/R
B/L
G/R
B/L 52 G/R B/L
Y/W R/B Br/R Br (B)
(B) Y/R Y/R
R/W L/W B
B
B/W R Br/R
(B) Br R/B
B B
L/Y
R/B G
Ch
G
Ch 53 G Ch
B B L/Y L/Y L/Y L/Y (Gy)

Ch Ch
Ch B
R
R
R L/Y B 36 Y/B Gy/R Br/R B B P/B
Dg Dg
Dg B B
Br B/Y R B/L B/L W L Gy/R
Br (L) (L) 41 P/B
1 Br
R B/Y
(B)
B/Y
B B Br/R P/B
54 W L Gy/R B/L
B
B
G 42 B G
(B) (B)
B B (Gy)
Ch Dg Ch Dg B
B
75 Br Y Br B
81 80 79 78 G G
R
G
R
R/L
R/Y 55
B
82 Y Br B B Ch 76 77 74 L W W R/W
W/B R/Y R/W R/L

Ch Dg G
84 (Br) (G) (Br) B Y L

W
85 86 B B B
Br B R W G
Br Y Y Br B B B
G B B Y/B Ch Dg Ch B Br B
Y B
Gy Br/R (Br) (G) Dg B
Br R W
83 85 (Br) Br
R/L
W/B
G Y/B Br B
Gy Br/R
Y
Lg/W
Lg/L
Br
Y Y W 56 W B Br Y
B B
59
L/G
L/G
G
L
G
L
B
W 57 W B G L
Lg/W
B B B B/W B/W
Lg/W W/L B/W
B
B
B B
B
B
Lg/W
60
B B Lg/L
Lg/L
W/L
G
58 B/W
B/W B R Br Y G L W W/L W/B B/W
B G/B B/W
B Lg/L Y/W
B B Br R/L Y L/G L/G Br Lg/L Lg/W B/W B
B B B
B B B Br/R
B W/R
B B (B)
B B B/W R
R
R
L/W
61
B B B
R/W
B Ch
B Dg
Br/W
L/R
B BB BB
B
B B B B 62 63
73 72 72
72 72
65 64
66 67
68 69
71 70 L/R G/B W/L Br/R W/R G B R
(Gy)
GPD125-A 2021
WIRING DIAGRAM
2 3
B
4 5 17
6 16
7 8
9
10
13
11 12
ON
OPEN
OFF
LOCK
(B) (B) 19
18 (B)
(B)
14 15
38 44
31 45
(B)
(B)
46
(B)
20
21
(R)
47 48
32
49
50 (B)
39
27
22 33
28 29 30
23 24 25 26 PUSH ON OFF
/
FREE FREE
FREE OFF 34 /
37 51
PUSH PUSH PUSH B
(R)
40 43 (B)
(B) (B)
/
B B
35 52
(B) (B)
(B)
53
(Gy)
36
(L) (L) 41
1 (B)
42 54
(B) (B)
(Gy)
75
81 80 79 78 G
74 55
82 76 77
84 (Br) (G) (Br)
85 86 B B B
(Br) (G)
83 85 (Br)
56
59
57
/
60
58 B/W
B/W
(B)
61
62 63
73 72 72
72 72
65 64
66 67
68 69
71 70
(Gy)

Yamaha N-Max 125 2021 - Service Manual-1

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Yamaha N-Max 125 2021 - Service Manual-1

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2021

IMPORTANT MANUAL INFORMATION

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

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

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

HOW TO USE THIS MANUAL

CYLINDER AND PISTON CYLINDER AND PISTON

CYLINDER AND PISTON REMOVING THE PISTON

Order Job/Parts to remove Q’ty Remarks

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

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

VEHICLE IDENTIFICATION NUMBER

ENGINE SERIAL NUMBER

Fuel meter TIP

Coolant temperature meter

3. Continue pushing the “MENU” switch. The TIP

1 The odometer shows the total distance traveled

Fuel reserve tripmeter TIP

V-belt replacement tripmeter

1. Fuel reserve tripmeter

Instantaneous fuel consumption display TIP

Battery voltage display

1. Instantaneous fuel consumption display

1. Average fuel consumption display

Yamaha diagnostic tool (A/I) 3-4, 3-7, 4-59,

Tappet adjusting tool 3-7

Steering nut wrench 3-15, 4-78

Thickness gauge 4-27

T-handle 4-72, 4-73

Fork seal driver weight 4-73, 4-74

Fork seal driver attachment (ø30) 4-73, 4-74

Compression gauge extension 122mm 5-2

Camshaft wrench 5-14, 5-18

Yamaha bond No. 1215 5-17, 5-55

Slide hammer bolt (M8) 5-20

Valve spring compressor 5-24, 5-28

Valve spring compressor attachment 5-24, 5-28

Valve guide remover (ø5) 5-25

Valve guide reamer (ø5) 5-25

Piston pin puller set 5-30

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

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

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

Socket wrench (39 mm) 5-37, 5-41

Sheave spring compressor 5-38, 5-40

Sheave fixed block 5-38, 5-40

Flywheel puller 5-44

Crankcase separating tool 5-53

Crankshaft installer pot 5-54

Crankshaft installer bolt 5-54

Adapter (M12) 5-54

Spacer (crankshaft installer) 5-54

Radiator cap tester 6-4, 6-4